MB 129 Eng

Mercedes-Benz
1990-2002 HVAC Air Compressor, Belt Orives- 129 Chassis
1990-2002 HVAC
Air Compressor, Belt Orives - 129 Chassis
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES-
AR13.00-Z-9104AB
ENGINE 104
Remove!install generator ENGINE 104, 111, 112, AR13.22-P-5700EA

poly-V -belt pulley 119, 601, 602, 604, 605,
606 ...
AR13.00-Z-9113AB
ENGINE 113
Remove, install poly-V -belt for ENGINE 113 ... AR13 .2 1-P-1 202RVK
compres sor
Remove, install poly-V -belt for ENGINE 113.990 in AR13.21-P-1202TZ
compres sor MODEL 219.376
Remove, install poly V -belt ENGINE 112, 113 ... AR13.22-P-1202B
Remove, install poly V -belt ENGINE 112, 113 ... AR13 .22-P-1202BA
Remove, install poly V -belt ENGINE 113.964 in AR13 .22-P-1202GZ
MODEL 164.175
Remove, install poly V -belt ENGINE 112, 113 ... AR13 .22-P-1202PV
Remove, install poly V-belt ENGTNE 112, 113 ... AR 13.22-P-1 202R
Remove/install poly V-belt ENGINE 113.971 in AR13.22-P-1202RT
MODELS 251.075/ 175
Remove!install poly V-belt ENGINE 113.990 in AR13 .22-P-1202RV
MODELS 211.076/276
Remo ve, install poly V -belt ENGINE 113.967 in AR13 .22-P-1202TY
MODEL 219.375
Remove, instan poly V -belt ENGINE 113 .990 in AR13 .22-P-1202TZ
MODEL 219.376
Remove!install poly-V belt ENGINE 112, 113... AR13.25-P-3200B
tensioning device
Remove/install poly V-belt ENGINE 112, 113 ... AR13.25-P-3200BA
tensíoníng devíce
Remove/install poly-V -belt ENGINE 113 .964 in AR13.25-P-3200GZ
tensioning device MODEL 164.175
Mercedes-Benz
Remove/install poly-V-belt ENGINE 112, 113 ... AR13 .25-P-3200R

tensioning device
Removíng/instaUing the poly- ENGINE 113.971 in AR13.25-P-3200RT
V -belt tensioning device MODELS 251.075 /175
Remove/install poly V-belt ENGINE 113.967 in AR13.25-P-3200TY
Remove/install poly-V-belt ENGINE 113.990 in AR13 .25-P-3200TZ
Remove/install tensíoning ENGINE 113 ... AR13.25-P-3217RVK
device of compressor poly-V-
belt
Remove/install tensíoníng ENGINE 113.990 in AR13.25-P-3217TZ
device for compressor poly-V- MODEL 219.376
belt
AR13.00-Z-9119AB
ENGINE 119
Remove/install generator ENGINE 104, 111 , 112, AR13.22-P-5700EA

poly-V -belt pulley 119, 601 , 602, 604, 605,
606...
AR13.00-Z-9120AB
ENGINE 120
IIRemoving and installing poly V-belt IENGINE 120 in MODEL 129, 140 IAR13.22-P-1202AO
REMOVING AND INSTALLING POLY V-BELT- AR13.22-P-1202
Removing and installing poly V-belt- AR13.22-P-1202AO
ENGINE 120 in MODEL 129, 140

Mercedes-Benz
Totuionlng pulloy
Vfbr;,tion d;, mpot
t2 P oiy V·bolt
A W otl<lng r;,ngo
P P o>itfon mJrHing
P I l 22.0277-<l!i
Fig. 1: Locating Poly V-Belt
~
Removing, installing
ITl
AR20.40-P-
1 Remove viscous fan
5660AO
Use size 14 wrench to slacken
2 tensioning pulley (1) as far as a stop
but not further (direction of arrow)
3 Take off poly V-belt (12)
lnspect belt pulleys and tensioning
n=srGF E.g. worn bearing points oftensioning
4 device for signs of darnage and dirt,
replace if necessary device, dents in belt pulleys
Fit on poly V -belt beginning at
5 tensioning pulley (1) and vibration
ITl Do not use belt wax or similar products.
damper (2) Running diagrarn see ?
AR13.22-P-
Poly V -belt running diagram
3902-02AO
IGrGF The position marking (P) is located in
lnspect seat ofpoly V-belt (12) on the working range (A) ifthe length of the poly
6
the belt pulleys V-belt (12) and the tensioning device are in
order
7 Install in the reverse order
Remove, instaD poly V-belt- AR13.22-P-1202B
ENGINE 112.945 in MODEL 463.232 /233 /244 /209 /245 /250

Mercedes-Benz
ENGINE 113 (except 113.981 /965) in MODEL 202, 208, 129, 210, 163
ENGINE 113.962 in MODEL 463.247 /240 /241 /206 /249 /248 /254
ENGINE 113.982 in MODEL 463.246/243
Shown on engine 112
1 vtscous '""
2 FMshroud
J Poly-V-b.Jt
4 Sludboft
5 Tensloolng pulay
Fig. 2: ldentifying Poly V-Belt Remove/lnstall Components- Shown On Engine 112
& Remove
1 Remove viscous fan ~GF Right-hand thread! AR20.40-P-5660C
(1)
2 Remove fan shroud [!rGF Modell29, 202, 208, 210.
(2). n:!rGF On model 163 unscrew bolts at
bottom of fan shroud.
Model463 AR20.40-P-6800V
3 Loosen and remove [!rGF F or tbis step, swivel stud bolt
the poly-V-belt (3) (4) at tensioning pulley (5) in anti-
clockwise direction Lock the tension
pulley with a pin or mandrel ( diameter
5mrn).
@ Extemal torx set Fig. 3
[IJ Check
4 Inspect belt pulley
sections and
Mercedes-Benz
tensioning device for

damage and dirt
5 Check poly-V-belt
(3)
~GF Check poly-V-belt in Engine 112, 113 (except AP13.22-P-1351GA
visible area for wear 112.942 /945 /970,
113.942 /962 /965 /981 /982)
Engine 112.945, 113.962 /982 in mode1 AP13.22-P-1352Z
463
Engine 112.942/970, 113.942/965/981 AP13.22-P-1351GH
in model163
[JJ Insta U
6 Fit on poly-V-belt tr::rGF Do not use belt wax or any
(3), then clamp similar products.
Proceed by the numbered sequence of
the respective belt routing pattern,
starting with the tension pulley: ?
Layout diagram of poly-V-be1t AR13.22-P-3902-
02B
7 Install fan shroud (2) tr::rGF Modell29, 163, 202, 208, 210.
Model 463 with engine 112, 113 AR20.40-P-6800V
8 Install the viscous tr::rGF llight-hand thread! AR20.40-P-5660C
fan (1)
Fig. 3: l dentifying Externa! Torx Set (001 589 76 09 00)
POLY V-BELT RUNNING DIAGRAM- AR13.22-P-3902
Poly V-belt running diagram - AR13.22-P-3902-02AO
Running diagram with air pump
Poly V-belt 1ength 2585 mm 8 grooves, as of 04/1996 6 grooves

Mercedes-Benz
1 Tonsionlng pu/lcy {Without groovets)

2 Crillll!shilft
3 AC comprc.ssor
5 Filn
7 Alrpump
8 Go ncriltor
Q Top gu/cto puRcy
10 Powor sfllcring pump
11 Coof.ilnt pump
P1 3 22-112 iS-111
Fig. 4: Polv V-Belt Running Diagram
Running diagram with 2nd generator in place of air pump
Poly V-belt length 2523 mm 8 grooves, as of04/ 1996 6 grooves
1 Trmslonlng pulloy {WithoutgroovcsJ

2 e nnft.s hilft
3 AC comprcssor
5 FiJn
S Gcncmor
812 Sccond gcncfiltor
11 Top gtlfdc puNcy
10 Powcr smc·rlng pump
11 Coolanr pump
P1l2241276·01
Fig. 5: Polv V-Belt Running Diagram
Running diagram of]Joly V-belt- AR13.22-P-3902-02B
6-groove single-belt drive, without AC compressor
Cr.,bhall
2 Gulaepulo:; 2
3 Power !<IHrlflll pun>p
4 Gu/dl pule:; 1
5 Generat:or
S Coolanr pump and fan
7 Tens/011 puley
Fig. 6: Running Diagram Of Poly V-Belt (6-Groove Single-Belt Drive, Without AC Compressor)
6-groove single-belt drive, with AC compressor

Mercedes-Benz
1 CrankshBft
2 AC compre$SOr
3 Powersteoringpump
4 Gulde puley 1
11 Generator
6 Coolant purnpandfan
7 Tonslon pu6oy
Fig. 7: Running Diagram Of Polv V-Belt (6-Groove Single-Belt Drive, With AC Compressor)
REMOVE/INSTALL POLY-V BELT TENSIONING DEVICE- AR13.25-P-3200B
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 211.061 /261 /065/265
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 (except 113.965/981) in MODEL 129, 163, 202, 208, 210, 211.070/270
ENGINE 113.982 in MODEL 463.243/246
Shown on engine 112
1 Viscous tan
2 Fans/Voud
..
3 Po,l y-VIJeft
4 TonsJonlng dov ice
TenlllM puley
4b H<>xogon
5 S hock ilbsolbor
Fig. 8: ldentifying Poly-V Belt Tensioning Device Remove/Install Components- Shown On Engine 112
& DJ Remove/install
1 Remove viscous fan ( 1) Except model 211 AR20.40-P-5660C
oc:!?GF Rioht-hand
o
Mercedes-Benz
thread!
2 Remove fan shroud (2). Except model 211
~GF On model 163,
unscrew bolts at bottom
of fan shroud.
h1odel 129,163,202,
208,210
Model463 AR20.40-P-6800V
3 Remove poly-V belt (3) Except model 211 AR13.22-P-1202B
Model 211 AR13.22-P-l202PV
4.1 Rotate the tensioner pulley Except model 211
(4a) in the counterclockwíse ~GF Lock tensioner
direction and lock pulley with drift or pin
( diameter 5 mm).
4.2 Rota te tensioning device at Model211
hexagon (4b) in an anti- ~GF Lock tensioning
clockwise direction and device with a drift or pin
lock ( diameter 5 mm).
5 Remove shock absorber (5) Model 129,202,210,
on coolant pump 211 with engine 112 and
manual transmission
&oanqerl *BA13.25-P-1004-01M
6 Remove tensioning device & oanqerl Engine 112 *BA13.25-P-1001-01M
(4)
& oa"""'' Engine 113 *BA13.25-P-1001-01D
7 Remove shock absorber (5) Model129, 202, 210,
from clamping device (4) 211 with engine 112 and
manual transmission
&oanqerl *BA13.25-P-1003-01M
• Oanaer! Belt tensiOnmg d ev1ce

.
Engine
112.910/911/91
2/913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/961/970/
Number Designation 972/973/975
BA13.25-P-1001- Self-tapping bolt, Thread not pre- N m 35
Mercedes-Benz
OlM belt tensíoner to tapped 1

timing case cover Thread pre-tapped Nm25
BA13.25-P-1003- Shock absorber, N m 25
OlM belt tensíoníng
devíce to ibelt
tensioning device
BA13.25-P-1004- Shock absorber, N m 35
0 1M belt tensioning
device to coolant
pump housíng
· Dangorl Bel t tenswmng d ev1ce

.
Engine
113.940/9411
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
BA13.25-P-1001- Self-tappíng bolt, Thread not pre- N m 35
OlD belt tensíoner to tapped
timíng case cover Thread pre-tapped 1 Nm25
MAIINTENANCE
CHECK CONDITION OF POLY V -BELT; TODO SO, GRADUALLY TURN THE ENGINE.-
AP13.22-P-1351-02C
l. Mark with chalk (arrow) the poly-V-belt (27) ata clearly visible point.
2. Turn the engine bit by bit usíng the starter.
~GF Tum the ignition key briefly into position 3.
3. Check poly-V-belt (27) for signs of damage.

4. Finish the process when the visual inspection has taken place over the complete poly-V-belt (27).
Mercedes-Benz
Fig. 9: Locating Mark On Poly-V-Belt
REPAIR & ADJUSTMENTS

REMOVING AND INSTALLING POLY V-BELT- RA13001041200X(13-1200)
Preceding work:
Viscous fan clutch removed (20-3120).
Operation no. of operation texts and work units or standard texts and flat rates
13-1202- 13-4001
1st version witb externa! damper

Mercedes-Benz
A E lfls\elootger (13) auf Madclerung 11) = Kodnppemomen U!lgespamt

8 E lfls!ebger 113) aufMat\Qerung 12) =KBIÍippernemen gespanrt
Fi~. 10: Locatin~ Belt Pulleys - 1St Version With Externa) Damper
Bolt ( 16) slacken approx. 1/4 - 1/2 turns.

Tensioning nut (5) slacken (turn to the left).
Poly V-belt (27) take off.
examine for signs of damage and dirt, replace if necessary (e. g. wom bearing points
Belt pulley
oftensioning device, dents in belt pulleys etc.) .
Setting poínter
turn to marking (1) (arrow).
(13)
fit on, begínníng at tensíoníng pulley (running díagrams see (13-1240)).
lVI
~
Poly V-belt
Do not use belt wax or similar products except, íf noíse problems exíst, spray poly V-
belt lubrícant 000 989 19 60 onto belt running surface and onto back of belt.
Tensioning nut (5) tension until setting point (13) is aligned with the marking (2) (arrow).
Bolt (16) tighten (75 Nm).
Seat of belt on belt .
examme.
pu11eys
TIGHTENING TORQUE IN NM
Mercedes-Benz
lsecuring bolt of tensioning de vice 75
Special tool
000 589 1 o99 01
Fig. 11: ldentifving Special Tool (000 589 10 99 01)
Preceding work:
Fan shroud removed (20-3400)
Viscous fan clutch removed (20-3120) .
13-1 202 - 13-400 1
2nd version witb internal damper as of September 1994

Mercedes-Benz
1990-2002 HVAC Air Compressor, Belt Orives - 129 Chassis
P13 20-0206-57
Fig. 12: Locating Tensioning Pulley - 2nd Version Witb Internal Damper
Tensioning
swivel clockwise at nut (1) waf 15.
pulley (7)
Poly V-belt
take ofi.
(27)
Profiles of examine for signs of damage and dirt; replace if necessary ( e.g. worn bearing points of
belt pulley tensioning device, damage to belt pulleys etc.
fit on beginning at tensioning pulley (7); swivel tensioning pulley (7) clockwise at nut (1)
for this step (for running diagram see {13-1240)).
D
Do not use belt wax or similar products.
NOTE:
Poly V-belt
The different versions of the tensioning pulley (7) 0 with 92 or 0 80 mm require
(27)
different Jengths of poly V-belts (13-1240).
If a 20 mm shorter poly V-belt is installed together with a smaller tensioning pulley (7) (0
80 mm) when perfonning repairs, the belt length should be entered on the last page ofthe
Maintenance Booklet and the Owner's Manual revised accordingly.
Mercedes-Benz
Nlc:hstsr
Service
10 ooo-
12500icm
Oder
POO.00-0485-33
Fig. 13: Identifying Service Label
Use oftensioning device with .internal damper (2nd version)
as of engine nurnber
104.941 lO 004 059
104.941 12 034 967
104.942 10 005 790
104.942 12 048 697
104.943 10 000 901
104.943 12 003 621
104.944 10 000 740
104.944 12 007 448
104.945 10 000 001
104.945 12 000 001
104.991 12 009 986
104.992 10 004 357
104.992 12 072 237

Mercedes-Benz
104.994 12 031 210
104.995 12 000 001
104.996 10 000 001
104.996 12 000 001
CHECKING POLY V-BELT, TYPICAL TYPES OF DAMAGE- RA13001041230X(13-1230)
Preceding work:
Hood raised to vertical position (01-0080) .
Fig. 14: Identifving Mark On Polv V-Belt
POL Y V-BELT CHECK

Poly V-belt (27) mark at clearly visible point with chalk (arrow).
Engine crank in stages with starter (01-0110) .
Poly V-belt (27) examine for signs of damage.
Examination end once marking (arrow) is agaín visible (one full belt revolution).
Types of damage
The poly V-belt must be replaced (subject to separate repair order) ifthe following types of damage are
encountered:
• Rubber lurnps in base ofbelt (C), dírt or grit embedded (D).

Mercedes-Benz
D D
!"2;-jtf:::c-±1• ~i~
Fig. 15: Locating Types OfDamage (Poly V-Belt)
• Wear to flanks (F)
Ribs are pointed - trapezoidal in shape when new (E) and cords visible in base ofbelt (G, brighter points).
mn
1
G~
1
Fig. 16: Identifying Ribs Point
• Splits (H) across several ribs.

Mercedes-Benz
Fig. 17: ldentifying Splits (H) Across Several Ribs
• Ríb detached from base ofbelt (arrow).
Fig. 18: Identifying Rib Detached From Base Of Belt
• Splits across the ribs (H) and/or sections ofrib torn out (J).
Fig. 19: ldentifying Splits Across Of Ribs
• Cord fractured at the side (K) or fraying (L) of outer cords.

Mercedes-Benz
Fig. 20: Locating Outer Cords
• Splits across the back (M)_
Fig. 21: Locating Splits Across Back
POLY V-BELT, RUNNING DIAGRAMS, DIMENSIONS- RA13001041240X(13-1240)
Running diagrams
Mercedes-Benz
P1l. 2().()20 7-57
1 Tensioning pulley 7 Air pump

2 Crankshaft B Generator
3 AC compressor 9 Top guide pulley
4 Bottom guide pliley 10 Power steering pump
5 Fan 11 Coolant ¡pump
Fig. 22: Poly V-Belt, Running Diagrams
Engine Model Remarks Optional Optional Airpump Belt length with 80

104 equipment equipment drive tensioning pulley mm
12.457(1) 12.458 (2) 092mm
up to -0-
941 202.028 004058 mechJnone 2080
1 ~~~;~¿~-
as of -0-
electric 2130 2100
004059 (J)
as of -2-
l034967
up to-0-
/1 8 mechJnone 2176
004058
lnn to-?-
Mercedes-Benz
1 lo34966 1 1 1 1
as of-0-
004059 (3)
/18 - 2225 2205
as of-2-
034967 (3)
as of -0-
006124 (4)
/ 18 - electric 2140 2120
as of-2-
063790 (4 )
- - electric 2140 2120
as of-2-
063790 (4)
- - electric 2140 2120
as of -0-
006124 (4)
/ 18 - electric 2245 2225
as of-2-
063790 (4) - - 2240 -
942 124.0..
up to -0-
- - mech./none 2330 -
005789
lup to -2-
1
048686 1 1
as of -0-
005790 (3) - /39 mech./none 2380 2360
as of -2-
048687 (3)
up to -0-
/ 16 - mech./none 2415 -
005789
lup to -2-
1 048686 1 1 1
as of -0-
005790 (3)
/ 16 - mech./none 2475 2445
as of -2-
048687 <3)
943 129.058 as of -O- /21 - electric 2225 2205

000901 (3)
as of -2-
003621 (3)
944 .
up
140 028 to -O-
000740 - - - 2445 -
¡up
to -2-
1 000447 1
as of -0-
000741 <3)
- 32/36 electric 2225 2205
1 1::~~ of -?- 1 1 1 1
Mercedes-Benz
1
loo7448 <3) 1 1 1 1
as of -0-
000741 <3)
- none 2225 2205
as of -2-
007448 (3)
945 210 .053 as ofs~rt of _ - - - 2120

productwn
as of start of
production
with - 2225
(1) = air conclitioning
(2) = exhaust gas recirculation

(3) = production breakpoint ofbelt tensioner with self-damping as of 09/ 1994, was rubber element prior
to this date
(4) = production breakpoint ofVDA power steering pump as of09/ 1995, was VT67 prior to this date
Engine Model Remarks Optional Optional Air pump Belt length with 80
104. equipment equipment drive tensioning pulley 0 mm
12.457 (l) 12.458 (2) 92mm
up to -0-
980 124·0 ·· 009076 with/none 2285
¡up to -2-
042810
as of -0-
with 2275
009077
¡as of -2-
042811
as of -0-
2176
009077
¡as of -2-
042811
up to -0-
with/none 2445
004956
lup to -2-
021004
as of -0-
with mech./none 2445
004957
¡as of -2-
021005
up to -0-
009076
with mech./none 2445
lup to -2-
042810
Mercedes-Benz
as of -0-
009077
with - mech./none 2415 -
¡as of -2-
1 042811 1 1
as of -0-
004957 - - mech./none 2355 -
¡as of -2-
1 021005 1 1
up to -0-
009076 - - mech./none 2355 -
¡up to -2-
1 042810 1 1
as of -0-
009077 - - mech./none 2330 -
~~s of -2-
1 042811 1
990 140.0328 grooves - - - 2337 -
8 grooves - - - 2440 -
up to -2-
991 129.063 009985 - - - 2330 -
as of -2-
009986 - - - 2130 -
up to -2-
009985
/21 - - 2415 -
as of -2-
009986 (3)
/21 - - 2225 2205
as of -2-
009986 (3)
/30 - - 2475 2445
as of -2-
30 /42 mech./none 2380 2360
009986 (3)
(I) = air conditioning
(2) = exhaust gas recirculation
(3) = production breakpoint of belt tensioner witb self-damping as of 09/1994, was rubber element prior
to this date
Engine Model Remarks Optional Optional Air pump Belt length with 80mm
104. equipment equipment drive tensioning pulley
12.457 (l) 12.458 (2) 0 92mm
up to - 1-
992 124.0.. 2330
004356
up to -2-
072236
Mercedes-Benz
as of -1-
004357 (3)
- - electric 2130
as of -2-
2445
072237 (3)
asof -1-
004357 (3)
- - mech./none 2380
as of -2-
2360
072237
up to - 1-
004356 / 16 - - 2415
up to -2-
072236 1 1 1 1
as of -1-
004357
/ 16 - - 2475
as of -2-
2445
072237
up to -2-
994 140.032/033 031209 - - - 2445
as of -2-
0312 10 (3)
- - electric 2225
2205
as of -2-
031210 (3)
- /32/36 mech./none 247 5
2445
as of start of
995 210.055
production
- - electric 2 140
2120
las of st~rt of with - electric 2240
1 product10n
2225
as of start of
996 463.2
production
-
1 1 1
2120
las of st~rt of with -
1 product10n 1 1
2380
(1) = air conditioning
(2) = ex.haust gas recirculation
(3) = production breakpoint ofbelt tensioner with self-damping as of 09/1994, was rubber element prior
to this date
REMOVING AND INSTALLING TENSIONING DEVICE - RA1300104320XX(13-3200)

Mercedes-Benz
Preceding work:
Fan shroud removed (20-3400) .
Operation no. of operation texts and work units or standard texts and flat rates:
13- 1202, 13-4001
1st version with external damper
P 13-5103-S7
Fig. 23: ldentifving Tensioning Device Remove/lnstaU Components- 1St Version With Externa) Damper
(1 Of2)
Bolts (23) and (25) ofbelt pulleys of coolant pump (24) and
slacken, tighten (32 Nm).
power steering pump (26)
slacken bolts of belt pulley of fan,
Engine 104.98:
tighten (15 Nm).
Poly V-belt (27) remove, install {13-1200).
Belt pulleys of coolant pump (24) and power steering purnp r P.mnvP in ~t::t ll P owP.r c::tPPrin a nnmn
Mercedes-Benz
(46-710).
remove belt pulley of fan with washer,
Engine 104.98:
install.
p 13-5104-S7
1 MSX 90he)(39oo bol 6 MS X 35bol •t lih wasll&

3 MSX 100hexagonb<ll 16 M12X 110!lol
4 Exce¡¡leng:n&104.98· MBX 65bol+wasller
Engr~e104.98-M8X 67 ti colar bdl
Fig. 24: Identifying Tensioning Device Removellnstall Components - 1St Version With External Damper
(2 Of2)
Damper (10) oftensioning device at unbolt, bolt on (Zl Nm).

front cover
Bolt (16) unscrew, screw on (21 Nm).
unscrew, screw on (2 1 Nm).
Bolts (1), (3) and (4) NOTE:
Counter-hold at nut (2) with wrench.
Strut (12) with bolt (16) and washer remove, install.

(15) Note re engine 104.98
Annlv .<:P.::~lina r.nmnmmct 001 "lN ?Q ?.0 tn thP frnnt ::~nct rP::~r <:ioP.s
Mercedes-Benz
ofthe mounting hole (arrow) ofthe stmt (12).

Setting pointer (13), tensioning
remove, install.
device (14) and sleeve (17)
Bolts (11) unscrew, screw on (21 Nm).
Power steering pump (28) swivel to outside.
Bracket (19) with tensioning nut (5)
remove, install.
and tensioning bolt (18)
TIGHTENING TORQUES IN NM
Bolts ofbelt pulleys offan clutch 15
Bolts ofbelt pulley of coolant pump and power 32
steering pump
Bolt of tensioning device 75
Bolts of strut and bracket 21
Special tools
001 589 72 21 00
Fig. 25: Identifving Special Tools (001 589 72 21 00)
001 589 66 21 00
Fig. 26: Identifying Special Tools (001 589 66 21 00)
Preceding work:

Mercedes-Benz
13-1202, 13-400 1
2nd version witb interna) damper
P 13.25-0Z00-57
Fig. 27: ldentifying Tensioning Device Removellnstall Components- 2Nd Version Witb Internal Damper
Bolts (23) ofbelt pulley of coolant pump (24) slacken, tighten (32 Nm).
Poly V-belt (27) remove, install (13-1200).
Belt pulley of coolant pump (24) unbolt, bolt on.
Belt pulley of tensioning device (7) unbolt, bolt on (45 N m).
Tensioning device (14) unbolt, bolt on (25 Nm).
Special tools
Mercedes-Benz
001 5B9 72 21 00
Fig. 28: ldentifying Special Tools (001 589 72 21 00)
Nut of belt pulley of tens ioning device 45
Bolts oftensioning device 25
REMOVING AND INSTALLING BELT PULLEY OF TENSIONING DEVICE (2ND VERSION)-

RA13001043250X(13-3250)
Preceding work:
Viscous fan coupling removed (20-3120) .
2nd version with interna) damper as of September 1994

Mercedes-Benz
7a
o @
P13 15-0207- 57
Fig. 29: Identifying Belt Pulley Remove/Installing Components - 2Nd Version With Internal Damper
Poly V-belt (27) remove, install (13-1200).

Belt pulley of
tensioning device unbolt, bolt on (45 Nm)_
(7)
check it is tight
,,,
~
The different versions of the tensioning pulley (7) with 0 80 mm and 93 mm

BaH bearing in necessitate different lengtb ofpoly V-belt (13-1240)_
tensioning pulley ~
(7) ,,,,
If a 20 mm shorter poly V-belt is installed together with the smaller tensioning pulley
(7) (0 80 mm) when performing repairs, the belt length should be entered on the last
page ofthe Maintenance Booklet and the Owner's Manual arnended accordingly_
Mercedes-Benz
Nlchster
Service
10 000-
126001cm
oder
POO.00-0485-:>3
Fig. 30: ldentifying Service Label
SpeciaJ tool
001 5B9 72 21 00
Fig. 31: Identifving Special Tool (001 589 72 21 00)
INut ofbelt pulley oftensioning device 45
REMOVING AND INSTALLING GUIDE PULLEY- RA13001043460X(13-3460)
Removing and installing guide pulley - RA13001043460X{l3-3460)
Preceding work:
Models 124, 210: viscous fan clutch removed (20-3120}.
Model129: fan shroud ring removed (20-3400)
Model 140: fan shroud removed (20-3400) .

Mercedes-Benz
29Nm
o---~
2
Fi~. 32: Identifyin~ Guide Pulley Removellnstall Components
Poly V-belt (27) slacken, tension (13-1200).

Poly V -belt (27) at guide pulley (4) take off, fit on.
Cover (2) pull off, fit on.
Bolt (3) unscrew, screw on (29 Nm).
Guide pulley (4) at fan bearing bracket or at air pump/generator support take off, fit on.
Special tool
001 589 72 21 00
Removing and installing guide ¡mUey- RA13001203460X{13-3460)

Mercedes-Benz
Preceding work:
Poly V -belt removed (13-3420).
Operation no. of the operation texts and work units or standard texts and flat rates
Fig. 34: Identifying Guide PuUey Remove/Install Components
Poly-V belt (l) remove, install (13-3420).

Cover (2) pull off, attach.
Bolt (3) unscrew, screw in (29 Nm).
Guide pulley (4) pull off, attach.
Special tool
Mercedes-Benz
001 589 72. 21 00

00
Fig. 35: Identifying Special Tool (001 589 72 21 00 00)
REMOVING AND INSTALLING SHOCK ABSORBER OF TENSIONING DEVICE-

RA13001 044000X(13-4000)
Preceding work:
Operatíon no. of operatíon texts and work units or standard texts and flat rates:
13-4000
Engines with tensioning device with external damper

Mercedes-Benz
-:;® 17Nrn
P13-5105-57
6 Hex screw MS x 35 wíth washer
6a Hex screw M7 x 35 wíth washer
Fig. 36: ldentifving Shock Absorber Remove/lnstall Components
Bolts (23) at belt pulley (24) of coolant pump slacken, tighten (32 N m).
Poly V-belt (27) remove, instaU (13-1200).
Belt pulley (24) of coolant pump remove, install.
Shock absorber (1 O) unbolt, bolt on (M7 17 Nm), (M8 21 Nm).
Belt pulley of coolant pump M8 32
M8 bolt top of shock absorber 21
M7 bolt bottom of shock absorber 17
Special tool
Mercedes-Benz
~----0_01_5_8_9_7_2_21_0_0____~~
Fig. 37: ldentifying Special Tool (001 589 72 21 00)
REMOVING AND INSTALLING CARRIER OF AIR PUMP/GENERATOR, MODELS 202, 210-

RA13001044200X(13-4200)
Preceding work:
Generator removed (AR15.40-5032EA).
If secondary air ínjection fitted: A ir pump removed (AR14.30-7251D). Viscous fan coupling removed (20-
3120).
Mercedes-Benz
15N~
2 MS X 30hexagonsod\etboa• wasl'lor 5 MSX 80 bolt • washer

3 MSX 40hexagonsod<el bol+ washer 6 M8 rut
4 M8X 70he)(8!)011 sod<et bol+ washer
Fig. 38: Identifying Air Pump/Generator Remove/lnstall Components
1st version: belt pulley ofviscous fan (21) hold with colmter-holder (1) 103 589 00 40 OO.
2nd version: belt pulley hold with counter-holder (01) 120 589 02 01 OO.
Belt pulley of viscous fan (21) unbolt, bolt on (15Nm).
Carrier of air pump/generator (40) unbo1t, bolt on (21 N m).
REMOVING AND INSTALLING POLY V-BELT- RA13001193420X(13-3420)
Preceding work:
Open hood, raise to vertical position (01-0080) .
13-1 202-13-4001
1st version
Mercedes-Benz
A B
Meter 119.950
A Se~ng porltal (13)1o mllMng (1)"' pot¡V-be\lsleckened
8 seting ~-ointor ~ 13) ID mallan;¡ (2) =JX*IV-bel slackened
Fig. 39: Identifying Poly V-Belt Remove/InstaU Components- 1St Version
Mod!el124: fan shroud remove, instaU.

Mod!els 129, 140: fan
take off, place over fan, fit on.
shroud ring
Bolt (16) slacken about 1/4-1/2 turns.
T ensioning nut ( 5) slacken (turn to the left).
Poly V-belt take off.
exanúne for signs of damage and dirt, replace if necessary (e.g. worn bearing
Belt pulley surfaces
poínts oftensíoníng devíce, dents in belt pulleys etc.).
Setting poínter (13) turn to marking ( 1).
fit on, starting at tensioning pulley (1) (see 13-3440 for running diagrams).
Poly V-belt ~
Tensioning nut (12) tighten unril settíng pointer (13) is located between the markings (2).
Bolt (16) tighten (100 Nm).
Seat of belt on belt
examine.
pulleys
Mercedes-Benz
2nd and 3rd version
2rld versaon 3rdwrsion
Fig. 40: Identifying Poly V-Belt Removellnstall Components- 2Nd And 3Rd Version
Model 124: fan shroud remove, install.

Models 129, 140: fan shroud
take off, place over fan, fit on.
nng
2nd version: hexagon head (3)
swivel counter-clockwise with wrench (WAF 17).
on tensioning arm (2)
3rd version: Torx (ElO) in
swivel counter-clockwise.
tensioning pulley
Poly V-belt (11) take off.
examine for signs of damage and dirt, replace if necessary (e. g. wom
Belt pulley surfaces
bearing points oftensioning device, dents in belt pulleys etc.).
fít on (running diagt·ams see 13-3440).
Poly V-belt (11) ~
Seat of belt on belt pulleys examrne.
Special tool
Mercedes-Benz
(Tensíoníng devíce 1st versíon)
0()1 589 66 2'1 00

00
Fig. 41: ldentifving Special Too) (001 589 66 21 00 00)
SpeciaJ tool
(Tensioning device 3rd version)
00 1 .58Q 76 09 00
00
Fig. 42: ldentifving Special Tool (001 589 76 09 00 00)
Bolt (16) oftensioníng device (tensíoníng devíce 1st lOO
version)
EXAMINING POLY V-BELT, DAMAGE PATTERNS- RA13001193430X(13-3430)
Examining poly V-belt, damage patterns- RA13001193430X(13-3430)
Preceding work:
Hood raísed to vertical posítion (01-0080) .

Mercedes-Benz
Fig. 43: Locating Poly V-Belt, Damage Points
EXAMINING
Poly V-belt (11) mark with chalk ata clearly visible point (arrow).
Engine crank with starter in stages (01-0110) .
Examination ended once marking (arrow) is again visible (one full revolution ofbelt).
Damage patterns
The poly V-belt must be replaced (subject to separate repair order) ifthe following damage patterns are present:
• Rubber clumps in base ofbelt (C), dirt or grid embedded (D).
D D
Fig. 44: Identifying Damage Patterns
Wear
• Wear to flanks (F)

Mercedes-Benz
Ribs are pointed- trapezoidal in shape when new (E) and cord is visible ín base of belt (G, lighter points).
E F
Fig. 45: Locating Ribs Pointed
• Rib (arrow) detached from base ofbelt. Splitting across severa! ribs (H).
Fi~. 46: Locatin~ Ribs
• Splitting across ribs (H) and/or sections ofbelt broken off (J).
Mercedes-Benz
Fig. 47: Splitting Across Ribs
• Cord fractured at the side (K) or fraying (L) of outer cords.
Fig. 48: ldentifying Drive Belt Fraying Of Outer Cords
• Splitting across the back (M).
Fig. 49: ldentifying Splitting Across Back
Examining }loly V-belt, typical damage- RA13001203430X(13-3430)
Preceding work:
Hood raised to vertical position (01-0080) _
Right cover over high voltage distributor removed.
Mercedes-Benz
Fig. 50: Identifying Mark On Poly V-Belt
EXAMINING
Poly V-belt (12) mark with chalk ata clearly visible point (arrow).
Engine crank in stages with starter (01-0110) .
Procedure end once marking (arrow) is again visible (one full
belt revolution).
Damage patterns
• The poly V -belt must be replaced (subject to separate repair order) if the foUowing damage pattems are
found:
Rubber clumps in base of ribs (C), dirt or grid embedded (D).
D D
m~ -:~;;:tz_¿~ ;;:i
D e
Fig. 51: Identifying Poly V-Belt- Damage Patterns
• Wear to flank (F), ribs are pointed- trapezoidal in shape when new (E) and cord visible in base ofrib (G,
Mercedes-Benz
lighter points).
E F
Fig. 52: ldentifying Drive Belts OfLighter Points
• Rib (arrow) detached from base ofbelt. Splits (H) across several ribs.
Fig. 53: Identifying Drive Belts Of Across Severa] Ribs
• Splits in ribs (H) and/or sections broken out ofribs (J).

Mercedes-Benz
Fig. 54: ldentifying Drive Belts Brokeo Out Of Ribs
• Cord torn out at the side (K) or fraying (L) of outer cords.
Fig. 55: ldentifying Drive Belts Fraying Of Outer Cords
• Splits (M) across the back
Fig. 56: ldentifying Splits Across Back
POL Y V-BELTS, RUNNING DIAGRAMS, DIMENSIONS- RA13001193440X(13-3440)
Engine 119.960, model 129.066
Belt length 2523 mm 6 grooves

Mercedes-Benz
1 TenSlonng pc.aey
2 Cnd\shalt
3 ACc orrpressot
4 Botom gulde J)lt-ll'f
5 Fan
7 A~pul1ll
8 AI!Bmalor
1O Powor steenng punp
11 comantpunp
Fig. 57: Poly V-Belts, Running Diagrams- With Air Pump
Engine 119.960, model129.066
Running cliagram without air pump
1 TonSionng pUiey
2 Crlri\shaft
3 AC eorrpr essor
4 GuldeptC&y
5 Fan
8 Atemai:OI
9 Top gu;de pt.Oey

10 PCWBI steanng punp
11 Coolantpunp
Fig. 58: Poly V-Belts, Ruuning Diagrams - Without Air Pump
Engine 119.960, model129.066
Running cliagram without air pump with 2nd altemator
1 Tensionng pl.lley
2 crancshall
3 AC CO!'Ill'BSSOI
4 Gtudepwey
5 Fllll
7 A~pu1J1>
8 ACometer
8f2 2nd a.lem a:cr
10 PC'NBI steenng punp
11 Coolant¡rump
Fig. 59: Poly V-Belts, Ruuning Diagrams- Without Air Pump Witb 2Nd Alternator
Engine 119.970 Modell40.050/051
119.971 Model 140.042/043

Mercedes-Benz
119.974 Model124.036
119.975 Model l24.034
Running díagram wíth air pump
Belt lengtb 2460 1) mm 8 grooves
1 TenSionng ptJJey
2 Cr!fli(sllafi
3 AC compre ssor
4 8ol!om gudepu e·t
5 Fen
7 Alrpump
8 Alemal or
1O Powar sblamg purrp
11 Coolartpurrp
1 ) Bei¡Meys<ia 88.5mm, ~toOS/1001
Be!tpti!ays<ia 104 rrm, as<lf 00f1991.
Bllll&ng!h 24 65 rrm
Fig. 60: Poly V -Belts, Running Diagrams - With Air P ump
Engine 119.970 Model l40.050/05 1
119.971 Modell40.042/043
119.974 Model l24.036
119.975 Modell24.034
Running diagram without air pump
1 Tensaorang pu'Jey
2 Cral11<shaft
3 AC<OIT'4JHissor
4 Bottom gutcie ptJJey
5 Fa:n
8 Atsmator
9 Tc-p gude pu'!ey
1O P<Jwer Sleenng pump
11 Coola.nt pump
Fig. 61: Poly V-Belts, Running Diagrams - Without Air Pump

Mercedes-Benz
Engine 119.970 Modell40.050/051/070
119.971 Model140.042/043/063
119.972 Modell29.067
119.974 Modell24.036
119.975 Model124.034
11
1 Tonsaoong pt.GB'{
2 Cnrtshaft
3 AC COOllfi! Ss.or
5 Foo
1 A• ptJf1'1l
B 120 A alemator
10 Powe~ steenng pu-np
11 Coolootpunp
Fig. 62: Poly V-Belts, Running Diagrams- With Air Pump
Engine 119.970 Model140.050/051
119.971 Model140.042/043
Running diagram without air pump with 2nd alternator
1 Tengonng ptl!ey
2 Cfari<shaft
3 AC eOllllf&S501
4 Botom ~ldii ptCey
5 Fan
8 Afomat()(
8tl 2lld alem alor
10 Power stoenng puno .... M?2-1S
11 Coolat~t punp
Mercedes-Benz
Fig. 63: Poly V-Belts, Running Diagrams- Without Air Pump With 2Nd Alternator
Engine 119.980 Model140.050/051/070
119.981 Model 140.042/043/063
119.982 Model129.067
119.985 Model210.072/272
Belt length without A/C compressor 2425 mm 6 grooves
Belt length with A/C compressor 251 Omm 6 grooves
1 TenSIMngpu!ey
2 CUIIilsha#t
3 AfC oomp!"es sor
5 Fan
8 Gonorelor
9 Top gude pt&y P13.2()1.(12:26-13

10 Power steanng punp
11 Coolant punp
Fig. 64: Poly V-Belts, Running Diagrams- Without A/C Compressor
REMOVING AND INSTALLING TENSIONING DEVICE- RA130011934SOX(13-3450)
Removing and installing tensioning device- RA13001193450X(13-3450)
Preceding work:
Poly V-belt removed (13-3420).
13-1202-4001
1st version
Mercedes-Benz
Fig. 65: Identifying Tensioning Device Remove/Install Components
IT ensioning device remove, instaD (100 Nm) (steps 1 to 3).
Fastening bolt oftensioning device 100
Bolt of tensioning pulley to bracket (M8X40) 30
l. Remove poly V-belt {13-3420).

2. Unscrew bolt (16).
Tightening torque 100 Nm.

Mercedes-Benz
Fig. 66: Locating Poly V-Belt Bolts
Iostallation iostruction
The setting pointer must be aligned with that ofthe first marking (1) in the untensioned condition.
13.----..
Fi~. 67: Identifyin~ First Markin~ In Untensioned Condition
3. Remove tensioning nut (12) together with tensioning bolt (8) from bracket (10) at the power steering
pump.
Installatíon is performed in the reverse order.

Mercedes-Benz
Fig. 68: Locating Poly V-Belt Bolts
Preceding work:
Poly V -belt removed (13-3420).
13-3200
2nd and 3rd version

Mercedes-Benz
A 2nd vooioo 11 M8lc30 haxa'Q1lO sockmlxll+washer

B 3CdV8f51011 12 M8l<30 haxagon sock&i bol+washer
Fig. 69: Identifying Teusioning Device Components - 2Nd And 3Rd Version
End cover ( 6) take off, fit on.

2nd version: bolt (5) unscrew, screw on (25 Nm).
3rd version: nut (5a) unscrew, screw on (25 Nrn).
Tensioning pulley (3) rernove, install.
Bolts (11) and (12) unscrew, screw on (21 Nrn).
Tensioning device (1) with sleeve (2) rernove, instail.
Bolts of tensioning pulley 25
Bolts of tensioning device 21
Special tool
Mercedes-Benz
/
oot 589 n 21 oo
00
Removing and installing tensioning device- RA13001203450X(13-3450)
Preceding work:
Víscous fan clutch removed (20-3120).
Operatíon no. of the operatíon texts and work units or standard texts and flat rates
13-3200
Mercedes-Benz
Bolts in pulley (lO) for power steering pump (4) Joosen, tighten (46-71 0).
Poly-V belt (5) remove, install (13-3420).
Pulley (1) oftensioning device (3) remove, install.
INSTALLATION NOTE
Bolt (la) tighten to 38 Nm with torque wrench 001 589 72 21
OO.
Pulley (10) for power steering pump (4) remove, install (46-71 0).
Bolts (2) M8 X 60 and bolts (7) M8 X 11 O unscrew, screw in (21 Nm).
Power steering pump (4) press outward in direction of arrow.
Tensioning device (3) remove toward front, instaU.
INSPECTING TENSIONING DEVICE (1ST VERSION)- RA13001193452X(13-3452)
Preceding work:
Tensioning device removed {13-3450).
o·
0 13-5131-57
Fig. 72: Tensioning Device Diagram (1St Version)

Mercedes-Benz
(1) fix in place at flats (arrow) (eg. vice).

tum about 30° to both sides.
T ensioning device
NOTE:
(1)
The tensioning device (1) must move back into its initial position after being
turned.
TECHNICAL MODIFICATIONS ENGINE 120 MECHANICAL ll - RA1300120TAOOX
13 BeJt drive
Designation Nature and reason for modification Production breakpoints Op. no.
Poly V-belt Conversion from 8-groove to 6-groove poly V-belt 04.95
Mercedes-Benz
1990-2002 ENGINE Air lntake, Turbo Charging - 129 Chassis
1990-2002 ENGINE
Air lntake, Turbo Charging -129 Chassis
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: AIR INTAKE, SUPERCHARGING- AR09.00-
Z-9104AB
ENGINE 104
Removing and ENGINE 104.941 /942 /943 /944 /991 /992 /994 AR09.10-P-
installing air ENGINE 104 in MODEL 202.028, 210.055 1050D
cleaner
Removing and ENGINE 104.941 /942 /943 /944 /991 /992 /994, AR09.10-P-
installing air 111.920 /921 /940 /941 /945 /946 /960 /961 /974 /977 8031G
cleaner cross
pipe
Removing and ENGINES 104.941 /942 /943 /944 /991 /992 /994 AR09.10-P-
installing intake 8221D
air scoop
Removing and ENGINES 104.94/99 (except 104.990) AR09.20-P-
installing intake 1310D
manifold
Removing and ENGINES 104.94/99 (except 104.990) AR09.20-P-
installing 1791D
resonance flap
Z-9113AB
ENGINE 113
Removing/installing air ENGINE 113 ___ AR09.10-P-1150AC

cleaner housing
Remove/install air cleaner ENGINE 113.964 in MODEL AR09.10-P-1150GZ
housing 164.175
Remove/install air filter ENGINE 113.971 in MODEL AR09.10-P-1150RT
housing 251.075 /175
Remove/install air filter ENGINE 112, 113 __ _ AR09.10-P-
housing 1150SVK
Remove/install air cleaner ENGINE 113.967 in MODEL AR09.10-P-1150TY
housing 219.375
Removinglinstalling the air ENGINE 113.990 in MODEL AR09.10-P-1150TZ
cleaner housing 219.376
Mercedes-Benz
1990-2002 ENGINE Air lntake, Turbo Charging- 129 Chassis
Remove/install intake ENGINE 112, 113 ... AR09.20-P-1310A

manifold
Remove/install intake ENGINE 113.964 in MODEL AR09.20-P-1310GZ
manifold 164. 175
Remove/install intake ENGINE 113.971 in MODELS AR09.20-P-1310RT
manifold 251.075 /175
Remove/install intake ENGINE 113.967 in MODEL AR09.20-P-1310TY
manifold 219.375
Remove/install top charge ENGINE 112, 113 ... AR09.41-P-
air distributor 1320SVK
Removing/installing the top ENGINE 113.990 in MODEL AR09.41-P-1320TZ
charge air distributor 219.376
Remove/install charge air ENGINE 113.990 in MODEL AR09.41-P-
cooler 211.076 /276 6817RVK
ENGINE 113.991 in MODEL
215.374, 220.074
Remove/install charge air ENGINE 112, 113 ... AR09.41-P-
cooler 68 17SVK
Removing/installing the ENGINE 113.990 in MODEL AR09.41 -P-6817TZ
charge air cooler 219.376
Remove/installlow ENGINE 113 ... AR09.41-P-
temperature radiator 6831RVK
Removing/installlng the low ENGTNE 11 3.990 in MODEL AR09.41-P-6831 TZ
temperature radiator 219.376
Remove/install charge air ENGINE 112, 113 ... AR09.41 -P-
cooler circulation pump 6832SVK
Removing and installing the ENGINE 113.990 in MODEL AR09.41 -P-6925TX
circulation pump for the 219.376
low temperature water
circuit
Remove compressor, install ENGINE 112, 113 .. . AR09.50-P-
4705SVK
Remove/instaU compressor ENGINE 113.990 in MODEL AR09.50-P-4705TZ
219.376
Remove and install ENGINE AR09.50-P-4786R
electromagnetic clutch 113.990 /991 /992 /995
compressor
Remove/instaH compressor ENGINES 112.960/961, AR09.50-P-4787R
belt pulley 113. 990 /991 /992 /995
Removelinstall recirculated ENGINE 113 .. . AR09.50-P-8843T
air flap actuator
Z-9119AB
Mercedes-Benz
1990-2002 ENGINE Air lntake , Turbo Charging- 129 Chassis
ENGINE 119
Remove/Install air filter ENGINE 119.97 /981 /982 AR09.10-P-1050E

ENGINE 119 inMODEL
210 with CODE (957a)
AMG engineering package
Removing and installing ENGINE 11 9.97 in MODEL AR09.1 O-P-8221EA
intake scoop 124.034/036
Removing and installing ENGINE 119.97 in MODEL AR09.10-P-8221EB
intake scoop 129
Removing and installing ENGINE 119.97/98, 120.98 AR09.10-P-822 1FB
intake scoop inMODEL 140
Removing and installing ENGINE 119.97 AR09.20-P-1310E
intake manifold
Removing and installing ENGINE 119.981 /982 /985 AR09.20-P-1310EA
intake manifold ENGINE 11 9 in MODEL
129, 21 0 with CODE (957a)
AMG technical package
TESTING AND REP AIR WORK: PASSENGER CARS: AIR INTAKE, SUPERCHARGING- AR09.00-
Z-9120AB
ENGINE 120
Removing and installing air cleaner ENGINE 120.98 AR09.10-P-1050F

AR09.10-P-
Removing and installing intake scoop ENGINE 120.98l/983 in MODEL 129
8221FA
ENGINE 119.97/98, 120.98 in MODEL
Removing and installing intake scoop AR09.10-P-8221FB
140
Removing and installing intake
ENGINE 120.980/981 AR09.20-P-1310F
manifold
Removing and installing intake AR09.20-P-
ENGINE 120.982/983
manifold 1310FA
REMOVING AND INSTALL ING AIR CLEANER- AR09.10-P-1050
Removing and installing air cleaner- AR09.10-P-1050D
ENGINE 104.941 /942/943 /944 /991 /992 /994
ENGINE 104 in MODEL 202.028, 210.055

Mercedes-Benz
e ModoJ 123
D ModtJ 140
411 O·rfnll
@
Arrow Rubl>cr mount
Fig. 1: ldentifying Air Cleaner Components
Cyclone separator (models 124, 140 only)
Fig. 2: ldentifying CvcJone Separator
Fig. item, etc. Work instructions

DJ Cyclone separator M odeis 124, 140
When retrofitting, replace
complete air cleaner.
Model129
Retrofitting not possible.
Air cleaner element is
provided with ftlter felt or
foam.
4/ 1 0-ring 1JJ lnstalling:
check, replace if
necessary. Oil for
Mercedes-Benz
1990-2002 ENGINE Air lntake , Turbo Charging - 129 Chassis
installing.
Anows Pins of air cleaner [[] Installing:
press into rubber mount
(arrow).
DJ Air cleaner housing Model202.028, 210.055 GF09.10-P-0001-02A
verswn code 957a, C 36, E 36
AMG
Removing!lnstalling Air Filter - AR09.10-P-1050E
ENGINE 119.97/981/982
ENGINE 119 in MODEL 210 with CODE (957a) AMG engineering package
Shown on engine 119.97
F ig. 3: ldentifying Air Filter (Shown On Engine 119.97)
Model210 E 50 AMG with holding-down clamp

Mercedes-Benz
P H.l S-ll205· D1
Fig. 4: ldentifying Air Filter (Model 210 E 50 AMG With Holding-Down Clamp)
n:.:!irGF ~ Removing, installing

1 Releas e trim panel ( 1) by
liftíng up
2 Detach air intake hoses
(2) on both sides at air
cleaner
Model210 E 50 AMG GF09.1 0-P-000 1-0 lA
3 Unscrew holding-clown Model 210 E 50 AMG
clamp (arrow)
4 Raise air cleaner (4) at ITJ Installation: ensure
front, release from the the mbber seal (7)
fixture and pull out to the between air cleaner and
front hot wire mass air flow
sensor ts m proper
condítion and correctly
installed. Replace rubber
seal (7), if necessary.
5 Install in the reverse
order
Removing and installing air cleaner- AR09.10-P-1050F
ENGINE 120.98
Sbown on engine 120.980/81 in model 140, air cleaner positioned on left of engine
Mercedes-Benz
4 AJr cla~ner
10 lnt•~c • Ir scoop
53 Sh;¡potf hoso
Sol Hoso clip
&tJ l.otr mos.s •Ir flolll sensor Wflll hOf
wlro, lo~•teff on ri(lht of on(lfne
8114 Rllllll m•s.s olr tfow sensor wlf/1 hol
Wlro. locotod on lofr of ongl no
81 716 Rl¡¡ 111/IOf Wfrc l ntallo ~~
tomper•turo sensor. loe •ID<f on Ioft
ofen¡¡lnc
~.
Fig. 5: ldentifying Air Cleaner Remove/Install Components
Fig. item, Work instructions

etc.
Detach from intake air scoop (10), pull out
to the rear.
Air cleaner together with hot wire or hot film
4 Model129 with engine 120 LH-SFI
mass air flow sensor B2/3 and B2/4
Pull off bracket of purge control valve at air
cleaner for right bank of cylinders
Bl7/6 Intake air temperature sensor connector Unplug
REMOVING AND INSTALLING AIR CLEANER CROSS PIPE - AR09.10-P-8031G
ENGINE 104.941 /942 /943 /944 /991 /992 /994, 111.920 /921 /940 /941 /945 /946 /960 /961 /974 /977
4/S Afr Cfo•notc tou pipe

817 Jnt>l<o illrln-cor lomporillurc
sensor
AffOWS RIIUfnln(l cips
Fig. 6: ldentifying Air Cleaner Cross Pipe And Intake Air In-Car Temperature Sensor
Mercedes-Benz
Fig. 7: ldentifying Air Cleaner Cross Pipe Retaining Clips
Fig. Work
item, instructions
etc.
Intake aír ín-car
Remove complete with coupling, install. OJ To do this, compress
Bl7 temperature
retainíng clíps (arrows).
sensor
Arrows Shaped hose Pay attention to correct ínstalled positíon
rrt off upwards.
Installing : Press the pins (arrows) of the air cleaner cross pipe
Air cleaner cross into the rubber mounts of the valve cover as far as the stop. The
4/5
p1pe ¡pins are hollow and run directly ínto the cross pipe. The hollow
pins actas an engine breather and at the same time as a means of
fixing the cross pipe.
Air cleaner cross GF09.10-P-
OJ pipe version
Model202.028, 210.055 code 957a C 36, E36 AMG
0001-03A
REMOVING AND INSTALLING INTAKE SCOOP- AR09.10-P-8221
Removing and installing intake air scoop - AR09.10-P-8221D
ENGINES 104.941/942/943/944/991/992/994
Model124, 1st version
4/4 Jnt•l<o • Ir scoop
Fig. 8: ldentifying Intake Air Scoop - Model124, 1St Version

Mercedes-Benz
Model124, 2nd version
414 lnta~c at scoop

4121 Splilsh gu•rd
Fig. 9: ldentifying Intake Air Scoop - Model124, 2nd Version
Model129
Fig. 10: ldentifying Intake Air Scoop- Model129
Model140
414 /nr•l<c •Ir scoop
Fig. 11: ldentifving Intake Air Scoop- Model140
Model202
Mercedes-Benz
4/4 lnt•ll• •Ir scoop
Fig. 12: ldentifying Intake Air Scoop - Model 202
Fig. ítem, Work instructions

etc.
Remove right headJamp unit, Model 124, 2nd version
DJ install See Rl Electrical System III Model124, Op. no. 82-4730
Model202
ITJ Remove radiator trim, install See Rl Body Removal and Installation II Model 202, Op.
no. 88-4000
4/22 Splash guard pay attent:iion to installed position
4/4 Inta.ke air scoop remove
Removing and installing intake scoop- AR09.10-P-8221EB
ENGINE 119.97
inMODEL 129
Left intake scoop illustrated
fQ lnt oKe seoop

81712 lntoAo d: ra mpar.>turo sensor
Atrows Exp•ndlng cfps
Mercedes-Benz
Fig. 13: Identifying Intake Scoop Remove/Install Components

Bl7/2 Coupling of intake air temperature sensor detach at left intake scoop
Arrows Expanding clips remove
Removing and installing intake scoop- AR09.10-P-8221FA
ENGINE 120.981/983
inMODEL129
Left intake scoop illustrated
10 lnr•lta oirscoop
10!1 Exp;ondlng clip
11 covcr
1111 ExpJndlng ~rfp
fCIL1~01
Fig.14: Identifying Intake Scoop Remove/Install Components

10 Intake air scoop Pull out expanding clip (10/ 1)
12 Cover Pull out expanding clip ( 12/ 1)
REMOVING AND INSTALLING INTAKE MANIFOLD- AR09.20-P-1310
Remove/install intake manifold - AR09.20-P-1310A
ENGINE 112.910 in MODEL 202.026/086
ENGINE 112.920 in MODEL 202.029/089
ENGINE 112.921 in MODEL 210.063/081 /263 /281
ENGINE 112.922 in MODEL 220.063/163
ENGINE 112.923 in MODEL 129.059
ENGINE 112.940 in MODEL 208.365/465
ENGINE 112.941 in MODEL 210.065/082/265/282

Mercedes-Benz
ENGINE 112.944 in MODEL 220.065/165
ENGINE 113.940 in MODEL 210.070/270
ENGINE 113.941 in MODEL 220.070/170
ENGINE 113.960 in MODEL 215.375,220.075/175
ENGINE 113.944 in MODEL 202.033/093
ENGINE 113.980 in MODEL 210.074/274
ENGINE 113.943 in MODEL 208.370/470
ENGINE 112.912 in MODEL 203.061/261, 209.361 /461
ENGINE 112.946 in MODEL 203.064/264
ENGINE 113.968 in MODEL 209.375/475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.987 in MODEL 209.376/476
ENGINE 112.955 in MODEL 209.365/465

Mercedes-Benz
ENGINE 112.916 in MODEL 203.081/281
ENGINE 112.953 in MODEL 203.084/284
ENGINE 112.972 in MODEL 220.067/167
ENGINE 112.975 in MODEL 220.087/187
ENGINE 113.948 in MODEL 220.083/183
ENGINE 113.966 in MODEL 220.084/184
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
ENGINE 113.988 in MODEL 203.076/276
Shown on engine 112
211 Cyfnderheadcovorbolt
6 Combfnarion v •tve
17/ 2 Feed llne
19 lnlalctn>MiffOid
11lf1 Bo/1
1!lf3 $ül
89 Exhaus:t gas recJrc:utation valve
IJfJ/2 Una
Arrow: Hole forcombinatfon v.arve
Mercedes-Benz
Fig. 15: Identifying Intake Manifold Components- Shown On Engine 112
2 Cr""l<c•u vonti'lolian ho..,

8912 lJne
1'09202137<11 1
Fig. 16: ldentifying Crankcase Ventilation Hose And Line
o::::rGF
~ .. Remove/install
o::::rGF Risk of No frre, sparks, open flames or smoking. AS47.0C
explosion Only pour fuels into suitable and appropriately marked containers. Z-0001-
caused by fuel Wear protective clothing when handling fuel. OlA
ignitíng, risk
of poisoning
caused by
inhaling and
swallowing
fuel and risk of
injury to eyes
and skin caused
by contact with
fuel
1 Remove key Only on vehicles with electronic ignition switch.
from electronic ITJ Vehicles with Keyless Go code 889: Switch off engine, remove Keyless
ignition switch Go-Cards out of vehicle and store outside of the sender range.
2 Remove cover Model129, 211, 215, 220, 230 only
on front side of
engme
3.1 Remove engine Except model 171.473, 203.076/276,, 209.376 /476 from 24.4.04
cover with DJ The air ftlter is integrated in the engine cover. Remove engine cover or air
integrated air filter by pulling it vertically up and off the cylinder head covers.
filter
3.2 Remove air Model 171.473 AR09.1<
filter housing Model203.076/ 276 P- l l50P
Model209.376/ 476 as of24.4.04
4 Remove hot Engine 112.910/920/ 921/940/941/942/ 970 AR07.0'
film mass air Engine 113.940 P- l 454P
flow sensor
with air intake
ptpe
Mercedes-Benz
Engine 112.922 /944 /972 /973 /975 AR07.0'

Engine 113.941/ 948/ 960/ 961 / 963/ 966 P-1454)
Engine 112.912 /913 /916 /917 /946 /947 /949 /954 /953 /955 AR07.0'
Engine 113.968 /967 /969 /987 /988 /989 P-I454S
Engine 112.923 /943 AR07.0'
Engine 113.943 /944 /980 /984 P-1454)
Engine 113.942 /965/981 AR07.0'
P-
1454M\
5 Disconnect DJ Release fue] pressure vía service valve and collect fuel.
lead line ( 17/2)
at the fuel
distributor
@ *BA07.!
P-1001-
!!M
DJ Fig.17
6 Removing fuel Engine 112.910 /920 /921 /923 /940 /941 /942 /943 /970 AR07.0:
raíl with Engine 113.940 /942 /943 /944 /961 /965 /980 /981 /984 P-145V
injection valves
Engine AR07.o:
112.912/913 /916 /917 /922 /944 /946 /947 /949 /953 /954 /955 /972 /973 /975 P-1451 P
Engine 113.941 /948 /960 /963 /966 /967 /968 /969 /987 /988 /989
7.1 Unscrew Model 230.475 only
cylinder head
cover (2/1) bolt
@ *BAOI.:
P-1001-
OlE
7.2 Remove Model 171.473 only
crankshaft DJ Remove cylinder head cover (2/l) bolt in order to detach exhaust gas
ventilation recirculation valve (89) bracket.
hose (2) and
line (89/2) and
place to one
side
@ *BAOl .~
P-1001-
OlE
8 Disconnect DJ Installation: Observe intake manifold connection diagram. ?
vacuum lines
from intake
pipe (19)
Engine 112 except 112.913 /917 /949 /954 AR09.2<
P-1310-
Mercedes-Benz
OlA
Engine 112.913/917 /949 /954 AR09.2<
P-1310-
OlT
Engine 112 with USA version, code 494, except engine AR09.2<
112.913 /916 /917 /949 /953 /954 /975 P-1310-
Engine 112.913/916 /917 /949 /953 /954 /975 with USA version, code 494 OlAA
Engine 113 except 113.967 /969 AR09.21
P-1310-
OlA U
Engine 113.967/969 AR09.2<
P-1310-
OlTA
Engine 113 with USA version, code 494, except engine AR09.21
113.948 /963 /966 /984 /967 /969 /989 /988 P-1310-
Engine 113.948 /963 /966 /984 /967 /969 /988 /989 with USA version, code OlAC
494
9 Disconnect
electrical
connectors
10 Unscrew acorn [TI Counterhold connection fitting when unscrewing.
nut from pipe
(89/2) to
exhaust gas
recirculation
valve (89)
® *BA14.:
P-1002-
OIB
11 Unscrew screw Except engine 113.987 as of24.04.04,
(19/ 1) Engine 113.988/989
® *BA 09.:
P-1001-
OID
11.2 Remove bolts Only with engine 113.987 as of24.04.04
from right Engine 113.988/989
combination
val ve ( 6) and
left
combination
valve (6)
® *BA09.:
P-1001-
OlD
12.1 Remove Except engine 113.987 as of 24.04.04
combination Engine 113.988/989
Mercedes-Benz
valve (6) ITJ lnstallation: Install new gasket

12.2 Loosen right Only engine 113.987 from 24.04.04
combination Engine 113 .988/989
valve ( 6) and ITJ InstaUation: Replace the gaskets.
left
combination
val ve ( 6) and
place to one
side
13 Dismount ITJ Plug intake ducts. Use centering bolt for exact positioning of intake
intake manifold manifold and for centering the gasket (19/3).
(19)
@ *BA09.;
P-1001-
w
ITJ Fig.18
14 Replace gasket
(19/3)
15 Install in the
reverse order
®eran kcase ven tila tion, cy1m

r d er h ead cover
Number Designation Engine
113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/9811
BA01.20- Cylinder 10
P-1001- headcover
OlE boltNm
®Fue) distributor
Engine 112 except
Number Designation 112.945/951/960/961
BA07.52-P-100 1-0 l A Fuel feed line to fuel N m 38
distributor
@Fu el distributor
N umber IDesignation Engine113.987 Engine113 .940/941/942/943/944/945/946/948/960/9611962/9
BA07.52- Fuel feed N m 38 38
P-1001- line to
Ol A fu el
distributor
® Intake manifold
Number Designation Engine112,113
BA09.20-P-1001- IBolt, intake M8 Nml20
Mercedes-Benz
'manifold to
cylinder head
®Exhaus t gas recrrcu 1a tion

112.910/912/916/920/921/922/923/940/941/942/943/944/945/946/947 /953/~
BA14.20- Union nut, N m 40
P-1 002- exhaust gas
OlB recirculation
pipe to
exhaust gas
recirculation
valve
x aust gas rec1rcu1ation

.
Number Designation Engine113.989
BA14.20-P-1002-0lB Union nut, exhaust gas N m 40
recirculation pípe to
exhaust gas recirculation
valve
119~046300
F ig. 17: ldentifving Pressure Hose (119 589 04 63 00)
112~026200
Fig. 18: Identifving Set OfDowel Bolts (112 589 02 62 00)
Intake manüold connection diagram- AR09.20-P-1310-01AC
Shown on engine 113 with USA version code 494a

Mercedes-Benz
312 Vaeuum control unlt conuol flap

lntake manifold
Jl3 Control rt~ $wllchovet valve
{lntak.e menlfo/<1)
3.11 Checkv.alve
6 A Ir ln}eel.ion conJIJinalion vatve
1!1 lntako millllold
89 Exhausr gu ll! ckculltlon va/Ve
8215 Hot film mass a/r flow sensor
828 Press a-e un sor
M151S Thtottle valveactuator
M33 /IIRpiJiflp
Y32 Alr pump .owftt:hovor valve
YW1 Pur~ control va/Ve
ro.uo 2003 oe
Fig. 19: Intake Manifold Connection Diagram - Shown On Engine 113 With USA Version Code 494a
Intake manifold connection diagram- AR09.20-P-1310-0IAU
Shown on engine 113
J/1' SecondM)Ivacuum COn.$1Jnwtr

conneetf<W'I
Y.l Vacuun control 11nit cofi(To/ ftap
lntakt nliltlifold
Jl3 Control f/~ swftchover valve
(In talco menlfold)
~ Chock va/ve
6 Alr inj&etion combln.atJ'on va/ve
19 lnWte llWiifold
89 Exllausl gas II!Ci'euta!lon vaAie
82115 Hot film mass a/r ffow sensor
M16/6 ThtOttle valveactuator
AW A~Ftpump
1'32 Air pump awltchovor va/ve
YSB/1 Purga control va /ve
1'0!1.20 200<.06
Fig. 20: Intake Manifold Connection Diagram - Shown On Engine 113
Removing and installing intake manifold- AR09.20-P-1310D
ENGINES 104.94/99 (except 104.990)

Mercedes-Benz
1il3 Gulct
1i15 Rul>l>or l>ools
Fig. 21: Identifying lntake Manifold Components (1 Of 2)
~GF~ Removing, installing

1 Remove fuel rail together AR07.03-P-1450D
with injection valves,
install
2 Pull off all vacuum pipes DJ lnstalling:
and electrical wiring Connect vacuum pipes as
stated in connecting
diagram?
Modell24, 129 AR09.20-P-1310-01DA
Modell40 AR09 .20-P-131 O-O IDB
Model202 AR09 .20-P-1310-0 lDC
Model210 AR09.20-P-131 0-0 IDE
3 Remove bolts for intake Model210 AR09.20-P-l310-09DA
noise muffler
4 Take offresonance intake Replace resonance intake
manifold, clean flange manifold, if necessary ?
surfaces
T o do this, remove AR09.20-P-1791D
resonance flap and install
in new resonance intake
manifold
@ ITJ Installing: *BA09.20-P-1001-01B
Replace gasket (19/3).
Check mbber boots
(19/6), replace if
necessary.
Mercedes-Benz
5 Remove ram manifold AR09.20-P-1310-02DA

¡g¡.. Intake manifold with BT09.20-P-0003-01A
mount for intake noise
muffler
6 Install in reverse Lt. When ínstallíng,
sequence ensure that no vacuum
pipes or electrical wiring
is trapped.
7 Check idle speed, adjust See DM Engine, Volume
1
@ Intake manifold
Number Designation Engine 104
BA09.20-P-l 001 -0 lB BoEts and nuts of intake N m 25
manifold on cylinder
head
Connecting diagram ofintake manüold - AR09.20-P-1310-01DA
Connecting diagram of vacuum supply HFM-SFI modell24, 129
40 0Rpnrilflm p rcSSllro rcgtll~tor
50 IAodut~t!ng pressure v~euum unlt

19 Bxh• u>t g.u roclrcul.tion Vil lile
(@(!>@)onl)'1
91 v~cuum cicment for upshíftdc l•y Y4
100 V.xuum cicmcnr s •nd E modo
125 A Ir pump
115 A Ir snur-o tr •~Aro •
127 Chet:/IC v~rvo (ln}or:tcd .atr)
121 Check Vilfvo (\f.xuum)
135 Chocl< Yillvo (\f«uum supply)
136 V iJr:uum tfJSGtvoir
rne.-e Jdle spccd control (ISC) •ctu~ror
mt4 Hat fMm engfno mm•¡¡omcnr

(HFbf..SF/) cont rol module
$1515 Tr;uumlsslon modc swlreh
(2nd modo)
YVJ Upshlft do i.>y sw/te.ho ver vdte
Y4 Swltellovcr Villvo (2nd rronsmlsslon
mode}
Yzve Rcson~nco lntlll<c m•nltil /chwlknOVotV~IVo Y5111 Pu rgo COI!!I'OIII•Afo

Yl7 EXII•usr ¡¡u roclrculorion (EGR) swlrenovor v•Afe • ro ->eliiiMcdch•rco•lc~nlrro r
(@(!>@onl~
Y12 Alr lnjoction pump swlknovcr v• lll•
Y.U EleciTomii(Jnotfc olr lnjoctlonpump clutrl!
Fig. 22: Connecting Diagram Of Vacuum Supply BFM-SFI
Rem<Jving and installing ram manifold- AR09.20-P-1310-02DA

Mercedes-Benz
¡g¡' lntake manifold with BT09.20-P-0003-01A

mount for intake noise
muffler
1213 SrOK:Kcf ot oonrrollcvcr
Fig. 23: ldentifving Bracket Of Control Lever
Prerequisite: resonance intake manifold removed
l_ Remove control cable frorn bracket of throttle controllever (32/3)_

2. Take offram manifold.
a_ Models with oil-to-water heat exchanger: unscrew bolt at the resonance intake manifold from the
pipe fixture with spacer sleeve.
b. Models witb oil cooler: unscrew bolt from the oil pipe fixture.
NOTE: Replace ram manifold, if necessary. Todo this, remove all the parts
attached to the ram manifold and fit onto new ram manifold. Replace
C.
gaskets.
3_ Install in re verse sequence.
ITl When installing, ensure that no vacuum pipes or electrical wiring is trapped.
Removing and installing intake manifold- AR09.20-P-1310E
ENGINE 119.97
Mercedes-Benz
Fig. 24: ldentifving Intake Manüold Remove/lnstall Components
~GF
~'
AR09.10-P-
1 Remove air cleaner, install
lOSOE
2 Partially drain coolant
Unplug all the plug connections of the
cables which run across the intake
3
manifold or of the electrical
components at the intake manifold
4 Unclip guide rail for ignition cables
Detach vacuum lines of the
5 components located at the intake
mPay attention to color coding of vacuum
hoses
manifold
AR09.20-P-
Connection diagram of intake manifold
1310-01E
Pay attention to accident prevention
121 Risk of explosion
regulations!
Release fuel pressure through service See Diagnosis Manual Engine, Volume 2,
6
valve at the fuel raíl Index 3.1
ITJ Fig. 25
m Fig.17
Unbolt fuel feed line ( 17/3) and return
7
flow line (17/2)
ITI Collect fuel
8 Disconnect vacuum line for brake unit m Fig. 27
ITJ Removal : pull plastic nipple out of
rruicle ni ece.
Mercedes-Benz
IJ:S='AP Do not damage guide piece.

9 Remove guide piece (27) GJ lnstallation : ensure that the plastic
nipple engages properly in the guide píece.
Detach Bowden cable (30) at throttle
10
controllever (9)
11
Pull Bowden cable (30) out of fix GJ Removal : press together plastic clip
lever (10) (28)
Detach control pressure Bowden cable
12.1 AT
(98)
Separate plug connection of electronic IJ:S='AP Ensure the electric cable of the
13 accelerator actuator (M 16/ 1x 1) and electronic accelerator actuator is correctly
detach cable routed:?
AR30.20-P-
Model124.036 up to 06/93
1262-0IA
AR30.20-P-
Model 124.034
1262-0lB
[g]' BT30.20-P-
Model 124.036 as of07/93
0001-0lA
Disconnect coolant hose (33) at front
1.4
of intake manifold
Disconnect coolant hose at rear of
15
intake manifold
DJ Pay attention to different lengths of
Unscrew bolts (14, 15, 16) bolts and different spacers (13). Oil bolt
16
threads with assembly oil. Tighten bolts
according to tightening diagram: ?
Tightening diagram of intake manifold AR09.20-P-
attachment 1310-03E
@ *BA09.20-P-
1001-01C
DJ When installing, ensure that no vacuum
lines and electric cables are jammed in
17 Take off intake manifold ( 19)
between and that the intake manifold
engages in the dowel pins.
18
Use straightedge to inspect flange A oanqerl lf necessary, process on dressing
surfaces plate, or:?
AR09.20-P-
replace íntake manifold
1310-04E
19 Replace gaskets (18)
AR30.10-P-
21 Adjust throttle control With ASR code 47la
lOlOEA
AR30.10-P-
Without ASR code 471 a
lOlOEB
Mercedes-Benz
IInspect idle speed, set lsee Diagnosis Manual Engine Volume 1
@ INTAKE MANIFOLD
119
BA09.20-P-1001-
Bolt of intake manifold to cylinder head Nm 28
OI C
BA09.20-P-1003- Bolt oftop part of intake manifold to bottom part of intake
Nm 25
Ol C manifold
Fig. 25: ldentifving Tester (103 589 00 21 00)
119 589 04 63 00
Fig. 26: Identifying Pressure Hose (119 589 04 63 00
Fig. 27: Identifying Ring Wrench Bit (000 589 70 03 00)
Connection diagram ofintake manifold- AR09.20-P-1310-0IE
Function diagram ofvacuum supply model124, engine 119.974/975

Mercedes-Benz
40 Ol•phr;,gmprouuro rogul•lf>r
50 MorJul•rfng prossuro v•c.uum un~
19 EJth•u~ SI"' rocl~ul.rtrm ""~"
91 V~uum c/cmcnttot upshlffdo~y
115 Alt pump
121! A ir si!U1·ott v.we
121 Chod va/Ve (socond•ry ln}oC'Iirm
illl}
121 Che<:K v•tve (V.J<:Uu"!)
1::5 Cll'"~ Vi~M (V.J<:UUm SUpp/Y)
156 EXII• u~ m•ntold
161M Elot:tronlc •ccoloriltor (!!A) •ctu•lf>r
N111 OIK$ s lgnrtion crmrrol unir
N3t1 A Ir llot wltc (I.H·SF/) control mo '*''"
$141! Economy modo •Witch
YJ/1 I.Jpshtrdol•y swltchovor v.a/vo Yn AltpUmpswttcllovorv•tvo Y$111 Purgo control v.a/vo

Y4 Ecrmomy modo swtclloVcr va/ve Y11 A ir pUmp oloctrom;,gncric coupfng • l'llilctiv;otodch•rco;ottlltcr
Y 21 EGR swttc hcvor Vil/Ve
Fig. 28: Function Diagram OfVacuum Supply Model
Function diagram ofvacuum supply model129, engine 119.972
40 0/ilphr;,gmprcssuro rcgulillf>r
60 11/orJul•rfng prossuro vuuum unit
19 Exhilu.st SJU rocitculiltion v~Aia
91 Vo>cuum oiemontfol upslllfr dolily
12$ Altpump
125 Alt ShUf•Off Vii~O
121 Choclf V11/Ve (soc CRdil ry /njc<:rfrm
•Ir)
121 Ch"~ v;o/vc (V~uum)
U! Choá V 11/Ve (ViiCUUm supp/y)
116 V~uum rcsarvolr
156 Extt•u~m•ntotd
161M Eloct ronfc acce1or..ror (!!A) actu•ro r
Nf/ 1 OIKSS l¡¡nfticn control unll
N311 Alt hof wlto (UHFI) control modulo
$115!5 Economy mr>do switch
YJ:1 Upshttdol•yswltchovcr ~r.~Jvc Y12 A/rpUmpswttchovorvalvo Y$111 PUttJO control v•tvc

Y4 Economy modo swtchovor v•IVC Yll Alt pUmp oloctrom;,gnorlc c.auping • D1 \Jctiv.Jtad ch¡ rca~ lnttnr
Y27 EGR swttchovcr v.a/Vo
Fig. 29: Function Diagram OfVacuum Supply- Model129, Engine 119.972
Function diagram ofvacuum supply mode1140, engine 119.970/971

Mercedes-Benz
Ut ven Ion up to 0$191

40 O/~phri9mprcuurc rc¡¡u/~to r
50 /llo rllll~rfng prossurc v~cuum untr

19 E.x'tJ¡j usf gtJS ra drcuJ~on v61Ato
91 V«uum e/cmonr tor upshl rr do,.y
125 Atrpump
126 A ir shUt·Oft Vi>IVC
111 C/lct/( v~/vc (sct ond~ry ln}cclion
~Ir)
121 Chod V•IVo (V«UUm)

1» Cllctl( v~/Vc (V«uum supp/y)
136 V ~cuum tcsctvolr
156 E1h• u.sr m~ nlfold
lA! M Elc<rronlc •oc clcr.>tor ¡EA) ••ru•ro r
N1t1 Olf<S:S l¡nlrion control uni r
NJ/1 A ir hot wlrc (LH·SFI) contlol modlllc
S11l!5 Economy modo switch
811111
Y4 E cono my modo swltcl>ovcr votvc Y31 A ir pump sw/rcnovct v•tvc YS I/1 Pur¡c <:ontro/ vo/vc
Y21 EGIR swlrchovcrv•lvc Y:JJ A ir pump Clc<trOIIIOQnCti< COUpNng ro ac rfvotcd ch• reo•/ tlltcr
Fig. 30: Function Diagram OfVacuum Supply- Model140, E ngine 119.970/971
Function diagram ofvacuum supply modell40, engine 119.970/971
2nd vers:ion •• of 06/Sl

40 O/~phri9m p rcssurc rc¡¡u/~tor
50 11/odUI~rfng p rossutc v~cuum unt
19 Exh•u.st g .. rccltcu/.orion Vi> /Ve
91 V•cuum e/emonr fi>r upshilf del~y
12S A ir pump
126 A Ir shut-oft v•IV•
111 Chocl( volvc (sct o nd~ry lnjc<rion
•Ir)
121 Chocl( v•N• (V«uum)
135 Cllctl( v.alvo (V«uum suppiYJ
~~ V~CUUffl lCSOIVOi r
156 EDI• u.sr m~ nlfotd
lA!M Slact:ronlc acc alartztor (EA} acti/Qto r
N113 OlKS,s fgnlrfon contto/ unlt
N3/1 A Ir hot wirc (LH.SFIJ control morflllo
Sta/5 Economy modo swlrch
YJ/3 Upshrt dcloy Sllllltchovcr v•lvc Y32 A fr pump sw/rc llover v • lvo Y5 111 Pur¡c control valv.c
Y4 Economy modo swftc!H>vor va/ve Y31 A Ir pump c/cctromaQncric coupKng ro •crivotcd eh~ rcool tltrcr
Yl1 EGR swlrchov.ct v,¡lvo
F ig. 31: F unction Diagram Of Vacuum Supply- Model 140, Engine 119.970/971
Tightening diagram for attaching intake mauüold - AR09.20-P-1310-03E
Tightening diagram for attaching intake manifold

Mercedes-Benz
Fig. 32: Tightening Diagram For Attaching Intake Manifold
Replacing intake manifold- AR09.20-P-1310-04E
@ INTAKE MANIFOLD
119
BA09.20-P-1003- Bolt oftop part of intake manifold to bottom part of intake
N m 25
OlC manifold
Take off all the parts attached to the removed intake manifold and fit on to the new intake manifold.
OJ Fit new rubber pieces (21 ).
1'1!020--11
Mercedes-Benz
F ig. 33: Identifying Intake Manifold Rubber Pieces
Removing and installing intake manifold- AR09.20-P-1310EA
ENGINE 119,981 /982 /985
ENGINE 119 in MODEL 129, 210 with CODE (957a) AMG technical package
F ig. 34: Identifving lntake Manifold Components
~GF ~ R emoving, installing

1 Remove fuel rail together with AR07.03-P-1451E
inj ectors, install
2 Remove hot film mass aír flow AR07.07-P-1453E
sensor, ínstall
3 Partially drain coolant
4 Separate plug connection of Fold locking arm up for
actuator (Ml6/ lxl) this step
5 Unplug all the plug
connections/sockets of the
electrical components at the
intake manifold
6 Detach vacuum hose of check
val ve
Connection diagram of AR09.20-P-1310-01EA
Mercedes-Benz
intake manifold
7 Detach coolant those (3 3/1) at
rear left of intake manifold
8 Detach coolant hose (33) at
front of intake manifold
9 Unscrew bolts (14, 15, 16) DJ Pay attention to
different bolt lengths.
Oil bolt threads with
assembly oil. Tighten
bolts according to
tightening diagram: ?
Tightening diagram of AR09.20-P-1310-03E
intake manifold
attachment
@ *BA09.20-P-1001-01C
10 Take offintake manifold (19) DJ
Model210 E 50 AMG,
129 SL 60 AMG: the
intake cross sections of
the top part of the
intake manifold are
enlarged.
DJ Installation: fit on
coolant hose (33).
18 Use straightedge for inspecting & Oanacrl If necessary'
flange surfaces process on dressing
plate, or: ?
replace intake manifold AR09.20-P-1310-04EA
@ lntake manifold
BA09.20-P-1001-01C Bolt of intake manifold to N m 28
cylinder head
BA09 .20-P-1 003-01 C Bolt of top part of intake N m 25
manifold to bottom part
of intake manifold
Connection diagram ofintake manifold - AR09.20-P-1310-0IEA
Function diagram of vacuum supply (except !lJ)

Mercedes-Benz
40 Dlophngm pre.ssuro rogulotor

us ChccKIIolvc (llocuumsupp'J)
136 V11cuumro.servoir
MIM Elcctron/c occcJCfiJtor (EA) octuiltor 118
HJ/10 Motoreleetronlcs (IAE) QOntrol
modulo
Y$1!1 Purgo control VJ.Itto
!O actA,IIl4 CMICO~f flltol
Fig. 35: Identifying Function Diagram Of Vacuum Su pply (1 Of2)
F unction diagram of vacuum supply ( ~)
40 Dloph~gm pressuro regulator

126 Alrshut--of'f valva 1315
fU e /lec¡¡ va/ve (voc uum supp'J)
136 Vacuur.nrc.scrvoir
821 Pressurc soMor
IAU Alrpump
MIM Elcctronlc occcluotor (EA) octuiltor
HJ/10 Motoroll>ctronlcs (liJE) cont rol
modulo
YSI/ 1 Purgo control Volvo
YJ2 A Irp ump 9Nitcho11or vo/vo
ro oct !Voff:d ch•rcool fitrcr
Y32
Fig. 36: Identifying Function Diagram Of Vacuum Su pply (2 Of2)
Replacing intake manifold - AR09.20-P-1310-04EA
@ Intake manifold
Number Designatiou E ngine 119
BA09 .20-P-1003-01 C Bolt of top part of intake Nm 25
manifold to bottom part
of intake manifold
Mercedes-Benz
Take off aJJ the parts attached to the removed íntake manifold and fit on to the new intake manifold .
OJ Fit new rubber pieces (21).
Fig. 37: ldentifving Intake Manifold
Removing and installing intake manüold- AR09.20-P-1310F
ENGINE 120.980/981
41 Tllrottle conrrol rol1y ie!ler

to Bnc~ct
1712 Riel retvm flow IJna
17fJ Riel food l no
20 Covcr of lllgh volaga d/srrlbutor
17 Guido ploco
21 Pl.utlt: clp
JQ Sowdon c:oblo
ti Control pressuro boW11cn c~lo
Fig. 38: ldentifving Intake Manifold Removellnstall Components (1 Of 2)

Mercedes-Benz
14 8olts
15 aors
16 aors
11 GóiSIIOIS
11111 Sh"f'Od seals
17 Loe lrlng S/oc""'
1~ lnt•lrc m•nlfold
1W1 lntormcdJJtc flilngc
Fig. 39: ldentifving Intake Manifold Remove/Install Components (2 Of 2)
~GF
~ ..
AR09.10-P-
1050F
Remove electronic accelerator
AR30.20-P-
2 actuator together with throttle valve
1262F
body, install
Remove cover of cable duct over
3
íntake manifold
4
Remove covers (20) of the high ITJ U se s crewdriver to releas e catch (arrow)
voltage distributors for this step
Disconnect all the plug connections
of the cables which run over the
5
intake manifold, and of the electrical
components at the intake manifold
Detach vacuum lines of the
6 components located at the íntake
ITJ Pay attention to color coding ofvacuum
lines
manifold
AR09.20-P-
Connection diagram of íntake manifold
1310-01F
ITJ Remove guide piece (27) for this step,
install. First of all, pull plastic nipple out of
Detach Bowden cable (30) at throttle
7 guide piece. When ínstalling, ensure that the
control relay lever (6)
plastic nipple properly engages in the guide
p1ece.
Press toQether nlastic clín (2R) and
Mercedes-Benz
pull out of bracket ( 1O) together with

8
Bowden cable (30)
Detach control pressure Bowden
9
cable (98)
Release fuel pressure through service See Diagnosis Manual Engine, Volume 2,
10
valve at fuel raíl Index 3.2
ITl Fig. 25
ITl Fig. 17
Disconnect fuel feed line ( 17/3) and
11
fue) return flow line (17 /2)
ITl CoUect fuel
12 Unscrew bolts ( 14)
Disconnect vacuum lines for brake
13 unit at right and left sides of intake
manifold
Disconnect lines of exhaust gas
14 recirculation on left and right at
intake manifold
Model 140
15 Remove air collecting box, install See Repair Instructions Automatic Heater
Model 140, op.no. 83-140
ITl Tighten bolt from tbe middle to the
16 Unscrew bolts (15) outside. Pay attention to different bolt
lengths.
@ *BA09.20-P-
1001-01C
Use straightedge to inspect flange
&oanQer!
surfaces; process on dressing plate if
Raise intake manifold (19) and take necessary.
17
off to the front ITl When installing, ensure that no vacumn
lines and electric cables are jammed in
between
@ *BA09.20-P-
18 Remove intermediate flange (19/1)
1002-0lC
&oanQer!Replace if necessary
ITI Replace shaped seals (18/1)
¡g¡ Metal intem1ediate flange replaces BT09.20-P-
mbber intermediate flange 0001-0lA
ITl Gaskets should engage in locking sleeves
(17)
AR30.10-P-
20 Adjust throttle control
1010F
21 Inspect idle speed, set See Diagnosis Manual Engine Volume 1
Mercedes-Benz
@ INTAKE MANIFOLD
BA09.20-P-1001-01C Bolt of intake manifold to cylinder head Nm28
BA09.20-P-1002-01 C Bolt of intermediate flange to cylinder head Nm28
103 5B9 00 21 00
\.
Fig. 40: Identifving Tester (103 589 00 21 00)
119 589 04 63 OD
Fi~. 41: ldentifyin~ Pressure Hose (119 589 04 63 00}
Connection diagram of intake manifold - AR09.20-P-1310-01F
Engine 120.980/981
Function diagram of secondary air in~tion and exhaust gas recirculation Model140 up to 06/91 base
and national version (except IJ:S=='wF llJ)
Mercedes-Benz
<10 Dl~phr~m prcssuro ro¡¡u/illrDr

50 lllocllll~ring prcssurc v~cuum unit
19 Lclt oxh•us:tg;n ra.:Jrculói!Jon v~o
Rtghr uh~ust g;n rc<:lrcul~on
·~
lfMVJl
91 AurDm~ric rr•nsmlsslon control
prcssutc e• blo
12$ Alrpump
125 Alr shutollv•tvo
111 Lotr che e~ •• ~o (lnjomd lir}
111~ Rl¡¡hr chcc~ v~lvc (lnjocled d)'
121 Check v~c (v.cuum}
11.$ Chcd v~o (v.cuum supply)
136 v~uum rucrvolr
/AlM Lolt c/octronlc •ocolararor (EA)
iiiCIUilltot
t.tf5,'4 Rl¡hr otocrronlc .tecolomor (EA)
actu11tor
fol1/<l l.olt DI fgnlrton control unr (I.H.SFI)
N11$ Rl¡hr 01/gn/rion corrrrol unir (1.11-
SR)
NV2 Le 1tsequontlill1mutriporr (I.H.SFI}
control unt
NJ/1 Rfghtsoqucnri~lmulriport{LH-SR} Yn A Ir pump swl:chcvcr villlvc Y$1/J Rlghf PI11S10 control ViiiiVO
control unir Y1J Alrpump ala«rom~norfc coupllng 11 to ;~ctiv-.Jted ch~rc~ltift1JT
$14'5 2nd drMng modc Sldch Y5tf2 Loltpurgo control volvo
Y" 2nd drMng modo swtrchovor vahfo
V2712 LoftEC/hWIII:hOVctViiiiVo
Y27f1 Righr Ec;RsWirchovor v~~·
Fig. 42: Function Diagram Of Secondary Air lnjection And Exhaust Gas Recirculation
Function diagram of secondary air injection and exhaust ~s recirculation Model140 as of 06/91, Model
129 as of 09/92 base and national version (except ~WF llJ)
Mercedes-Benz
40 Dloph~mp rouuro rc¡¡uloror

50 IAodul~ring pross..uto v~cuum unlt
19 lc tr cxh•usr ps rccfrculilfion v;~tvc
IP. Rl¡¡ ht cxh• u.r ¡¡.s roclrcu/ilflon
vaJv-o
Ql Automilfic rr•nsmfssl on control
prcssurc •• ole
115 Airpump
125 A ir ShU!OffV;t/VC '
121 l.ctr chccl( ••~• (lnjoe!Od illr}
121• Rl¡¡nt encelo: volvc (lnj<>ctod •Ir)
12f e ncol( v •lvc (Vocuum) y¿
135 ChocH votvo (Vóleuum suppiYJ
125 Vocuum tcsorvolr
Mten l.e rr e/ce tronrc •• ce/ero ror (EA)
•cruoror
Mf6~ Rl¡¡nt c/ccrronlc ••cc/ororor (EA) YJ/3 Upshltr dcl•ysWftchovcrv•tvc ro •cllvotodch•rcoo/fRtor

..1Ctlllt0f Y4 1nd drfvfn¡¡ modo swfrr:hovorvo/vo rr red
N1/ 4 l.otr DJ f¡¡nftJon control uni (UHiFI) Y21f1 L ctr EGR sWfh:I!OVCl V;t~o gr ¡¡rey
N t!S Rl¡¡ ht Dl lgnllfon <JOnt ro/Unlt (LH· Y21{) Rl¡¡ntEGR sw/rchovcrv.rvo sw bloc!(
SR)
Y32 A lrpump swltehovcr volvo tr neutrt~l
NJ/2 Lotr StJqUOntf.>l mUitJpcrt (J..H.SFI) YJJ A lrpump o/ocrrom~ncl1c coupllng
control unlt vi purplo
Y51f1 L ott pUfSIC 'ontrol VilllfC /Ir IITOWil
NJIJ Rl¡¡ lit scqucnllol mu/rjlorr (I.H·SFI)
control unlt Y51/J Rl¡¡nt purgo control v•rvo bl b/1/o
51fll5 2nd dr~lng modo switch
Fig. 43: Function Diagram Of Secondary Air I nj ection And Exhaust Gas Recirculation Model 140 As Of
06/91
Function diagram of air injection and exhaust gas recirculation as well as vacuum supply ll$" WF rtJ
model year 1992
Mercedes-Benz
otO D l•phr~mprcswrc rcgut•ror

50 lllodUI•tfng prcssuro vocuum unlt
te Lclf c.r:~st g;as rcclrcu/i>tlon v.a/Vc
19.> Rl¡¡hrcxh•uJt ga rcclrcu/.Jtfon
tnlvc
91 Auromotfc rransm/slon control
prcssurc call/o
125 Airpump
116 A ir shurotf vorvc
121 Lclf che c/c v•IVc (lnjoctr>d ~r)
117• R!Qnt choc/c volvo (lt!jcc!Dd • IIJ
121 Chccll va/ve (Vocuum)
1J$ Chcc/c v•rvc (V..uum suppJy)
1$6 V.cuum rcs.arvolr
IA16n l ott eloc tronlc •• cclcra ror (f!AJ
oclllot or
IA16J4 R 1¡¡ ht c/orlronlc iiCt o/ofilfor (f!A)
ocllliltor
N 1f-t Lert Dl lllflltlon control un/t (I.H-SR) Y27t1 t. clf EGR swf~llovcr vo!Vo ro octfvotcd cllorcool flltcr
N115 Rljlht DI ljlnltion control uni r (I.Jj•SFI) YV/1 RljlhtEG/t swltcllovcr volvc rr rod
N~ t.cft sequcntlol muJttlort (I.H·SRJ YJ2 A Ir pump swlchovcr volvc jlt jltOY
control unir Y1J A l rpump clcct rom¡¡gnoltc coupllng sw lllocll
NJ/1 Rfjlltt scqucntfol multfpon (I.H-.$ R) Y5111 L cl't pUrjlc c.ontrol volvo tr ncurr.aJ
control unlt Y51/1 Rljlhtp<Jrgc conrrolvolvc vi purplo
YJIJ Upshrt dcloy swltcllovcr voJvc
llr llrown
bl 11/uo
Fig. 44: Function Diagram Of Air l n jection And Exhaust Gas Recir culation As Well As Vacuum Supplv
Function diagram of secondar y air injection and exhaust gas recirculation as well as vacuum supply
n::rwF [l] model year 1993
Mercedes-Benz
40 D/ophrilflm prouvro rogu/~lor

150 lllodlllorlng pro$$ uro vocuum unir
18 Lotf cxhaust gos roclrcul.atlon vaNo
l io R/glll oxhoust gos ro,lrcullfion
Valve
;r Auto~ tic transmlssfon control N3l!
prossutc c<J blo
12$ Alrpump
126 Alr snuloffvo.tvo
121 Lolt che e /Ir valllo (lnjo<!Od • lt)
121• R/¡¡111 checK vo/vc (injccled olr)
121 Chod vo~lve (Voouum)
135 ChecK va/Vo (V~uum suppl)')
126 V.xuum rcscrvolr
/816!3 Lolt eloc rron/c ~ccoloraror (EA)
actu•ror
/tf18.iil R/¡¡111 e/ocrronlc ~'clor'.ator (EA)
oiiC tllilfO/
128 N.S/3
IQ8 20-02-''~
N114 Lcfi DI/gnlrlon control unir (I.H-$R) Y2:112 L off EGR s!Nfrcnovcr va/Ve ro ocrfvarad cnarcoalfNrar
N1f 5 RfghtDI/ilniUon conrro/Un/1 (I.H~ SR) Y21!3 RlghiEGR :swlr,llovcr valva rt red
NJ/2 Lclr scqucnrlal mutrj>ort (I.H-SR} Y32 A lrpump swltcnovcr ViJivc gr gróy
Y33 A lrpump electromi~f~noric coupllng bi~K
N313 Rfgnr sequenrfal mulrlport (I.H·SR} Y5112 L otrpurgo control vo/vo tr neutr.JI
corrt.rol u n it vi purpla
Y!Jia Rlght purgo control v atvc
YJ/3 1/pslll't dcloy swlrcllovcr v~vo
l:>r l:>rown
/)/ blu.o
Fi2. 45: Function Dia2ram Of Secondary Air Injection Vacuum Supply- Model Year 1993
Removing and installing intake manifold - AR09.20-P-1310FA
ENGINE 120.982/983
1712 FucJ rorurn tlow lino

1711 FucJ leed Mne
20 Covcr
I'CO 2o..o2M. 1 ,
Fig. 46: l dentifving Intake Manifold Remove/lnstall Components (1 Of 2)

Mercedes-Benz
14 Bolts
f5 Bolts
15 Bolts
11 Gas.\:ots
1/&11 Shoped rubbcr sc;ols
11 Locllini slao•cs
19 lnt•l'io monlfold
1011 lntormarlim f~n/10
Fig. 47: Identifying lntake Manifold Remove/lnstall Components (2 Of 2)
~GF
~'
AR09.10-P-
lOSOF
AR30.20-P-
2 actuator together with throttle valve
1262FA
body, instaH
Remove cover of cable duct over
3
intake manifold
4 Remove covers (20)
muse screwdriver to release catch
( arrow) for this step
Take off straps securing all the
5 electric cables which mn over the
fuel rail
AR15.12-P-
6 Remove ignition coils, install
2003FA
Detach vacuurn lines of the
components located at the intake
mPay attention to color coding of
vacuurn lines
manifold
AR09.20-P-
Connect ion diagram of intake manifold
1310-0lFA
Pay attention to accident prevention
~ Risk of explosion
regulations!
Release fuel pressure througb service See Diagnosis Manual Engine, Volume
7
valve at fuel rail 2, Index 3.2
m Fig. 25
Mercedes-Benz
[IJ Fi2.11
Dísconnect fuel feed líne ( 17/3) and
8
fuel retum flow line (17/2)
1IJ Collect fuel
Detach vacuum lines for brake unit at
9
right and left sides of intake manifold
10 Unscrew bolts (14)
Model 140
See Repair Instructions Automatic
11 Remo ve air collecting box, install
Heater
~odel 140, op.no. 83-140
IIJ Tighten bolts from the middle to the
12 Unscrew bolts (15) outside. Pay attention to different bolt
lengths.
@ *BA09.20-P-
1001-0lC
Unscrew bolt ( 19/1 O) at bracket
13
(19/ 11)
Unclip power steering pump
14
reservoir and push to the side
1IJ Do not detach lines
Use straightedge to inspect flange
&.oanaer!
surfaces; process on dressing plate íf
Raíse íntake manifold (19) and take necessary.
17
off to the si de 1IJ When installing, ensure that no
vacuum lines and electric cables are
uammed in between
@
*BA09.20-P-
18 Remove intermediate flange (19/ 1) Replace ifnecessary
&.oanaer!
1002-01C
IIJ Replace shaped rubber seals (18/ 1)
19 Replace gaskets ( 18)
IIJ Gaskets should engage in the locking
sleeves ( 17)
@ INTAKE MANIFOLD
BA09.20-P-1001-01C Bolt of intake manifold to cylinder head Nm 28
BA09.20-P-1002-01C Bolt of íntermedíate flange to cylínder head N m 28
Mercedes-Benz
1035S9 00 21 00
Te!IB!
119 589 04 63 00
Fig. 49: ldentifying Pressure Hose (119 589 04 63 00)
Connection diagram of intake manifold- AR09.20-P-1310-0IFA
Engine 120.982/983
Function diagram of secondary air injection and vacuum supply model 129, 140 witb engine 120 ME-SFI
40 D~ph~~m p rouuro rcgul•tor

125 Scconrhry olr pump
126 Lotf ¡ /r $/>U!•Otf lla/Vo
126• R/¡¡IIUirshut-o"ttQ/vo
127 Choc~ v.tlvc (lnjoctod Mt)
121 Choa valvo (V~~euum)
UJ C/toc~ VotiVO (VIICUUm supp/Y)
1J:a Vacuum rcsatvol r
Mf0-4 Eloctronlc •ecc/or~or ('EA)Ieru/so
ecntrcl (Cqlfdlo spoodeonrrol{lsq
.acru.atot, toc.atod on lclf of cngtno
1111&.14 Eloetronlc .accolorotor (EA}Icrulsc
eo ntrol (Cqt!dlospood control (l$q
ocfltotot, locotod on ri¡¡ht of cnglnc
...,_.,.,
YJZ Alt pump SWI!<hOVOt VoNO Yl!ii/J R lghtpurgo controlv•lvo rt rod
YJJ Alt pump o/lcctrom~nclte eouplng • ro IICtAI.Jtod eh•reo¡J filtot gr grey
Y51/Z Lclf purgo control v•Jvo • ., bl•d
tr ncut,.l
Mercedes-Benz
Fig. 50: Function Diagram Of Secondary Air Injection And Vacuum Supply- Model129
Function diagram of secondary air injection and vacuum supply model 129, 140 ~ with engine 120 ME-
SFI
40 Dl•phrilSJm prossuro ro¡ul•lor

125 Se<:ondi>ry • Ir pump
126 l.otr •Ir shut-ott ,.,,.
126• Ripht • i rshut. oftv•l...,
121 Choc~ v•Jvc (lnjoc'tod ~r)
121 Che<:~ v•llf• (VO<:uum)
135 Chad v•IVa (Vo><:UIIm &Upply)
1i/6 V ••uum rcsorvo/r
821/1 utr lnfiiKD m•ni~VId prcssuro sensor
821/1 Ripht /nto~o m•n~old prossuro
sonsot
Ml&/3 Eloctronfc •ccoloiilfor ('EA)Icrufso
conrro/ (CC}IftJ/c spcod control {JSC}
~ctu~tor, loc~tod on Jctt of cngtno
MI& ~ Eloctronlc •ec olotilfor (EA)Icrulso
conrrol (C'CJ!Idlc spccdcont roi{IS'CJ
•ctv•tor, loc•rod on tl¡¡ht of cnglno
YJ2 Air pump swl rcnovor v•lvo YSifJ R lgnt purgo switcnovor Vi>lvo rt red
Yl1 Alr pump olecrromilflnotlc couplng • ro •crAt.rorJ cn•tc ..l ffltct 111 grey
Y5112 Lotr purgo control v•lvo sw blocK
tr ncutr•l
Fig. 51: Function Diagram OfSecondarv Air Injection And Vacuum Supply Model129, 140
REMOVING AND INSTALLING RESONANCE FLAP- AR09.20-P-1791D
ENGINES 104.94/99 (except 104.990)
2211 c;,.sKcr
2213 V.Jc-u um connoction
Y2llfS Ros<>n•nco lnr•~• m•nlfo/d
sWircllóoro; lf.iA'o
Arrow Couplfn¡
Fig. 52: Identifying Resonance Flap Components

Mercedes-Benz

1JJ Arrow Couplíng pull off vacuum
connection (22/3) at the
resonance intake
manifold switchover
valve (Y22/6)
22/2 Gasket replace

REMOVING AND INSTALLING AIR CLEANER- RA09001040015X(09-0015)
Removing and installing air cleaner- RA09001040015X(09-0015)
Operatíon No. of operatíon texts and work units or standard texts and flat rates:
09-0015
1P09-2007 -35 rw•:eoo¡=a
Fig. 53: Identifying Air Cleaner Remove/Install Components
Electrical connector at intake air temperature sensor

dísconnect, connect.
(B 17/2)
Air intake hose (2) at aír cleaner, detach, fit on.
Mercedes-Benz
Nuts (arrows) unscrew, screw on.

for crankcase ventilation, disconnect,
Shaped hose ( 1)
connect.
Air cleaner (4) take off, fit on.
NOTE: When installing, ensure rubber seal (7) between air cleaner (4) and mixture
control unit is in good condition and properly seated.
Replace rubber seal (7), ifnecessary.
Fie. 54: ldentifyine Air Cleaner And Rubber Seal
Removing and lnstalling Air Cleaner- RA09001190015X(09-0015)
09-0015
Mercedes-Benz
@4
mmm
Fig. 55: Identifying Air Cleaner Remove/Install Components
Cover (1) remove upward, insert.

Air intake hoses (2) detacb from air cleaner, fit on.
Crankcase ventilation
detach, fit on.
hose (3)
Electric cable for
electronic accelerator remove upward, insert from above.
pedal at air cleaner
pull up at the front, remove from mounting, insert.
Then pull air cleaner forward out of rear mounting (5), insert (see note, step
2).
Installation notes
lnstall air cleaner housing so that the vacuum pipe of the brake servo unit runs
Air cleaner (4)
over the air intake connection. Check clearance of cover (1) to brake vacuum
pipe (arrow). Specify clearance 8 mm (see note, step 1).
When installing the air cleaner, ensure the rubber seal between air cleaner and
air flow sensor is in proper condition and properly seated; replace seal if
necessary.
Notes
l. When installing tbe air cleaner (4), it is essential to ensure tbat the vacuum pipe of the brake servo unit
(arrow) runs over the air intake hose (2).
Mercedes-Benz
Fig. 56: Identifying Air Cleaner And Air Intake Hose
2. Since October 1989 the bearíng bracket at the front for the aír cleaner cover has been modified in shape in
order to increase the clearance to the ignition cable duct.
5 Ra.<ai ~ fi :er moun5ng
Fig. 57: ldentifying Rear Air Filter Mounting
PRODUCTION BREAKPOINT 10/89

Model Engine E ngine end no.
129.066 119.960 002 294
Cyclonic separator - RA0900KE20015X(09-0015)
The cycloruc separator acts asan air pre-filter. This makes it possible to extend the intervals for intermediate
cleaning which are necessary in dusty regions.
Mercedes-Benz
Fig. 58: Identifving Air Pre-Filter- Engine 102
The inducted air is swirled by the spiral-shaped guide vanes (1) in the cyclonic housing. As a resuJt, the larger
and heavier dust particles impact the outer wall, collect in the rear part of the housing and pass through the dust
emptying valve (4) to atmosphere.
The intake air which has been pre-filtered in this manner passes through an intake manifold with a smaller
diameter (2) to the air cleaner element in which the fine dust particles are trapped .
Check the dust emptying valve (4) to determine whether the sealing lips are stuck togetber. Ifnecessary, clean
or replace.
Guidevane
2 lrtal<e mwifokl WJiti sma=er <úam otor
4 Dust .em~ng wt.te
a Air irtot
b To a,- claanor hoo sing
Fig. 59: Identifying Spiral-Shaped Guide Vanes And Dust Emptving Valve
Do not remove dust emptying valve otherwise the effíciency of the cyclone will be signifícantly reduced.
Mercedes-Benz
The cyclonic separator cannot be retrofitted to the air cleaner housing. The complete air cleaner must be
replaced.
REMOVING AND INSTALLING INTAKE AIR SCOOP- RA09001040060X(09-0060)
Removing ancl installing intake air scoop - RA09001040060X(09-0060)
Operation No. of operation texts and work units or standard texts and flat rates:
09-0060
Fi2. 60: ldentifyin2 lntake Air Scoop RemovellnstaiJ Components - Model124
Fi2. 61: ldentifyin2 Intake Air Scoop Removellnstall Components - Model124
Air intake hose remove, install.

Clip (arrow) remove, insert (2 clips on model 129).
re mo ve. i nsert.
Mercedes-Benz
Push lever (5) down on model l24.

Intake air scoop (4) Installation instruction
Intake air scoop (4) must engage in the mount at the bottom (only on model 124).
Removing and Installing Intake Air Scoop - RA09001190060X(09-0060)
09-0060
Fig. 62: Identifying Electric Coupling Of Intake Air Temperature Sensor And Expanding Clips
Intake air hose detach, fit on.

Electric coupling of intake air temperature sensor (B 17/2) at left intake air scoop, detach, fit on.
Expanding clips (arrows) press out, press in.
TECHNICAL MODIFICATIONS ENGINE 119 COMBUSTION KE INJECTION- RA0900119T AOOX
09 Air Cleaner
Op. Designation Nature and reason for modification Production

no. breakpoint
09- Front bearing bracket for air Shape modified to provide more clearance to
10189
001 5 cleaner cover ignition cable duct
Mercedes-Benz
AIR CLEANER - RA0900KE20010X(09-0010)
The air cleaner is positioned on the mixture control unit. A seal is installed between air cleaner and mixture
control unit. Access to the mixture regulating screw is obtained, if necessary, through a recess in the top part of
the air cleaner.
Air cleaners trap the dust in the intake air and thus prevent engine wear. Dust levels on paved roads are approx.
1 g of dust over a distance of 1000 kilometers. The dust content may in extreme cases rise by 40 times on
unpaved roads.
Fig. 63: ldentifving Air Cleaner Example - Engine 102
The intake scoop is positioned next to the radiator in such a way that as little dust as possible is drawn in.
A further task ofthe air cleaner is to dampen the intake noise so asto satisfy legal requirements in respect of
overall vehicle noise.
The intake air temperature sensor (B 17/2 or B 17/ 1) is positioned at the air cleaner housing or in the intake
scoop, dependíng on version. This influences the KE ínj ection system or the EZL ignition system, respectively.
Mercedes-Benz
IP09-2012-13
Fig. 64: Identifying Air Cleaner- Engine 102.983/99
The air cleaner housing is made of plastic (except engines 102.961, 116, 117).
The air cleaner is harmonized to the engine in order to optimize engine output, fuel consumption, noise
insulation.
Fig. 65: ldentifving lntake Scoop - Model124
The paper air cleaner element should be serviced regularly. The perforated metal sheet in tbe air filter element
acts as a reinforcement so that the filter segments also w íthstand frequent cleaning (knocking out, blowíng clean
with compressed air) without damage. The filtering effect is not altered by the perforated metal sheet
Mercedes-Benz
j:P 09-2019-U
Fi¡:. 66: Cleanin¡: Air Filter Element
IP09-202S.13 PtO- 21):1, I.Í 1
Fig. 67: Identifying Air Filter Element
Engíne 104
Mercedes-Benz
Shapedhose, aankcase
\'lllillali0/1
2 A.-lftake hose
4 A.-claanar
Fig. 68: ldentifying Air Cleaner, Shaped Hose, Crankcase Ventilation And Air Intake Hose
Engines 116, 117
The a ir cleaner is made of light al!oy.
Fig. 69: ldentifving Air Cleaner- Model107 Engines 116, 117

Mercedes-Benz
Fi¡:. 70: Identifyin¡: Air Cleaner- Model126 En¡:ines 116, 117.965
On engine 117.968 the air cleaner housing is provided with two intake scoops (double snorkel). Since engine
output increase 09/87 all engines in model 126 have been fitted with a double snorkel.
Fig. 71: ldentifving Air Cleaner- Model126 Engine 117.968
Engine 119
Mercedes-Benz
1 Cover
2 A• IJ'teka he ses
3 Cr lllk ase Yllll•lallon
4 A• claaner
Fig. 72: Identifving Air Cleaner, Shaped Hose, Crankcase Ventilation And Air Intake Hose
On engines 103.942, 116, 117, 119 the intake air temperature sensor (B 17/2) is positioned at the intake scoop.
The intake scoop is attached with spreader clips.
Fig. 73: Identifving Intake Air Temperature Sensor And Spreader Clips
COMPONENT MODIFICATIONS
METAL INTERMEDIATE FLANGE REPLACES RUBBER INTERMEDIATE FLANGE - BT09.20-P-
0001-01A
ENGINE 120.981 ## as of 004623 as of 1.3.94,
120.980 ## as of 025578 as of 1.3.94
STANDARD PRODUCTION BREAKPOINTS/MODIFICATIONS/NEW FEATURES

Engine LHS Transmission Engine Engine Production Production Nature and Reference/Remarks
RHS end end period as period up reason for
no. as no.up of to modification
Mercedes-Benz
of to
120.980 025578 1.3.94
120.981 004623 1.3.94
Since March 1994 a metal intermediate flange is installed between intake manifold and cylinder head in place
of the rubber intermediate flange_
OJ When installing the metal intermediate flange, always use the bolts supplied with the part (lower head). The
previous rubber intermediate flange is discontinued_
INTAKE MANIFOLD WITH MOUNT FOR INTAKE NOISE MUFFLER- BT09.20-P-0003-0IA
ENGINE 104.941 #O as of 005691 as of 23.5.95,
104.941 #2 as of 058497 as of 23.5.95,
104.942 #O as of 006736 as of 23.5.95,
104.942 #2 as of 060693 as of 23.5.95,
104.943 #O as of 001165 as of 23.5.95,
104.943 #2 as of 004755 as of 23.5.95,
104.944 #O as of 000951 as of 23.5.95,
104.944 #2 as of 011614 as of 23.5.95,
104.991 #2 as of 014252 as of 4.5.95,
104.992 #O as of 005167 as of 4.5.95,
104.992 #2 as of 093513 as of 4.5.95,
104.994 #2 as of 048780 as of 4.5.95
PRODUCTION BREAKPOINT/MODIFICATIONS/NEW FEATURES

Engine LHS Transmission Engine Engine Prod. Prod. Nature and Reference/Remarks
RHS end no. end no. period period reason for
as of up to as of up to modificatiion
104.941 o 00569 1 23.5.95
104.941 2 058497 23.5.95
104.942 o 006736 23.5.95
104.942 2 060693 23.5.95
104.943 o 001165 23.5.95
Mercedes-Benz
104.943 2 004755 23.5.95

104.944 o 000951 23.5.95
104.944 2 011614 23.5.95
104.991 2 014252 4.5.95
104.992 o 005167 4.5.95
104.992 2 093513 4.5.95
104.994 2 048780 4.5.95
The top part of the intake manifold part no. 104 140 44 O1 replaces part no. 104 140 39 Ol. The top part of the
intake manifold is fitted with mounting points for the intake noise muffier.
Mercedes-Benz
1990-2002 ENGINE Complete Engine- GENERAL INFORMATION- 129 Chassis
1990-2002 ENGINE
Complete Engine- GENERAL INFORMATION- 129 Chassis
GENERAL INFORMATION
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS- AHOl.OO-P-0300-0lA
Enginell2,113,122,134,135,137,166,275,285,611,612,613,628,629,639,642,646,647,648
Pressure gloss marks, smoothings
Individual blank points, e.g. in the middle of the cylinder barre) or around the cylinder head bolts.
~ Tbe crankcase can be reused.
1'01 J!On265 11
Fig. 1: ldentifying Pressure Gloss Marks On Cvlinder Walls
Visible mottling, friction marks
Starting from reverse are a of the upper pisten ring tapering down.
Traces of dry mbbing which cannot be felt, caused by oil film being washed off by fuel, for example from many
cold starts when driving for short distances.
These traces of friction occuning mainly around the cylinder head bolts and on the pressure side are not a
problem provided that they are smoothed out.
The pisten rings are not damaged.

Mercedes-Benz
1990-2002 ENG INE Complete Engine- GENERAL INFORMATION- 129 Chassis
~ The crankcase can be reused.
Fig. 2: ldentifying Visible Mottling And F riction Marks On Cylinder Walls
Ring shaped imprints
Visible imprints on cylinder barrel in the upper and lower reverse area of piston rings are not a cause for
complaint.
~ Tbe crankcase can be reused.
~1 A<le026511
Fig. 3: ldentifving Visible lmprints On Cylinder Barrel

Mercedes-Benz
Rotary bright, specular, polisbed upper surfaces of cylinder
Startíng from the reverse area ofthe upper piston ring with measurable, partial cylinder wear.
~ The cylinder barrel is unusable.
Fig. 4: ldentifying Cylinder Wear
Roughened mottling, frictiou scoring
Startíng from first and second piston ring, tapering toan end only in bottom part of cylinder. Progressive signs
of friction lead to friction score marks.
Where these signs of friction are perceptible, the cylinder barrel is unusable.
~ The piston rings may be damaged.

Mercedes-Benz
Fig. 5: ldentifying Friction Score Marks
Continuous individual traces of scratch
Caused by dirt, for example, through back pulsation of soot particles from the exhaust.
B The crankcase can be reused.
Piston seizure
Most of cylinder wall perceptibly roughened over the entire length.
Material deposits and perceptible scoring marks on cylinder wall and at piston skirt.
~ The cylinder barrel is unusable.
Brown coloring of cylinder upper surface.
A brown coloration over large areas of the cylinder barrel is oil varnish and indicates that the engine has been
driven at a high temperature level.
B The crankcase can be reused if no impermissible cylinder warping is visible
Oil varnish above piston ring zone is normal and is not a reason for complaint.
BOLT DIAGRAM CYLINDER HEAD COVER- AH01.20-P-5014-04AO
Engine 120
Mercedes-Benz
RIQitt·h~ntl<yflntlor ho•fl•ovor
1 M6 x 40 wlthso~l 01 washcr
2 ltl6 "Jt U withsa•l ot Wiuhor
J 1.16 " 51 wlthso•l 01 -•r
Fig. 6: ldentifying Rigbt-Hand Cylinder Head Cover
Lcfr-h.,ntl oyl ntlc1 ho...t covcr

1 M6 '<40 wlth~o•l or w.uher
2 M6 " 11 wlthse•l or wuher
J 11.16 v M wrth S-Dtil 1 or ~v.Jshor
P>ll 2~-'11245-IQ
Fig. 7: ldentifying Left-Hand Cylinder Head Cover
INFORMATION FOR CYLINDER HEAD- AH01.30-P-1000
Notes on application of sealant to cylinder head gasket- AH01.30-P-1000-04V
Engine 113
Engine 113
~B efare installing the left cylinder head, it is necessary to apply sealant to the cylinder head gasket in the area
of the timing case cover because of porous areas in the left cylinder head.
~ Repair note
The sealant must be applied only in the manner shown, with a bead of 2.0 mm± 0.5mm.
The sealant must be used within 1Oruin.
The silicone bead must not be spread.

Mercedes-Benz
Fig. 8: ldentifying Application Of Sealant To Cylinder Head Gasket
Information on cylinder bead contact surface- AHOL30-P-1000-05A
Engine 112, 113
The cylinder head contact surface must only be machined if mechanically damaged points are present.
The cylinder head contact surface must not be re-worked (face-ground) if a variation exists in the flatness of the
cylinder head contact surface in the longitudinal direction and transverse direction (distortíon).
Wben the cyJinder head is fitted on again, the distortion is compensated for by tightening the cylinder head
bolts.
Stock removal on the cylinder head and at the crankcase of an engine must together be not more than 0. 3 mm.
The valve seats must be re-set if the cylinder head separating smface is machined .
Information for assigning tbe cylinder bead gaskets - AH01.30-P-1000-06V
Engines 112, 113
The assignment of the applicable cylínder head gasket on the left and right to the matching engine can be
verified when the cylinder heads are installed at the visible round notch between cylinder head and front of
crankcase.
~ Incorrectly installed cylinder head gaskets, e.g. with marking B instead of A, cause a knocking engine noise,
particularly at high idling speeds, as the pistons touch the proj ecting cylinder head gasket. If a complaint exists,
replace cylinder head gasket.
Mercedes-Benz
Illustration sbows M112/113
...... 1.~
c-.,... 1
u
~
~
>--
• 2.1
IIJIID A
ft»'-··· [ ~
fA
J
- 0800-
h
,.,..
11R.
J~~ ¡-
.UI.
o o!
Ul'l ..-
111...M1
•112
le.!
... ,.,,110
-~
A
.lilA
~,
... nlillll«aM•
~
...... :111:
1'01.30-2107 06
Fig. 9: Information For Assigning Cylinder Head Gaskets (1 Of 2)
The assignment of the applicable cylinder head gasket on the left and right to the matching engine can be
verified when tbe cylinder heads are installed at the visible round notch between cylinder head and front of
crankcase.
~ Incorrectly installed cylinder head gaskets, e.g. with marking B instead of A, cause a knocking engine noise,
particular!y at high idling speeds, as the pistons touch the projecting cylinder head gasket lf a complaint exists,
replace cylinder bead gasket
lllustration shows M112/113

Mercedes-Benz
•••
f\!)1.30 21 0 1 ~ 5
Fig. 10: Information For Ass.igning Cylinder Head Gaskets (2 Of 2)
NOTES ON APPLICATION OF SEALANT- AH01.40-P-1000
Notes on application of sealant timing case cover- AH01.40-P-1000-01B
Engine 112, 113
Application of sealant to timing case cover
~ The timing case cover is sealed with a silicone sealant at points A, C, D.
~ No sealant must be applied to the timing case cover at points B , pressure oil galleries to crankcase, with
the exception around the bolt hole G . Sealant which is applied to the points B , is entrained by the oil flow and
blocks the oil supply drillings of: Main bearings, camshaft bearings, rocker arms and oil spray nozzles.
Mercedes-Benz
P01A062851él
Fig. 11: Identifving Application Of Sealant Timing Case Cover
~ Clean sealing snrfaces
Apply sealant only to the specified surfaces with a bead of2.0 mm± 0.5 mm.
The sealant must be applied within 1O minutes!
The silicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
use d.
Notes application of sealant to end cover witb radial shaft seaJ- AH01.40-P-1000-06A
Engine 112, 113
Application of sealant to end cover
~ The lines drawn G, E and the arrow D mark the application of sealant.
~ Clean sealing surfaces, apply sealant only to the specified surfaces with a bead of2.0 mm ± 0.5 mm.
The sealant must be applied within 10 minutes!
The silicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
use d.
Mercedes-Benz
Fig. 12: ldentifying Application Of Sealant To End Cover With Radial Shaft Seal
NOTES ON APPLICATION OF SEALANT OIL PAN - AH01.45-P-0001-01D
Engine 113.940/943/944/961/980/984
Application of sealant to top part of oil pan
~ The line drawn F marks the application of sealant.
~ Clean sealing surfaces, apply sealant only to the specified surfaces with a bead of2.0 mm ± 0.5 mm.
The sealant must be applied within 1O minutes!
The s ilicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
used.
POU5·21112-81
Fig. 13: Identifying F Marks

Mercedes-Benz
Application of seaJant to bottom part of oil pan
~ The line drawn F marks the appllcation of sealant.
~ Clean sealing surfaces, apply sealant only to the specified surfaces with a bead of2.0 mm± 0.5 mm.
The sealant must be applied within 10 minutes!
The silicone bead must not be spread. Only the silícone sealant listed in the section Repair products may be
use d ..
o o
POUO~J17 · i2
Fig. 14: ldentifving F Marks

Mercedes-Benz
1990-2002 ENGINE Complete Engine- REPAIR & ADJUSTMENTS- 129 Chassis
1990-2002 ENGINE
Complete Engine - REPAIR & ADJUSTMENTS - 129 Chassis

ENGINE AND MODEL SURVEY - RA01 001040010X(Ol -0010)
Eogioe aod model survey- RA01001040010X(Ol-0010)
Engine(l) Model Sales O utput in kW Displacemen t in Compression

designation atrpm cem Ratio: 1
104.941
202.028 C280 Sedan 142/5500 2799 10.0
HFM-SFI
104.941
202.028 C36 AMG Sedan 206/5750 3606 10.5
HFM-SFI
104.942
124.008 E 280(2) LWBch. 142/5500(3) 2799 9.2
HFM-SFI
104.942
124.028 E 280(2) Sedan 142/5500(3) 2799 9.2
HFM-SFI
104.942
124.029 E 280(2) SedanLWB 142/5500(3) 2799 9.2
HFM-SFI
104.942 124.088
(4) E 280(2) T-model 142/5500(3) 2799 9.2
HFM-SFI
104.943 129.058
(4) SL280 Roadster 142/5500 2799 10.0
HFM-SFI
104.944 140.028
(4) S 280 Sedan 142/5500(3) 2799 10.0
HFM-SFI
104.945
210.053 E280 Sedan 138/5500 2799 10.0
HFM-SFI
104.980 CFI 124.031 300E-24 Sedan 170/6200 2960 10.0
E3.4
104.980 CFI 124.031 Sedan 200/6500 33 14 10.5
AMG
300 CE-
104.980 CFI 124.051 Coupe 170/6200 2960 10.0
24
CE3.4
104.980 CFI 124.051 Coupe 200/6500 33 14 10.5
AMG
104.980 CFI 124.061 300 E-24 Conv. 170/6200 2960 10.0
104.980 CFI 124.091 300 TE 24 T -model 170/6200 2960 10.0
TE 3.4
104.980 CFI 124.091 T-model 200/6500 33 14 10.5
AMG
104.981 CFI 129.061 300 SL 24 Roadster 170/6200 2960 10.0
104.990 LH- 140.032 100 SF. Sedan 170/6200 3199 10.0

Mercedes-Benz
SFI 3.2<2)
300 SEL
~~~· 990 LH- 140.033 3.2<2) SedanLWB 170/6200 3199 10.0
104.991
129.063 SL320 Roadster 162/6200 3199 10.0
HFM-SFI
104.992
124.032 E 320(2) Sedan 162/5500 3199 9.2
HFM-SFI
104.992
124.052 E 320C(2) Coupe 162/5500 3199 9.2
HFM-SFI
104.992 E36
124.052 Coupe 200/575 0 3606 10.5
HFM-SFI AMO
104.992
124.066 E 320(2) Conv. 162/5 500 3199 9.2
HFM-SFI
104.992 E36
124.066 Conv. 200/5750 3606 10.5
HFM-SFI AMG
HFM-SFI = HFM sequential rnultiport fuel injection !ignition system
CFI = Continuous fuel injection system, electronic
LH-SFI = LH sequentia1 multiport fuel injection system
(1) Optiona11ow compression 12.276 or 012.496 Optional ernissions control 012.458
(2) Sales designation revised as of 0711993

(3) Up to 04/1993 with 145 kW standard, HM 0011 Motronic control unit, was HM 0002.
(4) A1so as RHS model
Emri.ne(l)
b
Model Sales Output in kW Displacement in Compression
designation at rpm ecm Ratio: 1
104.992
124.092 E320(2) S.W. 162/5 500 3199 9.2
HFM-SFI
124.092 ¡~¿;
104.992
S.W. 200/5750 3606 10.5
HFM-SFI
104.994
140.032 S 320 Sedan 162/5 500 3199 10.0
HFM-SFI
104.994
140.033 S 320 SedanLWB 162/5500 3199 10.0
HFM-SFI
104.995
210.055E 320 Sedan 162/5500 3199 10.0
HFM-SFI
104.996
HFM-SFI
463.2 320GE ccv 155/5500 3199 9.2
HFM-SFI = HFM sequential multiport fuel injection!ignition system

CFI = Continuous fuel injection system, electronic
LH-SFI = LH sequential multiport fuel injection system
3) Up to 04/ 1993 with 145 kW standard, HM 0011 Motronic control unit, was HM 0002.
4) A lso as RHS model
Mercedes-Benz
1990-2002 ENGINE Complete Eng ine - REPAIR & ADJUSTMENTS- 129 Chassis
(1) Optionallow compressjon 12.276 or 012.496 Optional emissions control 012.458

(2) Sales designation revised as of 07/1993
Engine and model survey- RA01001190010X{Ol-0010)
Engine Model Sales Output in kW Compr. Displacement in

designation atrpm ratioCompression Ratio : ccm
1
las of7/93 up to
1 6/93 1 1
~~; ° CIS6
129.066
500
SL
240/5500 10 4973
500
119.960 CIS 129.066 245/5500 10 4973
SL
11 9.960 CIS 500
~(1 )
129. 066 235/5500 8.8 4973
SL
~~i70 LH 140.050
500
SE
240/5700 10 4973
119.970 LH 500
~(l)
140. 050 8.8 4973
SE
~~i70 LH 140.051
500
SEL
240/5700 10 4973
119.970 LH 500
~(l) 140. 05 1 8.8 4973
SEL
~~;70 LH 140.070
500
SEC
240/5700 10 4973
119.970 LH 500
~(l)
140. 070 8.8 4973
SEC
¿~; 70 LH 140.050S 500 235/5600 10 4973
¿~; 70 LH 140.051 S 500 (LWB) 235/5600 10 4973
~~;70 LH 140.070S 500 (Coupe) 235/5600 10 4973
¿~; 71 LH 140.042 400

210/5700 10 4196
SE
¿~; 71 LH 140.043 400
210/5700 10 4196
SEL
~~;7l LH 140.042 S 400 205/5700 11 4196
¿~; 71 LH 140.043 S 400 (LWB) 205/5700 11 4196

Mercedes-Benz
1990-2002 ENGINE Complete Engine - REPAIR & ADJUSTMENTS - 129 Chassis
¿~{ 71 LH 140.063 S 400 (Coupe) 205/5700 11 4196
¿~;n LH 129.067 SL 500 500

235/5600 10 4973
SL
¿~{ 74 LH 124.036 500 E 240/5700 10 4973
119.974 LH 124.036E 500 235/5600 10 4973
119.975 LH
124.034 400 E 210/5700 10 4196
CAT
119.975 LH
124.034E 400 205/5700 11 4196
CAT
CIS = Continuous electronic fuel injection system
LH = LH-SFI = Air mass metering with hot wire
(I) Fuel-economy
E ngine Model Sales Output in kW Compr. Displacement in

designation at rpm ratioCompression Ratio : ccm
1
¡as of 7/93 up to
1 6/93 1 1
¿~;so ME 140.050S 500 235/5600 11 4973
¿~;so ME 140.050S 500 235/5600 11 4973

119·9 SO ME 140 OSOS 500
~(l ) . 230/5600 9.1 4973
¿~;so ME 140.051 S 500 (LWB) 235/5600 11 4973
~C~)SO ME 140.051 S 500 (LWB) 230/5600 9.1 4973
¿~¡so ME 140.070S 500 (Coupe) 235/5600 11 4973

119.9SO ME
NV(l) l40.070S 500 (Coupe) 230/5600 9.1 4973
¿~;s 1 ME 140.042S 400 205/5700 11 4196
h~iSI ME 140.043S 400 (LWB) 205/5700 11 4196
¿~;s 1 ME 140.063 S 400 (Coupe) 205/5700 11 4196
h~iS 2 ME 129.067SL 500 235/5600 11 4973
119 985 ME
Mercedes-Benz
CAT 210.072E 420 205/5700 11 4196

h~{ 85 ME 210.272E 420T 205/5700 11 4196
CIS = Continuous electronic fuel injection system
LH = LH-SFI = Air mass metering with hot wíre
ME = ME-SFI = Electronic engine management
(1) Fuel-economy
Engine and model survey - RA01001200010X(Ol-0010)
Engine Model Sales designation Output in kW at rpm Compression Ratio : 1

120.980 140.056 600 SE 300/5200(2) 10.0
120.980 140.057 600 SEL 300/520oC2) 10.0
120.980(1) 140.056 600 SE 280/5200 8.0
120.980(1) 140.057 600 SEL 280/5200 8.0
120.980 140.076 600 SEC 290/5200 10.0
120.980(1) 140.076 600 SEC 280/5200 8.0
120.981 129.076 600 SL 290/5200 10.0
120.981 (l) 129.076 600 SL 280/5200 8.0
120.982(3 ) 140.056 S 600 290/5200 10.0
120.982(3) 140.057 S 600 (LWB) 290/5200 10.0
120.982(3) 140.076 S 600 ( Coupee) 290/5200 10.0
120 983(3) 129.076 SL600 300/5200 10.0
(1) Fuel-optimized, without catalytic converter (TWC)
(2) 290/5200 as of model year 1993
(3) Motronic as ofmodel year 1995
WARNING INSTRUCTIONS WHEN HOOD OPEN- RA01001040085X(Ol-0085)
&oanaerl
A risk of injury exists when the hood is opened and the engine is running. The engine is equipped with an
electronic distributor ignition (DI) system. Because ofthe high ignition voltage it is extremely dangerous to
toucb components of the ignition system (ignition coil, ignition cables, spark plug connectors, test socket) when
• the engine is running,

• the engine is started,
• the key in the steering lock is in position 2 and the engine is cranked by hand.
Mercedes-Benz
1990-2002 ENGINE Complete Engine- REPAIR & ADJUSTMENTS - 129 Chassis
Gefahrtiche Hochspannung!
Vorsfcht be4Arbe4ten an der
Zündan~ge
Danged High voltage

O~erve caution when worlcing
on the ignl11on system
Danger! Haute tenslon

Attentíon lors de travaux au
systeme d'aUumage
Fig. 1: Identifying Instructions For Performing Work On Breakerless Transistorized Ignition

System
Pay attention to instructions regarding perfonning work on the breakerless transistorized ignition system ( 15-
0505)!
TESTING COMPRESSION PRESSURE- RA01001040100X(Ol-0100)
Testiug compression pressure- RA01001040100X(Ol-0100)
Preceding work:
Warning instructions when hood open {01-0085).
01-1200
Mercedes-Benz
P01-5824-57
01 Veráctrungssthrmber, Sond91'Neik2oog001 589 7711 00
02 ZWJScheosWck
03 Dlegmmmbla'l
Fig. 2: Testing Compression Pressure
Engine warm up to normal operating temperature.

Sparkplug remove, install (AP15.00-l580CA).
Compression tester connect.
crank severa! times by pressing contact switch on compression tester, in idle
Engine s~ed position and handbrake applied, to expell residues and soot (01-0110) .
C!:Js~ Do not crank engine at ignition/starter switch.
Diagram sheet (03) insert into compression tes ter (01).
Compression tester (O 1) press into spark plug boJe of respective cylinder.
Tiuottle valve open fully.
Engine crank approx. 8 revolutions with starter (01-0110).
All cylinders check in this manner.
If minimum compression
check cylinders for leaks (01-1300).
pressure not achieved
TEST DATA
Test data when engine at normal operating temperature Overpressure in bar
normal comnression min. 10 max. 14
Mercedes-Benz
Compressíon pressure at fuel-optimized min. 6 max. 10

Pennissíble difference between individual cylinders max. 1.5
Special tool
001 589 76 21 00
Fig. 3: Identifying Special Tool (001 589 76 21 00)
Testing compression pressure- RA01001190100X(Ol-0100)
01-1200
Mercedes-Benz
01 CompresSionms!Df, specta! tool001 589 77 21 00

02 Adaplll
03 Dlagram shoel
04 Señlg eone
Fig. 4 : Testing Compression Pressure
Engine warm up to operating temperature.

Spark plugs remove , install (15-1031) .
Engine crank with starter to expel residues and soot (01-0110).
Diagram sheets (03) insert into compression tester (01).
Compression push tester (O 1) into spark plug hole of relevant cylinder.
Engine crank about 8 revolutions with starter (01-0110).
All the cylinders check in this way.
Spark plug recesses blow out with compressed air.
lf minimum compression pressure not reached, check cylinders for leaks (01-0150).
TEST DATA FOR ENGINE AT NORMAL OPERATING TEMPERATURE, PRESSURE IN BAR

Normal compression min. lO max. 14
Compression pressure at
Fuel-optirnised min. 6 max. 10
Permissible difference between individual cylinders max. 1.5
Spec.i al tools
Mercedes-Benz
001 589 76 2~ 00
01
l~
\02 589 02 09 00
15
1195890200 00
15
Testing compressiou Jlressure, bazard waroiogs - RA01001200100X(Ol-0100)
01-1200
Mercedes-Benz
01 COIYJllas-saonpcessuere-corder,spi~clliltooi001 589 77 21 00
02 Adaptar
03 Dlagam sñee!
()4 Sea/íng C0/18
Fig. 8: Testing Compression Pressure
Model 129
&.oanQerl
Risk of injury when hood opened and engine running.
The engine is equipped with an electronic ignition system. Because of the high ignition voltage, it is extremely
dangerous to touch any of the ignition components (igni tion coil, distributor, ignition cables, spark plug
connectors, test socket) when
• the engine is running.

• the engine is started.
• the key in the steering lock is in position 2 and the engine is being cranked by hand.
Mercedes-Benz
Gefahr!iche Hochspannung!
Vors1cht bei Arbeitsn an der
Zündan~g e
Dangerl High voltage

Obse.....e t:aution wtten working
on the ignition system
Oanger! HatJte 1enslon

Atternion lors de travawc au
systeme d'allumage
P-15-0241-13
Fig. 9: Identifying Hazard Warning Label
the engine is being cranked by hand.
Pay attention to notes regarding working on breakerless transistorized ignition system (15-0550)!

Sparkplugs rernove, install {15-1031) .
crank several times to eliminate residues and soot (01-0110) by pressing at
Engine contact handle of compression pressure recorder (O 1) in closed throttle
position and parking brake applied.
Diagram sheet (03) insert into compression pressure recorder (O 1).
Compression pressure
pre ss in into spark
recorder (01) with
adapter (02) and sealing
plug hole of relevant cylinder.
cone (04)
Model 140: Throttle
open fully by means of accelerator pedal.
valves
Engine crank with starter approx. 8 revolutions (01-0110).
All cylinders test in the same manner.
Spark plug reces ses blow clean with compressed air.
Fault memory ofDI
read (see Diagnosis Manual Engine
control module
(Nl /4 and Nl/5) Volume 2, Index 0).
If minimum compression test cylinders for leaks {01-0 150).
pressure not achieved
NOTE: Model 129: Test cylinder 12 with 90° adapter (05) beca use of fuel lines.
Modell40: Test cylinders 6 and 12 with 90° adapter (05).

Mercedes-Benz
MOOel 129
Fig. 10: Identifying Compression Pressure Recorder
TEST DATA
Compression ratioCompression Ratio 10 - 0.4 (8.0)(1)
Pressure in
Test data for engine at operating temp.
bar
max.
min. 10
Normal compression Fuel- 14
Compression pressure at
optimized max.
min. 6
10
Pem1. difference between individual
max. 1.5
cylinders
(l) Fuel-optimized
Special tools
001 589 76 2i 00
01
F ig. 11: ldentifving Special Tool (001 589 76 21 00)

Mercedes-Benz
~ ~
1os
120 689 02
0/
00
15
1 1958~020000
,S
Fig. 13: Identifying SpeciaJ Tool (119 589 02 09 00)
CRANKING ENGINE AT FRONT OF CRANKSHAFT- RA01001040120X(Ol-0120)
Cranking engine at front of crankshaft - RA01001040120X(Ol-0120)
Preceding work:
Waming instructions when hood open (01-0085).

Mercedes-Benz
1990-2002 ENGINE Complete Engine - REPAIR & ADJUSTMENTS- 129 Chassis
P01-5825-57
~lal a-3Smm
Fig. 14: Sectional View Of Crankshaft
Cranking crankshaft from below
MODELS 124, 129, 202, 210

Fan cowl remove, install (20-3400) .
Vehicle raise on lift platform, lower.
Bottom engine
remove, install.
compartment panel
crank with torque wrench (1) and wrench socket (2) 001 589 65 09 00 WAF
Crankshaft
27 in direction of rotation of engine.
crauk with torque wrench ( 1) hexagon socket WAF 2 7 in direction of rotation
~odel202: crankshaft
ofengiue.
MODEL 140
Fau cowl riug offan cowl take off, fit on (20-3400) .
Vebicle raise on lift platform, lower.
Mercedes-Benz
remove, install (Maintenance

Bottom engine compartment panel
Manual6190).
Crankshaft with torque wrench (1) and wrench socket (2) 001 589 65 09
00 W AF 2 7 in direction of rotation of engine crank.
Cranking engine at crankshaft from above
MODELS 124, 129, 140,210

Fan cowl remove, install (20-3400).
Cran.kshaft crank with torque wrench ( 1) and wrench socket (2) waf 27 in direction of rotation of engine.
MODEL202
Viscous fan clutchremove, install (20-3120) .
Crankshaft crank with torque wrench (1) hexagon socket waf 27 in direction of rotation of engine.
Special tools
000 58910 99 01
001 589 65 09 00
Fig. 16: Identifving Special Tools (001 589 65 09 00)
Cranking engine at front of cranlksbaft- RA01001200120X(Ol-0120)

Mercedes-Benz
ea
1 2
P01-5713-57
Fig. 17: Cranking Engine At Front Of Crankshaft
ROTATING CRANKSHAFT FROM BELOW MODELS 129, 140

Fan sbroud remove, install (20-3400)
Car raise on lift platfonn, lower
Bottom engine
remove, install (Maintenance Manual6190)
compartment panel
rotate with torque wrench (1) and wrench insert (2) 001 589 65 09 00 waf27
Crankshaft
in direction of rotation of engine
ro tate with torque wrench ( 1) socket bit waf 2 7 in direction of rotation of
Model202: crankshaft
engme
MODEL 140
F an sbroud ring remove from fan sbroud, fit on (20-3400)
Car raise on lift platform, Iower
Bottom engine
remove, install (Maintenance Manual 6 190).
compartment panel
Mercedes-Benz
rotate with torque wrench ( 1) and wrench socket (2) 001 589 65 09 00 waf 27
Crankshaft
in direction of rotation of engine
ROT ATING AT CRANKSHAFT FROM ABOVE MODELS 129, 140

Fan shroud remove, install (20-3400)
Crankshaft rotate with torque wrench (1) and wrench socket (2) waf27 in direction of rotation of engine
Special tools
000 589 10 99 01
001 589 65 09 00
TESTING CYLINDERS FOR LEAKS- RA01001040150X(01-0150)
Testing cylinders for leaks- RA01001040150X(Ol-0150)
Preceding work:
Warning instmctions when hood open (01-0085).
Air cleaner removed (AR09.10-1050D)
Mercedes-Benz
01-1300
P01-5a2~S7
Fig. 20: Testing Cylinders For Leaks

Ground cable at
disconnect, connect, encode radio, model 140 normalize power windows.
battery
Sparkplugs remove, install (AP15.00- 1580CA).
Cap (1) on expansion
open, leave open, close.
reservoir (2)
Coolant level adjust to correct level (20-0100) .
Oil filler cap (3) take off, fit on.
Cylinder leak tester (5) connect to compressed air system.
Tester (5) calibrate.
Connection hose (5a) screw into ftrst spark plug hole.
rotate at crankshaft with setting device to ignition TDC (01-0120).
Piston of cylinder to be
tested NOTE:
See table for pistons in TDC.
Connection hose (5a) connect to tester (5).
Mercedes-Benz
pressurize (approx. 5 bar).

&.oentter!
Compression chamber
When doing this, do not rotate the crankshaft; ifnecessary, lock crankshaft in
position to prevent it tuming (03-5000) .
Throttle valve open by band.
read off
Pressure loss at tester
Determine whether the pressure escapes through intake manifold, exhaust, oil
5
( ) (in%) filler opening, spark plug hole ofadjacent cylinder or through coolant opening.
A ll cylinders test in firing order (1-5-3-6-2-4).
DATA
Total pressure loss max. 25%
At val ves and cylinder head gasket max. 10%
At pistons and piston rings max. 20%
PISTO N AT TDC WITH MARKING INDEX ON VIBRATION DAMPER

Marking TDC b=l20° a=240°
Piston at TDC of cylinder 1 and 6 2 and 4 3 and 5
CO~RC~LLYAV~ABLETOOL
lcylinder leak tester e.g. Bosch, EFA W 21 OA Sun, CLT 228
NOTE: After spraying oil onto the piston crown, it is possible to determine whether the
leak exists at the piston rings or at the valves, or at the cylinder head gasket.
Testing cylinders for leaks- RA01001190150X(Ol-0150)
Operatíon no. of operation texts and work units or standard texts and flat rates
01-1300
Engine warm up to operating temperature.

Ground cable at battery ctisconnect, connect.
Spark plugs remove, install (15-1031) .
open, close.
Cap on.coolant .
&.011naer! Do not open cap tmless coolant temperature is below 90 °C. Risk of
expanswn reserv01r
scalding!
Coolant level adjust to correct level (20-0100) .
Oil filler cap open, close.
Cylinder leak tester connect to compressed air system.
Tester calibrate.
Connection hose screw in to first spark plug hole, remove.
Pi<:tnn nf r.v linrlP.r tn hP position with adjuster by turning crankshaft to ignit1on TDC.
Mercedes-Benz
tested
Piston in ignition TDC see table.
Connection hose of
connect, disconnect.
tester
pressunze.
Compression chamber &oanqer! The crankshaft must not rotate; if necessary secure crankshaft with
locking device to prevent it rotating (03-5000) .
Throttle valve open by hand.
Pressure loss on tester
read off.
in%
determine whether leak through intake manifold, exhaust, oil filler opening,
Pressure
spark plug hole of adjacent cylinder or coolant filler opening (at reservoir).
All cylinders test in firing order (l -5-4-8-6-3-7-2).
DATA
At valves and cylinder head gasket max. lO%
Marking index Piston in TDC

o 1 and 6
90 5 and 3
180 4 and 7
270 8 and2
COMMmRCMLLYAV~ABLETOOL
lcylinder leak tester e.g.Bosch, EFAW 210A Sun, CLT 228
Testing cylinders for Jeaks- RA01001200150X{Ol-0150)
Preceding work
Open hood, raise to vertical position (01-0080)
01-1300
DATA
At valves and cylínder head gasket max. lO%
Mercedes-Benz
lspark plugs 25
Special tools
120 589 0:2 os 00

15
119 589020900
15
001 580 65 09: 00

03 07 32 )
Fig. 23: Jdentifying Special Tool (001 589 65 09 00)

Mercedes-Benz
001 589 72 21 00
00
COMMmRCMLLYAV~ABLETOOL
Bosch, EFAW 210 A
Cylinder leak tester eg. Sun, CLT 228
Testing
l. Wann engine up to operating temperature.

2. Disconnect ground cable at battery.
3. Remo ve air cleaner together with mass air flow sensory (09-0015) .
4. Remove viscous fan clutch (20-3120).
5. Blow out spark plug recesses with compressed air.
6. Unscrew spark plugs {15-1031) .
Fig. 25: Unscrewing Spark Plug
7. Adjust coolant to conect leve! (anow) and leave filler opening on coolant reservoir open.
8. Take off oil filler cap.
9. Connect cylinder leak tester toa compressed air system and calibrate tester.
Mercedes-Benz
10. Screw connection hose into fust spark plug hole, fit on whistle.
Fig. 26: ldentifving Oil Filler Cap
11. Turn piston of cylinders to be tested to ignition TDC with socket wrench, special tool 001 589 65 09 OO.
The respective pistons are in ignition TDC, or in TDC position, when the following markings on the
vibration damper are aügned with the TDC pointer.
NOTE: The markings at 60, 180 andl 300 on the vibration damper are affixed as of
July 1992 (phased-in). lf an engine is not provided with these markings,
determine the respective TDC position by means of the spark plug hole
and the piston.
Fig. 27: Locating Markings On Vibration Damper
Marking number Pistons at TDC

O 1 and 6
Mercedes-Benz
60 7 and 12
120 2 and 5
180 8 and 11
240 3 and 4
300 9 and 10
12. Fit on connection hose oftester and pressurize combustion chamber (approx. 5 bar).
The crankshaft must not be rotated when performing this step.
13. Open throttle valves by hand.

14. Read offpressure loss at tester (in%).
15. L isten to determine whether the pressure escapes through the intake manifold, exhaust, oil fi ller opening,
spark plug hole of adjacent cylinder or coolant fille r opening.
16. Test all the cylinders in the firing order (1 -12-5-8-3- 10-6-7-2-11-4-9).
NOTE: lt is possible that the piston ring gaps of individual pistons are positioned
immediately above each other and therefore falsify the result of the test. In
cases of doubt, run engine and recheck the cylinders for leaks after short
period.
1 12 s a a 10 a 1 2 tt .a a
Fig. 28: ldentifying Firing Order
INSPECTING CYLINDERS WITH INSPECTION LAMP, ASSESSING - RA01001040200X(Ol -0200)
I nspecting cytinders with inspection Jamp, assessing- RA01001040200X(Ol-0200)
Preceding work:
Removing, installing spark plugs (AP15.00- 1580CA)

Mercedes-Benz
Warning instructions when hood open (01-0085)
01-1321
••
P01-6031-37
Fig. 29: Ideotifying Cylinders Inspection Equipment
Pis ton set to BDC; see table.

connect.
Motoskop and lense probe Motoskop TW 12 V to car battery
Motoskop TW 220 V to mains.
Lenseprobe insert into cylinder, remove.
Cylinder inspect, assess; see note.
COMMffiRC~LYAV~ABLETOOL
Mercedes-Benz
Karl Storz GmbH,

78532 Tuttlingen
Motoskop TW (cold light)
Cylinder inspection equipment e.g. wíth lense probe
103 26 CW (570 mm)
86590CF (700 mm long, focussable)
Marking ind.ex at TDC pointer Piston in BDC position

60 3 and4
180 1 and 6
300 2 and 5
NOTE: In assessing the honing pattern of the cylinder surface it is necessary to

distinguish between "visual" streaks or "seizure" streaks.
Visual streaks are not roughened and may originate from the ring gap; the traces ofhoning are still visible.
In the case of seizure streaks or cylínder wear, the cylinder surface is roughened, or smoothed and the traces of
honing are no longer visible.
Inspecting cylinders with light probe, assessing cylinders - RA010011 90200X{Ol-0200)
Preceding work:
Removing, installing spark plugs (AP 15.00-1580CA)
Hazard warnings when hood opened (01-0085)
01-1321
Mercedes-Benz
® •
Fig. 30: Inspecting Cylinders With Ligbt Probe
Piston position to BDC, see table.

connect.
Motoskop and lens pro be Motoskop TW 12 V tocar battery
Motoskop TW 220 V to mains.
Lens probe insert into cylinder, remove.
Cylinder inspect, assess, see note.
COMMffiRCMLLYAV~ABLETOOL
Karl Storz GmbH,
78532 Tuttlingen
Cylinder inspection lamp e.g. Motoskop TW (cold light)
with lens probe
103 26 CT (210 mm)
Marking index on TDC pointer Piston in BDC position

Mercedes-Benz
o 4 and 7
90 8 and 2
180 1 and 6
270 5 and 3
NOTE: lf complaints are received regarding an engine because of noises, overheating,

oil consumption etc., it is good practice to perform a visual inspection with a
cylinder inspection lamp with the cylinder head installed.
The information which follows is designed to help in assessing the cylinder walls, in taking a proper
professional decision regarding the condition and further use of the crankcase.
l. Normal condition
Mat grey surface, no honíng pattern.
If it is not possible to assess the cylínders with sufficient certainty by means of a visual inspection with
the cylinder inspection lamp, the cylinder head should then be removed.
2. Bright pressure marks, smoothing
Individual bright points e.g. in the rniddle of the cylinder or in the area of the cylinder head bolt pipes.
Continue using crankcase.

Mercedes-Benz
·P01 -6017- 3S
Fig. 31: Identifying Bright Points In Middle Of Cylinder
3. Bright cylinder surfaces, polisbed and reflective all round
Usually starting :from the first piston ring, in the top area of cylinder, with measurable partial cylinder
wear.
Cylinder wall unserviceable.

Mercedes-Benz
P01-601a..35
Fig. 32: ldentifying Bright Cvlinder Surfaces
4. Visual streaks, traces of rubbing
Starting from fust piston ring, extending for about 30 mm. Traces of dry rubbing wbich cannot be felt,
caused by fuel ablutíon of the oil film, e.g. frequent cold starting in short-distance drivíng. These traces of
rubbing, wbich are likely to be found in the area of the cylinder head bolts and on the pressure side, are
acceptable if smoothed. The pis ton rings are not damaged. Continue using crankcase.
Mercedes-Benz
.P01 -6019-35
Fig. 33: Identifying Visual Streaks, Traces Of R ubbing
5. Roughened streaks, traces of seizure
Starting :from the first and second piston ring and extending initially to the bottom part of tbe cylinder.
Traces of rubbing as described in section 4 have progressed to seizure. Piston rings may be darnaged.
If the streaks can be felt, cylinder wall unserviceable.

Mercedes-Benz
P01-6020.35
Fig. 34: ldeotifying Rou ghened Streaks, T races Of Seizure
6. Ring-shaped impressions
Visible in the top and bottom piston ring reversal area, are acceptable.

Mercedes-Benz
P01-6017-35
Fig. 35: Identifying Ring-Shaped lmpressions
7 _ Traces of individual, continuous scratches
Caused by dirt, e.g. by soot particles being pulsated back out of the exhaust.
8_ Piston seizure
Cylinder wall usuaHy roughened over the entire length to the extent that this can be felt
Material accumulation and traces of seízure on cylinder wall and pisten skirt whích can be felt
Cylinder wall unserviceable.
9_ Brown discoloration of cylinder surfaces
Oil vamish exists over considerable areas of the cylinder wall and indicates that the engine has been
driven in a very high temperature leveL
Continue using crankcase provided no impermissible cylinder distortion ex:ists.
Oil varnish above the oiston ring zone is normal and is acceotable_
Mercedes-Benz
Inspecting cylinders witb inspection Lamp, assessing - RA01001200200X(Ol-0200)
Preceding work:
Removing and installing spark plugs (15-1031).
01 -1321
Fig. 36: ldentifving Cvlinder lnspection Eguipments
Front engine compartment panel at bottom take off, fit on (step 1).
set to BDC ( socket wrench
Respective piston
001 589 65 09 00, step 2).
Cable mounting at engine components unbolt, push forward when testing cylinders 6 and 12, bolt on
partition (step 3).
Motoskop and lens probe connect, disconnect (step 4).
Cylinder contact surface examine (step 5).
Special tool
001 sao 63 an oo
03 07 32 /

Mercedes-Benz
COMMffiRCULLYAV~ABLETOOL
Karl Storz GmbH,
D-78532 Tuttlingen
Cylínder inspectíon equípment eg. Motoskop TW (cold light)
with lens probe 103 26 CW
(570 mm)
l. Take offfront engíne compartment panel at bottom (Maintenance Manual Volume 2, Op. No. 6190).
2. Turn piston oftbe cylinder to be examined into BDC position with socket wrench 001 589 65 09 OO.
When performíng this step, the marking numbers on the víbration damper must be alígned with the TDC
pointer (see below).
NOTE: The markings on the vibration damper at 60, 180 and 300 have been fitted
additionally as of July 1992 (phased-in). lf the engine is not provided with
these additional markings, determine the respective BDC position by
means of the spark plug hole.
Fig. 38: ldentifying Markings On Vibration Damper
Marking number on TDC pointer Pistons in BDC position

o 8 and 11
60 3 and4
120 9 and 10
180 1 and 6
240 7 and 12
300 2 and 5
3. Modell40: Unbolt cable mounting at engine components partition (arrows) and push forward when
examining cylinders 6 and 12.
Mercedes-Benz
Fig. 39: Locating Cable Mounting At Engine Components Partition
4_ Connect Motoskop lamp and lens probe_
Motoskop TW 12 V to vehicle battery.
Motoskop TW 220 V to mains supply.
5 _ Examine cylinder contact surface.
Assessment
The cylinder contact surfaces are electrolytically treated after boring and honing_ This causes the aluminum to
be set back to the extent that the píston rings and the chromed or iron-coated líght alloy pistons are in contact
only with the approx. 0.02 mm to 0.05 mm large silicone crystals, which produce a wear-resistant contact
surface. No honíng traces are visible on these cylinder contact surfaces. When assessing cylinder walls with
stríatíons or streaks, ít is often difficult for the workshop to decide wbether major damage already exists,
necessítating engine repairs, or wbetber the markings are of no significance. Tbe followíng information is
intended to assist you in coming to a professional and proper decision regarding the condition and continued use
oftbe crankcase. If it is not possible to assess this witb a reasonable degree of certainty wben performing a
visual inspection with the inspection lamp, the cylinder head must be removed.
Mercedes-Benz
Fig. 40: Identifying Cylinder I nspection Equipments
NOTE: 1. Normal state
Mat grey surface, no honing1pattern
2. Glossy pressure points, smooth areas Individual bright points, eg. in the
middle of the cylinder or in the area of the cylinder head bolt ribs.
Crankcase can continue to be used.
3. Brown discoloration on cylinder surfaces Oil varnish is present over
extensive areas of the cylinder wall (normal above the piston ring zone)
and indicates that the engine has been driven within a very high
temperature level. Crankcase can continue to be used.
4. Visual streaks, traces of rubbing
Starting from the first piston ring and tapering out after about 30 mm.
Traces of dry rubbing which cannot be felt caused by fuel ablution of the
oil film, eg. as a result of frequent cold starting when driving short
distances.
These traces of rubbing which tend to occur in the area of the cylinder
head bolts and on the delivery side do not represent a problem if they are
smoothed. The piston rings are not damaged.
Crankcase can still be used.
5. Ring-shaped impressions
Visible in the top and bottom reversa! area of the piston rings, are not a
problem. Crankcase can continued to be used.
6. Individual continuous scratches

Mercedes-Benz
Caused by impurities, eg. as a result of back-pulsation of soot particles

from the exhaust. Crankcase can continued to be used.
7. Roughened streaks, friction seizures
Starting from the first and second piston ring and not tapering out until
bottom part of cylinder. Traces of rubbing as described in item 4, progress
to form friction seizures. Piston rings may be damaged. lf can be felt,
cylinder wall unusable.
8. Piston seizures
Cylinder contact surface is usually felt to be rough over the entire length.
Material wear and traces of rubbing can be felt on cylinder contact surface
and piston skirt. Cylinder wall unusable.
9. Bright, reflective, polished cylinder surfaces all round
Usually starting from the first piston ring, in the upper area of the cylinder,
with a measurable partial cylinder wear. Cylinder wall unusable.
FUNCTION DESCRIPTION OF CRANKCASE VENTILATION - RA01001040400X(Ol -0400)
Function descriptioo of crankcase ventilation- RA01001040400X(Ol-0400)
Engine 104.98 CFI-J etronic

Mercedes-Benz
-----
--
- -.....---
--
----
-----
----
---- --~----
P01-5843-57
1 Crankcase 10 ktill<ll ma.n;fold

2 An aOOIJSSIOil ~enng 11 crañ<caso 11 0flin dar he:ed ro·•er
2a Openng for ol ot/Jel 12 Alrdeanor
3 Gasket 13 011soparalor
4 Gombalejon supportla.TedlnJSSJon housmg) 14 f>.Jr edlmsSion cr wm hose
5 Otl oulot~ 15 Ttfolle w.vo
6 011SIITlp A. Frostl air
7 Alr EltWn1Ssi011 we 8 Pert load bla.v.by gases
8 Resrdon dnl ng, 2 mm da. e F~ loadblcw-bygases
9 lelo spoed aor port
Fig. 41: Crankcase Ventilation Function- Diagram (Engine 104.98 CFI-Jetronic)
Function at idJe speed position and mid-load
(Throttle val ve (15) closed or only slightly open, high intake manifold vacuum)
The crank:case (1) is vented in part load via the combination support (4) through a 2 mm dia. restriction drilling
(8) in the intake manifold (10) to the idle speed air port (9).
Entrained engine oil is separated out in the combination support (4) and passed along an oil outlet pipe (5) to the
oil sump (6).
The vacuum whích is thus produced in the crankcase draws in fresh air from the air cleaner ( 12) through the air
admission or vent hose ( 14). The addition of fresh air is an additional measure to prevent the formation of
sludge in the engine oil.
Mercedes-Benz
Function at upper part load to fuU load
Throttle valve ( 15) open:
At fll!llload the entire ventilation quantity is passed through the oil separator (13) in the cylinder head cover
(11), the air admission and vent hose (14), the air cleaner (12) the intake manifold (10) to the combustion
chambers.
Engine 104.990 LH-SFI-Jetronic
P01·5844-57
1 Cmnktase 10 Wal<e ma!llloló

2 Ñr admtSSIOfl cpenng 11 crarl<u:se 11 Cyi:nder hilad C<IV9t
:?a Oporing fOf ~ ou!let 12 Alr deaner
3 Gasl<ot 13 Oll sepata10f
4 C001tMnaion S>Jppolt(a:r admtsSion houSing) 14 Alr adrms S!<m and wnt hose
5 Oil ooCet ptpe 15 fuolle valva
6 Oit sump A Frestt an
7 Alr adtmsSton ptpo 8 Part load blo·~ gases
7a Ñr admtSSICn prpe e Fulloadblcw-b'{gases
8 Reslne5on dnl ng 2mm cia
9 kle spaed .ss port
Fig. 42: Crankcase Ventilation Function- Diagram (Engine 104.990 LH-SFI-Jetronic)
Function at idle speed position and midload

Mercedes-Benz
(Throttle valve ( 15) closed or only slightly open, high íntake manifold vacuum)
The crankcase ( 1) is vented in part load vía the combina tion support (4) of the vent pipe (7) through a 2 mm dia.
restriction drilling (8) in the intake manifold ofthe vent pipe (7a) to the intake manifold (10).
Entrained engine oil is separated out in the combination support (4) and passed along an oil outlet pipe (5) into
the oil sump (6).
Ftmction at top part load np to fullload
Throttle valve (15) open:
At fullload the entire ventilation quantity is passed through the oil separator (13) in the cylinder head cover
( 11 ), the air admission and vent hose ( 14), the air cleaner ( 12), the intake manifold ( 1O) to the combustion
chambers. The vacmun thus produced in the crankcase draws in fresh air from the air cleaner (12) along the air
admission and vent hose (14).
The addition of fresh air is an additional measure to prevent the formation of sludge in the engine oil.
Engine 104.941/942/943/944/945/991/992/994/995/996 with HFM sequential muJtiport fuel

injectioo/ignition system (HFM-SFI)
Mercedes-Benz
10
1t
A e::>
B ...
c ..
P01-5845-57
1 Cmnkc'as& 10 lltal<& maflifold

2 Au adrmsston opering 11 creñ<case 10a 111a1<e au p¡pe
2a Op6nng for oi otftlol 11 Cyf¡lder haad oovar
2b Fl &r 13 Od separa!or •Mtl s)phon
3 Gask&t 138 011separelor 'Mtl s')Phon
4 Cornblll&)on Sl.Jpport ( ¡g admJsgon llougng) 14 /IJr adm¡sgon andvort hose 0 9 rrm
5 Oil oueat ptp& 14a Alr adrmssaon andvort hose 0 7 rrm
6 Oilsump
15 Ttrolle valva
Alr adnussaon ~
A Frosn Blr
A Frosh au
7a V&mp~pe
B Par( load biD!~ gases
8 Restncjon dnl ng 2mm á a
e Ful loadblcw.&¡gasas
Fig. 43: Multiport Fuel Injectionllgnition System (HFM-SFI) Function - Diagram
Function at idle speed position and midload
(Throttle valve (15) closed or only slightly open, high intake manifold vacuum)
The crankcase ( 1) is vented in part load through the combination support (4) with filter (2b) of the vent pipe (7)
through a 2 mm dia. restriction drilling (8) in the manifold ofthe vent pipe (7a) to the intake manifold (10).
The addition of fresh air is an additional measure to prevent the formation of sludge in the engine oil. The vent
connections (14) and (14a) have a scoop adapted to the pressure fluctuations in the intake air line (lOa).
Function at top part load up to fullload Throttle valve (15) open:
Mercedes-Benz
At fullload the entire ventilation quantity is passed through the oil separators (13) and (13a) in the cylinder
head cover (11) to the air admission and vent connections (14) with 0 9 mm reduction and (14a) with 0 7 mm
reduction of the intake air line (1 Oa), to the intake manifold (1 O) to the combustion chambers.
Entrained engine oilis separated out in the combination support (4) and passed along the oil outlet pipe (5) into
the oil sump (6).
The vacuum which is thus produced in the crankcase draws in fresh air from the intake a ir line ( 1Oa) through the
air admission and vent connections (14) and (14a).
Function description of crankcase veutilation- RA01001190400X(Ol-0400)
Crankcase ventilation at idle· speed and midpart load
8 4
1 CfllOkcase 10 lntake mlllllold

2 Rigtt 111ake dld 11 lol'tcytndol hoad C<lVDf
3 lettutal<e Wd 11a 011 separabon chamber 1111111t q indor head covor
4 Ven" eoon l ne ~d!e spaedllowM paJt load) 12 Ri gtt cyirl dor head c.over
5 Ventla!Jon l na (upper plllt loadiM lcad) 12a Oíl saparabon chamber m ngtt c¡linder head cowr
6 Ttrotie~<e 13 Syphoo
7 RUbbMklmel A Fresh &r
8 Ros~don onhco, 1.5 mm tía. 8 8cwbygases
9 Oll sepaf8!0fllleftc;linder head at rear
Fig. 44: Function Description Of Crankcase Ventilation At Iclle Speed And Midpart Load
Mercedes-Benz
Engine 119.97/98
The blowby gases flow at id le speed and at lower part load out of the front of the crank:case ( 1) along the left
intake duct (3) into the oil separation chamber (lla) in the left cylinder head cover (11).
The blowby gases then flow along the connection line (4) with the 1.5 mm dia. restriction orifice (8) to the
combustion chambers.
At the same time, fresh air flows into the crank:case (1) through the vent pipe (5), right cylinder head cover ( 12),
oil separation chamber (12a) and intake shaft (2).
When performing repairs, check the flow through the vent pipes 4 and 5 and also the restrictor trimming (8).
Ventilation at upper part load and full load
8 4
1 Cmnkcase 9 Oil sepam!O( ille!tqlinder headal rea;

2 Rlgtt lltal<O d!Jct 10 ttako manlold
3 Lalt1rnake d!Jct 11 Lofi cyinder head covor
4 Voo&labon i ne lí<l& speedllo•mr part load) 118 01 sopasaboo chamb«ll loll e)lindar headc Ovef
5 Vent lation l oe (uppei paltloerdih4 load) 12 Rigl1 cyind!lf head COV9f
6 Throele \'Bive 128 Olsepamboo ch<o..mh« 11 n¡j'lt cytnder haad rever
7 Rubber ilmol A. l=resh au
8 Rasrnc ~oo oofic o, 1.5 mm di a. 8 SlOWby gBS8S
Fig. 45: Function Description Of Crankcase Ventilation At Upper Part Load And FuU Load
Mercedes-Benz
Engine 119.97/98
The blowby gases flow at upper prut load and at fullload out ofthe front ofthe crankcase (1) along the right
intak:e duct (2) into the oil separation chamber (12a) of the right cylinder head cover (12), along the ventilation
line (5) into the intake manifold (1 O) and from there to the combustion chambers.
Entrained engine oil flows through the oil separation chamber (12a) and the downstrerun siphon (13) ínto the oil
separator (9) in the right cylinder head.
The oil separator (9) with rubber funnel (7) defoams the entrained engine oil.
OIL DRAIN PIPE IN BOTTOM OF CRANKCASE, ARRANGEMENT- RA01001040430X(Ol-0430)
Operatíon no. of operation texts and work uníts or standard texts and flat rates:
B
1
! 1
-1-------+----------- -
?01.40-0234- 'S7
Ellg;¡19 104.941/942.94319451991.992/9951'996 e fnQII1e 104.980

asO:FebruBIY1995 ang!o 51 msteadol45 • o fnQIIf1e104 990
B fnQile104.944/994
Fig. 46: Identifying Oil Drain Pipe In Bottom Position
install in position illustrated.

NOTE:
Mercedes-Benz
drain The oil drain pipe (5) is designed as a siphon. This prevents engine oil being drawn in
pipe (5) together with the blow by gases if the opening of the oil drain pipe (5) is positioned below
the oil leve l. The oil drain pipe (5) is knocked into the oil drain hole in the crankcase (1) in a
particular position.
NOTES REGARDING CRANKCASE - RA01001041000X(01-1000)
Notes regarding cra nkcase - RA01001041000X(Ol -1000)
Model designation identification
Replacement crankcases and short blocks do not have a stamped engine model designation and engine number.
The workshop performing repairs must stamp the engine model designation in the crankcase in the space
provided for the engine number (arrow) on the right in front of the engine support to enable the engine of the
vehicle to be properly identifíed ( e.g. by vehicle inspection authority after vehicle has been laid up or by
Customs if vehicle is exported etc.).
Example:
104.941 (engine model designation in model202.028), see also (01-0010).
The engine compression ratio (Compression Ratio) is stamped after the engine number.
P01 .40-02'~1 3
Fie. 47: Locatine E neine Number
Since January 1991 crankcases with additional bearing seat openings on the side (1) have been used as standard.
This improves the pressure distribution in the crank chamber.

Mercedes-Benz
Threaded boles in crankcase, see (01-1220).
Fig. 48: Identifying Additional Bearing Seat Openings On Side
The crankcase of engine 104.990 has been strengthened with additional cast ribs ( 1) at the outer contours. This
results in a change in the knock sensor signals (KSS) which necessitates a modified ignition control module
(DI).
Production breakpoint April 1991 (2nd version)
as of engine as ofvehicle ident no.
104.990-10-000 081 140.032/033-lA-002520
104.990-12-001 169
As of April 1991 2nd version

Mercedes-Benz
P<l1.40.02'69-1 3
Fig. 49: ldentifying Additional Cast Ribs - As Of April1991 2nd Version
When replacing the crankcase or installing a reconditioned engine, the matched ignition control module (DI)
should be used (see table). Except for USA models.
Up to April 1991 1st versíon
P01.40.02'70-1 3
F ig. 50: ldentifving Additional Cast Ribs- Up T o April19911st Version
MATCHING CRANKCASE AND DI IGNITION CONTROL MODULE (EXCEPT USA MODELS)

Crankcase Boscb DI Siemens DI
1st version 009 545 64 32 009 545 67 32
up to Apríl 1991 up to Apríl 199 1 up to Aprill 992
2nd version 012 545 71 32 012 545 72 32
as of Apríl 1991 as of Apríl up to June 1991 las of Apríl up to June 1991
2nd version 012 545 80 32 012 545 81 82
as of April 1991 as of June 1991 las of June 1991
Notes on crankcase- RA01001191000X(Ol-1000)
Ooeration no. of ooeration texts and work units or standard texts and flat rates
Mercedes-Benz
ldentification of model designations
The engine number 1st version is stamped at the rear left in the engine flange, behind cylinder 8.
Engine number l st version up to January 1991 :
119.960 12 up to end ofproduction
119.970 12 000 265
119.97112000531
119.972 12 000 016
119.974 12 000 300
The engine number 2nd version is stamped at the top front left (arrow) in the crankcase.
Engine number 2nd version as ofFebruary 1991:
119.970 12 000 266
119.971 12 000 532
119.972 12 000 017
119.974 12 000 301
19.98 as of start of production
Replacement crankcases and short blocks are not stamped with an engine number or engine model designation.
To make it possíble to identify the engine installed in a vehicle, the workshop performing repairs has to stamp
the engine model designation in the crankcase in the engine number block
Mercedes-Benz
P01..0185-13
Fig. 51: Locating Engine Number 2Nd Version
Example:
119.974 (engine model designation in model
124.036), see 01-0010 in this connection.
PG1-5307-1 3
Fig. 52: Locating Engine Model Designation Number
The "closed-deck" design of crankcases are fitted from the start of series production with HELI-COIL inserts
for the cylinder head bolts.
Standard up to engine:
119.970 12 045 020

Mercedes-Benz
119.970 12 045 886 up to 045 892
119.971 12 017 446
119.972 12 008 660
119.972 12 008 924 up to 008 998
119.974 12 008 760
119.974 12 008 820 up to 008 821
119.975 12 010 515
P01..soo6-13
Fig. 53: ldentifving Cvlinder Head - Closed-Deck Design Of Crankcases
The "open-deck" design of crankcases are installed from the start of series production without HELI-COIL
inserts for the cylinder head bolts.
Standard as of engine:
119.970 12 045 021 up to 045 886
119.970 12 045 893
119.971 12 o17 447
119.972 12 008 661 up to 008 923
119.972 12 008 999

Mercedes-Benz
119.974 12 008 761 up to 008 819
119.974 12 008 822
119.975 12 010 516
The different crankcases can be recognized from the cast number when installed (01-1100).
P01·6~1 3
Fig. 54: Tdentifving Cvlinder Head - Open-Deck Design Of Crankcases
DIMENSIONS FOR PRESSING IN STRAIGHT PINS IN CRANKCASE- RA01001041020X(Ol-1020)

Mercedes-Benz
20
21
?01.4 0-023a- 57
Fig. 55: Dimensions For Pressing In Str aight Pins In Cran kcase
install, do not knock in as far as the stop.

Straight pins (20) NOTE:
and (21) The specified installation dimensions must be observed so that the appropriate
attachment, e.g. guide rail provides adequate bearing guide.
MEASURING, BORING AND HONING CYLINDER BORES- RA01001041100X(Ol-1100)
Measuring, boring a nd boning cylinder bores- RA01001041100X(Ol-1100)
ENGINES 104.98 1)
Allocation Group No. (l ) Cylinder dia. Piston dia.
Standard 0 88.5 A 88.500- 88.506 88.473 - 88.479
X 88.506- 88.512 88.478 - 88.486
B 88.512 - 88.518 88.485 - 88.491
1st repair size+O.5 A 89.000- 89.006 88.973 - 88.979
X 89.006- 89.012 88.978 - 88.986
B 89.012 - 89.018 88.985 - 88.991
Mercedes-Benz
2nd repair síze+ l. O A 89.500- 89.506 89.473- 89.479

X 89.506 - 89.512 89.478 - 89.486
B 89.512 - 89.518 89.485- 89.491
1) Except AMG engines
(I) The group code letters are located on the piston crown and are stamped in the contact surface ofthe
crankcase.
ENGINES 104.94/99 1)
Allocation Group No.(l) Cylinder dia. P iston dia.
Standard 0 89.9 A 89.900 - 89.906 89.873 - 89.879
X 89.906 - 89.912 89.878 - 89.886
B 89.912 - 89.918 89.885- 89.891
1st repaír size+0.25 A 90.150 - 90.156 90.123 - 90.129
X 90.156 - 90.162 90.128 - 90.136
B 90.162- 90.168 90. 135- 90. 141
2nd repair size+0.5 A 90.400 - 90.406 90.373 - 90.379
X 90.406 - 90.412 90.378 - 90.386
B 90.412- 90.418 90.385- 90.391
1) Except AMG engines
(1) The group code letters are located on the piston crown and are stamped in the contact surface ofthe
crankcase.
Wear límit in direction oftravel and in transverse direction 0.10

whennew 0.007
Pemussible deviation of cylinder shape
wear limit 0.05
Perrnissible deviation of rectangularity related to cylinder height 0.05
A veraged peak-to-valley height (Rz) after ceramic fmal honing 0.003 - 0.006
Perrnissible waviness (Wt) 50 % ofpeak-to-valley height
Chamfering of cylinder bores see note
Honing angle 50±10°
IQuick callipers for intemal measurements, dia. 80 - 100 mm
NOTE: When performing repairs, all the cylinder bores should be finished to the sizes
of the existi ng pistons in accordance with the allocation table.
Measuring
Measure the cleaued cylinder bores with an internal measuring instrurnent at the 3 measuring points (1 , 2 and 3)
in the longitudinal and transverse directions.
Mercedes-Benz
Measumg p-ot rts 1- 3

A longlu!ñnaJ éiredlcn
8 Transvorse diredon
a lJpperreversalpo~rtol1stptstonnng
b i3otom dead canh of p¡ston
e lcwcr reversel po1Tt ol oJ scmper nng
Fig. 56: ldentifving Cvlinder Bores Measuring Points
Fig. 57: ldentifving Chamfer Cvlinder Bores Position
Installing cylinder liners- RA01001191100X(Ol-1100)
CYLINDER LINERS
Engine Crankcase cast number< 1) Cylinder liner part number(2) Crankcase design
119.960 - 117 011 02 10 "closed deck"
119.971/975/981/985 119 011 06 01 119 011 02 10 "closed deck"
119 011 08 01 1190110210 "closed deck"
119 011 10 01 119 011 02 10 "closed deck"
119 011 12 01 119 011 02 10 "closed deck"
119 011 14 01 119 011 02 10 "closed deck"
119 011 16 01 119 011 02 10 "closed deck"
1190111801 11901102 10 "closed deck"
119 011 22 01 119 011 02 10 "open-deck"
119.970/972/974/980/982119 011 07 01 119 011 01 10 "closed deck"
119 011 09 01 1190110110 "closed deck"
119 011 11 01 119 011 01 10 "closed deck"
Mercedes-Benz
1190111301 1190110110 ''closed deck"

119 011 15 01 119 011 01 10 "closed deck"
119 01117 01 1190110110 "closed deck"
119 011 19 01 1190110110 "closed deck"
119 011 23 01 119 011 01 10 "closed deck"
1190112401 11901 1 0110 "open-deck"
( 1) The number is cast on the side left behind the engine support
(2) The material ofthe cylinder liner is identical to the crankcase
MACIDNING DIMENSIONS IN CRANKCASE

117 011 02 10
Cy linder linerO) 119 01 02 10
119 011 01 10
Basic bore for cylinder liner 95.500 - 95.535 100.00 - 100.035
Basic bore for liner collar 97.500 - 97.535 102.00 - 102.035
Insertion depth for liner collar seat 4_4- 4.5 14.4- 4.5
(1) The cylinder liner in the crankcase can be widened to standard size and 1st repair size +0.5 mm (01-
1120).
Measuring cylinder bores - RA01001201100X(Ol-1100)
Allocation Group no. (l) Cylinder dia. Piston dia.

Standard size 89.0 dia. o 89.000 - 89.008 88.978- 88.988
1 89.008- 89.016 88.988 - 88.998
2 89.016 - 89.024 88.998- 89.008
1st repair size +O.3 5 C2) o 89.350- 89.358 89.328 - 89.338
89.358- 89.366 89.338- 89.348
2 289.366 - 89.374 89.348- 89.358
2nd repair size +0.7 (2) o 89.700 - 89.708 89.678- 89.688
89.708- 89.710 89.688 - 89.698
2 89.716- 89.724 89.698 - 89.708
( l) The group number on new engines is stamped in the contact surface of the crankcase, next to the
cylinder bore.
(2) The group number is imprinted on the piston crown with paint and is additionally inscribed on the
side next to the piston crown.
DATA
Maximum wear limit of cylinder bores in longitudinal or transverse direction at upper and lower
0.10
reversa! poínt ofthe 1st piston ring
MACIDNING TOLERANCES
1 w hen 1
Mercedes-Benz
new 0.013
Pennissible difference from cylinder shape wear
0.05
limit
Perrnissible difference from rectangularity relative to
0.05
cylinder height
Averaged peak-to-valley height (Rz) after polishing 0.001
Averaged peak-to-valley height (Rz) after silicone-
0.001- 0.003
lapping
50% ofpeak-to-valley height after
Permissible waviness (Wt)
silicone lapping
COMMffiRCMLLYAV~ABLETOOLS
Interna! measuring instrurnent for 50- 150 mm dia. with 0.01 SUNNEN Products Comp. USA-
mm indícation and measuríng poínt pressure relíef, e. g. GRM e.g. 791 OManchester St. Louís Mo.
2125 63143
Adjusting micrometer for ínternal measuríng instrument GRM SUNNEN Products Comp. USA-
2125 with 50 - 200 mm setting range, e. g. SUNNEN CF-1000 e.g. 7910 Manchester St. Louis Mo.
M 63143
Measuring
Use a measuring instrument with measuring point pressure relief for measuring the cylinder bores otherwise tbe
cyl1nder contact surface wi ll be scored as a result ofthe measuring point bearing surface and the measuring
point bearing surface of the intemal measuring ínstrument will suffer premature wear.
Set the self-centeríng internal measuring instrument to the cylinder día. before measuring. Measure cylinder
bore at room temperature of22 - 24 °C.
If the measuring temperature díffers, a dimensional correction must be performed.

Mercedes-Benz
1 lnterneJ roosslJI'lng insUllment

2 M1aometer
Fig. 58: Measuring Cylinder Bore
The amount by whích the alumínum surfaces stand back (0.5 -1.5 1-1m) between the silicon crystals can only be
measured after silicone-lapping (fmal state) índirectly by means ofthe averaged peak-to-valley height (Rz).
The specified exposed depth of the silicon crystals is obtaíned by the time-limited control duríng silicon-lapping
and the result of the sílícon paste used.
FACING CONTACT SURFACE OF CRANKCASE- RA01001041200X(Ol-1200)
Facing contact surface of crankcase- RA01001041200X(Ol-1200)
Preceding work:
Pistons removed (03-3160) .
Operation no. of operatíon texts and work units or standard texts and flat rates
Mercedes-Benz
53.5
P01-58a8-55
Fig. 59: ldentifying Facing Contact Surface Of Crankcase
DATA
282.25-
Height "H" of crankcase when new
282.35
Minimum height after necessary stock removatCl) 281.95
upper crankcase contact surface 0.03
Permissible unevenness
lower crankcase contact surface 0.04
Pemussible deviation of parallelism of upper to lower contact surface of crankcase in 0.1
longitudinal direction transverse direction 0.05
0.005-
upper crankcase contact surface
Peak-to-valley height (Rz) 0.020
lower crankcase contact surface 0.025
Test pressure with air in water in bar gauge 1.5
Chamfering of cylinder bores see note
(1) The stock removal at the crankcase and at the cylinder head of an engine must together not be more
than 0.4 mm (see 01-4180).
NOTE: Face crankcase together with the timing case cover.
After facing, chamfer the cylinder bores as shown in the drawing opposite.
Mercedes-Benz
Fig. 60: Identifving Chamfer Cvlinder Bores Position
Chamfer cylinder bores with a suitable handmilling cutter as shown in the drawing. Equalize bottom edge of
chamfer with políshíng stone.
Fig. 61: Identifying Chamfer Cylinder Bores
Facing crankcase mating surface- RA01001191200X(Ol-1200)
Preceding work:
Engine, pistons, cylinder heads and crankshaft removed.

Mercedes-Benz
P<l1-0263-35
Fig. 62: Identifying Crankcase Height
DATA
Engine 119.96 119.97/98
245.35- 228.90-
Height "A" of crankcase
245.45 229.00
Minimum height after required stock removal(l) 245.25 228.80
in longitudinal
0.08
Permissible variation of parallelism of top mating surface direction
to crankshaft center in transverse
0.05
direction
Permissible variation of evenness of top mating surfaces 0.02
Averaged peak-to-valley height (Rz) of top mating surface 0 .006-0.016
Pressure-testing pressure: water chamber with air under water in bar gauge 3
Chamfers of cylinder bores see note
(1) The stock removal at the crankcase and at the cylinder head of an engine must together be not more
than 0.4 mm (see 01-4180).
NOTE: Face crankcase together with timing case cover. Always tace right and left bank
of cylinders by the same amount.
After facing, chamfer the cylinder bores as shown in the sketch.

Mercedes-Benz
1990-2002 ENG INE Complete Eng ine- REPAIR & ADJUSTMENTS- 129 Chassis
P03-0190-13
Fi~. 63: ldentifyin~ Cylinder Bore Chamfer Dimension
Chamfer cylinder bores with a suitable handrnilling cutter as shown in the sketch. Equalize bottom edge of
chamfer with polishing stone.
Ifthe crankcase mating surface is machined, the tinúng must be checked (see 05-2150 ).
P01-2573-13
Fig. 64: Chamfering Cvlinder Bore With Handmilling Cutter
REP AIRING THREADED BORES FOR CYLINDER HEAD BOLTS- RA01001041220X(Ol-1220)
Preceding work:
Cylinder head removed (01-4150).
Mercedes-Benz
P01.40-0237-55
Fig. 65: ldentifving Cvlinder Head Bolts And Threaded Bores Position
Bore
HELI-COIL thread
HELI-COIL thread
widen, pay attention to core plug depth.
tap.
screw m.
DATA IN MM
0 size a 14.00- 14.27
Twist drill 0 12.5
Core hole depth from contact surface 35
HELI-COIL threaded insert below contact surface 5.3
HELI-COIL thread length screwed in 26
HELI-COIL thread length block size 23.1
Bollhoff GmbH
Postfach 14 02 29
HELI-COIL Ml2 hand thread tap for pre-tapping e.g. D-33622 Bielefeld
Order no. 0140 0120 104
Mercedes-Benz
Bollhoff GmbH
Postfach 14 02 29
HELI-COIL M12 hand thread tap for final tapping e.g. D-33622 Bielefeld
Order no. 0140 2120 102
Bollhoff GmbH
Postfach 14 02 29
HELI-COIL M12 hand ínstallation tool e.g. D-33622 Bielefeld
Order 110. 0150 0112 300
Bollhoff GmbH
Postfach 14 02 29
HELI-COIL M12 X 1.75 threaded insert e.g. D-33622 Bielefeld
Order 110. 0130 0120 024
CLEANING, SEALING MAIN OIL GALLERIES - RA01001041300X(Ol-1300)
Precedíng work:
Crankshaft removed (03-1800) .
E11gines with pisto11 crow11 cooling up to 12/93: Oil spray 11ozzles (pistons) removed 08-1300) .
Operation no. of operation texts and work u11its or standard texts and flat rates:
Cleaning
Mercedes-Benz
P01-5850-57
Fig. 66: Cleaniog Main Oil Galleries
Front plug (2) knock in on one side with the screwdriver, press out.
knock out with round bar (6)
Rear steel hall ( 5)
(approx. 11 mm día., length 750 mm)
Oil galleríes clean.
Sealing
Mercedes-Benz
7
F.t1
~
P01-SSS2-57
F ig. 67 : ldentifying Sealing Specifica tion F or Main Oil Galler ies
FRONT MAIN OIL GALLERY

Main oil galleries clean.
New plugs (2) coat around circumference with Loctite 270 high strength 002 989 93 71 10.
New plugs (2) knock in with drift 102 589 12 15 00 untíl tool makes contact.
SEALING REAR MAIN OIL GALLERY WITH STEEL BALL

Steel knock in 2 mm deeper than origínally with drift 102 589 07 15 00 so that steel ball is provided
hall with 0 a new seat in the 14.75 bore.
NOTE: This method is only successful if no leak existed beforehand as a result of

porosity in crankcase oil gallery (ball seat).
The steel ball must be free of damage and rust.
SEALING REAR MAIN OIL GALLERY WITH SCREW PLUG

Rear main oil gallery (4) widen by drilling (0 16 mm, depth about 15 mm).
M 18Xl.5 thread tap in end ofmain oil gallery (4).
Swarf thoroughly blow out of oil galleries.
Mercedes-Benz
Thread and screw plug (7) remove grease.

Ml8X1.5 screw plug (7)
coat with sealing adhesive 000 906 01 40 00, screw in, tighten.
000 906 018 00
Special tool
102 5891215 00
102 599 07 15 00
REPLACING CORE PLUGS IN CRANKCASE- RA01001041400X(Ol-1400)
Precedíng work:
Attached parts in area of core plugs removed.
Coolant drained (20-0100) .
01-8501-8741
Mercedes-Benz
Fig. 70: Identifving Core Plugs In Crankcase
Core plug (121) remove (steps 1 aud 2).

Core plug hole clean with activator, combi-pack 002 989 09 71.
Core plug hole coat with sealant 002 989 45 20 10.
Core plug (121) Knock in with drift, special tooll02 589 00 15 OO.
Sealant allow to harden.
Engine check for leaks.
Special tool
102. 589 00 15 00
Mercedes-Benz
Replacing
L Use a screwdriver to knock core plug ( 121) in on one side until it has turned.
- ' '
.. ,. ...
.·.:-.........· ·.. ·
- ' .
. -.... ...
1 • - ·
' .. 4' • • •
. •
''
Fig. 72: ldentifying Knock Core Plug
2. Grasp core plug (121) at the collar and remove.
Fig. 73: ldentifying Gr.a sp Core Plug
3. Thoroughly clean core plug hole. Spray the sealing surface with activator. Sealing surface must be free of
grease.
4_ Coat core plug with sealant 002 989 45 20 10.
Mercedes-Benz
Fig. 74: Locating Sealing Sur face Of Core Plug
5. Knock in new core plug flush using the insertion drift 102 589 00 15 OO.
NOTE: Allow the sealant to cure for approximately 45 minutes before pouring in
coolant.
6. Run engine to warm up and check for leaks.
Fie. 75: Knockin~ Core Plu~ Flush Usine Insertion Drift
REMOVING AND I NSTALLING TIMING CASE COVER- RA01001042100X(Ol-2100)
Removing and installing timing case cover - RA01001042100X{Ol -2100)
Preceding work:
Mercedes-Benz
ol-8000-8009
A Models 124, 129 with engines 104.98
MotOf 104.98
Fig. 76: ldentifying Timing Case Cover Removellnstall Components (1 Of 2)
B. Model140
Mercedes-Benz
10Nm
P0 1- Mtl • i7
MotO!' 104.99
Fig. 77: Identifying Timing Case Cover Removellnstall Components (2 Of2)
disconnect, connect, encode radio, model 140

Ground cable at battery
normalize power windows.
Air cleaner and intake air scoop remove, install (AR09.10-1050D).
Bottom engine compartment panel remove, install.
Viscous fan clutch remove, install (20-3120) .
Securing bolts ofbelt pulleys:
fan clutch (210), coolant pump (273), slacken, tighten (step 6).
power steering pump (284)
Poly V -belt remove, install (13-1200) .
Belt pulley:.fan clutch (210), coolant pump (273), take off fit on (ste 8).
power steermg pump (284) ' P
Belt pulley, vibration damper remove, install (03-3420) .
Cap of cooling system open (release pressure).
remove heating water return pipe (270), install,
Model124, 129 engine 104.98:
replace seal (26) (step 11 ).
Opening of coolant pump seal.
Front cover at top remove, install (01-2120).
Timing chain with camshaft sprockets mark with colored markings.
Bracket of tensioning device (213) slacken, swivel, seal and attach (step 14).
Model 140 engine 104.99: unbolt bracket at timing case cover, bolt on.
Mercedes-Benz
unbolt power steering pump, swivel, bolt on (step

Model 124, 129 engine 104.98:
15).
detach, attach (remains in vehicle with lines/wiring
Air pump (94)
connected).
remove, engine 104.98 replace seal (97), install21
Fan bearing bracket (21 7)
Nm (step 17).
TDC sensor ( 100) remove, install (step 17).
remove, install (steps 18, 19).
Generator (326) w ith support (93) NOTE:

lnsert bolts for support (93) until they make
contact, tighten front bolt first of all.
Timing case cover (96) at front and bottom unbolt, bolt on; M6: 10 Nm, M8: 21 Nm (step 20).
Timing case cover (96) with TDC sensor bracket take off, seal and fit on (pay attention to dowel pins
(102) 96a), (steps 21 to 23).
Engine run, check for leaks.
Securing bolts of oil sump M6l0
T" . nk M69
lffilng case cover to era case MS
21
Securing bolts of belt pulley M6l0
Securing bolts of tensioning de vice 7 5
Special tool
001 589 72 21 00
R emoving, installing
l. Disconnect ground cable at battery.
lnstallation note
Mercedes-Benz
Encode radio, model 140 normalize power windows.
2. Pull air scoop off the air ftlter and remove.

3. Remove air cleaner, install (AR09.10-1050D).
4. Unscrew bottorn engine compartment paneL
5. Remove viscous fan clutch (20-4200) .
6. Slacken bolts (arrows).
7. Remove poly V -belt {13-1200) .
8. Unscrew bolts (arrows), take offbelt pulleys offan clutch (210), coolant pump (273) and power
steering pump (284).
9. Remove belt pulley, vibration damper and hub (03-3420).
10. Open cap of cooling system (release pressure).
Fig. 79: Locating Slacken Bolts
Models 124, 129
11 . Remove heating water return pipe.
Installation note
Replace seal between heating water return pipe (25) and coolant pump.
Mercedes-Benz
Fig. 80: ldentifving Heating Water Return Pipe (1 Of2)
Hose remains connected. Seal opening at the coolant pump.
Fig. 81: ldentifving Heating Water Return Pipe (2 Of 2)
12. Remove front cover at top (01-2120).

13. Mark timing chain with camshaft sprockets with colored dots.
Models 124, 129
14. Slacken bolt (211) and tmscrew bolts (215, 651 , 652) together with spring washers.
Swivel bracket (213).

Mercedes-Benz
Fig. 82: ldentifving Slacken Bolt And Swivel Bracket
Model140
Slacken bolts (3 and 4) and unscrew. Swivel bracket (213). Unscrew bolts (1) for bracket of
combination support (2).
Fig. 83: ldentifying Unscrew Bolts Bracket Of Combination Support
lnstallation note models 124, 129
Apply sealant 002 989 45 20 to the front and rear ofthe mounting hole (arrow) ofthe bracket (213).
Mercedes-Benz
Fig. 84: Locating Mounting Hole
Models 124, 129
15. Unscrew bolts (277, 278). Swivel power steering pump (280) in direction of arrow.
16. Unscrew air pump from bracket (remains on vehicle with pipes connected).
Fig. 85: ldentifying Unscrew Bolts And Swivel Power Steering Pump
17. Unscrew bolts (214, 214a), tightening torque 21 Nm, and remo ve fan bearing bracket (217).
Unscrew nut (99).
Take offTDC sensor (100) together with cable and place to the side.
NOTE: TDC sensor bracket (1 02) remains on timing case cover.

Mercedes-Benz
If timing case cover is replaced, set TDC sensor (03-3450) .
Fi2. 86: ldentifyin2 Unscrew Bolts, Fan Bearin2 Bracket And Nut
18. Unplug cable connector at generator.

19. Unbolt generator together with support, take off.
Installation note
Insert side and front bolts for support until they make contact, tighten front bolts frrst of all so that
support is installed free of stress.
20. Unbolt timing case cover from crankcase and oil sump.
21. Detach timing case cover together with bracket of TDC sensor.
NOTE: Do not damage oil sump gasket!
Ifnecessary, replace oil surnp gasket. Examine radial seal; replace, ifnecessary.
22. Clean seaiing surfaces of crankcase and of timing case cover. Apply an even coating of sealant 002
989 47 20 to the sealing surface ofthe timing case cover.
NOTE: The timing case cover is fixed in place by two roll pins on the
crankcase.
Pay attention to projection of 6 rnm (arrow).
Do not damage oil surnp gasket. First of all~ tighten bolts of oil sump, tightening torque 1O Nm.
Timing case cover to crankcase:
M69Nm
Mercedes-Benz
M8 21 Nm
P01.60-0201-1 3
Fig. 87: Locating Roll Pins Projection
Models 124, 129
23. Replace seal (97).
Vers100 oog;ne 104.98
Fig. 88: ldentifving Seal
24. Install in the reverse order.

25. Check oillevel in engine and adjust to correct level.
26. Run engine and check for leaks.
C. Models 202, 210

Mercedes-Benz
Preceding work:
Front cover at top removed (01-2120)_
Support ofair pump/generator removed (01-2110)_
Model202 with tensioning device 1st version: tensioning device removed (13-3200) _
Viscous fan clutch bearing bracket removed (20-3140) _
Belt pulley/vibration damper removed (03-3420) .
o1-8000-8009
96a
21Nm
37 Mibt-40 b1ll+wash9r M002 hexagon socket bol+washer

38 M11x60 lxllt+w1l'Jhor Rolptn
Fig. 89: ldentifying Timing Case Cover Remove/Install Components
Timing chain to camshaft sprockets mark with colored marking (arrows).

with
Bracket (101) unbolt, bolt on (21 Nm).
Mercedes-Benz
Timing case cover (96) at front and unbolt, bolt on (M6 10 Nm; M8 21 Nm).
bottom
remove, install.
Timing case cover (96)
~Do not damage oil sun1p gasket (arrows).
Roll pins (96a) do not lose, see note.
Sealing surfaces clean.
coat with sealant 002 989 47 20.
Sealing surfaces ~ Ensure that no sealant gets into the oil chamber (96b) of the
chain tensioner.
Radial shaft seal (8) examine, replace if necessary (03-3240) .
Engine mn and check for leaks.
M8 bolts of timing case cover to crankcase 21
M6 bolts of oil sump to timing case cover 1O
Special tool
001 589 72 21 00
NOTE: The timing case cover is fixed in position by two roll pins at the crankcase.
Pay attention to projection of 6 mm (arrow).

Mercedes-Benz
\,.~
6 r:
. . . , ---B~:rt--~~~
¡~~,_,.. _ __
---1---t.--~~-----
P01.00-0W1-1 3
Fig. 91: Locating Roll Pins P rojection
Removing and installing timing case cover - RA01001192100X{Ol -2100)
01 -0080, 8009
A. Engine 119.960
Mercedes-Benz
Fig. 92: Identifying Timing Case Cover Remove/Install Components {Engine 119.960)

Bolts ofbelt pulley fan support slacken, tighten (1 ON m, step 2).
Front covers at top (30, 30a) remove, install (01-2120).
Poly V-belt and tensioning device (24) remove, install (13-3450) .
set to 45° before ignition TDC at No. 1
Engine
cylinder (step 5).
Bottom engine compartment panel remove, install (step 6).
Left exhaust pipe and cover of starter mounting detach, attach (step 7).
insert (step 8), special toolll6 589 01 40
Engine retaining lock
OO.
mark and pin, special tool 111 589 03 15
All four camshaft gears together with
00
timing chain (steps 9 and 10).
Nut at left and right camshaft adjuster slacken, tighten (65 Nm, step 12).
Altemator (3) together with carrier (8) remove, install, seal bolts (step 13).
Chain tensioner (6) remove, install (05-3100) .
T op slide rails remove, install (05-3350) .
Both camshaft adjusters (5, 5a) partially remove, install (05-2170) .
r.oo 1:l nt :lt r:lli i:ltor clr:lin nonr in (20-01 00)
Mercedes-Benz
Coolant hoses at fan carrier (2) and thermostat housing take off, instan (step 18).
Fan carrier belt pulley (2a) unscrew, screw on (step 19).
A ir pump ( 1) with angle bracket (25) remove, install (step 20).
Fan carrier (2) remove, install (step 21).
Belt pulley (12) with vibration damper (13) and hub (16) remove, install (03-3420) .
Radial seal ( 17) remove, install (03-3240) .
Coolant pump cover (lla) remove, install (step 24).
Coolant pump ( 11) remove, install (step 25).
Carrier with guide pulley remove, install (step 26).
If air conditioning fitted: air conditioning compressor (22)
detach, attach (step 27).
with lines connected
TDC sensor remove, install (step 28).
Carrier (21 ), air conditioning compres sor or guide pulley remove, install (step 29).
Oil pump (25) remove, install (18-2100) .
remove, insta!L Special tool 117 589 00 31
Dipstick guide tube (4)
00 (step 31).
Top section of oil sump (20) detach, install (01-3100).
Bolts of timing case cover at front and on cylinder head unscrew, screw on (steps 33, 38 and 39).
Timing case cover (9) with oil pump chain (25a) remove, install (steps 34 to 37).
0-rings (23) oftiming case cover renew.
Leaktightness check
TIGHTENING TORQUE SPECIFICATION

Annature of camshaft adjuster 7
Nut of camshaft adjuster 65
Angle bracket to fan bearing bracket25
Bolts ofbelt pulley to hub 35
Coolant pump to crankcase 21

Air conditioning compressor or guide pulley to carrier 21
Bracket of air conditioning compressor to crankcase 21
Bolts of cylinder head to timing case cover 21
Radiator drain plug (reference value) l.5-2
Belt pulley to fan carrier 1O
Timing case cover to crankcase 21
Mounting bracket of alternator 21
Special tools
Mercedes-Benz
603 589 00 40 00
111589031 500
116 589 01 40 00

Mercedes-Benz
001 589 72 21 00
001 589 65 09 00
11 9 589 01 14 00
Fig. 98: ldentifying SpeciaJ Tool (119 589 0114 00)
117 589 00 31 00
Mercedes-Benz
119 589 01 63 00
Fig. 100: ldentifving Special Tool (119 589 0163 00)
l. Remove viscous fan clutch (20-3120) .

2. Slacken bolts of fan belt pulley, using tool ( 1) 603 589 00 40 00 to hold tight.
3. Remove front covers at top (01-2120).
4. Remo ve poly V -belt and tensioning device (13-3450) .
Fig. 101: Identifying Tool
5. Set engine to 45° before ignition TDC at No. 1 cylinder.

6. Unscrew bottom engine compartment lining (Maintenance Manual6190).
7. Unscrew left exhaust pipe and cover of starter mounting.
8. Use locking tooll16 589 01 40 00 to prevent engine from tuming.
Mercedes-Benz
Fig. 102: ldentifying Engine Setting Point
9. Mark all four camshaft timing gears and the tirning chain witb colored dots (arrows).
Fig. 103: Locating Colored Dots On Camsbaft Timing Gears And Timing Chain
1O. Secure all camshaft gears on left and right side witb pins ( 1) 111 589 03 15 00 to prevent them
turning.
Mercedes-Benz
Fig. 104: Identifying Pins
11. Unscrew armature (4) of camshaft adjuster.
lnstallation note
The roll pin (arrow) in tbe annature (4) must be aligned with the flat face on the timing plunger
(18).
12. Slacken nut (6) on left and right camshaft adjuster.
Fig. 105: Identifying Roll Pin, Armature And Timing Plunger
13. Remove altemator together with carrier.
lnstallation instruction
The bolts must be coated with sealant when fitted.
14. Remove chain tensioner (05-3100).

15. Remove top slide rails (05-3350) .
Mercedes-Benz
1
p
10Nm
Fig. 106: ldentifying Ring, Camshaft Gear, Adjusting Piston And Spring
16. Detach both camshaft adjusters by unscrewing nut (6) and raísing tíming chaín.
Take off cover with ring (12) and camshaft gear (13) together with adjusting píston (14) and spring
(14a).
Fít timing chain onto the markings beginning at the left exhaust camshaft.
17. Drain coolant at radiator (20-0100) .

18. Remove coolant hoses at the fan carrier and thermostat housing.
19. Unscrew belt pulley offan carrier.
20. Unscrew air pump with angle bracket and take off.
InstaU angle bracket free of tensíon.
21. Unscrew fan carríer from crankcase.

Mercedes-Benz
Fig. 107: ldentifying Air Pump
22. Remove belt pulley together with vibration damper, hub and seal (03-3420) .
23. Remove radial seal (03-3240).
Fig. 108: Removing Radial Seal
24. Unscrew bolts ( l ), take off cover (2) of coolant pump with engine lifting eye.
Installation instruction
Renew gasket (2a).

Mercedes-Benz
Fig. 109: ldentifying Coolant Pump Components
25. Unscrew coolant pump, take off.
Replace gasket, ínstall bolts wíth washers as specífied in díagram.
Fig. 110: ldentifving Tightening Seguence OfBolts
11Bolt M8x60 5 Bolt M8x601

Mercedes-Benz
2 Bolt M8x60 6 Bolt M8x90

3 BoltM8x607 BoltMbx35
4 Bolt M8x85 8 Bolt M8x65
26. Unscrew bolts (1) with washers. Take off carrier with guide pulley.
Fig. 111: ldentifying Bolts
27. If air condítioning fitted: unscrew bolts (1) with washers and nut (2). Place air conditioning
compressor to the side with lines connected.
28. Unscrew TDC sensor on timing case cover and take off
Fig. 112: ldentifying Bolts And Nut
29. Unscrew bolts (1) with washers, take offbracket.

30. Remove oil pump (18-2100) .
Mercedes-Benz
31. Use a plastic-headed hanuner to knock out dipstick guide tube upward.
Iustallation instruction
Use special toolll7 589 00 31 00 to knock in dipstick guide tube.
32. Unscrew top section of oil sump and lower oil sump downward (01-3100).
33. Unscrew bolts on front oftiming case cover and on cylinder head. Refer to steps 37 and 38 for bolt
diagram.
Bolt diagram, see steps 38 and 39.
Fig. 114: Knocking Out Dipstick Guide Tube Upward
34. Take offtiming case cover and detach the oil pump chain from the crankshaft gear when
Mercedes-Benz
performing tills step.
Lt.oanQerl
Do not damage cylinder head gaskets.
Renew all four 0-Tings for sealing the water ducts.
35. Clean sealing surfaces and coat sealiug surface oftirning case cover with sealant 002 989 47 20 10.
36. Coat cylinder head gaskets with engine oil.
37. When fitting on timing case cover, fit the oil pump chain onto the crankshaft gear with a bent sheet
ofmetal.
Fig. 115: ldentifying Tightening Seg uence Of Bolts
38. Screw on timing case cover. Install bolts wi.th washers 1, 5, 7, 9, 10, 11 and 12 and tighten to 21
Nm.
1 Bolt M8x50
2 Bolt M8x75
3 Bolt M8x70
4 Bolt M8x150
5 Bolt M8x50
6 Hexagon socket boltM8x80
7 Bolt M8x30
8 Hexagon socket bolt M8x60
Mercedes-Benz
9 Bolt M8x50
lOBolt M8x50
llBolt M8x50
12 Bolt M8x50
39. Tighten bolt-and-washer assemblies of cylinder heads to timing case cover as shown in diagrarn
with a torque of 25 N m.
a Hexagon socket bolt+washerM8x120

bHexagon socket bolt+washerM8x90
e Hexagon socket bolt+washer M8x75
d Hexagon socket bolt+washer M8x50
e Hexagon socket bolt+washerM8x75
f Hexagon socket bolt+washer M8x50
40. Install in the reverse order as from step 30.

41. Check for leaks.
Fig. 116: Identifying Tightening Sequence Of Bolts
B. Engine 119.97/98
Preceding work:
Tensíoning devíce removed (13-3450) .
Cylínder head covers removed (01-0500).
01-5800
Mercedes-Benz
P01-5791-57
Fig. 117: ldentifying Timing Case Cover Remove/lnstall Components- Engine 119.97/98 (1 Of 3)
Cylinder 1 position to 45° before ignition TDC (arrow).

fix in position with pins (01), special tool lll 589 03 15
Camshafts
OO.
Left cylinder head: bolts ( l ), ( 1a) and (2) unscrew, screw on (21 Nm)_
place to the side, install.
- - - Installation note
Mou~~g p1ate With power steenng pump ( 11 ) Coat bo1t (2) with sea1ant 002 989 47 20 10.
and oll lines connected E ngme
· 1 19.97 : msta
· 11 bo lt ( 1a) wtt
· h retammg
· - brae ket (4)
of wiring hamess.
Front covers at top (30) and (30a) remove, install (01-2120)_
mark relative to camshaft sprockets (31), (32), (33) and
Timing chain
(34) with colored marking (arrows).
Chain tensioner ( 6) remove, install (05-3100) .
Camshaft adjusters (32) , (33) and exhaust
remove, install (05-2170) .
camshaft sprockets (31) and (34)
Vibration damper remove, install (03-3420) .
detach, lower, bolt on (01-3100).
&oanoorl
Oil sump
Do not damage oil sump gasket; remove oil sump, if
necessarv. and reolace gasket (01-3100).
Mercedes-Benz
P01-5792-57
e MSx1Whexa:goo sod<ot itcoler b-olorM8x120 boll+wesl18f
b M8x74 he)(ílgon sockot it colarbolor MSx74 bo:t+wasller
d M1lx50 he)(ílgon sockllt OOC+wasllar
e M8x75hexagon sod<et OOC•washaf
Fig. 118: ldentifving Timing Case Cover Removellnstall Components- E ngine 119.97/98 (2 Of 3)
Coolant pump (3) remove, install (20-2100) _

unscrew, screw on (15 Nm).
Screwplug (35) with seal (36)Installation note
Replace seal (36) according to condition.
remove with impact puller (02) and threaded insert (03), special tools 116
Tensioning rail pin (37)
589 20 33 00 and 11 6 589 01 34 OO.
Tensioning raíl (38) remove, install.
NOTE:
When performing repairs, fit collar bolts or the bolts+washers should
Fit collar bolts (a) and (lb) be installed depending on the bolts fitted previously.
and bolts (d) and (e) of
timing case cover
On engines 11 9.98, the center bolts (b and e) are discontinued; ifthe
timing case cover is replaced on engines 119.97, it should be bolted on to
the left and right cylinder head with two bolts each.
Mercedes-Benz
P01.S794-57
MBlc:30ool+was~
g M8x40bol+was~
h M8X50boi+Washef
Fig. 119: ldentifying Timing Case Cover Remove!Install Components- Engine 119.97/98 {3 Of 3)
Front crankshaft radial seal (15) remove, replace (03-3240).

Oil pump (25) remove, install {18-2100) .
Bolts (f), (g) and (h) at front of
timing case cover (9)
take off, fit on.
NOTE:
Use a bent piece of metal to detach oil pump chain (26) at the
Timing case cover (9) crankshaft sprocket (27) and attach .
Replace front crankshaft radial seal {03-3240) .

&o""""'' Do not damage cylinder head gaskets (arrows).
O rings (23) and (24) for sealing the
repace.
1
coolant ducts
Sealing surfaces coat with sealant 002 989 47 20 1O
Mercedes-Benz
Cylinder head gaskets (arrows) coat with eng ine oiL

Dowel sleeve (29) and dowel pin
note.
(29a)
Leaks check wíth e ngine running.
Special tools
001 589 72 21 00
11 6 589 20 33 00
11 6 589 01 34 00
REMOVING AND INSTALLING FRONT COVER AT TOP- RA01001042120X(01-2120)

Mercedes-Benz
Removing and installing (ront cover at top - RA01001042120X(Ol-2120)
Preceding work:
Follower at camshaft removed {01-2130).
01-5700
A . Engines with CFI and LH-SFI
En¡Jno 104.9B
Fig. 123: ldentifying Front Cover Top Remove/lnstall Components - Engines Witb CFI And LH-
SFI (1 Of2)
Mercedes-Benz
Eng~ne 104.99
Fig. 124: ldentifving Fron t Cover Top Remove/lnstall Components - Engines Witb CFI And LH-
SFI (2 Of2)
Engine 104.990: drain coolant at radiator, pour in (20-0100) .

Guide rail at top remove, install (05-3400) .
Heating water retum pipe (25) or high voltage
unbolt, bolt on.
cable tml. 4 of timing case cover
Shock absorber (34) of tensioning device of front
unbolt, push down and turn, bolt on (2 1 Nm).
cover
remove connection fitting for coolant return, install
Engine 104.990:
(21 Nm), replace 0-rings (30b+30c).
remo ve.
NOTE:
lf the front cover is replaced, the camshaft position
Front cover (30) at top
sensor must be adjusted.
Clearance 0.2 to 0.6 mm (AR 15. 12-2 143G).

Gasket (24) replace.
install with bottom right bolt (32), seal, bolt on (21
Cover
Nm) (steps 9 to 13).
Screw plug to guide raiEbolt
Ifparts are replaced, adjust position sensor. unscrew, screw on (step 6).
Clearance 0.2 mm to 0.6 mm_
lcvlinder head cover to cvlinder head 10 1
Mercedes-Benz
Distributor rotor to follower (reference value)2.5

Front cover at top to cylinder head 21
Follower to camshaft 16
Special tools
001 589 72 21 00
Fig. 125: ldentifying Special Tools (001 589 72 .21 00)
103 589 0114 00
l. Engine 104.990: drain coolant at radiator (20-2100).

2. Remove guide rail at top (a) (05-3400) .
NOTE: lf the top curved guide rail (a) is taken out of its mounting, the
pressure pin in the chain tensioner is moved one detent in the
pressure direction. The chain tensioner must be removed to avoid
the timing chain being over-tensioned.
Mercedes-Benz
Fig. 127: ldentifying Guide Rail Top
3_ Engine 104.98: unbolt heating water return pipe (25) from the fan bearing bracket (28). Unbolt
guide pulley (32).
F ig. 128: ldentifying Heating Water Return Pipe And Fan Bearing Bracket
4. Engine 104.99: unbolt cable terminal4 between high voltage distributor and ignition coil from
timing case cover (b).
Mercedes-Benz
Fig. 129: Locating Timing Case Cover
5. Unplug connectors at position sensor, camshaft and solenoid.

6. Unbolt screw plug (arrow).
lnstallation note
Push back spacer pinto enable front cover to be more easily installed. Install front cover, screw on
plug (arrow).
P01-588~1 3
Fig. 130: Locating Screw Plug
7. Unbolt shock absorber (e) tensioning device from front cover, push down and turn.
8. Unscrew bolts ( arrows) for front cover, take off cover with bolt ítem (e).
Engine 104.99: bolts (d) only in case of coolant return through the front cover.
Mercedes-Benz
lnstallation note
Pay attention to packing at shock absorber of tensioning device.
Fig. 131: ldentifying Unbolt Shock Absorber Tensioning Device
9. For sealing, apply sealant 002 989 45 20 in each case in the fom1 of a dot into the oil-free groove of
the timing case cover on the left and right at the joint (arrows) to the cylinder head.
10. Insertnew gasket dry (without sealant) into the oil-free groove. Coat the top side ofthe gasket with
a little engine oil.
11 . Coat front cover at the contact surfaces to the cylinder head with sealant 002 989 47 20.
Fig. 132: Identifying Cylinder Head Joint
12. Fit insertion sleeve (a), part no. 103 589 0114 00 (for camsbaft ID 20 mm) to exhaust
camsbaft. Coat sealing lip of radial seal all round witb engine oil .
Mercedes-Benz
Fig. 133: ldentifving lnsertion Sleeve
13. Install front cover with inserted bottom right bolt (e). Ficst of all tighten the bottom bolts .
Fig. 134: Locating Bolt
Preceding work:
Coolant connection fitting at front
Cover removed (20-1200).
B. Engines with HFM-SFI

Mercedes-Benz
3 M3x60 bol..,.,eshor P01-5a54-57
Fig. 135: Identifying Fr ont Cover Top Removeflnstall Components - Engines With HFM-SFI
remove, install (05-3400) _
NOTE:
Guide raíl at top (42) lf the top curved guide rail (42) is taken out of its mounting, the
pressure pin in the chain tensioner is moved one detent in the
pressure direction. The chain tensioner must be removed to avoid
the timing chain being over-tensioned.
Heating water retum pipe (25)
at fan bearing bracket and unbolt, bolt on.
coolant pump
Seal (26) replace.
Connectors (L5/ 1) of camshaft
position sensor and (Y49) unplug, plug in_
camshaft adjustment actuator
- - - t- fitt d disconnect vacuum pipes and connector at switchover valve (Y27), fit
If second ary arr mJeC 10n 1 e :
on_
If 1st version tensioning device unbolt shock absorber of tensioning device (34) at front cover (30), push
fitted: down, bolt on (21 Nm).
Screw plug (35) with seal (36) unscrew, screw on.
Top guide raíl pin (37) n sP i m n~r.t Pxtr~r.tnr (0?) 11 () .:¡lN ?O Ti 00 ::~nrl trP.::~ rl P.rl im:P.rt (O'i) 1 1()
Mercedes-Benz
589 O1 34 00 in order to pull off

Bolts (3) and (4) at front cover ( N )
( 0) unscrew, screw on 21 m .
3
remove with bottom right bolt (arrow), install.
30
Front cover ( ) &oanaerl Do not apply pressure to front cover (30) when removing.
Seal (30c) and shaped rubber

replace.
gasket (24)
Fig. 136: Locating Cylitnder Head Joint SeaJant Applying Area
Sealant 002 989 45 20 apply on left and right at joint (arrows) to cylinder head in the form of a do t.
New shaped mbber gasket
insert dry (without sealant) into the oil-free groove.
(24)
Top side of shaped rubber
coat with a little engine oil.
gasket
Front cover (30) at contact
coat with sealant 002 989 45 20.
surfaces to cylinder head
fit on, frrst of all tighten bottom bolts (4) (21 N m).
&oanacrl When installing the front cover (30), ensure that the shaped rubber
gasket (24) ís not shifted; chamfer edge on cover (30) at bottom for thís
purpose.
Front cover (30) NOTE:

lf the front cover is replaced, the camshaft position sensor must be
adjusted.
Clearance 0.2 to 0.6 mm (AR15.12-2143G).

Engíne check mn, for leaks.
Soecial tools
Mercedes-Benz
001 589 72 21 00
11 6589 01 34 00
Fig. 138: ldentifving Special Tools (116 589 01 34 00)
116 589 20 33 00
Removing and installing front covers at top- RA01001192120X(Ol-2120)
Preceding work:
Hazard warnings when hood opened (01-0080).
Removing, installing cylinder head covers {01-0500}.
Mercedes-Benz
01-5700
A_ Engine 119.960 in model129
Fig. 140: ldentifving Front Covers Remove/lnstall Components (Engioe 119.960 In Model129)
Bracket ( 1O) of actuator detach, attach (21 Nm) (step 1).

Shielding caps (1) aud high voltage distributor (2) remove, instalL
Covers (la) remove, instalL
lguitiou cable holder, right side unbolt, bolt on.
Power steering pump (11) (1st versiou) with mountiug
remove, iustall (step 5) (46-710).
plate
Poly V-belt slacken, tens ion (13-3420) _
Bracket ofpoly V -belt tensioning device unbolt, bolt on (21 N m)_
Power steering pump (11) with mounting plate and unbolt, place to the side, bolt on (21 Nm) (step
liues/wiriug counected 7) (46-710).
Power steering pump (11) (2nd version) wíth reservoir
remove, iustall (step 8).
(13)
Power steeriug pump (11), oil in reservoir (13) extract, adjust oil to correct level (step 9).
Mercedes-Benz
Oilline (15) at reservoir (13) unbolt, bolt on (step 10).

Seal (14) replace according to condition.
Filter (18) remove, install.
Reservoir (13) unbolt, bolt on (8 N m) (step 12).
Gasket (12) replace according to condition.
Distributor rotor (3) and follower (4) remove, install.
Protective cover ( 5) and seals (6) take off, fit on.
Connector of solenoid (8) of camshaft adjuster unplug, plug in.
Front covers at top (30), (30a) remo ve.
Sealing surfaces coat with sealant 002 989 47 20 10.
install with insertion sleeve, special tool 119
Front covers (30), (30a)
589 00 14 OO.
Leaks check with engine running.

Cylinder head cover to cylinder head 9
Distributor rotor to follower (reference value)2.5
Front cover at top to cylinder head 21
Mounting plate of power steering pump 21
Reservoir to power steering pump (Torx) 8
Special tools
001 589 72 21 00
Fig. 141: l dentifving Special Tool (001 589 72 21 00)

Mercedes-Benz
119 589 00 14 00
Fig. 142: ldentifying Special Tool {119 589 00 14 00)
112 589007200
l. Unscrew bolts from bracket of actuator.
lnstallation note
Bolts sbould be coated witb sealant
002 589 47 20 10 wben installing.
2. Unbolt shielding caps and higb voltage distributors and take off
3. Unbolt coverings from front cover.
4. Unbolt right ignition cable holder at cylinder head.
5. Ifpower steering fitted witb non-removable reservoir (1st version) perform steps 8 to 9.
6. Slacken poly V-belt (13-3420) .
7. Unscrew bolts (arrows). Place mOlmting plate with power steering pump (11) and lines/wiring
connected to the side. Tightening torque 21 Nm.
lnstallation note
ThP. holt w hir.h i« «r.rPwPrl into thP r.vlinrlP.r hP.::lO M thP fmnt mn«t hP r .oMPrl w ith «P.::lhnt w hP.n
Mercedes-Benz
installed. Pay attention to angle bracket ( 1) of wiring harness.
Fig. 144: ldentifying Power Steering Pump
8. If power steering pump with detachable reservo ir (2nd version) is fitted perfonn steps 11 to 14.
9. Extract oil from the reservoir ofthe power steering pump with the handpump, special tool112 589
00 72 00 for extracting oil.
Installation note
Fíll power steering ptunp and bleed.
Fig. 145: Extracting Oil From Reservoir Of Power Steering Pump With Handpump
10. Unbolt oilline (15) atreservoir.
Installation note
Mercedes-Benz
Replace seal according to conditíon.
11. Remove filter in reservoir of power steering pump.

12. Unscrew bolts (Torx) (arrows). Take offreservoir (13). Tightening torque 8 Nm.
lnstallation note
Replace gasket of reservoir ( 13) according to condition.
Fig. 146: ldentifying Oil Line And Reservoir Bolts
13. Unbolt distributor rotor and follower.
Installation note
The slot of the follower must engage o ver the pin in the camshaft.
14. Unplug connector of solenoid of camshaft adjuster.

15. Unscrew bolts of covers at front, take off cover.
16. Clean sealing surfaces.
17. Coat front covers witb sealant 002 989 47 20 10.
Fit insertion sleeve, special tool
119 589 00 14 00, onto exhaust camshaft sprockets and install front covers.
18. Coat front cover bolts with sealant.
19. Install in reverse order.

Mercedes-Benz
20. Run engine, check for leaks.

B. Engine 119.97
Preceding work:
Cylinder head cover removed (01-0500).
Driver removed (01-2130).
01-5700
Fi~. 147:
18
ldentifyin~
"'
21Nm
Front Covers Remove/lnstall Components- En~ine 119.97 (1 Of2)
Left front cover (30a): cap (23) and filter (18) at

remove, install.
reservoir (13) ofpower steering pump
extract with handpump, special tool
112 589 00 72 OO.
Left front cover (30a): oil in reservoír (13)
lnstallation note
Fill power steering pump and bleed.
nnhnlt hnlt nn
Mercedes-Benz
Installation note
Left front cover: oilline (15)
Replace 0-ring (14).
Left front cover (30a): bolts (17) (Torx E8) unscrew, screw on.
remove, install.
Left front cover (30a): reservoir (13) with gasket (12) Installation note
Replace gasket (12) according to condition.
Connector of solenoid (Y49) of camshaft adjuster unplug, plug in.
unbolt, bolt on.
Installation note
Bracket ofcover (1) or (la)
Clip ignition cable and ignition cable duct into
bracket ofcover (1) or (la).
:tt1 Ml)](:l~he)(Bgoo soó«Jt owwasn!lf
29 MBx35he)IBg0{1 sockatbol+wash!lf
Fig. 148: ldentifving Front Covers Remove/lnstall Components- Engine 119.97 (2 Of 2)
Front covers (30) and (30a) unbolt, remove.

Front covers (30) and (30a) at contact surfaces to
coat with sealant 002 989 47 20 10.
cylinder head
Bolts (28) and (29) coat with sealant 002 989 47 20 10.
fit onto exhaust camshafts, pull off, special tool ] 19
lnsertíon sleeve (01)
589 00 14 OO.
Front covers (30) and (30a) fit on, bolt on (21 Nm).
Leaks check with engine running.

Bolts of front covers 25
Reservoir at power steering pump (Torx E8) 9
Special tools
Mercedes-Benz
001 589 72 21 00
11 9 589 00 14 00
C. Engine 119.98 in model 210
Preceding work:
Cylinder head covers removed (01-0500).
Poly V -belt removed (13-3420)
01-5700
Mercedes-Benz
C1D
21Nm
~
Y49~ 30a
~1Nm
P01 1O-OZ60-59
Fig. 151: ldentifving Front Covers Remove/Install Components- Engine 119.98ln Model 210 (1 Of
.ll
lmbolt power steering pump with supporting plate (11 ), bolt on (25
N m).
NOTE:
Left front cover (30a) on version This is done by removing bolt at front (2) and bolts at rear (1).
with power steering pump:
When installing bolt at front (2), coat with sealant 002 989 47 20 10.
Iftandem pump fitted, pump remains installed; unscrew bottom left
bolt for front cover witb extended bexagon socket bit.
Right front cover with secondary ainmbolt secondary air injection valve at air pump support, push to the
injection: side, bolt on_
r Onnf~r.tor of r.:::nn~h:~ft ::titiHStP.T
Mercedes-Benz
solenoid (Y49) unplug, plug in.

Front cover (30) and (30a) unbolt, remove.
P01-5797.:53
18 Mllx25 haxagoo socket bol+washar
29 MBx35helCI>gOfl socket boft.,Nashor
Fig. 152: Identifying Front Covers Remove/Install Components- Engine 119.98 In Model210 (2 Of
11
Contact surfaces of front cover (30) and (30a) to
coat wíth sealant 002 989 47 20 10.
cylinder head
Bolts (28) and (29) coat with sealant 002 989 47 20 10.
fit on, pay attention to dowel pins, screw on (25
Front covers (30) and (30a)
N m).
Engine run and check for leaks.

IBolts of front covers 251
Special tool
001 589 72 21 00

Mercedes-Benz
REPLACING RADIAL SHAFT SEAL IN FRONT COVER AT TOP- RA01001042140X(Ol-2140)
Replacing radial sbaft seal in front cover at top- RA01001042140X(Ol-2140)
Preceding work:
Follower at camshaft removed (01-2130).
Engine 104.980/981/990
Fig. 154: ldentifying Radial Shaft Seal In Front Cover Removellnstall Components
u.se a screwdriver to prise out

Radial shaft seal (1) &oanQCrl Do not damage camshaft (1 O) and mounting boJe for radial shaft
seal; use clean cloth as a base.
Insertion sleeve (7) 103 589 fi t on to cams 11aft ( 10) .
0 1 14 00
Sealing lip of radial shaft coat with engine oiL
seal (1) with &oanaerl Do not use grease.
fit into insertion sleeve (71 nress in flush (arrows)

Mercedes-Benz
with sleeve (8) (shop-made ).
Radial shaft seal ( 1) NOTE:

The radial shaft seal (1) must be positioned vertical to the camshaft (10)
so that it provides a proper sea l.
Special tool
103 589 0114 00
Fig. 155: ldentifying Special Tool (103 589 0114 00)
Shop-made tool
Sleeve for pressing on radial shaft seal in front cover.
P01·DIS-15
Fig. 156: ldentifying Shop-Made Tool Dimension
Mercedes-Benz
Replacing radial shaft seals in front covers at top- RA01001192140X(Ol-2140)
Preceding work:
Follower at camshaft removed {01-2130)
A. Engine 119.96/97 with front cover installed
P01...S799-57
Fig. 157: Replacing Radial Shaft Seals In Front Cover
Inse1tion sleeve (7) fit on to exhaust camshaft (10), special tool119 589 00 14 OO.
coat with engine oiil.
&oanaorl
Sealing lip of radial seal (1)
Do not use grease! Grease prevents the return delivery swirl on the sealing
lip of the radial shaft seal ( 1) transporting back the engine oil.
Radial shaft seal (1) fit onto insertion sleeve (7).
press in with sleeve (8) (shop-made) to size "A=5 mm".
Radial shaft seal ( 1) NOTE:

The radial shaft seal (1) must be positioned vertically to the camshaft
(10) in order to provide a proper seal.
Holder of shield caps of high remove, install.
tension distributors
nre~~ out w íth a ~crrewcirí ve r
Mercedes-Benz
&oanqcrl Do not damage camshaft (1 O) and mounting hole for radial shaft
Radial shaft seal (1)
seal ( 1).
Special tool
119 589 00 14 00
Shop-made tool
Sleeve (8) for pressing radial shaft seal into the front cover.
4.11:
~
1'..' '"' '\.'"\.,. '\.' "\,. '\.' '\.'\."'-'
r O)
~ C'?
o
•1
·r-·- ·- · -· - ·- ·-r-
-- O,!x45° 0,5x.4~ 0
P01-5B07-1 3
Fig. 159: ldentifying Shop-Made Tool Dimension
B. Engine 119.96/97 with front cover removed
Preceding work:
Front covers removed {01-2120).
Mercedes-Benz
111l11 0 01i>1 3
Fig. 160: ldentifying Drift
press out with a screwdriver.

Radial shaft seal
Do not damage mounting hole for the radial shaft seal.
&oanqerr
Radial shaft seal ( 1) fit onto drift (01) 119 589 01 15 OO.
press in withdrift (01).
Radial shaft seal NOTE:
The insertion depth of 5 mm is obtained by using the drift (01).
Special tool
11 9 589 01 15 00
Replacing radial seals in the front covers - RA01001202140X(Ol-2140)
Preceding work:
Model 129: Open hood, raise to vertical position (01-0080)
Mocle.l 140· R::~cliator n~movecl {20-4200)

Mercedes-Benz
IIO'I•atZ•Sf
Fig. 162: ldentifying Viscous Fan, Sbield Caps, IDgh Voltage Distributor, Distributor Rotor And Radial
Seal
Only for right radial seal: viscous fan (20) remove, install (20-3120).
Shield caps (11, 14 and 15) remove, install (steps 2 and 3).
High voltage distributor (12) with holder (13) remove, install {15-3010) (steps 4 and 5).
Distributor rotor (6), screw (5), and follower (4) remove, install (steps 6 and 7).
Guard cover (2) and seals (3) remove, fit on (step 8).
Radial seals ( 1) remove, install (steps 9 to 12).

Distributor rotor to follower (reference value) 2.5
Follower to camshaft (Torx T30) 16
Special tools
Mercedes-Benz
00\ 589 72 21 00
00
Fig. 163: Identifying SpeciaJ Tool (001 589 72 21 00 00)
103 589 0 1 14 00
01 J
00058901 1000
00
Shop-made tool
Sleeve for pressing on radial seal in front cover.

Mercedes-Benz
PO"I-1211-15
Fig.l66: ldentifying Shop-Made Tool Dimension
l . Only for right radial seal: remove viscous fan (20-3120) .

2. Pull shíeld cap (14) to the front, remove.
3. Unclip shield caps (11) and ( 15) at the side, remove.
Fig. 167: ldentifying Shield Caps
4. Unscrew hígh voltage distributor (12) with ígnítíon cables connected (15-3010) .
5. Remove screws (18), take off shield cap holder (13).
Mercedes-Benz
Installation notes
Modell40: Clip cable ofTDC sensors (Ll/1) and (Ll/2) into left and right holders (13).
Left holder (13): Clip oillines (21) and (22) into holder (13) (arrow).
Model 129: Clip ignition cable 4 into right holder (13).
Model129: Clip cable ofTDC sensors (Ll/1) and (Ll/2) into left holder.
Fig. 168: ldentifving High Voltage Distributor, TDC Sensors And Oil Lines
6. Unscrew distributor rotor (6) and remove. Tightening torque 2.5 Nm.
P01 • !i2M ·13
Fig. 169: ldentifying Distributor Rotor And Follower
7. Remove screw (5) (Torx T30), take offfollower (4).
lnstallation note
The slot ofthe follower (4) must engage in the locating pin (arrow) in the camshaft.
Mercedes-Benz
Tightening torque 16 Nm_
8. Remove guard cover (2) together with seal (3)_
Fig. 170: ldentifving Follower
9 _ Press out radial seal ( 1) with a screwdriver.
¿DanQerl
Do not damage camshaft and mounting hole for radial seaL
Use a clean cloth as a base.
Fig. 171: Pressing Out Radial Seal With Screwdriver
10. Fit insertion sleeve (7) 103 589 01 14 00 onto camshaft

11. Coat sealing lip of radial seal with engine oiL
Mercedes-Benz
6.oanqerl
Do not use grease! Grease prevents the sealing lip of the radial seal transporting back the engine oil.
Fig. 172: ldentifving Insertion Sleeve
12. Fit radial seal (1) onto insertion sleeve (7) 103 589 01 14 00 and press in flush (arrows) with sleeve (8)
(shop-made).
6.oanQOrl
The radial seal (1) must be vertical relative to the camshaft (10) to achieve proper sealing.
13. Install in the reverse order, beginning with step 8.

Mercedes-Benz
1 Radial seal
7 fns eltiofl skl:ew
8 S1e9Ve
10 Camshafi
20 Frorn OOVBfS
P01·I'.illl-17
Fig. 173: ldentifving Radial Seal, lnsertion Sleeve, Camshaft And Front Cover
REMOVING AND INSTALLING END COVER- RA01001042220X(01-2220)
Removing ancl installing end cover- RA01001042220X(Ol-2220)
Preceding work:
Manual transrnission: two-mass :flywheel removed (03-4620)
Automatic transmission: driven plate removed (03-4100)
01-8913
Mercedes-Benz
P01•oo::sa-&t
Fig. 174: ldentifying End Cover Remove/lnstall Components
End cover (119) together with unbolt.

radial shaft seal (322)
End cover press off at plates (arrows), pay attention to oil sump gasket!
examine.
Contact surface of radial shaft
If contact surface has grooves, remove radial seal (03-3270) and install
seal at crankshaft
repair size radial seal with sealing lip offset to the inside.
coat sealing surface with sealant
End cover
001 989 45 20 10.
coat with engine oil.
Sealing lip of radial shaft seal .&.oan®r! Do not use grease. Grease prevents the re turn flow swirl on the
sealing lip transporting back the engine oil.

End cover (119) press on over insertion too] together with radial seal (320).
Bolts (120) tighten first of all, 9 Nm.
Bolts (151) tighten, 10 Nm.
Mercedes-Benz
1990-2002 ENG INE Complete Eng ine - REPAIR & ADJUSTMENTS - 129 Chassis
IRear of engine check for Jeaks {01-2240).
End cover to rear of crankcase 9
Securing bolts to oíl sump 10
Special tools
001 5B9 72 21 00
Fig. 175: ldentifying Special Tools (001 589 72 21 00}
601 589 03 43 00
Fig. 176: lden tifying Special Tools (601 589 03 43 00}
NOTE: The end cover is sealed with sealing compound at the crankcase and centered
with 2 dowel pins. In addition, it is bolted to the oil sump and sealed at the
bottom by the oil sump gasket.
There must not be any scoring or unevenness in the sealing surface of the end cover and of the crankcase.
End covers with integrated radlial shaft seal (version B) should be replaced by the end cover with press-fitted
radial shaft seal (version A) when performing repairs.
Mercedes-Benz
A B
P0 1 40-0238-55
A E nd ccver 'Mtl pr &ss-ltiod radull ~'f se al
B End ccver wtl ortegated retialshaft seal and Vl.koo~e~ seafrlglip
Fig. 177: ldentifying End Cover With Press-Fitted Radial Shaft Seal (Version A)
Removing and installing end cover- RA01001192220X(Ol-2220)
Preceding work:
Transmission removed (27-6000).
01-8913
Mercedes-Benz
Fig. 178: ldentifying End Cover Removellnstall Components
Driven plates (20) rernove (03-4100) .

Bolts (11 and 13) unscrew.
End cover (14) wíth radial seal (15) press off (step 3) using M8 bolts at tapped holes (arrows).
Sealant apply (step 5).
Sealing líp of radial seal coat with engíne o:íl ( step 6).
coat wíth sealant (step 7).
Bottom síde of end cover
Sealant 002 989 45 20.
End cover (14) with radial sea! (15) press on over insertion too!, special tool 117 589 00 43 00 (step 8).
Bolts (13) tighten first of all (9 Nm).
Bolts (11) tighten (9 Nm).
Leaks check at rear of engíne when runníng (01-2240).

IEnd cover to cran.kcase 9Nm
Special tools
Mercedes-Benz
001 589 72 21 00
117 589 00 43 00
&.oanaer! lnsertion tool
Use only insertion sleeve 117 589 00 43 00 (2nd version) wíth hole for locating pin.
lnsertion sleeve 117 589 00 43 00 (1st version) can be modified by hole with the dimensions "A, B, C" as
shown in drawing.
SizeA = 38 mm
B= 15.6mm
C= lO mm
Mercedes-Benz
Fig. 181: ldentifying Holes Dimension
NOTE: The end cover seals the main oil gallery (arrow); for this reason, particular care
must be employed when installing.
The sealing surfaces of the crankcase and of the end cover must not have any scoring.
The tapped boles in the crankshaft flange are drilled through. When the bolts are removed and the engine is
tilted, engine oil runs out of the tapped boles.
Fig. 182: Locating Main Oil Gallery
Rem oval
L Remove driven plates together with ring gear (03-4100) .

2. Unscrew end cover together with radial seaL
3. Use bolts at M8 tapped holes (arrows) to press off tight end cover.
&oanoer!
Do not damage gasket of oil sump.

Mercedes-Benz
Fig. 183: Locating M8 Tapped Boles
lnstallation
4. Carefully clean sealing surface on crankcase and on end cover.

5. Coat the sealing surface ofthe end cover evenly with sealant 002 989 45 20.
When doing this, ensure that no sealant gets into the oil gallery (arrow).
Fig. 184: Locating Oil Gallerv
6. Coat radial seal between dust and sealing lip with engine oil.
&.oenQer!
Do not use grease. Grease prevents the angled webs on the sealing lip transporting back the engine oil.
7. Coat underside of end cover with sealant 002 989 00 20 1O.

Mercedes-Benz
8. Push end cover (14) together with radial se al ( 15) over the inner part of the bolted-on insertion tool,
special toolll7 589 00 43 00, and bolt on. Do not damage oil sump gasket. Ifnecessary, replace oil sump
gasket. First of all tíghten bolts (13), then bolts (11 ).
Pay attention to different length ofbolts (13).
9. Check for leaks at rear of engine when running (01-2240).
Fig. 185: ldentifying Eud Cover And Radial Seal
Removing and installing end cover- RA01001202220X(Ol-2220)
Preceding work:
Transmissíon removed (27-6000).
Driven plates (20) with ring gear removed (03-4100).
01-8913
Mercedes-Benz
PG1 • 5281 • 57
Fig. 186: ldentifying End Cover Remove/Install Components
Bolts (1), (2) and (3) unscrew.

End cover (14) witb radial seal (15) and
take off (steps 2 and 3).
gasket (16)
Sealing surfaces clean (step 4).
Sealing lip of radial seal coat with engine oil (step 6).
End cover ( 14) with radial seal ( 15) press on over insertion tooll17 589 00 43 00 (step 7).
Bolts (1 and 2) tighten ftrst of all (9 N m) (step 9).
Bolts (3) tighten (9 Nm).
Oillevel in engine check and adjust to correct level.
Driven plates (20) with ring gear install (03-4100) .
check with engine running before installing transmission
Leakage (01-2240).

End cover to crankcase 9Nm
Initial tightening torque 30-40 Nm
Stretch bolts for driven plates
Tightening angle 90-100°
Mercedes-Benz
SpeciaJ tools
001 589 72 21 00
00 J
117 589 00 43 00
03
Fig. 188: ldentifying Special Tool (117 589 00 43 00 00)
ffi oanaer! lnsertion tool
Use only ínsertion sleeve 117 589 00 43 00 (2nd versíon) w íth hole for locatíng pín.
Insertíon sleeve 117 589 00 43 00 (1 st versíon) can be modified by drilling a hole with the sizes "A, B, C" as
shown in drawing.
SizeA = 38 mm
B = 15.6mm
C= lO mm
Mercedes-Benz
Fig. 189: ldentifyiog Hole Sizes
NOTE: The end cover eloses the main oi 1passage (arrow). For this reason, particular
ca re must be employed when installing end cover. The sealing surfaces of the
crankcase and of the end cover must not show any scoring.
Fig. 190: ldentifyiug Main Oil Passage
l. Unscrew end cover (14) together with radial seal (15).

2. Press off end cover ( 14) together with radial seal (15) at the side (arrows) with a screwdriver.
Aoanqcrl
Do not damage oil pan gasket.

Mercedes-Benz
Fig. 191: ldentifving End Cover And Radial Se al
3. Take off gasket (16).

4. Carefully clean sealing surface on crankcase and on end cover.
5. Insta!] new gasket ( 16) without sealant.
NOTE: Pay attention to locating sleeves (4).
6. Coat radial sea! between dust and sealing lips with engine oil.
&oanoer!
Do not use grease. Grease prevents the augled webs on the sealing lips trausportiug back the engiue oil.
Fi2. 192: Identifying Smeeves And Gasket
7. Push end cover ( 14) together with radial se al ( 15) o ver the screwed-on inner part of insertion tool ( 6) 117
.SR9 00 41 00 anrl screw on.
Mercedes-Benz
6.oanqerl
Do not damage oil pan gasket (arrows); to avoid tbis, tilt end cover (14) back slightly at tbe top when
fitting on.
lfnecessary, replace oil pan gasket.
Fig. 193: ldentifying End Cover, Radial Seal A.nd Insertion Tool
8. lnstalJ bolts according to bolt diagram.

9. Tigbten front cover bolt (1 and 2) first of all.
BoJt diagram
l. Hexagon bolt+washer M6 X 20
2. Hexagon bolt+wasber M6 X 25
3. Hexagon bolt+washer M6 X 50
4. Roles for locating sleeves
Mercedes-Benz
P01·12M· 1:J
Fi~. 194: ldentifyin~ Ti~htenin ~ Seguence Of Front Cover Bolts
CHECKING FOR LEAKS AT REAR OF ENGINE - RA01001042240X(Ol -2240)
Checking for leaks at rear of engine- RA01001042240X(Ol -224 0)
Preceding work:
Manual transrnission: two-mass flywheel removed (03-4620)
Automatic transmission: driven plates removed (03-4100)
Mercedes-Benz
[oooo ;:J
t .~ 516/1
=
S16/3
P01.4o.<l23Q. 57
Fig. 195: ldentifying Starter Lockout Switch Bridge Contacts (816/1)
Rear of engine clean.

Dried surrounding area spray with Mercedes-Benz w hite contrast spray, part no. 000 989 03 59.
Oil level in engine
Manual transmission: check, adjust to correct level (18-0020) .
two-mass flywheel install (03-4620) .
Automatic transmission: install (03-4100) .
driven plate with ring gear
Starter (1) bolt to crankcase with X M lO 60 hexagon bolts (2).
Engine support in installation position at rear and secure.
Automatic transmission
bridge contacts (anows) at starter lockout switch (Sl6/ l).
722.3:
bridge contacts (arrows) at starter lockout switch (S I6/3).
722.5:
start, check for leaks.
NOTE:
Engine
Automatic transmission 722.5: Stored faults which may originate from
disconnecting cables or simulation during test operations, must be erased
in the fault memory after completing work.
Mercedes-Benz
Checking rear of engine for leaks wben running- RA01001192240X(Ol-2240)
Preceding work:
Driven plates removed (03-4100).
Transmission 722.3
P 01-5801-53
Fig. 196: Locating Starter Lockout Switch
Rear of engine clean.

Dried surrounding
spray wíth Mercedes-Benz whíte contrast spray, part no. 000 989 03 59.
are a
Oillevel in engine check, adjust to correct level {18-0020) .
Driven plates witb install (03 _4100) .
ring gear
Starter with bracket bolt to crankcase, special tool
(1) 119 589 00 40 OO.
Engine in
support at rear and secure.
installation position
Automatic
bridge contact at starter lockout switch (S16/3) (arrows).
transmission
start, check for leaks.
Engine NOTE:
Stored faults which may originate from testing work involving disconnecting
wiring or simulation, must be erased in the fault memory after completing work.
EXAMINING, TIGHTENING CYLINDERHEAD BOLTS- RA01001044050X(Ol-4050)

Mercedes-Benz
L
"',...
~
[}1 ~
1
"' a
P01-0<l44-53
Fig. 197: ldentifving Cvlinder Head Bolts Length
EXAMINING
examme.
Length (L) of NOTE:

cylinder head bolts
The cylinder head bolts are subjected to a certain stretch each time they are
tightened. Jf the maximum Jength (L) is exceeded, the bolts should be replaced.
TIGHTENING
Threads of cylinder clean
head bolts and threaded R-. · • •
boles in crankcase ill oanQerl Fhuds forced mto the tbreaded boles may damage the crankcase.
Threads of cylinder
head bolts and contact oil with engine oil.
surfaces of washers
Cylinder head bolts tighten in stages in the order ofthe tightening diagram, starting with l.
lst stage 55 Nm
2nd stage 90° tightening angle
3rd stage 90° tightening angle
&oanQcr! The cylinder head gasket is not watertight until the engine has reached its
normal operating temperature and the gasket has swollen. For this reason, do not
pressure-test the cooling system until the engine has reached normal operating
temperature.
1st stage
Cylinder bead bolts, engine cold 2nd stage 90° tightening angle 55
3rd stage 90° tightening angle
LENGTH OF CYLINDER HEAD BOLT IN MM

Length (L) when new Maximum length (L)
160 163.5 mm
Mercedes-Benz
Special tool
·6 17 589 00 10 00
Fi~:. 198: Identifyin~: Special Tool (617 589 00 10 00)
REPAIRING SPARK PLUG THREADS- RA0100U)44070X(Ol-4070)
Repairing spark plug threads- RA01001044070X(Ol-4070)
Preceding work:
P01-5858-55
Fi~:. 199: Repairin~: Spark Plu~: Threads (1 Of 3)
Pisten of respective cylinder position to 20 - 30° B TDC.

Mercedes-Benz
Grooves (arrows) of combination

thread tap (9) of thread tapping pack with grease.
unit
Stop ring (lO) puB off, fít on.
Combination thread tap (9) screw into damaged thread.
Combination thread tap (9) guide with guide bush (11) pushed into spark plug recess.
screw in sufficiently until guide tube (12) touches and is resting against
the groove (arrow) on tl1e guide bush (11).
Combination thread tap (9) ¿oanqcrl With the cylinder installed, unscrew combination thread tap (9)
after each 5 revolutions approximately, clean grooves of swarf and
grease and re-pack with grease.
Length ofHELI-COIL threaded
insert (8)
check.
Use HELI-COIL insert (8) with
10.2 mm block length.
16
?01-5859-55
Fig. 200: Repairine Spark Plue Threads (2 Of 3)
HELI-COIL threaded insert into fitting tools so that the stud (arrow) of the inset (8) is facing the pre-
insert (8) tensioning cartridge (16).
HELI-COIL insert screw in flush (arrow) into pre-tensioning cartridge (16) using the spindle (13).
Fitting tool fit onto tapped hole.
Jacket sleeve (15) hold tigbt.
turn sufficiently until the stop ring (14) is resting against the jacket sleeve (15).
Screw-in spindle (13)
NOTE:
Mercedes-Benz
lf jacket sleeve (15) jams tight when screwing in, turn back slightly.
25Nm
• P01-5S6C-55
Fig. 201: Repairing Spark Plug Threads (3 Of 3)
Sleeve (18) fit over driving stud (arrow).

Driving stud (arrow) fix in place with pliers (17) (serrations (s)).
Sleeve ( 18) turn to left as far a stop.
move up and down slightly, break off dríving stud (arrow).
Pliers ( 17) & oana••' If driving stud drops onto the piston crown, it must be removed with a
magnet.
Degreased caulking tool . . d t. hte t N
(ó) screw m an tg n o 25 m.
crank: with starter (01-0110) to remove any swarfwhích may have dropped onto
Engine
the piston crown.
Special tools
Mercedes-Benz
102 589 00 99 00
120 589 02 09 00
001 589 66 21 00
Repairing spark plug threads- RA01001194070X(Ol-4070)
SpeciaJ tools
Mercedes-Benz
102 589 00 99 00
01
102 589 0 2 09 00
15
001 589 72 21 00
00
NOTE: The spark plug threads in the cylinder head can be repaired with the HELI-COIL
Repair Set.
Repairing
l. Remove appropriate cylinder head cover, install (01-0500).

2. Set piston at respective cylinder to 20° - 30° before TDC.
3. Pack grooves (arrows) ofthe combination thread tap (9) ofthe thread tapping unit with grease and screw
combination thread tap into the damaged thread. When performing thís step, push the guide bush ( 11) into
the soark plug recess.
Mercedes-Benz
D
If cylinder head is fitted, unscrew combination tap after approx. each five turns, clean grooves of swarf
and grease and re-pack with grease.
Fig. 208: Identifying Combination Thread Tap Grooves And Guide Bush
4. Check length ofHELI-COIL threaded insert (8).
Use only the HELI-COIL insert with 10.2 mm block length.
Fig. 209: Cbecking Lengtb Of HELI-COIL Threaded lnsert
5. Instan HELI-COIL threaded insert.
Todo this, place HELI-COIL insert (8) into the installation tool so that the tang (arrow) ofthe insert is
facing the pretensioning cartrídge (16). Tum HELI-COIL insert with fitting spindle (13) through the
Mercedes-Benz
pretensioning cartridge far enough for the tang (arrow) to be flush with the face end ofthe pretensioning
cartridge_
16
Fig. 210: Identifying HELI-COIL Insert, Pretensioning Cartridge And Fitting Spindle
Fit installation tool onto the tapped hole, hold jacket sleeve (15) tight and turn insertíon spindle unti l the
stop ring (14) is resting against the jacket sleeve_
NOTE: When screwing in the HELI-COIL threaded insert, turn back jacket sleeve
(15) slightly if it jams.
Fig. 211: ldentifving Jacket Sleeve And Stop Ring
6. Break offtang (arrow) ofHELI-COIL threaded insert
This is done bv fittini! sleeve (18) of tan!! breakinf! unit over the tan!!. íntroducin!! ooened oliers (17) into
Mercedes-Benz
the sleeve as far as the marking (arrow) and closing pliers. The serrated lock (S) must engage.
Turn sleeve ( 18) to the left as far as the stop and hold tight.
M ove pliers slightly up and down and break off tang.
¿Oanacrl
If tang inadvertently drops onto pisten crown, it must be removed with a magnet.
Ro tate crankshaft severa! times with struter and contact handle in order to remo ve any swarf which may
have dropped onto the pisten crown.
Fig. 212: ldentifving Fitting Sleeve, Opened Pliers And Serrated Lock
7. Caulk: HELI-COIL threaded insert. Todo this, grease the tapered thread ofthe caulk:ing tool (6), screw
caulking tool into the installed HELICOIL insert, tighten to 25 N m and remove caulking tool.
Mercedes-Benz
Fig. 213: ldentifving Caulking Tool
EXAMINING, FACING CONTACT SURFACE OF CYLINDER HEAD- RA01001044180X(Ol-4180)
Examining, facing contact surface of cylinder bead - RA01001044180X(Ol-4180)
Preceding work:
Valves removed.
01-7162
Mercedes-Benz
P01-54366-57
Fig. 214: ldentifying Cylinder Head Of Contact Surface Position
Reference size (H) measure and note.

Cylinder head contact surface face. Pay attentíon to note.
Sharp edges on edge of combustion d b
eurr.
ehamb er
Reference síze (H) once agaín measure. Determine stock removaL
Valves (42) and (43) insert
measure; to do this, ínsert 0 6 mm bar centered ínto the base of the
Reference sizes (T) between end of camshaft bearing and measure size (T) with caliper gauge.
valve stem and camshaft bearing &oanaert If size measured is less than size "T", correct valve clearance
base compensation is no longer possible; replace val ve seat ring or
eylinder head if necessary.
Valve seats machíne accordíng to stock removal on cylinder head (05-2910) .
DATA IN MM
Total height "H" of cylinder head 135.9-136.0
Total height "H" of cylinder head 135.9-136.0
Mínimum height after machining (l) 135.5
longitudinal!y 0.08
Permissible deviation from evenness of contact surface
transversely 0.0
Permissible deviation of parallelism of top to bottom contact surface in longitudinal
0.1
direction
Mercedes-Benz
Peak-to-valley height 0.003- 0.010

with standard síze camshaft bearíng dia. inlet 24,21 - 24,75
Reference size "T" exhaust 22,21 - 22,75
inlet 23,96-24,51
wíth repair size camshaft bearing dia.
exhaust 21 ,96 -22,51
(1) The material removal at the cylinder head and at the cylinder crank housing of a motor may together
amount to max. 0.4 mm (seeOl-1200).
COMMffiRCMLLYAV~ABLET OOLS
Surface grinding machine with milling device for light alloy surfaces
Knife-edge straight edge
NOTE: Only machine cylinder head contact surface if porous or damaged points are
present or if an impermissible deviation from the evenness in the longitudinal
direction is determined.
The top cylinder head contact surface must not b e machined as otherwise the basic bores ofthe camshaft
&.oanQcrl
bearíngs are altered.
If cracking ís suspected (intemal loss of coolant), the cylínder head must be pressure-tested.
Checking cylinder head mating surface, facing - RA01001194180X(Ol-4180)
Preceding work:
Valves removed.
01 -7162
Mercedes-Benz
'
1 1
Fig. 215: Identifying Cylinder Head Mating Surface Dimension
DATA
Reference sizes H1 H2 T
Whennew 130 6 (l) 145 ,9 (l) -
l13o> 146,0
Minimum height after stock removal 130 4(1) 145,7(1) -
'
With camshaft bearing dia. 23,07
Standard size 23,81
in longit. dir. 0,08
Permissible variation from evenness of mating surface in transv.
0,0
dir.
Pem1issible variation of parallelism of top to bottom mating surface in
0,1
longitudinal direction
Peak-to-valley height 0,003-0,0 lO
Test pressure with air under water in bar gauge 2
(1) Measure by inse1ting a shaft and dressing halfthe diameter. The stock removal at the cylinder head
and at the crankcase ofan engine must together not be more than 0.4 mm (see 01-1200).
CO~RCULLYAV~ABLETOOLS
P. Schoenleber GmbH
Caorle
Surface grínding machine with milling tool for light alloy surfaces e.g. Cramer-Klettstr. 8
D-83229 Aschau
Order no. 9033 0006
Set of mounts for side attachment M 119 Order no. 90330037
Roaro u Fí
Mercedes-Benz
1990-2002 ENG INE Complete Eng ine - REPAIR & ADJUSTMENTS - 129 Chassis
IKnife-edge straightedge approx. 500 mm long e.g. Schio 1Italien
NOTE: Only machine cylinder head mating surface if porous or damaged points exis t
or if an impermissible variation has been measured from the evenness in the
longitudinal direction.
Lt, OanQerl
The top cylinder head mating surface must not be machined otherwise the basic bores of the camshaft bearings
will be altered.
If cracking is suspected (internal loss of coolant), the cylinder head must be pressure-tested (01 -4200).
Facing
l. Measure reference sizes Hl and H2 and note.

2. Face cylinder head matíng surface. Deburr sharp edges at edge of combustion chamber.
3. Agaín measure reference sizes Hl and H2. Determine stock removal and note.
4. Re-position valve seats by the same amount ofthe stock removal at the cylinder head (05-2910) .
5. Measure reference size (T) between end of val ve stem and base of camshaft bearing.
NOTE: To do t his, insert 0 6 mm round bar in the middle of the base of the
camshaft bearing and measure size "T" with caliper gage.
Ifthe síze obtained is less than the size "T", it is no longer possible to achieve correct valve clearance
compensation; replace valve seat ring or cylinder h ead.
6. Check timing (05-2150) .
Lt.oanoerl
It is not permitted to rework the valves. Ifthe valve seat has to be reworked, the valve should be replaced.
Checking, machining cylinder head contact surface - RA01001204180X(Ol-4180)
Preceding work:
Valves removed.
01 -7162
Mercedes-Benz
P 01-5B66-S7
Fig. 216: ldentifying Overall Height Of Cvlinder Head
Reference size (H) measure and note

Cylinder head contact surface face, pay attention to note
Sharp edges at edge of combu stion chamber deburr
Reference size (H) once again measure, determine stock removal
Valves (42) and (43) insert
Reference dimensions (T) between end of val ve measure; insert 6 mm dia. round bar into base of
stem and base of camshaft bearing camshaft bearing as measuring aid
rnachine according to stock rernoval at cylinder
Valve seats head (05-2910)
DATA IN MM
135.9-
Overall height "H'' of cylinder head
136.0
Mínimum height after machining (l) 135.5
Permissible difference frorn flatness of contact longitudinal!y O. 08
surface transversely 0.0
Permissible difference in paralleüsrn of top to bottorn
0.2
contact surface longitudinally
0.003-
Peak-to-valley height
0.010
with cam~haft hearin2 ciia inlet 24.21 -

Mercedes-Benz
standard size 24.75

22.21 -
exhaust
22.75
Reference dimension "T" w ith camshaft bearing 23.96-
inlet
dia.repair size 24.51
21.96 -
exhaust
22.51
(l) The stock removal at the cylinder head and at the crankcase of an engine must together be not more
than 0.4 mm (see 01-1200).
COMMffiRCMLLYAVAaABLETOOLS
Surface grinding machine with milling device for light alloy Sceledum, type RTY Roaro u. Fi. Schio 1
surfaces eg_ Italy
Knife-edge straightedge 1
NOTE: Machine cylinder head contact surface only if porous or damaged points exist
or if an impermissible difference f rom the flatness in the longitudinal direction
is measured.
&oanQerl
The top cylinder head contact surface must not be machined as otherwise the bearing bores of the camshaft
bearings will be altered.
If cracks are suspected (internalloss of coolant), the cylinder head must be pressure-tested_
WIDENING CAMSHAFT BEARING BORES (REPAIR SIZE)- RA01001044190X{Ol-4190)
DATA IN MM
29.947
Camshaft
29.963
Standard size
30.000
Cylinder head
30.021
30.434
Camshaft
30.450
Repair size
30.500
Cylinder head
30.525
Camshaft bearing bores Peak-to-valley height 0.001 - 0.004
Pemussible difference in shape of cylinder 0.012
Permissible misalignment of 1st and 7th bearing bore 0.040
radial 0.035
Bearing play
axial 0.06 - 0.21
Mercedes-Benz
NOTE: lf bearing seizing or severe scoring is present, the camshaft bearing bores can
be widened by 0.5 mm and a camshaft with oversized bearing journals installed.
Code number of this camshaft see (05-2200) .
&oenaer! When performing repairs, camshafts with an oversize of +0.5 mm should be used for reconditioned
engines with +0.5 mm camshaft bearing bores.
SERVICING THREADS FOR CAMSHAFT BEARING CAP BOLTS- RA01001044192X(Ol-4192)
Preceding work:
Camshaft removed (05-2200) .
Operation no. of operation texts and work tmits or standard texts and flat rates
¡¡., MB
l
o
P01 30-0274- 5.5
Fig. 217: Identifying Servicing Threads For Camshaft Bearing Cap Bolts Dimension
Dowel sleeves remove, install.

Bore widen, pay attention to core plug depth.
HELI-COIL thread tap.
HELI-COIL threaded insert screw in.
DATA IN MM
Twist drill 0 8.4
Core plug depth from contact surface 28
Threaded insert below contact surface 6
Mercedes-Benz
ILength of thread screwed in 20
COMMERCIALLY AVAILABLE TOOLS

Bollhoff GmbH
Postfach 14 02 29
HELI-COIL hand thread tap M8 pre-tap e.g.D-33622 Bíelefeld
Order no. 0140.108 0104
Bollhoff GmbH
Postfach 14 02 29
HELI-COIL hand thread tap M8 final tap e.g. D-33622 Bielefeld
Order no. 0140.208 0102
Bollhoff GmbH
Postfach 14 02 29
HELI-COIL hand installation tool e.g. D-33622 Bíelefeld
Order no. 0150.040 800
Bollhoff GmbH
Postfach 14 02 29
HELI-COIL threaded insert M8X20 e.g. D-33622 Bielefeld
Order no. 0130.008 0020
CLEANING, SEALING OIL LONGITUDINAL GALLERIES IN CYLINDER HEAD-

RAOI001044300X(Ol-4300)
Precedíng work:
Cylínder head removed {01-4150).
Camshafts removed (05-2200) .
Bucket tappets removed {05-2110).
Operatíon no. of operation texts and work units or standard texts and flat rates:
Mercedes-Benz
A B 32
Ptt-A72-1J
34
P01-5871-57
25 Sleel baJ, 8 nm día. 34 Oílou!et galoly, illet sido, 7,85 mm da

22 Oll galely, buckottawe:s oll ~. 35 Olltransverse gaSecy, nxhoostslde, 7.85mm óa
oldlalJS! Sldll, 7.85 rrm da 36 Oll transvers:e gawry, rrtet Slde, 7.85mm ó a
23 Ollgalory, buckettappels OtlstWtJ, 37 Ollnser gale¡y, c;lrldor haad
utet slde, 7.85 mm óo
33 OtlouSet gaJ91Y, exheJJSt sada, 7.85 nm da
Fig. 218: ldentifying Cylinder Head Components In Cleaning, Sealing Oil Longitudinal Galleries (1 Of 2)
Screw plugs (26) with seals unscrew, screw on (15 Nm) (Fig. A).
Steel balls (25) in oil galleries (22), (23),
knock out with round bar (6) dia. 6X700 mm
(33)
and (34) from the front (Figs. B and C).
Plug (32) prise out with a screwdriver (Fig. C).
Oil galleries (22, 23, 33 and 34) at rear widen dia. X 9 8 mm deep (Fig. D).
knock in with a punch (8) into oil galleries (22) and (23) (Fig.
SteeL balls (25) at side
D).
Steel balls (25) knock out from front with round bar ( 6).
Oil galleries (35) and (36) at side widen dia. 9X8 mm deep.
Mercedes-Benz
P01-5876-53
Fi~. 219: Identifyin~ Cylinder Head Components In Cleanin~. Sealin~ Oil Lon~itudinal Galleries (2 Of 2)
M10Xl thread tap in oil galledes (Fig. E).

Oillongitudinal galleríes and all boles carefully clean.
Bolt head contact surface at oil galleries
face.
(35 and 36) at side
coat around circumference with Loctite high strength 270,
New plug (32a)
002 989 93 71 10 (Fig. E).
New plug (32a) knock in flush with suitable drift (Fig. E).
Screw plugs (26a)
part no. 000 908 01 00 02 with seals screw in (15 Nm) (Fig. F).
part no. 007 603 O1 O1 03
Special tool
\__ 001 5B9 72 .21 00
Fi~. 220: ldentifyin~ Special Tool (001 589 72 21 00)
SEALING AIR GALLERY IN CYLINDER BEAD- RA01001044400X(Ol-4400)
Preceding work:
Carnshaft removed (05-2200) .

Mercedes-Benz
Operatíon no. of operation texts and work uníts or standard texts and flat rates
1 10
2 3
4
A ~
P01.30.0273-55
A longaiJdinal bolo of a1: galerym cyW!der head 2 Certer of c')findar hoad
B Augaler;comedootocert!ll alllaust Sido 3 Rear of cytndar head
Frort cf cylrlder head
Fig. 221: ldentifving Sealing Air Gallerv In Cylinder Head Dimension
Bore (A) in front of

cylinder head (1) and inspect for specified 0 of 12.00 to 12.04 mm.
in rear (3)
knock into bore (A).
New cap (4) part no. NOTE:

000 443 012 001 lf a cylinder head with secondary air injection gallery, connection bore (8), is
used for an engine without secondary air injection, the connection bore (B) (0
15.1 Oto 15.12) should be sealed with a cap (5) part no. 1 04 016 00 33.
REMOVlNG AND INSTALLING ENGINE- RA0100104A300X(Ol-0300)
Removing and installing engine- RA0100104A300X(01-0300)
Preceding work:
Bottom engíne compartrnent panel removed (Maint. Manual)
Aír cleanerremoved (AR09.10-1050D)

Mercedes-Benz
Radiator removed (20-4200)
Viscous fan coupling removed (20-3120)
01-2400, 2800
A. Models 124, 129, 140
11
• 9
Fig. 222: ldentifying Engine Remove/lnstall Components
Engíne with transrnissíon remove, ínstall.

disconnect, connect, encode radio, model 140 norrnalize power
windows.
Coolant draín at crankcase.
If AC fitted attach guard plate to condenser.
Air-to-oil cooler pipes (1) at air-to- d. t t( t )
oil cooler Isconnec , connec s ep 3 .
Mercedes-Benz
If AC fitted: take off poly V -belt, fit on {13-3200) .

Power steering pump extract oil from reservoir, adjust oil to correct level (step 5).
AC compressor (4) remove with piping connected, place to the side, fit on.
Oil pipes ofpower steering pump, take off, seal and fit on (steps 7-8).
automatic transmission
Fuel pipes take off, seal, open fuel filler cap briefly first of al!, fit on (step 9).
Bowden cable (accelerator control) take off, fit on (30-1010, step 10).
Heating water retum pipe detach, attach.
Component compartment cover remove, install model 140 (step 14).
Right cable duct remove, instaU model 140 (step 14).
Electrical connections disconnect, connect (steps 15 to 21).
Electrica] connections, starter disconnect, connect (steps 23, 24).
V acuum pipes for brake pressure
detach, attach.
regulator etc.
Exhaust system remove, install (49-0045 , 49-0170 ) .
Flexible disc (5) oftransmission (6) detach, attach, replace self-locking nuts step 25).
Clamping nut and intermediate
slacken, tighten (steps 26, 27).
beari.ng fixture
Shíft rods at transrnission detach, attach (step 28).
If manual transmission fitted: unbolt hydraulic pipes for clutch, bolt on (step 29).
disconnect starter lockout switch, transmission overload protection,
If automatic transmission fitted:
electric wiring, connect (steps 30, 32, 33, 34).
Engine hoist attacb to lifting lugs, detach (step 35).
Transmission support.
Rear engine support (7) without
remove, install (step 37).
engine mounts
Exhaust bracket at transmission unbolt, bolt on (step 38).
Front engine mounts (8), left and
unbolt from below, bolt on (step 39).
right
Guard plate at component
insert, take off.
compartment wall
Engine raise with engine hoist, lower ( step 41 ).
Front and rear engine mmmts examme.
Coolant, oil and fuel hoses examme.
If au.tomatíc transmission fitted adjust Bowden cable for control pressure (27-1 00).
Oil drain plugs check tightening torque.
Oil level in engine and transrnission adjust to correct level (18-0020) .
pour in, check anticorrosion/antifreeze agent and adjust to correct
Coolant
ratio (20-0100) .
Idle speed check, adjust (07-2056).
read, erase (step 52).
NOTE:
Mercedes-Benz
Faults stored in the fault memories must be rectified after

completing the work and erased.
F ault memory
See Diagnosis Manual Volume 2:
Index 0: Connecting and using test equipment.
Leak tíghtness check after test run of engine.
TI GHTENING TORQUES IN NM
Oil pipes to air-to-oil cooler 30
Oil pipes to air-to-oil cooler 30
Knock sensors to crankcase<l) 20
(1) Bolt head contact surface and thread oíled
Special tools
001 589 66 21 00
COMMERCIALLY AVAILABLE TOOLS AND TESTERS

Wilbar GmbH & Co KG
Removal devíce components model 3188 (liftíng capacity 500 kg) e.g. Herder Str.
42895 Remscheíd
Mercedes-Benz
SHOP-MADE TOOLS
Guard plate for radiator /condenser sizes approx. 400x680xl mm
Metal plate for component compartment wall sizes approx. 320x380xl mm
NOTE: In the case of engine damage involving damage to the pistons, valves
&oanQGr!
etc., parts may have got in as far as the catalytic converter, or pre-catalytic
converter.
When replacing the engine, it is essential to remove such parts otherwise they will be pu1sed back into the
cylinders as a result of the gas vibrations in the exhaust system and may once again cause engine damage.
In addition, these parts may cause mechanical damage to the catalytic converter.
lt is therefore essential to remo ve any foreign bodies in the exhaust system in the case of such engine damage.
Catalytic converters which ha ve been damaged must be replaced.
Engine 104.990 in model140
When replacing the crankcase or installing a reconditioned engine, the matched ignition control module (DI)
should be used, see (01-1000).
Removing and installing engine with transmission.
l. Disconnect grotmd cable at battery.
lnstallation note
Encode radio, model 140 normalize power windows.
2. lf AC fitted: attach guard plate to condenser of AC system.

3. Unbolt air-to-oil cooler pipes at air-to-oil cooler (arrows)
Mercedes-Benz
MOOi!l 140
Fig. 225: Locating Unbolt Air-To-Oil Cooler Pipes
Model140
• Unbolt oil cooler pipes at body (arrows)_

4. If AC fitted: remove pol y V -belt (13-3420) .
Model 140
Fig. 226: Locating Unbolt Oil Cooler Pipes And Body
5 _ Extract oil from the reservoir of the power steering pump with the priming pump for extracting oiL
lnstallation note
Check fluid level ofpower steering system_ Fill up power steering with the specified fluid. Top up fluid to
the marking with the engine running_ Turn steering several times from fullleft to full right lock. When
flnio is ::1t nnrm:::tl onP.r:::ttinP tP.mnPr:::ttnrP it nmst PYtP.no tn :::thnnt ?O mm hPlnw thP P.OPP nfthP rP.sP.rvnir-
Mercedes-Benz
when fluid is cold to 6-8 mm below the marking.
Fig. 227: ldentifviug Top Up Fluid
6. Detach AC compressor of air conditioning system from the eugine.
Unscrew bolts (35) and nuts (for attaching pipe assy) ; attach AC compressor to the side at the bottom of
the engine compartment with the pipes com1ected.
Fig. 228: ldentifving Unscrew Bolts And Nuts
7. Unbolt suction and pressure oil pipes at power steering purnp and tandem high pressure pump,
respectively (arrows).
Installation note for tandem pump
Bleed pressure oil pump (level section) oftandem pump (32-6300).

Mercedes-Benz
Fig. 229: ldentifving Unbolt Suction And Pressure Oil Pipes
8. Unbolt delivery pipe oflevel pump (1), unscrew M8 bolts (3) ofmetal bracket (2) and press pressure pipe
out ofthe metal brackets (arrows).
Model 140
Fig. 230: ldentifving Unbolt Delivery Pipe OfLevel Pump And Metal Bracket
9. Briefly open filler cap in the fuel tank to release the pressure.
Unbolt fuel pipes (arrow) and seal with special tool 000 589 40 37 OO. Counter-hold the connection fitting
(1) when slackeníng the fue! pipe.
Mercedes-Benz
Ertg11e 104.98, models 124, 129
Fig. 231: ldentifying Unbolt Fuel Pipes And Seal (Engine 104.98, Models 124, 129)
Ertgtr~e 104.99
Fig. 232: ldentifving Unbolt Fuel Pipes And Seal (Eugine 104.99)
10. Detach Bowden cable (30) from accelerator controllever (9). Compress plastic clip (28) and pull out
Bowden cable.
lnstallation note
Adjusting Bowden cable (30-1010).

Mercedes-Benz
Fig. 233: ldentifving Bowden Cable, Plastic Clip And Accelerator Control Lever (Engine 104.98)
11. Detach Bowden cable (30) from accelerator controllever (9). Compress plastic clip (28) and pull out
Bowden cable.
lnstallation note
Adjusting Bowden cable (30-300).
Engíne 104.99
Fig. 234: Identifving Bowden Cable, Plastic Clip And Accelerator Control Lever (Engine 104.99)
12. Detach heater hoses and vacuum pipes in the engine compartment. If automatic transrnission fitted, pull
off vacuum pipe at 2-way val ve.
Models 124, 129
13. Detach connector from the oillevel gauge and from the oil pressure sensor.
Mercedes-Benz
Slacken aU cable straps ofthe engine wiring harness. Detach all connectors along the engine wiring
harness.
Remove engine wiring hamess
Model140
14. Remove component compartment cover (3), open cable duct (1) and remove right-hand side.
Model140
Fig. 235: ldentifying Cable Duct And Component Compartment Cover
15. Unplug connectors (items X26/17 and Ml6/ lxl) ofthe engine wiring harnesses. Press ratchet (arrow) and
tum to release the connector (16/lxl).
16. Place engine wiring hamesses on the engine.
Madol 140
Fig. 236: Unplugging Connectors
17 At the irrn ition control morlul e. unnhw cranks haft nosition sensor connector fT ,5)_ T,H controlmorlnl e
Mercedes-Benz
connector (B), knock sensors connector (A 16) and detach vacuum pipe (arrow).
18. Detach suction pipe of the evaporative emission control system from the connector on the left-hand
wheelhouse.
Fig. 237: Unplugging Crankshaft Position Sensor Connector (LS)
Modell24
19. Detach cable connector terminal TD (arrow) next to diagnostic socket (X11).
Models 124, 129, 140
20. Unbolt diagnostic socket (X11), detach cable from TD sensor on rear of diagnostic socket.
1
1 __:;;
Fig. 238: Identifying Diagnostic Socket Cable Connector Terminal TD
Models 124, 129

Mercedes-Benz
21. Disconnect wiring (327) at the generator.
Fig. 239: ldentifving Generator Wiring
22. Remove exhaust system ( 40-0045, 49-0170 ).

23. Remove heat shields above front and underfloor catalytic converter (model 140 only).
Model140
24. Unbolt starter wiring harness X27 and terminal 30 at screw connection X4/1 O on front right of firewall
from below.
Fig. 240: ldentifving Unbolt Starter Wiring Harness X27
25. Detach propeller shaft by unscrewing bolts (arrows).
NOTE: The propeller shaft is balanced together with the flexible joint.
Mercedes-Benz
Fig. 241: Identifying Propeller Shaft Unscrewing Bolts
26. Slacken bolts for propeller shaft intermediate bearing but do not remove.
27. Slacken clamping nut (waf 41/46) ofpropeller shaft. Push back propeller shaft as far as possible.
Tightening torque 30-40 Nm.
Fig. 242: Identifying Smacken Nut Of Propeller Shaft
28. Ifmanual transmission fitted: take shift rods offthe transmission shift levers after pressíng offthe clip
locks.
29. Ifmanual transmission fitted: separate hydraulic pipe (arrow) to the slave cylinder at the hose connection.
Seal pipes with dummy plugs or extract fluid from the rear chamber of the combined expansion reservo ir.
Mercedes-Benz
Fig. 243: Separating Hydraulic Pipe To Slave Cvlinder Hose Connection
30. Ifautomatic transmission fitted: slacken cable strap (23) and unscrew cable (6) at the kickdown solenoid
valve (61) or puU off. Unscrew fastening bolt for the pulse generator (arrow) and pull out the pulse
generator.
31. Unbolt ground cable at t:ransmission.
Fig. 244: ldentifving SEacken Cable Strap, Unscrew Cable And Solenoid Valve
32. Remove connector for starter lockout switch (8).
&oanaorl The connector for tbe starter lockout switch is secured by a locking element (white plastic ring,
arrow).
Before pressing off the connector, the Jocking element must be turned up (direction of arrow ).
Detach shift rod (9) in the range selector lever.

Mercedes-Benz
Fig. 245: ldentifving Starter Lockout Switch Connector
33. Use two screwdrivers to carefully press offthe connector (8) at the cable outlet and at the tab.
Fig. 246: ldentifving Connector And Screwdrivers
34. Unscrew connector for transmission overload protection (arrow).

Mercedes-Benz
Fig. 247: ldentifying Transmission Overload Protection For Unscrew Connector
35_ Attach engine hoist to the lifting lugs ofthe engine.
Adjust engine hoist so that the engine can be raised horizontally.
36. Support transmission in trolley jack or in inspection pit lift

37_ Unbolt rear engine support without engine mounts. Unscrew bolts ítem l.
38. Unscrew securing bolts (2) of the exhaust bracket (3) at the transmission.
Fig. 248: ldentifving Exhaust Bracket And Unscrew Securing Bolts
39. Unscrew bolts (a) at the left and right front engine mounts from below.
Mercedes-Benz
~1oúel 140
Fig. 249: ldentifving Left And Right Unscrew Bolts
40. Insert guard plate between component compartment wall and engine.
4 1. Move engine together with transmission into angled position and lift out of engine compartment by
repositioning engine hoist severa! times, and install in the same way.
NOTE: When tilting engine, pay attention to rear lifting lug and to oil filter (arrow).
Fig. 250: ldentifving Oil Filter
42. Installation is performed in the reverse order.
Installation note model140
Before installing the engine, install right engine mount in front suspension, left engine mount can be
installed with the engine.
Mercedes-Benz
43. Examine front and rear engine mounts.

44. Examine coolant, oil and fuel hoses.
45. If automatic transrnission fitted, adjust cable for control pressure (27 -1 00).
46. Check tightening torque of oil drain plugs.
47. Adjust oillevel in engine and transmission to correct leveL
48. Pour in coolant, check anticorrosion/antifreeze agent, adjust to correct ratio (20-0100) .
49. Check idle speed (07-2056).
NOTE: lf engine is replaced, read fault memory of the following control modules
and erase any faults which may be stored.
• CFI control module

• LH-SFI control module
• DIIKSS ignition control module
• Electronic accelerator (if fitted)
• Diagnostic module (California), see Diagnosis Manual Engine Volume 2.
Removing and installing engine- RA0100119A300X(Ol-0300)
Preceding work:
Aír cleaner (4) removed (09-0015) .
Bottom engine compartrnent panel removed (Maintenance Manual 6190).
Radiator removed {20-4200) .
01-2400, 2800
A. Models 124, 129, 140

Mercedes-Benz
11
Motor 119, Typ 140

•'
Fig. 251: Identifying Engine Removellnstall Components- Models 124, 129, 140
Ground cable at battery disconnect, connect.

Coolant at crankcase drain.
If AC fitted:
attach, remove.
guard plate at condenser
Model140: left Bowden cable d t h tt h
( engine compartment Jock) e ac ' a ac ·
Heating water Jines at rear of
intake manifold and at
detach, attach.
connection pipe to rear of
crankcase
Viscous fan clutch with fan
(2)
If AC fitted: remove, install (13-3420) .
oolv V-belt (3)
Mercedes-Benz
take off, seal witb special tool

Fuellines 000 589 40 37 00, fit on. Open fuel filler cap
btiefly beforehand.
Electrical connections (engine d t h tt h
.. h ) eac a ac.
wmng amess '
V acuum lines detach, attach.
Bowden cable (accelerator remove, install (30_0025) .
control)
Model 124: accelerator
remove, install.
controllinkage at rear
Vacuum line of brake servo
tmbolt, bolt on.
unit
Power steering pump, oil in extract, special toolll2 589 00 72 OO.
reservou Adjust oil to correct level (46-0715) .
Oillines of power steering
detach, seal, attach.
pump
lf air injection fitted: air pump d t h 1 .
plug connection e ac ' p ug m.
Model 124: front bmnper remove, install (88-2000).
Model 124: right headlamp remove, instaH (82-4730).
Model 124: air duct, left
remove, install.
engine mount cooling
Model 140: oil cooler line
tmbolt, bolt on.
bracket
Oil cooler lines at air-to-oil
cooler (l3) and (l 4) unbolt, seal, bolt on {18-1300).
Model 124:. left oil cooler line unbo1t, bolt on.
( 13) at 01 1sump
If level control fitted: high
unbolt, bolt on.
pressure hose
Model 124: left oilline,
unbolt, bolt on.
Bolt for piping behind AC
unbolt, bolt on (25 Nm).
compressor
AC compressor (11) with
detach, place to the side, attach (83-5300).
piping connected
Plug connection, oxygen
disconnect, connect.
sensor (6) (lambda sensor)
Exhaust system (7) complete remo ve, install (49-0045 , 49-0170 ).
Shield over starter tmbolt, bolt on.
Modell29: electrical
detach, attach.
connection, starter
Wiring harness, starter and
altemator from engine and tmbolt, bolt on.
transmission
Mercedes-Benz
Model 124: strut below oil

unbolt, bolt on.
sump
detach, attach. Replace self-locking nuts (41 -0050).
Propeller shaft of flexible
coupling (8) NOTE:
Flexible coupling remains on transmission.
Clamping nut and
intermediate bearing slacken, tighten (41 -0050).
attachment of propeller shaft
Ground cable at transmission unbolt, bolt on_
Rear engine c.arrier (1 O)
without engine mount
Bracket of exhaust at
unbolt, bolt on_
transrnission
Sbift rod at transmission detach, attach.
Electrical connections at
disconnect, connect
transmission
Front engine mounts (12) on unbolt, bolt on (22 _2110) _
left and right from below
Model 124: sealing strip of
component compartment pull off, fit on.
panel
Engine hoist at lifting eyes attach, detach.
Engine with engine hoist move into angled position and raise.
Model 129: wiring harness of b lt b
alternator un °' 01
t on_
Engine remove, install.
Front and rear engine mounts examrne.
Coolant, oil and fuel hoses examrne.
Automatic transmission,
Bowden cable for control adjust (27-110) _
pressure
Idle speed check, adjust
Oil drain plugs check tightening torques.
Oil level in engine and
adjust to correct leveL
transmission
pour in, check anti-corrosion/anti-freeze concentration and adjust to
Coolant
correct level (20-0100) _
Cooling system check for leaks, special tool 124 5 89 15 21 00 (20-0 170) _
Engine run.
check
NOTE:
Faults stored as a result of disconnecting cables or simulation during
Mercedes-Benz
removal and installation or test operations, should be processed and

erased in the fault memories after completing the work. Re-code or
normalize radio and power windows, as appropriate.
Engine leaks
Perform final control actuations.
Diagnosis Manual Volume 2, Index 0:
Connecting and using test equipment.
Special tools
001 589 66 21 00
124 589 15 21 00
112 589 00 72 ()0

Mercedes-Benz
COMMERCIALLY A V AILABLE TOOLS

Engine hoistNo. 3188e.g.Backer GmbH
andCOKG
self-locking
D-42895 Remscheid
SHOP-MADE TOOL
IGuard plate for radiator/condenser Dimensions approx. 400x680xll
REMOVING AND INSTALLING ENGINE AIR ADMISSION HOUSING (COMBINATION

SUPPORT)- RA0100104A420X(Ol-0420)
A Model129
Fig. 255: Identifying Engine Air Admission Housing Remove/Install Components

Mercedes-Benz
Engine compartment panel, bottom and side left unbolt, bolt on.
Poly V-belt tensioning device remove, instan {13-3200) .
Pressure pipe ofpower steering pump (47) disconnect, connect.
Power steering pump (5) unbolt, place to the side, bolt on.
AC compressor (6) with piping/wiring connected unbolt, place to the side, bolt on (step 5).
A ir admission hose (43) of combination supports take off, fit on (step 6).
Engine air admission housing (17) remove, clean, instan (step 7).
Engine run.
Leaktightness check

Engine air admission housing to crank:case 21
l. Unscrew engine compartment panel at bottom and at right side.

2. Remove V-belt tensioning device (13-3200) .
3. Unbolt delivery pipe from power steering pump.
4. Unbolt power steering pump from bracket and place to the side.
5. Remove AC compressor with piping/wiring connected; unscrew bolts (35) for this step.
6. Detach air admission hose (43) from combination support (17).
Fig. 256: ldentifying Air Admission Hose And Combination Support
7. Remove engine air admission housing by unscrewing bolts (32).

8. Clean engine air admission housing and sealing surface of engine block
9. Replace gasket.
Mercedes-Benz
NOTE: As of 7/95 the gasket has been modified. As a result of the modified
gasket, the dowel sleeves for fixing the engine air admission housing in
place have been discontinued.
On engines with dowe] sleeves, remove dowel sleeves and install new gasket without dowel sleeves.
10. Assemble in the reverse order.

Fig. 257: ldentifving Bolts
REMOVING AND INSTALLING CYLINDER HEAD COVER- RA0100104A500X(Ol-0500)
Removing ancl installing cylinder bead cover- RA0100104ASOOX{Ol-0500)
Preceding work:
Air cleaner removed (09-0015) .
01-5070
A. E ngines with CFI (continuous fuel injection system, electronic)

Mercedes-Benz
1101- fOti ••, 1
Fig. 258: ldentifving Cvlinder Head Cover Removellnstall Components
take off cover of engine wiring hamess at component

Modell24:
compartment partitíon, fit on.
Engine vent hose (12) at cylinder head cover detach, fit on.
Covers (7+9) over spark plug cables take off, ínstall.
Spark plug connector (8) disconnect, plug in.
Arrangement of spark plug connectors on
observe as índicated in the díagram.
cylinder head cover
Bolts (14) of cylinder head cover unscrew, screw on (10 Nm).
Cylinder head cover with gasket (2) and
take off, fit on, replace only together.
shaft seals (3)
Engine run.
Leakti ghtness check, particularly at rear.

lcylinder head cover bolts 1ol
Special tool
Mercedes-Benz
001 589 72 21 00
Ensure that lap joints ofvalve cover seal at rear (arrows) are installed correctly.
Fig. 260: ldentifying Lap Joints OfValve Cover Seal
Use version B only together with front cover with cast part no. 104 O16 07 06.
Production breakpoint of version B as of 02/ 1990 _
Engine 104 980 1O 00 1 729
12 007 925
104 981 10 000 340
12 002 895
Engine 104.98
Mercedes-Benz
A Fnst w rsion
B S ocood vllfSlon
Fig. 261: Locating Front Cover
Removing and instaUing cylinder head cover- RA0100104C500X(Ol-0500)
C. Engines with HFM-SFI (HFM sequential multiport fuel injection/ignition system)
Preceding work:
Ignition coils removed (AR15.12-2003G)
01-5014
Mercedes-Benz
P01 30-0234-Si
Fig. 262: Identifying Cylinder Head Cover Remove/Install Components
Cover (7) and (6) remove, instan_

Bolts (14) and (15) with spacer
unscrew, screw on; see bolt diagram (lO Nm)_
sleeves (l4a) and (15a)
Take off, fit on; replace only together_
NOTE:
Cylinder head cover (1) with gaskets Remove grease from sealing groove and existing re-usa~le
) d ( ) d haft ( ) gasket (2) so that the gasket (2) adheres better to the cyllnder
(2 an 2a an s sea1s 3 head cover (1 ).
(Do not grease new gasket!)_

Engine nm_
check, particularly at rear (arrows) at the gaskets (2a) and in the
Leaktightness
spark plug reces ses_
Removing and installing cylinder head covers- RA01001190>500X(Ol-0500)
Preceding work:
Mercedes-Benz
Engine 119.96/97: Air cleaner removed (09-0015) _
01-5070
Motor 119.97 P01-57ag..57
Fig. 263: ldeotifying Cylinder Head Cover Remove/Install Components
Model 21 0: cover over intake manifold remo ve, install

Crankcase ventilation lines (4) and (5) detach, fit on.
Engine 119.960: vacuum line at
detach, fit on.
crankcase ventilation line (4)
Engine 119.960/97: engine wiring
hamess (19) at right cylinder head cover unbolt, bolt on.
(6a)
Vacmun line ( 16) of brake servo unit at
unbolt, bolt on.
intake manifold
Covers (1) and (la) over higb voltage
unclip, remove, instalL
distributors
Fuel filler cap open, release pressure, close.
Fn~tnP: 11 Q Q(-)0 - fi 1PI ltnP:s ::lt nrP:ssnrP
Mercedes-Benz
regulator and fuel distributor disconnect, connect {07.3-1674) .

disconnect, connect. Use box wrench bit 000 589 68 03 00; see
note.
Engine 119.97/98: fuel pipes ( 17) and
&oanqort lnstallation model 210
( 18) at fuel rail
Ensure the pipes are correctly routed; fuel pipes must not be
touching cylinder head cover and engine cover.
Shaft covers ( 14) and (14a) over spark unscrew, take off, fit on.
plug cables and ignition coils
Engine 119.96/97: spark plug
unplug, plug in (15-1031) .
connectors
Engine 119.98: ignition coils unscrew, remove, install.
Engine 119.985 in model 210: unbolt, swing to the side with lines connected so that left
windscreen washer fluid reservoir cylinder head cover can be removed and installed.
remove, screw on (9 Nm).
Bolts of cylinder head covers with seals
&oanqort Pay attention to different lengths ofbolts (see bolt
( lO)
diagram).
take off, fit on_
Cylinder head covers (6) and (6a) with NOTE:

gaskets (7) and (7a) and shaft seals (8) Replace all gaskets together, ensure crankcase ventilation
siphon at left cylinder head cover is correctly located in the
drain hole.
run and check for leaks, particularly at rear; see installation
Engine
note.

IBolts of cylinder head cover 9
Special tools
001 589 72 21 00

Mercedes-Benz
~~---0_
00_5_8_
9_68_0_3_00____~)
Note engine 119.97/98
Use box wrench bit (02) 000 5 89 68 03 00 to lmscrew fu el pipes ( 17, 18) and to screw on.
P01.1()..{)261-1 3
Fig. 266: ldentifying Box Wrench Bit And Fuel Pipe
Installatioo note
Overlaps at the cylinder head cover gaskets at rear (arrows) must be correctly installed.
&oanaer!
Replace gaskets which are kinked outwards or inwards at the side.
When performing repairs, install gaskets with identification 119 O16 08 21 RA on right side and 119 O16 07 21
LA on left si de (identification in raised lettering).
Mercedes-Benz
Fig. 267: Locating Overlaps Cylinder Head Cover Gasket
Bolt diagram
P 01-5700-57
Esgne 119.97
1st version (bolt head height 6 mm) 2nd version (bolt head height 4 mm)
11 M~O heXBgr>...n sorket bol 12 MBx33 hemgon sorket bol
12 M6J<35 hoxagon soc ket lxll 13 M6x4 5hemgon sockel bol
13 M6ló45hoxagonsot:k elbo
Fig. 268: Identifying Bolt Diagram - Cylinder Head Cover Bolts

Mercedes-Benz
CRANKING ENGINE WITH STARTER- RA0100104BUOX(Ol-0110)
Cranking engine with starter- RA0100104B110X(Ol-0110)
B. Model129
Preceding work:
Warning instmctions when hood open (01-0085).
001581772100
P01-5820-57
Fig. 269: Cranking Engine With Starter
Ignition switch off.

Cover ( 1) o ver component compartment
remove, install.
panel
Plug of connector (X27) unplug.
Clamp (A) of compression pressure
recorder 001 589 77 21 00 at pin 1 of connect.
connector (S)
Cover of connector (X4/l O) open, close.
Clamp (B) of compression pressure
connect to terminal block (X4/10).
recorder
Mercedes-Benz
crank by pressing contact handle (arrow) on compressíon

pressure recorder in idle speed position and parking brake
Engine
applied.
&oanQerl Do not crank engine at ignition/starter switch.
Cranking engine witb starter- RA01001190110X(Ol-0110)
A. Model124.034
Fig. 270: Cranking Engine With Starter (Model124.034)
Ignition switch off

Cover over engine component compartment detach, attach.
Cover ofterminal block (X4/ 10) open, close.
Connector (S) of plug connectíon (X27) unplug, plug in.
Crocodíle clamp (A) of compressíon tester at
· 1 f t
d' . t · t
connect, tsconnec , specta1 oo1 001 589 77 21
oo _
pm o connec or
Crocodile clamp (B) of compression
pressure recorder at the terminal block connect, disconnect
(X4/ 10)
Engine crank in idle speed posítíon and with parking brake applied
hv nush in Q" contact hanrlle (arrow) on comnression teste e
Mercedes-Benz
& oanacrl Do not crank engine using ignition starter switch.
B. Model 124.036
Fig. 271: Cranking Engine With Starter (Modell24.036)

Cover over engine component
take off, install.
compartment
Cover ofterminal block (X4/10) open, close.
Connector (S) of plug connection
unplug, p1ug in.
(X27)
Adaptor cable (01) with plug
connect, separate, special tool 124 589 36 63 OO.
connection (X27)
Adaptor cable (01) with cable (02)
connect, separate, special too! 00 l 589 77 21 OO.
of compression tester
Crocodile clamp (B) of
connect to terminal block (X4/ 10, disconnect.
compression tes ter)
Engine crank in idle speed position and with parking brake applied by
nnshinQ" conta.ct hanclle ( arrow) at the comnression tester
Mercedes-Benz
& oanQorl Do not crank engine using igni tion starter switch.
C. Model129 witb engine 119.960
Fig. 272: Cranking Engine With Starter (Model129 Witb Engine 119.960)
Ignition switch off

Cover over component
remove, install.
compartment
Connector of plug connectíon ·
(X2 ?) unp 1ug, p 1ug m.
Crocodile clamp (A) of connect at pin 1 of connector (S), disconnect, special tool 001 589 77 21
compressíon tester OO.
Cover of terminal block
open, close.
(X4/ 10)
Crocodi1e clamp (B) of
connect tester to terminal block (X4/10), disconnect.
compressíon
crank in ídle speed posítíon and with parking brake applíed by pushíng
Engine contact handle (arrow) on compression tester.
&oa"""'' Do not crank engine using ignitíon starter switch.
Mercedes-Benz
013 lrr¡)uisz.á!tor
0 75 Adaptor lrmuiSialter
X11/4 Pruk\¡lpkJngfir Oiagros'8(38polig)
Fig. 273: Cranking Engine With Starter (Typ 140)
Left cover over EZL

take off, fit on.
ignition control unit
Crankshaft position sensor
(L5) at EZL ignition unplug, plug in.
control unit (Nl/3)
crank in idle speed position and with parking brake applied using ignition
Engine
starter switch (82/ 1).
read, erase (see Diagnosis Manual Engine Volmne 2, Index 0).
NOTE:
EZL ignition control unjt
(Nl/3) fault memory lf the engine is started with the crankshaft position sensor (L5)
unplugged, a fault is stored in the EZL ignition control unit (N1/3) fault
memory (contact 17, pulse readout 17). This must be erased after
completing the work.
E. Model210
Mercedes-Benz
Hazard warníngs when hood opened (01-0085)_
P01 10-0263-57
Fig. 274: Cranking Engine With Starter (Model 210)
Ignition switch off

Cover (2) over engine component - t
compartment remove, ms a 11 -
Connector of plug connection
unplug, plug in.
(X22) ( circuit 50)
Clamp of cable (O 1) connect to pin 1 ofplug connection (X22) circuit 50, disconnect
Cable (01) connect to cablle (02) of compression recorder, disconnect
Cover ofterminal block (Xl2/3) open, close.
Clamp (03) of compression
connect to terminal block (X12/3) circuit 30, disconnect
recorder 001 589 76 21 00
crank by pressing the contact switch (arrow) on the compression
Engine recorder, transmission in Neutral and parking brake applied.
.&.oanQer! Do not crank engine at ígnitíon/starter switch_
Special tools
Mercedes-Benz
001 589 77 21 00
201 589 00 99 00
Cranking engine with starter- RA01001200110X(Ol-0110)
Preceding work:
Hood opened, raísed to vertical position (0 1-0080).
A. Model129
Mercedes-Benz
P01 . 5648 _,.,
Fig. 277: Cranking Engine With Starter- Model129

Cover of engine component compartment (2) take off, fit on.
Cover of connector (X4/ 1O) open.
Fuse of connector (X27) pull off, fit on.
Connector (S) of plug connection (X27) unplug, plug in.
Crocodile clamps (A) and (B) of compression connect to pin 1 of connector (S) and connector
pressure recorder 001 589 77 21 00 (X411 0).
crank by pressing the contact handle (arrow) on
Engine
compression pressure recorder.
6 oanQerl Engine do not crank with ignition switch.
Preceding work:
Hood opened, raised to vertical position (01-0080).
B. Model140
Mercedes-Benz
01l Pulse OOUJIBr

075 PIJiso toUliDr adaptor
X11f4 Data Id( cometlof (38-ptn)
Fig. 278: Cranking Engine With Starter- Mod~l140
Covers on left and right over DI control modules (Nl/4 and

take off, fit on.
Nl/5)
Com1ector of crankshaft position sensor (L5/4 and L5/5) of
both DI control modules tmplug, plug in.
(Nl/4 and Nl/5)
Engine crank with ignition switch (S2/ l ).
read (see Diagnosis Manual Engine
Fault memory ofDI control module (Nl/4 and Nl/5)
Volume 2, Index 0).
TECHNICAL MODIFICATIONS ENGINE 104 MECHANICAL 1- RA0100104TAOOX
01 Engine removal and installation, crankcase, cylinder head and crankcase ventilation
Designation Nature and reason for modificat ion Production Op.

breakpoint no.
Conversion to new sealant for timing case 01-
Sealant 5/93
cover and front cover 2120
Mercedes-Benz
01 -
End cover End cover with integrated radial shaft seal
2220
Engíne air admission housing Dowel sleeves for fixing in position 01 -
07/95
(combination support) discontinued; gasket modified as a result 0420
HAZARD WARNINGS WHEN HOOD OPENED- RA01001190080X(Ol-0080)
&.oanacrl Do not raise hood by the handle.
The windshield wiper arm must not be tilted forward when opening the hood.
Risk of injury if the hood is opened and the engine is running.
The engine wíth DI ignítíon system is very hazardous because of the high ignition voltage.
Do not touch components of the ignition system (ígnition coil, dístributor, ignition cables, spark plug
connectors, test socket) when
• the engine is nmning,

• the engine is started,
• the key in the steering lock is in position 2 and the engine is being cranked by hand.
Pay attention to information regarding working on the breakerless transistorized ignition system (15-0505).
Getahr1iche Hochspannung!
Vo~ctlt bet Atbeit90 an dt r
Zündanjage
Dangerl High voltage

O~erve caution when working
on the ignition system
Danger! Haute tensíon

Attentlon Jors de 1ravaux au
sysléme d'allumage
Fi2. 279: ldentifyin2 Information Re2ardin2 Workin2 On Breakerless Trans,istorized I2nition Svstem
MEASURING, HONING AND SILICON-LAPPING CYLINDER BORES - RA01001191120X(Ol-U20)
MATCHING PISTONS TO CRANKCASE WITH NUMERICAL IDENTIFICATION

Engine 119.960/970/972/974 Class identification Index Piston o(t) Cylinder o<2)
o 52 96.483-96.493 96.498-96.503
O+ 53 96.488-96.498 96.503-96.508
Mercedes-Benz
Standard size Std 96.5 0 1 54 96.493-96.503 96.508-96.513

1+ 55 96.498-96.508 96.513-96.518
2 56 96.503-96.513 96.518-96.523
o 96.983-96.993 96.998-97.003
1st repair size+0.5 1 96.993-97.003 97.008-97.013
2 97.003-97.013 97.018-97.023
o 97.483-97.493 97.498-97.503
2nd repair size+ l. O 1 97.493-97.503 97.508-97.513
2 97.503-97.513 97.518-97.523
(l) Group identification stamped on piston crown with color.
(2) Group identification stan1ped at top next to cylinder bore.
MAT CHING PISTONS TO CRANKCASE WITH LETTER IDENTIFICATION

Engine 119.980/982/970/972/974 Group identific ation Index Piston 0 <2> Cylinder 0(1)
A 52 96.482-96.495 96.500-96.508
Standard size Std 96.5 0 B 54 96.491 -96.504 96.508-96.516
e 56 96.499-96.512 96.516-96.524
A 96.982-96.995 97.000-97.008
1st repair size +O.5 B 96.991 -97.004 97.008-97.016
e 96.999-97.012 97.016-97.024
A 97.482-97.495 97.000-97.508
2nd repair size + 1.0 B 97.491 -97.504 97.508-97.516
e 97.499-97.512 97.516-97.524
(l) Group identification stamped at top next to cylinder bore.
(2) Group identification stamped on piston crown.
MAT CHING PISTONS TO CRANKCASE WITH NUMERICAL IDENTIFICATION

Engine 119.9711975/981/985 Group identification lndex Piston e (l ) Cylinder 0 (2 )
o 52 9 1.983 -91.993 91.998-92.003
O+ 53 91.988-9 1.998 92.003 -92.008
Standard size Std 92.0 0 1 54 91.993 -92.003 92.008-92.013
1+ 55 91.998-92.008 92.013 -92.018
2 56 92.003-92.013 92.018-92.023
o 92.483-92.493 92.498-92.503
1st repair size +0.5 1 92.493-92.503 92.508-92.513
2 92.503-92.513 92.518-92.523
o 92.983-92.993 92.998-93.003
2nd repair size + 1.0 1 92.993-93.003 93.008-93.0 13
2 93.003-93.013 93.018-93.023
Grouo identification stamoed on oiston crown with color.
Mercedes-Benz
(1)
(2) Size stamped at top next to cylinder bore.
MATCHING PISTONS TO CRANKCASE WITH LETTER IDENTIFICATION

Engine 119.9711975/981/985 Group identification Index Piston 0 (2) Cylinder 0 {l)
A 52 91.982-91.995 92.000-92.008
Standard size Std 92.0 0 B 54 9l. 991-92.004 92.008-92.016
e 56 91.999-92.012 92.016-92.024
A 92.482-92.49 5 92.500-92.508
1st repair size +O. 5 B 92.491-92.504 92.508-92.516
e 92.499-92.512 92.516-92.524
A 92.982-92.99 5 93.000-93.008
2nd repair size + 1.0 B 92.991 -93.004 93.008-93.016
e 92.999-93.012 93.016-93.024
(1) Group identification stamped at top next to cylinder bore.
0.004-
Whennew
Piston clearance 0.026
Wear limit 0.08
Maximum wear limit of cylinder bores in direction of travel or transverse direction at top and
bottom 0.10
reversa! point of 1st pis ton ring
MACHINING TOLERANCES
When new 0.013
Permissible variation of cylinder shape
Wear limit 0.05
Permissible variation of rectangularity related to cylinder height 0.05
Averaged peak-to-valley height (Rz) after polishíng 0.001
A veraged peak-to-valley height (Rz) after silicon-lapping 0.001 - 0.003
Pemússible wave depth (Wt) 50% of peak-to-valley height after silicone-lapping
e hamfer of cylinder bores see ill. step 14
NOTE: See pistons, matching and dimensions 03-3165 for further tolerances and
assignments.
COMMERCIAL TOOLS
Automatic cylinder repair machine
SUNNEN eK- 10-G with honing oil filter and oil cooler
orCV 616
Mercedes-Benz
Honing head CK-3000 for dia. 76-127 mm or CK-2600

SUNNEN honing oil MB 30( 1) Germany:
Prehoning stone set C 30-A 53, 70 mm longC2) e.g. Hommel Handel GmbH
2 DonatusstraBe 24, D-5000 Koln 71
Final honing stone set e 30-J 84, 70 mm long ( )
Polishing stone set C 30-C 03-81
other countries:
Stone holder for felt insert CK-30 35
e.g. SUNNEN Products Comp.
USA-7910 Manchester
Felt insert holder set CK-3130
St. Louis, Mo. 63143
Felt inserte 30-F 85
SUNNEN silicon paste AN-30 Hommel Handel Export Division
Box for silicon paste and felt inserts AN-35 P.O. Box 1206 D-6806 Viernheim
Interna! measuring instrument for 50 - 150 mm día., with 0.01 mm indication and measuring point
pressure relief, e. g. SUNNEN GRM 2125
Setting micrometer for intemal measuring instrument GAM 2125 with setting range 50- 200 mm, e.g.
SUNNEN CF-1000 M
(1) When refi.lling approx. 170 liters.
(2) These stones are available only with a length of 89 mm and must be shortened at the top to 70 mm
with a hack.saw (see step 3).
NOTE: The light alloy cylinder bores are very sensitive to damage, scratching and also
dirt and must therefore be handled with grate care.
The cylinder bores should be adapted when honing to the sizes of the available repair size pistons with the
Group No. O, 1 or 2. The specified pisten clearance must be observed.
Measuring
Use a measuring instnunent with measuring point pressure relief for measuring the cylinder bores as the
cylinder barrel will otherwise be scored by the measuring point tip and the measuring point tip ofthe instrument
will wear prematurely.
Set the self-centering interna! measuring instrument to the cylinder dia. before measuring. Measure the cylinder
bores at a room temperature of 22 - 24 °C.
Mercedes-Benz
1 ktemalme.ss.llnng ils.trumonl:
2 Settl'lgmicromoter
Fig. 280: ldentifying Interna} Measuring Instrument And Setting Micrometer
Following silicon-lapping (final state) it is only possible to measure the amount by which the aluminum
surfaces stand back between the silicon crystals (0.5 - 1.5 J.!m) indírectly by means ofthe averaged peak-to-
vaHey heíght (Rz).
The specified exposed depth ofthe silicon crystals results from the limited-time control during silicon-lapping
and from the silicon paste used.
Honing and silicon-lapping
Where severe scoring and severe cylínder wear exísts (> 0.10 mm) etc., the cylinder bores can be honed to the
stated repair sízes.
The silicon crystals must be undamaged and be flattened on the cylinder surface following the honing
operations.
After the honing operations (prehoning, final honing and polishing) it is essential to perform "silicon-lapping"
based on the Sunnen method so that the silicon crystals are exposed.
lf the "silicon-lapping" operation is not performed, this will inevitably result in piston seizure .
&oancaer!
The following operatíons can only be performed wíth a h oning machine wíth honíng oíl filter and oil cooler.
The silicon partícles must be filtered out ofthe honing oíl.
The honíng oíl must be cooled to a constant temperature of 20 oc to avoid excessive heatíng of the crankcase.
Only the specified honing oil may be used to achieve good honing quality.
Mercedes-Benz
l. Prepare honing machine CK-1 0-G.
Perform aU the honing and lapping operations without the direction guide shoes.
The honing stone runout (arrow) size x:
Engine 119.96 14 mm
Engine 119.97 13. 5 mm
_,
Fig. 281: ldentifving Honing Stone Runout Size
2. Cut offprojection ofbronze bars at bottom ofmain guide shoe (arrow) as only approx. 14 mm undercut
for the honing stone nmout is available at the cylinders.
- f'""
•
~
t. (
ht ._ 1-
.e:. -• -• J
Fig. 282: Locating Projection Of Brooze Bars At Bottom Of Main Guide Sboe
3. The specified stone sets of 89 mm length must be shortened to 70 mm. Only the honing stone, not the
holder, should be cut off at the top with a hacksaw.
Mercedes-Benz
Sizs a~ 70 mm
~ ~~~~~~~
¡:¡ ,____ _ _ __ _ __ __,.
M-- -- - . _ _ _ __,
Fig. 283: Identifying Honing Stone Length
4. Tighten crankshaft bearing cap bolts and nuts to 50 Nm in the order ofthe tightening diagram.
l 2 3 4 a
411
@1
@
-=-.
----
® -® ®
® ® @
.... litO• O
Fie. 284: Identifying Crankshaft Bearing Cap Bolts And Nuts Tightenine Sequence
5. Fix disassembled and cleaned crankcase with crankshaft bearing caps installed and tightened in the
honing machine wíth the square steel bar ( 1).
Mercedes-Benz
Fig. 285: ldentifving Steel Bar
6. Set stroke setting (cylinder length) on the stroke scale (arrow) according to the "prehoning" table.
Fig. 286: Locating Stroke Setting (Cvlinder Lengtb) On Stroke Scale
7. Set stone projection (arrow) with the gauge according to the table.
Mercedes-Benz
Fig. 287: Locating Stone Projection
8. Set feed (auow) according to table.

9. Set strokes/min and rpm accordíng to table.
Fig. 288: Locating Feed
Prehoning
SETTING OF HONING MACHINE

Engine 11 9 960 119.970 119.97 1
. 119.974
Cylinder dia. settíng for 1st repaír size (+0.5)96.5 mm96.5 mm 92.0 mm
Cylinder length (L) 154 mm 137.5 mm
Stroke setting 156 mm 140mm
Revolutions/rnin 125
Mercedes-Benz
Strokes/min 49 (eK-10-G) 57 (CV616)

Feed 4
Stone projection approx. 12 mm
Prehoning stone set e 30-A 53 (e30-J55)
Indication % approx. 30
Stock removaVmin 0.07 mm
Feed scale/stock removal lO graduations/0.05 mm
10. Prehone all the cylinder bores at full honing oil feed up to approx. 0.08 mm before fmal size otherwise
the silicon crystals will be tom out or destroyed by the cutting pressure.
&.o••ae,, A deviation of approx. +0.02 mm is obtained when measuring immediately after prehoning as a
result of heating.
The heating of the crank:case is dependent among other things on the outside temperature.
11. Insert stone set for fmal honing and cut to length as described in step 3.
12. Set honing machine according to the "precision honing" table.
Precision honing

119.970
Engine 119.960 119.971
119.974
eylinder dia. setting for 1st repair size (+0.5)96.92 mm96.92 mm 92.42 mm
Cylinder length (L) 154mm 137.5 mm
Revolutions/min 125
Strokes/min 49 (eK-10-G) 57 (eV616)
Feed 3
Precision honing stone set e 30-J 84
Stock removal/min 0.05 mm
Feed scale/stock removal lO graduations/0.05 mm
13. Precision-hone all cylinder bores at full honing oil feed up to approx. 0.02 mm before final size.
&.oonae,, A deviation of approx. +0.01 mm is obtained when measuring directly after precision-honing as a
result of heating. Heating of the crankcase is dependent among other things on the outside temperature.
14. Chamfer cylinder bores according to the sketch prior to "polishing".

Mercedes-Benz
Fig. 289: ldentifying Cylinder Bore Dimension
15. For chamfering, use a su itable handmilling cutter with an angle as shown in the sketch above.
Fig. 290: Cbamfering Cvlinder Bore Using Handmilling Cutter
16. Insert stone set for polishing.
New polishing stones should be corrected in the tightest cylinder bore before starting machining.
17. Set honing machine according to "polishing" table.
Polisbing

Engine 119 960 119.970 119.971
. 119.974
Cylinder dia. setting for 1st repair size (+0.5) 96.98 mm96.98 mm 92.48 mm
Mercedes-Benz
eylinder length (L) 154 mm 137.5 mm

Stroke setting 156mm 140mm
Revolutions/min 125
Strokes/min 49 (eK-10-G) 57 (eV616)
Feed 2
Polishing stone set e 30-C 03-81
Stock removaVmin 0.01 mm
Feed scale/stock removal 10 graduations/0.0 1 mm
18. Polish all cylinder bores at fuJl honing oil feed up to end size.
19. Allow crankcase to cool.
20. Measure cylinder bores.
When performing this step, allow for the required cyhnder día. (Group No.) for the existing pistons and
the specified piston clearance.
Re-polish once again if necessary.
Fig. 291: Measuring Cylinder Bore
21. elean cylinder walls with fíltered honing oil so that all silicon partid es are removed and do not cause any
scratches during the subsequent silicon-lapping operation.
22. Press felt inserts e 30-F 85 into the holders eK-3130 and the latter into the stone holders eK-3035.
&oanc¡er!
After pressing in the felt inserts, remove all material deposits on the holder.
Mercedes-Benz
Fig. 292: Pressing Felt lnserts C 30-F 85 lnto Holders Ck-3130
23. Perform setting of cylinder diameter with the setting gauge.
Fig. 293: Setting Of Cvlinder Diameter Witb Setting Gauge
24. Soak felt inserts with filtered honing oil and insert into the honing head.
25. Shut off honing oil feed.
26. Set honing machine according to "siliconlapping" table.
Silicon-lapping

119.970
Engine 119 .960 119.974 119.971
Cylinder dia. settíng for 1st repair size (+O.5) 97 mm 97 mm 92.5 mm
Cylinder length 154 mm 137.5 mm
Mercedes-Benz

Revolutions/min 185 (CK-10-G) 230 (CV616)
Strokes/min 73 (CK-10-G) 80 (CV616)
Infeed 2
Felt insert projection 2mm
Felt insert e 30-F 85
Indication % ca.30
Stock removal/min not measurable
Feed scale 18 graduations approx. 70 seconds operation
27. ThoroughJy stir AN-30 silicon paste and then rub into the dry cylinder walls fully.
28. Likewise apply silicon paste to felt inserts.
29. Introduce honing head with felt inserts into cylinder bore.
30. With honing machine running, slowly turn the feed wheel to the right until the indicating instmment has
reached 30%.
Fig. 294: ldentifving Instrument Indication V aJue
31. Set feed scale to 18 graduations.
The honing machine switches off after approx.
70 seconds. The cylinder surface then has a mat appearance.
No honing angle is visible.
The peak-to-valley height is 0.001 - 0.003 mm.

Mercedes-Benz
Fig. 295: ldentifving Honing Machine
32. Thoroughly clean aH sílicou paste residues from cyliuder bores with filtered honíng oil aud a suítable
soft-brístle brush aud dry cyliuder bores.
U sed silicon paste must not be re-used!
Fi2. 296: Cleaning Silicon Paste Residues From Cylinder Bores With Soft-Bristle Brush
REPAIRING TAPPED HOLES FOR TRANSMISSION MOUNTING- RA01001191240X(Ol-1240)
Preceding work:
Engine removed (01-0300)
Engine 119.960
Mercedes-Benz
P01•l5tD ..35
Fig. 297: Locating Tapped Boles For Transmission Mounting
Core hole wíth HSS twist drill bore out (step 1).
Swarf blow out (step 2).
connect (step 2).
Bore (4) with oil return duct
Right cylinder bead remove, instan (01-4150).
Oi.l sump remove, instan (01-3100).
Swarf in oil duct blow out from above.
HELI-COIL mounting thread tap (step 3).
Swarf blow out (step 4).
HELI-COIL threaded insert MlO screw in (step 5).
&oenQer!
observe (step 5).
Insertion depth
Tang of HELI -COIL threaded insert break off with a drift, remove.
Ease of movement of threads check (step 7).
Stud bolts screw into bore 1 and 4 (step 8).
COMMERCIAL TOOLS
HELI-COIL tap M lO
Alt. No. 0140 0100104
HELI-COIL threaded insert MIO e.g. Bollhoff & Co.
Standard Art No. 0130 0100020 D-4800 Bielefeld 14
Mercedes-Benz
HELI-COIL hand instaHation tool M lO

Art. No. 0150 0410000-1
NOTE: Torn threads for transmission mounting should be replaced by HELI-COIL

standard threaded inserts, Art. No. 0130 0100020 with a length corresponding to
twice the diameter of the bolts (11 threads).
R econditioning
l . Dríll core hole approx. 27 mm deep with an lO mm día. H SS twist drill.
Mínimum core hole diameter 10 mm, maximum 10.3 mm.
F ig. 298: Drilling Core Hole With HSS Twist D rill
2. Blow out swarf.
Lt. oanQérl Bore (4) merges into oil retwn duct.
When repairing bore (4), remove and instan right cylinder head (01-4150).
Remove and instan oil sump (01-3100).

Mercedes-Benz
1 'Wld4 M10srud~
1and 3 M10
thread
Fig. 299: ldentifying Tapped Boles For Transmission Mounting
&oanqorl
Blow swarffrom bore (4) out of oil duct from above (arrow).
Fig. 300: Locating Tapped Hole
3. Tap HELI-COIL mounting thread with HELICOIL MlO tap (outer diameter 12.0 mm), Art. No. 0140
0100104, approx. 25 mm deep. Lubricate tap with honing oil when performing this step.
4. Blow out swarf.
&oanQer!
Bore (4, see step 2).

Mercedes-Benz
Fig. 301: Taping HELI-COIL Mounting Thread With HELICOIL MIO Tap
5_ Screw in oiled HELI-COIL MIO standard threaded insert, Art No. 0130 0100020, with the MIO hand
installation tool, Art No. 0150 0410000-1.
& oanoer!
The top thread must stop approx. 2 mm below the mating surface_
6. Break offtang ofHELI- COIL threaded insert with a drift
Fig. 302: Screwing In Oiled HELI-COIL MIO Standard Threaded Insert, Art. No. 0130 0100020
7 _ Examine inserted thread for possible misalígnment and for ease of operation of threads by screwing in a
bolt
The insertion depth should be approx. 23 mm.

Mercedes-Benz
8. Install stud bolts (1) and (4).
&oanaorl
The microencapsulated stud bolt (4) seals the oil duct in the crankcase.
The stud bolts lose their sealing effect after being removed. They may only be used once.
1 and 4 M10 stud 001

2!Yld3 M10
lhread
Fig. 303: Locating Stud Bolts
REMOVING AND INSTALLING DRIVER ON CAMSHAFT- RAOI001192130X(OI-2130)
Preceding work:
Removing and installing intake air beses (09-0015) .
Model124: removing and installing intake air scoops (09-0060) .
Engine 119.96/97
Mercedes-Benz
1 5N~~~~o®.
~1jf
2•
3
eNm 4 6
~~~~~~
H1~
Fig. 304: Identifying Camshaft Remove/Install Components
Shielding caps (1) and (la) at the side unclip, take off, fit on.
High voltage distributors (2) and (2a) unbolt, bolt on.
Dístributor rotor (3) unbolt, bolt on (2.5 Nm).
unbolt, bolt on (9 N m).
lnstallation note
Driver (4)
The slot of the driver (4) must engage in the locating pin in the
camshaft.
Protective cover (5) together with seal tak ff fit
(ó) e o , 1 on.
NOTES ON CYLINDER HEADS- RA01001194000X(Ol-4000)
The cylinder heads for the "closed-deck" and "open-deck" crankcases (01-1000) have dífferent combustion
chamber shapes.
"closed-deck" oval on one side
"open-deck" straight on both sides
In addition, the oil retum flow gallery at the rear is positioned offset.
The "ooen-deck" cvlinder heads have one M8 bolt hole less at the front.
Mercedes-Benz
Engines 119.971/975
The "open-deck" design of cylinder heads can be used on "closed-deck" crankcases when performing repairs.
Engines 119.970/972/974
The "closed-deck" design of cylinder heads can be used alternatively on "closed-deck" and "open-deck"
crankcases when performing repairs, as of engine number
119.970 12 021 287
119.972 12 as ofsta1t ofproduction
119.974 12 004 782
REMOVING AND INSTALLING CYLINDER HEADS- RA01001194150X(Ol-4150)
Removing and installing cylinder heads- RA01001194150X(Ol-4150)
Precedíng work:
Coolant drained (20-0100) .
01-5800
A. Models 124, 140, 210

Mercedes-Benz
P01-5804-57
Fig. 305: ldentifving Cylinder Head Remove/Install Components - Models 124, 140, 210
Intake manifold remove, install.

Front cover at cylinder head to be removed remove, install (01-2120).
Guide rail of cylinder head at cylinder head to be remove, install (05 -3350) .
removed
Camshaft adjuster at cylinder head to be removed remove, install (05-2170) .
Left cylinder head: bolts (1), (la) and (2) unscrew, screw on (21 Nm).
place to the side, install.
lnstallation note
Retaining plate with power steering pump ( 11)
Coat bolt (2) with sealant 002 989 47 20 10.
and oíllínes connected
Engine 119.97: install bolt (la) with retaining bracket
(4) of wiring harness.
Right cylinder head: dipstick guide tube (22) unbolt, bolt on.
Guide raíl (23) for ignition cables remove, install.
Right cylinder head: dipstick guide tube (12),
unbolt, bolt on.
Front exhaust system at exhaust manifold unbolt, bolt on (49-0170) .
Rigbt cylinder head

Mercedes-Benz
1'01·110GoC7
P01-~57
a M8x120 hllxagcn sockelfitc'Oiarbol or e RoiJW~

bol•wash8f t Dowel sleeve
b M8>c74 hexegon socketfitcolar bol or
txll•washM
Fig. 306: ldentifving Cvlinder Head Removellnstall Components - Right Cylinder Head
Left cylinder head

Mercedes-Benz
@
(!20@0(!)0@
@ @ @ _..,..,.,.,
P01-5806-57
d M8x50 he>cagoo sodrot bol!+wBShor
e M8x75heli8QOI1 socket bol+wanr
1 0owe1Sie8\IBS
Fig. 307: ldentifying Cylinder Head Remove/InstaU Components- Left Cylinder Head

Right-hand cylinder head: fit
collar bolts or bolts+washers NOTE:
(a) and (b) to timing case
cover When peñorming repairs, install fit collar bolts or the bolts+washers
depending on the bolts u sed previously.
Left-hand cylinder head: bolts
(d) and (e) to timing case unscrew, screw on (25 Nm).
eover
slacken with screwdriver bit in stages in reverse order oftíghtening
diagram, beginning with 10, remove, special tool119 589 00 10 OO.
Cylínder head bolts when NOTE:

engine cold Models 124, 140: cylinder head bolt 10 cannot be removed with
cylinder head installed; for this reason, raise and secure.
M()rlPl ? 1 O· r.vlinrlP.r hP::~rl h()lt~ Q ::~nrl 1 O ()f h()th rvlinrlP.r hP.::~rl s r.: mn()t hP.
Mercedes-Benz
removed witb cylinder head instaUed; for this reason, raise and secure. On
"closed-deck" crankcases, the cylinder headl bolts installed have different
lengths; refer to bolt diagram.
First aud fourth camshaft
bearing caps ( 18) of inlet slacken, unscrew.
camshaft
bolt ou wíth bearing cap bolts and dowel sleeves ( 18a) instead of first and
Bracket ( 17)
fourth camshaft bearing caps (18), unbolt, special tool1 19 589 01 40 OO.
Engine hoist attach to bracket (17).
Cylinder heads (13) and (14) raise, remove.
Cylinder head contact surface examine (01-4180).
Tapped holes of cylinder head c~eau.
b0 l Ll::. Oanoer!
ts Free of oil and water.
replace.
&.o..nqerl
Cylinder head gaskets (19) The cylinder head gasket ís not watertight until the eugine has reached
and (20) normal operating temperature, in other words until a swelling process has
taken place. F or this reason, the cooling system must not be pressure-
tested until after the engíne has reached normal operating temperature.
Cylinder heads ( 13) and (14) insta1L
Dowel sleeves (f) or roll pins
(e) note.
examme.
NOTE:
Cylinder head bolts (15)
The cylinder head bolts (15) are subjected toa certain permanent
stretch each time they are tightened. lf the maximum length is
exceeded (see table), the bolts should be replaced with new ones.
Cylinder head bolts (15) oil at thread and at contact surface ofbolt head.
Cylinder head bolts (15) with insert.
washers (15a)
tighten in stages in sequence of tightening diagram, beginning with l.
Cylinder head bolts
Tightening torques see table.
Special tools
Mercedes-Benz
001 589 66 21 00
1 04 589 00 40 00
000 589 0 1 10 00

Mercedes-Benz
11 9 589 00 10 ()0
---~-8----1
P01-0072-13
Fig. 312: Identifying Cylinder Head Bolt Length
CYLINDER HEAD BOLTS (TWELVE-POINT SOCKET WITH "CLOSED-DECK")

Thread 0 D M12
Stretch shank 0d when new 10.75±0.05 mm
Thread length a 13 5 mm
B h L whennew 160±0.8 mm
01 1
t engt max_ bolt length 162.70 mm
CYLINDER HEAD BOLTS (TWELVE-POINT SOCKET WITH "OPEN-DECK")

Thread 0 D Ml2
Stretch shank 0 d when new 10.75±0.05 mm
Thread length a short bolt 135mm
long bolt 190 mm
when new 160±0 _8 mm
short bolt 218±0.9 mm
L long bolt
Bolt length
max. bolt length 162.70 mm
short bolt 221.60mm
long bolt
TIGHTENING TORQUE SPECIFICATION AND TIGHTENING ANGLE

Mercedes-Benz
Cylinder head bolts, engine cold (l) 1st stage 55

2nd stage 90° tight. angle
3rd stage 90° tight. angle
Bolts of camshaft bearing caps M7 15
Bolts of cylínder head timing case cover M8 25
(l) Moisten washers and thread and contact surface ofbolts with oil before installing.
Bolt diagram
"closed-deck"
cylinder head bolts 1 to 1O =
M12 x 160 mm
"open-deck"
cylinder head bolts 1, 3 and 5 =
M12 x 218 mm
cylinder head bolts 2, 4, 6,7, 8, 9, 10 =
Ml2 x 160 mm
P01-5035-13
Fig. 313: ldentifving Tigbtening Seguence Of Cvlinder Head Bolts
NOTE: Cylinder head bolts
Cylinder head bolts match with washers.

Mercedes-Benz
"closed-deck" cylinder head bolts are phosphatízed, washers chrome-plated.
"open-deck" cylinder head bolts are chrome-plated, washers are phosphatized.
No "HELI-COIL" inserts are instalJed in crankcase of "open-deck" version.
HELI-COIL inserts may be used when perfonning repairs.
B. Model129 with engine 119.960
Right cylinder head
ol-5800-5855
Fig. 314: ldentifving Cvlinder Head Removellnstall Components- Model129 With Engine 119. 960
(Right Cylinder Head)
Mercedes-Benz
Left cylinder head
Fig. 315: Identifying Cylinder Head Remove/Install Components - Model129 With Engine 119. 960
(Left Cylinder Head)
Hood raise to vertical position (01-0080).

Coolant drain, pour in (20-0100) .
Poly V-belt slacken, tension (13-3420) .
Left cylinder head: power steering with mounting plate and lines/wiring connected unbolt, place to the
pump (21) side, bolt on (step 5).
Right cylinder head: altemator (1) unbolt, place to the side, bolt on.
Cylinder head covers remove, install (01-0500).
Front cover of cylinder head to be remove, ms· ta ll (0
_ 1-2 12 o)_.
removed (2) or (3)
Engine at cylinder 1 position to 45° before ignition TDC (step 11).
Mercedes-Benz
All four camsbaft sprockets (4), mark (step 12).

(5), (6) and (7) togetber with Installation note
timing chain Check, adjust basic setting of camshafts (05-2230) .
Chain tensioner (10) remove, install (05-3100) .
Top guide rails (8) and (9) remove, install (05-3350) .
Exhaust camshaft sprockets (4)
and (7) and camshaft adjusters (5) unbolt, install (05-2170).
and (6) at cylinder
bead to be removed
Intake manifold remove, install (14-1310) .
Left cylinder head: coolant hose at d t b tt h
e ac , a ac .
rear
Right cylinder head: dipstick
guide tube (12), automatic unbolt, bolt on.
transmission
Exhaust system at cylinder bead to
be removed (13) or (14) at exhaust unbolt, bolt on.
manifold
Exhaust system at transmission
slacken, tigbten.
bracket
Right cylinder head: wiring
unbolt, bolt on.
harness at bottom right
Cylinder
. . head bolts (15) and bolts unscrew, specta · 1too 1119 589 00 1o 00
oft m1mg
case cover (16) at cylinder head to (ste s 20 to 21 ).
be removed P
Bracket ( 17) of special tooJ 119
589? 1 40 00 in place of c~mshaft attach detach (ste 22).
beanng cap (1.8) at the cylinder ' P
bead to be removed
Engine hoist attach to bracket (17), detach, special toolll9 589 0140 OO.
Cylinder heads (13) and (14) take off, fit on (step 23).
Cylinder head contact surface examine, face (01-4180).
clean.
Tapped hose of cylinder head
&oanaerl
bolts
Free of oil and water.
replace (step 26).
&oanQGrl
The cylinder head gasket is not watertight until the engine has
Cylinder head gaskets ( 19) and
reached normal operating temperature, in other words until a swelling
(20)
process has taken place. For this reason the cooling system must not
be pressure-tested until after the engine has reached normal operating
temperature.
Cylinder head bolts (1.5) examine, tighten (step 27 to 29).
Mercedes-Benz
Special tools
617 589 00 10 00
11 9 589 00 10 00
Fig. 317: Identifving Special Tool (119 589 0010 00)
11 9 589 01 40 00

Mercedes-Benz
001 589 65 09 00
001 589 66 21 00
CYLINDER HEAD BOLTS (TWELVE-POINT SOCKETHEAD)

Thread dia. D Ml2
Stretch shaft día. d When new 10.75±0.05 mm
Length of thread a 135mm
L When new 160±0.8 mm
Length of bolt
Max. bolt length 162.70 mm
,.._____ L- - - -..,
Fig. 321: ldentifying Cylinder Head Bolt Length

Cylinder head bolts, engine cold (l) lst stage 55
'2nd stage 90° angle of rotat.
Mercedes-Benz
l3rd stage 90° angle of rotat.

Bolts of cylínder head, tíming case cover M8 25
Bolts of camshaft bearing caps M7 15
(1) Moisten thread and contact surface ofbolts and washers with oil before ínstalling.
NOTE: Take off cylinder head together with camshafts and exhaust manifold once
engine has cooled down.
l. Raise hood to vertical position (01-0080).

2. Dísconnect ground cable at battery.
3. Drain coolant at crankcase (20-0100).
4. Remove poly V-belt (13-3420).
5. Left cylinder head: unscrew bolts (arrows).
Detach mountíng plate with power steering pump (1 1) from tensioning device and place to the side
with lines/wiring connected.
lnstallation note
The bolt which is screwed into the cylínder head from the front must be coated with sealant when
installed.
Pay attentíon to angle bracket (1) ofwiring harness.
6. Right cylinder head: unbolt alternator from bracket and place to the s.ide with wiring connected and
secure.
Fig. 322: ldentifving Angle Bracket Of Wiring Harness

Mercedes-Benz
7. Remove cylinder head covers (01-0500).

8. Remove front cover of cylinder head to be taken off (01-2120).
9. Rotate engine at cylinder l to 45° before ignition TDC.
Fig. 323: Identifying Engine Setting Point
lO. Mark all four camshaft sprockets and the timing chain with colored dots (arrows).
Installation note
Examine, adjust basic setting of camshafts (05-2230) .

12. Remove top guide rails (05-3350) .
13. Unbolt exhaust camshaft sprockets and camshaft adj usters at the cylinder head to be removed (05-
2170).
Mercedes-Benz
Fig. 324: Locating Colored Dots On Camshaft T iming Gears And Timing Chain
14_ Remove intake manifold (14-1310) _

15. Left cylinder head : detach coolant hose at the rear.
16. Right cylinder head: unbolt dipstick guide tube at rear of automatic transmission.
17. Unbolt exhaust system at the cylinder to be removed at exhaust manifold.
18_ Detach exhaust system at transmission bracket
19 _ Right cylinder head: unbolt wiring harness at bottom right
20_ Unscrew bolts+washers (a), (b), (e), (d), (e), (f) ofcylinder head to be removed.
Fig. 325: ldentifying Removal Sequence Of Cylinder Head Bolts
21. Slacken cylinder head bolts at the cylinder head to be removed with screwdriver insert (1) 119 589
00 1O 00 in stages in reverse order of tightening diagram, beginning with 1O, when engine cold.
Fig. 326: ldentifying Screwdriver lnsert

Mercedes-Benz
Fig. 327: Identifying Tightening Sequence Of Cylinder Head Bolts
22. Install bracket 119 589 O1 40 00 at the cylinder heads to be removed. Todo this, unbolt second and
fourth camshaft bearing caps ofthe inlet camshaft at tbe right and left cylinder head, respectively,
and install bracket with dowel sleeves (18a).
119 589 014000
Fig. 328: Tdentifying Bracket And Dowel Sleeves
23. Attach engine hoist to bracket, raise cylinder heads and remove.
&.oanQerl
Do not damage guide rails and pay attention to exhaust manifold.
24. Examine cylinder head contact surface, face (01-4180).

25. Clean tapped holes of cylinder head bolts.
&.oanaorl

Mercedes-Benz
Ó.oanaer!
The cylinder head gasket is not watertight until the engine has reached normal operating
temperature, in other words until a swelling process has taken place. For this reason, the cooling
system must not be pressure-tested untíl after the engine has reached normal operating temperature.
lnstallation note
Pay attention to dowel sleeves or roll pins for fixing cylinder head in position on crankcase.
27. Examine cylinder head bolts. The cylinder head bolts are subject toa permanent stretch each time
they are tightened. Ifthe maximum length (L) of 162.70 mm is reached or exceeded before re-
using, replace the bolts with new ones.
28. Oil the thread of the cylinder head bolts and the contact surface of the bolt heads and insert.
L----iJ
~·~1¡@
29. Tighten cylinder head bolts in stages in the order of the tightening diagram, beginning with l.
1st tightening stage 55 Nm.
2nd tightening stage 90° angle of rotation .
3rd tightening stage 90° angle of rotation .
Installation note
Tighten bolts+washers according to diagram to 25 N m once the intake manifold is installed.
a. a M8xl20 hexagon socket bolt+washer

b. b M8x90 hexagon socket bolt+washer
c. e M8x75 hexagon socket bolt+washer
d. d M8x50 hexagon socket bolt+washer
e. e M8x75 hexagon socket bolt+washer
f. fM8x50 hexagon socket bolt+washer
Mercedes-Benz
Fig. 330: Identifying Tightening Sequence Of Cylinder Head Bolts
Removing and installing cylinder beads- RA01001204150X(Ol-4150)
Preceding work:
Model 140 only: Engine removed (01-0300)_
Front covers removed (01-2120).
Chain tensioner removed (05-3100) _
Guide rail housing removed (05-3500) _
01-5800-5855
Mercedes-Benz
__ ...,
L~ cyfndor head
Fig. 331: ldentifying Cylinder Head Remove/Install Components (1 Of 4)
Left cylinder head: Ventilation pipe (19) remove, install (01-0450).

pull off with impact extractor 116 589 20 33 00,
Left cylinder head: Guide raíl pins
install (step 2).
Secondary air inj ection lines ( 1 and 2) unbolt, bolt on.
Modlel 129: Exhaust system at exhaust manifolds unbolt, bolt on (49 -0 170).
Modlell29: Exhaust system at carrier for exhaust
unbolt, bolt on (49-0071 ).
bracket at transmission
Modlel129, left cylinder head: Exhaust pipe (22) at front · t ( t )
: !' ld remove, ms a 11 s ep 7 .
manuo
Mercedes-Benz
Let Cifr¡d!ll head
Fig. 332: ldentifying Cylinder Head Remove/lnstall Components (2 Of 4)

Mercedes-Benz
P01 . 5el7 - 57
Rígltqt nderhead
Fig. 333: ldentifying Cylinder Head Remove/lnstall Components (3 Of 4)
Modlell40, right cylinder head: Air cleaner (5) of secondary air pump remove, ínstall.
Right cylinder head: Dipstick guide tube (6) at oil pan unbolt, turn to the side, ínstall.
Right cylinder head: Dipstick guide tu be of autornatic transmission (7) remove, install (step 9).
Right cylinder head: Crankcase ventilation (8) unbolt, bolt on (step 10).
Mercedes-Benz
Rigttc'jincler head
Fig. 334: Identifying Cylinder Bead Remove/Install Components (1 Of 4)
Modell40: Exhaust manifold at

unbolt, bolt on (step 11).
crankcase
Coolant at crankcase drain (step 12).
Model 129: Coolant hose (9) at rear of
take off, fit on (step 13).
cylinder head
Coolant hose (10) at rear of cylinder
heact
Cylinder head bolts ( 11) on cylinder
tmscrew, screw on (step 15).
head to be removed
fit on in place of camshaft bearing caps (13) at cylinder head to
Bracket (12) 104 589 00 40 00
be removed, take off (step 16).
attach to bracket (12) 104 589 00 40 00 and torear engine
Engine hoist
suspension point, detach.
Cylinder heads (14 and 16) take off, fit on.
Cylinder head contact surface examme.
Cylinder head gaskets (17 and 18) replace (step 19).
Cylinder head bolts ( 11) examine, tighten (steps 20 to 23).
Basic setting of camshafts check (05 -2230).
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lüil level of automatic transmission check, adjust to correct level.
CYLINDER HEAD BOLTS (INTERNAL TWELVE-POINT)

Thread día. D M 12
Thread length a 70mm
whennew 168mm
Bolt length L
max. bolt length 171 mm
......-~--- L----~
~-- a --~
Fig. 335: ldentifying Cylinder Head Bolt Lengtb
TIGHTENING TORQUE SPECIFICATION l)

Cylinder head bolts on cold engine lststage 55
2nd stage, 90° tightening angle
3rd stage, 90° tightening angle
Bolts of camshaft bearing caps 21
l) Thread and contact surface ofbolts as well as washers moístened wíth engíne oíl before ínstallíng.
Special tools
118 539 20 3300

os

Mercedes-Benz
001 589 1)6 2'1 oc

00
,.,.-;;.--===-~"',
001 589 65 09 00
,_ 03 07 32 ..J
Fig. 338: Identifying Special Tool (001 589 65 09 00 03 07 32)
617 5!9 00 10 00
01
104 589 00 40 00
01
Mercedes-Benz
, 6 589 0 1 54 00
os
F ig. 341: lden tifying Special Tool (116 589 01 34 00 OS)
0005890 \ 1000
00
NOTE: Remove cylinder heads together with camshafts and exhaust manifolds once
engine has c ooled down.
Rotate crankshaft 30° after ignition TDC on cylinder 1 (arrow).
In this position, the camshafts can be rotated without the valves coming into contact with the piston crowns.
Mercedes-Benz
Fig. 343: ldentifying Engine Setting Point
Mark all four camshaft sprockets and the timing chain to each other wíth dots ofpaint (arrows).
Le: cyW!dar head
Fig. 344: Locating Dots On Camshaft Sprockets And Timing Chain
l. Left cylinder head: Remove ventilation pipe (5) (01-0450).

Mercedes-Benz
Fig. 345: ldentifying Ventilation Pipe
2. Left cylinder head: pull off guide raíl pin (1) with impact extractor 116 589 20 33 00 and threaded insert
116 589 01 34 OO.
Installation note
The thread in the guide rail pin (arrow) must be positioned to the front (in direction oftravel) when
installed.
3. Model 140: Unbolt air c1eaner of secondary air injection, remo ve.
4. Unbolt lines of secondary air injection. Right cylinder head: 1 cylinder head bolt, 1 engine carrier bolt,
modell40: l oil pan bok
Left cylínder head: 1 cylinder head bolt, 1 craukcase bolt below front exhaust manifold, model 140: 1 bolt
on left engine carrier.
InstaHation note
Replace gaskets.
Mercedes-Benz
Fig. 346: ldentifying Guide Raíl Pin
5_ Modell29: Unbolt exhaust system at exhaust manifolds (49 -0045, 49 -0170).

6. Model 129: Unbolt exhaust system at carrier of exhaust bracket at transmission (49-0071 ).
7_ Modell29, left cylinder head: Unbolt exhaust pípe at front manifold in order to gain access to the drain
plug in the crankcase.
8_ Unbolt dipstick guide tube from oil pan, turn to the side.
lnstallation note
Re place 0-ring according to condition.
9. Right cylinder head: Unbolt dipstick guide tube (7) of automatic transmission at crankcase (arrow) and at
automatic transmission.
NOTE: Seal hole of guide tube at automatic transmission.
10. Right cylinder head: Unbolt crankcase ventilation line (8) from right cylinder head (arrow)-
Mercedes-Benz
Fig. 347: Identifying Crankcase Ventilation Line
1 L Modell40: Unbolt exhaust manifold at rear of crankcase (arrow).
Fig. 348: Locating Exhaust Manifold Bolt
12. Drain coolant at crankcase; todo this, unscrew hexagon socket bolts (arrow) with seal next to left and
right engine carriers. Tightening torque 30 Nm.
Mercedes-Benz
Fig. 349: Locating Hexagon Socket Bolt
13_ Model 129: Take off coolant hose (9) at rear of cylinder head_
14. Take off coolant hose (1 O) at rear of cylinder head.
Fig. 350: ldentifving Coolant Hoses
15. Slacken cylinder head bolts on cylinder head to be removed in stages in the reverse order oftightening
diagram, beginning at 14, with engine cold.
Mercedes-Benz
®r:\0r:\®r:\®rn@®~@
~~~ '10 tt 12
@ @ @ ® ® @
Fig. 351: ldentifying Removal Seguence Of Cvlinder Head Bolts
16_ Install bracket 104 589 00 40 00 at the cylinder head to be removed.
Unbolt 1st camshaft bearing cap of exhaust camshaft on the ríght cylinder head and ínstall bracket with
dowel sleeves (18a).
Unbolt 2nd carnshaft bearíng cap of exhaust camshaft on left cylínder head and ínstall bracket with dowel
sleeves ( 18a), tightening torque 21 N m_
17 _ Attach engine hoíst to bracket and to rear engine suspension poínt, lift and remove.
&oanQerl
Do not damage tensioning rail or guide raiL

Mercedes-Benz
Fig. 352: ldentifving Bracket And Dowel Sleeves
18. Examine cylinder head contact surface.

19. Install cylinder head gasket.
Installation note
Pay attention to dowel pins (1) and dowel sleeves (2) for locating the cylinder bead on the crankcase.
:0.0~0,0,
2 1
Fig. 353: ldentifying Dowel Pins And Dowel Sleeves
20. Examine cylínder head bolts. The cylínder head boJts are subj ected toa permanent stretch each time they
Mercedes-Benz
are tightened. Ifthe maximum length (L) of 171 mm (whennew 168 mm) is reached before next
tightening, the bolts should be scrapped and replaced by new ones.
21. Clean threaded holes.
22. Oil the thread ofthe cylinder head bolts and the contact surface ofthe head and insert.
,~ iJ
Q 1
t a
1@
1
,.,.0012'11
23. Tighten cylinder head bolts in stages in the order ofthe tightening diagram, starting with l.
1st tightening stage 55 Nm .
2nd tightening stage 90° tightening angle .
3rd tightening stage 90° tightening angle .
¿DanQerl
The cylinder head gaskets are not watertight until the engine has reached its normal operating
temperature, in other words until a swelling has occurred. For this reason, tbe cooling system must not be
pressure-tested until after the engine has reached its operating temperature.
Mercedes-Benz
H l - --u
Fig. 355: ldentifying Tightening Sequence Of Cylinder Head Bolts

25. Check basic setting of camshafts (05-2230) .
26. Check oillevel of automatic transmission, adjust to correct leve l.
Removing and installing cylinder· head- RA010A1044150X(Ol-4150)
01-5800-5855
A. Models 124, 129 with engine 104.98

Mercedes-Benz
21Nm
~'
Fi¡:. 356: Identifyin¡: Cylinder Head Remove/lnstall Components - Models 124, 129 With Engine
104.98
B. Model 140
Mercedes-Benz
\
21Nm
Fig. 357: ldentifying Cvlinder Head Removellnstall Components - Model 140
Ground cable at battery disconnect, connect, encode radio, modell40 normalize power windows.
Coolant drain, pour in (20-0100 , step 1).
Piston of cylinder 1 position to ignition TDC (step 2).
Front cover at top remove, install (01-2120).
Timing chain with
mark (step 4).
camshaft sprocket
Pm (41) of guide raíl pull off, insert (step 5).
Engine 104.98: remove guide sprocket (2) (left-hand thread), install (35 Nm, step 6).
Armature (3) at camshaft remove, install.
adjuster
Timing chain on camshaft take off fit on.
sorockets '
Mercedes-Benz
Cable of position sensor

at right wheelhouse
Engine 104.98: take off engine wiring harness, fit on (step 10).
Tempomat cruise control
linkage
Engine 104.99: take off engine wiring harness, fit on (step 12).
Vacuum lines at intake
take off, fit on ( step 13).
manifold
Exhaust system at exhaust b Jt b lt
.~: ld
man11o un o , o on.
take off air injection pipe (5) at cylinder head, fit on (step 15), replace seal
Engine 104.98:
(5a).
Engine 104.99: detach hose at non-retum val ve (5b) of air injection pipe, fit on (step 16).
Bracket of dipstick guide
tube (6a) and intake unbolt, bolt on (step 17).
manifold support ( 6)
Line of crankcase air
admission, combination take off, fit on (step 18).
support
Fu el filler cap (pressure) open, close (step 19).
Engine 104.98: disconnect fuel pipes a t fuel distributor, connect (step 19).
disconnect fuel pipes at left
Engine 104.99:
wheelhouse, connect (step 19).
If automatic transmission . . . .
fitted: unbolt dtpsttck gUide tube at cylinder head, bolt on (step 20).
Bowden cable
take off, fit on ( step 21).
(accelerator control)
Control pressure cable take off, fit on ( step 23 ).
Coolant hoses. and( heating
) take o ff, fit on ( step 24) . N ot mod e1 140.
wat erreturn l me 8
Cylinder head bolts (9) slacken (step 25).
Cylinder head (lO) take offtogether with intake maillfold and exhaust manifold (step 26).
replace (step 28).
&oanaer!
eylm. der head gaske t ( 11 ) operatmg

The cylinder head gasket is not watertight until the engine has reached
. temperature, m· other words, untl·¡ a swe ¡¡·mg operat10n
· h as taken
place. For this reason, the cooling system must not be pressure-tested untiil
after the engine has reached operating temperature.
Camshafts position, secure (step 29).
Piston of cylinder 1 position to TDC (step 30).
Cylinder head bolts (9) examine (01-4050).
Cylinder head ( 1O) install, tighten (steps 31 , 33, 34).
Timing chain fit on (step 35).
Mercedes-Benz
Bolts for cylinder head cover 1O

Bolts of camshaft bearing caps 21
l. Bolt head surface and thread oiled
Special tools
116 589 01 34 00
Fig. 358: ldentifying Special Tool116 589 0134 00
116 58920 33 00
Fig. 359: ldentifving Special Tool116 589 20 33 00
1 04 589 00 40 00
Fig. 360: Identifying Special Tool104 589 00 40 00

Mercedes-Benz
617 589 00 10 00
001 589 72 21 00
Fig. 362: ldentifving Special Tool 001 589 72 21 00
001 589 65 09 00
Fig. 363: ldentifying Special Tool 001 589 65 09 00
NOTE: Take off cylinder head together with camshafts, intake manifold and
exhaust manifold once engine has cooled down.
Seal secondary air injection hole on side right at cylinder heads for engines without secondary air
injection hole with end cover part no. 104 016 00 33.
l. Drain coolant at crankcase (20-0100) . Disconnect coolant and heating hoses at cylinder head.
Mercedes-Benz
2. Position pisten of cylinder 1 to ignition TDC.

Fig. 364: ldentifying Coolant And Heating Hose
4. Mark position of camshaft sprockets to timing chain. Todo this, apply colored markings (arrows.)
Fig. 365: Identifying Colored Markine On Camshaft Sprockets
5. Pull offpin (1) for guide rail or friction rail with impact extractor 116 589 20 33 00 and threaded
bolt 116 589 01 34 OO.
Installation note
The thread in the pin ( 1) must be located at the front (in direction of travel) when installed.
Mercedes-Benz
Eng;¡~a 1 04.9"8
Fig. 366: ldentifying Guide Raíl Pin
Engl) Q¡ 104.99
Fig. 367: Installing Guide Rail Pin
Engine 104.98
6. Unbolt guide sprocket (1) (left-hand thread) and take offtogether with bearing body (2).
7. Unbolt arrnature at camshaft adjuster.
Mercedes-Benz
Fig. 368: Identifying Guide Sprocket And Bearing Body
8. Take timing chain off camshaft sprockets.

9. Unplug posit1on sensor at right wbeelhouse.
Installation note
The connector must be plugged in watertight
Engine 104.99
10. Take off engine wiring hamess; todo this, slacken all the cable ties ofthe wiring hamess and
unplug all tbe connectors.
11. Disconnect cruise controllinkage.
Engine 104.99
12. Unplug connector at engine separation point (X26/17).
Unplug connector of electronic accelerator actuator (M16/lxl), press ratchet (arrow), connector
tums through 90° by means of a spiral spring.
Remove engine wiring harness from cable duct.

Mercedes-Benz
Model 140
Fig. 369: ldentifying Engine Separation Point And Electronic Accelerator Actuator
13_ Detach vacuum pipes at intake manifold (arrow), fit on_
Eng¡n e 104 _9iJ
Fig. 370: Locating Vacuum Pipes
14 _ Unscrew bolts for exhaust system at flange of exhaust manifold.

15 _ Detach secondary air injection pipe ( 1) at the cylinder head, fit on. Replace seaL
Mercedes-Benz
Eng;-.e,104.98
Fig. 371: ldentifying Secondary Air lnjection Pipe
16. Detach hose at non-return valve of secondary air injection pipe (arrow), unbolt bracket (1).
Eng;JJe 104.99
Fig. 372: Locating Hose At Noo-Return Valve Of Secondary Air Injectioo Pipe
17. Unbolt bracket of dipstick guide tube and intake manifold support (arrows).
Note regardiog model140
Remove dipstick guide n1be.

Mercedes-Benz
Fig. 373: Locating Intake Manifold Support
18_ Detach pipe (43) of crank:case air admission at combination support (17).
Fig. 374: Identifying Crankcase Air Admission Pipe And Combination Support
19. Briefly open fue! filler capto release pressure in fuel tank
Unscrew fuel pipes (arrows). Counter-hold the connection fitting (1) when slackening the fue! pipe.
Mercedes-Benz
Models 124, 129

Engme 104.95
Fig. 375: Locating Fuel Pipes
Engine 104.99
Fig. 376: ldentifying Conoectioo Fitting
20. If automatic transmission fitted, unbolt dipstick guide tube at rear of cylinder head (arrow).
Mercedes-Benz
Fig. 377: Locating Dipstick Guide Tu be Bolt
21. Detach Bowden cable (30) from the accelerator controllever (9). Compress plastic clip (28) and
pull out Bowden cable.
Installation note
Adjust Bowden cable (30-1010).
22. Detach control pressure cable (4 ), compress plastic clip ( 5) and guide plastic clip with linkage
through the bracket.
Eng;;ne 104.98
Fig. 378: ldentifying Bowden Cable, Accelerator Control Lever, Plastic Clip And Control
Pressure Cable
Mercedes-Benz
E.rtgl'l & 104.99
Fig. 379: ldentifving Bowden Cable, Plastic Clip And Control Pressure Cable
24 Slacken hose straps at the coolant hose to the coolant pump. Remove heating water retum pipe.
25 When engine cold, slacken cylinder head bolts in stages in the reverse order of the tightening
diagram, beginning with 14.
Fig. 380: ldentifying Removal Sequen ce Of Cylinder Head Bolts
26 Remove camshaft bearing caps 9 and 13 . Installlifting lugs, part no. 104 589 00 40 OO. Lift off
cylinder head with engine hoist and lifting tackle.
Mercedes-Benz
Fig. 381: Locating Camshaft Bearing Caps
27 Clean contact surface on crankcase and on cylinder head.

28 Replace cylinder head gasket.
&oanaer!
The cylinder head gasket is not watertight until the engine has reached operating temperature, in
other words, until a swelling operation has taken place. For this reason, the cooling system must not
be pressure-tested until after the engine has reached operating temperature.
Cylinder head identification Engine 104.98 Engine 104.99

104 016 16 20 104 016 17 20
b k!onUica~on pan oo.

< k!enlillcaton re{9sses
Eng!ne 104 .98, 2 recesses
Englne 104 .!19, 3 re<esses
Stm 0: Eng!ne 104.98

002 mm•0.5
Engme 104.99
90.9 mm+<~ S
Fi~. 382: ldentifyin~ Cylinder Head ldentification Part No. And ldentification Recesses
Installation note
Pay attention to dowel pins for locating cylinder head on crankcase.
29 Rotate camshafts so that bottom edge of holes in camshaft flange form a leve! with top edge of
the cylinder head and check with 4 mm pins (1 ).
Mercedes-Benz
Fig. 383: ldentifving Pins
30 Check TDC position of pisten in cylinder 1.
Fig. 384: ldentifying TDC Position Of Piston In Cvlinder 1
31 Fit on cylinder head with lifting tackle.

32 Examine cylinder bead bolts (01-4050).
33 Oil the thread and the bolt head contact surface ofthe cylinder head bolts and insert.
34 Tighten cylinder head bolts in stages in the order of the tightening diagram, beginning with 1
(01-4050).
35 Fit on timing chain, pay attention to markings.
36 Remove pins from the camshaft :flange.
37 Install in reverse order.
TECHNICAL MODIFICATIONS ENGINE 119 MECHANICAL I- RA0100119TAOOX

Mercedes-Benz
01 Engine removal and installation, crankcase, cylinder bead and crankcase ventilation
Designation Nature and reason for modification Production O p.

breakpoints no.
The crankcase has been modified for production
Open-deck design of 01-
engineering reasons. The cylinders are now open in the 04.93
cran.kcase 1000
top part.
Center bore with thread at contact surface to cylinder head 01-
Timing case cover 04.93
offset. 2100
A standard cylinder head has been designed for the 01-
Cy linder head 9.95
engines 119.98 in order to reduce the variety of parts. 4000
Compressíon Has been íncreased to Compressíon Ratio 11 for engines 01-
9.95
pressure M119.980/982. 0010
Cover at front of Both high tension distributors on M1 19.98 are 01-
9.95
cylinder head discontinued with in.troduction of Motronic system. 2120
REMOVING AND INSTALLING VENTILATION PIPE (CRANKCASE VENTILATION)-

RAOl 001200450X(Ol-0450)
Preceding work:
Guide rails (4) and (6) on cylinder heads removed (05-3450) .
Camsbaft adjuster of left inlet camshaft removed (05-2170) .

Mercedes-Benz
/21Nm
z 120589 0631 00
--~-
~--...... ..-.vs..o~
P01·1n&-e•
Fig. 385: ldentifying Ventilation Pipe (Crankcase Ventilation) Remove/lnstall Components
Ventilation pipe (5) at camshaft bearing cap unbolt, bolt on (21 Nm).
Ventilation pipe (5) turn to the front and remove upward, install.
Gasket (5a) replace according to condition.

IBolt of camshaft bearing cap (Torx T40) 21
SpeciaJ tools
Mercedes-Benz
001 589 72 21 00
00
000 589-01 10 00
00
Fig. 387: Iden tifying Special Tool (000 589 0110 00 00)
NOTE: The gasket (Sa) seals the ventilation pipe (5) of the crankcase ventilation to the
ventilation chamber with oil separator; see function of crankcase ventilation
(01-0400).
Fig. 388: lden tifying Gasket A nd Ventilation Pipe
TECHNICAL MODIFICATIONS ENGINE 120 MECHANI CAL 1- RA0100120TAOOX

Mercedes-Benz
01 Engine removal and installation, crankcase, cylinder bead and crankcase ventilation
Designation Nature and reason for modification Production Op.

breakpoints no.
Cast oil nozzle in rear
Replaces for production reasons the oil nozzle inserted as
of right and left 09.93
single part in cylinder head.
cylinder head
M120.982/983 Motronjc.
Modífied arrangement of camshaft sensors eliminates need
Left cylinder head 01-
for dowel sleeves for locating cylinder head cover. The 04.95
cover 0500
boles for attaching the camshaft sensors are sealed with a
plug.
Due to elimination of TDC sensor on models
TDCmarking Ml20.982/983, the TDC marking was cast on the timing 04.95
cover.
Both high voltage distrubutors on M120.982/983
Cover at front left of
díscontinued with introductíon of Motronic. The hole on
cylinder head 01-
the left cover (previous version) is sealed with an end 04.95
Cover at front right 2120
cover.
cylínder head
Modified version with mounting for camshaft sensors.
REMOVING AND INSTALLING OIL SUMP- RA010Al043100X(Ol-3100)
Rcmoving and installing oil sump- RA010Al043100X(Ol-3100)
Preceding work:
01-7500
A. Models 124, 129

Mercedes-Benz
10Nm
Fig. 389: ldentifying Oil Sump Removellnstall Components - Models 124, 129
B. Modell40
Mercedes-Benz
Fig. 390: ldentifying Oil Sump Removellnstall Components - Models 140 {1 Of 2)
Fig. 391: ldentifying Oil Sump Removeflnstall Components- Models 140 (2 Of 2)
disconnect, connect, encode radio, model140 normalize

power windows.
Mercedes-Benz
Intake air scoop remove, install.

Fan cover ring detach, attach (steps 3+4).
Bottom engine compartment panel remove, install.
Engine oil drain, pour in, oil drain plug 25 Nm {18-0020) .
Both front engine moUil!tS unbolt from below, bolt on, 25 Nm (22-2110) .
Connector (7) of oil level switch unplug at oil sump.
Connector (24), oil pressure unplug, plug in (step 9).
Automatic transrnission: unbolt oil pipes (14, 15) at oil sump, bolt on.
Oil cooler pipes (21) at oil sump unbolt, bolt on.
remove torsion bar ( 17), insta U.
Modell24, 129: Model124 (32-300)
Model 129 (AR32.20-0300B)
unbolt front torsion bar (17), lower and bolt on. (AR32.20-
Model140:
0300B).
Engine raise, lower (step 13).
raise with engine supporting bar, lower (step 16).
Model140: Engine
(AR3 3 .1 0-0 100-01 A).
Model 140: Springs offront axle remove, install (32-200).
Model 140: Bolt of steering coupling unscrew, screw on (step 18).
Model140: Front axle support with vehicle jack adaptor (step 19).
Model 140: Securing bolt of :front axle unscrew, screw on (steps 20+21).
Model 140: Front axle lower, partially remove, raise.
Model 140: Oil sump unbolt, take out (steps 22+23), bolt on.
Models 124, 129: Left drag link with
unbolt, detach, attach and bolt on (46-550).
steering damper
Models 124, 129: Drag link turn to rear right.
unbolt at crankcase, bolt on ( step 17).
Models 124, 129: Oil sump (4)
M6: 10 Nrn, M8: 22 Nm.
Models 124, 129: Oil sump take out forward and down, install.
Se1f-1ocking bolts and nuts rep1ace.
Gasket (3) replace.

Oil drain plug to oil sump25
Oil sump to crankcase
M6 hexagon bolts 1O
M8 hexagon bolts 25
M lO hexagon bolts 40
Oil lines to oil sump 1O
Tightening torques of :front axle see 33-100

Mercedes-Benz
Special tools
001 589 72 21 00
140 589 01 61 00
Fig. 393: ldentifying Special Tool140 589 01 61 00
140 589 00 62 00
Fig. 394: Identifying Special Tooll40 589 00 62 00

Mercedes-Benz
001 589 67 21 00
Fig. 395: Identifying Special Tool 001 589 67 21 00
COMMERCIALLY AV AILABLE TOOL

lwrench socket set 21 mm 6-sided, 1 /2" drivee.g. Hazet Werk 42853 Remscheíd 1 Order no. 900-211
lnstallation note
Encode radio, model 140 normalize power wíndows.
2. Remove intake air scoop.
Models 124, 129
3. Remove fan cover ring by withdrawing locking pin and turning ring to the left. Place ring on the
fan.
Installation note
Ensure that the four engagíng points are correctly located.
4. Remove fan cowL

5. Remove bottom engine compartment paneL
6. Drain engíne oil (approx. 7.0 1). Replace gasket. Install oíl drain plug.
7. Unscrew bolts on left and right engine mounts (a) from below. Unscrew nuts (b) ofthe torsion bar,
lower torsion bar. (Model 140) Replace self-locking nuts.
Mercedes-Benz
Model140
Fig. 396: Identifying Left And Right Engine Mounts
8. Detach connector of oillevel switch on left of oil sump.

9. Detach oil pressure connector so that it is not damaged when raising the engine.
1O. If automatic transmission fitted, unscrew oil pipes from oil sump.
11. Unscrew oil cooler pipes from oil sump.
12. Remove torsion bar.
Modell24: (32-300)
Mode1129: (AR32.20-0300B)
Model140: Unbolt torsion bar, lower.
13. Models 124, 129: Attach engine hoist to front lifting lug.
14. Models 124, 129: Unscrew drag link on left and steering damper on right, detach (46-550).
15. Models 124, 129: Turn drag link to the rear right.
16. Modell40: Raise engine with engine supporting bar (AR33.10-0100-01A).
Mercedes-Benz
Mcdel 140
Fig. 397: Raising Engine With Engine Su pporting Bar
&oanQer!
Raíse engíne only far enough for cylínder head to be restíng agaínst component compartment wall.
17. Model140: Remove springs offront axle, install (op. no. 32-200).
18. Model140: Unscrew bolt (1) of steering coupling, push steering spindle up (arrow).
Model 140
Fi~. 398: Identifyin~ Steerin~ Couplin~ Bolt
19. Modell40: Support front axle wíth vehícle jack adaptor (1), unscrew plastíc covers over the two
rear mountíng poínts of the front axle.
Mercedes-Benz
Model140
-~-~-
---
Fig. 399: ldentifving Vehicle Jack Adaptor
20. Modell40: Unscrew 4 bolts ofthe main mounting points at the front axle (22) with 6-sided socket,
waf21 mm. Clean securing thread in the body with Ml4 X 1.5 tap to remove locking vamish of
microencapsulated bolt threads. Use new bolts.
21. Model 140: Lower front axle until it is hanging clear at the shock absorbers and at the top control
arms.
&oanacrl
When lowering the front axle, pay attention to the routing ofhoses and piping to avoid damaging
them.
22. Model140: Unbolt oil sump at crankcase.

23. Model 140: Pull front axle forward and down and remove oil sump to the front.
&oanacrl
Do not damage dipstick guide tu be ( 1) and strainer of oil pump (2).

Mercedes-Benz
Model 140
Fig. 400: ldentifying Dipstick Guide Tube And Oil Pump Strainer
24. Models 124, 129: Unbolt oil sump at crankcase.

25. Models 124, 129: Take out oil sump forward and down.
26. Replace gasket, replace self-locking nut.
lnstallation note
Before belting oil sump tight, align the conttact surface to the transmission otherwise problems may
result from noises and vibrations.
Removing and installing oil sump- RA010B1193100X(Ol-3100)
Preceding work:
Air cleaner removed (09-00 15) .
Dípstíck guide tube removed {18-0023) .
Víbration damper removed (03-3420) .
Tensioning device removed (13-3450).
01-7500
B. Model129 with engine 119.960

Mercedes-Benz
Fig. 401: ldentifying Oil Sump Removellnstall Components
Hood raise to vertical position (01-0080).

Air scoops remove, instalJ (09-0015) .
slacken, tighten, use holder 603 589 00 40 00 (10 Nm)
BoJts (2) offan carrier belt pulley (4)
(step 5).
Poly V -belt and tensioning device remove, install (13-3450) .
Fan carrier belt pulley (4) unbolt, bolt on.
Cylinder 1 of engine tum to TDC.
Bottom engine compartment panel remove, install (Maintenance Manual6190).
Engine oil d.rain, pour in, oil drain plug (40 N m) (step 10).
Belt pulley (12) with vibration damper (13) remove, instaU (35 Nm) (03-3420) .
Carrier (22a) with guide pulley remove, instaJJ (21 Nm) (step 12).
If AC fitted: AC compressor (22) with
detach, attach (21 Nm) (step 13).
lines/wiring connected
TDC sensor at timing case cover unbolt, bolt on.
Carrier (22a) of AC compressor remove, install (21 Nm) (step 15).
Bottom bolt (26) of alternator unscrew, screw on (step 16).
Mercedes-Benz
Alternator (3) swivel up.

Air pump ( 1) with angle bracket (25) unbolt, bolt on (21 Nm) (step 18).
unbolt, push forward, bolt on (21 Nm). (Cooling hoses
Fan carrier (27) at timing case cover
remain connected).
Oillines of automatic transmission (23) unbolt, bolt on.
T orsíon bar (28) remove, install (32-3000).
Bottom part of oil sump (21) remove, install, seal (step 22).
Dipstíck guide tube (4) remove, install. Special tool 117 589 00 31 00 (step 23).
Both front engíne mounts (9) unbolt from below, bolt on (25 N m) (step 24).
Engine raise, lower (step 25).
Oil sump (20) unbolt at crankcase, bolt on M6 (11 Nm).
Oil sump (20) remove, seal, ínstall (step 27).
Leaks check.

Dípstick guíde tu be to alternator bracket21
Oil drain plug to oil sump 40
Oil sump 11
Fan carrier 21
AC compressor to carrier 21
AC compressor or guíde pulley carríer 21
Air pump to bracket 21
Special tools
603 589 00 40 ()0
Fig. 402: Identifving Special Tool603 589 00 40 00

Mercedes-Benz
11 6 589 03 07 00
Fig. 403: ldentifying Special Tool116 589 03 07 00
~_ ___0_01_5_89_7_2_2_
1 _00_____)
Fig. 404: ldentifying Special Tool 001 589 72 21 00
001 589 66 21 00

Mercedes-Benz
11 7 5B9 00 31 00
Shop-made tool
IGuard plate for radiator/condenser Dim.: approx. 480x6ool
NOTE: The oil sump is sealed to the crankcase by a gasket.
l. Raise hood to vertical position (01-0080).

2. Disconnect ground cable at battery.
3. Remove air scoops (09-0060) .
4. Remove viscous fan clutch (20-3120) .
5. Slacken bolts of fan carrier belt pulley; todo this, counter-hold with counter-holder 603 589 00 40
OO.
6. Remove poly V -belt tensioning device (13-3450) .
7. Unbolt belt pulley - fan carrier.
8. Rotate engine until cylinder 1 at TDC.
Mercedes-Benz
Fig. 407: Identifving Tool
9. Unscrew bolts and remove bottom engine compartment panel (Maintenance Manual6190).
10. Drain engine oil (approx. 81) into a suitable vessel. Replace seaL Tigbtening torque of oil drain
plug40Nm.
11. Unscrew bolts together with circlips, take offbelt pulley and vibration damper (03-3420) .
12. Unscrew bolts ( l) together with washers, take off carrier together with guide pulley.
lnstallation note
Pay attention to fixing sleeves.
Fig. 408: Identifying Bolts
13. If AC fitted: unscrew bolts (1) together with washers and nut (2). Place AC compressor to the side
with lines/wiring connected.
lnstallation note
Pay attention to fixing sleeves.

Mercedes-Benz
Fig. 409: ldentifying Bolts And Nuts
14. Unbolt TDC sensor from timing case cover.

15. Unscrew bolts ( 1) with washers, take off front bracket and side carrier.
16. Unscrew bottom bolt ofaltemator. Slacken top bolt.
17. Swivel altemator up.
18. Unbolt air pump together with angle bracket and take off.
lnstallation note
Install angle bracket free of tension.

Mercedes-Benz
Fig. 411: ldentifying Air Pump
19. Unbolt fan carrier from timing case cover and push forward with cooling hoses connected.
20. Unbolt oillines of automatic transmission.
21. Remove torsion bar at front (32-3000).
22. Unscrew bolts, slacken cable straps, take offbottom part of oil sump.
23. Unscrew bolt of dipstick guide tube and knock out from below.
Installation note
Knock in dipstick guide tube from above with tool
117 589 00 31 OO.
Fig. 412: ldentifving Dipstick Guide Tu be Bolt
24. Unscrew bolts at left and right front engine motmts from below.
Mercedes-Benz
Tightening torque 25 N m.
25. Raíse engine untíl oil sump can be removed forward and down.
26. Unbolt oil sump at crankcase. Unscrew bolts. Tightening torque M6: 11 Nm.
lnstallation note
The rear contact surface of the oíl sump must be alígned to the rear contact surface ofthe
crankcase. Ifthe oíl sump ís not alígned to the crankcase, this may result in noíse and vibratíon
problems.
27. Remove oil sump down and forward.
Installation note
Replace gasket. Apply sealant 002 989 45 20 (Omnivísc) in the rear area ofthe oíl sump and on the
crankcase.
Install in the re verse order.
28. Run engine. Check for leaks.
REAR SUSPENSION EYES OF ENGINE STRENGTHENED- BT01.00-P-0001-01A
ENGINE 112,113
e; El El CJ EJ t1
E1;;L1 ¡j LJ l1 [j
9"¡ (1\jLJr/EJEH~
'-.,_ _ _
oD_t _58_9_7s_ o_9_oo_ _....-./
Fig. 413: Identifying External Torx Set 001 589 76 09 00
l. @ The Mercedes emblem and two numbers (XX) must be stamped on the suspension eyes which are
firted to the vehicle.
2. IZJ Ifthe two suspension eyes do not have this marking, they must be replaced.
Mercedes-Benz
P{J1.10-20 19-11
Fig. 414: ldentifying Mercedes Emblem And N umbers

Mercedes-Benz
1990-2002 ENGINE Complete Engine - TESTI NG & REPAIR - 129 Chassis
1990-2002 ENGINE
Com¡plete Engine - TESTING & REPAIR - 129 Chassis
TESTING & REPAIR

INSPECTING CYLINDERS WITH LIGHT PROBE - AR01.00-P-0200AU
ENGINE 112, 137, 275, 285, 112.945, 113.962/982
ENGINE 113 in M ODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Fig. 1: Inspecting Cvlinders W ith Light P r o be
Shown on engine 112
!GirAP rr::rer R emove/install

[[] Risk of death caused by Do not toucb parts whicb AS15.10-Z-0001-01A
contact wíth parts conduct high voltages.
conductíng high voltages. Persons who have
electronic implants ( e.g.
pacemakers) must not
perform any work on the
ignition system.
[[] Risk of ínjury to skín and Wear safety gloves, ASOO.OO-Z-0002-0 l A
eyes caused by handling protective clothing and
hot or glowing objects. safety glasses, if necessary.
[I] Risk of death cased by Align vehicle between the ASOO.OO-Z-00 1O-OlA
vebicle slippíng or colunms of the hydraulic
Mercedes-Benz
1990-2002 ENGINE Complete Engine- TESTING & REPAIR - 129 Chassis
toppling off of the lifting hoist and position the four

platform. support plates below the
hoist support points
specified by the vehicle
manufacturer.
1 Remo ve a spark plug Type 208.474
from each cylinder Type 202.088
Model 210.062/262
@) Replace spark plugs Model129 with engine AP15.10-P-1580AC
112.923/943, 113.961
Model 163 with engine AP 15.10-P-1580GH
112, 113
Model 209, 21 O except AP 15.10-P-1580A
21 0.062/262, 208 except
208.474, 202 except
202.088 with engine 112,
113
Model 203, 170 with
engine 112
Model 215, 220 with AP15.10-P-1580L
engine 137
Model 215,220, 230 witb
engine 275
Model 215, 220 with
engine 285
Model 211 with engine AP15.10-P-1580AB
112, 113
Model 215 with Engine
113
Model 220 with engine
112, 113
112, 113
Model240 with engine 285 AP15.10-P-1580H
Model 463 with Engine AP 15.10-P-1580GA
112, 113
2.1 Remove bottom engine Model240 AR61.20-P-11 05H
compartment paneling
3 Position pistan of T o do this, crank the AR01.00-P-1300-03HA
cylinder to be inspected engine at the central bolt of
toBDC the crankshaft in the
direction of rotation of tbe
engine: ?
Firing order
4 Connect cylinder !lJ Cylinder inspection *WH58.30-Z-1014-0SA
inspection lamp (05) and equipment
Mercedes-Benz
1990-2002 ENGINE Complete Eng ine - TESTING & REPAIR - 129 Chassis
insert the flexible test llJ Flexible inspection light *WH58.30-Z-1 006-0SA
pro be for the inspection
lamp via the spark plug llJ Flexible inspection light *WH58.30-Z-1007-05A
bore into the respective
cylinder
~ Check
5 Inspect cylinder walls [g] Normal condition:
Ma.t-grey surface, no
honing pattern.
If the condition of the
cylinder wall is not clearly
recognizable: ?
Model 129, 163, 170,202,
203, 208, 209, 210,
215,220,230,463
Remove cylinder head
Model 129 with engine AR01.30-P-5800B
112, 113
Model 202, 208, 21 O with
engine 113
Model 163 with engine ARO 1.30-P-5800MV
112, 113
Model 170,202, 208, 210 AR01.30-P-5800BA
with engine 112
112, 113
Model 230 with engine 113
Model 203 with engine AR01.30-P-5800PV
112, 113 except 203.764
112, 113
Type 203.764 AR01.30-P-5800L
Model215, 220 with
engine 137
Model 215, 220 with ARO 1.30-P-5800M
engines 275.950/ 980
275.951
Model 463 with Engine ARO 1.30-P-5800GV
112, 113
Model240 AR01.10-P-2400H
Remove engine
@ General information on Engine 112, 113, 134, 135, AHOI.OO-P-0300-0 lA
inspecting cylinder walls 137, 166, 275, 285, 611 ,
612,613,628,639, 646,
Mercedes-Benz
647,648
6 Inspect the remaining
cylinders following the
same procedure
order
e ommerc1a
·nty availabl e too1s
Number Designation
WH58.30-Z-l006-05A Flexible endoscope, package contents l (complete
unit), Firma Richard WolfGmbH D-75438
Knittlingen Firma Karl Storz GmbH D-78532
Tuttlingen
WH58.30-Z-l 007 -OSA Flexible endoscope package contents 2 (for
workshops which already have an approved
endoscope from the Wolf or Storz company), Firma
Richard WolfGmbH D-75438 Knittlingen Finna
Karl Storz GmbH D-78532 Tuttlingen
WH58.30-Z-1 O14-0SA Cylinder inspection equipment
TESTING COMPRESSION PRESSURE- AR01.00-P-1200B
ENGINE 112
Air fiJter positiooed at vehide side.
ENGINE 113
Air mter positiooed at vehide side.

Mercedes-Benz
01 f:tl CompNss/on r.cotdet·
Fig. 2: Identifying Compression Recorder
~AP ~Gi"" BT Remove/install

OJ Risk of accident caused Secure vehicle to prevent it ASOO.OO-Z-0005-0lA
by vehicle starting offby from moving by itself.
itself when engine is Wear closed and snug-
mnn.ing. Risk of injury fitting work clothes.
caused by contusions and Do not grasp hot or rotating
burns during starting parts.
procedure or when
working near the mnning
engine
1 Bring engine to operating [g]
'
temperature (approx. 80° Only test compression when
C) engine is at operating
temperature.
2 Remove engine trim
panel
3 Remove air filter housing
4 Remove resonance pipe [g] AR07.07-P-1454A
with resonance body All except model 163 with
engine 113.942/981.
o Disconnect plug
connection for hot
film mass air flow
sensor (HFM-SFI) for
this step and
Mercedes-Benz
o unbolt resonance pipe

at cylinder head
cover.
[g]..
The resonance pipe is
attached to the rear of the
intake manifold with a
i%astic bracket.
..
Do not damage plastic
plate.
5 Remo ve spark plugs Remove only one spark
plug at each cylinder: ?
@) Models 210, 208, 202 with AP15.10-P-1580A
eng:ine 112
Model210 with engine 113
@) Model 163 with engines AP15.10-P-1580GH
112 , 113
6 Crank. engine with ~ Do not crank engine at AROl.lO-P-OllOV
starter. steering lock but use
contact switch of the
compression recorder.
[g] Crank engine severa!
times with the starter in
order to eliminate
combustion residues in the
cylinder.
~ Checking
7 Insert compression tester .&.ounQerl Fig. 3
into spark plug bore
8 Open throttle valve
9 Cran.k engine with starter ~ Do not crank engine at AROl.lO-P-011 OV
steering lock but use
contact switch of the
compression recorder.
[g] To check the
compression pressure, crank
the engine by at least 8
revolutions.
10 Cany out test procedure
at the remaining
cylinders in the same
way
Mercedes-Benz
11 Compare measurements *BE01.00-P-1001-01D

obtained with the *BE01.00-P-1002-01D
specified pressures *BE01.00-P-1003-01D
If necessary, ifthe pressure
is below the mínimum
compression pressure or if
permissible difference
between individual
cylinders is exceeded:?
Inspect cylinders for leaks AR01.00-P-1300HV
order
e ompress10n pressure
Number Designation Engines 112.910/ Engines 112.910/ Engine
911/912/920/921/:923/940/941/ 911/920/921/ 113.944
942/943/960, 113.940/942/ 922/923/940/ Standard
943/961/963 low compression 941/942/943/ compression
944/945/946/947'
113.940/941/942/
943/960/961/962/
963/965/968/969
normal
compression
BE01.00- Compression bar 10... 12 12 to 14 11 to 13
P-1001- installation
01D tolerance or
new value
BE01.00- Compression bar 8.0 9.0 10.0
P-1002- pressure wear
OID limit or limit
value
BE01.00- Compression bar 1.5 1.5 1.5
P-1003- pressure
OlD permissible
difference
between
individual
cylinders
Compress10n pressure
Engiues 113.980/
981/982/984 Engine
Standard Engine 113.992/995
Number Designation compression 113.992/995 990/9911993
BEO 1.00-P- Comoression bar 11 to 13 11 to 13 9 to 12
Mercedes-Benz
1001-01D installation
tolerance or new
value
BEOl.OO-P- Compression bar 10.0 8.0 8.0
1002-0lD pressure wear
limít or lirnit value
BEOl.OO-P- Compression bar 1.5 1.5 1.5
1003-0lD pressure
permissible
difference
between
individual
cylinders
001 589 76 21 00
Fq:. 3: Identifyin~ Compression Recorder (001 589 76 21 00)
INSPECT CYLINDERS FOR LEAKS- AR01.00-P-1300HV
ENGINE 112,137,285
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Mercedes-Benz
§ 11:2, 113
0 1 fllercap
1 Ext»nslon ruorvo lr- 19 Spetlcplug
2 Endcover 04 Cyf nder lolil<•ge tesler
Fig. 4: Inspecting Cylinders For Leaks
Shown on Engine 112
!GirAP rr::rer Remove, Install

OJ Risk of accident from Secure vehicle to prevent it ASOO.OO-Z-0005-0lA
l vehicle starting off by from moving off by itself.
itself when engine Wear closed and elose-
mnning. Risk of injury fitting work clothes.
suffered in the form of Do not grasp hot or rotating
bruises or burns to the fHJrts.
hands when reaching in Check the cylinder for
while the engine cranks leaks only when the engine
or runs is at normal operating
Bríng engine to temperature.
operating temperature
( approx. 80 °C)
OJ Risk of injury to skin Do not open cooling system AS20.00-Z-0001-01A
and eyes suffering unless coolant temperature is
scalding from contact below 90 °C. Open cap
with hot coolant spray. slowly and release the
Risk of poisoning from pressure. Do not pour
swallowing coolant. coolant into beverage
bottles.
Wear protective gloves,
protective clothing and eye
protection.
Mercedes-Benz
2 Open cap
.
(2) of . In Model 463 with Engine
expans10n reservou 112, 113, a cap (2) with a
detent is built-in llll
Tum cap carefully up to the
fust pre-detent, relieve the
pressure and then unscrew
the cap (2).
llll A 1-stage cap is fitted to
Model 163 with Engine 112,
113.
llll Turn the 1-sta<.re
o and 2-
stage cap half a revolution
counterclockwise, relieve the
pressure, then unscrew the 1-
stage or 2-stage cover.
3 Remove a spark plug
@) (19) from each cylinder Model202,208, 209, 210 AP15.10-P-1580A
with Engine 112, 113.
Model203, 170 with Engine
112.
@) Model 163 with Engine 112, AP15.10-P-1580GH
113.
@) Model215, 220 with Engine AP15.10-P-1580L
137.
@) Model230.474/475, 211, AP15.10-P-1580AB
220 with Engine 112, 113
@) Model 240 with Engine 285. AP15.10-P-1580H
@) Model 463 with Engine AP15.10-P-1 580GA
112,113
4 Position pisten of llll Crank the engine at the
cylinder to be tested to center bolt of the cranksha:ft
ignition TDC in the direction ofrotation of
engme.
5 Connect cylinder leak llll Calibrate cylinder
tester (04) leakage tester (04) and screw
the connection hose into the
[i¡ark plug bore
Cylinder leak tes ter '* WB58.30-Z-1015-05A
6 Remove the oil filler cap
(3)
~ lnspection
7 Apply compressed air to Cylinder Jeaktightness '*BE01.00-P-1001-02Z
the cylinder, read off permissible loss total
pressure loss on the indication
cylinder leakage tester Cylinder leaktightness *BE01.00-P-1002-02Z
Mercedes-Benz
(04) and determine the permissible losses at val ves

cause if there is an and cylinder head gasket
increased pressure loss Cylinder leaktightness '*BE01.00-P-1003-02Z
permissible losses at pistons
and piston rings
Ifthe crankshaft rotates:?
Engine 112, 113, 137.
Install retaining lock for
crankshaft AR03.30-P-5000B
Engine 285.
Lock cranksba.ft with
counterholder.
& oanQerl Retainer Fig. 5
8 Conduct the test of the AR01.00-P-1300-03HA
other cylinders in the
firing order of the
engine
9 Install in tbe reverse
order
e;yJun der 1eak a2e

Number Designation AH Engines
BEO l. 00-P -1 00 1-022 CyEinder leakage % < or=25
permissible loss total
indication
BEO 1.00-P-1 002-022 Cylinder leakage % < or = 10
permissible losses at
valves and cylinder head
gasket
BEO 1.00-P-1 003 -022 CyEinder leakage % < or=20
permissible losses at
pístons and piston rings
Fi2. 5: ldentifyin2 Counterholder (112 589 00 40 00}
Commercially available tools

Mercedes-Benz
1990-2002 ENGINE Complete Engine- TESTING & REPAIR- 129 Chassis
Number Designation
WH58.30-Z-l O15-05A Cylinder leakage testing unit
Firing order- AR01.00-P-1300-03HA
P01ll0>22!12,01
Fig. 6: ldentifying Firing Order (Engines 111, 601, 604, 611, 271)
1 2 4 a 3
P01..00o0031G1
Fig. 7: Identifying Firing Order (Engines 602, 605)
~111824
Fig. 8: ldentifying Firing Order (Engines 603, 606)

Mercedes-Benz
~112 o o
~
o
1 2 3
o
o o o
0~0o
4 !5 6
o o o
143625
P01 .10~'311 01
Fig. 9: ldentifying Firing Order (Engine 112)
§t1S
....
,15426378
1'01.00 ~57 o1
Fig. 10: ldentifying Firing Üirder (Engine 113)
o~
o~
t'1$42837$
Fig. 11: ldentifving Firing O r der (Engine 273)
~272
~
00
46 5
. o o o
143625
Mercedes-Benz
Fig. 12: Identifying Firing Order (Eogine 272)
ENGINES 137,275,285
1'101.00 2321Hl 1
Fi2. 13: Identifyin2 Firin2 Order <Eneines 137,275,285)
DTSCONNECTINGAND CONNECTING ENGINE WTRTNG HARNESS- AROl.OO-P-2410
Discoonecting, coonecting engine wiring haroess - AR01.00-P -2410AO
ENGINE 120.981 in MODEL 129
Fig. 14: ldentifving Engine Wiring Harness Removeflnstall Components (1 Of2)

Mercedes-Benz
Fig. 15: Identifying Engine Wiring Harness Remove!Install Components {2 Of 2)
~AP
u=:rsr
l Remo ve trim panels ( 17, 18 and 21)
Unplug connector of engine wiring hamess
2
(X26/l7)
3 Remove cross-head screws (arrows)
4 Remove component partition (19)
5 Unbolt diagnostic sockets (Xll /2 and Xll/3)
Crankshaft position sensors (L5/43 and
Unplug the following connectors at the DI control
6 L5/5) and knock sensors (A16gl and
modules (Nl /4 and N1/5)
A16g2)
7
Unplug the connectors ofthe camshaft position [g] Installation : pay attention to
sensors (X47/3 and X47/4). pamng
Detach the connectors of the electronic accelerator
8 actuator (M16/3x1 and Ml6/4xl) at the left and
right wheelhousing
9 Detach the connector ofthe air pump (Y33x1)
Remove the exhaust shield (20) at the bottom front
10
right
Unbolt starter cable (30) :from the terminal block
11
(X4/ l0) and bracket (2)
Unplug the connector of the generator wiring
12
harness (X27)
Unplug the connector of the EGR switchover valves
13 (Y27/2 and Y27/3) at the right and left intake
manifold
Mercedes-Benz
Disconnect the ignition cable 4 at the high voltage

14
distributor and at the ígnitíon coil
15 Unbolt ground strap at the left cylinder head cover
16 Unplug connector of AC compressor
Discoonecting and connecting engioe wiring harness- AR01.00-P-2410AV
ENGINES 112, 113 in MODEL 129
Shown on model129 with engine 112
Shown on model129 w~h englne 112

1 Trrmpom:l
Sh•pe<t rulll>er sc•l
Trrmp•m:l
4 Covcr ot control unt box
.5 A l rclc•ncr
v~uumline
C•l>losrrap
WfO B.ottr:ty grourtd ull/o
P01.1l0·201HI5
Fig. 16: Locating Engine Wiring Harness - Shown On Model129 With Engine 112 (1 Of 3)

Mercedes-Benz
1990-2002 ENGINE Complete Engine - TESTING & REPAIR- 129 Chassis
Stlown on modo11:zll w~tl e,ngi no 112
•
9
Sh~po4ttJI>I>OtS#~I
Vi!Cuum l no lnr.a~e manifold-

br~J..:c
booster
10 8olrs
S cp~r~ring p•nol
"
12 Eng111e p~nel {botlflm)
H~10 IIE.SR control unir
wn,, Ground c~l>le eng;,o- l>ooy
W16JO Ground ot r/gllt m•)oruscml>llc.s
comp;tttmcnr
XJ ~" Cont rol unir box connoc!Dr
P01JIO·l 075·05
F ig. 17: Locating Engine Wiring Harness - Shown On Model 129 With Engine 112 (2 Of 3)
Sh own on modo! l:zll w~ h onglno 112

11 Shlo/d
14 Rel~ lovor
15 sr..~ct
15 Pos/lfvo colllc
11 St•ttct
11 G oncr•tor
19 Shlold
X2 :112 Autom.tlo rr·•nsmfssfon conncctor
POI OO·l 07HHi
Fig. 18: Locating Engine Wiring Harness - Shown On Model 129 With Engine 112 (3 Of 3)
MODIFICATION NOTES
Specification revised from 15 Specification in BA15.40-P- 100 1-0lA revised *BA15.40-P-
14.4_00
Nmto 18Nm for series 112, 113 engines 1001-01A
Value changed from 16 Nm Specification in BA15.30-P-1 001 -0IA revised *BA15.30-P-
6.7.00
to 14 Nm for modified engine 112, 113 1001-01A
Mercedes-Benz
[!rAP
Removing/installing
n:::?'BT
[gJ'
Remove luggage compartment trim panel on
right.
Installation :
Disconnect ground cable AR54.10-P-
1 After connecting, read out fault memory and
(WlO) ofbattery, connect 0003A
erase.
Encocle radio and normalize power windows.
Vehicles with stationary heater: adjust time
display on stationary heater.
Remove shaped rubber sea!
2
(2)
3 Remove cover ( l)
4 Remove trim panel (3)
Remove cover of control unit
5
box (4)
6 Remove air cleaner (5)
[g]
Detach vacuum line (6) and
7 On engine 113, detach vacuum line (6) on rear of
take off cable strap (7)
intake manifold .
Remove shaped mbber seal
8
(8)
Detach vacuum line (9) from
9 brake booster to reaT of intake
manifold
lO Unscrew bolts ( l 0).
11 Remo ve partition panel (11)
[g]
Disconnect connectors of ME- '
12 Press down plastic plate and turn over locking
SFI control unit (N3/1 O)
clamp.
Disconnect connector
13
(X35/63)
Unbolt ground of major
14 assembly compartment on the
right (W l6/6)
Remove engine compartment
15
panel (12)
Unbolt ground cable (Wll/5)
16
on transmission
Remove shields ( 13) of re la y
17
lever (14)
18 Unbolt bracket ( 15)
D ic;:r.onnPr.t nos1tivP r::~hlP. (1 ())
Mercedes-Benz
19 on starter ( 17) [g] Pull off protective cap.

*BA15.30-P-
B
1001-0lA
Disconnect positive cable (16)
20 [g] Pull off protective cap.
on generator ( 18)
*BA15.40-P-
B 1001-01A
Dísconnect connector (X22/2)
21
of automatic transmission
[g] First remo ve shield ( 19).
22 InstaH in reverse order
[g] Stored faults possíbly caused by prevíous
símulatíon or by cables dísconnected in the
process of installation or testing must be
Read fault memory with HHT
23 processed and erased in the DTC memoríes once
and erase
aH work is completed.
Diagnosis Manual Volume 2 Index 0: Connecting
and usíng test equípment
BSTARTER
Number Designation Engine 112 except 112.951, Engines
113.94/96/98 113.990/991/993
BA15.30-P-1001- Nut of connectíon of
N m 14 14
OlA circuit 30
BGENERATOR
Number Designation En gines 112.91/92/94/953/954/955/96/97,
113.94/96/98
BA15.40-P-1001- INut of círcuít B+ to
N m 18
OlA ¡generator
TESTING AND REPAIR WORK: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE

VENTILATION, CYLINDER HEAD, CRANKCASE- AR01.00-Z-9113AB
ENGINE 113
Inspecting cylinders with light ENGINE 112, 113, 137, AR01.00-P-0200AU

pro be 275, 285 ...
Inspecting cylinders with light ENGINE 113.964 in AR01.00-P-0200GZ
pro be MODEL 164.175
Inspecting cylinders with light ENGINE 113.971 in AR01.00-P-0200RT
pro be MODEL 251.075 /175
Inspecting cylinders with light Engine 113.967 in model AR01.00-P-0200TY
pro be 219.375 Engine 113.990
in model219.376
Mercedes-Benz
1990-2002 ENGINE Complete Engine - T ESTING & REPAIR - 129 Chassis
lnspecting cylinders with light ENGINE 113.989 in AROl.OO-P-0200VT

pro be MODEL 171.473
Testing compression pressure ENGINE 112, 113 ... AR01.00-P-1200B
Testing compression pressure ENGINE 113.964 in AROl.OO-P-1200GZ
MODEL 164.175
Testing compression pressure ENGINE 113.971 in AROI.OO-P-1200RT
MODEL 251.075/175
Testing compression pressure ENGINE 113.995 in AR01.00-P-
MODEL 230.472 1200RVK
Testing compression pressure Engine 113.967 in model AROI.OO-P-1200TY
219.375 Engine 113.990
in model 219.376
Testing compression pressure ENGINE 112, 113 ... AROl.OO-P -1200V
Testing compression pressure ENGINE 113.989 in ARO 1.00-P-1200VT
MODEL 171.473
Inspect cylinders for leaks ENGINE 113.964 in AR01.00-P-1300GZ
MODEL 164.175
lnspect cylinders for leaks ENGINE 112, 113, 137, AR01.00-P-1300HV
285 ...
Inspect cylinders for leaks ENGINE 113.971 in AROI.OO-P-1300RT
MODEL 251.075/175
Inspecting cylinders for leaks ENGINE 113.995 in AROI.OO-P-
MODEL 230.472 1300RVK
lnspect cylinders for leaks Engine 113.967 in model AR01.00-P-1300TY
219.375 Engine 113.990
in model 219.376
Inspect cylinders for leaks ENGINE 113.989 in AROI.OO-P-1300VT
MODEL 171.473
Disconnecting and connecting ENGINES 112, 113 in AR01.00-P-2410AV
engine wiring hamess MODEL 129
Disconnecting 1 connecting the ENGINE 113.964 in ARO 1.00-P-241 OGZ
engine wiring harness MODEL 164.175
Disconnecting, connecting engine ENGINE 112 in AROI.OO-P-2410K
wiring harness MODEL 210,208,202
ENGINE 113 in
MODEL 210,208,202
Disconnecting, connecting engine ENGINE 112, 113 in AROl.OO-P-2410M
wiring hamess MODEL 220
Disconnecting/connecting the ENGINE 112, 113 ... AR01 .00-P-2410PV
engine wiring harness
Disconnect, connect engine wiring ENGINE 112, 113, 275 ... AROl.OO-P-2410R
harness
Disconnect, connect engine wiring ENGINE 113.971 in AROl.OO-P-2410RT
harness MODEL 251.075 /175
Mercedes-Benz
Disconnect, connect engine wiring ENGINE 112, 113 ... AROI.OO-P-2410TC

harness
Disconnect/connect engine wiring Engine 113.967 in model ARO 1.00-P-241 OTY
harness 219.375 Engine 113.990
in model219.376
Disconnecting and connecting ENGINE 112, 113 ... ARO 1.00-P-241 OV
engine wiring harness
Disconnecting, connecting engine ENGTNE 113.989 in AR01.00-P-241 OVT
wiring harness MODEL 171.473
Cranking engine with the starter. ENGINES 113, 272, 273 AR01.10-P-0110GZ
inMODEL 164
Crank engine with starter. ENGINE 111 , 112, 113, AROl.lO-P-OllOPV
156, 271...
Crank engine with starter. ENGINE 113.971 in AR01.10-P-0110RT
MODEL 251.075 / 175
Crank engine with starter Engine 113.967 in model AROI.IO-P-OIIOTY
219.375 Engine 113.990
in model219.376
Cranking engine with starter. ENGINE 112, 113, 137, AROl.lO-P-OllOV
275, 285 ...
Remove/install engine ENGINE 112, 113 1 AR01.10-P-2400AB
(except 112.975,
113.948 /966) in
MODEL220
Removing and installing engine ENGINE 113.988 in ARO 1.1 O-P-2400AC
MODEL 203.076/276
with TRANSMISSION
722.6
Remove/install engine ENGINE 112, 113 ... AR01.10-P-2400CA
Removing and installing engine ENGINE 112, 113 ... AROl.l O-P-2400CB
Remove/install engine ENGINE 113.964 in ARO 1.1 O-P-2400GZ
MODEL 164.175
Remove/instaU engine ENGINE 112, 113 ... AR01.10-P-2400IW
Remove, install engine ENGINE 113 ... AR01.10-P-2400Q
Removíng and ínstalling engine ENGINE 113.963 in AROI.l0-P-2400R
MODEL 230.475
Remove/install engine ENGINE 113 ... AROI.IO-P-
2400RVK
Remove/instaH engine ENGINE 112, 113 ... ARO 1.1 O-P-2400TC
Remove/install engine ENGINE 113.967 in ARO 1.1 O-P-2400TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Removing and installing engine ENGINE 113.989 in AR01.10-P-2400VT
Mercedes-Benz
MODEL 171.473 with

TRANSMISSION
722.907
Removing/installing the engine ENGINE 113.964 in AR01.10-P-2405GZ
cover MODEL 164.175
Remove/install engine cover ENGINE 113.971 in AR01.10-P-2405RT
MODEL 251.075 /175
Remove/install engine with front ENGTNE 113.964 in AROl .l O-P-2500GZ
axle carrier MODEL 164.175
Remove/install engine with front ENGINE 113.971 in AR01.10-P-2500RT
axle carrier MODEL 251.075/175
Detaching and attaching engine on ENGINE 113.964 in AR01.1 0-P-2510GZ
front axle carrier MODEL 164.175
Detaching and attaching engine on ENGINE 113.971 in ARO 1.1 0-P-251 ORT
front axle carrier MODEL 251.075/175
Remove/install cylinder head cover ENGINE 112, 113 ... AR01.20-P-5014B
Remove/install cylínder head cover ENGINE 112, 113 ... AR01.20-P-5014BV
Remove/install cylinder head cover ENGINE 113.964 in AR01.20-P-5014GZ
MODEL 164.175
Remove/install cylinder head cover ENGINE 113.971 in AR01.20-P-5014RT
MODELS 251.075 / 175
Remove/install cylinder head cover ENGINE 113.995 in AR01.20-P-
MODEL 230.472 5014RVK
Remove/install cylinder head cover Engine 113.967 in model AR01.20-P-5014TZ
219.375 Engine 113.990
in model 219.376
Remove/install cylinder head cover ENGINE 113.989 in AR01.20-P-5014VT
MODEL 171.473
Repairing spark plug thread ENGINE 112, 113 ... AR01.30-P-5440BV
Repairing spark p1ug thread ENGINE 113.964 in AR01 .30-P-5440GZ
MODEL 164.175
Repairing the spark plug thread ENGINE 113.971 in AR01.30-P-5440RT
MODELS 251.075 /1 75
Repairing spark p1ug thread ENGINE 113.995 in AR01.30-P-
MODEL 230.472 5440RVK
Repairing spark p1ug thread Engine 113.967 in model AR01.30-P-5440TY
219.375 Engine 113.990
in model 219.376
Repairing spark plug thread ENGINE 113.989 in AR01.30-P-5440VT
MODEL 171.473
Remove/install cylinder head ENGINE 112 in AR01.30-P-5800B
MODEL 129 ENGINE
113 inMODELS 129,
202,208,210
Mercedes-Benz
Remove/install cylinder head ENGINE 112, 113 ... ARO 1.30-P-5800BA

Remove/install cylinder head ENGINE 113.964 in ARO 1.30-P-5800GZ
MODEL 164.175
Remove/instaH cylinder head ENGINE 112, 113 ... ARO 1.30-P-5800MV
Remove/install cylinder head ENGINE 112, 113 ... AR01.30-P-5800PV
Remove/install cylinder head ENGINE 113.971 in ARO 1.30-P-5800RT
MODELS 251.075 / 175
Remove/install cylinder head ENGINE 113.995 in AR01.30-P-
MODEL 230.472 5800RVK
Remove/install cylinder head Engine 113.967 in model ARO 1.30-P-5800TZ
219.375 Engine 113.990
in model219.376
Remove/install cylinder head ENGINE 113.989 in AR01.30-P-5800VT
MODEL 171.473
Remove/install timing case cover ENGINE 112, 113 ... AR01.40-P-8000B
Remove/install timíng case cover ENGINE 113.964 in AR01.40-P-8000GZ
MODEL 164.175
Remove/install timing case cover ENGINE 112, 113 ... ARO 1.40-P-8000PV
Remove/install timíng case cover ENGINE 113.995 in AR01.40-P-
MODEL 230.472 8000RKV
Remove/install timing case cover ENGINE 113.971 in AR01.40-P-8000RT
MODELS 251.075 / 175
Remove/install timing case cover ENGINE 113.990 in AR01.40-P-
MODELS 211.076 /276 8000RVK
ENGINE 113.991 in
MODELS 215.374,
220.074 / 174
Remove/install timing case cover ENGINE 113.967 in AR01.40-P-8000TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install timíng case cover ENGINE 113.989 in AR01.40-P-8000VT
MODEL 171.473
Remove/instaH end cover ENGINE 113.988 in ARO 1.40-P-891 3AC
MODEL 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Remove/install the end cover ENGTNE 112, 113 ... AR01.40-P-8913B
Removing/installing the end cover ENGINE 113.964 in ARO 1.40-P-89 13GZ
MODEL 164.175
Removing/ínstaHing the end cover ENGINE 113.971 in AROI.40-P-8913RT
MODELS 251.075 / 175
Remove/install end cover ENGINE 113.995 in AR01.40-P-
MODEL 230.472 8913RVK
Mercedes-Benz
Removing/installing the end cover ENGINE 113.967 in AR01.40-P-8913TY

MODEL 219.375
ENGINE 113.990 in
MODEL219.376
Measuring, boring and honing ENGINE 112, 113 ... AR01.40-P-9201AA
cylinder bores
Measure cylinder bores ENGINE 112, 113 ... AR01.40-P-9202AV
Measuring cylinder bores ENGTNE 113.964 in AR01.40-P-9202GZ
MODEL 164.175
Measuring cylinder bores ENGINE 113.971 in AR01.40-P-9202RT
MODELS 251.075/175
Measuring cyJinder bores ENGINE 113.967 in ARO 1.40-P-9202TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install oiJ pan ENGINE 112 in AR01.45-P-7500F
MODELS 210.06/26 / 66
ENGINE 113 in
MODEL 210 ENGINE
113.980 in MODELS
210.074 /274
Remove/instaU oil pan ENGINE 112, 113 ... AR01.45-P-7500FB
Remove/install oil pan ENGINE 112 in AR01.45-P-7500FC
MODELS 208, 202
ENGINE 113 in
MODEL 208 ENGINE
113.944 in MODELS
202.033 /093
Remove/install oil pan ENGINE 112, 113 in AR01.45-P-7500FD
MODEL 129
Remove/install oil pan ENGINE 113.964 in AR01 .45-P-7500GZ
MODEL 164.175
Remove/install oiJ pan ENGINE 112, 113 1 AR01.45-P-7500l
(except 112.975,
113.948 /966) in
MODEL220
Remove/install oil pan ENGINE 112, 113 ... ARO 1.45-P-7500IW
Remove/install oil pan ENGINE 112, 113 ... ARO 1.45-P-7500PV
Remove/install oiJ pan ENGINE 113 ... ARO 1.45-P-7500R
Remove/install oil pan ENGINE 113.971 in AR01.45-P-7500RT
MODEL 251.075 /1.75
Remove/install oil pan ENGINE 112, 11.3 ... AR01.45-P-7500TV
Remove, insta U oil pan ENGINE 113 .967 in AR01.45-P-7500TY
MODEL 219.375
ENGTNE 113.990 in
Mercedes-Benz
MODEL 219.376
Remove/install oil pan ENGINE 113.989 in ARO 1.45-P-7500VT
MODEL 171.473
Remove/instaH bottom part of oil ENGINE 113 .988 in ARO 1.45-P-7555AC
pan MODELS 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Remove/install bottom part of oil ENGTNE 113.964 in AR01.45-P-7555GZ
pan MODEL 164.175
Remove/install bottom part of oil ENGINE 112, 113 ... AR01.45-P-7555IW
pan
Remove/install bottom part of oil ENGINE 112, 113 ... ARO 1.45-P-7555PV
pan
Remove/install oil pan bottom ENGINE 113 ... AR01.45-P-7555R
section
Remove/install bottom part of oil ENGINE 113 .971 in ARO 1.45-P-7555RT
pan MODEL 251.075 / 175
Remove/install oil pan bottom ENGINE 113 .967 in ARO 1.45-P-7555TY
section MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install bottom part of oil ENGINE 112.942 in AR01.45-P-7555V
pan MODEL 163.154
ENGINE 112.970 in
MODEL 163.157
ENGINE 113.942 in
MODEL 163.172
Remove/install bottom part of oil ENGINE 112, 113 ... AR01.45-P-7555VA
pan
Remove/instaH bottom part of oil ENGINE 113.965 in ARO 1.45-P-7555VE
pan MODEL 163.175
ENGINE 113.981 in
MODEL 163.174
TESTING AND REP AIR WORK: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE
VENTILATION, CYLINDER BEAD, CRANKCASE - AR01.00-Z-9120AB
ENGINE 120
Disconnecting, connecting engine wiring AROl.OO-P-

harness 2410AO
AROl.lO-P-
Remove, install engine ENGINE 120.981 in MODEL 129
2400AO
Remove/install engine ENGINE 120.980 in MODEL 140 ARO 1.1 O-P-2400AP
AR01.20-P-
Mercedes-Benz
Removing, installing cylinde r head cover ENGINE 120.980 /981 /982 /983 5014AO
ENGINE 120 in MODEL 129, AR01.30-P-
Remove/install top front cover
140 5703AO
AR01.40-P-
Repairing threaded holes for cylinder head bolts ENGINE 120
1220AO
AR01.40-P-
Remove/install timing case cover ENGINE 120
8000AO
AR01.45-P-
Removing and installing oil pan ENGINE 120 in MODEL 129
7500AO
Removing and installing oil pan ENGINE 120 in MODEL 140 AROI .45-P-7500AP
AR01.45-P-
Removing and installing shield in oil pan ENGINE 120
7510AO
CONNECTING COMPRESSION TESTER- AROl.lO-P-0010-0lAV
Fig. 19: Identifying Compression Tester (001 589 76 21 00)
El!itli«< connedlOn se1
Fig. 20: Identifying Electrical Connection Set {201 589 00 99 00)
l_ Remove rubber profi le ( 1)-

2. Remove cover (2).
3_ Remove panelling (3).
4. Remove control module box (4).
Mercedes-Benz
Pll 1.10-l1 J1-10
Fi~. 21: lden tifyin~ Rubber Profile, Cover, Pan elli n~ And Control Module Box
5. Disconnect connector (X35/63) in control module box.

6. Lt.oanoe•' Connect adapter line (5)to pin 6 of connector(X35/63).
7. Lt.oanoerl Connect adapter line (5)with the compression tester line.
P0 1 ·1tD-21JHJ1
Fig. 22: ldentifving Adapter Line To Pin Of Connector
8. Remove engine cover (6).
Pll11 1D-l1J3·61
Fig. 23: ldentifying Engine Cover
9. Pull offprotective cap of tenninal30 (8) of generator (G2).

Mercedes-Benz
1.0. Connect terminal (A) of Aoanacrl compression tester to terminal30 (8) of generator (G2).
~ Make su re that the electricaJ line of terminal (A) of the compression tester does not get in
contact with the exhaust manifold .
Fig. 24: Identifying Compression Tester To Terminal And Generator
CRANKING ENGINE WITH STARTER.- AR01.10-P-0110V
ENGINE 112 in MODELS 129, 163, 170,202,208,210,211,220,230
ENGINE 113 in MODELS 129, 163, 202, 208, 210, 211, 215, 220, 230
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 137 in MODELS 215, 220
ENGINE 285 in MODEL 240
ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243/246
ENGINE 275 in MODELS 215, 220, 230
Shows model 202

Mercedes-Benz
1990-2002 ENGINE Complete Eng ine - TESTING & REPAIR- 129 Chassis
01 Compruslon recor<J.r
02 Co-dswitch
1 lgnltionfsfMtll' awftch
POI IQ-02 18 O~
Fig. 25: Identifying Cranking Engine With Starter - Shows Model 202
!GirAP rr::rer Remove/install

~ Danger! Risk of accident caused Secure vehicle to prevent ASOO.OO-Z-0005-0lA
by vehicle starting off by it from moving by itself.
itse1f when engine is Wear closed and snug-
running. Risk of inj ury fitting work clothes.
caused by contusions and Do not grasp hot or
burns during starting rotating parts.
procedure or when
working near the running
engine
1 Switch off ignition [g] Vehicles with
Keyless-Go Code 889:
press Start/Stop button
rep eatedly until ígnition
is switched off.
2 Connect compression Model 129 AROl.lO-P-0010-0lA V
recorder (O1) Model163.1 AR01.10-P-0010-01 V
Model 170 ARO 1.1 0-P -00 10-0 1CA
Model210 with engine ARO 1.10-P-001 0-01B
112 up to production date
1.3.1997
Model210 with engine ARO 1.1 0-P -00 10-0 1E
112 from production date
2.3.1997,
Models 202, 208 with
engine 112, Models 21 O,
202, 208 with engine 113
Model2 11 ARO 1.1 0-P -00 10-0 l T
Model215, rnodel220 ARO 1.1 0-P -00 10-0 1L
Model230 AR01.10-P-0010-01R
Mercedes-Benz
Model240 ARO 1. 10-P-00 10-0 lH

Model463.2 AROl.lO-P-0010-0lGV
~oanaer! Compression Fi2. 3
recorder
Aoanaer! Electrical Fi2. 26
connectíon set
L:hoanaorl Adapter cable Fig. 28
3 Crank engine [g] Press contact switch
(02) on compression
recorder (O 1) for this
step.
[g] Do not crank engine
vía ignition/starter switch
(8), EIS (EZS] control
unit or Start-Stop button.
5 Read out fault memory [g] If the ignition was *WH58.30-Z-1 048-13A
and erase if necessary switched on during the *WH58.30-Z-1 036-13A
~ocess:?
Stored faults which
may be caused by
removal and installation
or test operations, must
be erased from the
diagnostic trouble code
memories after
STAR DIAGNOSIS
diagnosis system
Handheld tester (HHT)
Fig. 26: Identifying Electrical Connection Kit (220 589 00 99 00)

Mercedes-Benz
001 589 7S 21 00
Fig. 27: ldentifying Compression Recorder (001 589 76 21 00)
124 5!11 39 63 00
Fig. 28: Identifying Adapter Cable {124 589 36 63 00)
e ommerc1a·uty ava1.• a ble t 00lS

Number Designation
WH58.30-Z-1 036-13A Handheld tester (HHT) 651 100 01 99
WH58.30-Z-l 048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
system, Compact Passenger Car
REMOVING AND INSTALLING ENGINE- AROl.lO-P-2400
Remove, instan engine- AR01.10-P-2400AO

Mercedes-Benz
P!l1 1 0.() 199·09
Fig. 29: ldentifving Engine Remove/lnstaU Components (1 Of 3)
Fig. 30: Identifving Engine Removellnstall Components {2 Of 3)

Mercedes-Benz
Pll 1.10.(1 101-1!11
Fig. 31: ldentifying Engine Remove/lnstaiJ Components (3 Of 3)
~AP
~BT
Remove/install
Remove lower engine compartment

1
paneling
AR49.10-P-
2 Remove exhaust system
7000F
Remove support for exhaust bracket AR49.10-P-
3
at transmission 7000F
AR09.10-P-
4 Remove left and right air filter
lOSOF
5 Remove radiator ra20001204200x
AR13.22-P-
6 Remove poiy-V-belt
1202AO
AR54.10-P-
7 Dísconnect grotmd cable at battery
0003A
Attach guard plate for condenser of
8
aír conditioníng
Bleed coolant (arrow) at left and
9 ra2000 12001 OOx
right side of crankca.se
Detach propeller shaft and push
10 back; flexible coupling remains at
transmission
Unbolt ground cable· (6) at
11
transmission
Support transrnissíon wíth
12
inspection pit lift or jack
Unscrew rear engíne support (1) AR22.10-P-
13
wíthout engine mount 1160AO
14 Lower transmission
Detach shift rod (9) of automatic
15
transmíssíon
Mercedes-Benz
[g] Traosmission 722.3 : The plug (S)

for the start lock-out switch is secured
Remove plug (S) for start lock-out by a lock (white plastic ring). Turn the
16.1
switch plastic ring upwards and carefully pry
off the plug (S) using two screwdrivers
at the cable outlet and at the sbackle.
17.1 Pull plug out at connector (X22/2)
[g] Traosmissioo 722.6 (New
Automatic Traosmission)
[g] Transmission 722.3 :
Transmission - overload protection
Dismount connectors from
18.1 Kick-down valve
2nd transmission mode switchover valve
Electronic speedometer
Bolts (arrows) to left and right front
19 ra2200 120211 Ox
engine mount
PuU out connector at oíl pressure
20
sensor (B5)
Unscrew bolts (ll) at AC
21 compressor and bolts (12) at air oil
cooler lines
Detach AC compressor (13) with [g] lnstallation : Installnew sealing
pipe system connected and air oil ríngs at air oil cooler lines.
22
cooler lines (14) at engine, secure to Pay attention to fitting sleeves at bracket
one side (oil filter housing) at front.
Unscrew high pressure expansion
23
hose (15) at the oil pan at bottom
24 Open tank lock and reduce pressure
Risk of explosion caused by
No frre, sparks, open flames or smoking.
ignition of flammable products,
Pour fuels only into suitable and
risk of poisoning caused by AS47.00-Z-
IJJ inhalíng fuel vapors or swallowing
appropriately marked containers.
0001-0lA
Wear protective clothing when handling
fu el as well as risk of injury to skin
fue l.
and eyes exposed to fu el.
25 Dismount fuellines
Suction off oil from the power
26 steering pump reservoir using the .&.oanaerl Fig. 32
hand pump to remove the oil.
Oilline (26)
High pressure hose (27)
Unscrew and dismount the
Return hose (28)
27 following oil lines at the power ra46097650715x
High-pressure expansion hose (29)
steering pump
[g] Installation : Bleed pressure oil
pump (level section) of tandem pump.
U nscrew vacuum líne at the brake
28
unit
Mercedes-Benz
AR30.10-P-
29 Unclip Bowden cable regulator [g] lnstallation : Adjust regulator 1010F
AROI.OO-P-
30 Disconnect engine wiring hamess
2410AO
Regeneration to both throttle valve
actuators.
Transmission 722.3: Transmission
upshift delay switchover valve for
31 Pull out the following vacuum línes
automatic transmission to right assembly
partition wall.
Vacuum line to center of intake
manifold atrear
Attach engine hoist to three engine [l] *WE58.40-Z-
32
lifting eyes 1012-llA
[l] *WH58.30-Z-
1003-07A
Tilt engine and transmission Motor
33
and raise slightly
34 Remove coolant hose (2 1) at rear
~ The removed engine must not be
lowered onto the oil pan bottom
section .
35 Remove engine [g] lnstallation : Check front and rear
engine mounts.
Check and adjust engine Correct engine
and transmission oillevels. Inspect for
leaks.
Calibrate starter according to engine or
crankcase replacement.
If the engine is replaced, use the
AR03.30-P-
improved versions of the coolant and
4350AO
heater hoses.
These hoses are identified with
"6254.12"
Stored faults possibly caused by
previous simulation or by cables
disconnected in the process of
installation or testíng must be processed
37 Read out fault memory and erase
and erased in the DTC memories once
all work is completed.
Diagnosis Manual Volume 2: Index 0:
Mercedes-Benz
112 589 00 72 Ol)

H DIIllptmp
Fig. 32: ldentifving Hand Pump (112 589 00 72 00)
Number Designation
WH58.30-Z-1003-07 A Hookmount
WORKSHOPEQU~MENT
IWE58.40-Z-1012-11A lLoad regulator (engine boist), self- locking
Removing and installing engine- AR01.10-P-2400CB
ENGINE 112 1 (except 112.921 /941) in MODELS 210 111, 208, 202, 129 (except 210.081 /281 /082 /282)
ENGINE 113 in MODELS 210,208, 202, 129
Shown on model 210 with engine 112
VISI:OU$ f ln
Z F•nshroud
3 l"o 1J V· l>olt
" FucJ/Inc
5 Sruo l>oascr vocuum Nno
e Rogcncr•l1on vocuumho$0
7 A lrtHrorhowsing
1 Ruonanco IIJbc
9 Ruonanco unff
1'0110-illll·OS
Fig. 33: Identifying Engine Components- Engine 113 (1 Of 3)

Mercedes-Benz
1990-2002 ENGINE Complete Eng ine- TESTING & REPAIR- 129 Chassis
10 E.xh~U$t :systom
lOo Sr•c~cr
11 P'ropol/ct $hotr
12 R'ooronglno ctonmemoor
11 8 oft
14 C:oólc or potKing shtr loc/1
15 F''owot stooring pump
16 A.C compressor
Fig. 34: ldentifving Engine Components - Engine 113 (2 Of 3)
17 Cool•nr llne
11 Coo/onr lino
ClrcuiJitfonpump - cool•nr pump
te Coo/ont llno tiJdlotor-coo/anr pump
20 Coolonfllnc riJdloror- thormo1t• r
hiXIS/ng
21 0 111/nc
22 0 111/nc
21 Connoc tor hose
24 Conncc rvr hosa
15 Connocring ploco
Fig. 35: ldentifying Engine Components - Engine 113 (3 Of 3)
Only models 208, 202 with engines 112, 113
Shown on engine 112

Mercedes-Benz
GJJJX1 OAYQCI! sctu.,r eonnecror

GJJ4x1 o.ry~ sctuor ·COtlflCCiot
PtQ 00-20111-lM
Fig. 36: Identifying Oxygen Sensor Connector
~APn::r-BT Remove/install
IIl Risk of deatb caused A lign vehicle between the ASOO.OO-Z-0010-0lA
by vehícle slipping or columns of the lifting platfonn
topplíng off of the and positíon the four support
lifting platform. plates below the lifting platform
support points specified by the
vehicle manufacturer.
~' Notes on self-locking AHOO.OO-N-0001-0lA
nuts and bolts
[g] &oanQer! Externa! torx set Fig. 38
&oanacrl Torx bit set Fig. 37
¡g¡ [l] *WH58.30-Z-100l-
06A
[lJ *WH58.30-Z-l002-
06A
1 Remove engine cover [g]
'\
or air filter
o The air filter is integrated
into the engine cover in
models 129, 202.093/033,
208.370/374/470 and
210.274/074
o Remove engine trim panel
o.r air ftlter by pulling it
vertically up and off the
cylinder head covers.
2 Inspect both rear ~ Engine suspension fittings
engine lifting eyes for without codes must be replaced.)
marking
@ Rear lifting eyes of Engine 112, 113 BTOl.OO-P-0001-0lA
engine reinforced
IIl Risk of explosion No fire, sparks, open flames or AS54.10-Z-OOOl-OlA
caused by smoking. Wear acid-resistant
oxyhydrogen gas. Risk gloves, dothing and safety
Mercedes-Benz
of poisoning and glasses. Only pour battery acid

caustic burns caused into suitable and appropriately
by swallowíng battery marked containers.
acíd. Risk of injury
caused by burns to skin
and eyes from battery
acid or when handling
damaged lead-acid
batteries
3 Disconnect battery [gJ Installation: After connecting ARS4.10-P-0003A
ground cable ground lead, read fault memory
and calibrate power windows.
V ebicles with stationary heater:
adjust time display on stationary
heater.
~ .. Notes on battery MODELall AHS4.10-P-0001-01A
4 Remove engine AR61.20-P-110SAB
compartment panelíng
[JJ Risk ofinjury to skin Do not open coolíng system AS20.00-Z-OOO 1-0lA
and eyes caused by unless coolant temperature is
scalding from contact lbelow 90°C. Open cap slowly and
witb bot coolant spray. release the pressure. Do not pour
Risk of poisoning coolant into beverage containers.
from swallowing W ear protective gloves, protectiv e
coolant. clothing and safety glasses.
5 Drain coolant from AR20.00-P-1142HA
radiator
6 Draín and collect ~ *BA01.45-P-1003-
engine oil OlB
CD *BF18.00-P-1001-
OlH
7 Detach connection [gJ Seal connections!
hoses (23, 24) at oil
línes (21 , 22) and fit
together witb
connection piece (25)
&oanqer! Set of plugs Fig. 40
~ Connection fitting for WFS8.50-P-2020-01A
automatic oil pipes
8 Remove viscous fan All except model 208.365/465 AR20.40-P-5660C
(1) with engine 112.
[gJ Right-hand thread!
9 Remove fan sbroud o On models fitted with
(2). suction fan, separate plug
connection of suction fan
Mercedes-Benz
before removing fan

shroud.
10 Remove air filter All except model129,
housing (7). 202.033/093, 208.370/374/470,
210.074/274
11 Remove resonance All except modell29, AR07.07-P-1454A
tube (8) and resonance 202.033/093, 208.370/374/470,
tmit (9') 210.074/274
o Separate plug connection of

hot ftlm mass air flow
sensor (HFM-SFI) for thís
step and
o Unbolt resonance pipe at
cylinder head cover.
[gJ..
The resonance pipe is attached to
the rear of the i.ntake manifold
with a plastic bracket.
~Do not damage plastic bracket.
12 Remo ve bot film mass Models 129, 202.033/093, AR07.07-P-1454AG
air flow sensor with air 210.074/274,208.370/374/470
intake pipe
13 Detach coolant lines
(18, 19) at coolant
pump
14 Detacb coolant li.ne
(20) at thermostat
housing
15 Detacb coolant line at Only fm· models 208, 202
top of expansion
reservo u
16 Remove radiator Models 21 O, 208, 202 with eugine AR20.20-P-3865HD
113
Model129 with engine 113 AR20.20-P-3865A V
17 Attach guard plate for
radiator 1 condenser
A Guard plate for WFSS.SO-P-0110-0lA
18 Detacb vacuum line (5)
from brake booster at
rear of intake manifold
19 Extract power steering &.oancwt Hand pump Fig. 32
Mercedes-Benz
pump (15) oil

20 Disconnect ground
lead at power steering
pump (15)
21 Detach retum flow and [g] Seal connections!
pressure lines of power
steering pump ( 15)
&oanaer! Set of plugs Fig. 40
~ *BA46.30-P-1002-
OlA
~ *BA46.30-P-1003-
OlA
22 Detach vacuum line (6) ¡g) Model 129
at intake manifold Detach vacuum line (6) directly at
purge control valve.
DJ Risk of explosion ¡No frre, sparks, open flames or AS47.00-Z-0001-01A
caused by ignition of smoking.
flammable products, Pour fuels only into suitable and
risk of poisoning appropriately marked containers.
caused by inllaling fuel W ear protective clotbing when
vapors or swaHowíng handling fuel.
fuel as well as risk of
injury to sk.in and eyes
exposed to fuel.
23 Disconnect fuelline ¡g) Release fuel pressure through
(4) at fuel distributor service valve!
Collect fuel.
~ Engine 112 *BA07.52-P-1001-
OlA
~ Engine 113 *BA07.52-P-1001-
OlA
6 eanaer! Pressure hose Fig. 41
24 Detacb coolant line ¡g) In model202.093/033 an
(17) additional coolant line is attached
to the right cylínder head.
The coolant líne at the right
cylinder head leads to an externa~
transmission oil cooler located on
the right, behind the front apron.
The routing of the coolant line to
the left cylínder head is the same
as that of production vehicles.
25 Disconnect engine Models 210, 208, 202 AROI.OO-P-2410K
wiríng harness
Modell29 AR01.00-P-2410A V
Mercedes-Benz
26 Remove poly-V-belt [g) Jnstallation: Lock tensioning

(3) device w ith a drift or pin
(diameter 5 mm).
Model 129, 210 with engine 113, AR13.22-P-1202B
208 with engln.e 113, 202 with
engine 113.
Model 210 with engine 112, 208 AR13.22-P-1202BA
with engine 112, 202 with engine
112.
[g) Jnstallation: Lock tensioning
device with a drift or pin
(diameter 5 mm).
27 Discotmect connector
from A/C compressor
(16)
28 Unscrew A/C [g] Attach AC cornpressor at side
compressor ( 16) from in bottom of engine compartment
timing case cover with lines connected.
~ *BA83.55-P-1001-
OlA
29 Detach exhaust system ~ Installation: In vehicles with
(10) at exhaust engine damage the exhaust systern
manifold must be examined for swarf and
any swarf present removed before
installing.
~ *BA14.10-P-1002-
OIB
30 Separate plug Only models 202, 208
connections of sensors
on right (G3/3xl) and
on left (G3/4xl) and
release
31 Remove bracket (lOa) All except model129
of exhaust system Support exhaust system.
[g] lnstallation: Replace nuts
32 Unscrew clutch slave Only model 210, 202, 129 with AR25.20-P-0150A
cylinder manual transmission.
[g] Do not disconnect line.
33 Take off propeller ~ *BA41.10-P-1 001-
shaft ( 11) at OlA
transmissi on
34 Release cable for AR27.60-P-0500-05B
parking shift lock (14)
35 Detach shíft rod from
transmission
Mercedes-Benz
36 Remove rear engine ~ F or this step support

crossmember (11) at transrrussion.
transmission
~ *BA22.10-P-1002-
OlL
~ *BA22.10-P-1003-
OIL
37 Unscrew bolts (13) of ~ *BA22.10-P-1001-
front engine mounts at OIL
front axle carrier
38 Press pressure line of Model 129 only
level control out of
fixtures at bottom part
ofoil pan
39 Attach engine hoist to [l] *WE58.40-Z-1012-
engine lifting eyes ~ On model 2 1O with engine 113 llA
and model208 with engines 112,
113 use the engine removal
fixture
[t] *WE58.40-Z-1 020-
llA
40 Attach engine hoist to
lifting eyes of engine
order
42 Inspect cooling system ~ If fitting new cylinder head AR20.00-P-1010HA
for leaks gaskets, bríng engine to operating
temperature beforehand.
[JJ Risk of accident Secure vehicle to prevent it from ASOO.OO-Z-0005-0lA
caused by vehicle moving by itself.
starting off by itself W ear closed and snug-fitting
when engíne is work clothes.
running. Risk of Do not grasp hot or rotating parts.
inj ury caused by
contusions and bums
during starting
procedure or when
working near the
running engine
43 Check oil level in AR27.00-P-0101A
automatic transmíssion
and correct if
necessary.
44 Run engine and inspect
for leaks
Mercedes-Benz
45 Read out fault memory Stored faults wruch can result

and erase from cables being disconnected or
from simulation during removal
and ínstallation or test work, have
to be processed and erased in the
fault memories after completing
the work:?
Diagnosis Manual Volume 2,
Index 0:
Connectíon and use of test
equípment
m
pan
1
Number Designation E ngines Engines

112.910/911/ 113.940/9411
912/913/914/ 942/943/944/
915/917/920/ 945/946/960/
9211922/923/ 9611962/963/
940/941/942/ 965/967/968/
943/944/945/ 969/980/9811
946/947/949/ 982/984/986/
951/954/955/ 992/995
960/961/970/
972/973/976
BA01.45-P- Oil drain screw M14 N m 30 30
1003-0lB to oil pan
~Fue) rail
Number Designation Engine 112 except
112.945/951/960/961
BA07 .52-P-1 001-0 lA Disconnect fuel feed line N m 38
at fuel raíl
~Fue) raiJ
Number Designation Engine Engines Engine Engines
113.987 113.990/ 113.992/ 113.940/941/
991 993/995 942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/988
BA07.52-P- Disconnect fuel Nm 38 38 38 38
Mercedes-Benz
1990-2002 ENGI NE Complete Engine - TESTI NG & REPAIR- 129 Chassis
llOOl -Ol A lfe~d line at fuel

rall
~ Exhaust manifold
Number Designation Engine 112 except Engines
112.951/976 113.940/9411
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/993/ 995
BA14.10-P-1 002- Flange connection, Nm 20 20
OlB exhaust manifold
and front exhaust
p1pes
~E
m .
ngmemounts, engme supports
Number Designation E ngines 112.910/920, 113.944 in E ngines
models 112.911/914/921/941,
202.026/029/033 /086/089/093 1 13.940/980 in model
210.061/062/
063/065/070/074/261/
262/263/265/270/274
BA22. 10-P- Bolt, front N m 35 35
1001-01L engine mounts
to front axle
carrier
BA22.10-P- Bolt, rear N m 30 30
1002-01L engine mount
to rear engine
crossmember
BA22 .10-P- Bolt, rear N m 40 40
1003-0 lL engme
crossmember
to body
~ E ngine mounts, engine supports

N umber Designation Engines E ngine 112.923/943,
112.921/941, 113.961 in model
113.940 in model 129.059/ 064/068
210.0811
082/083/281/
Mercedes-Benz
282/283
BA22.1 0-P-1 001- Bolt, front engine Nm 35 25
OlL mounts to front axle
carner
BA22 .1 0-P-1002- Bolt, rear engíne N m 35 30
OlL mount to rear engine
crossmember
BA22.1 0-P-1 003- Bolt, rear engine Nm 40 40
OlL crossmember to
body
~
m
E ngme mounts, engme supports
Number Designation Engine 112.940,
113.943/984 in model
208.365/ 370/374/465/470
BA22.1 0-P-1 001-0lL Bolt, front engine N m 35
mounts to front axle
camer
BA22.l0-P-1002-01L Bolt, rear engine metmt N m 30
to rear engine
crossmember
BA22.10-P-1003 -01L Bolt, rear engine N m 40
crossmember to body
~ Driveshaft
N umber Designation Model129 Model202
BA41.10-P- Self-locking nut of Ml O N m 40 40
1001-0lA flexíble joint to
transmission or Ml2 Nm60 60
front propeller shaft 1
~ Driveshaft
Number Designation Model208 Model210
BA41.10-P- Self-locking nut of MIO N m 40 40
1001-0lA flexíble joint to
transmission or Ml2 N m 60 60
front propeller shaft
~p
m
ower st eermg_pump
N umber Designation Model 202.026/029/ Mo del
033/086/089/093 208.365/370
374/465/470
BA46.30-P- Return line to power steering Nm 2 2
1002-0lA pump
Mercedes-Benz
BA46.30-P- Hígh-pressure Ml4x1.5

1003-0 l A expanswn
hose to power M 16x 1-5 Nm40 40
steeríng pump
~p
m
ower steermg pump
Number Designatioo Models Model129.058/
210.061/063/ 060/061/063/
065/070/074/ 066/067/076
081/082/083/
261/263/265/
270/274/281/
282/283/ 663
BA46.30-P- Return line to power steering Nm2 40
1002-0lA pump
BA46.30-P- High-pressure M 14x 1.5 Nm- -
1003-0lA expansion hose
to power Ml6xl.5 Nm45 45
steeríng pump
~R
m
err·tgeraot compressor
Number Designation Engines Eogines 112.910/911/
112.923/943, 920/921/940/941,
113.961 in model 113.940/943/944/980/ 984 in
129 models 202,208, 210
BA83.55-P- Bolt, refrígerant N m 20 20
1001-0lA compressor to
bracket
CDE.
ogme lb'
u ncatwn
Number Designation Engioe 112 except Engioes Engine 113.944/
112.916/953/975 113.940/941/ 944980/984 /984/
942/943/960/ 986/991
961/962/969/
982
BF18.00- Engine Fíllíng capacíty Líters 8.0 8.0 7.5
P-1001 - oíl with oil filter
OlH Filling capacity Liters 7.5 - -
without oil
filter
Specifications Sheet 8800.40-P-0229- 8800.40-P- -
for Operating OlA 0229-0lA
Fluids Sheet 8800.40-P-0229- 8800.40-P- -
03A 0229-03A
Sheet 8800.40-P-0229- IBB00.40-P- 8800.40-P-0229-
Mercedes-Benz
losA 10229-0SA losA
000 589 Ot 10 00
Tolllllil sat
Fig. 37: Identifving Torx Bit Set (000 S89 01 10 00)
9";E1 El el El ti
9'";L1 l1 L1 \j [j
9"o E1~\:Jrlrlr1~
OOt 589 76 09 00
&.a mal Tm ul
Fig. 38: Identifying External Torx Set (001 S89 76 09 00)
1 12 589 00 72 00
Fig. 39: ldentifying Hand Pump (112 S89 00 72 00)
129 589 00 91 00
Fig. 40: Identifving Set Of Stop Plugs (129 S89 00 91 00)

Mercedes-Benz
\. 11 9 ~9904 5300
''---------------
Fig. 41: Identifying Pressure Hose (119 589 04 63 00)

Number Designation
WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose
clamps with worm drive
WH58.30-Z-1 002-06A 7 mm socket hexagon on flexible shaft for hose
Workshop equipment
WE58.40-Z-1012-11A Load regulator (engine hoist), self-locking
WE58.40-Z-1020-11A Removal fíxture for engine
REMOVING, INST ALLING CYLINDER HEAD COVER- AR01.20-P-5014
Removing, installing cylinder head cover- AR01.20-P-5014AO
ENGINE 120.980 /981 /982 /983
Shown on engine 120.980/981

Mercedes-Benz
1~
v- . 14
~~··
Pll 1 20..01 U-05
Fie. 42: ldentifying Cylinder Head Cover Remove/lnstall Components
~AP
fGrBT
AR09.20-P-
1 Remove intake manifold Engine 120.980/981
1310F
AR09.20-P-
Engine 120.982/983
1310FA
AR20.40-P-
2 Remove viscous fan clutch
5660AO
3 Fit on guard plate to intake passages
Take off shielding caps (14, 15, 16) at high voltage
4
distributor
5.1 Unclip spark plug connectors (2), unplug and fit on Engine 120.980/98 1
Unbolt recesses (3) of spark plug cables at cylinder
6.1 Engine 120.980/981
head covers (4 and 5)
Unbolt high voltage distributor (6) and holder (6a) on
7.1 Engine 120.980/981
left
8.1 Remove camshaft position sensor Engine 120.980/981
Take off recesses (3) of spark plug cables with higb
9.1 Engine 120.980/981
voltage distributor ( 6) and spark plug connectors
10.1 Remove ignition coils Engine 120.982/983
Unclip crankcase ventilation lines at holder of
11
cylinder head covers
Mercedes-Benz
Unbolt dipstick guide tube (7) at right-hand cylinder

12
head cover
~
¡g] Seals have been
¡taced by washers.
13 Unscrew bolts (9) with seals (10) or washers (10) Installation : bolt on *BA01.30-P-
ground strap also at left 1004-0lB
cylinder head bolt.
Pay attention to different
bolt length see ?
Bolt diagram of cylinder AH01.20-P-
head cover 5014-04AO
¡g] lnstallation : always
replace gaskets and recess
Take off cylinder head covers (4 and 5) together with seals together. AR01.20-P-
14
gaskets ( 11 aud 12) and recess seals ( 13) Check gasket of cylinder 5014-01AO
head cover to ensure
correctly installed.
Check locating pins of
AR01.20-P-
cyliuder head cover to
5014-05AO
ensure correctly installed.
15 Iustall in the reverse order
16 Run eugine
Secure vehicle to prevent
Risk of accident as a result ofvehicle starting off it starting off.
m when engine running. Risk of injury as a result of Wear closed aud elose- ASOO.OO-Z-
bruises and burns if you insert your hands into engine fitting work clothes. 0005-0lA
when it is being started or when it is running. Do not grasp hot or
rotating parts.
Pay particular attention to leaktightness at rear and in
17
spark plug reces ses
~ CYLINDE R HEAD
N umber D esignation Engine 120
BA01.30-P-1 004-01B Bolt of cylinder head cover to cylinder head Nm9
Cbecking correct location of gasket of cylinder bead cover - ARO 1.20-P-5014-0IAO
The overlaps at the val ve cover gaskets at rear (arrows) should be correctly installed.
Mercedes-Benz
P0 1 20.02t5-01
Fig. 43: ldentifying Gasket Of Cylinder Head Cover Location
lnspecting correct instaUation of locating pins of cylinder head cover- AR01.20-P-5014-05AO
On engines Ml20.980/981 , the locating pin (arrow) is required for aligning the left-hand cylinder head cover to
the camshaft position sensors.
The locating pin (arrow)(Q 12 mm) in the left-hand cylinder cover at cylinder 1, should be pressed-in to ensure
it is captive before removal and installation work as it will otherwise drop out and cause engine damage.
Fig. 44: Locating Pins Of Cylinder Head Cover
Remove/install cylinder head cover- AR01.20-P-5014B
ENGINE 112
Air filter positioned at vehide side.
ENGINE 113
Air mter positioned at vebide side.
Shown on engine 112

Mercedes-Benz
1 Al r lílrer ho.uslng
2 ResonBtJe-e un/ r
3 Resonan.-. !l.lbe
4 R /{111 eytinder hfolld cover
5 L e!i cyllnderheod cover
5 R /{111 J9n ltion col/s
7 L@ft lgn klon coh
a R/ {111 conneelfon
Letl connee oon
10 Leh eonnec don
Fig. 45: Identifying Cylinder Head Cover Removellnstall Component- Shown On Engine 112
[!rAP n:::r- BT l Remove/install

[g]' Lhoanae•' Extemal torx set F i2:. 38
.&. Danaorl T orx bit set Fig. 37
1 Remove engine trím panel
( 1).
3 Remove resonance body
(2)
4 Remove the resonance [gJ
'
tube (3) wíth hot film At thís time pull out the
mass air flow sensor hot film mass air flow
sensor plug.
~Removal:
Pay attention to the
mounting projection of
the resonance tube (3)!
All except model163 AR07.07-P- 1454A
w ith engine 113 .942/981
Modell63 with eugine AR07.07-P-1454MV
113.942/981
5 Unbolt dipstick guíde
tube of automatic
transmission
6 Unbolt ignition coils (6, AR15.12-P-2003A
7) at cylinder head covers ~ *BA01.20-P-1002-01E
7 Disconnect spark plug [g]
Mercedes-Benz
connectors Pay attention to markings

for spark plug connectors
on cylinder head covers
and ignition coils
&.oanaer! Fi2. 48
8 Detach the vacuum hoses
at connections (8, 9) of
the cylinder head covers
9 Detach crankcase [g] Only on left side.
ventilation hose at
cylinder head cover fitting
(lO)
[JJ Risk of explosion caused N o fire, sparks, open AS47.00-Z-0001-0lA
by ignition of flammable flames or smoking. Pour
products, risk of fuels only into suitable
poisoning caused by and appropriately marked
inhaling fuel vapors or containers.
swallowing fuel as well as W ear protective clothing
risk of injury to skin and when handling fuel.
eyes exposed to fuel.
10 Disconnect fue! line at [gJ Only in case of
fuel rail vehicles with a non-
flexible fuel line.
Release fue] pressure
througb service valve!
fu0anaer! Pressure hose Fig. 41
~ *BA07.52-P-1001-01A
~ *'BA07.52-P-1001-01A
11 Remove cylinder head ~ *BA01.20-P-1001-01E
covers (4, 5) [g] Installation: AR01.20-P-5014-01B
Ensure cylinder head
cover gasket is correctly
installed.
[JJ Risk of accident caused Secure vehicle to prevent ASOO.OO-Z-0005-0lA
13 by vehicle starting off by it from moving by itself
itself when engine is W ear closed and snug-
mnning. Risk of injury fitting work clothes.
procedure or when
working near the mnning
engine
Run engine and inspect
for 1eaks
Mercedes-Benz
~e
m
ran k case ventt••atwn,
• cyJrm d er h ead cover
Engine
112.910/911/
912/913/914/
915/916/9171 Engines 113.940/
920/921/922/ 941/942/943/
923/940/9411 944/948/960/
942/943/944/ 961/962/963/
945/946/9471 964/965/966/
949/9511953/ 967/968/969/
954/955/960/ 9711980/9811 Engine
9611970/972/ 982/984/986/ 113.987/988/
Number Designation 973/975/976 992/995 990/991/993
BA01.20-P- Screw of Nm 8 10 8
1001 -0lE cylinder head
cover
BA01.20-P- Bolt of Nm 8 8 8
1002-0IE ignition coils
to cylinder
head cover
~Fuel raíl
Engine 112 except Engine
112.945/9511 Eugine Engine 112.960/
Number Designation 960/961 112.945 112.960/ 976 961 AMG
BA07.52-P- Disconnect fuel N m 38 38 24 35
1001-0 lA feed line at fuel
rail
~Fuel rail
E ngines 113.990/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
Engines Engine 969/971/980/
Engine 113.990/ 113.990/ 981/982/984/
Number Designation 113.987 991 993/995 986/988
BA07.52-P- Disconnect fuel N m 38 38 38 38
1001-0lA feed line at fuel
rail
Mercedes-Benz
9';EJ ~ éJ \J El
9";\:1 tJ \i r1
Éii \j{j~ ~
Fig. 46: Identifving External Torx Set (001 589 76 09 00)
Tiaaaaa1111
11H Hti HB Hi
it)c:!]c¿JC!JCLJ
000 589 01 10 00 _)
TatttíU e l
Fig. 47: ldentifving Torx Bit Set (000 589 0110 00)
110 589 01 01 00 _)
Ocnbleope01 and 1o11:<ndl
Fig. 48: Identifying Double Open-End Wrench (110 589 01 01 00)
119 589 0<163 00
Fig. 49: Identifying Pressure Hose (119 589 04 63 00)
Ensure gasket of cylinder bead cover is correctly instaUed - AROI.20-P-5014-01B
l. lnspect gasket ( arrows) of cylinder head cover to ensure it is correctly Iocated ]n the sealing groove of the
cylinder head cover, particularly at the rear ofthe cylinder head.
Mercedes-Benz
Fig. 50: Locating Cylinder Head Cover Gasket
Remove/install cylinder bead cover- AR01.20-P-5014BV
ENGINE 112
Air cleaner arranged on tbe engine side
Air cleaner arranged on tbe engine side
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
Sbown on engine 112.945
1 E!ngíne coverwfth l ntegratodalrfilter

2 Rl/111 cytlnder head covor
3 Lelt eylinder l u!ltd cove."
4 Rl /111 (gnl!lon colls
5 Lefl lgn~lan oo.ifs
S Rl /111 ccnn o<lion
7 Lefl connoeO'on
8 Lefl connecO'on
Fig. 51: Identifying Cvlinder Head Cover Removellnstall Component- Shown On Engine 112.945
Mercedes-Benz
(!rAP IJ3=" BT R emove/instaiJ

1.1 Remove engíne trím 1!!1 Unclip covering on front side of
panel with integrated engine. Remove air filter by pulling
air filter (1) vertically up and off the cylinder
head covers.
1.2 Remove aír filter Model 170.466 AR09.l0-P-
Model203.065/265, 1150SVK
Model 211.076/276,
Models 215.374,220.074/174,
Model 230.474
2.1 Unscrew the guíde except models 170
tu be of the automatic Models 203, 209.375,
transmission oil Model208
dípstíck Models 211.061/065/070,
Model 230.475
3 Detach right ígnítíon Except engínes AR15.12-P-2003A
coíls (4), left ígnítíon 112.911/914/915/917/954,
coils (5) on right Engine 113.969
cylinder head cover
(2) and left cylinder ~ *BA01.20-P-1002-
head cover (3) OlE
4 Disconnect spark plug 1!!1 I nstaiJation: Observe marking for
connectors spark plug connectors on the cylinder
head covers and ígnitíon coils.
& oanQorl Double open-ended wrencb Fig. 48
5 Pull off vent hoses on
right connector (6)
and on left connector
(7) of the ríght
cylinder head cover
(2) and left cylinder
head cover (3)
6 Pull off engine vent
hose on left connector
(8) of left cylinder
head cover (3)
[[] Risk of explosion No fire, sparks, open flarnes or AS47.00-Z-0001-
caused by fuel smoking. OlA
ignitíng, risk of Pour fuels only into suítable and
poisoniing caused by appropriately marked containers.
inhaling and Wear protective clothing when
swallowing fue] as handling fuel, date service.
well as risk of inj ury
to eyes and skin
caused by contact
with fuel.
Mercedes-Benz
7.1 Disconnect fuel 1ine at ¡g¡ Only in case of vehicles with a

fuel rail non-flexible fuelline and.
Models 211.061/065/ 070/076/276,
Mode1215.374
Model220.074
Model230.474/475
Release fu el pressure through service
valve!
~Engine 112 *BA07.52-P-1001-
OlA
~Engine 113 *BA07.52-P-1001-
MA
& oanaerJ Pressure hose Fi~. 41
8 Remove right cylinder ¡g) Installation: Check cylinder head
head cover (2) and covers for leaks, see: ?
left cylinder head Ensure cy linder head cover gasket .iis AR01.20-P-5014-
cover (3) correctly installed. 01B
~ *BA01.20-P-1001-
OlE
order
OJ Risk of accident Secure vehicle to prevent it from ASOO.OO-Z-0005-
10 caused by vehicle moving by itself. OlA
starting offby itself Wear closed and snug-fitting work
when engine is clothes.
running. Risk of Do not grasp hot or rotating parts.
injury caused by
contusions and burns
during starting
procedure or when
working
. near. the
runmng engme
Run engine and
inspect for leaks
~ Crankcase ventilation, cylinder head cover
Engines
112.910/911/
912/913/914/
915/91 6/9171 Engines 113.940/
920/921/922/ 941/942/943/
923/940/9411 944/948/960/
942/943/944/ 961/962/963/
945/946/9471 964/965/966/
949/951/953/ 967/968/969/
Mercedes-Benz
954/955/960/ 971/980/981/ Engines

961/970/972/ 982/984/986/ 113.987/988/
Number Designation 973/975/976 992/995 990/991/993
BA01.20-P- Screw of Nm 8 10 8
1001-0lE cylinder head
cover
BA01.20-P- Bolt of Nm 8 8 8
1002-0lE ignition coils
to cylinder
head cover
~ Fuel raiJ
Engine 112 except Engines
112.945/9511 112.960/961
Number Designation 960/961 Engine 112.945 AMG
BA07.52-P- Disconnect fuel N m 38 38 35
1001-0lA feed line at fuel
rail
~Fue) raiJ
Engines
113.940/9411
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
Engines Engine 969/971/980/
Engine 113.990/ 113.992/ 981/982/984/
Number Designation 113.987 991 993/995 986/988
BA07.52-P- Disconnect fuel Nm 38 38 38 38
1001-0IA feed line at fuel
raíl
Fig. 52: ldentifving Double Open-End Wrench (110 589 01 01 00)

Mercedes-Benz
119 589 04 S3 00
Fig. 53: ldentifving Pressure Hose (119 589 04 63 00)
REPAIRING SPARK PLUG THREAD- AR01.30-P-5440BV
ENGINE 112
ENGINE 112.945 in MODEL 463.209/232/233 /244/245/250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
ENGINE 113 (except 113.995) in MODEL 129, 163,202, 203, 208, 209, 210, 211, 215, 220, 230
Fig. 54: Identifying Tapped Hole Device
IJ:3rAP Remove,
~BT Instan
1 Remo ve Air cleaner located at vehicle side. AR01.20-
cylinder Air cleaner located at engine side. P-5014B
Mercedes-Benz
head AR01.20-
cover P-
5014BV
2 Remo ve
@) spark Model463.206/209/ 232/233/240/241/243/244/245/246/247/248/249/250/254 AP15.10-
plugs P-
1580GA
@) Model220, 230.474/475,211.061/065/070 AP15.10-
P-
1580AB
@) Model 170,202,203,208,209,210 AP15.10-
P-1580A
@) Model129 AP15.10-
P-
1580AC
@) Model Series 163 AP15.10-
P-
1580GH
3 Position [g] Inlet val ve and exhaust valve of the relevant cylinder must be closed.
piston of
relevant
cylinder
to 20°-
30°
before
TDC
4 Remo ve [g] Model230.474 with Engine 113.992 replace cylinder head if spark plug
cylinder thread is faulty.
head [g) It is then only necessary to remove the cylinder head if it is not possible to
insert the thread tap unit into the spark plug thread for space reasons!
Mode1 AR01.30-
463.206/209/232/233 /240 /241 /24 3/244/245 /246/247 /248 /249/250 /254. P-
5800GV
Model202, 208, 210 with Engine 113 and Model129 with Engine 112, 113 AR01.30-
P-5800B
Model220 with Engine 112, 113 and Model210, 170, 202, 208 with Engine AR01.30-
112, 230.474/475 P-
5800BA
Model 203, 209, 211.061/065 /070 AR01.30-
P-
5800PV
Model Series 163 AR01.30-
P-
5800MV
5 Tap [g) Pack the swarf grooves of the combination thread tap with grease for AR01.30-
Mercedes-Benz
thread in bonding the swarf. Blow out cylinder and spark plug thread with compressed P-5440-
spark air before screwing in the threaded insert. OlB
plug
hole and
screw m 6.oanqerl Fi¡:. 56
threaded
insert
6 Crank ¡gj If the cylinder head was not removed, the engine must be cranked severa! AROl. lO-
engine times with the starter. P-OllOV
with All Models except Model203, 209 Model203, 209 ARO l. lO-
starter. P-
OllOPV
7 Caulk AR01.30-
threaded P-5440-
insert 02B
8 Instan in
the
reverse
order
Fig. 55: ldentifving Heli-Coil Repair Set (102 589 00 99 00)
Tap thread in spark plug hole and screw in threaded insert- AR01.30-P-5440-01B
Fig. 56: ldentifying Heli-Coil Repair Set (102 589 00 99 00)
l . Remo ve pilot bushing ( 1) of tapped hole de vice & oanacrl .

2. Fill the swarf grooves of the combination tap (4) with grease for bonding the swarfs.
Mercedes-Benz
3. Cut combination tap (4) into corresponding spark plug thread. Screw in combination tap (4) until the
guide tube (3) is seated and forms a fully compress with the stop ring (2).
¡gj Screw out after 5 revolutions on removed cylinder head combination tap (4 ), clean the swarf grooves
from swarfs and grease, refill with grease and fmish cutting thread. After cutting.
Blow out spark plug thread and cylinder with compressed air.
1'01::!0-21137.06
Fig. 57: Identifying Pilot Bushing, Stop Ring, Guide Tube And Combination Tap
4. Select heli-coil threaded insert (8) with block length 10.2 mm.
5. lnsert threaded insert (8) witb primary pump drive pointing in direction ofprestessing cartridge (16) in
the installation tool (13) (arrow).
6. Screw in threaded insert (8) flush to prestessing cartridge (16) (arrow).
Mercedes-Benz
Fi~. 58: Identifyin~ Installation Tool, Threaded Insert And Cartrid~e
7_ &oanqer! Position HC-instaHation tool on tapped hole

8. Hold jacket sleeve ( 5)
9. Rotate screw-in spindle (6) until the stop ring (7) is positíoned on the jacket sleeve (5). Slightly tum back
a clamping jacket sleeve when screwing-in.
Fig. 59: Identifying Jacket Sleeve, Spindle And Stop Ring
10. Insert sleeve (9) via primary pump drive ofHELI-COIL insert
Mercedes-Benz
1.1. Guide open pliers & o""""'' to the marking in the sleeve (9) and fix with primary pump drive
12. Close pliers & oanaerl , the serrated lock of pliers must lateh.
1.3. Ro tate sleeve (9) toward left as far as the stop and hold
14. Dismount primary pump drive, todo so move pliers &oan110r1 slightly up and down.
¡gj Remove with a magnet the primary pump drive which had fallen onto the piston crown!
1'01.30 2139 08
Fig. 60: Identifving Sleeve
CauJk tbreaded insert - AR01.30-P-5440-02B
Fig. 61: Identifying Heli-Coil Repair Set (102 589 00 99 00)
l. Grease caulk drift, &oanQorl screw into installed HELI-COIL insert and tighten with a torque of approx. 25-
30Nm.
Mercedes-Benz
Fig. 62: Identifying Caulk Drift
REMOVE/INST ALL TOP FRONT COVER- AR01.30-P-5703AO
Sbown on engine 120.980/981
Sllown o n ongino 120.9-1

1~ 8rK ~ot of lnt~rcnce supp rcsslon
cap
0 /stribcttor rotru cnj11nc 120 .U0.911
4 Orívcr englno 120.9101911
5 Prolllf:lfvo cover onglno 120.9101981
5• Su/lng rlng onglno f 20.9.101911
5 Sh•pod IUbbcrga5kCt
O·rl ngs
Rcsorvolr of powcr stcorlng pump
9• Coolont hose
11 er~Mr
12 Po~r~rlngpump
12• c onnoclfn¡¡ pipo of powor stocrln¡¡
pump
12b s ..11n¡¡ rlng
f¡ Slldln¡¡ r•ll bridge C'over
10 R l¡¡ht front covcr
10• l.clr tront covor
P!l1 )0-413'5·05
Fig. 63: ldentifving Top Front Cover Removellnstall Components

Mercedes-Benz
(!rAP
n:::?'BT
Remove/lnstall
AR01.20-P-
l Remove cylinder head covers
5014AO
2.1 Remove radiator Model 140 ra20001204200x
AR13.22-P-
3 Remove poly-V-belt
1202AO
4 Remove coolant thermostat housing ra20001201120x
5 Remove guide pulley ral 3001203460x
6 Place guard plate onto intake ports
7.1 Remove coolant hose (9a) Model 129
AR01.30-P-5703-
8 Detach top front cover
01AO
*BA01.30-P-
~
1001-0lB
*BA05.20-P-
~ 1002-01F
*BA15.12-P-
~ 1001-0lC
&oanqerl Fig. 66
&oanae.r! Fig. 37
*BR00.45-Z-
Sealant
1013-01A
Secure vehicle
to prevent it
from moving.
Risk of accident . Accidents may result if the vehicle starts
Wear closed
offunintentionally with the engine running. Risk ofinjury.
and snug- ASOO.OO-Z-0005-
OJ Cmshing and burn injuries may result while working on
fitting work OlA
engine during when it is being started or when it is in
clothes.
operation.
Do not grasp
hot or rotating
parts.
10 Run engine, check for leaks
~ CYLINDER HEAD
Nomber Designation Engine 120
M6 Nm -
BA01.30-P-1001-01B Bolt of front cover at top
M8 N m 25
~CAMSHAFT
INomber ¡nesignation IEngine 120
1
Mercedes-Benz
1
IBA05.20-P-1002-0IF IBolt of driver to ínlet camshaft Nml16 1
~ ECI IGNITION SYSTEM

BA15.12-P-100 1-0lC Bolt of distributor rotor at driver N m approx. 2.5
í
'
@
103 SS9 Ot 14 00
S!ea~e
Fig. 64: ldentifying Sleeve (103 589 0114 00)
/ IDN
Dli$~31 1 111
'
11a ~~ ~ ~ ~~
iDCTic¿Jc¿]c[)
O!>!l5S9 01 10 OD
\...
TOIX~ UI
F ig. 65: Identifying Torx Bit Set (000 589 0110 00)
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013-01A Sealant A 003 989 98 20
Detach/attacb front cover- AR01.30-P-5703-01AO
~ CYLINDER HEAD
Number Designa tioo Engine 120
M6 Nm-
BA01.30-P-100 1-0 lB Bolt of front cover at top
M8 N m 25
~CAMSHAFT
BA05.20-P-1002-01F Bolt of driver to inlet camshaft Nm 16
~ ECI IGNITION SYSTEM

1 1 1 1
Mercedes-Benz

BA15.12-P-1001-01C Bolt of distributor rotor at driver Nm approx.2.5
Fig. 66: Identifying Sleeve (103 589 0114 00)
000589 Ot 10 00
Tor. b.t-stl
Fig. 67: Identifying Torx Bit Set (000 589 0110 00)
Fig. 68: ldentifying Sleeve (03 589 0114 00)
REPAIR MATERIALS
Number Designatiou Order number
BR00.45-Z-1013-01A Sealant A 003 989 98 20
l. Engine 120.980/981: Remove distributor rotor and driver (4).
¡gj lnstallation : The groove ofthe driver (4) must latch into the locating pin (arrow) in the camshaft
2. Engine 120.980/981: Remove protective cover and sealing ring

3. Remove power steering pump reservoir with hoses toward top
Mercedes-Benz
Fig. 69: Loc.ating Pin
4. Unscrew bracket (1 1), remove.
1J HcXiiJIOn soC"IIct hc;¡¡fl scrcw wl ltl WiJSIJM (Ion; Rr:cw IJc;¡¡~ IAB x
u
14 HCXiiJIOn socllet heiJd screw wlltl WiJSIJU 181 x iS
PD 1 3 0~ 30·01
Fig. 70: ldentifying Unscrew Bracket And Hexagon Socket Head Screw With Washer
5. Unscrew connecting pipe (12) at power steering p ump (12)
¡gj lnstallation : Replace sealing ring.
Fig. 71: Identifying Power Steering Pump
6. Unscrew bolts (arrows), remove front cover.

7. Insta!] new shaped rubber gasket and 0-ring of coolant duct in the :front cover.
Mercedes-Benz
8. Clean sealing surfaces of front cover of cylinder head and shaped nut of timing case cover.
Rlght front co vor
Fig. 72: Locating Bolts And Right Front Cover
9. Check shaped gaskets (arrows of slide rail bridge cover (13) for damage and replace if necessary.
P!l t J IHJJ51·01
Fig. 73: Locating Gaskets On Slide Rail Bridge Cover
10. Apply the sealing compound Loctite 5970 ptmctual at the joint to the cylinder head on 1eft and right
(arrows) in the oil-free groove ofthe timing case cover.
11. Place newly dried shaped gasket (without sealing compound) in the oil-free groove. Slightly coat the top
side ofthe shaped rubber gasket with engine oiL
12. Coat front cover at the contact surfaces to the cylinder head with sealing compotmd Loctite 5970
Mercedes-Benz
P\1 1 )~~352 - 01
Fig. 74: Locating Cylinder Head Joint
13 . Engíne 120.980/98 1: Place assembly sleeve (1) 103 589 01 14 00 onto the exhaust camshaft Coat líp of
radial sealing ring (2) with engine oiL
14. Mount front cover_
[g] When installing the front covers ensure, that the bottom shaped rubber gasket (arrows) is not
displaced, for this purpose break the edge at the bottom ofthe cover_
On the left cover, unscrew screw plug (31), remov e sliding rail pin, reinstall after assembly.
p.¡J t l 0-1ll5HI1
Fig. 75: Identifying Sleeve, Radial Sealing Ring And Unscrew Plug
15 _ Mount bolts according to bolt diagram, first of all tighten the lower bolts.
~ Mount left front cover with lower bolt (2).

Mercedes-Benz
Lcff tront cov"~:r

1 Bolr+-washcr wlrn axtem~al hcx~agon 1118·v 6.!S
1 &lt•washor 1118 x 55
3 &it+washcr 1At x 50
P01 JIJ-.11351·111
Fig. 76: ldentifying Left Front Cover
Rignt f ront c:o ver

& . .w~ashcr wtth cxtcrn~al ncxason tn "' 55
&lt • w~Jshcrtn x 65
llorJc/140: Wlth br~c:ltct c:;ablc 1iDC .scru.or
Bolt • washoriA8 x 65
P01 J0-41)55·01
Fig. 77: ldentifying Right Front Cover
REMOVEIINSTALL CYLINDER HEAD- AR01.30-P-5800B
ENGINE 113 in MODELS 129, 202, 208, 210

Mercedes-Benz
1'01 J O·lOJHI9
10 l.cff 11/nlr.lon co/ts

V l scous f~n 11 c;cnortlto r
2 F~nshroud 12 CIJ•In lflnsionor
l P o/y·V·bo lf 11 lnt•~ • m•n liold
4 A l rtHrcrhouslng 14 ~ms/J~ rr posllion sensor
s Reson~ncc ruoc 15 Cool•nCllho
5 RMon~ nco unit 16 c:Jif!Sh.Jrt S¡II~~CC5
R fgllt cyl/ndcr hUd COVOf 17 Coms!J•If b . .ring· bddgos
R lgllt lgnl!lon colls 11 011 filrcr llouslng wiCil oll-wJtcr llCJf cxcll•ngot
L.Cif C)f/nclcr hUd COVCf
Fig. 78: Identifying Cvlinder Head Components (1 Of 2)
20 8olts cy/lndcr /Jcod- rimtng cüa

covcr
11 Cy6nrlor hood bolts 1111 X141.S
zz L ort c¡tlnclcr hoicl
2J R lgnr cyl lndor llo•d
24 Lcrr c)flnclcr hcodg.. ~o r
25 R lgllr cyllndcr hc•d gukot
25 Oowcl stocvcs
1'01 J0-4l9HI6
Fig. 79: ldentifving Cylinder Head Components (2 Of 2)
[$'"AP~BT Remove/install
~' Notes on self-locking nuts M ODEL all AHOO.OO-N-0001-0lA
Mercedes-Benz
and bolts
[[] Risk of accident caused Secure vehicle to prevent ASOO.OO-Z-0005-0lA
by vehicle starting off by it from moving by itself
itself when engine is W ear elosed and snug-
nmning. Risk of injury fitting work clothes.
procedure or when
engine
ITJ Risk of explosion caused ~ofire, sparks, open AS54.10-Z-0001-01A
by oxyhydrogen gas. Risk flames or smoking. Wear
of poisoning and caustic acid-resistant gloves,
burns caused by clothing and safety
swallowing battery acid. glasses. Only pour
Risk of injury caused by battery acid in to suitable
burns to skin and eyes and appropriately marked
from battery acid or when containers.
handling damaged lead-
acid batteries
1 Disconnect battery ground [g] Installation: After AR54.1 0-P-0003A
cable connecting, read out fault
memory, encode radio
and normalize power
windows.
Vehicles with stationary
heater: adjust time
display on stationary
heater.
~ .. Notes on battery MODEL all AH54.10-P-0001-01A
2 Remove engine AR61.20-P-1105AB
compartment paneling
[[] Risk of injury to skin and Do not open cooling AS20.00-Z-0001-01A
eyes caused by scalding system unless coolant
from contact with hot temperature is below 90°
coolant spray. Risk of C. Open cap slowly and
poisoning from release the pressure. Do
swallowing coolant. not pour coolant into
beverage containers.
W ear protective gloves,
¡protective clothing and
safety glasses.
3 Drain coolant [g] At radiator AR20.00-P-1142HA
4 Remove engine cover or [g] Modell 29,
air filter 202.033 /093, 208.3701
374 /470, 210.074 /274
Mercedes-Benz
The air filter is integrated

in the engine cover.
Remove engine trím
panel or aír filter by
pulling it vertically up
and offthe cylinder head
covers.
5 Remove viscous fan ( 1) ¡g] Ríght-hand thread! AR20.40-P-5660C
6 Remove fan shroud (2).
7 Attach guard plate for
Lh Guard plate for radiator 1 WF58.50-P-0110-01A
condenser
8 Remove air ftlter housing Models 210.070/ 270
(4).
9 Remove resonance tube ~ Do not damage plastic
(5) and resonance unít (6) bracket.
¡g] The resonance pipe is
attached at the rear at the
intake manifold wíth a
plastic plate.
Separate plug connectíon
of hot film mass air flow
sensor (HFM-SFI) for
this step and Unbolt
resonance pipe at
Models 210.070/ 270 AR07.07-P-1454A
10 Remove hot film mass a ir Modell29, 202., AR07.07-P-1454AG
:flow sensor (HFM-SFI) 208./470, 210.074/ 274
OJ Risk of explosion caused !No fire, sparks, open AS47.OO-Z-0001-01A
by ignition of flanunable flames or smoking.
products, risk of Pour fuels onJy ínto
poisoning caused by suítable and appropriately
inhaling fuel vapors or marked containers.
swallowing fuel as well as W ear protective clothíng
risk of injury to skín and when handling fu eL
eyes exposed to fuel.
11 Disconnect fuelline at ¡g] Release fuel pressure
fuel rail through servíce valve!
Collect fuel.
~Mll2 *BA07.52-P-1001-01A
~M113 *BA07.52-P-1001-01A
Lt. oanoer! Pressure hose Fig. 41
Mercedes-Benz
12 Rernove ígnition coils (8, AR15.12-P-2003A

10)
13 Remove cylínder head Models 210.070/ 270 AR01.20-P-50 14B
covers (7, 9)
Modell29, 202., AR01.20-P-5014BV
208./470, 210.074/ 274
14 Remove intake manifold ~ The intake manifold AR09.20-P-1310A
(13) system must not be
disassembled.
~ Installation: On
vehicles with engine
damage, the intake
manifold must be
inspected for swarf
before assembly and any
swarf present must be
removed.
¡g] Remove intake
manifold together with
fuel raíL
15 Remove camshaft ¡g] Only necessary íf ríght AR15.10-P-2000A
position sensor ( 14) cylinder head ís removed.
16 Remove poly-V-belt (3) [g] Installation: Lock AR13.22-P-1202B
tensioning device with a
drift or pin (diameter 5
mm).
17 Detach coolant line (15) [g] On Model 202. an
at left cylínder head additional coolant line ís
attached at the right
cylinder head.
The coolant line at the
right cylinder head leads
to an extemal
transmission oil cooler
located on the right,
lbehind the front apron.
l.lJ Wrench hexagon *WH58.30-Z-1001-06A
[lJ Wrench hexagon *WH58.30-Z-1 002-06A
18 Detach exhaust system at ~ Installation: On
exhaust manifold vehicles with engine
damage the exhaust
system must be examined
for swarf and any swarf
present removed before
installing.
Mercedes-Benz
~ *BA14.10-P-1002-01B
19 Position crankshaft to 40° ~ Engine must not be AR05.1 O-P-6858V
after ignition TDC of cranked back.
cylinder 1 [g] Rotate engine at
crankshaft in direction of
rotation until 40°
marking on belt pulley/
vibration damper is
aligned with marking on
timing case cover.
The grooves on the
camshafts must be
pointing toward the inner
V.
20 Lock camshafts with A oanqorl Locating plate Fi1z. 82
locating plate
AoanQer! Locating plate Fig. 83
21 Remove oil filter housing Models 129, 208 with AR18.20-P-3471B
(18) with oil/water heat engine 113
exchanger
22 Remove chain tensioner AR05.1 0-P-7800C
(12)
23 Remove camshaft ~ If the camshaft
sprockets ( 16) sprockets are removed,
the engine must no longer
be cranked otherwise the
timing chain might jam.
[g] Model 129, 208 with
Engine 113:
Ti e timing chain tight on
both camshaft sprockets
w ith cable straps.
[g] All except model 129,
208 with engine 113.
Right camshaft sprocket:
T ie timing chain tight on
camshaft sprocket with
cable strap.
Left-hand camshaft
sprocket:
Mark camshaft sprocket
to timing chain and
remove camshaft
Orocket.
It is not possible for
the timing chain to jump
Mercedes-Benz
across at the cranksbaft

and balancing shaft.
&.oanaer! Open-end wrench Fil!. 84
&.oanQerl Insertion tool Fil!. 85
&.oanaer! Torque wrench Fig. 88
~ *BA05.20-P-1001-01B
[g] After installation: ?
In spect basic position of AR05.10-P-6858V
camshafts.
Necessary after
checking:?
Set the basic position of AR05.20-P-6020AU
camshafts.
24 Remove camshaft bearing AR05.20-P-7103AU
bridges ( 17)
25 Unscrew bolts (20) of ~ *BA01.40-P-1002-01C
cylínder head to timing
case cover
26 Slacken cylinder head ~ Slacken cylinder head AR01.30-P-5800-09B
bolts (21) in stages, lbolts as specified in
unscrew slackening diagram once
engine has cooled clown.
~ Installation: Observe AR01.30-P-5800-07B
tightening pattem and
tightening instructions of
cyl inder head bolts. Oil
thread and head contact
surface of cylinder head
lbolts.
&.oanoerl Screwdriver bit Fil!. 91
&.oanaerl Screwdriver bit Fig. 92
~ *BA01.30-P-1001-01D
27 Remove cylinder bead ~ lnstallation: On
Engine 113 sealing
compound must be
applied on tbe left
cylinder head gasket due
to porous points in the
left cylinder head.
~' Information on applying Engine 113 AHO 1.30-P-1 000-04V
sealant to cylinder bead
gasket
Loctite 5900 sealant. *BR00.45-Z-1013-01A
[g] The sealant must be
Mercedes-Benz
applied wíthin 10
minutes.
[g]' Information on cylinder Engine 112, 113 AH01.30-P-1 000-0SA
head contact surface
28 Inspect version of Assignment of cylinder AH01.30-P-1 000-06V
cylinder head gasket head gasket
Engine 112, 113
~ Checking
29 Check cylinder head bolts 0 AR01.30-P-5800-03B
(21)
30 Clean sealíng surfaces, ~ Pay attention to dowel *BR00.45-Z-1013-01A
check for cracks, shrink sleeves (26) for locating
holes and flatness, clean the cylinder head.
bolt holes
Loctite sealant 5900
[g] Sealing surfaces of
crankcase and cylinder
head are provided with an
O. 8 mm thick silicone
!ayer during series
production. Silicone
sealant is applied in the
gasket area when
carrying out repairs only
if shrink holes are
esent.
0 The sealant must be
applied within 1O
minutes.
32 Run engine and inspect
for leaks
33 Inspect cooling system for [g] Warm up engine to AR20.00-P-1010HA
leaks operating temperature
and then inspect cooling
system or leaks.
34 Read out fault memory [g] Stored faults which
and erase can result from cables
being disconnected or
from simulation during
removal and installation
or test work, haveto be
processed and erased in
the fault memories after
completing the work: ?
Mercedes-Benz
Diagnosis Manual
Volume 2lndex 0:
Connecting and using test
~uipment
lliJ Star-Diagnosis
~e
m ran k case, tumng case cover, end cover
Number Designation Engine 112 except Engine 112.951/
112.951/ 976 976
BAOlAO-P-1002- Bolt, cylinder head Nm 20 20
OlC to timing case cover
~e ran k case, ti mmg

. case cover, en d eover
Number Designation Engines Engine 113.9871
113.940/941/ 988/990/991/993
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/995
BA01.40-P-1002- Bolt, cylinder head Nm 20 20
~eJ'lun der head

Number Designation Engine Engines Engine Engine
112.910/911/ 113.940/941/ 113.987/ 113.990/991/992/993/995
912/913/914/ 942/943/944/ 988
915/916/917/ 948/960/961/
920/921/922/ 962/963/965/
923/940/941/ 966/967/968/
942/943/944/ 969/971/980/
945/946/947/ 981/982/984/
949/951/953/ 986/992
954/955/960/
961/970/972/
973/975/976
BA01.30- Bolt, Stage l Nm lO lO 10 lO
P- 1001- cylinder Stage 2 Nm3 0 30 30 30
OID head to Stage 3 Angle0 90 90 90 90
crankcase Stage 4 Angle0 90 90 90 90
~ Camshaft
Mercedes-Benz
Number Designation Engine 112 except Engine

112.951/976 112.9511 976
BA05.20-P- Bolt, M12x45 Stage 1 N m 50 50
1001-0IB camshaft
sprocket Stage 2 Angle 0 90 90
~Camsbaft
Number Designation Engines
113.940/941/
942/943/944/
948/9611962/
963/964/965/
966/967/968/
969/9711980/
9811982/984/
986/992/995
BA05.20-P- Bolt, camshaft M12x45 Stage 1 N m 50
1001-01B sprocket Stage 2 Angle 0 90
~ Camshaft
Number Designation Engine Engine
113.987/988/ 113.991
990/993
BA05.20-P- Bolt, M 12x45 Stage 1 N m 50 50
1001-01B camshaft
sprocket Stage 2 Angle0 90 90
1
~ Fuel rail
Number Designation Engine 112 except
112.945/9511 960/961
BA07.52-P-1001-01A Disconnect fuel feed line N m 38
at fuel rail
~Fuel raíl
Number Designation Engine Engines Engine Engines
113.987 113.990/ 113.990/ 113.940/941
991 993/995 942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/988
Mercedes-Benz
BA07.52-P- Discom1ect fuel N m 38 38 38 38

1001-01A feed line at fuel
rail
~ Exhaust manifold
112.9511 976 113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
9811982/984/
986/992/993/ 995
BA14.10-P-1001- Nut to exhaust Nm 16 16
OlB manifold
BA 14.1 0-P-1 002- Flange connection, N m 20 20
OIB exhaust manifold
and front exhaust
p1pes
BA14.10-P-1003- Bolt to exhaust Nm- 20
OIB manifold
BA14.10-P-1004- Collar nut of Nm-
OlB exhaust manifold to
cylinder head
e;Er;L1EJ EJl1 r~LJ EJ r1\j [j

~¡ E1\1\:JrJEJE1EJ
______
..___
"..... OO t 5B9 76 09 00 __
Er.t2rnal Torx oel
Fig. 80: Identifying External Torx Set (001 589 76 09 00)

Mercedes-Benz
- Uli$~111111
ma ~~ ~~ ~~
ill~c:!Jc¿)C[]
Ol>D 5S9 01 10 OD
TCfx bit &el
Fig. 82: ldentifving Locating Plate (112 589 00 32 00)
t 12 5!!9 ot s2 oo
Fig. 83: Identifving Locating Plate {112 589 01 32 00)
11 2 5!!9 00 01 00
Fig. 84: ldentifying Open End Wrench {112 589 00 01 00)

Mercedes-Benz
~~----
11_
2_5$
__o•_o_3_oo____)
tmlllion 1001
Fig. 85: ldentifving Insertion Tool (112 589 01 03 00)
\_ 000 5!39 03 10 00 _)
Stn•lld&\1111 In Hit
Fig. 86: ldentifying Screwdriver Insert (000 589 03 10 00)
000 589 04 10 00
Fig. 87: ldentifying Screwdriver Insert (000 589 04 10 00)
001 589 72 21 00
Fig. 88: ldentifying Torque Wrench (001 589 72 21 00)

Mercedes-Benz
.í
' 11958!! 046300 ._)

fJUSIUB hOS~

Number Designation
WH58.30-Z- 100 1-06A 6 mm socket hexagon on flexible shaft for hose
WH5 8.30-Z- l002-06A 7 mm socket hexagon on flexible shaft for hose
clamps with worm d.rive
Repair materials
BR00.45-Z-1013-0 l A Seaiant A 003 989 98 20
C hecking cylinder head bolts- AR01.30-P-5800-03B
Cylinder head/Cylinder head bolts

Engines E ngines
112.910/911/ 113.940/941/
912/913/914/ 942/943/944/
915/916/9171 945/946/948/
920/921/922/ 960/961/962/
923/940/9411 963/964/965/
942/943/944/ 966/967/968/
945/946/9471 969/971/980/
949/951/953/ 981/982/984/
954/955/960/ 986/987/988/
9611970/972/ 990/9911992/
Number Designation 973/975/976 993/995
BEOL30-P- Cylinder head Thread M 11 11
1001-04B bolt diameter
Length (L) mm141.5 141.5
whennew
Length (L) mm < or = 144.5 < or = 144.5
See picture AR01.30-P-5800- AR01.30-P-5800-
03B 03B
1 Mercedes-Benz
1
Cylinder head/cylinder head bolts

Number Designation Engine 113.989
BEO 1.30-P-1001- Cylinder head bolt Thread diameter M 11
04B Length (L) when mml4L5
new
Length (L) mm < or = 144.5
See picture AR01.30-P-5800-
03B
l. Measure length (L) of cylinder head bolts.
[gJ If the length (L) exceeds the maximum permissible dirnension then the cylinder head bolts must be replaced.
@ [] u 11
PllL30-ll295. 1O
Fig. 90: Identifying Length Of Cylinder Head Bolts
Tightening instructions for cylinder bead bolts- AR01.30-P-5800-07B
8 Cylinder head
Engines
112.910/911/
912/913/914/
915/916/9171 Engines
920/921/922/ 113.940/941/
923/940/941/ 942/943/944/
942/943/944/ 948/960/961/
945/946/9471 962/963/965/
949/951/953/ 966/967/968/ Engine
954/955/960/ 969/971/980/ Engine 113.987/
961/970/972/ 981/982/984/ 113.987/ 991/992/
Nomber Designation 973/975/976 986 988 993/995
BA01.30-P- Bolt, Stage 1 Nm 10 10 10 10
1001-01D cylinder Stage 2 Nm 30 30 30 30
head to Stage 3 Angle o 90 90 90 90
crankcase Stage 4 Angle o 90 90 90 90
~ Cl:linder head
Mercedes-Benz
Number Designation Engine 113.989 Engine 113.964

BA01.30-P- Bolt, cylinder Stage 1 Nm 10 10
1001-0lD head to Stage 2 Nm 30 30
crankcase Stage 3 Angle 0 90 90
Stage 4 Angle o 90 90
000 589 03 10 00
Fig. 91: Identifying Screwdriver Insert (000 589 03 10 00)
000 589 04 10 00 J
~~~e
Fig. 92: Identifying Screwdriver Insert (000 589 04 10 00)
Tightening pattern/bolt assigument
Left and right cylinder head M 112
1-8 Collar bolt Mll
a. a Combination bolts M850(to timing case cover)

b. b Combination bolts M830(to timing case cover)
Mercedes-Benz
..
Fig. 93: Identifying Tightening Pattern/Bolt Assignment {Left And Right Cylinder Head M 112)
Tigbtening instructions for left and right cylinder beads M 112
Use ÓoanQorl wrench bit to tighten cylinder head bolts.
¡g] Observe sequence, see tightening pattern.
[g] lf the tightening torque is exceeded on a cylinder head bolt, unscrew the cylinder head bolt, inspect shank
length ofthe cylinder head bolt in question (replace bolt ifnecessary) and tighten again fully, beginning with
stage l.
¡gj Cylinder bead bolts must not be retigbtened.
Tightening diagram/bolt assiignment
Left and right cylinder bead M 113

Mercedes-Benz
1to 1() Colar bolt 11111

a Comblna1ionbdm Ml x SO (lo llmlng case co..,.J
b Comblna1ion bdm MI x 30 (lo llmlng case eov.,)
Fig. 94: Identifving Left And Right Cvlinder Head M 112 {Left And Right Cvlinder Head M 113)
Tightening instructions for left and right cylinder heads M 113
Use & o""'""' wrench bit to tighten cylinder head bolts.
¡g] Observe sequence, see tightening pattern.
[gl Ifthe tightening torque is exceeded on a cylinder head bolt, unscrew the cylinder head bolt, inspect shan.k
length ofthe cylinder head bolt in question (replace bolt ifnecessary) and tighten again fully, beginning with
stage l.
[gJ Cylinder head bolts must not be retightened.

Slackening diagram for cylinder head bolts- AR01.30-P-5800-09B
OCIO 589 03 10 00
Fig. 95: Identifving Screwdriver lnsert (000 589 03 10 00)

Mercedes-Benz
OC() 589 04 10 00
Fig. 96: ldentifving Screwdriver Insert (000 589 04 10 00)
Engine 112
P01.300291 01
Fig. 97: Identifying Loosening Sequence Of Cylinder Head Bolts -- Engine 112
l. Unscrew bolts (a, b).
Engine 113
Mercedes-Benz
Fig. 98: ldentifying Loosening Seguence Of Cvlinder Head Bolts -- Engine 113
2. Loosen cylinder head bolts (1 to 8 or 1O) as per the numerical sequence and remo ve.
REPAIRING THREADED HOLES FOR CYLINDER HEAD BOLTS- AR01.40-P-1220AO
ENGINE 120
1'()1 l 1J.O l52-ll5
Fig. 99: ldentifving Cylinder Head Bolts And Threaded Boles Dimension
ll$AP
n::::r"BT
1 Remove cylinder head ra01001204150x
2 Widen hole
[g] 0 12.5 mm, pay attention to core hole *BE01.40-P-1002-
drilling depth 02C
3 Tap HELICOIL thread *BF:01.40-P-1 002-
Mercedes-Benz
02C
[l]
Screw in HELICOIL [g] Pay attention to installation depth. Set *WHS8.30-Z-1001-
4
threaded insert installation depth by means of setting ring on 33A
spindle.
Use snap to snap off
5
driver stud and remove
InstaU in the reverse
6
order
TEST DATA OF CRANKCASE

Thread 0 M 12
Threaded insert below contact
mm5
surface dimension "A"
Dimension "B" mm 2.5-3.5
Dimension "C" mm 14.4-14.6
Screw-in depth Heli-coil threaded
mm 14.4-14.6
BE01.40-P- Threaded bol e for cylinder head insert dimension "D"
1002-02C bolts repair version Original thread length dimension
mm 40
"E"
Core hole depth from contact
mm 45
surface dimension "F"
Dimension "G" mm 51
AR01.40-P-
Fig. see
1220AO
COMMffiRC~LYAV~ABLETOOLS
Number Designation
WH58.30-Z-l001-33A HELICOIL- special version ofworkshop packingM12
SCREW DIAGRAM FOR TIMING CASE COVER - AR01.40-P-8000-01B
Assignment of bolts for timing case cover
[gJ Apply sealant at the bolts marked (arrows).

Mercedes-Benz
1 MI X1 8
2 JlfX23
3 JlfX 4 S
4 JIB X30
11 JISX34
7 MB XTO
11 Ms x ao
11 JI8Xll0
10 JIBX100
11 JIB X110
12 JIB X140
13 Jl12lt 1, 5
POI><O 201 1 oe
Fig. 100: ldentifying Timing Case Cover Bolts & Bolts Needing Sealant
DETACH/ATTACH TIMING CASE COVER- AR01.40-P-8000-03AO
~ CRANKCASE, TIMING CASE COVER, END COVER

M6 Nm9
BA01.40-P-100 1-0 lF Timing case cover to crankcase
M8 N m 21
BA01.40-P-1009-01F Bolt of bracket for air pump/generator M8 Nm 25
6tl3 5B!I 00 40 00
Fig. 101: Identifying Counterholder (603 589 00 40 00)
REPAIR MATERIALS
Number Designation Order rmmber
BR00.45-Z-1013-01A Sealant A 003 989 98 20
l. Unscrew belt pulley (1 O) of power steering purnp, remove.
[g] For this step place poly-V-belt (21 )above the belt pulley ( 1O) of the power steering pump (12), fit on
bracket (14) 603 589 00 40 00 and slacken bolts (arrows)
Mercedes-Benz
Fig. 102: Slackening Bolts
2. Unscrew bolts (arrow) ofpower steering pump an.d press power steering pump (12) with connected oil
lines to the síde.
3. On engines with TDC sensor: Unscrew (Ll/1) an.d (Ll/2) at timing case cover (7).
P!l1 CC-lll4Hl1
Fig. 103: Locating Bolts
4. Unscrew aír cleaner (4) ofaír pump, remove.

5. Unscrew bolts (15, 16) and remove bracket (3) of aír pump/generator.
[g] lnstallation : Observe fitted sleeves at the lower bolts (15, 16).
Model 129: Screw together bracket of generator wiring harness to lower bolt (16).
Clip vacuum líne of aspirator shutoff valve into bracket (3) (arrow).
6. Modell29: Remove air injection line.

Mercedes-Benz
Fig. 104: ldentifving Air Cleaner, Bracket And Lower Bolt
7. Remo ve chain tensioner

8. Unscrew bolts (17, 18, 19) and remove timíng case cover (7).
~Do not damage oil pan gasket (arrows).
9. Clean sealing surfaces at timing case cover (7) and crankcase.
Model l 29: Remove bolts (arrows) if lower oil pan is removed.
1'01 & ~Hll'Hl1
Fig. 105: ldentifving Timing Case Cover Bolts
10. Coat sealíng surface (arrow) of oil duct at tíming case cover (7) with sealing compound.
~ Make sure that no sealing compound enters the oil duct (arrow).
Mercedes-Benz
1 0-rlngs
20 Fim:d slr::ovcs
Plll1 CO..j))U-(11
Fig. 106: ldentifving 0-Ring And Fitted Sleeves
11_ Coat sealing surfaces at timing case cover with sealing compound Loctite 5970
[g] Ensure that no sealing compound enters the oil separator (arrow) ofthe crankcase ventilation,
otherwise the function of the crankcase ventilation is no longer assured_
12. Replace 0-rings (8) in order to seal the coolant ducts.
Fig. 107: Locating Oil Separator
13. Mount timing case cover (7).
[g] Do not damage oil pan gasket (arrows), observe fitted sleeves.
14. First of all tighten front bolts (17, 18).
[g] Ifthe timing case cover is replaced, the TDC sensors (Ll/1) and (Ll/2) must be set (up to 12/93).
Mercedes-Benz
17 Hoxag·an socilot hc~d .scrcw wilh w~hcr 118 x50

17~
Modc/129~ Hcxagonsocifct ho~dscrcw wifh b racl«: tof ~fr
fnjcct/on
11 Hcngon socJc ct hc~d .scrcw with wuhcr tllx.SO
P01 4lJ.o!l H 5·01
Fig. 108: Locating Oil Pan Gasket
15. Inspect color identification (arrows) ofthe camshaft sprockets with the timing chain.
16. Install chain tensioner
17. Install in the reverse order, starting at the digit 6.
18. Run engine, check for leaktightness.
P01 10-4) ) {]·111
Fig. 109: Locating Color Identification
REMOVE/INSTALL TIMING CASE COVER- AR01.40-P-8000AO
ENGINE 120
Mercedes-Benz
Fig. 110: ldentifying Timing Case Cover Remove/lnstall Components
(!rAP
R emove/lnstall
n.::r-er
AR01.30-P-
1 Remove front cover
5703AO
2 Remove coolant pump (2) ra20001202100x
AR09.10-P-
3 Remove air cleaner and mass air flow sensor
1050F
AR14.30-P-
4 Remove air pump (9)
7251F
5 Remove generator (13)
Rotate crankshaft 30° toward ignition TDC at 1st
6
cylinder
7 Identify timing chaín with camshaft sprockets. [gJ Color coding
8 Remove belt pulley 1 vibration damper ra0300 1203420x
AR01.40-P-8000-
9 Detacb/attach timing case cover (7)
03AO
*BA01.40-P-
~
1001-01F
*BA01.40-P-
~ 1009-01F
&oan®rl Fh!.101
[gJ Check front
crankshaft radial *BR00.45-Z-
sealing ring, replace 1013-01A
if necessary see o
Renlace front
Mercedes-Benz
crankshaft radial
ra01001202140x
se al
1O Install in the reverse order
Secure vehicle to
. it from
. k of acc1·dent . A cc1·dents may resu 1t 1·f the ve h.1c 1e prevent
R IS
starts offunintention aHy with the engine running. Risk mwov mgl. d d
[JJ · · e hing and burn mJunes
o f mJury. rus
· · ·
may resu1t w 1 e
h.l ear e ose an
fitf k ASOO.OO-Z-0005-
1
working on engine during when ít is being started or snlutgh- mg wor ¡lli
h · · · · e o es.
w en It 1s m operat10n. Do not grasp hot or
rotating parts.
11 Run engine and inspect for leaktightness
~ CRANKCASE, TIMING CASE COVER, END COVER

M6 Nm 9
BA01.40-P-1001-01F Timing case cover to crankcase
M8 Nm 21
BAO1.40-P- 1009-0 lf Bolt of bracket for air pump/generator M8 Nm25
sro sag O!l 40 oo
Fig. 111: ldentifying Counterholder (603 589 00 40 00)
REPAIR MATERIALS
BR00.45-Z-1013-01A Sealant A 003 989 98 20
REMOVE/INSTALL TIMING CASE COVER- AR01.40-P-8000B
ENGINE 112 in model129, 163, 170, 202,208, 210.061 /063 /065/261 /263 /265/663, 220
ENGINE 113 (except 113.991) in MODELS 129,163, 202, 208, 210, 215, 220, 230.475 /474 (except,
215.374,220.074/174)
Shown on engine 112 in model210

Mercedes-Benz
POUO 2097-09
OJI pon bottom socrfon 18 Coo/ant /In e

1 Visco u& tan dutch 11 Power atoeJing ptmp 19 Ttnfng ,.•• ua6ng rlngs
2 Po/y-11-btll 12 Cootanr pump 20 Alrpump
3 F.nshrolld 13 l?lormost.ll hous/llfl 21 Bo/1$
4 Vlbnttlon demptr 14 Ctoaln rensloner 22 O//pan
6 Poly-V.J>olttensloning dovko 1~ AJJ~ 23 A TF lno bta ckel
& Cyltodor hud e ovo /S 11 Coolantlfne A9 ~e&igerant compressor
1 011 ffhr hou$/ng wírh oll-water heal 17 Coolillll b'no G2 Gener•tor
<rXchiiO!JOT
Fig. 112: Identifying Timing Case Cover Remove/Install Components - Shown On Engine 112 In Model
210
Modification notes
1.9.04 Value changed Value in row 1003 changed for engine *BA20.10-P-
from 10 Nm to 14 112.910/911/912/913/914/915/916/9171 1003-01M
Nm 920/921/922/923/ 940/9411942/943/944/
945/946/947/949/953/954/955/960/961 1
970/972/973/975
Val ue changed V alue in series 1004 changed for engine *BA20.10-P-
from 10 Nm to 14 112.910/911/912/913/914/915/916/9171 1004-0lM
Nm 920/921/922/923/940/941/942/943/944/
945/946/947/949/9 53/9 54/95 5/960/961 1
970/972/973/975
~AP
~BT Remove/install
OJ Risk of No fire, sparks, open flames or smoking. Wear acid- AS54.10-Z-
explosion resistant gloves, clothing and safety glasses. Only pour 0001-0I A
caused by battery acid into suitable and appropriately marked
oxyhydrogen containers.
gas. Risk of
poisoning and
Mercedes-Benz
caustic burns
caused by
swallowing
battery acíd.
Risk of injury
caused by
burns to skin
and eyes from
battery acid or
when handling
damaged lead-
acid batteries
1 Disconnect Models 129, 163, 170, 202,208,210 AR54.10-P-
battery ground 0003A
cable Model215, 220 AR54.10-P-
00031
Model230.474 /475 AR54.10-P-
0003R
~ .. Notes on Allmodels AH54.10-P-
battery 0001-0lA
2 Remove engine Modell29,202,208,2 10 AR61.20-P-
compartment 1105AB
panelíng Models 163.172/ 174/175 AR61.20-P-
1105GH
Modell70 AR61.20-P-
llOSA
Model215, 220 AR61.20-P-
1105M
Model230 AR61.20-P-
1105R
IIl Risk of injury Do not open cooling system unless coolant temperature is AS20.00-Z-
to skin and below 90°C. Open cap s lowly and release the pressure. Do 0001-0lA
eyes caused by not pour coolaut into beverage coutainers.
scalding from Wear protective gloves, protective clothiug and safety
contact with glasses.
hot coolant
spray. Risk. of
poisoning from
swallowing
coolant.
3 Drain coolant Engiue 112, 113 in models 129, 163, 202, 208, AR20.00-P-
from radia tor 210,215,220 1142HA
Engine 113.963 in models 230.475
Engine 112.960 in model 170.466 AR20.00-P-
1142RVK
Engine 113.992 in model230.474
Mercedes-Benz
1990-2002 ENGINE Complete Engine - TESTING & REPAIR - 129 Chassis

1142SV
4.1 Remove engine Model l29
cover with Type 170.465
integrated air Model 202.033/ 093
filter Model208.370 /374 /470
Model 220
~pe 230.475
Unclip covering on front side of engine. Remove the
engine cover with integrated air fllter from the cylinder
head covers vertically in the upward direction.
4.2 Remove aír Engine 112.960 in model 170.466 AR09.l0-P-
filter Engine 113.992 in model230.474 1150SVK
5.1 Remo ve Engine 112 in model 210, 202, 129 AR20.40-P-
viscous fan Engine 112 in model l63.154/157 5660C
clutch (1) Engine 113 in model210, 208,202, 129
Engine 113 in model 163.172
[g] Right-hand thread!
6.1 Remove heater Model 170.465 with retrofitted stationary heater Thermo AR83.70-P-
unit Top C. 5302NB
7.1 Remove fan Engine 113 in model 215 AR20.40-P-
shroud (3) Engine 112 in model 220 6800AB
Engine 113 in model 220
Engine 113.992 in model 230.474
7.2 Remo ve [g] Model 163 unscrew bolts at bottom of fan shroud.
electric fan Engine 113.965 in model163.175 AR20.40-P-
5000GH
Engine 112.947 in model170.465 AR20.40-P-
5000SV
8 Attach guard
plate for
radiator 1
condenser
& Guard plate for Engines 112,113, 137, 271, 272, 275, 285, 602, 604, 605, WF58.50-P-
radiator 1 606, 611 , 612 , 613 , 628 ~ 648 0110-0lA
condenser
9.1 Remove poly- Engine 113.992 in model230.474 AR13.21 -P-
V-belt for 1202RVK
supercharger
9.2 Remove poly ENGINE 112 in models 129, 163 AR13.22-P-
Mercedes-Benz
V-belt (2) 1202B

Engine 113 in model129, 202, 208, 210
Engine 113 (except 113.965 /981) in model 163
Engine 112 in model202, 208, 210 AR13.22-P-
1202BA
Engine 112 in model220
Engine 113 in model215.373 /375
Engine 113 in models
220.070 /073 /075 /083 /084 /170 / 173 1175 /183 / 184 /875
Engine 113.965 in model 163. 17 5
Engine 113.984 in model208.374 /474
Engine 113.963 in models 230.475 AR13.22-P-
1202R
1202SV
10 Remove Engine 112, 113 air filter located on vehicle side AR01.20-P-
cylinder head 5014B
covers (6) Engine 112, 113 air filter located on engine side AR01.20-P-
5014BV
11 Detach coolant
line (17, 18)
from coolant
pump (12).
12 Detach coolant
line ( 16) at
thermostat
housing (13).
13 Dismount [g] Place to the side with lines connected.
refrígerant ~
compressor *BA83.55-P-
(A9) 1001-01A
14.1 Remo ve Engine 113.963 in models 230.475 AR15.40-P-
alternator (G2} Engine 113.992 in model230.474 5032R
15.1 RemoveATF Model230
líne bracket
(23).
15.2 DetachATF Model163
line from front
axle carrier
16 Remove oil pan Engine 112.942 in modell63.154 AR01.45-P-
bottom section 7555V
(9) Engine 112.970 in mode1163.157
Mercedes-Benz

Engine 113.965 in model 163.17 5 AROL45 -P-
7555VE
Engine 112 in models 210, 208, 202, 170, 129, engine 113 AR01.45-P-
inmode1210, 208,202, 129 7555VA
Engine 112 (except 112.975) in model 220
Engine 112.975 in model220 AROL45-P-
7555IW
Engines 113.948/ 966 in model 220
Engine 113.963 in models 230.475 AROI.45-P-
7555R
17.1 Removeoil Engine 112, 113 in model l63 AR18.10-P-
pump 6020B
18.1 Remove oil pan Engine 112, 113 in model 129 AR01.45-P-
(22) 7500FD
Engine 112.942 in model163.154 AROL45-P-
7500FB
Engine 113.965 in modell63.175
Engine 113.981 inmodell63.174
Engine 112.947 in model 170.465 with transmission 722.6 AROL45-P-
7500SV
Engine 112.960 in model170.466 with transmission 722.6
Engine 112 in model 202, 208 AROL45-P-
7500FC
Engine 113.944 in model202.033 /093
Engine 112 in models 210.06 /26 166 AROL45-P-
7500F
Engine 113 in model 21 O
Engine 112 (except 112.975) in model220 AROL45-P-
75001
Engine 112.975 in model220 AR01.45-P-
7500IW
Engines 113.948/ 966 in model 220
Engine 113.963 in models 230.475 AROL45-P-
7500R
19.1 Remo ve Engine 113.992 in model 230.474 AR13.25 -P-
Mercedes-Benz
tensioning 3217RVK
device for
compressor
poly-V-belt
20 Remove poly- Engine 112 in models 129, 163 AR13.25-P-
V-belt 3200B
tensioning Engine 113 in modell29, 202, 208, 210
device (5) Engine 113 (except 113.965 /981) in model163
[g]Models 129, 202, 210 with manual transmission.
Unscrew damper of belt tensioning device at coolant
pump.
Engine 113.963 in models 230.475 AR13.25-P-
3200R
Engine 113.992 in mode1230.474
21 Remove Engine 112 in models 129, 163 AR03.30-P-
vibration 1600C
damper (4) Engine 113 in mode1s 129, 202.033 /093
Engine 113 (except 113.981) in model 163
Engíne 113 (except 113.980) in model210
Engine 113 (except 113.984) in model208
1600CA
Engine 112 in model202, 208, 210, 220
Engine 113 .981 in model 163.1 74
Engine 113 (except 113.991) in models 215, 220.
1600RVK
22 Remove chain ENGINE 112 in models 129, 163 AROS.lO-P-
tensioner (14) Engine 113 (except 113.965 /981) in mode1163 7800C
Engine 113 in modell29, 202, 208, 210
Engine 112 in modell70, 202, 208, 21O AR05.10-P-
Engine 113 in modell63.174 /175 7800CA
Engíne 112 in mode1 220 AR05 .1 0-P-
Engine 113 in model215.373 /375 7800AM
Engine 113 in models
220.070 /073 /075 /083 /084 /170 / 173 1175 /183 / 184 /875
Engine 113 in model230.474 /475
23.1 Remove oil Engine 113 .992 in model230.474 AR18.20-P-
fi1ter housing 3471RKV
23.2 Remove oíl Engine 112 in models 170, 202, 208, 210, 220 AR18.20-P-
filter housing 3471BA
with oil/water Engine 113 in model 220
heat exchanger Engine 113.963 in models 230.475
(7)
Mercedes-Benz

Engine 113.981 in mode1163.174
Engine 112 in models 129, 163 AR18.20-P-
3471B
Engine 113 in modell29, 202, 208, 210
Engine 113 (except 113.965/981) in mode1163
24.1 Remove oil Modell63
reservorr on [g) Removal: Extract oil from reservoir. Remove circlip.
power steering ¡g] Installation: Replace sealing ring. Check that circlip is
pump (11) correctly seated.
@) Power steering AP46.00-P-
- checking and 4611BB
correcting oil
level .&. DanQerl Hand pump Fig. 113
24.2 Detach power ¡g¡ Do not disconnect lines.
steering pump B *BA46.30-P-
( 11) with oil 1005-0lA
reservo u. B *BA46.30-P-
1010-0lA
~ *BA46.30-P-
1010-01C
25.1 Detach guide Model230.474 *BA13.25-P-
pulley at timing B 1008-01D
case cover
25.2 Take off guide ¡g] Except mode1230.474
pulley (15) at Take plastic cover off guide pulley.
coolant pump ~ *BA20.10-P-
1001-0lC
B *BA20.10-P-
1001-01M
26.1 Remo ve Engine 112.960 in model 170.466 AR09.50-P-
compressor Engine 113.992 in model230.474 4705SVK
27 Remove air Engine 112 (except 112.960) in model170 AR14.30-P-
pump (20) Engine 112 in 163, 202, 208, 210 7251A
Engines 113 in 163, 202, 208, 210
7251AA
Engine 112.944 in model220.065 /1 65
Engine 112.972 in model 220.067 /1 67
Engine 112.975 in model220.087 /187
Engine 113.941 in models 220.070/170
Engine 113.948 in model220.083 /1 83
Engine 113.960 in model220.075/175
Mercedes-Benz
Engine 113.960 in model2 15.375

Engíne 113.963 in models 230.475
Engíne 113.966 in model220.084 /184
7251RVK
28 Separate
electricalline
from coolant
temperature
sensor
29 Unscrew bolts ~ *BA01.40-P-
(2 1) of cylinder 1002-01C
head to timing
case cover on
right and left
30 Remove screws [gJ Installation: Apply sealant to marked bolts, observing *BR00.45-Z-
of the timing the bolt diagram for the timing case cover: ? 1015-01A
case cover Bolt diagram for timíng case cover engíne 112, 113 AR01.40-P-
8000-01B
Bolt diagram for timing case cover engine 113.992, AROL40-P-
8000-01RVK
~ *BA01.40-P-
1001-0lC
~ *BA01.40-P-
1002-01C
31 Take offtiming [gJ lnstallation: The bolt threads for the coolant pump,
case cover the belt tensioning device, and the power steeríng: pump
are not cut into a new timing case cover. F or this reason,
use new self-tapping bolts in combination with a new
timíng case cover for attachíng the coolant pump, the belt
tensíoníng device and the power steering pump. Pay
attention to tightening torque with non-pre-tapped threads.
B *BA13.25-P-
1001-01D
~ *BA13.25-P-
1001-0l.M
B *BA13.25-P-
1005-01D
~ *BA13.25-P-
1006-01D
B *BA13.25-P-
1007-0ID
B *BA20.10-P-
1001-01C
Mercedes-Benz
B *BA20.10-P-
1001-01M
B *BA20.10-P-
1002-01C
B *BA20.10-P-
1002-0lM
B *BA20.10-P-
1003-01C
B *BA20.10-P-
1003-01M
B *BA20.10-P-
1004-0lC
B *BA20.10-P-
1004-01M
B *BA46.30-P-
1010-01A
B *BA46.30-P-
1010-01C
Clean sealing smfaces, apply sealant only to specified *BR00.45-Z-
surfaces in form ofbead with height and width of2.0 mm 1013-0IA
± 0.5 mm. The sealant must be apphed within 10 minutes!
The silicone bead must not be spread!
~ Notes on AH01.40-P-
'
apphcation of 1000-0lB
sealant to ~ Installation: If sealing compound enters the oil ducts,
tirning case this is carried by the oil flow and will clog the oil supply
cover bores.
o Do not damage cylinder head gasket.

o Replace seals on t iming case ( 19).
o Replace front crankshaft radial sealing ring : ?
Engine 112 in modell29 AR03.20-P-
Engine 113 in model 129 3000B
Engine 113 in modell63, 202, 208, 210
Engine 112 in models 170, 202, 208, 210, 220 AR03.20-P-
Engine 113 in model215, 220 3000BA
32 Install in the
reverse order
IJJ Risk of Secure vehicle to prevent it from moving by itself. ASOO.OO-Z-
accident Wear elosed and snug-fitting work clothes. 0005-0IA
caused by Do not grasp hot or rotat ing parts.
vehicle starting
Mercedes-Benz
off by itself
when engine is
running. Risk
of injury
caused by
contusions and
burns during
starting
procedure or
when working
near .the .
runnmg engme
33 Run engine and

inspect for
leaks
34 Inspect cooling First warm up engine to operating temperature.
system for Engine 112 (except 112.947 /960) AR20.00-P-
leaks Engine 113 (except 113.992 /963) l OlOHA
Engine 112 in Model 170 AR20.00-P-
lOlOP
35 Perform basic Model215, 220 AROO. l9-P-
programmmg All exceptmodel215, 220: Code radio and nom1alize 0200M
power window.
Vehicles with stationary heater: adjust time display on
stationary heater.
36.1 Read out fault All except models 215, 220, 230
memory and [gJ Stored faults which can result from cables being
erase disconnected or from simulation during removal and
installation or test work, ha ve to be processed and erased
in the fault memories after completing the work:?
Diagnosis Manual Volume 2 Index 0:
36.2 Read out fault Model220, 230
memorywith
STAR
DIAGNOSIS
and erase if
necessary.
® Connect STAR ADOO.OO-P-
DIAGNOSIS 2000-04A
and read out
fault memory
STAR DIAGNOSIS diagnosis system *WH58.30-Z-
[gJ Stored faults which can result from removal and 1048-13A
installation or test work, have to be processed and erased
Mercedes-Benz
lin the fault memories after completing the work.

~e
m
ran k case, timmg case cover, en d cover
Engine 112 E ngine 113.9871
except 112.9511 Engine 112.9511 988/990/
Number Designation 976 976 991/993
BAOL40-P- Timing case N m 20 20 20
1001-0lC cover to
crankcase
BA01.40-P- Bolt, cylinder N m 20 20 20
1002-0lC head to timing
case cover
~ e ran k case, ti mmg

. case cover, en d cover
Engines
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/9711980/
981/982/984/ Engine 113.987/
Number Designation 986/992/995 988/990/991/993
BA01.40-P-1001- Timing case cover N m 20 20
OIC to crankcase
BA01.40-P-1002- Bolt, cylinder head N m 20 20
~B el t t eDSlOOIDg d eVICe
.
E ngine 112.910/911/91
2/913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/9611970/
N umber Designatiou 972/973/975
BA13.25-P-1001- Self-tappi.ng bolt ofThread not pre- N m 35
OlM belt tensioner to tapped
tilning case cover Thread pre-tapped 1 Nm 25
~ Belt tensionim! device

Mercedes-Benz
E ngine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/ Engine
969/971/980/ 113.990/
981/982/984/ 991/992/
Number Designation 986/987/988 993/995
BA13.25-P- Se1f-tapping bolt Thread not pre- N m 35 35
1001 -01D of belt tensioner tapped
to timing case Thread pre- Nm 25 25
cover tapped
BA 13.25-P- Bolt ofbelt M7x25 N m 35 35
1005-01D tensioner to
timing case cover
BA 13.25-P- Self-tappíng bolt Thread not pre- Nm- 35
1006-01D of compressor tapped
belt tensioner to Thread pre- Nm - 25
timing case cover tapped
BA 13.25-P- Bracket for charge air cooler Nm 7 14
1007-01D water pipes
BA 13.25-P- Bolt of guide M8x78 Nm - 68
1008-01D pulley for
compressor and
major assembly
belts to timing
case cover
~e
m
oo1ant p ump, coolant th er mostat
Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992
Number Designatioo 993/995
B A20.10-P- Self-tappíng Thread not pre- M6 N m 14
1001 -01C screw for tapped
~oo.lant pump to Thread not pre- M8 N m 35
tlmmg case tapped
Mercedes-Benz
Thread pre- M6 N m lO
tapped
Thread pre- M8 N m 25
tapped
BA20.10-P- Belt pulley to coolant pump NmlO
1002-0lC
BA20.10-P- Bolt, coolant thermostat housing M6 N m lO
1oo3-01 e
BA20.10-P- Coolant pump at the timing case M7 NmlO
1004-01C
~e
m
oo1an t·pump, coo ant th ermostat
E ngine 112.910/911/91
2/913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/961/970/
BA20. l0-P- Self-tapping Thread not pre- M6 N m 14
1001 -01M screw for tapped
coolant pump Thread not pre- M8 Nm 35
to tirning case tapped
Thread pre- M6 NmlO
tapped
Thread pre- M8 Nm25
tapped
BA20.10-P- Belt pulley to coolant pump Nm9
1002-0IM
BA20.10-P- Bolt, coolant thermostat M6 Nml 4
1003-0lM housing
BA20.10-P- Coolant pump at the timing M7 Nml4
1004-0I M case
~p ower st eermg pump

Number Designation Model170
BA46.30-P-1 005-0lA Screw, power steering Nm 25
pump to cylinder liner
collar seat or crankcase
~ Power steering pump

1 1
Mercedes-Benz
Models 210.061/063/
065/070/074/08
M o del 1/082/083/261/
208.365/370/ 263/265/270/27
Number Designation 374/465/470 4/281/282/283/ 663
BA46.30-P- Self-tapping Thread not N m 35 35
1010-01A bolt, power pre-tapped
ste~r~g pump Thread pre- Nm20 20
to ttmmg case tapped
m
ower steermg pump
Model
Model 202.026/029/ 129.059/
Number Designation 033/086/089/093 064/068
BA46.30-P- Self-tapping Thread not pre- N m 35 35
1010-01A bolt, power tapped
steering pump Thread pre- Nm20 20
to timing case tapped
~p ower st eermg pump

Model
215.374/ Model 220.083/084/08
Number Designation 375/378/ 379 7/183/184/187
BA46.30-P- Self-tapping Thread not pre- N m 35 35
1010-0lC bolt, power tapped
steering pump Thread pre- Nm20 20
to timing case tapped
m
ower steermg pump
M o deis
220.063/065/
070/073/075/ Model230 Model 230
165/170/173/ 175 without with code
Number Designation without code 487a code 487 487
BA46.30-P- Self-tapping Thread not Nm 35 35 35
1010-0IC bolt, power pre-tapped
steering
pump to Thread pre- Nm20 20 20
timiug case tapped
~ Refrigerant compressor
Engine 112.910/911/ Engine

920/921/940/941, 112.923/943,
113_940/943/944/9RO /9R4 in 113.961 in
Mercedes-Benz
Number Designation model202, 208, 210 model129

BA83.55-P- BoJt, refrigerant Nm 20 20
1001-01A compressor to
bracket
~R
m
err·tgeraut compressor
E ugine 111.977,112.942, Engine
112.970,113.942 1965/981 112.947/960 in
Number Desiguation in model163 model170
BA83.55-P-1001- Bolt, refrigerant N m 20 20
OlA compressor to
bracket
~Rerr·Jgeran t com pressor

Engines
112.922/944 in Engine 113.960 in
Number Designation mode1220 mode1215
BA83.55-P-1001- Bolt, refrigerant Nm 20 20
OlA compres sor to
bracket
~R
m
efr"tgerant compressor
Engine
113.941/960 in Engine 113.963/992/995
Number Designation model220 in model230
BA83.55-P-1001- Bolt, refrigerant N m 20 20
OlA compressor to
bracket
Fig. 113: ldentifying Hand Pump (210 589 00 71 00)
e ommerc1a·uty avail a bl e too s

Number Designation
WH58.30-Z-l 048-13A STAR DIAGNOSIS diagnosis 6511180100
Mercedes-Benz
lteparr ma t ena
. 1s
BR00.45-Z-1013-01A Sealant A 003 989 98 20
BR00.45-Z-1015-01A Sealant A 002 989 71 20
EXAMINING ltEAlt OF ENGINE FOlt SIGNS OF EXTEltNAL OIL LEAKS, DETERMINING-

Alt01.40-P-8913-01AO
m Risk of accídent as a Secure vehicle to prevent ASOO.OO-Z-0005-0lA

result of vehicle starting it starting off. Wear
off when engine running. closed and elose-fitting
Risk of injury as a result work clothes
of bruises and bums if Do not grasp hot or
you insert your hands into rotating parts
engíne when ít is being
started or when ít is
runrung
ltEP.AIR. MATEIDALS
Number Designatioo Order n umber
BR00.45-Z-1001-03A Crack detector A 000 9'89 03 59
l . Remove driven plates together wíth ring gear.

2. Clean rear of engine.
3. Spray dried surrounding area with Mercedes-Benz white contrast spray.
4. Install driven plate.
5. Check oillevel in engine.
~722.3
-
Fig. 114: ldentifying Hexagon Bolts And Starter Lockout Switch
6. Bolt starter (17) to crankcase with Ml0x8 O hexagon bolts (18).

7. Support engine in installation position at rear.
8. Transmíssion 722.3: bridge contacts (arrows) at starter lockout switch (Sl6/3).
Mercedes-Benz
9. Run engine and ínspect for leaks.

10. Read fault memory and erase.
¡gj Stored faults which can result from cables being disconnected or from simulation during test work,
have to be processed and erased in the fault memories after completing the work.
REMOVE/INSTALL THE END COVER- AR01.40-P-8913B
ENGINE 1123.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209, 210, 220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 208, 209, 210, 220, 230.474 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065 /265
ENGINE 113.967 in MODEL 211.070 /270
ENGINE 113.982 in MODEL 463.243 /246
ENGINE 112.917 in MODEL 211.080 /280
ENGINE 112.954 in MODEL 211.082 /282
ENGINE 113.969 in MODEL 211.083 /283
Sbown on engine 112

Mercedes-Benz
Sndcovttr
Fllttlg sle.ves
3 CronlcshiJII tlldl al sed119 ri119
Fig. 115: ldentifying E nd Cover Remove/Install Components - Shown On E ngine 112
~AP rr::r" BT Remove/install

1 Remove flywheel/drive AR03.30-P-8001C
plate
2 Remove the end cover (1). [gJ Pry off end cover ( 1)
carefully at both marked
points with a slanted
screwdriver (see
magnified section).
[g] The crankshaft radial
sealing ring (3) must
always be replaced when
end cover ( 1) is removed.
~ *BA01.40-P-1004-01C
3 Install a new rear [gJ The rear cranksbaft
crankshaft radial seal (3) radial sealing ring (3)
must only be removed
on ce end cover ( 1) has
been removed.
~ Installation :
Circurnference and lip of
the cranksbaft radial
sealing ring (3) as well as
the counter tread on the
crankshaft must be free
of oil and grease, in order
to guarantee a proper
function.
Mercedes-Benz
lnstaU crankshaft radial AR03.20-P-3063-0IB

seal (3)
~oanaer! Fil!. 116
[g] Installation: Pay
attention to fitted sleeves
(2) when pressing on end
cover!
¡g¡' Notes on application of AHO 1.40-P-1000-06A
sealant to end cover with
Sealant *BR00.45-Z-1013-01A
radial shaft seal
4 lnstall in the reverse order
OJ Risk of accident caused Secure vehicle to prevent ASOO.OO-Z-0005-0lA
by vehicle starting off by it from moving by itself
itself when engine is W ear e losed and snug-
caused by contusions and Do not touch hot or
procedure or when [g]
'
working near the engine
as it is running
5 Carry out engine test run [g] Before installing

transmission, inspect for
oilleaks
~ Crankcase timino¡;, case cover end cover

' '
Eogine 112 except
Number Designation 112.951/ 976
BA01.40-P-1004- End cover screw Thread not pre- N m 14
OIC tapped
Thread pre-tapped 10
~e ran k case, f umng

. case cover, end cover
Engine
113.940/941/
942/943/944/
945/946/948/
960/9611962/
963/964/965/
966/967/968/ Engine
969/9711980/ 113.987/
9811982/984/ 988/990/
Number Designation 986/992/995 9911993
BA01.40-P- End cover Thread not Nm - -
1004-0lC screw pretapped
Mercedes-Benz
Thread pre- NmlO

tapped
111 589 oa 43 oo
Fig. 116: ldentifying InstaUation Tool (111 589 08 43 00)
. ls
R epa1r matena
BR00.45-Z-l 013-0 lA Sealant A 003 989 98 20
CHAMFER CYLINDER BORES- AR01.40-P-9201-01A
l. Chamfer off the burr which has accumulated on the cylinder bores after drilling out using a suitable tool
(e.g. hand milling cutter).
¡g¡ Equalize d1e bottom edge of chamfer with a polishing stone.
POUO 0229 O1
Fig. 117: Chamfer Cylinder Bores

Mercedes-Benz
1'01 ~o 02'30 01
Fig. 118: ldentifying Chamfer Angle Of Cylinder Bore
CHAMFERING CYLINDER BORES - AR01.40-P-9201-01AW
Engine 601, 602 except 602.982, 603

Number Designatioo Eogine 601, 602.91196,
603.91/96
BEOL40-P-1006- Chamfer of cylinder bore at crankcase contact
02D
mm 0.6-lx75°
surface

BEO 1.40-P-1 006-02D Chamfer of cylinder bore at crankcase contact surface mm 0.6-lx75°
l. After widening or machining, chamfer cylinder bares with an appropriate tool (e.g., hand milling cutter)
as shown in the drawing.
2. Equalize bottom edge of chamfer with polishing wheel.
Fig. 119: ldentifving Cbamfer Cylinder Bores And Hand Milling Cutter
Mercedes-Benz
Pil 1 t~ - 201lHI1
Fig. 120: Identifving Cbamfer Cvlinder Bores Dimension
3 _ If the cylinder barre! has been machined, additionally debur bottom cylinder runout in the rock are a of the
pístons wíth a fine grindstone.
OD1.11HI95lHl 1
Fig. 121: Identifying Rock Area Of Pistons
MEASURING, BORING AND HONING CYLINDER BORES- AR01.40-P-9201AA
ENGINES 112.910/911 /912 /920 /921 /922 /923 /940 /941 /942 /943 /944 /945 /946 /947 /960 /961 /970
ENGINES 113.940/941 /942 /943 /960/961 /962 /963 /965/968 /981 /982 /990 /991 /992 /993/995
Mercedes-Benz
1, 2. 3 MoasiiÍIIg polnts
A longi tudinal d'reefion
S TrM~S veru dreetifltl
• Upper ret~eTsai pcfnlfor 1stplston
b
rlng
Souom dead contar of plslon •
e Souom reversa/ pol nl of o./1
SC~Mdr(l
•
• ~
1
~ ...---- - ., 2
..
3
Fig. 122: Identifying Measuring Points Of Cylinder Bores
1 Cleau cylinder bores

2 Measure cylinder bore [g] Measure cylinder
bores with an interna}
measuring instrument at 3
measuring points (1 , 2, 3)
in a longin1dinal direction
(A) and transverse
direction (B).
Cylinder diameter *BE01.40-P-100I-01F
Cylinder bore *BE01.40-P-1001-02E
Cylinder length *BE01.40-P-1004-01F
Undercut *BE 01.40-P-1005-01F
~ Internal measuring * WE58.40-Z-1 003-21A
instrument 0 50 to 150
mm,
with 0.01 mm indication
and measuring point
pressure relief
~ Setting micrometer for * WE58.40-Z-1004-21A
interna] measuring
instrument GRM 2125
with setting range 50 to
200mm
3 Set honing machine for Cylinder diameter setting *BE01.40-P-1002-01F
¡pre-honing for repair size (+0.25)
Stroke setting with 70 * BEO 1.40-P-1006-01 F
Mercedes-Benz
mm stone length on 70th

stroke scale of machine
Stone overrun at top and *BE01.40-P-1007-01F
bottom
Engine speed *BE01.40-P-1008-01F
Feed *BE01.40-P-1009-01F
Stroke *BE01.40-P-1010-01F
Display *BE01.40-P-1011-01F
f.ll Automatic cylinder *WE58.40-Z-1002-21A
repair machine
f.ll Set of stones for rough *WH58.30-Z-1031-04A
honing e 30-A 53, or
e30 J64, 70 mm long
4 Cylinder bore pre-honing [g] With full honing oil
feed.
5 Measure cylinder bore [g] Immediately after pre- *BE01.40-P-1003-01F
honing, the measurement
deviates by approx.
+0.02 mm dueto heat
expanswn.
f.ll Interna! measuring *WE58.40-Z-1003-21A
mm, with 0.01 mm
indication and measuring
po int pressure relief
precision honing for repair size (+O .25)
Stroke setting with 70 *BE01.40-P-1006-01F
Stone overrun at top and *BE01.40-P-1007-01F
bottom
Engine speed * BE01.40-P-1008-01F
Feed *BE01.40-P-1009-01F
Stroke *BE01.40-P-1010-01F
f.ll Finish-honing, stone *WH58.30-Z-1 032-04A
set e 30-J 84, 70 mm
long
7 Cylinder bore precision [g] With full honing oíl
honing feed.
8 Measure cylinder bore [g) Immediately after *BE01.40-P-1003-01F
precision honing, an
oversize of approx. +0.01
Mercedes-Benz
mm is obtained because
ofheating.
llJ Internal measuríng *WE58.40-Z-1003-21A
mm, with 0.01 mm
indication and measuring
point pressure relíef
9.1 Chamfer cylinder bore [g] Except engines AR01.40-P-9201-0IA
112.945, 113.962 /982 in
model463 .
polishing for repair size (+0.25)
Stone overrun at top and *BEOI.40-P-1007-0IF
bottom
Feed *BE01.40-P-1009-01F
Stroke *BE01.40-P-I010-01F
llJ Set of stones for 1
:WH58.30-Z-1033-04A
polishing C 30-C 03-81,
70 mm long
11 Polish cylinder bore [gl Polish with fu U honing *BE01.40-P-1003-01F
oil feed up to fmal repair
SlZe.
12 Measure cylinder bore [g] Allow crankcase to
cool down to approx. 20°
C lbefore measuring
Cylinder diameter *BE01.40-P-1001-01F
llJ Interna! measuring * WE58.40-Z-1 003-21A
mm, with 0.01 mm
índication and measuring
point pressure relief
13 Clean cylinder bore and
dry
14 Set honing machine for [gl Set to same diameter
lapping as after polishing (fmal
diameter).
Cylinder diameter *BE01.40-P-1003-01F
according to machining
stage.
Mercedes-Benz

mm felt length on 70th
stroke sea!e of machine
Felt insert overrun at top *BE01.40-P-1013-01F
and bottom
Feed * BE01.40-P-1 009-0lF
Stroke *BE01.40-P-1010-01F
[l] Felt insert C 30-F 85 * WH58.30-Z-1 036-04A
[l] Set of felt insert *WH58.30-Z-1 035-04A
bolders CK3130
[l] Stone holder for felt * WH58.30-Z-l 034-04A
insert CK-30 35
15 Rub-in cylinder bore and [g] Without boning oil
filter insert using honing feed, the cylinder wall
paste must be dry. Only the
specified boning paste
may be used. Only this
one guarantees the
specified final result.
Polmot honing paste
order no. 600.11 * BR00.45-Z-1 050-06A
16 Lap cylinder bore and [g] Without honing oil
expose silicone crystals. feed.
Operating time of honing
machíne *BE01.40-P-1014-01F
17 Coat filter ínsert again [g] Do not coat cylinder
with honing paste bore wíth boning paste.
Polmot honing paste
order no. 600.11 * BR00.45-Z-1 050-06A
18 Lap cylinder bore and [g] Without honing oil
expose silicone crystals. feed, removed material
cannot be measured.
Operating time of honing
machíne *BE01.40-P-1014-01F
19 Clean cylínder bore and ~ Clean crankcase very
dry carefully with honing
paste. If possíble, clean
crankcase in a major
assembly wasbing
machine, so tbat no
cy linder wall damage will
be caused by residues
when running the engine
Mercedes-Benz
later.
20 Inspect cylinder bore [g] Allow crankcase to
cool down to approx. 20°
e before inspecting.
Cylinder diameter of
reparr slZe *BE01.40-P-1001-01F
Check values for craokcase

Eogine 112 except
112.951,
113.940/9411
942/943/944/
945/946/948/
960/961/963/ Eogioe
965/966/9671 113.962/982/
968/980/981/ 987/988/989/
Number Desiguation 984/986/992/ 995 990/991/993
BE01.40-P- Cylinder bore Peak-to-valley mm 0.001 to 0.0045 0.001 to 0.0045
1001-02E height (Rz ) of
top separating
surface
W ear limit at mm < or = 30.03 < or = 0.03
BDCand TDC
of 1st piston ring
Perrnissible mm 0.014 0.007
deviation of
cylinder shape
contact surface J.lll - -
peak-to-valley
height
Ch ee k va ues or cy!lin der b ore

Engine 112.913/920/921/922/
923/940/941/942/943/
Engine 112.910/ 944/945/949
Number Designation 911 113.940/941/942/943/945
BE01.40-P- Cylinder día. Standard mm 83.200 ... 83.215 89.900 ... 89.915
1001-0 1F marking X
Auxiliary mm 83.250 ... 83.265 83.250 ... 83.265
stage
Marking
Repair size mm 90.150 ... 90.165 90.150 .... 90.165
BE01.40-P- Cylinder Pre-honing mm 83.200 89.900
1002-01F dia., setting Precision mm 83.380 90.080
for repair honin{!
Mercedes-Benz
size (+0.25) Polishing mm 83.430 90.130

BE01.40-P- Cylinder dia. Pre-honing mm 83.380 90.080
1003-01F according to Precision mm 83.430 90.130
machining honing
phase Polishing mm 90.150 ... 90.165 90.150 ... 90. 165
BE01.40-P- Cylinder length mm 129.5 129.5
1004-01F
BE01.40-P- Undercut mm 12 12
1005-01F
BE01.40-P- Stroke setting with 70 mm mm 130 130
1006-01F stone length on 70th
stroke sea!e of machine
BE01.40-P- Stone overrun at top and mm 9.5 9.5
1007-0lF bottom
BE01.40-P- Engine Pre-honing rpm 125 125
1008-01F speed Precision rpm 125 125
honing
Polishing rpm 125 125
Lapping rpm 230 230
BE0 1.40-P- Feed Pre-honing 4 4
1009-01F Precision honing 3 3
Polishing 2 2
Lapping 1 1
BE01.40-P- Stroke Pre-honing rpm 57 57
1010-01F Precision rpm 57 57
honing
Polishing rpm 57 57
Lapping rpm 80 80
BE01.40-P- Display Pre-honing % 20 to 30 20 to 30
1011 -01F Precision % 20 to 30 20 to 30
honing
Polishing % 20 to 30 20 to 30
Lapping % 20 to 30 20 to 30
1012-0 1F felt length on 70th stroke
scale of machine
BE01.40-P- Felt insert overrun at top mm 2 to 4 2 to 4
1013-01F and bottom
BE01.40-P- Operating time ofhoning S 40 40
1014-0 1F machíne
Check values for cylinder bore

1 1
Mercedes-Benz
Number Designation Engine 112.951/961 112.970

BEOL40-P- Cylínder día. Standard mm 89.900 ...89.915 97.000 to
1001-01F markingX 97.015
Aux ílíary stage mm 89.950 to 89.965 97.050 to
Marking 97.065
Repair size llilll 90.150 ... 90.165 97.250 to
90.165
BE01.40-P- Cylinder dia., Pre-honing mm - 97.000
1002-01F setting for Precision mm - 97.180
repau stze honing
(+0.25) Polishing mm - 97.230
BE01.40-P- Cylinder dia. Pre-honing mm - 97.180
1003-01F according to Precision mm - 97.230
machining honing
phase Polishíng mm - 97.250 ...
97.265
BE01.40-P- Cylinder length mm - 130.90 to
1004-0lF 131.00
BE01.40-P- Undercut mm - 0.6 ... 1.0
1005-0lF
BE01.40-P- Stroke setting with 70 mm stone mm - 132
1006-0lF length on 70th stroke scale of
machíne
BE01.40-P- Stone overrun at top and bottom mm - 9.5
1007-01F
BE01.40-P- Engine speed Pre-honing rpm - 125
1008-0lF Precision rpm - 125
honing
Polishing rpm - 125
Lapping rpm - 230
BE01.40-P- Feed Pre-honing - 4
1009-01F Precision honíng - 3
Polishíng - 2
Lapping - 1
BE01.40-P- Stroke Pre-honing rpm - 57
1010-01F Precisíon rpm - 57
honing
Polishing rpm - 57
Lapping rpm - 80
BE01.40-P- Display Pre-honing % - 20 to 30
1011-01F Precision % - 20 to 30
honing
Polishíng l% 1- 20 to 30
Mercedes-Benz
1990-2002 ENGINE Complete Engine - TESTING & REPAIR - 129 Chassis
ILapping % - 20 to 30
BE01.40-P- Stroke setting with 70 mm felt mm - 115
1012-01F length on 70th stroke scale of
machine
BE0 1.40-P- Felt insert overrun at top and mm - 2 to 4
1013-01F bottom
BE01.40-P- Operating time of honing S - 70
1014-01 F machín e
Chee k va ues or cyilinder bore

Engine 112.946/947/
Number Designation 948/960 Engine 112.912
BE01.40-P- Cylinder dia. Standard mm 89.900 ... 89.915 83.200 ... 83.215
1001 -01F marking X
Auxiliary mm 89.950 to 83.265 83.250 ... 83.265
stage marking
Repair size mm 90.150 ... 90.165 83.450 to 83.465
BEO 1.40-P- Cylinder dia., Pre-honing mm 89.900 83.200
1002-01F setting for Precision mm 90.080 83.380
reprur slZe honing
(+0.25) Polishing mm 90.130 83.430
BE01.40-P- Cylinder dia. Pre-honing mm 90.080 83.380
1003-0lF according to Precisíon mm 90.130 83.430
machining honing
phase Políshing mm 90.150 ... 90.165 83.450 to 83.465
BE01.40-P- Cylinder length mm 129.5 129.5
1004-0lF
BE01.40-P- Undercut mm 12 12
1005-0lF
1006-01F stone length on 70th stroke
scale of machíne
BE01.40-P- Stone overrun at top and mm 9.5 9.5
1007-01F bottom
BE01.40-P- Engine speed Pre-honing rpm 125 125
1008-0lF Precision rpm 125 125
honing
Polishing rpm 125 125
Lapping rpm 230 230
BE01.40-P- Feed Pre-honing 4 4
1009-0IF Precísíon honíng 3 3
Polishing 2 2
Lapping 1 l.
Mercedes-Benz
BE01.40-P- Stroke Pre-boning lrpm 157 57

1010-01 F Precísion rpm 57 57
honing
Polishing rpm 57 57
Lapping rpm 80 80
BE01.40-P- Display Pre-boning % 20 to 30 20 to 30
1011-01F Precision % 20 to 30 20 to 30
h oning
Polishing % 20 to 30 20 to 30
Lapping % 20 to 30 20 to 30
1012-01F felt length on 70th stroke
scale of machine
BEOL40-P- Fe lt insert overrun at top and mm 2 to 4 2 to 4
1013-01F bottom
BE0 1.40-P- Operating time of honing S 40 40
1014-01F machine
Cb ee k va ues or cyJlinder b ore

E ngine 113.960/961/
962/963/964/
965/967/968/
971/980/981/
982/984/9871
988/989/990/
Number Designation 991/992/993/ 995
BEO 1.40-P-1001- Cylinder dia. Standard marking X mm 97.000 to 97.015
01F Auxiliary stage mm 97.050 to 97.065
Marking
Repair size mm 97.250 to 97.265
BEO 1.40-P- 1002- Cylinder dia. , Pre-honing mm 97.000
01F setting for repair Precisíon hon ing mm 97.180
size (+0.25) Polishing mm 97.230
BEO 1.40-P- 1003- Cylinder dia. Pre-boning mm 97.180
OlF according to Precision honing mm 97.230
machining pbase Polishing mm 97.250 to 97.265
BEO 1.40-P-1 004- Cylinder length mm 129.5
OIF
BEO 1.40-P-1 005- Undercut mm 12
OIF
BEO l. 40-P-1 006- Stroke setting with 70 mm stone lengtb mm 130
OlF on 70th stroke scale of machine
BEO 1.40-P-1007- Stone overrun at top and bottom mm 9.5
Mercedes-Benz
OlF
BE01.40-P-1008- Engine speed Pre-honíng rpm 125
OIF Precision honing rpm 125
Polishing rpm 125
Lapping rpm 230
BEO 1.40-P-1009- Feed Pre-honing 4
01F Precision honing 3
Polishing 2
Lapping 1
BEO 1.40-P-1010- Stroke Pre-honíng rpm 57
01F Precision honing rpm 57
Polishing rpm 57
Lapping rpm 80
BEO 1.40-P-1011- Display Pre-honing % 20 to 30
OlF Precision honing % 20 to 30
Polishing % 20 to 30
Lapping % 20 to 30
BEO 1.40-P-1012- Stroke setting with 70 mm felt length on mm 115
OIF 70th stroke se ale of machine
BEO 1.40-P-1013- Felt insert overrun at top and bottom mm 2 to 4
01F
BEO 1.40-P-1 O14- Operating time of honing machine S 70
OIF
eommercta·uty avat.•able too1s

Number Desiguation
WH58 .30-Z- l 030-04A Honíng head CK-3000 for 76-127 mm dia. CK-
2600,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910
Manchester St. Louis, Mo.63143
WH58.30-Z- l 031 -04A Pre-honing, stone set C 30-A 53, or C30 J64, 70 mm
long,
Filma Hommel Prazision GmbH D-50767 Koln
WH58.30-Z-1032-04A Precision honing, stone set C 30-J 84, 70 mm long,
WH58.30-Z-l 033-04A Polishing, stone set C 30-C 03-81, 70 mm long,
Firma Hommel Prazisíon GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -79 10
Mercedes-Benz

WH58.30-Z-l 034-04A Stone holder for felt insert CK-30 35,
Manchester St Louis, Mo.63143
WH58.30-Z-1035-04A Felt insert holder set CK3130,
Firma Sum1en Products Comp. USA- -7910
WH58.30-Z-l 036-04A Felt insert C 30-F 85,
Firma Homrnel Prazision GmbH D-50767 Koln
work shop eqmpmen t

WE58.40-Z-l 002-21A Automatic cylinder repair machine
WE58.40-Z-1 003-21A Internal measuring device (50 ... 150 mm dia., with
O. O1 mm display and measuring point for pressure
relief)
WE58.40-Z-l 004-21A Adjusting micrometer for internal measuring device
(with adjustment range 50-200 mm)
R epatr ma t ena
. ls
Order
Number Designation number
BROOA5-Z- Polmot honing paste Order no. 600.11 Polmat-
1050-06A Poliertechnik
GmbH
Troggberg 11
38302
Wolfenbuttel
Gennany
MEASURE CYLINDER BORES- AR01.40-P-9202AV
ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
ENGINES 112 /945, 113.962 /982

Mercedes-Benz
1, 2, 3 M8uurlng points ol cybndiY bore

A Lo.ngltud/nal draction
e Transvorsa rirection
E~
a Uppar te versal polnt of 1st pfston
rlng
A
b Bottom ctead centiY of pfsron
e Bottom reversa/ po/nt of o /1
&CfiPIY ring
•
.. •
. . *"""-----, 2
lt
Fig. 123: ldentifying Measuring Points Of Cvlinder Bore
Figure item, etc. Work instructions

..
[g] Cylinder bore Measure diameter of the
cleaned cylinder bores
with an interna!
measuring instrument in
the longitudinal and
transverse directions.
1,2,3 Cylinder bore diameter at Measure
&oanqnr! the measuring points Fig.124
[ll *WH58.30-Z-1001-12A
[ll *WH58.30-Z-1011-12A
Cylinder diameter code *BE01.40-P-1001-01F
letter X
Cylinder diameter code *BE01.40-P-1001-01F
letter
Repair size *BE01.40-P-1001-01F
Check va ues or cyilinder bore

Engines
113.960/961/
962/963/964/
965/967/968/
971/980/981/
982/984/9871
988/989/990/
Number Designation 991/992/993/ 995
Mercedes-Benz
BEO 1.40-P-1 001- Cylinder día. Standard Marking X mml97.000 to 97.015

OlF Auxiliary stage mm97.050 to 97.065
Marking
Repair size mml97.250 to 97.265
Cheek va ues or cy¡linder b ore

Engines
112.913/920/921/922/
923/940/941/942/943/
Engine 112.910/ 944/945/949
Number Designation 911 113.940/941/94 2/943/ 945
BE01.40-P- Cylinder dia. Standard mm 83.200 ... 83.215 89.900 ...89.915
1001-0lF Marking X
Auxiliary mm 83.250 ...83.265 89.950 to 83.265
stage
Marking
Repair size mm 83.450 to 83.465 90.150 ...90.165
001 589 53 21 00
Fig. 124: ldentifying Dial lndicator (001 589 53 21 00)
e ommerc1a·uty ava1.• a ble too1s

Number Designation
WH58.30-Z-l 00 1-12A Quick calipers for interna} measurements
WH58.30-Z-l O11-12A Interna! measuring instrument
OIL PAN BOLT DIAGRAM- AR01.45-P-7500-06F
Upper part of oil pan shown on engine 112 with 4 MATIC

Mercedes-Benz
1 So~ M6 x 20
2 So/1 M6 x 4D
3 So/t M6 x ll$
• So/t 1118 x JO
Fig. 125: ldentifying Oil Pan Bolt Diagram- Upper Part Of Oil Pan Sbown On Engine 112 Witb 4
MATIC
Upper part of oil pan shown on engine 112 without 4 MATIC
1 So/111M x 20
2 So/1 M6 x 4D
J 8o/l M6 x 90
4 So/11118 x JO
Fig. 126: ldentifying Oil Pan Bolt Diagram - Upper Part Of Oil Pan Shown On Engine 112 Witbout 4
MATIC
Upper part of oil pan sbown on engine 113

Mercedes-Benz
1 so• Me x 20
2 Soilllf6 x40
J Sol! Me x eo
4 Sol! MS xJO
POI A 5-025!Hl5
Fig. 127: Identifying Oil Pan BoJt Diagram- Upper Part Of Oil Pan Shown On Engine 113
REMOVING AND INSTALLING OIL PAN- AR01.45-P-7500AO
POU 5·D211·06
Fig. 128: Identifying Oil Pan Remove/Install Components (1 Of 2)

Mercedes-Benz
A Bolto w... hcr 116 x 21

S Bo/t- -hcr/16 x so
81 So/ro WiiShcr 116 " 50 Wlth b rniiDt
e Bo/toW"IItSilcr 1n '<40
0 Bo/t- WiiShcr 111 O )< 40
Fig. 129: ldentifying Oil Pan Remove!Install Components (2 Of 2)
~AP
~ BT
AROl.lO-P-
1 Remove engine
2400AO
2 Remove generator
~
*BA01.45-P-
3 Drain engine oi l into a suitable vessel ¡g] Installation : replace 1003-01A
seals
U nbolt A TF lines of automatic transmission at
4
oil pan
Unclip electric cable of oil pressure sensor (1 O)
5 at bottom part of oil pan ( 18) and detach from
oil pressure sensor
~
¡gj I nstallation : repla.ce *BA01.45-P-
6 U nbolt bottom part of oil pan ( 18)
gasket (19) according to 1006-01A
condition
7 Replace gasket (19) according to condition
8 Remo ve support of oil pump (7)
Unplug connector (2) of oillevel sensor (S43)
at oil pan
*BA01.45-P-
10 Unscrew bolts (arrows) of oil pan on inside ~
1001-0IA
11 Remove dipstick guide tube (3)
¡gj lnstallation : repla.ce
seal (3a)
Mercedes-Benz
12 Remove belt pulley/vibration damper ra03001203420x

13 Remove secondary air injection line (23)
14 Unbolt end cover (22)
*BA01.45-P-
15 Unscrew bolts of oil pan ~ 1001-0lA
~ Installation : replace oil
pan gasket (21).
The rear contact surface
should be aligned to the
transmission before the oil
16 Remove oil pan (20)
pan is bolted tight.
If the oil pan is not aligned
to the transmission, this can
result in noise and vibration
problems.
¡g¡ After engine damage,
dirt may have gathered AR01.45-P-
17 Remove shield in oil pan
behind the shield; it is 7510AO
essential to remove any dirt.
Secure vehicle to prevent it
Risk of accident as a result of ve hiele starting
starting off.
offwhen engine running. Risk of injury as a
m result ofbruises and burns ifyou insert your
W ear elo sed and elose-
fitting work clothes.
ASOO.OO-Z-0005-
OlA
hands into engine when it is being started or
Do not grasp hot or rotating
when it ís running.
parts.
19 Run engine and inspect for leaks
~OILPAN
M6 Nm 10
BA01.45-P-l001-01A Bolt of oíl pan to crank:case M8 Nm 21
MIO N m 40
M12 N m 40
BAO 1.45-P-1 003-0 lA Oil drain p1ug to oil pan
Ml4 Nm -
BA01.45-P-1006-01A Bolt ofbottom part of oil pan to oil pan 1 Nm9
REMOVE/INSTALL OIL PAN- AR01.45-P-7500FD
ENGINE 112, 113 in MODEL 129

Mercedes-Benz
:=t
3
P01.45·2011·Cll
Englno e omp• rtmcnt 1/nln¡¡ Sc;rcws

Vlsc:ous f•n 10 Rislhf on¡¡ino mounr
l F on thro ud 11 Loft cng!no mo unr
4 A lrfHtcr 12 Solt
5 Hor fllmm~s• lrfl owscnsor 13 Shl ol d
A lrln~Kcplpc 14 Top p •rt of oMpan
ON p1n bottom sectiDn 840 OfiiOVCI S CllSOI
OH pipe
Fig. 130: ldentifying Oil Pan Remove/Install Components
~AP
[$"BT
Remove/install
Risk of explosion caused by

oxyhydrogen gas. Risk of
poisoniog aod caustic burns No fire, sparks, open flames or smoking. Wear
caused by swallowing battery acid. acid-resistant gloves, clothing and safety AS54.10-Z-
OJ Risk of injury caused by burns to glasses. Only pour battery acid ínto suitable 0001-0lA
skín and eyes from battery acid or and appropriately marked contaíners.
when handling damaged lead-acid
batteries
AR54.10-
1 Disconnect battery ground cable
P-0003A
AB54.10-
~' Notes on battery All models P-0001-
OlA
Remove engine compartment AR61.20-
2
covering (1) P-llOSAB
*BA01.45-
3 Drain and collect engine oil ~ P-1003-0lB
*BF18.00-
0 P-1001-
OlH
Mercedes-Benz
4 Remove air filter (4).

[gJ Remove air filter by lifting vertically up
and off the cylinder head covers.
AR20.40-
5 Remove viscous fan (2) ¡g¡ Right-l1and thread! P-5660C
[g] OnJy for engine 112
On vehides fitted with suction fan, first of all
6 Remove fan shroud (3)
separate the plug connection of the suction
fan.
Remove hot film mass air flow
AR07.07-
7 sensor (5) together with air intake
P-1454AG
pipe (6)
Take offbracket of ATF lines at
8 bottom part of oil pan (7) and at top
part of oil pan (14)
Detach ATF lines on right and left
[gJ Only w ith engine 113
9 Collect ATF, place ATF lines to the side and
at transmiss ion bell
seal connections !
& oanQerl Fig. 40
AR01.45-
10 Remo ve oil pan bottom section (7)
P-7555VA
*BA01.45-
~ P-1002-0l B
*BR00.45-
Z-1013-
OlA
Separate electric cab le at oil level
11
sensor (B40)
Unscrew bolts (9) offront engine *BA22.10-
12
mounts (1 O, 11) at front axle carrier
~ P-1001-0lL
¡g¡'
Unscrew one bolt at cylinder head cover!
13 Remove oil pipe (8) from dipstick
Remove cable strap at oil p ipe (8).
Installation : Install new sealing ring.
*BA01.20-
~
P-1001-0lE
14 Put on engine support bracket
~ Ensure that the engine and the attached
15 Raise engine parts do uot touch the body!
Do not over-tensíon coolant lines!
Unscrew bolts (12) of engine mount *BA22.10-
16 ~ P-1004-0lL
( ll) at engine support
lnstallation :
~
'
Mercedes-Benz
o The anti-twist lock (arrow) at the engine

mount (11) must fit in the retaining
Remove engine mount ( 11) groove (arrow) ofthe engine support.
17
together with shield (13) o The notch in the shield (13) must fit in
the anti-twist lock ofthe engine mount
(11 ).
Take out oil pan to the front in direction of
travel for this step; rotate crankshaft slightly, if
necessary.
18 Remove oil pan top section( 14) [gJ Installation :
o Pay attention to different lengths and

diameters ofbolts!?
AR01.45-
Screw diagrarn of oil pan
P-7500-06F
*BA01.45-
~ P-1001-0lB
o Clean sealing surfaces. Apply sealant to
the sealant surfaces with a bead of2.0 *BR00.45-
mm ± 0.5 mm. The sealant must be Z-1013-
applied within 1Ominutes! The silicone OlA
bead must not be spread! ?
..
[g] Notes on application of sealant to AH01.45-P-
Engine 112
oil pan 0001-01C
AH01.45-
Engine 113 .940/943/944/9611980/984 P-0001-
OID
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving by
running. Risk ofinjury caused by itself. ASOO.OO-Z-
DJ contusions and bums during Wear closed and snug-fitting work clothes. 0005-0lA
starting procedure or when working Do not grasp hot or rotating parts.
near the running engine
Check oillevel in automatic
AR27.00-
20 transmission and correct if [gJ Only with engine 113. P-OlO lA
necessary.
Stored faults which can result from cables
being disconnected or from simulation during
removal and installation or test work, have to
21 Read out fault memory and erase be processed and erased in the fault memories
after completing the work: ?
Diagnosis Manual Volume 2 Index 0:
22 Run engine and inspect for leaks
Mercedes-Benz
B CRANKCASE VENTILATION, CYLINDER HEAD COVER

112.910/911/912/913/914/915/916/917/920/921/922/923/940/941/942/943/944/945/946¡
Screw
BA01.20- of
P-1001- cylinder Nm 8
OlE head
cover
BOILPAN
112.910/911/912/913/914/915/917/920/921/922/923/940/941/942/943/944/9·
BA01.45- Bolt, oil M6 Nm9
P-1001- pan to
OlB crankcase M8 Nm
Thread
Self- not N m 14
BA01.45- tapping pretapped
P-1002- screw of
OlB oil pan to Thread
oil pan pre- Nm
tapped
BA01.45- Oil drain
P-1003- screw to Ml4 Nm 30
OlB oil pan
BA01.45- Oil pan bottom
P- 1004- section bolt at oil Nm-
OlB pan upper section
B ENGINE MOUNTS, ENGINE SUPPORTS

Number Designation Engine 112.923/943, 113.961 in model
129.059/064/068
BA22.10-P-1001- Bolt, front engine mounts to front
N m 25
OlL axle carrier
BA22.10-P-1 004- Bolt of front engine mount to
N m 55
011 engine support
0 ENGINE LUBRICATION
Number Designation Engine 112 Engine
e:xcept 113.940/941/942/943/960/961/962/969/982
112.916/953/975
Filling capacity L"t
.th . fil 1 ers 8.0 8.0
WI 011 1 ter
Filling capacity Liters 7.5-

without oi 1
Mercedes-Benz
fi lter
. BB00.40-P-0229-
Ltters OlA BB00.40-P-0229-01A
BFI8.00-
P-1001- Engine Specifications BB00.40-P-0229-
0 lH oil for Operating Sheet 03A BB00.40-P-0229-03A
Fluids
Sheet : : :0·40-P-0229- BB00.40-P-0229-05A
Fig. 131: ldentifying External Torx Set (001 589 76 09 00)
, _ _ ,_29_s_e9_oo_9_1o_o_ _,../
891 Of ~O J) J)IU~ 9
Fig. 132: ldentifying Set Of Stop Plugs (129 589 00 91 00)
REPAIR MATERIALS
BROO .45-Z-10 13-0 lA Sealant A 003 989 98 20
REMOVING AND INSTALLING SHIELD IN OIL PAN- AR01.45-P-7510AO
ENGINE 120
Mercedes-Benz
PllU5~295·1 1
Fig. 133: Identifying Shield In Oil Pan Remove/Install Components
~AP Removing,
~BT installing
AR01.45-P-
1 Remove oil pan Model 129
7500AO
AR01.45-P-
Model140
7500AP
Remove oil pan
2 [g] Unscrew self-tapping bolts (20) for thís step
shield (14, 17)
~ After engine damage, dirt may have gathered
3 Clean oil pan
behind the shields. It is essentíal to remove thís dirt.
Install in the reverse
4
order
REMOVE/INSTALL BOTTOM PART OF OIL PAN- AR01.45-P-7555VA
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODELS 129, 170, 202, 208, 210
ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODELS 129, 202, 208, 210
ENGINE 113.982 in MODELS 463.243 /246
ENGINE 112 (except 112.975) in MODEL 220
ENGINE 1131 (except 113.966 /948) in MODEL 220

Mercedes-Benz
ENGINE 113.993 in MODELS 463.270 /271
1 O M~ l>ofl'om scctlon
Fig. 134: ldentifying Bottom Part Of Oil Pan
~AP IJ:3" BT Remove/instaU

[JJ Risk of death Alígn vehícle between the columns ofthe ASOO.OO-Z-0010-
caused by vebicle lifting platform and position the four mA
slipping or toppling support plates at the lifting platform support
off the lifting points specified by the vehícle
platform. manufacturer.
1 Lift/jack up vehicle All except model 463.
Model 463. only AROO. 60-P-1OOOG
2.1 Remove engine All except model463, 220, 170 AR61.20-P-
compartment 1105AB
paneling
Model220 AR61.20-P-1105M
Model170 AR6 1.20-P- 1105A
2.2 Remove underride [gJ Only model463 except 463.246/271.
guard
Model 463.246 wíth engine 113.982 AR88.30-P-
OOlOMG
On model463_271 with AMG underride AR88.30-P-
guard in stainless steel. OOIOMG
3 Drain andl collect [gJ lnstaUation: Replace sealing ring of the
engíne oíl oil drain screw.
~ *BA01.45-P-1003-
~
CD *BFIS.OO-P-1001-
Mercedes-Benz
OIH
4 Detach bracket of
automatic oillines
at oil pan bottom
section ( 1)
5 Remove oil pan [gJ Installation : Observe application of
bottom section ( 1) sealing compound to oil pan bottom
section:?
[gJ' Notes on Engine 112 AH01.45-P-0001-
application of OlC
sealant to oil pan
Engines 113.940/943/944/961/980/984 AH01.45-P-0001-
!m
Engines 113.941/942/960/962/9811982/993 AHO 1.45-P-000 1-
OlE
~ *BA01.45-P-1002-
&U!
Sealant *BR00.45-Z-1013-
OlA
6 lnstall in the
reverse order
pan1
Number Designation Engines Engines Engines

112.910/9111 113.940/941/ 113.987/
912/913/914/ 942/943/944/ 988/991
9 15/917/920/ 945/946/960/
9211922/923/ 961/962/963/
940/9411942/ 965/967/968/
943/944/945/ 969/980/9811
946/947/949/ 982/984/986/
951/954/955/ 992/995
960/961/970/
97 2/973/976
BA01.45-P- Self-tapping Thread not N m 14 14 -
1002-0IB screw, oil pre-tapped
pan to oil Thread pre- NmlO 10 10
pan tapped
BA01.45-P- Oil drain M14 N m 30 30 30
1003-0IB screw to oil
pan
Engine 112 E ngines E ngines 113.944/

excep t 113.940/941/942/943/960/ 944/980981/984 /984/
Mercedes-Benz
112.916/9S3/975 961/962/969/ 982 986/991

BFI8.00- Engine F illing Liters 8.0 8.0 7.5
P- 1001- oil capacity with
OlH oil filter
F ílling Líters 7.5 - -
capacity
without oil
filter
Specifications Sheet BB00.40-P- BB00.40-P-0229-01A -
for Operating 0229-0lA
Fluids Sheet BB00.40-P- BB00.40-P-0229-03A -
0229-03A
Sheet BB00.40-P- BB00.40-P-0229-0SA BB00.40-P-0229-
0229-0SA OSA
0E ngme
. lb.
u nca t"100
113.987/988/
990/992/993/ 99S
BF18.00-P-1001- Engine oil Filling capacity with Liters 8.5
01H oil filter
Filling capacity Liters 8.0
without oil filter
Specifications for Sheet -
Operating Fluids Sheet -
Sheet BB00.40-P-0229-
OSA
R epa1r matena
. 1s
BR00.45-Z-1013-01 A Sealant A 003 989 98 20
Mercedes-Benz
2001-2003 ENGINE COOLING Cooling Fans- 129,208 & 210 Chassis
2001-2003 ENGINE COOLING
Cooling Fans -129, 208 & 210 Chassis
MODEL IDENTIFICATION
NOTE: The following table identifies applicable models covered in this article.
MODEL IDENTIFICATION
Model (Year) Chassis Number Engine N umber
CLK 430 Coupe (2001-02) 208.370 113.943
CLK 430 Cabriolet (2001 -03) 208.470 113.943
CLK 55 AMG Coupe (2002) 208.374 113.984
E320 Sedan (2001-02) 210.065 112.941
E320 Sedan 4MATIC (2001-02) 210.082 112.941
E320 Wagon (2001 -03) 210.265 112.941
E320 Wagon 4MATIC (2001 -03) 210.282 112.941
E430 Sedan 4MATIC (200 1-02) 210.070 113.940
E430 Sedan (200 1-02) 210.270 113.940
E55 AMG Sedan 4MATIC (2001-02) 210.074 113.980
SL500 (2001-02) 129.068 113.961
DESCRIPTION & OPERATION

Thermal viscous fan drive a is coupling used to connect the fan blades to the water pump shaft through a union
nut. Union nut is right hand threaded. Viscous fan coupling allows fan to be driven in a normal manner. This is
done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher
engine speeds. Until additional engine cooling is necessary fan will remain ata reduced RPM regardless of
engine speed.
When sufficient heat is present, will the viscous fan drive engage. Air flow through the radiator core causes
viscous fan drive to lock-up which increases fan speed províding additional engine cooling. Once the engine has
cooled, the coolant temperature will drop. Viscous fan drive again reacts and fan speed is reduced to disengaged
speed.
DRAIN, FILL & BLEEDING COOLING SYSTEM
CAUTION: Risk of injury to skin and eyes from scalding from hot coolant. DO NOT
open cooling system until coolant temperature has dropped below 193°F
(90°C). Wear protective clothing and eye protection.
NOTE: During procedure number(s) and letter(s) in parentheses correspond to number

(s) and letter(s) inside the illustration(s).
Mercedes-Benz
2001-2003 ENGINE COOLING Cooling Fans - 129, 208 & 210 Chassis
DRAINING & FILLING COOLING SYSTEM
L Open cooling system cap (2) on coolant expansion reservoir (1). Remove radiator cap as follows :
• Cap with detent: 'furn cap carefully as far as the frrst detent, release the pressure, then unscrew cap.
• For 2-stage and 1-stage caps: Give cap a halfturn anti-clockwise, release pressure, remove cap.
2. Remove lower engine compartment paneling. See Fig. 1 -Fig. 3 _
3_ Drain coolant See Fig. 4 _Observe local regulations on the disposal of coolant
4. Replace coolant, bleed the cooling system Let the engine nm. Set the heater to full heat output See
BLEEDING COOLANT SYSTEM _
G00317434
Fig. 1: ldentifying Lower Engine Compartment Paneling (Chassis 129)

Courtesy ofMERCEDES-BENZ OF NORTH AMERICA.
Mercedes-Benz
2001-2003 ENGINE COOLING Cooling Fans- 129, 208 & 210 Chassis
1
•
1
f
1
G00317433
Fig. 2: ldentifying Lower Engine Compartment Paneling (Chassis 208)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Mercedes-Benz
G00317432
Fig. 3: ldentifying Lower Front Engine Compartment Paneling (Chassis 210)

Mercedes-Benz
Shown on Model 202

1 Coolant expanslon reservoir 3a Drain hose (lnslde diameter 12 mm)
2 Cooling system cap 4 Crankcase drain plug
3 Radiator drain plug 4a Draln hose (lnside diameter 14 mm)
G00317431
Fig. 4: Draining & Filling Coolant System (Chassis 202 shown, 129, 208 & 210 Similar)
BLEEDING COOLANT SYSTEM
NOTE: Vehicle manufacturer does not provide bleeding procedure.
Observe coolant level on chassisl29, 208 and 210 with engine 112,113. When the coolant is cold, the level must
reach the "MIN" marker on the coolant expansion reservoir (arrow) and when the coolant is warm, the level
must be approximately I cm over the "MIN" marker. See Fi~. 5 , Fig. 6 or Fig. 7.
Mercedes-Benz
G00317437
Fig. 5: ldentifying "MIN" Mark On Coolant Reservoir (Chassis 129)

Mercedes-Benz
G00317436
Fig. 6: ldentifying "MIN" Mark On Coolant Reservoir (Chassis 208)

Mercedes-Benz
G00317435
Fig. 7: l dentifying "MIN" Mark On Coolant Reservoir (Chassis 210)

Cour tesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING
NOTE: Manufacturer does not supply information at this time.
TROUBLE SHOOTING
AUXILIARY FANS
Disconnect hamess plug connectors from auxiliary fans. Spin fan wheel by hand several times and check for
imbalance or grinding noises, if imbalance or grinding noise is found, replace cooling fan motor. See
Mercedes-Benz
AUXILIARY FANS ASSEMBLY under REMO VAL & INSTALLATION.
AUXILIARY FAN DOES NOT RUN
Possible causes of auxiliary fans uot running include, faulty fan motor, fan relay, PCM, engíne coolant
temperature sensor, A/C pressure transducer, fuse or wiring faults. Test and repaír auxiliary cooling fan circuits
according to wiring diagrams. See WIRING DIAGRAMS .
VISCOUS F AN CLUTCH
Spin fan by hand several times and check for imbalance or grinding noises. On a cool engine fan should not
bind orbe locked up. Ifany ofthese symptoms exist, replace viscous fan clutch. See COOLING FAN &
VISCOUS FAN CLUTCH under REMOVAL & INSTALLATION.
REMOVAL & INSTALLATION

AUXILIARY FANS ASSEMBLY

Removal & Installation (129.068 Chassis)
l. Drain coolant. See DRAIN, FILL & BLEEDING COOLING SYSTEM .

2. Remove radiator with condenser. See RADIATOR.
3. Press out 6 clips ( 1), remove box frame. See Fig. 8
4. Disconnect harness plug connectors (M4xl & M4x2).
5. Loosen clamps (arrows)
6. Remove auxiliary fan assembly from condenser, remove 3 bolts (2).
7. Remove retainer, 2 bolts each (5).
8. Install fans ín reverse order. Test functions of auxiliary fans (direction of rotation) before completion of
installation of radiator. Fill and bleed coolíng system. See DRAIN, FILL & BLEEDING COOLING
SYSTEM.
Mercedes-Benz
G00017<130
Fig. 8: Removal & Installation Of Auxiliary Cooling Fans (Cbassis 120.068)

Removal & Tnstallation (208 Chassis)
NOTE: Vehicle manufacturer does not provide information on auxiliary cooling fan(s)
removal and installation.
Removal & Installation {210 Chassis)
l. Tum 2 plastic clips (2) 90 degrees and remove grill (1 ). See Fig. 9 .
2. Unclíp cover (5) and remove cover.
3. Disconnect auxiliary fan hamess connector (X64/4).
4. Pull off clips (6).
5. Remove fasteners (4) and remove radiator cross member.
6. Place hood pull cable torear out ofway.
7. Unclip hamess wire (9) on cross member, remove fastener (8) and hang brace (7) with hom to side.
Mercedes-Benz
8. Remove 2 fasteners (11) from auxilíary fan assembly.

9. Unclip 6 plastic clips (arrows) and remove auxiliary fan assembly shroud (1 0). See Fig. 1O .
10. Remove poly V-belt (13) from fan motor M4.
11. Remove 3 fasteners (12) and remove fan motor M4 fan assembly.
12. Installatíon ís reverse of removal procedure.
Grille
2 Plastic clips 7 Brace
3 Radiator cross member 8 Screw
4 Screw 9 Horn wire
5 Cover M4 Auxiliary fan
6 Clips X64/4 Auxiliary fan connector
000317439
Fi~.
9: Removal & Installation Of Auxiliarv Fan Assembly
Mercedes-Benz
2001 -2003 ENGINE COOLI NG Cooling Fans - 129, 208 & 210 Chassis
1O Auxiliary fan shroud 13 Poly-V-belt

11 Screw 14 Support element
12 Screw M4 Auxiliary tan
G00317440
Fig. 10: RemovaJ & InstaJiation Of Auxiliarv Fan Motor

Courtesy of MERCEDE S-BENZ OF NORTH AMERICA.
COOLING FAN & VISCOUS F AN CLUTCH
CAUTION: lf the viscous tan drive is replaced because of mechanical damage, the
cooling tan blades should also be inspected. lnspect for fatigue cracks,
loose blades, or loose rivets (if equipped) that could have resulted from
excessive vibration. Replace tan blade assembly if any of these conditions
are found. Also inspect water pump bearing and shaft assembly for any
related damage due to a viscous tan drive malfunction.

NOTE: For special tool identification, see SPECIAL TOOLS .
Removal
l . Position counter-hold tool (1) agaínst hexagon bolts of the water pump belt pulley (2). See Fig. 11 .
NOTE : Union nut has right hand thr eads.
2. Counter-hold and loosen union nut at viscous fan (3).

3. Unbolt fan from viscous clutch.
Mercedes-Benz
1 ~ Counterholder
2 Belt puf/ey
3 Viscous tan
4 Torque wrench
5 ~ Open-end wrench bit
G0031742.4
Fig. 11: Removal & Installation OfViscous Fan Clutch

Installation
l_ InstaU in reverse arder, instaU fan onto viscous clutch. Tighten fan to viscous clutch. See TORQUE
SPECIFICATIONS _
2. Use a torque wrench with an open-end wrench bit (5). See Fig. 11 _Tighten union nut to viscous clutch.
See TORQUE SPECIFICATIONS _
RADIATOR

Removal (Chassis 129)
l. Drain radiator coolant See DRAIN, FILL & BLEEDING COOLING SYSTEM _
Mercedes-Benz
2. Remove viscous fan (1). See COOLING FAN & VISCOUS FAN CLUTCH _
3. Remove fan shroud (2). See Fig. 12 .
4. Discharge (recycle) air conditioning system. See appropriateA/C-HEATER SYSTEMS- AUTOMATIC
article in CLIMATE CONTROL.
5. Remove cable strap.
6. Remove radiator cover (3).
7_ Remove horns (place to the side).
8. Disconnect hamess plug connector (M4x1) from fans.
9_ Disconnect coolant lines (4, 5)
10_ Disconnect coolant lines (6, 7)
11. Remove ATF lines (8, 9). See Fig. 12 . Seal off open connections. See SPECIAL TOOLS .
12. Remove bracket (lO) of ATF line (8) at radiator (11).
13. Remo ve clarnps ( 12).
14. Remo ve condenser with radiator ( 11).
15_ Remove auxiliary fans. See AUXILIARY FANS ASSEMBLY _
Shown on Model 210 wilh M112 wílhout 4-Matic

1 Vlscous fan 9 Clamps tor fan shroud
2 Fan shroud 1o Radiat<>r crossmember
3 Alr cleaner ínlet pipe 11 Coolant line (radiator lhermostat housing)
4 Protectíve grílle 12 Coolant line (radiator. coolant pump)
5 Bracket for ATF fine 13 Coolant fine (expansion reservoir radial.or)
6, 7 ATF Une 14 Coolant line (expansíon reservoir radiator)
8 Radiator 15 Radiator clamps
Gom17438
Fig. 12: Identifying Radiator Related Components (Chassis 129)

Mercedes-Benz
[nstallation
Installation is reverse of remo val procedure. Fill cooling system, check the coohng system for leaks. See
DRAIN, FILL & BLEEDING COOLING SYSTEM . Do not grasp hot or rotating parts. Check the oillevel
in the automatic transmission and correct if necessary. Recharge air conditioning system.
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Line-To-Condenser 21-27 (29-37)
A utomatic Transmission Line-T o-Radiator 15 (20)
Banjo Bolt 22 (30)
Viscous Clutch-To-Bearing Body 33 (45)
Hose Line-To-Condenser 11-13 (15- 18)
TNCHlbs.
Fan-To-Viscous Clutch 88 (10)
Hose Clamp (Coolant Roses) 26 (3)
SPECIAL TOOLS
113 589 00 01 00 113 589 00 40 00

Open-End Wrench Bit Counterholder
G00317425
Fig. 13: ldentifving Tools Reguired to Remove & lnstall Viscous Fan Clutch
Mercedes-Benz
04
03
01
~06 07 08
129 589 00 91 00
Set of plugs
G00317442
F ii:. 14: ldentifyini: Tools Used To Seal Open Fluid Lines

WIRING DIAGRAMS
NOTE: See COOLING FANS in appropriate SYSTEMS WIRING DIAGRAMS article in

ELECTRICAL.
Mercedes-Benz
1990-2000 ENGINES Engine Cooling Specifications- All Models
1990-2000 ENGINES
Engine Cooling Specifications - All Models
IDENTIFICATION
NOTE: To identify Mercedes-Benz model, chassis and engine codes, see MERCEDES-
BENZ MODEL IDENTIFICATION .
SPECIFICATIONS
ENGINE SERIES 104
Models 124 & 202
Designation Engine 104.941 Engines

in model202 104.9421
980/992 in
model124
Cooling system Fllling quantities, total without air LHers. 10.0 9.0
condHioning
with air Liters 10.5 9.5

conditioning
Filling quantities, corrosion without air LHers 5.0 4.5

protection/anti-freeze agent condHioning
down lo -37•c witllalr Uters 5.25 4.75
condltionlng
Fllllng quantities, corrosion wahoutair Liters 5.5 5.0
protection/anti-freez.e agent conditioning
down to -45•c withair L.~ers 5.75 5.25
conditioning
G00040200
Fig. 1: Engine 104 In Models 124 & 202- Specifications

Models 129 & 140

Mercedes-Benz
Designation Engines Engines

104.943/ 104.944/
9811991 in 990/994 in
model129 model140
Cooling system Filllng quantlties, total without arr Lfters 11.5 14.5
conditionlng
wfthair Liters 11.5 14.5

conditlonlng
Filling quantities, corrosion without air Llters 5.75 7.25
protection/antl-freeze agent conditioning
down to -37•c w"hair Liters 5.75 7.25
cond~ioning
Filling quantitles, corrosion without air Liters 6.25 8.0

protection/anti-freeze agent conditionrng
down to -45•c withair Liters 6.25 8.0
condltioning
G00040201

Models 210 & 463
Designation Engines Engine 104.996

104.945/ in model463
9951n model
210
Cooling system Filling quantities, total wrthootair Lite!"$ 8.0 11 .8

condltooning
withair Uters 8.0 11.8

conditioning
Filling quantitíes. corrosion without air Lite<s 4.0 5.9
protection/anti-freeze agent conditioning
down to -37"C wlth air Lite<s 4.0 5.9
conditioning
Filling quantities. corrosion withoutair Liters 4.5 6.5
protection/anti-freeze agent conditioning
down to -45•c withair Liters 4.5 6.5
conditionlng
G00040210

ENGINE SERIES 111
Models 202, 124, 210, 208, & 170

Mercedes-Benz
D&slgnation Engine Engine

111.920/9211941 /9441 111.943/9581
9451961 /9741975 9731983
In model 202, In model 170
111.940/960
in model124,
111.9421947/970
in model 210,
111.944/9451975
in model 208,
111.946 In model170
Cooling system Total capacity wlthoutAC liter 8.0 8.5

withAC liler 8.5 9.0
Capacity of anlicorrosion/ without AC líter 4.0 4.25
antifreeze agent down to -
37 ·e
with AC '"er 4.25 4.5
Capaeity of anticorrosion/ withoutAC l~er 4.5 4.7

antifreeze agent down to - with AC líter 4.75 5.0
45 •c
G00040214
Fig. 4: Engine 111 In Models 202, 124, 210, 208 & 170- Specifications
Models 203 & 163
Deslgnation Engine Engine 111.977

111 .951/955/981 in model 163
in model203
Cooling system Total capacity withoutAC líter .. a.5 -10.5

withAC liter - 8.5 - 10.5
Capacity of anticorrosion/ withoutAC l~er -4.25 - 5.25
antifreeze agent down to - with AC llter • 4.25 - 5.25
37 •e
Capacity of anlicorrosion/ withou!AC liter • 4.75 ... 5.75
antifreeze agent down to - with AC l~er • 4.75 .. 5.75
45•c
G00040Z15

ENGINE SERIES 112 & 113
Models 170, 202, 208, & 210

Mercedes-Benz
Designation Engine 112 Engines Engine

in model170 112.910 /920 112.911 /921 /941
in model 202, in model210
112.940
in model208
Cooling system Total capacity lilers "'8 ~ 9.5 - 10.0

Capacity or
anUcorrosiontanlifreeze agenl liters
down lo -37 ·e •4 - 4.75 • 5.o
Capacity of
anticorrosion/antífreeze agent lfters
down to -45 ·e -4.5 • 5.25 - 5.5
600040216
Fig. 6: Engine 112 In Models. 170,202, 208 & 210- Specifications

Models 203, 220, 129, & 463
Designation Englne Engine Engines

112.912/946 112.922/944 112.923/943
in model203 in model220 in model 129,
112.945
in model463
Cooling system Total capacity lilers "' 10.5 "' 10.5 "' 11.75
Capacity of
anticorrosion/antífreeze agent líters
down to -37 ·e - 5.25 - 5.0 - 6.0
Capacity of
antlcorrosion/antífreeze agent liters
down lo -45 ·e • 5.75 - 5.5 - 6.5
600040217
Fig. 7 : Ent:ine 112 In Models 203, 220, 129 & 463- Specifications
Models 163,210,208, 202, 215, 220, &163

Mercedes-Benz
Designation Englnes Engine Englne

112.942 113.941/960 113.942/981
in model163, in models 215, In model163
113.9401980 220
In model210,
113.9431984
in model 208,
113.944
In model202
eootlng system Total capacíty liters • 11.0 - 11 .5 - 11 .5

eapacíty of
anticorrosion/antifreeze agent líters
down to -37 •e - 5.5 - 5.75 • 5.75
eapacityof
anticorrosion/antlfreeze agent l~ers
down to -45 •e - 6.0 - 6.25 - 6.25
G00040218
Fig. 8: Engine 112/113 In Models 163, 210, 208, 202,215, 220 & 163- Specifications
Models 129 & 463
Designation Engine 113.961 Engine 113.962

in model129 in model463
Cooling system Total capacíty liters - 12.75 "' 11.9

Capacity of
antlcorrosion/antífreeze agent liters
down to -37 oc - 6.25 - 5.95
Capacity of
anticorrosion/antifreeze agent liters
down to -45 oc -7.0 ... 6.55
G00040219

ENGINE SERIES 119
Models 129 & 140

Mercedes-Benz
1990-2000 ENGINES Engine Co oling Specifications - All Models
Oesignation Engines Engines

119.960/ 119.970/
9721982 in 971 /980/981 in
model129 model140
Coollng system Filling quantilies, total without aír Lilers 15 16.5

condítloning
wíthaír Lilers 15.5 16.5

conditloning
Fililng quanlities, corrosion withoutalr Líters 7.5 8.25
protectlon/anti-freeze agent conditionlng
down lo -37•c withair Liters 7.75 8.25
conditioning
Filiing quantities. corrosion withoutair Liters 8.25 9.0
protection/anti-fre~ze agent conditioning
down to -45•c withair Lfters 8.5 9.0
conditioning
G00040203
Fi~. 10: En~ine 119 In Models 129 & 140- Specifications

Models 124 & 210
Fig. 11: En~ine 119 In Models 124 & 210- Specifications

ENGINE SERIES 120
Models 129 & 140

Mercedes-Benz
Designation Engine Engine

120.980/982 120.981/983
In model140 in model129
Cooling system Total capacity liters 18.5 19

Capacity of antifreeze/anti-
corrosion agent down to -37 ·e liters 9.25 8.5
Capacity of antifreeze/anti-
corrosion agent down to -45 •e liters 10.25 9.5
G00040205

ENGINE SERIES 601, 602, & 603
Engines 601.911/921 & 601.912
Designation Englne Engine 601.912

601.911/921
Cooling system Total capacity w/oAe Uters 8.5 8.5

withAC Líters 8.5 9.0
eapacity of anticorrosion 1 w/oAC Uters 4.25 4.25
antifreeze ag. down to -37 ·e wíth AC Uters 4.25 4.5
Capaclty of anticorrosion 1 w/oAC Liters 4.75 4.75
antifreeze ag. down to -45 •e with AC Liters 4.75 5.0
G00040206
Fig. 13: Engine 601.911/921 & 601.912 - Specificatioos

Engioes 601.913 & 602.911/961

Mercedes-Benz
1990-2000 ENGINES Engine Cooling Specifications - All Models
Oesignatlon Engine 601 .913 Engine

602.911/961
eooling system Total capacity w/o Ae L~ers 8.0 8.0

withAe Liters 8.0 -
eapacity of anticorrosion 1 w/o Ae Liters 4.0 4.0
antifreeze ag. down to -37 •e with Ae L~ers 4.0 -
eapacity of anticorrosion 1 w/oAe L~ers 4.5 4.5
antifreeze ag. down to -45 •e with Ae L~ers 4.5 .
G00040207
Fig. 14: Engine 601.913 & 602.911/961- Specifications

E ngines 602.912, 603.913/960/962/963 & 602.930
Deslgnatlon Englne 602.912, Engine 602.930

603.913/960/
96.21963
eooling system Total capacity w/o Ae Lit.ers 9.0 10.5

with Ae L~ers 9.5 .
eapacity of anticorrosion 1 w/oAe Liters 4.5 5.25
antlfreeze ag. down to -37 •e with Ae Liters 4.75 -
eapacity of anticorrosion 1 w/oAe Llters 5.0 5.75
antífreeze ag. down to -45 •e with Ae ~ers 5.25 -
G00040208
Fig. 15: Engine 602.912, 603.913/960/962/963 & 602.930 - Specifications

Engines 602.931 & 602.938/939/942/946/947

Mercedes-Benz
Designation Englne 602.931 Engine 602.938/

939/942/946/947
eoolíng system Total capacity w/oAe Lrters 9.0 10.5

withAe Liters - -
eapacity of antlcorrosion 1 w/o Ae Uters 4.5 5.25
antifreeze ag. down to -37 •e with Ae Líters - -
eapacity of anticorrosion 1 w/oAe Líters 4.95 5.75
antifreeze ag. down to -45 •e with Ae Líters - -
G00040209
Fig. 16: Engine 602.931 & 602.938/939/942/946/947 - Specifications

Engines 602.962 & 602.982
Designatlon Engine 602.962 Engine 602.982
Cooling system Total capacity w/o Ae liters 8.0 8.75

with Ae Liters 8.0 -
eapacity of anticorrosion 1 w/oAe Lrters 4.0 4.5
antifreeze ag. down to -37 •e with Ae Líters 4.0 -
Capacity of anlicorrosion 1 w/oAe Liters 4.5 5.0
antifreeze ag. down to -45 •e with Ae Líters 4.5 -
G00040211
Fig. 17: Engine 602.962 & 602.982- Specifcations

Engines 602.983 & 603.931/972
Oesignation Engine 602.983 Engine

603.931/972
eooling system Total capacity w/oAe liters 9.5 9.5

with Ae Líters - -
eapacity of anticorrosion 1 w/oAe Liters 4.75 4.75
antifreeze ag. down to -37 •e withAe líters - -
Capaclty of anticorrosion 1 w/oAC Liters 5.25 5.25
antifreeze ag. down to -45 ·e with Ae Líters - -
G00040212
Mercedes-Benz
Fig. 18: Engine 602.983 & 603.931/972 - Specifications

Engines 603.961/970/971 & 603.996
Oes ignation Engine Engine 603.971 Englne 603.996

603.9611970
eooting system Total capadty w/oAC Lrt~ts 10.0 10.0 10.0

withAC Ln= - -
eapacity of antlcorrosion 1 w/o AC Liters 4.5 5.0 5.0
antifreeze ag. down to -37 •e wilh AC Utets - - -
Capacity of anticorrosion 1 w/oAC Lil;!rs 5.5 5.5 5.5
antifreeze ag. down to -45 •e with AC Utets - - -
G00040213
Fig. 19: Engine 603.961/970/971 & 603.996- Specifications

ENGINE SERIES 604, 605 & 606
Modificatiou Notes
10.12.99 Figure for total capacity modified from 9.5 lílers lo All figures in row 1001 modified for
10.3 liters engine 611 .961
10.12.99 Figure for total capacity modified from 12.51iters lo 10.6 All figures in row 1001 modified for
liters enoine 612.961
10.112.99 Figure for total capacity modified from 13.4 liters to 11.2 All figures In row 1001 modified for
liters engine 613.961
20.112.99 Figure for total capacity modified from 5.85 liters to Figure in fine 1001 for engine 611.962
6.0 liters modified
G00040220
Fig. 20: Modification Chart

Engines 604.910/915 & 604.912/917
Deslgnatíon Englne Engine Englne Englne

604.910191 5 604.9101915 604.9121917 604.91219·11
witooutAC withAC wlthoutAC withAC
Cooling system Total capacity Uer 6.0 7.0 6.0 7.0

eapacity of anticorroslon/
antifreeze agent l.Jier 3.0 3.5 3.0 3.5
down to -37 •e
eapaclty or anticorrosiool
antlfreeze agent down lo 45 •e lle< 3.5 4.0 3.5 4.0
G0004022 1
Mercedes-Benz
Fig. 21: Engine 604.910/915 & 604.912/917- Specifications

Engines 605.910/960/962, 605.911 & 605.912
Designation Englne Englne Englne

605.910/960 /962 605.911 605.912
eoolíng system Total capacity Later 7.5 7.5 7.0
eapacity of anticorrosion/
antlfreeze agent L~er 3.75 3.75 3.5
down to -37 ·e
Capacity of anticorrosion/
antifreeze agent down to 45 •e L~er 4.25 4.25 4.0
G00040222
Fig. 22: Engine 605.910/960/962, 605.911 & 605.912- Specifications

Engines 606.910, 606.912, 606.962,606.964 & 606.961
Deslgnation Engine Engine Engine Engine Englne

606.962 606.964 606.961 606.910 606.912
wlthlwithout AC with AC
Cooling system Total capacity ~er 9 .0 10.0 10.0 8.0 7.5

eapacity of antlcorrosion/
antífreeze agent L~er 4.5 5.0 5.0 4.0 3.75
down to -37 •e
antlfreeze agent down to 45 •e ~er
5.0 5.5 5.5 4.5 4.25
G00040223
Fig. 23: Engine 606.910/912, 606.962, 606.964 & 606.961 Specifications

ENGINE SERIES 611
Engines 611.960, 611.961 & 611.962

Mercedes-Benz
Designation Engine Engine Engíne

611 .960 611 .961 611.962
Cooling sys tem Total capacity Liter 8.0 - 10.3 · 11 .9

antifreeze agenl Líler 4.0 - 5.2 - 6.0
down to -37 •e
antifreeze agenl down lo 45 •e Lfter 4.5 - 5.7 - 6.5
G00040224
Fig. 24: Engine 611.960, 611.961 & 611.962 - Specifications

ENGINE SERIES 612
Engines 612.961 , 612.962 & 612.963
Designation Engine Engine Engine

612.961 612.962 612.963
eooling system Total capacity Uler - 10.6 · 12.4 - 11 .0

antifreeze agent Laer - 5.3 - 6.2 • 5.5
down lo -37 •e
anlifreeze agent down to 45 ·e Lher .. 5.8 oo 6.8 .. 6.25
G00040225
Fig. 25: Engine 612.961, 612.962 & 612.963 - Specifications

ENGINE SERIES 613
Engines 613.960 & 613.961

Mercedes-Benz
Designation Engine Engine

613.960 613.961
Cooling system Total capacity Liter ... 15.5 .... 11.2

antifreeze agent Liter ... 7.75 "' 5.6
down to -37 oc
Capacity of antícorrosíon/
antifreeze agent down to 45 oc Líter -a. o ... 6.2
G00040226
Fig. 26: Engine 613.960 & 613.961 - Specifications

ENGINE SERIES 628
Eugines 628.960, 628.962 In 463
Designation Engine Engine Englne

628.962 628.962 628.960
in model4ó3 in model463
with Code H12 without
Code H12
Coollng system Total capacity L~er · 15.25 · 14.71 • 16.5

Capacity of anticorrosíon/
antifreeze agent Liter -7.62 -7.36 - 8.25
down to -37 ·e
~8.39 ~8.10 - 9.1
antifreeze agent down to 45 ·e Liter
G00040227
Fig. 27: Engine 628.960 & 628.962 (Model 463)- Specifications

Mercedes-Benz
1990-2002 ENGINE Crank Assembly - 129 Chassis
1990-2002 ENGINE
Crank Assembly - 129 Chassis
GENERAL INFORMATION
INSTALLATION NOTES FOR CRANKSHAFT RADIAL SHAFT SEALS- AH03.20-P-0001-01AO
Fig. 1: ldentifying I nstallation Tool (117 589 00 43 00)
ITJ Insertion tool

Use only insertion sleeve 117 589 00 43 00 (2nd version) with hole for the locating pin.
Insertion sleeve 117 589 00 43 00 (1st version) can be modified by making a hole with the dimensions "A, B,
C" as shown in the drawing.
Dimension A = 38 mm
B = 15.6mm
C = lO mm
F ig. 2: l dentifying Crankshaft Radial Shaft Seal Insta llation Dimensions
ITJ The end cover guides the engine oil from the main oil gallery (arrow) to the two oil galleries for the oil
~nnnhr ()f thP rvl1ntiPr hPl'lti l'lnn i ~ ~Pl'I I Pti mith l'l al'I~I<Pt
Mercedes-Benz
The bottom edge ofthe end cover is sensitive to distortion (oilleak). For this reason, use insertion tooll l7 589
00 43 00 to replace radial seal only when the end cover is fitted to the crankcase.
In the case of a leak at the rear, support engine, nm and determine the leakage point.
Pil J 20-41l!IH I1
Fig. 3: Identifying End Cover Guides Engine Oil F rom Main Oil Gallery
BASIC KNOWLEDGE
BELT PULLEYNJBRATION DAMPER ARRANGEMENT- GF03.30-P-1600-0IC
Engines 112, 113
Shown on engine 112
1 ltf16 x 1.5 x 77 cenital bo/1

2 Vlb111t/on damper secondMypart .4----"""VP
3 e ..tomer a--iú6díft(¡:j
4 Vlbrollon dampor prtn.ry pwt
5 W oodr rB it.oy 2
e lfedllllahllfl sea/
7
11
t
Tlmlng cese covw
Cran/raltafl spi'OClcet (llmlng ..lvo}
Cranlrshafl sproclcel (ol pump dr!tte)
:+=4M~ 10
10 Cranlr&hllfl
11 Top pMI ofoll pan
12 So ~ for attuNng ol pNI
1'03 .3(1.0282 11
Fig. 4: ldentifying Belt PullevNibration Damper Arr angement
FLYWHEEL, TWO-MASS FLYWHEEL , DRIVEN PLATE ARRANGE MENT- GF03.30-P-8001-01B
Engine 112, 113
Sbown on engine 112

Mercedes-Benz
1990-2002 ENG INE Crank Assembly - 129 Chassis
1 Cr-!hMt po$Tiion stnsfl'

2 Flywheel wfth starter rlng gear
3 Endcover
4 Cr-!halt
5 StnJ/ghtpln
6 Radlalua/
~~Hrr-s '
¡;:tHf-+t-t---8
POJ..3!>«28< 0 3
Fig. 5: Locating Flvwheel, Two-Mass Flvwheel, Driven Plate Arrangement
DRIVEN PLATE DESIGN- GF03.30-P-8002-01AO
Ct.m" CilJC
R l nggc•r 1
Bolt (drlv<m pl•re 1st vcrslon a
2 nd voul on. rlvofed) a
4
5
Nut (drlvcn pl•to 1st versl on
2ndvcrs/on, rfvcred)
R ..r cnd cov or
S
1
'
Bo/t
Orlvcn plm 1 mm. 0 211 mm
Orlvcn plm 1.s mm, 0 2PG mm •'
•
W..shor4.5mm 10
10 Woshcr4.6 mm 11
11 Strotr: hbo lr 12
12 Cr.n~!h•tr
13 Loc•tln¡¡ pln
14 Rodlal sc•l 11
15 L.oc•rtng pln
11 B olt 1'
18 Tootncd scgmcnt 111
11
18
POl l0-4llO!I-I l
Fig. 6: ldentifying Driven Plate Design
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: CRANKASSEMBLY- AR03.00-Z-9113AB
ENGINE 113
Mercedes-Benz
Piston removal and ENGINE 112, 113 ... AR03.10-P-7021AV

installation
Piston removal and ENGINE 113.964 in AR03.10-P-7021GZ
installation MODEL 164.175
Piston removal and ENGINE 113.971 in AR03.10-P-7021RT
installation MODELS 251.075/175
Piston removal and ENGINE 113.995 in AR03.10-P-7021RVK
Piston removal and ENGINE 113.967 in AR03.10-P-7021TY
installation MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Piston removal and ENGINE 113.989 in AR03 .1 0-P-7021 VT
Remove/install piston rings ENGINE 112, 113 ... AR03.10-P-7311BV
Removing/installing piston ENGINE 113.964 in AR03.10-P-7311GZ
nngs MODEL 164.175
Removing/installing piston ENGINE 113.971 in AR03.10-P-7311RT
nngs MODELS 251.075 /175
Remove/instaU piston rings ENGINE 113.967 in AR03.10-P-7311TY
MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Removinglinstalling piston ENGINE 113.989 in AR03.10-P-7311VT
rings MODEL 171.473
Replace front crankshaft ENGINE 112, 113 ... AR03.20-P-3000B
radial seal ring
Replace front crankshaft ENGINE 112, 113 ... AR03.20-P-3000BA
radial sealing ring
Replace front crankshaft ENGINE 113.964 in AR03.20-P-3000GZ
radial sealing ring MODEL 164.175
Replace front crankshaft ENGINE 113.971 in AR03.20-P-3000RT
radial sealing ring MODEL 251.075/175
Replacing front crankshaft ENGINE 113 ... AR03.20-P-3000RVK
radial sealing ring
Replace front crank.shaft ENGINE 113.967 in AR03.20-P-3000TY
radial sealing ring MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Replace rear crankshaft radial ENGINE 113.988 in AR03.20-P-3063AC
sealing ring MODEL 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Replace rear crankshaft radial ENGINE 112, 113 ... AR03.20-P-3063B
Mercedes-Benz
sealíng ríng
Replace rear crankshaft radial ENGINE 113.964 in AR03.20-P-3063GZ
seal MODEL 164.175
Replace rear crankshaft radial ENGINE 113.971 in AR03 .20-P-3063RT
seal MODEL 251.075 /175
Replacing rear crankshaft ENGINE 113 ___ AR03 .20-P-3063RVK
radial seal
Replace rear crankshaft radial ENGINE 113.967 in AR03.20-P-3063TY
seal MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Remove/install crankshaft ENGINE 113.988 in AR03.20-P-4351AC
MODELS 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Remove/install crankshaft ENGINE 113 __ _ AR03.20-P-4351BV
Removelinstall crankshaft ENGINE 113.964 in AR03.20-P-4351GZ
MODEL 164.175
Remove!install crankshaft ENGINE 113.971 in AR03.20-P-4351RT
MODELS 251.075 / 175
Remove!install crankshaft ENGINE 113.995 in AR03.20-P-4351RVK
MODEL 230.472
Remove/install crankshaft ENGTNE 113.9671n AR03.20-P-4351 TY
113.990 in MODEL
219.376
Remove/install belt ENGINE 112, 113 __ _ AR03.30-P-1600C
pulley/vibration damper
Remove/install belt ENGINE 112, 113 ___ AR03.30-P-1600CA
Remove/install belt ENGINE 113.964 in AR03.30-P-1600GZ
pulley/vibration damper MODEL 164.175
Remove/install belt ENGINE 113.971 in AR03.30-P-1600RT
pulley/vibration damper MODEL 251.075 / 175
Remove/install belt ENGINE 113 ___ AR03.30-P-1600RVK
Remove/install belt ENGINE 113.967 in AR03.30-P-1600TY
pulley/vibration damper MODEL 219.375 ENGINE
113.990 in MODEL
219.376
Remove!install retaining lock ENGINE 112, 113, 137, AR03.30-P-5000B
for crankshaft 1ring gear 275 ___
Removing/installing retain.ing ENGINE 113.964 in AR03.30-P-5000GZ
lock for crankshaft 1ring gear MODEL 164.175 with
Mercedes-Benz
TRANSMISSION 722.901
Removing/installing the ENGINE 113.971 in AR03.30-P-5000RT
retaining lock for crankshaft 1 MODELS 251.075 /175
nng gear
Removing/installing the ENGINE 113.967 in AR03.30-P-5000TY
retaining lock for crankshaft 1 MODEL 219.375 ENGINE
nng gear 113.990 in MODEL
219.376
Remove/install flywheel 1 ENGINE 113.988 in AR03.30-P-8001AC
drive plate MODELS 203.076 /276
ENGINE 113.989 in
MODEL 171.473
Remove/install flywheel 1 ENGINE 112, 113, 137 ... AR03.30-P-8001C
drive plate
Remove/install flywheel 1 ENGINE 113.964 in AR03.30-P-8001GZ
drive plate MODEL 164.175 with
TRANSMISSION 722.901
Remove/install flywheel 1 ENGINE 113.971 in AR03.30-P-8001RT
drive plate MODELS 251.075 /175
Removelinstall flywheel 1 ENGINE 113.995 in AR03.30-P-8001RVK
drive plate MODEL 230.472
Remove/install flywheel 1 ENGINE 113.967 in AR03.30-P-8001 TY
drive plate MODEL 219.375 ENGINE
113.990 in MODEL
219.376
TESTING AND REPAIR WORK: PASSENGER CARS: CRANK ASSEMBLY- AR03.00-Z-9120AB
ENGINE 120
Remove/install piston rings ENGINE 120 AR03.10-P-7311AO

Replacing rear crankshaft radial seal ENGINE 120 AR03.20-P-3063AO
Setting ring gear relevant to starter ENGINE 120 AR03.30-P-4350AO
Removing and installing retaining lock for crankshaftlring gear ENGINE 120 AR03.30-P-SOOOAO
Removing and installing driven plate ENGINE 120 AR03.30-P-8003AO
Replacing ring gear of driven plate ENGINE 120 AR03.30-P-8313AO
PISTON REMOV AL AND INST ALLATION- AR03.10-P-7021AV
ENGINE 112
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
Mercedes-Benz
ENGINE 113.982 in MODEL 463.243/246
Shown on engine 112
- 5 Conne cUng r<>d b&a.rlng c•p

l'lll . 1 0.2029~9
1 C/rcllp 5 Conrodboi'ls
2 Pi.stonpln 7 ConnecUng rod b -lng sholl
3 Pl"stons Anl!-twlsrtock
4 C onrad GJOove
10 ~ Cla!nplng súitp
F ig. 7: ldentifying Piston Components
~' Removing
&oanocrl Risk of death caused by Align vehicle between the ASOO.OO-Z-001O-OlA
vehicle slipping or columns of the lifting
toppling off ofthe lífting platform and position the
platform. four support plates at the
lifting platform support
points specified by the
1 Remove engine Model463.206/ 209/ 232/ ARO 1.10-P-2400CC
233/ 240/ 241
Model463.244/ 245/ 247/ AR01.10-P-2401GT
248/249/ 250/ 254
Model463.243/ 246 AR01.10-P-2401MG
Model230.475 ARO 1.1 O-P-2400R
Model230.474 AR0 1.10-P-2400RVK
Model 220 without ARO 1.1 O-P-2400AB
4MATIC
Mercedes-Benz
Model 220 with 4MATIC AR01.10-P-2400IW

Model210 with 4MATIC AR01.10-P-2400C
Model 129,202,208,210 AR01.10-P-2400CB
without 4MATIC
Model 203 without AR01.10-P-2400PV
4MATIC, 209 with engine
112
Model 203 with 4MATIC AR01.10-P-2400PW
Model 209 with engine 113 AR01.10-P-2400Q
Models 211.061/065/070 AR01 .10-P-2400TC
Model 170 AR01.10-P-2400SV
Model 163 ARO 1.10-P-2400CA
2.1 Remove automatic Model463.206/ 209/232/ AR27.10-P-0500BD
transmission from 233/240/241
engine Model 463.243/ 244/ 245/ AR27.10-P-0500GA
246/247/ 248/ 249/250/
254
Model230.475 AR27.10-P-0500R
Model 230.474
Model 220 without AR27.1 0-P-0500I
4MATIC
Models 129, 170, 202, 208, AR27. 10-P-0500B
210
Model 203 without AR27.10-P-0500P
4MATIC, 209 with engines
112, 113
Model 211.061/065/070 AR27.10-P-0500T
Modell63 AR27 .1 0-P-0500GH
2.2 Remove manual Models 129,202,210 AR26.10-P-0020A
transmission from Models 203, 209 with AR26.10-P-0020P
engine engine 112
Model 211.061 AR26.10-P-0020T
Model 208 with AR26.1 0-P-0020E
transmission 716.662/622
Model 170, AR26.10-P-0020D
Model 208 with
transmission 716.663
3 Remove oí l pan top Model 463.206/ 209/ 232/ AR01.45-P-7500FG
section 233/ 240/ 241/243/ 244/
245/246/247/248/249/
250/254
Model 230. AR01.45-P-7500R
Mercedes-Benz
Model 220 without AR0 1.45-P-7500I

4MATIC
Model220 with 4MATIC AR01.45-P-7500IW
Model210 with 4MATIC AR01.45-P-7500FA
Model210 wíthout AR01.45-P-7500F
4MATIC
Models 208, 202 AR01.45-P-7500FC
Model 203 wíthout AR0 1.45-P-7500PV
4MATIC, 209 wíth engínes
112, 113
Models 21 1.061/065/070 AR01.45-P-7500TV
Model170 AR01.45-P-7500SV
Model163 AR01.45-P-7500FB
Model129 AR01.45-P-7500FD
4 Take off cylínder head IIJ Remove intake manifold
with complete wiring
hamess during this step.
Model463.206/ 209/ 232/ AR01.30-P-5800GV
233/240/ 2411 243/ 244/
245/ 246/ 247/ 248/249/
250/ 254 Engine 112 in
model129 and engine 113
in model129, 202, 208, 210
Engine 112 in
Model 170,202, 208, 210, AR01.30-P-5800B
220 and Engine 113 in
Model220, 230.474 /475 ARO 1.30-P-5800BA
Modell63 AR01.30-P-5800MV
Model203, 209 with engíne ARO 1.30-P-5800PV
112, 113
Models 211.061/065/070
5 Remove oil pump IIJ For this step, push back
chain tensíoner and take off
chain.
All except 203, 209, AR18.10-P-6020B
211.061/065/070, 220
without 4MATIC,
230.474 /475
Model 203 without AR18.1 O-P-6020PV
4MATIC, 209,
211.061/065/070
Model203 with 4MATIC, AR18.1 O-P-6020PW
model 220 with 4MATIC
Model230.474/475 AR18.10-P-6020R
Mercedes-Benz
6 Remove connecting rod ITJ For this step, mark

bearing cap ( 5) conrod (4) and connecting
rod bearing cap (5) on one
side relative to each other.
7 Remove conrod (4) ITJ If pistons have been used
together with pistons (3) (3), the arrows indicating
by lifting up and out the direction of the travel
aud the markings on the
pistons may no longer be
visible due to carbon
deposits. For this reason,
remove the carbon deposits
from the pistons. If the
arrows indicating directíon
of travel on the pistons are
no longer recognizable,
these must be re-marked.
8 Remo ve circlip ( 1) of ITJ D o not damage pisten
pisten pin (2) (3). Place a clean cloth
undemeath.
9 Press out pisten pin (2)
¡g¡ Instan
10 Assign pisten (3) to AR03.1 O-P-7021-02BV
cylinder bore
11 Oil pisten pin (2) and
conrod bush
12 Assemble piston (3) and ITI Install piston (3) with
conrod (4) arrow in direction of traveL
13 Push in pisten pin (2) by
hand
14 Insert circlip (1) of ITJ D o not damage pisten
piston pin (2) in the (3). Place a clean cloth
groove on pisten (3) unde rneath.
15 Oil tbe cleaned parts
( cylinder bore, conrod
bearing journal, conrod
bearing shells and
pistons)
16 Fit the tensioning strap ITJ Pisten rin~gaps must be Fig. 8
(10) and tighten offset 120°. r¡ Tensioning
strap
17 Install piston (3) with lii Rotate crankshaft
arrow pointing in suffi ciently so that the
direction of travel connecting rod does not
Mercedes-Benz
touch the connecting rod

journal when the piston is
pushed into the cylinder
bore.
18 Inspect the conrod bolts Thread and shank length AR03.10-P-6lll-OlBV
(6) *BE03.10-P-1 001-03A
19 Install the conrod @ The connecting rod AR03.10-P-6111-06AV
bearings and fit the bearing shell (7) with oil
conrod bearing cap (5) drilling (arrowed) must be
mounted in the connecting
rod, otherwise the piston pin
(2) is not lubricated.
The anti-twist locks (8) of
the connecting rod bearing
shells (7) must be seated in
the grooves (9) in the
conrods (4) and connecting
rod bearing caps ( 5).
The connecting rod and
connecting rod bearing cap
are cracked (broken)
(arrowed). They must not be
installed the wrong way
round!
20 Tighten comod bolts (6) B AR03.10-P-611 1-02BV
*BA03.10-P-1001-01E
21 Rotate crankshaft IIl To check for
unobstructed movement.
22 Instan oil pump o Ensure that the oil
return shutoff val ve is
correctly located.
o Clean the oil pump
strainer.
o Fill the oil pump with
engine oil before
installing, so that oil
is delivered at the
initial startup.
All except 203, 209, AR18.10-P-6020B
211.061/065/070, 220
without 4MATIC,
230.474 /475
4MATIC, 209,
211.061/065/070
Mercedes-Benz
Model 203 with 4MATIC, AR18.10-P-6020PW

model 220 with 4MATIC
Model230.474/475 AR18.10-P-6020R
23 Fit the cylinder head Model463.206/ 209/232/ AR01.30-P-5800GV
233/240/ 241/ 243/ 244/
245/246/247/ 248/ 249/
250/254
Engine 112 in modell29 AR01.30-P-5800B
and engine 113 in model
129,202, 208, 210
Engine 112 in Model 170, AR01.30-P-5800BA
202, 208, 21 O, 220 and
Engme 113 in Mode1220,
230.474/475
Model163 AR01.30-P-5800MV
Model203, 209 with Engine AR01 .30-P-5800PV
112, 113
Models 211.061/065/070
24 Fit the oil pan top Model463 AR01.45-P-7500FG
section Model 230.474/475 AR01.45-P-7500R
Model 220 without AR01.45-P-75001
4MATIC
Model 220 with 4MATIC AR01.45 -P-7500IW
Model 210 with 4MATIC AR01.45-P-7500F A
Model 21 O without AR01.45-P-7500F
4MATIC
Models 208, 202 AR01.45-P-7500FC
4MATIC, 209 with engines
112, 113
Models 211.061/065/070 AR01.45-P-7500TV
Modell70 AR01.45-P-7500SV
Model163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
25.1 Fit the automatic Model 463.206/ 209/ 232/ AR27.10-P-0500BD
transmission 233/240/ 241
Model463.243/ 244/245/ AR27.10-P-0500GA
246/ 2471 248/ 249/ 250/
254
Model230.475 AR27.10-P-0500R
Model230.474
Model 220 without AR27.10-P-05001
4MATIC
Mercedes-Benz

Model210, 208, 202,170. AR27.10-P-0500B
129
4MATIC, 209 wíth engines
112, 113
Models 211.061 /065/070 AR27 .1 O-P-0500T
Model163 AR27.10-P-0500GH
25.2 Fit on manual Models 210,202, 129 AR26.10-P-0020A
transmission Models 203, 209 with AR26.10-P-0020P
engine 112
Model211.061 AR26.10-P-0020T
Model 208 with AR26.1O-P-0020E
transmission 716.662/622
Modell70, AR26.1 O-P-0020A
Model 208 with AR26.10-P-0020D
26 Install engine Model463.243/ 244/ 245/ AR01.10-P-2400CC
246/2471 248/ 249/250/ 254
Model230.475 AR01.10-P-2400R
Model 230.474 AR01.10-P-2400RVK
Model 220 without ARO 1.10-P-2400AB
4MATIC
Model210 with 4MATIC AR01.10-P-2400C
Model210 without AR01.10-P-2400CB
4MATIC,208,202, 129
4MATIC, 209 with engine
112
Model 209 with engine 113 AR01.10-P-2400Q
Model211.061 /065/070 AR01.10-P-2400TC
Model 170 AR01.10-P-2400SV
Model163 AR01.10-P-2400CA
Test data for conrod bolts

N umber Designation Engine 112 ex.cept Engine
112.951/976, engine 113.992/995
113.94/96/971/
980/981/982/
984/986
BE03.10-P- Conrod Thread dia. M 8x1 8xl
Mercedes-Benz
1001-03A bolts 0 1
Shank When new mm47 42
length
Max. mm 47.6 42.6
Part no. - -
~e
m
onnecf mg ro d
Nomber Designation Engine 112,113
BA03JO-P-1001- Connecting rod bolt Stage 1 Nm5
OlE Stage 2 Nm25
Stage 3 Angle 0 90
p
~
r
.......
--...
.;1
'
l'w.. H
[JI
r-. ~
000 589 04 14 00
\.. J
Fig. 8: ldentifying Retaining Strap (000 589 04 14 00)
Assigning normal-size pistons to cylinder bore - AR03.10-P-7021-02AO
l. Install pistons according to tolerance identification.
DJ The pistons are marked with respect to the crankcase w ith the code letters A, X, B orO, 1, 2 (arrows).
When performing repairs, match the pistons to the cylinder bores in the crankcase and ínstall as follows.
Plston and cyNndcr /dcnrfflciltlon. fst vcrslon
Fig. 9: Piston A nd Cvlinder ldentification,lst Version

Mercedes-Benz
Plston ~nd cyNndc r ldr:ntlflc~tlo n, 2nd vcrs./on
Pll 3 HHI11ó-111
Fig. 10: Piston And Cylinder Identification,2nd Version
ASSIGNMENTS
Cylinder bore identification Approved pistons Supplementary code for ordering pistons
A orO A or X, O or 1 52 for A or O pístons
X or 1 A or X or B, O or 1 or 2 54 for X or 1 pistons
B or 2 B orX, l or 2 56 for B or 2 pistons
REMOVE/INSTALL PISTON RINGS- AR03.10-P-7311
Remove/install piston rings- AR03.10-P-7311AO
ENGINE 120
1 Pl•;n comprcsslon ring

1 T•por·f•cod hoolt scropcr rln¡¡
Doublo bovolod oll e ontrol rln¡¡
(ol/ scrJJ>or rln¡¡)
4 Hosc sprln¡¡
•
10
Hoo~odsp rlng
i!ll'lfcrs
PO l.10.0210-05
Fig. 11: ldentüving Piston Ring Components
IFig. ¡work
item, etc.instructions
Mercedes-Benz
Remove pistons ra03001203160x

AR03.10-P-7021-
Assign standard size pistons to cylinder bore
02AO
*BE03.10-P-1001-
OSA
*BE03.10-P-1016-
02C
1, 2, 3 Pisten rings Measure side clearance
*BE03.10-P-1017-
02C
*BE03.10-P-1018-
02C
[l] Use pliers (1 O) for removing.
WInstallation : measure width of pisten rings. Install
pisten rings with the same width.
1, 2, 3 Pisten rings Pay attention to installation position, "top" or Fig. 12
manufacturer's designation faces toward pisten crown.
Insert hook spring (8) in oil scraper ring (3) offset 180°
to joint (arrow).
TEST DATA OF PISTON RINGS

Double beveled oil control ring (1st piston ring) mm l. 480-1.492
BE03.10-P- 1001-05A Pisten ring beight Taper-faced hook scraper ring (1st pisten ring) mm 1.980-1.990
Oil scraper ring (1st pis ton ring) mm 2.975-2. 990
TEST DATA OF PISTONS

Number Designation Engine Engine 120 with CODE 473 (fuel-
120 optimized)
Groove mm 1.53-1.54 1.53-1.54
BE03.10-P-1016- Pisten ring
(1) Side 0.010-
02C mm 0.010-0.040
clearance 0.040
Groove mm 2.00-2.01 2.00-2.01
BEOJ.lO-P-1 01 7- Pisten ring
02C (2) Side 0.010-
mm 0.010-0.030
clearance 0.030
3.000-
Groove mm 3.000-3.015
BEOJ.lO-P-1018- Pisten ring 3.010
02C (3) Side 0.038-
mm 0.038-0.065
clearance 0.065
Mercedes-Benz
Fig. 12: ldentifving Pliers (000 589 51 37 00)
Remove/install piston rings- AR03.10-P-7311BV
ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
ENGINE 112 /945, 113.962 /982
1 Comproso/on rlng {p llfn eo.mptosslon

rlng)
2 Co mprus/on rlng (l ~r-lae.ed hoolc
SCtltpOI' rlng}
J 011 scrap<trrlr,g
.f Pl'scons
IS Plsron crown
POl. IO 2022.06
Fig. 13: Identifying Piston Rings
Figure item, etc. Work instructions

4 Piston removal and AR03.10-P-7021A V
installation
1,2,3 Piston rings remo ve Fig. 12
~ Pliers
W Removal: Oil scraper ring with the pliers.
The oil scraper ring (3) must be
removed and installed by hand.
mlnstallation: Compression rings o Measure width of *BE03.10-P-1003-05B
compression rings ( 1, 2).
Mercedes-Benz
o Note the installation

position of compression
rings (1,2). The
inscription "Top" or the
manufacturer's
designation must point
toward the pisten crown
(5).
1,2 Measure the side AR03.10-P-7311-01V
clearance of the
compression rings
1,2 Measure end gap of the AR03.10-P-7311-02V
compresswn rmgs
Ch ee k va ues ~or p1ston rmgs

Number Desigoation Engine 112.910/ Engine Engine
911/912 112.913 112.920/
921/922/923/
940/941/942/
943/944/945/
946/947/948/
960, Engine
113.940/941/
942/943
BE03.10- Dimension Plain mm 83.2xl .5x3.1 89.9xl.5x3.1 89.9xl.5x3.1
P-1003- compresswn
05B rmg
Taper-faced mm83.23.53.589.91.753.5 89.9x1.75x3.5 89.9x3.5x3.5
hook scraper
nng
Ch ee k valu es tor ptston rmgs

BE03.10-P-1 003- Dimension Plain compression mm 89.91.53.1
05B ring
Taper-faced hook mm 89.91.753.5
scraper nng
Ch ee k va ues ~or p1ston rmgs

Number Designation Engines Engines Engine
113.944/980/ 113.960/961/ 113.960/9611
981/982/984 962/963/964/ 992/995
965/968/971
BE03.10-P- Dimension Plain mm 97.0x1.2x3.5 97.0x1.5x3.1 97.0x1.2x3.5
1003-05B compres sien
Mercedes-Benz
ríng 1
T aper-faced mm97.01.54.0 97.0x3.5x3.5 97.0xl.75x3.5
hook scraper
rmg
¡'
000 589 51 37 00
Pie es
Measure end clearance ofpiston rings - AR03.10-P-7311-01V
Modification notes
12.6_02 Val ue in series 1001 for Value in BE03.10-P- *BE03.10-P-1001-0SB
engíne 113.967 modified l 00 l-05B for engine
from 0.012 .. .0.060 to 113.967 modífied
0.033 ... 0.07 and from
0.010...0.030 to
0.01...0.04
Inspection data for piston rings

N umber Designation Engine 112.910/ Engines 112.920/ Engines
911/912 921/922/923/ 113.944/980/
940/941/94.2/ 981/982/984
943/944/945/
946/947/948/
960, Engine
113.940/941/
942/943
BE03. 10-P- Piston ríng Groove 1 mm0.012 ... 0.060 0.012 ... 0.060 0.012 ... 0.060
100 1-05B vertical
clearance Groove 2;
l mm 0.01 0 ... 0.030 0.010 ... 0.030 0.010 ... 0.030
lnspection data for piston rings

113.960/961/
962/963/964/
965/968/971
BE03 .10-P- Piston ríng Groove 1 mm 0.012 ... 0.060 0.033 ... 0.070
1001 -05B vertical 1
Mercedes-Benz
lctearance Greeve 2 mm0.010 ___ 0_030 lo.o l __ _o_o4
e ommerc1a· ulY available t001S

Number Designation
WH58.30-Z-l004-12A Feeler gauge
l. Measure the side clearance ef the cempressien rings between the cempressien ring and the metmting
greeve in the pisten with a ~ feeler gauge. Re place the cempressien rings er the pisten if necessary _
IJJ The end clearance ef the eil scraper ring cannot be checked because ef its three-part design_ The oil
scraper ring must alse be replaced when the cempressien rings are replaced.
Fig. 15: ldentifying Side Clearance Of Compression Rings
Measure piston ring end clearance - AR03.10-P-7311-02V
1nspection data fior p1ston rmgs

Number Designation Engine Engines 112.920/ Engines
112.910/911/912 921/922/923/ 113.944/980/
940/941/942/ 981/982/984
943/944/945/
946/947/948/ 960,
Engine
113.940/941/942/943
BE03.10- Pisten Groeve 1 mm 0.200 __ _0.350 0.200 __ _0.350 0.200 ___ 0_350
P-1 002- ring end
Greeve 2 1 mm0.200 ___ 0.400 0.200 ... 0.400 0.200 ___ 0.400
05B gap
. t on rmgs
1nspection d a t a f¡or pts
113.960/961/
962/963/964/
965/968/971
BE03.10-P- Pisten ring end Greeve 1 mm 0.200 ___ 0.350 0.200 ...0.350
1
Mercedes-Benz
booz-osB lgap Groove 2 mm O.200 ___ O.400 lo.zoo ___ o.4oo

e ommerc1a·ulY availa ble t001S
Number Designation
WH58.30-Z-1 004-12A Feeler gauge
l. Clean cylinder walL

2_ Insert the two compression ríngs one after the other ínto the unworn area ofthe cylínder barrel and
measure the end gap with a ~ feeler gauge. Replace the pisten rings if necessary _
ITJ The gap clearance of the oil scraper ring cannot be checked because of íts three-part design. The oil
scraper ring must also be replaced when the compression rings are replaced.
Fig. 16: Measuring Cylinder Wall
REPLACE FRONT CRANKSHAFT RADIAL SEAL RING- AR03.20-P-3000B
ENGINE 112.945 in MODEL 463.209 /232/233 /244/245 /250
ENGINE 113.962 in MODEL 463.206/240/241 /247/248/249/254
ENGINE 113 in MODEL 210,208, 202, 163, 129
ENGINE 113.982 in MODEL 463.243/246
Shown on Engine 112 in Modell29

Mercedes-Benz
f \lf$00 fMl
2 Poly-V-beJts
3 F.n •brouc/
4 Conrr•J bo/1
5 \lfb1111/on dfltn(Jot (bellpuloY1
4 f!ll Assomb~ sletvo
1 Cranlcmw/1 radial sediV n·ng
Fig. 17: Identifying Front Crankshaft Radial Seal Ring, Fan Shroud, Vibration Damper
, ...
~¡g¡ Remove, Install
1 Remove engine 11odel 129,208,210 AR61.20-P-1105AB
compartment paneling Model Series 163 AR61.20-P-1105GH
2.1 Remove air guide Model163 with Engine
113.942
3 Remo ve viscous fan (1) OJ Right-hand thread! AR20.40-P-5660C
4 Remove the fan shroud
(3). OJ On Model 163
of fan shroud.
Model 463 AR20.40-P-6800V
5 Remove poly V-belt (2) DJ InstaUation: Lock AR13.22-P-1202B
tensioning device with a
drift or pin (diameter 5
mm).
6 Remove vibration damper ModeJ 129,463 AR03.30-P-1600C
(belt pulley) (5) Model163, 202, 210 with
Engine 113
7 Remove crankshaft radial OJ Do not damage
sea] (7) crankshaft and mounting
ho le for crankshaft radial
seal. Use a clean cloth as
a base. Circtunference
and seaJing Jip of the
crankshaft radial seal as
well as the mating contact
Mercedes-Benz
surface on the vibration

damper must be free of
oil and grease. Do not
coat radial seal with
sealant
DJ Removal: Press out AR03.20-P-3000-01B
with screwdriver.
Installation: Install front
crankshaft radial seaL
[l] Insertion tool Fig. 18
[l] Sleeve Fig. 20
order
Risk of accident from Secure vehicle to prevent ASOO.OO-Z-0005-0IA
vehicle starting off by it from moving off by
ítself when engíne ítself
running. Risk of injury W ear closed and close-
suffered in the form of fitting work clothes.
bru:ises or burns to the Do not grasp hot or
hands when reaching in rotatíng parts.
wbile the engine cranks
or runs
9 Run engine and inspect DJ Determine oilleak *BR00.45-Z-1001-03A
for leaks after spraying the cleaned
and dríed surroundíng
area with MB 'white'
contrast spray.
\..
®
611 589 00 14 00
l, . ,mnloal
./
Fig. 18: ldentifving lnsertion Tool (611 589 00 14 00)

Mercedes-Benz
Fig. 19: Identifying Sleeve (119 589 01 14 00)
. 1s
R eparr matena
BR00.45-Z-l 00 l-03A Crack detector A 000 989 03 59
InstaU front crankshaft radial seal - AR03.20-P-3000-01B
Fig. 20: Identifying Sleeve (119 589 01 14 00)
l. Deburr edge of mounting bore for crankshaft radial sealing ring at timing case cover.
2. Push the crankshaft radial sealing ring onto the side (a) of the [l] sleeve (2).
OJ Circumference and sealing lip of crankshaft radial seal as well as the mating contact surface on the
vibration damper must be free of oil and grease .
•
• b
I'Ol20.2065 o1
Fig. 21: Identifying Crankshaft Radial Sealing Ring Onto Side

Mercedes-Benz
3. Align groove ofl:ll sleeve (2) to the Woodruffkey ofthe crankshaft.
DJ Turn to ensure that the slot in the llJ sleeve (2) ís alígned wíth the Woodruff key in the crankshaft.
4. l:ll Push sleeve (2) onto crankshaft and press in crankshaft radial sealing about 2 mm.
DJ l:ll If necessary, knock in sleeve (2) with light blows from a hammer until it is possible to insert the
central bolt (3).
5. l:ll Draw in sleeve (2) with central bolt (3) as far as the stop.
6. l:ll Detach sleeve (2).
® The crankshaft radial sealing ring must be positioned at right angles to the crank journal otherwise
proper sealíng is not assured.
Showo oo eogioe 112
1'03.20 :205!1 o 1
Fig. 22: ldentifyiog Crankshaft Sleeve & Central Bolt
DJ Repair size 1 is identified by a 3 mm wide shoulder on the contact surface.

7. l:ll Turn sleeve (2) and push onto the crankshaft with side ofrepair size 1 (b).
DJ Turn to ensure that the slot in the l:ll sleeve (2) is aligned with the Woodruff key in the crankshaft.
8. l:ll Draw in sleeve (2) with central bolt (3) as far as the stop.
9. llJ Detach sleeve (2).
Shown on engine 112
Mercedes-Benz
Fig. 23: Identifying Crankshaft Sleeve & Central Bolt
10. Check installation location ofthe crankshaft radjal sealing ring (1) to the crankpin (4).
@ The crankshaft radial sealing ring (l)must be p ositioned at right angles to the crankjournal (4)
otherwise proper sealing is not assured.
WThe installation depth (B) ofthe crankshaft radial sealing ring (1) is preset through the llJ sleeve (2)
and must not be altered subsequently.
Shown on engine 112
1'63.20 2061 01
Fig. 24: ldentifying Crankshaft Radial Sealing Ring To Crankpin
REPLACING REAR CRANKSHAFT RADIAL SEAL - AR03.20-P-3063
Replacing rear crankshaft radiaJ! seaJ - AR03.20-P-3063AO
ENGINE 120
Mercedes-Benz
6 rrrJ l nnor ~rr of lm4rrfon too/

7 !llJ tnsortfon too/
15 Rad~ lso•l
20 Orfvcn plato Wfth rin~ g ..,
Fig. 25: ldentifving Radial Seal, Driven Plate And Ring Gear
~'
[g]' Removing, installing
Remove rear crankshaft radial ITJ Do not damage crankshaft and mounting hole
1 for the radial seal.
seal (15)
Use a clean cloth as a base.
Install rear crankshaft radial AR03.20-P-3063-
2
seal (15) OlAO
[l] Fig. 1
Pay attention to installation notes for crankshaft AH03.20-P-0001-
radial seal. OlAO
3 Instan in the reverse order
Inspect rear of engine for AR01.40-P-8913-
4
leales OlAO
Fig. 26: ldentifving Installatii.on Tool (117 589 00 43 00)
lostalling rear cranksbaft t-adial seal - AR03.20-P-3063-01AO

Mercedes-Benz
Fig. 27: Identifying Installation Tool (117 589 00 43 00)
l. Screw inner part (6) of ~ 117 589 00 43 00 to crankshaft.

2. Coat radial seal with engine oil between dust lip and sealing lip.
OJ Do not use grease! Grease prevents the sealing lip ofthe radial seal transportíng back the engine oil.
The contact surface for the rear radial seal on the crankshaft is hardened and twist-:free.
3. Push radial seal onto inner part (6) ofOCI 117 589 00 43 OO.
f'ID3_20.()291-ll1
Fig. 28: Identifying Radial Seal Installed Ooto Inoer Part
4. Use the insertion tool (7) 117 589 00 43 00 to press in radial seal flush with end cover.
lf wear groove exists on the crankshaft, press in radial seal 2 mm deeper.
OJ The dust lip must not be resting on the crankshaft otherwise leaks will occur as a result of the pumping
action.
Mercedes-Benz
Fig. 29: ldentifying Radial Seal Flush With End Cover
Replace rear crankshaft radial sealing ring - AR03.20-P-3063B
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129,163, 170,202,203,208, 209, 210,220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 208, 209, 210, 220, 230.474 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.982 in MODEL 463.243/246
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
Shown on engine 112

Mercedes-Benz
t Endewer
2 Cranksl!aft radlal uol
3 FtywtrHI
Fig. 30: ldentifving Rear Crankshaft Radial Sealing Ring, End Cover, Flvwheel
~¡g¡ Remove/install
1 Remove flywhe el (3)/ AR03.30-P-800 1C
driven plate
2 Remo ve end e over ( 1). AR01.40-P-8913B
3 Remove crankshaft radial 1JJ The crankshaft radial
seal (2) sealing ring (2) at the end
cover (1) cannot be
exchanged. This end
cover ( 1) is fitted at the
factory and therefore
must be replaced.
IJJ Crankshaft radial
sealing ring (2) must not
be pushed out when the
end cover ( l) is fitted.
IJJ lnstallatiou: First
install the end cover ( l)
and then install the
crru1kshaft radial sealing
ring (2):?
Install crankshaft radial
sealing ring (2). AR03.20-P-3063-0IB
~ Fig. 32
4 Install in the reverse order 1JJ Before installing
transmission, inspect for
oilleaks
Mercedes-Benz
111 S89 08 43 00
Fig. 31: Identifying Installation Tool (111 589 08 43 00)
Installing rear cranksbaft radial seal - AR03.20-P-3063-01B
Fig. 32: Identifying Installatiion Tool (111 589 08 43 00)
l . Deburr edge of mounting hole around entire circumference for rear crankshaft radial sealing ring (4) and
clean mounting hole (arrow).
2. Fit intemal component (1) ofll:J installation tool to crankshaft.
I'O"J.20-2ll07 .o1
Fig. 33: Locating Crankshaft Radial Sealing Ring
3. Carefully push rear crankshaft radial sealing ring ( 4) over the internal component ( 1) of the IIJ installation
tool and the crankshaft journal.
OJ Ensure that the sealing lip (6) of the rear crankshaft radial sealing ring (4) is not damaged or
compressed.
Mercedes-Benz
Círcwnference (5) and sealing lip (6) of the rear crankshaft radial sealing ring (4) as well as the mating
contact surface on the crankshaft must be free of oil and grease.
1'03.20 :il9D!l 02
Fig. 34: Identifying Rear Crankshaft Radial Sealing Ring
4. Position the outer part (2) of the ~ mounting tool.
DJ Use outer part (2) with chamfer.

5. Screw in bolt (3) until a resistance is felt.
6. ~ Detach the mounting too l.
Fig. 35: Identifying Crankshaft Radial Seal Mounting Tool
7. Check installation location of the crankshaft rear radial sealing ring (4).
@ The rear crankshaft radial sealing ring (4) must be positioned at right angles to the crankshaft (7)
otherwise proper sealing is not assured.
Mercedes-Benz
ITJ The clearance between the edge ofthe end cover (8) and the rear crankshaft radial sealing ring (4)
must be approx. 1 mm ( dimension a) around the entire circumference.
Fig. 36: ldentifying Crankshaft Rear Radial Sealing Ring
REMOVE/INSTALL CRANKSHAFT- AR03.20-P-4351BV
ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 208, 209, 210, 211, 215, 220, 230
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
1'03.20 31:12.09
Cranltshilfl 1hri1Sl washeB 10 Cr.anks!JB/r b1YTtlg cap

2 Cranltshatl OHrln¡¡ shetr wíih off cranl<shatl burb'lg bolrs 11 Connecdf!ll roas
drllf!11 and oifgroove (crankc.a..,) (M8 X 75 TORJQ 12 Connoc.-df!ll rod bolls
3 Cranltshilfl I>Hrln¡¡ shel Cl'.nl<shafll>Nrln¡¡ bolts 13 Conneedf!ll roa buring smll
4 Cranicshatl I>Hrln¡¡ c.ap (MI OX .90 TORXJ 14 And·IWISt hlek
5 FlllltirO.g Cl'anl<sllafl be11b'lg bolls al sldl 15 Groove
(M8 x 40 TORX) 16 Connectlf!ll rod bearlng cap
Fig. 37: Identifving Crankshaft, Crankshaft Bearing Cap, Thrust Washer

Mercedes-Benz
Modification notes
27.2.04 Figure modified from 30 Val ue modified in series *BA03.20-P-1003-01D
Nm and 90 < or = 0 to 5 BA03.20-P-1003-01D on
Nm, 30 N m and 90 < or engines 112, 113
=o
~ .. Removing
1 Remove engine Model 463.206/ 209/ 232/ 233/ 240/ 241 AROl.lO-P-
2400CC
Model463.244/ 245/ 247/248/ 249/ 250/ 254 AROl.lO-P-
240 1GT
Model463.243/ 246 AROl.lO-P-
2401MG
Model230.475 AR01.10-P-2400R
Model 230.474 AROl.lO-P-
2400RVK
Model220 AROl.lO-P-
2400AB
Model 209 AROl.lO-P-2400Q
Model 210 without 4-MATIC, 208,202, 129 AROI.IO-P-
2400CB
Model211.070 AROl.lO-P-
2400TC
Modell63 AROl.lO-P-
2400CA
2 Remove automatic Model 463.206/ 209/ 232/ 233/ 240/ 241 AR27.10-P-
transmission from OSOOBD
engine Model463.243/ 244/ 245/ 246/ 247/248/ 249/ AR27.10-P-
250/ 254 0500GA
Model230.475 AR27.10-P-0500R
Model 230.474
Model220 AR27.10-P-0500I
Model 209 AR2 7.10-P-0500P
Models 210, 208, 202, 129 AR27.10-P-
0500B
Model211.070 AR27.10-P-0500T
Modell63 AR27.10-P-
0500GH
3 Remove oil pan Models 463.209 /232 /233 /244 /245 /250 with AR01.45-P-
top section Engine 112.945 _ 7500FG
Models 463.206 /240 /241 /247 /248 /249 /254
with Engine 113.962.
MODELS 463.243 /246 witb ENGINE
113.982
Mercedes-Benz
Model230. AR01.45-P-7500R
Model220 AR01.45-P-7500I
Model210 without 4-MATIC AR01.45-P-7500F
Model211.070 AROL45-P-
7500TV
Models 208, 202 AR01.45-P-
7500FC
Mode1209 AR01.45-P-
7500PV
Modell63 AR01.45-P-
7500FB
Model 129 AR01.45-P-
7500FD
4 Remove oil pump [JJ For this step, push back chain tensioner and AR18. 10-P-
take off chain. 6020B
Model230. AR18.10-P-6020R
Models 209, 211.070 AR18. 10-P-
6020PV
5 Detach belt Models 129, 208, 210, 463, 163 except AR03.30-P-
pulley/vibration 163.174 1600C
damper Models 163.174, 209.375 AR03.30-P-
1600CA
Model211 except 211.076 /176
Model215 except 215.374
Model 220 except 220.074 /174
Model 230 except 230.474
Models 211.076/1 76 AR03.30-P-
1600RVK
Model21 5.374
Models 220.074/174
Model 230.474
6 Detach AR03.30-P-
flywheel/driven 8001C
plate
7 Take off end cover AR01.40-P-
8913B
8 Take off timing Model463.209 /232/233 /244 /245/250 with AR01.40-P-
case cover Engine 112.945. 8000GV
Model463.206 /240 /241 /247 /248 /249 /254
MODELS 463.243 /246 with ENGINE
113.982
Models 230.474 /475, 220, 210 without 4- AR01.40-P-
MATIC,208, 202, 163,129 8000B
Mercedes-Benz
Models 209, 211.070 AR01.40-P-

8000PV
9 Remove OJ While tuming the crankshaft ensure that the
connecting rod connecting rods (11) do not getjammed.
bearing cap ( 16) IJJ Todo this, mark connecting rod (11) and
connecting rod bearing cap (16) on one si de
relative to each other.
10 Unscrew the OJ Pay attention to the bolt release pattern: ? AR03.20-P-4351-
crankshaft bearing Tightening diagram of crankshaft bearing caps 02BV
cap bolts
11 Remove the OJ Befare removing, mark the crankshaft
crankshaft bearing bearing caps (4, 10) and fitted bearing (5).
caps (4, 1O) and Carefully lever out crankshaft bearing caps
fitted bearing ( 5) (10) and (5).
12 Take crankshaft
( 1) out of the
crankcase
13 Take crankshaft
bearing shells with
oil hole and oil
groove (crankcase)
(2) and thrust
washers (6) out of
the crankcase
[g]
' Installing
14 Insert crankshaft OJ Oi1 the crankshaft journals and cranksbaft
(1) bearing shells.
If a new crankshaft is being installed AR03.20-P-4341-
OlCV
If crankshaft is being repaired AR03.20-P-4341-
OlCVA
15 Tighten the @ The crankshaft bearing cap bolts M8x75 AR03.20-P-4351-
crankshaft bearing and M10x90 must always be replaced 02BV
caps otherwise there is a risk of cranks and fracture.
1JJ Tigbten all bolts at the same time as
specified in the tightening diagram.
~ Crankshaft bearing cap bolt *BA03.20-P-
1001-0lD
~ Side crankshaft bearing cap bolt *BA03.20-P-
1002-0lD
~ Crankshaft bearing cap bolt *BA03.20-P-
1003-0lD
16 Check axial play of If a new cranksbaft is being installed AR03.20-P-4291-
crankshaft 03AV
Mercedes-Benz
17 Inspect connecting El Test data: ? AR03. 10-P-6111-

rod bolts (12) Thread and shank length OlBV
*BE03.10-P-
1001-03A
18 Install connecting @ The connecting rod bearing shell (13) with AR03.1 0-P-6lll -
rod bearings and fit the drilling (arrowed) must be installed in the 06AV
connecting rod connecting rod (11), otherwise the connecting
bearing cap ( 16) rod bearíngs will not be lubricated.
The autí-twíst lock (14) on the connecting rod
bearing shell (13) must be located in the
grooves ( 15) of the conuecting rods(ll )and of
the connecting rod bearing cap ( 16).
DJ connecting rod ( 11) and connecting rod
bearing cap ( 16) are cracked They must not be
installed on the wrong side, as dimensional
accuracy would be lost
19 Tighten connecting AR03.10-P-6111-
rod bolts (12) 02BV
*BA03.10-P-
B Connecting rod bolt 1001-01E
20 Rotate crankshaft [TITo check that it turns freely.
21 Fít on end cover DJ Fít new radial sealing ring. The sealing líp AR01.40-P-
of the radial sealing ring and its mating surface 8913B
must not be oiled or greased. Pay attention to
the fitted sleeves when pressing on the end
cover.
22 Mouutthe AR03.30-P-
flywheel/drive 8001C
pi ate
23 Mount the timing DJ Replace 0-rings and radial seaL The
case cover sealing lip of the radial sealing ring and its
mating surface must not be oiled or greased.
Pay attention to the fitted sleeves when
pressíng on the end cover.
Models 463.209 /232 /233 /244/245 /250 with AR01.40-P-
Engine 112.945. 8000GV
Models 463.206 /240 /241 /247 /248 /249 /254
MODELS 463.243 /246 wíth ENGINE
113.982
Models 220, 210 without 4-MATIC, 208, 202, AR01.40-P-
163, 129,230.474/475 SOOOB
Models 209, 211.070 AR01.40-P-
8000PV
24 Mouut belt All except model163.174, 208, 209.375, 220. AR03.30-P-
Mercedes-Benz
pulley/vibration 1600C
damper Models 163.174, 209.375 AR03.30-P-
1600CA
Model 211 except 211.076 /176
Model220 except 220.0741174
Models 211.076/176 AR03.30-P-
1600RVK
Model 215.374
Models 220.074/174
Model 230.474
25 Mount the oil OJ Ensure oil retum flow check valve is
pump correctly located. Clean the oil pump strainer.
Fill oil pump with engine oil before installing,
so that oil is delivered at the initial startup.
Models 129, 163, 202, 208, 210, 220, 463 AR18.10-P-
6020B
Models 230. AR18.10-P-6020R
Models 209, 211.070 AR18.10-P-
6020PV
26 Fit the oil pan top Models 463.209 /232 /233 /244 /245 !250 with AR01.45-P-
section Engine 112.945. 7500FG
Models 463.206 /240 /241 /247 /248 /249 /254
MODELS 463.243 /246 witb ENGINE
113.982
Model 230. AR01.45-P-7500R
Model 220 ARO 1.45-P-7500I
Model 210 without 4-MATIC AR01.45-P-7500F
Model 211.070 AR01.45-P-
7500TV
7500PV
Models 208, 202 AR01.45-P-
7500FC
Model l63 AR01.45-P-
7500FB
Model129 AR01.45-P-
7500FD
27 Check engine AR05.10-P-
valve timing 6858V
28 Fit automatic Model463.206/ 209/ 232/ 233/ 240/ 241 AR27.10-P-
transmission 0500BD
Mercedes-Benz
Model463.243/ 244/ 245/ 246/ 247/ 248/ 249/ AR27.10-P-

250/ 254 Type 230.475 0500GA
Model230.474 AR27.1 O-P-0500R
Model220 AR27.10-P-0500I
Models 210, 208, 202, 129 AR27.10-P-
0500B
Model21 1.070 AR27.10-P-0500T
Mode1209 AR27.10-P-0500P
0500GH
29 Install engine Models 463.206/ 209/ 232/ 233/ 240/ 241 AROLlO-P-
2400CC
Models 463.243 / 244/ 245/ 246/ 247/248/ AROLlO-P-
249/ 250/ 254 240IGT
Models 463.243 / 246 AROLlO-P-
2401MG
Model 230.475 ARO 1.1 O-P-2400R
Model230.474 AROl.lO-P-
2400RVK
Mode1220 AROL l O-P-
2400AB
Model209 AROLlO-P-
2400PV
Model210 without 4-MATIC, 208, 202, 129 AR01.10-P-
2400CB
Model21 1.070 AROLlO-P-
2400TC
Modell63 AROLlO-P-
2400CA
Cb ee k va ues or connectmg ro d b o1ts

N umber Designation Engine 112 except
112.951/976, E ngine
113.94/96/9711
980/981/982/984/986
BE03.10-P- Connecting rod Thread día. 0 M 8xl
1001-03A bolts Shank length Whennew mm47
max. mm47.6
Part no. -
~ Connectiug rod
N umber Designation E ngine 112 except
112.951/976, Engines
113.940/941/942/
Mercedes-Benz
943/944/945/946/
948/960/9611962/
963/964/965/966/
967/968/9711980/
981/982/984/986/
987/988/990/991/ 992/993
BA03.10-P-1 001- Connecting rod Stage 1 Nm5
OlE bolt STAGE2 Nm25
STAGE3 Angle0 90
~e
m
ran k sh a f t b earmg cap
Engines
Number Designation 112,113
BA03.20-P- Crankshaft M8 Stage 1 N m 20
1001-01D bearing cap bolt Stage 2 Angle 0 90
BA03 .20-P- Side crankshaft M8 Nm30
1002-01D bearing cap bolt
BA03.20-P- Crankshaft M lO Stage 1 Nm5
1003-0lD beari ng cap lbolt Stage 2 Nm30
Stage 3 Angle 0 90
e; El EJ r1 e1 El
~;t1 ~too' \i rJ
~¡ \j LJ~ r1
Fig. 38: ldentifying External Torx Set (001 589 76 09 00)
Tiiaaa•••••
1HH H~ HB H~
;})Qic:!JC!JCLI
000 589 01 10 00
TbotWRI
REMOVE/INSTALL BELT PULLEY/VIBRATION DAMPER- AR03.30-P-1600C

Mercedes-Benz
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 (except 113.980) in M ODEL 210
ENGINE 113 in MODEL 202.033/093
ENGINE 113.982 in MODEL 463.243/246
Shown on engine 112
1 \ffscoU's fan
2 PolyV-~~
J F1111shroud
4 CMter b<>ll
5 Vlbutlon c/Mnper
Fig. 40: Identifving PullevNibration Damper, Polv V-Belt, Center Bolt
Modification notes
9_1_06 Center bolt to vibration *BA03.30-P-1001-01D
damper
,,
1 Remove engine Mode l 163 only AR6120-
compartment P-1105GH
Mercedes-Benz
paneling
2 Remove front
air filter cover
or engine hood
3 Remove UJ Right-hand thread AR20.40-
viscous fan (1) P-5660C
4 Fan shroud (3) ~odel 163, 208, 210
Model AR20.40-
463.206 /209 /232 /233 /240 /241 /243 /245 /246 /247 /248 /249 /250 /254 P-6800V
5 Remove poly AR13.22-
V-belt (2) P-1202B
llJ Externa} torx set Fi~. 38
6 Unscrew center llJ U se extension ? Fig. 42
IJ3="wF bolt(4) WExcept model 463 W F58.50-
Extension for WOn models fitted with automatic transmission: ? P-0330-
counterholder WDo not counterhold at the ring gear (with retaining lock) for removing 02A
the center bolt! It is necessary to counter-hold at the spokes of the
vibration damper because of the bigb torque.
7 Take off WInstallation: Oil thread and bolt head contact surface of center bolt.
vibration ~ *BA03.30-
damper (5) P-1001-
~
WLocation of vibration damper. GF03.30-
P-1600-
OlC
Installation: A particular installation position is determined by the spring
wedge.
8 Install in the
reverse order
9 Check oil
viscosity after
performing
engine test run
~FI
m
ryw bee,
l d.
nve p1a t e, VI"brat10n damper, starter nng gear
Number Designation Engine 112 Engine 113.94/96 /97/98
BA03.30-P- Center bolt to Stage 1 N m 200 200
1001-0lD vibration
damper Stage 2
l Angle0 90 90
Mercedes-Benz
e;El \:1 EJ ~El

~; t1 t1 \"'' ~"1 ~~
i; tltltl ~
Fig. 41: ldentüving Externa) Torx Set (001 589 76 09 00)
112 589 00 40 00
Fig. 42: ldeotifyiog Counterbolder (112 589 00 40 00)
SETTING RING GEAR RELEVANT TO STARTER- AR03.30-P-4350AO
ENGINE 120
1 St •rltlr
z Snlm
J Orlven pl•t e wlrh r~ SI''"'
" Conracr surraco on cranl\cuc
lA Dlmonsion or cont.xt s.utf~~c .Jt
e ran~c .aso lo drlvo n pt.o trJ wirh rfng
Sl••r
Plll l 0-4llU·IIéi
Fig. 43: ldentüving Ring Gear Setting Relevant To Starter
1[gl installing
~ IRemoving,
Mercedes-Benz
1 Remove starter
OJ The specified arrangement of the starter to the ring gear ís set
by using shims (2) part no. 120 151 00 52.
Set clearance of
The specified clearance ( dimension M) assures trouble-free *BE03.30-P-
2 starter to ring gear
engaging and disengaging of the starter pinion. When carrying out 1001-04B
with shims (2)
remo val and installation work, pay attention to shims (2) and set
clearance of contact surface of crankcase to starter.
lnstall in the reverse
3
order
TEST DATA OF STARTER RING GEAR

Clearance of contact surface of starter at crankcase mm 25.6-26.5
to front edge of starter ring gear
Fit shíms qty. o
Clearance of contact surface of starter at crankcase
mm 24.6-25.5
to front edge of struter ring gear
BE03.30-P- Dímensíon
Fít shims qty.l
1001-04B "M"
Clearance of contact surface of starter at crankcase
to front edge of starter ring gear
mm 23.6-24.5
Fít shíms qty. 2
AR03.30-P-
Fig. see
4350AO
REMOVING AND INSTALLING RETAINING LOCK FOR CRANKSHAFTIRING GEAR- AR03. 30-
P-5000
Removing and installing retaining lock for cranksbaft/ring gear- AR03.30-P-SOOOAO
ENGINE 120
Mercedes-Benz
1 R otainftlg loe~
Z Covor
POllO<Dl07-0!I
Fig. 44: Identifying Retaining Lock And Cover
~ '
[g] Removing, installing
1 Remove engine compartment panel at bottom

AR49.10-P-
2 Remove exhaust system Model 140
7000F
Left-hand
3 Remove cover (2) at left-hand flange for starter
steering
Insert retaining lock ( 1) into ring gear so that it locks in place;
4 ~ F ig. 45
ro tate crankshaft if necessary
6!1 2 &99 00 4il 00
Fig. 45: ldentifving Retaining Lock (602 589 00 40 00)
Remove/install retaining lock for crankshaft 1 ring gear- AR03.30-P-5000B
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGTNE 112 in M O DEL 129. 163. 170. 202. 203. 208. 209. 21 O. 220. 230.467
Mercedes-Benz
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 208, 209, 210, 211.076 /276, 215, 220, 230.472 /474 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.982 in MODEL 463.243/246
ENGINE 275.950 /980 in MODEL 215, 220
ENGINE 113.988 in MODEL 203.076/276
Shown on engine 112
1 Rolalnlng loe k
Fig. 46: ldentifving Retaining Lock For Crankshaft 1 Ring Gear

Mercedes-Benz
&oanQerl Risk of death Align vehicle between columns of vehicle lift and position four ASOO.OO-
caused by support plates at verucle lift support points specified by vehicle Z-0010-
vehicle manufacturer. OlA
slipping or
toppling off the
lifting
platform_
1 Remove starter Model203.065 /265 /764
Model210.074/274
Model215.373
Model 220 _073/163/173
Model202, 208.474 with engine 113
Model463 with engine 112.945 AR15.30-
P-
7100GW
Model463 with engine 113.962/ 982 AR15.30-
P-7100GV
Model 129 AR15.30-
P-7100CS
Model211 except 211.076/276
Model163 with engine 112, 113 AR15.30-
P-7100GH
Model 170 with engine 112.947 /960 AR15.30-
P-7100GA
Model171.473 AR15.30-
P-7100VT
Model202.026 /086 with engine 112.910 AR15.30-
P-7100ED
Model202.029 /089 with engine 112.920
Model202.088 with engine 112.915
Model203.061 /261 with engine 112.912 AR15.30-
P-7100P
Model AR15.30-
210.061 /062 /063 /065 /081 /082 /261 /262/263 /265 /28 1 /282 /663 P-7100FF
Mercedes-Benz
with ENGINE 112

Mode1210.070 /270 /083 /283 with engine 113
Mode1215.378 AR15.30-
P-7100N
Mode1220.178 /878 with engi.ne 137.970
Model 215, 220, 230 with engine 275 AR15.30-
P-7100H
Model 215.375 with engine 113 AR15.30-
P-71001
Mode1220.070/ 075/170/175/ 875 with engine 113
Mode1220.063 /065 /067 /165 /167 with engine 112
Model 203 .081 /084 /281 /284, 220.087 / 187 with engine 112 AR15.30-
P-7100PW
Model 220.083 /084 /183/184 with engine 113
Model 211.076/276 with engine 113 AR15.30-
P-7100R
Model215.374 with engine 113
Model220.074 / 174 with engine 113
Model230 with engine 112, 113
2 Insert retaining OJ Slide retaining lock (1) into starter opening and allow to latcb in
lock (1) ring gear; if required crank engine at crankshaft in direction of
rotation.
llJ Retaining lock for engine 112, 113, 137 Fig. 47
llJ Retaining lock for engine 275 Fig. 48
3 Install in the
reverse order
Fig. 47: Identifving Retaining Lock (112 589 03 40 00)

Mercedes-Benz
Fig. 48: Identifying Retaining Lock (285 589 02 40 00)
REMOVE/INSTALL FLYWBEEL /DRIVE PLATE- AR03.30-P-8001C
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129,163, 170,202,203,208,209, 210,220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 208, 209, 210, 211.076/276, 215, 220, 230.474/475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.982 in MODEL 463.243/246
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
Shown on Engine 112 with manual transmission

Mercedes-Benz
1 FlywiiHI wfrh Sllllf•t dng Q-

2 Waahet
3 8olts
4 SrrBlghl pkl
5 Ctw*shMt
o Relllnln¡¡ loe/!
Fig. 49: ldentifving Flywheel 1 Drive Plate, Straigbt Pin, Crank Sbaft
~~ Remove/install
&.oanqerl Risk of death caused by Aligo vehicle between the ASOO.OO-Z-0010-0lA
vehicle slipping or co lumns of the lifting
toppling off of the lifting platform and position the
platform. four support plates below
the líftíng platform
support points specified
by the vehícle
manufacturer.
1.1 Remove automatíc Model 129, 170, 202, AR27.10-P-0500B
transmíssíon 208, 210
Model 463 AR27.10-P-0500BD
Model463 AR27.10-P-OSOOGA
Model 230.474 /475 AR27.10-P-0500R
Model215 , 220 wíthout AR27.10-P-0500I
4MATIC with engíne
112, 113
Model220, 211 with AR27.10-P-0500IW
4MATIC with engíne
112, 113
Model215, 220 with AR27.10-P-05001
engine 137
4MATIC, 209 with
engine 112, 113
Model 211 wíthout AR27.10-P-OSOOT
Mercedes-Benz
4MATIC with engine

112, 113
Model 163 with engine AR27.10-P-0500GH
112, 113
1.2 Remove manual Model210, 202, 129 with AR26.10-P-0020A
transmíssion engíne 112
Model 203, 209 with AR26.10-P-0020P
engine 112
Model 211 with engine AR26.10-P-0020T
112
Model 170 AR26.10-P-0020D
1.3 Remove Sequentronic Model 203, 208, 209.3 AR26.10-P-0020E
automated manual with engine 112
transmíssion (AMT) Model 211. Owith engine AR26.10-P-0020TA
112
2 Install the retaining lock AR03.30-P-SOOOB
(6) for the crankshaft (5)
and starter ring gear
3.1 Dismount clutch V ehicles with manual
transmission
OJ Only unscrew or screw
in bolts by 1 to 1.5 turns
ata time
Models 129, 163, 170, AR25.10-P-OOSOA
202, 208, 210
Model203,209,211 AR25.10-P-0050P
~ Bolt of pressure plate *BA25.10-P-1001-01A
to flywheel or two-mass
flywheel
4 Unscrew bolts (3) of ® lnstallation: Replace
flywheel or of drive plate bolts, because if they are
used again, the
connection may loosen
and the bolts may shear
off
~ T orx bolts of two- *BA03.30-P-1002-01D
mass flywheel/driven
plate at crankshaft
5 Remove washer (2)
6 Remove flywheel with OJ lnstallation: The
starter ring gear ( 1) and cylinder pin (4)
drive plate detemúnes the installation
posítion.
n::3rGF Flywheel, two-mass Engine 112, 113 GF03.30-P-800 1-0 lB
Mercedes-Benz
flywheel, drive plate,

location
8 Carry out initialization IT1 If a new flywheel or
driv e plate is installed,
¡perform initialization in
the ME control unit w ith
STAR DIAGNOSIS in
the menu ítem "Control
unit adaptation".
STAR DIAGNOSIS *WH58.30-Z-1048-13A
diagnosis system
~m Fl 1 dr'tven p:1ate, vi'b r ation d amper, starter rrng gear

1yw bee,
Number Designation E ngine 112
BA03.30-P -1002- Torx bolts oftwo-mass Stage 1 N m 45
OlD flywheel/ drive plate at
Stage 2j Angle0 90
crankshaft
~
m Fl
tywlbee1, d.
n ven p:l a t e, VI'b ration damper, s tar ter rmg gear
E ngine
E ngine 113.990/
113.94/96/ 991/992/
Num ber Designation 97/98 993/995 Engine 137
BA03.30-P- Torx bolts oftwo- Stage 1 N m 45 45 45
1002-0lD mass flywheel/ drive
plate at crankshaft Stage 21 Angle 0 90 90 90
~ C lutch
Number Designation Model129, 140, Model 461,463
163, 170, 202, 203,
208, 209, 210,211,
230
BA25 .l0-P-100 1- Bolt of pressure N m 25 25
OlA pJate to flywheel or
two-mass flywheel
e om mere•'allty ava1.• a ble t 0 0 1S

Number Designation
WH58.30-Z- l048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
REMOVING AND INSTALLING DRIVEN PLATE - AR03.30-P-8003AO

Mercedes-Benz
ENGINE 120
-
Fig. 50: Identifying Driven Plate Remove!Install Components
~ ~
[g]' Removing, installing

1 R emove transmission
Install retaining lock for AR03.30-P-
2
cranksbaft/ring gear SOOOAO
DJ Installation : inspect stretch bolts; measure diameter of
Unscrew stretch bolts (11) stretcb shank and length of stretch bolts. lf the specified
3 or micro-encapsulated mínimum 0 "d" at the stretch shank or the max. bolt length
straight-sbank stretch bolts "L" ofthe stretch bolts is reached, they should be replaced.
Replace straight-shank stretch bolts.
*BA03.30-P-
~ 1002-0lC
Driven plate 1st version
DJ Installation : install thicker driven plate (8, thickness
1.5 mm) at crankshaft side.
Take off driven plates (7,
4 Driven plates and ring gear are individually balanced and
8) and ring gear (2)
can be replaced without balancing.
DJ Contact surface of driven plates (7, 8), of bolts and
washers should be free of dirt and damage.
GF03.30-P-
Driven plate position/design
8002-0lAO
Driven plate 1st version

5
DJ Installation : the ring gear (2) should be installed in
Take ciriven nlates (7 _ 8) such a wav that the 1?11 .5 mm holes (arrows) in th e rin Q
Mercedes-Benz
off the ring gear gear (2) and in the driven plates (7, 8) have the same angle
position otherwise proper operation of the ignition is not
assured.
~FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR

120
lst
N m 35
BA03.30-P- Stretch boJt or micro-encapsulated straight shank stretch bolt stage
1002-0lC for driven plate to crankshaft Ml2 x 1.5 o
2nd
90
stage Angle
REPLACING RING GEAR OF DRIVEN PLATE- AR03.30-P-8313AO
ENGINE 120
Ring liD M 1st lfors/on

(rl nQ gc•r(1) b oltcd ro rtrl lfOn p~tcs)
Fig. 51: ldentifying Ring Gear Of Driven Plate
Fig. Work
item, instructions
etc.
ITI Removing: driven plates and ring gear are individually balanced and can be
replaced without balancing.
2 Ring gear ITI lnstallation : the ring gear (2) should be installed in such a way that the 3.5
mm 0 boles (arrows) in the ring gear (2) and in the driven plates (7, 8) have the
same angle position otherwise proper operation of the ignition is not assured.
Mercedes-Benz

REMOVING AND INSTALLING CRANKSHAFT - RA03001041800X(03-1800)
Removing and installing cranksbaft- RA03001041800X(03-1800)
Preceding work:
Engine removed {01-0300).
Oíl pump removed {18-2100).
Oil shield at crankshaft removed (18-2180) .
End cover removed {01-2220) .
Timing case cover removed {01-2100).
03-4351
Mercedes-Benz
.. e
21 21 21
... 21 B
24 24 24 A
P0:>5296-S7
A. Crllliu:ase
B Baoongcap
C F1lbi1811ng atooamgpou"t 5
Fig. 52: Identifving Crankshaft, Crankcase And Bearing Cap
Conrod bearing cap unbolt, remove_

unbolt, remove_
Crankshaft bearing
NOTE:
cap
The crankshaft bearing caps are consecutively numbered, beginning with the
first crankshaft bearing cap at the front.
remove, install.
Crankshaft (20) NOTE:

Crankshaft bearing shells (24) in the crankcase have an oil groove and an oil
feed drilling.
Crankshaft bearing
install, pay attention to fit, see note_
cap
install in cranksbaft bearing point (5).
Axial bearings (22)
and (23) NOTE:
The thrust washers in the bearing cap each have two retaining lugs asan anti-
Mercedes-Benz
twist lock. The oil grooves (arrows) in the thrust washers (22) and (23) must
tace toward the crankshaft thrust sides.
Bolt thread and bolt
head! contact surface oil.
tighten from inside to outside.
Bolts of crankshaft lnitial torque 55 N m.
bearing caps Tightening angle 90 - 100°.
Re-use bolts up toa bolt length ofmax. 63.8 mm.
lubricate with engine oil and install bearing cap.
~
Conrod bearing cap
Pay attention to marking. Install the bearing shells with the oil drilling in the
conrod otherwise the conrod bushes will not be lubricated.
Conrod bolts tighten (03-3100).
Crankshaft (20) rotate, check clearance.
TIGHTENING TORQUES IN NM OR ANGLE OF R OTATION

initial torque 55
Bolts (1) of crankshaft bearing cap
angle of rotation
(1) Re-use bolts up toa bolt length ofmax. 63.8 mm.
Special tools
001 589 72 21 00
Fi~. 53: Identifyin ~ Special Tools (001 589 72 21 00)
001 589 66 21 00
Mercedes-Benz
Fig. 54: Identifying SpeciaJ Tools (001 589 66 21 00)
NOTE: The 7 crankshaft bearing caps are fitted at the side in the crankcase (arrows).
The fit is off centered so that the bearing caps can only be installed in one
position.
TI1e crankshaft bearing caps are machined together with the crankcase.
Following bearing damage, the conrods must be taken out and any swarf present in the conrod bores, tbe
crankshafts and crankcase oil galleries removed.
Replace oil filter, oil cooler and oil pump.
Fig. 55: Locating Crankshaft Bearing Caps Dimension
The forged conrods are guided axially in the pistons (piston-guided conrods) (arrows).
P03 . 6.181· 13
Fig. 56: ldentifving Forged Pistons-Guided Conrods
Removing and installing crank~haft- RA03001201800X(03-1800)
Preceding work:
Mercedes-Benz
Engine removed (01-0300) .
Guide rails in cylinder heads removed (05-3450) .
Tensioning raíl removed {05-3300).
Guide raíl in crankcase removed (05-3400) .
Oil pump removed {18-2100) .
End cover removed (01-2220) .
Operation no . of operation texts and w ork units or standard texts and flat rates 03-4700, 6401, 7021
1
~ ~ ••4
18
""
11
7
ID\) ou
POI • II03e • M
1 Boi 18X 1 sX 45 mm 12 W~&f5 4. 5mmtnck
13 Onvenple~ 1.5mmlhck, 296 nm dia.
2 Disk spmg {4 off)
3 Be, pú!ayNibrebon dampef 14 Onven pla~ 1 mm ene!<, 287 mm da,
4 Qanksh~ sprockel 15 Slretch bollor drwen pli*es
5 CmnksllS: M 12X 1.5>< 23(8off)
6 Wooáufkey 16 Ring gaar !Mth segmerts
7 CrankshS:. b&!lllnQ shel m aanktase 17 F~edbols M 6 >< 12 mm
8 Crsnksha1 !}allllng shelln !}e:anng cep 18 Spmgwasher86
9 Thru& washers m aaokalse
19 fllltM6
10 Thrus'- wag, ers m baanng rep
20 L<Kallngpm
11 C«Tod she[S
F ig. 57: ldentifving Crankshaft Remove/lnstaJJ Components
Special tools
Mercedes-Benz
001 589 72 21 00
00
Fig. 58: Identifying Special Tools (001 589 72 21 00 00)
001 589 61) 2'1 00

00
Fig. 59: ldentifving Special Tools (001 589 66 21 00 00)
NOTE: The 7 crankshaft bearing caps manufactured from malleable cast iron are fitted
at the side into the crankcase. The fit is off-centered so that the bearing caps
can only be installed in one position.
The 5 middle bearing caps are additionally bolted to the side walls of the crankcase.
The crankshaft bearing caps are machined together with the crankcase.
If bearing damage has occurred, the conrods must be removed and any swarf in the conrod bores and crank.shaft
oil passages must be removed.
Carefully clean the oil passages in the crankcase, crankshaft, timing case cover, oil filter housing, end cover, oil
pump, etc.
l. Take timing chain off camshaft sprockets and crankshaft sprocket and remove.
2. Remove oil pump chain together with tensioning raíl, tensioning spring, and sleeve.
3. Unscrew oil deflector plate at crankcase and remove.

Mercedes-Benz
4. Unscrew conrod bearing caps and remove.

5. Unscrew crankshaft bearing caps and remove.
6. Remove crankshaft.
24 u e • 30
•o ..
.. ,
33; 3 $ tl5
~ 1 ~ '13
3 5
H 11 !1 .., m
F ig. 60: Identifyi ng Cr a nkshaft Bearing Caps T ightening Seguence Diagram
7. Tighten crankshaft bearing caps to the specified torque in the order of the tightening diagram. Oil the bolt
thread and head and the contact surface of the nut.
Tightening torque:
Nuts M8 X 1:30 Nm
MIO X 1: 50Nm.
Side bolts M8 X 60: 30 Nm.
NOTE: Pay attention to marking, 1 i s to the front. The fit is off-centered, the
crankshaft bearing caps can only be installed in one position. Use bolts of
quality 10.9 for the side bearing cap bolted connection.
8. Lubricate conrod bearing shells with SAE 30 engíne oíl and install bearing caps.
Pay attention to marking (arrow) !
Install the bearing shells, with the oil passage in the comed otherwise the comed bushes will not be
lubricated.
Mercedes-Benz
Fig. 61: Locating Marking On Bearing Shells
9. Tigbten conrod bolts (03-3100).
Fig. 62: Tightening Conrod Bolts
1O. Measure axial conrod bearing play. Check ele arance of conrods in pisten.
Disassemble oil pump, clean, replace if necessary. Replace oil pressure valve. Replace oil filter, carefully
clean air-to-oil cooler or replace.
Mercedes-Benz
Fig. 63: Measuring Axial Conrod Bearing Plav
CHECKING, REPLACING AND TIGHTENING CONROD BOLTS- RA03001043100X(03-3100)
Checkiog, replacing and tightening conrod bolts - RA03001043100X(03-3100)
03-4341, 4351
STRETCH SHANK BOLT (1ST VERSION) (1)

Conrod bolt part no. 102 038 00 71
Thread dia. M9X1
Stretch shaft dia. (e) when new 7,4-0.1
Mínimum streteh shaft dia. (e) 7,1
Length (L) when new 52-0,3
(1) Engine 104.98 up to 11/90
Mercedes-Benz
Fig. 64: Identifying Stretch Shank Bolt Dimension (1St Version)
TIGHTENING TORQUE IN NM OR TIGHTENING ANGLE

Initial torque (l) 30
Stretch shank bolt
(1) Thread and contact surface ofbolt moistened with engine oil when installing.
STRAIGHT STRETCH SHANK BOLT (2ND VERSION) (1)

Thread día. (d) M9Xl
Length (L) when new 52-0 3 (2 )
'
(1) Engine 104.98/104.99 as of 11190
(2) Re-use conrod bolt up to max. 52.9 mm.
P03-5031-1 3
Fii. 65: Identifving Straiiht Stretch Shank Bolt Dimension (2nd Version)
TIGHTENING TORQUE IN l\TM OR TIGHTENING ANGLE

30 (40) (2 ) Initial torque ( 1)
Straight stretch shank bolt
(1) Thread and contact surface ofbolt moistened with engine oil when installing.
(2) For fJrst tightening
STRAIGHT STRETCH SHANK BOLT

(3rd version)
Thread di a. (d) M9Xl
Length (L 1) when new 52-0.3 (l)
Mercedes-Benz
1(1) Re-use conrod bolt up to max. 52.9 mm.
~-------- L ----------·~
P00-5270-13
Fig. 66: Identifying Straight Stretch Shank Bolt Dimension (3rd Version)
TI GHTENING TOR QUE IN NM OR TIGHTENING ANGLE

First tightening 40
Straight stretch shank bolt (l) Initial torque Re-tightening 30
Tightening angle 90- 100°
(l) Thread and contact surface ofbolt moistened with engine oil when installing.
Conrod bolts re-use up to m ínimum stretch shaft dia. or up to max. stretch shaft length.
Weight pay attention to differences.
Thread and
bolt head oil before installing.
contact surface
Conrod bolts tighten initially with torque wrench 001 589 66 21 OO.
tighten with tightening angle wrench. Pay attention to tightening torques.
&
The conrod bolts differ in weight. Only identical conrod bolts may be instaHed in an
engine.
Conrod bolts
NOTE:
lf no tightening angle wrench is available, the conrod bolt can be tightened further
with a socket wrench and tommy bar by the specified angle in a single tightening
operation. A flexi-rod torque wrench must not be used for tightening to degrees of
angle in order to avoid angle errors.
Special tool
Mercedes-Benz
001 5B9 72 21 00
Cbecking, re]Jlacing and tightening conrod bolts- RA03001193100X(03-3100)
Operation no. of operation texts and work units or standard texts and flat rates 03-4341 bzw.
03-4351
STRETCH SHANK BOLT (1ST VERSION) 1)

Part no. 116 038 05 71
Thread 0 M lO X 1
Stretch shank 0 [(e) when new] 8.4-0.1
Mín_ stretch shank 0 (e) 8.0
a 4.2
Size b 4.5
e 4.2
Length (L) ( when new) 49.2-49.5
Conrod nut heíght (H) 9
(1) Engine 119.96
Mercedes-Benz
t'
...J
P03..10-0221-17
Fig. 68: ldentifving Shank Bolt Length (1st Version)
TIGHTENING TORQUES IN NM AND TIGHTENING ANGLE (NUT)

Engine 119.960 1 1
Initial torque First tightening 55
Conrod nut (l) Repeat tightening 45
Tightening angle
90°
(1) Nut and thread and contact surface ofbolt moistened with engine oil before installing.
STRAIGHT STRETCH SHANK BOLT 2ND VERSION 3

Part no. 102 038 02 71
Thread 0 M9xl
Shank 0 [ (e)when new] 8.7-0.2
Min. shank 0 (e) 8.2
whennew 52-0.3
Mercedes-Benz
ILength (L) max. 52.9

(l) Engine 119.97
•- - - L 1 - -.....
P03-5275-13
Fig. 69: ldentifving Stretch Shank Bolt Length (2nd Version)
TIGHTENING TORQUE IN NM AND TIGHTENING ANGLE (STRAIGHT STRETCH SHANK

BOLT)
Engine 119.97 1 1
Initial torque F irst tightening 45
Conrod bolt (1) Repeat tightening 40
Tightening angle
90°
(1) Tirread and contact surface ofbolt moistened with engine oil before installing.
STRAIGHT STRETCH SHANK BOLT (3RD VERSION) (1)

Part no. 1110380071
Thread 0 M9x 1
when new 52-0.3
Length (L)
max. 52.9
(1) Engine 119.97/98
Mercedes-Benz
~--·-- L ---~--.~
P03-5270-13
Fig. 70: Identifying Stretch S hank Bolt Length (3rd Version)
TI GHTENING TORQUE IN NM AND TIGHTENING ANGLE (STRAIGHT STRETCH SHANK

BOL T)
Engine 119.97/98 1 1
lnitial torque First tightening 40
Conrod bolt (l) Repeat tightening 30
Tightening angle
90°
(I) Thread and contact surface of bolt moistened with engine oil before installing.
Conrod bolts re-use up to mínimum stretch shank 0 or up to max. stretch shank length.
Thread and
bolt head oil before installing.
contact surface
Conrod bolts tighten initially with torque wrench OO l 589 66 21 OO.
tighten with tightening angle wrench; pay attention to tightening angle.
,&.
The conrod bolts have different weights. Only conrod bolts of the same weight may be
installed in an engine.
Conrod bolts
NOTE:
lf no tightening angle wrench is available, the conrod bolt or conrod nut can be
t ightened further in a single step by the specified angle using a socket wrench and
tommy bar. Do not use a flex i-bar torque wrench for tightening to degree settings in
order to avoid any angle errors.
Special tool
Mercedes-Benz
001 589 66 21 00
Fig. 71 : ldentifying Special Tools (001 589 66 21 00)
Replacing ( l st version)
2 Knock out conrod bolts.
3 Press new conrod bolts into the conrod with a pressure of about 45,000 N or knock in with a hammer and
drift. Place conrod on a ground steel plate (shop-made tool) when pe1fonning this step.
Fig. 72: Identifying Ground Steel Plate Dimensions (Shop-Made Tool)
Tightening
4 Coat conrod nuts and thread and contact surface of conrod bolts with engine oil.
5 T ig hten conrod nuts and conrod bolts, respective!y.
Initial tightening torque
Engine 119.96 45 Nm
(55 Nm for new conrod bolt)

Mercedes-Benz
Engine 119.96: if conrod bolts knocked in with hammer, tighten the first time to initial torque of 55 Nm and
then toa tightening angle of90-100°.
It is esseutial to observe this instruction otherwise the nuts or conrod bolts may slacken.
C hecking, replacing, and tightening conrod bolts- RA03001203100X(03-3100)
Operation no. ofoperation texts and work units or standard texts and flat rates 03-4341 , 03-4351
.....---l1 --~
~r-------l-----~~
P03 • !031 • 13
Fi~. 74: Identifyin~ Conrod Bolts Len~tb
Conrod bolts re-use up to max. 52.9 mm.

Thread and bolt head contact surface oil before installing.
Conrod bolts pre-tighten with torque wrench 001 589 66 21 OO.
tighten with angle tightener.
Conrod bolts Pay attention to note.
Mercedes-Benz
NOTE: From 05.93 modified conrod bolts are installed. The tightening torque remains
unchanged. Stretch shank bolt with rolled head.
DIMENSIONS OF CONROD BOLTS IN MM

Part no. 111 038 00 71
Thread dia. d M9X 1
Stretch shaft dia. e when new 8.7-0.2
Mínimum stretch shaft dia. e 8.2
Lengtb L 52.0- 52.9 (l)
(l) Re-use conrod bolts up to max. 52.9 mm.
Initial tightening torque C1) 30 (40) (2)
Conrod bolt
Tightening angle 90-l 00°
(1) Thread and contact surface of nut and bolt moistened with engine oil before fitting.
(2) For initial tightening.
SpeciaJ tooJ
001 589 ó6 21 00
00
NOTE: lf no angle tightener is available, the conrod bolt can be further tightened by the
specified angle in a single operation with a socket wrench and lever. Do not use
bending-rod torque wrenches to avoid any angle errors when tightening
according to angle of rotation.
Mercedes-Benz
Fig. 76: ldentifving Conrod Bolt Tightening Angle
SERVICING, ALIGNING AND MOUNTING CONROD BEARINGS- RA03001043130X(03-3130)
Servicing, aligning and mounting conrod bearings- RA03001043130X(03-3130)
Preceding work:
Conrod removed
03 -6 11 1 - 03 -6401
A B
Fig. 77: Measuring Conrod Bearing Basic Bore
REPAIRING
Conrod bolts check {03-3100).
Conrod bearing caps install; oil thread and bolt head contact surface for this step and tighten to 40 N m.
measure (Fig. A).
Mercedes-Benz
NOTE:
Jf basic bore exceeds the value of 51.619 mm or is conical, dress contact
Conrod bearing basic surface of conrod bearing capto max. 0.02 mm.
bore
Mach:ine conrod cap together with conrod.

press in (Fig. B).
NOTE:
N ew conrod bush Press in new conrod bush so that the oil drillings are aligned (arrows).
Insertion pressure 2450 N.

Conrod bush tum orream.
Contact surfaces of
dress on a dressing plate.
conrod at side
PO:>S294-53
Fig. 78: Identifving Conrod Bearing Bore To Conrod Bush Bore Alignment
ALIGNING
check with bearing shells and piston pins installed with conrod
Conrod
inspection eq uipment
Conrod align with comod alígníng equipment
Parallelism of conrod bearing bore to
align (Fig. C).
conrod bush bore
Twist of conrod bearing bore to conrod align (Fig. D).
bush bore
Mercedes-Benz
Fig. 79: Measuring Conrod Bearing Bore To Conrod Bush Bore
FITTING NEW BEARINGS

Conrod basic bore measure, note.
Conrod bearíng journal 0 measure, note.
Conrod radial bearing play calculate.
Conrod bearing shell match.
Conrod install on pistons {03-3160).
Mercedes-Benz
~-$1$2-1$
2 lderüiceboo 6 Top corred beatllg stlol
3 Bottcm balanr111g we¡ght 7 Bcttcm roni'OO bf}8flng 5001
4 X 8 Baamg shel locall'lg kJgs
M9 1 coorodbol 8 BoBil'l'lg shel locabrtg llgs
5 Dowel sleevo Arrow Oir&ctloo oftravel
Fig. 80: ldentifving Conrod Basic Bore And Conrod Bearing Shell Dimension
DATA
Engine 104.94 104.98/99
Center of conrod bearing bore to center of conrod bush bore (L) 148.995- 149.005 144.995- 145.005
Width of conrod at conrod bearing bore (B) 2 1.948 - 22.000
Width of conrod at conrod bush bore (b) 21.948 - 22.000
Conrod bearing sheJl basic bore (D 1) 51.600 - 51.619
Conrod bush basic bore (dl) 24.500- 24.571
DATA
Conrod bush inner 0 (d) 22.007 - 22.013
Piston pin play in conrod bush 0.013-0.018
Peak-to-valley height of conrod bush on inside 0.005
Permissible twist of conrod bearing bore to conrod bush bore 0.15
Permissible difference in axial parallelism of conrod bearing bore to conrod bush bore 0.07
Permissible difference in concentricity of conrod bearing bore 0.01
Permissible difference in weight of complete conrod within an engine 4g
Mercedes-Benz
CRANKSHAFT IDENTIFICATION AND MACHINING DIMENSIONS

Color coding on crankshaft web
Crankshaft Size (2) Machining dimensions (l)
Standard none 47.955 - 47.965

Standard 1 (2 ) orange 47.945-47.955
Standard 2 (2 ) blue 47.935-47.945
Conrod bearing journal 0 1st repair size - 47.700 - 47.715
2nd repair size - 4 7.450 - 47.465
3rd repair size - 4 7.200 - 47.215
4th repair size - 46.950 - 46.965
Conrod bearing joumal Standard 27.958- 28.042
width Repair size up to 28.300
(l) The crankshaft should be machined so asto maintaín the specified bearing play with the existing
bearing shells.
(2) Up to 12/93
TEST DATA
radial 0.02 - 0.04
Conrod bearing play
axial piston-guided
CONROD BEARING SHELLS

Color coding red yellow blue
WaH thickness in mm 1 1
Standard 1.806 - 1.81 o 1.810 - 1.814 1.814- 1.818
Standard 1 (l) 1.811 - 1.815 1.815 - 1.819 1.819 - 1.823
Standard 2 (l) 1.816 - 1.820 1.820 - 1.824 1.824- 1.828
1st repair size - 1.995 - 1.999 -
2nd repair size - 2.060 - 2.064 -
3rd repair size - 2.185- 2.189 -
4th repair size - 2.310 - 2.314 -
(l) Standard 1 and standard 2: wall thicknesses are not supplied as replacement parts.
Special tools
Mercedes-Benz
001 589 66 21 00
001 589 53 21 00
Fig. 82: Identifving SpeciaJ Too) (001 589 53 21 00)
e.g. Model BC 501
Conrod tester KWT
63128 Díetzenbach
e.g. Model BC 503
Conrod alígning tool KWT
63128 Dietzenbach
Quick-caliper for intemal measurements
0 20-40 mm
0 40 -60mm
Micrometer
O- 25 mm
50-75 mm
NOTE: Conrod and conrod caps are marked together (arrow).
Conrods which have been overheated because of bearing damage (blue discoloration) must not be re-used.
The conrod shaft must not have any cross scores and notches.
Conrods wíth machined conrod bush are supplíed as a replacement part.

Mercedes-Benz
The conrod and the conrod cap are located relative to each other with fit sleeves.
Pay attention to difference in weight when replacing the conrod.
Fig. 83: Locating Conrod And Conrod Caps Marked
Repairing and aligning conrod- RA03001193130X(03-3130)
03-6111
Engine 119.96
Engine 119.97/98
Mercedes-Benz
_,
Fif'. 84: ldentifying Conrod Dimensions CEnf'ine 119.96)
Fi~. 85: Identifying Conrod Dimensions (Engine 119.97/98)
DATA
Mercedes-Benz
Engine 119.96 119.97/98

154.550 149.050
Centre of conrod bearing bore to center of conrod bush bore (L)
154.450 148.950
24.890
Width of conrod at conrod bearing bore (B)
24.857
28.000 22.100
Width of conrod at conrod bush bore (b)
27.900 21.900
51.619
Basic bore for conrod bearing shells (D)
51.600
29.021 27.210
Basic bore for conrod bush (d)
29.000 27.000
26.013 24.013
Conrod bush ID (d1)
26.007 24.007
0.007 0.007
Pis ton pin play in conrod bush
0.013 0.018
Peak-to-valley height of conrod bush on inside 0.004 0.005
Engine 119.96 119.97
Permissible twist of conrod bearing bore relative to conrod bush
0.15
bore
Permissible variation of parallelism of conrod bearing bore to
0.07
conrod bush bore
Permissible variation of conrod bearing bore from roughness 0.01
Pemussible difference in weight of complete conrod wi thin an
4g
engine
Special tool
~~---0_
01_5_8_9_66_2_1_00_____ )

ModelBC 501
Conrod tester e.g.KWT
D-6057 Dietzenbach
Mercedes-Benz
Model BC 503
Comod straightening device e.g.KWT
D-6057 Dietzenbach
Quick-callipers for interna} measurements
dia. 20 - 40 mm
dia. 40 - 60 mm
Micrometer
O -25 mm
50 -75 mm
NOTE: Conrods which have been overheated as a result of the bearing damage (blue
discoloring) must not be re-used.
Comod and comod caps are marked together. The comod stem must not have any transverse scoring and
notches.
Conrods are supplied with machined conrod bush as a replacement pmt.
Conrod and crankshafts with ctifferent thrust collar dia. rnay be installed together when performing repai1s.
Engine 119.97: The conrod and the conrod cap are fixed together with fit sleeves.
Pay attention to difference in weight when replacing the conrod.
COflf'Od of BflgiOO 119.960

1 Wetghtba.lance
9 Locatllg grooves
10 Oiool ng
Fig. 87: ldentifving Weight Balance, Locating Grooves And Oil Drilling
Repairing
l. Check conrod bolts, replace if necessary (03-3100).

Mercedes-Benz
Fig. 88: Checking Conrod Bolts
2_ Engine 119.96: Examine bores for conrod bolts. Fit conrod cap onto a conrod bolt Ifthe conrod cap
moves down as the result of its own weight, the conrod must be replaced.
Fig. 89: ldentifying Conrod Cap & Conrod Bolt
3 _ Install conrod bearing caps. Oil thread and bolt head contact surface for this step and tighten to 40 Nm.
4. Measure conrod bearing basíc bore_ If the basíc bore exceeds the value of 51.619 mm or ís conícal, dress
bearing cover at its contact smface on a dressing plate up to max. 0.02 mm.
Mercedes-Benz
Fig. 90: Measuring Conrod Bearing Basic Bore
5. Press in new conrod bush so that the oil bores are aligned (arrows).
Insertion pressure 2500 N.
6. Tum or ream conrod bush.

7. Dress side contact surfaces of conrod on the dressing plate.
Coo-ooct Engana 119.95
Fig. 91: lden tifying Conrod Dimensions
Aligning
Mercedes-Benz
8. Align conrod with conrod tester.

9. Align conrod bearing bore to conrod bush bore (parallelism).
Fig. 92: ldentifying Conrod Bearing Bore To C onrod Bush Bore (Parallelism)
1O. Examine twist of conrod bearing bore to conrod bush bore and correct if necessary.
Fig. 93: Examining Twist Of Conrod Bearing Bore To Conrod Bush Bore
Repairing and aligning conrod - RA03001203130X(03-3130)
Operationno. of operation texts and work units or standard texts and flat rates 03-6111
Mercedes-Benz
PD;3-G18 t ·1S
R Cornod, nght !ild& 5 Oowel ~ve
l Ccorod,left stde 6 C.oorod beam g shol s at top
1 BalanciO[l Wllt!}tt at !Dp 7 C«rodbeamgsha satbottom
2 Mad<Jog 110 03 8 locaung klg otbeanng stlel
3 Ba!aneing WBlgttat bo(tom & 12mn
4 Comod~M9 X 1 f 10mn
A.rrow Onodioo of travel
Fig. 94: Identifying Conrod Length
DATAINMM
Center of comod bearing bore to center of comod busb bore (1) 153.95- 154.05
Widtb of comod at comod bearing bore (B) 21.948 - 22.000
Widtb of conrod at conrod busb bore (b) 19.90 - 20.1 0
Basic bore of comod bearing sbeJls (Dl) 51.600 - 51.619
Basic bore of conrod bush (d 1) 24.500 - 24.521
Inner dia. of conrod bush ( d) 22.007- 22.013
Piston pin play in conrod bush 0.013- 0.018
Peak-to-valley heigbt of conrod bush on inside 0.005
Permissible twist of conrod bearing bore to conrod bush bore 0.15

Pennissible deviation of axial parallelism of conrod bearing bore to conrod bush bore 0.07
Permissible deviation of comod bearing bore from concentricity 0.01
Pennissible difference in weight of complete conrod within an engine 4g
SpeciaJ tools
Mercedes-Benz
0()1 589 t)6 21 00

00
001 589 63 21 00
00
CO~UMERCMLLYAV~ABLETOOLS
ModelBC 501
Conrod tester e.g.KWT
W -6057 Dietzenbach
Model BC 503
Conrod aligning tool e.g.KWT
W -6057 Díetzenbach
Quick calípers for interna! measurements
Día. 20 - 40 mm
Día. 40-60 mm
Outside mícrometer
O- 25 mm
50 - 75 mm
NOTE: Conrods which have been overheated because of bearing damage (blue
discoloration), must not be re-used.
Comed and comed cover are marked together. The comed shaft must not display any cross scores and notches.
Comods with machined comed bush are supplied as a replacement part.

Mercedes-Benz
Pay attention to difference in weight when replacing comods.
Repairing
l. Examine comed bolts, reptace ifnecessary {03-3100).

2. Install conrod cover. Oil thread and bolt head contact surface for this purpose and tighten to 40 N m.
3. Measure basic bore of comed bearings. lf the basic bore exceeds 51.619 mm or is conical, dress conrod
cover to max. 0.02 mm at its contact surface. Machine conrod cover together with conrod.
Fig. 97: Measuring Basic Bore Conrod Bearings
4. Press in new conrod bush so that the oil passages are alígned (arrows ).
lnsertion pressure 2500 N .
5. Tum or ream conrod bush.

6. Dress síde contact surfaces of conrod on the dressing plate.
PU-11131-13
Fig. 98: Pressing Conrod Bush
Alionino
Mercedes-Benz
7. Check conrod with bearing shells and piston pins fitted with a conrod tester.
8. Align conrod with a coruod aligning tool.
9. Correct parallelism of conrod bearing bore to conrod bush bore.
Fig. 99: Identifying Correct Parallelism Of Conrod Bearing Bore To Conrod Bush Bore
1O. Correct twist of conrod bearing bore to conrod bush bore.
Fig. 100: Identifving Correct Twist Of Conrod Bearing Bore To Conrod Bush Bore
REMOVING AND INSTALLING PISTONS- RA03001043160X(03-3160)
Removing and installing pistons- RA03001043160X(03-3160)
Preceding work:
Engine removed (01-0300) .

Mercedes-Benz
Cylinder head removed (01-4150) .
Oil pump removed {18-2100) _
Oil shield removed (18-2180) .
03-7061
oO
•
5
P03-5289-57
Fig. 101: Identifying Pistons Remove/Install Components (1 Of 2)
REMOVING PISTONS
unbolt.
Conrod bearing
cap (1) NOTE:
Conrod (2) and conrod bearing cap (1) are marked together.
remove upward.
NOTE:
r()nmrl (?\ w ith The direction of travel arrow is stamped at the top in the piston crown.
Mercedes-Benz
piston (4)
On certain versions, the direction of travel arrow is no longer visible if the pisten is
worn; in this case, mark direction of travel on pis ton.
TAKING OFF, FITTING ON PISTONS

prise out with a screwdriver.
Piston pin circlip &
(5)
U se clean cloth as base.
Conrod repair, aligo (03-3130).
Piston ring gap
and top clearance check (03- 3170).
Piston pin (6) and .
011
comod bushes ·
install together.
NOTE:
The retaining slots (8) of the conrod bearings must tace toward the left side of the
Piston (4) and
engine. The raised face (4a) on one of the two piston pin bosses must tace in the
conrod (2) opposite direction of travel.
& Pay attention to matching pistons and dimensions (03-3165).

Mercedes-Benz
P03 -5345-S7
Fig. 102: ldentifying Pistoos Remove/lostall Components (2 Of 2)
Pis ton pin ( 6) press in by hand.

Piston pin circlip (5) insert ínto groove (arrow).
oil.
Cleaned cylinder beres, cenred bearing jeurnals, cenred .1:.
bearing shells and pisten (4) Install the cenred bearing shell with eil
drilling ínto the conrod (2).
INST ALLING PISTON

Tensiening strap (7) 000 589 04 14 00 fer pisten rings fit en, tensien.
Piston (4) install with arrew in directien ef travel.
Conrod (2) and conred bearing cap (1) install with marking (arrow) facing each other.
Conrod bolts (3) check, tighten (03-3100).
Crankshaft tmn, check clearance.
Special tools
Mercedes-Benz
001 589 72 21 00
000 589 04 14 00
NOTE: lnstall new pistons with piston rings in used engines only if the cylinder bore
does not have any abnormal wear, and is within the dimensional tolerances for
cylinder shape and concentricity.
The honing should be visible and undamaged.
In the case of reconditioned engines, determine repair size (01-1100), then
order pistons on the basis of the val id parts documentation.
Pistons to prevent increased oil consumption
Production break-point :
104.980 10 007 303
104.980 12 033 749
104.981 10 001 753
104.981 12 015 196
Removing and installing ¡Jistons- RA03001193160X(03-3160)
PrPr Prlin o wnrk--

Mercedes-Benz
Removing engine (01-0300) .
Removing cylinder head (01-4150).
Removing oil sump (01-3100) .
03-7021
Cylinder identification and pis ton identifications must agree (see arrows).
NOTE: The group classification has been converted from numerals to letters and
reduced to three stages.
The pistons with numerals may be installed in a crankcase with a letter grouping, but not vice versa (see
Pistons, matching and dímensions 03-3165).
When performing repairs, all the cylinder bores should be honed to the dimensions of the existing pistons plus
piston play, see "Measuring, PQ3-2024-13 honing and silicone-lapping cylinder bores" (01-1120).
The p iston pins are matched to the pistons and must not be mixed up.
Fig. 105: ldentifying Piston And Cylioder Head Surface With Numerals
Mercedes-Benz
P03.10-0214- 13
Fig. 106: l dentifying Piston And Cylinder Head Surface With Letters
NOTE: The group number of the pistons (e.g. +1) must agree with the group number of
the cylinder bores (standard production).
This ensures that the specified pisten play is maintained.
pisten play (see table).
The pisten pins are matched to the pistons and must not be mixed up.
Removing
l. Unbolt conrod bearing caps and lift out conrod together with pistons.
NOTE: Conrod and conrod bearing caps are marked together.
Do not damage cylinder contact surfaces with cornod.
2. Inspect conrod bolts (03-3100) .

3. Use screwdriver to remove pisten pin retainer and press out pisten pin.
4. Service conrod and align, if necessary (03-3130).
Mercedes-Benz
. -tOJt-U.
Fig. 107: Removing Piston Pin Retainer
Installing
5. lfpistons are wom, inspect gap and axial clearance ofpiston rings (03-3170) . Check that piston rings
move freely. Pay attention to installation pos.: "Top" faces up.
Distribute ring gaps evenly around circumference.
6. Oil piston pin and conrod bushes.

7. lnstall piston so that the arrow faces in direction oftravel and the locking slots in the conrod (arrows) as
well as the drawing of the conrod are facing to the outside of the engine.
NOTE: The conrods are asymmetrical, the wide thrust collars point toward the
crankshaft webs.
Fig. 108: Locating Locking Slots In Conrod

Mercedes-Benz
8. Press in pistan pin by hand.
Fig. 109: Pressing Piston Pin
9. Insert piston pin retainer into the groove.

1O. Oil cleaned cylinder bares, conrod bearing journals, conrod bearing shells and pistons .
• • -11 . . - 11
Fig. 110: Locating Piston Pin Retainer & Groove
11. Fit on tensioning strap for pistan rings and insert pistan into the cylinder bore with arrow facing direction
of travel.
Do not damage cylinder contact surface with conrod.

Mercedes-Benz
Fig. 111: Inserting Piston luto The Cylinder Bore
12. Fit conrod bearing cap onto the conrod with the identification (arrow) facing each other. Moisten conrod
nuts and thread and contact surface of conrod bolts with engine oil and tighten.
Tightening torque (see 03-3100).
Pay attention to instaUation position of conrod bearings. Install comed bearing shell with oiJ driJling in
the conrod otherwise lubrication of the piston pin is not assured.
Pay attention to tightening torques ofthe conrod bearings (see Inspecting, replacing and tightening
conrod bolts 03-3100).
13. Ro tate crankshaft and check whether it ro tates freeJy.
Fig. 112: ldentifving Conrod Bearing Cap On The Conrod With The ldentification Facing Each
Mercedes-Benz
Other
Special tool
000 589 04 14 00
Removing and installing pistons - RA03001203160X(03-3160)
Preceding work:
Remove engine (01-0300) .
Remove cylinder head (01-4150) .
Remove oil pan (01-3100) .
03-7021
NOTE: The group number of the pistons (e.g. 1) must agree with the group number of
the cylinder bores (series production).
This insures that the specified piston clearance is maintained.
piston clearance (see table).
The piston pins are matched to the pistons and must not be interchanged.
The direction of travel arrow is stamped on the piston crown and is no longer visible on used engines.
R em oving, installing
l . Unscrew conrod bearing caps and remove conrod together with pistons upward.
Mercedes-Benz
NOTE: Conrod and conrod cover (arrow) are marked together.
Do not damage cylínder contact surfaces wíth coruod.
Fig. 114: Locating Marking On Conrod And Conrod Cover
2. Examine conrod bolts {03-3100).

3. Remove pis ton pin retainer with screwdriver and press out piston pin.
Do not damage pistons, use a clean cloth as a base.
4. Repair conrod and align, ifnecessary (03-3130).
lfia 11 '\• RPmnvina Pidnn Pin RPt~in Pr

Mercedes-Benz
5. Check the end and axial clearance ofpíston ríngs on used pístons (03-3170).
Check the píston ríngs for ease of movement.
Pay attention to install position: "Top" is at the top.
Distribute ríng joints evenly around the circumference.
NOTE: Oil scraper ring (3)
The wíre in the garter spring (4) of the oil scraper ríng (3) has a hook (8). This hook (8) must be inserted
into one ofthe recesses (arrow) on the oil scraper ring (3).
6. Oil piston pins and conrod bushes.
Fig. 116: Locating Oil Scraper Ring, Garter Spring And Hook
7. Install pistons so that the piston code number (5) next to the piston pín and group number (6) are pointíng
in the direction oftravel and the identificatíon (9) on the conrod is facing to the outside ofthe engíne.
NOTE: The conrods are off-center, 1he wide thrust collars (7) tace the crankshaft
webs.
Mercedes-Benz
e
7 ~-Aal-15
Fig. 117: Locating Piston Code Number
8. Press in piston pins by hand.
Fig. 118: Pressing Piston Pins
9. Insert piston pin retainer in the groove (arrow).

10. Oil cleaned cylinder bores, conrod bearing journals, conrod bearing shells and pistons.
Mercedes-Benz
1181-tfM-11
Fig. 119: Locating Piston Pin Retainer
11. Fit on tensioning strap (1) 000 589 04 14 00 for piston rings and insert pis ton into the cylinder bore with
arrow or piston code number and group number facing direction of travel.
Do not damage cylinder contact surface with conrod.
Fig. 120: Identifving Tensioning Strap
12. Fit conrod bearing caps onto the conrod with the marking (arrow) faci ng each other.
Moisten the threads and contact surfaces of the conrod bolts with engine oil and tighten.
Pay attention to installed position of conrod bearings. lnstall the conrod bearing shell with oil passage in
Mercedes-Benz
the conrod otherwise lubrication of the piston pin is not assured.
Tightening torque: 40 N m (45 N m for initial tightening)
Tíghtening angle: 90 - 100°
13. Rotate crankshaft and check ease ofmovement.
Fig.121: Locating Conrod Bearing Caps Fitted On Conrod
TIGHTENING TORQUES JIN NM

initial tightening torque (1) 40 (45) <2)
Conrod bolts
tightening angle 90- 100°
(1) Thread ancl contact surface ofnut or bolt moistened with engine oil before installing
(2) For frrst tightening
Special tool
000 588 04 14 00
03 13
Fi~. 122: Identifying Special Tool (000 589 04 14 00 03 13)

Mercedes-Benz
MATCHING PISTONS AND PISTON DIMENSIONS - RA03001043165X(03-3165)
Matching pistons and piston dimensions - RA03001043165X(03-3165)
When performing repairs, the pistons with the code letters stated below should be installed in the case of
cylinder bores with "standard size".
Cylinder bore identification Piston identi:fication (1)
A A or X
X X orA, B
B B orX
( 1) If pistons
with standard size are replaced when performing repairs because of a noíse problem, match
up the pistons properly in accordance with the cylinder bore identification. Additional code when
orderíng pistons 52=A, 54=X, 56=B
NOTE: When perfarming repairs, the cylinder bares shauld be finished ta the
dimensians af the existing pistans in accardance with the table far matching
the pistans; see "Measuring, baring and haning cylinder bares" (01-1100) .
Pistan play when the pistans are new is 0.02 ta 0.04 mm.
The measuring paint is abaut 12 ta 14 mm abave the battam edge af the pistan
at right angl es ta the pistan pin. lt is nat passible ta canduct an exact
measurement af used pistans as the pistan skirt has "sunk" at the measuring
paint pravided.
POl-5343-13.
Fig. 123: Locating Pistons And Piston Dimensions
Pistons, matching and dimensions - RA03001193165X(03-3165)

Mercedes-Benz
Cylinder identificatien and pisten identificatiens must agree (see arrews).
NOTE: The group classification has been converted from numerals to letters and
reduced to three stages.
The pistens with numerals may be installed in a crankcase with a letter greuping, but net vice versa (see table).
When perferming repairs, all the cylinder beres sheuld be hened te the dimensiens ef the existing pistens plus
pisten play, see "Measuring, honing and silicene-lapping cylinder beres" (01-1120) .
Fig. 124: Identifving Piston And Cylinder Head Surface With Numerals
P0-3.10-0114-1 3
Fig. 125: ldentifying Piston And Cylinder Head Surface With Letters
Letter cylinder identification

Mercedes-Benz
o A A
O+ 1 B B
1+ 2 e e
TEST DATA
Engine 119.96 119.97 119.98
Piston clearance o.004-0.026 0.004-0.026 0.004-0.026
Dífference in weíght of pistons within an engine 8g 18g 8g
Pis ton pin 0 25.995-26.000 24.000 24.000
Piston pin c1earance in piston 0.004-0.008 lo.oo4-o.oo8 o. 004-0.008

Engine 119.960/970/972/974 Class identification lndex Piston o(l) Cylinder e<2)
o 52 96.483-96.493 96.498-96.503
O+ 53 96.488-96.498 96.503-96.508
1+ 55 96.498-96.508 96.513-96.518
2 56 96.503-96.513 96.518-96.523
o 96.983-96.993 96.998-97.003
1st repair size+O .5 1 96.993-97.003 97.008-97.013
2 97.003-97.013 97.018-97.023
o 97.483-97.493 97.498-97.503
2nd repair size + l .O 1 97.493-97.503 97.508-97.513
2 97.503-97.513 97.518-97.523
(1) Group identification stamped on piston crown with color.
(2) Group identification stamped at top next to cy1inder bore.

Engine 119.980/982/970/972/974 Group identification lndex Piston o<2> Cylinder 0(1)
A 52 96.482-96.495 96.500-96.508
Standard size Std 96.5 0 B 54 96.49 1-96.504 96.508-96.516
e 56 96.499-96. 512 96.516-96.524
A 96.982-96.995 97.000-97.008
1st repair size+0.5 2) B 96.991-97.004 97.008-97 .O 16
e 96.999-97.012 97.016-97.024
A 97.482-97.495 97.000-97.508
2nd repair size+l.02) B 97.491-97.504 97.508-97.516
e 97.499-97.512 97.516-97.524
(1) Group identification stamped at top next to cy1inder bore.
Group identification stamped on piston crown.
Mercedes-Benz
(2)

Engine 119.9711975/981/985 Group identification Index Piston o<t) Cylinder o<2>
o 52 91.983-91.993 91.998-92.003
O+ 53 91.988-91 .998 92.003-92.008
1+ 55 91.998-92.008 92.013-92.018
2 56 92.003-92.013 92.018-92.023
o 92.483-92.493 92.498-92.503
1st repair size+0.5 2) 1 92.493-92.503 92.508-92.513
2 92.503-92.513 92.518-92.523
o 92.983-92.993 92.998-93.003
2nd repair size+l.O 2) 1 92.993-93.003 93.008-93.013
2 93.003-93.013 93. o18-93.023
(l) Group identification stamped on piston crown with color.
(2) Size stamped at top next to cylinder bore.

Engine 119.971/975/981/985 Group identification lndex Piston 0(2) Cylinder e<t)
A 52 91.982-91.995 92.000-92.008
Standard size Std 92.0 0 B 54 91.991-92.004 92.008-92.016
e 56 91.999-92.012 92.016-92.024
A 92.482-92.495 92.500-92.508
1st repair size+0.5 2) B 92.49 1-92.504 92.508-92.516
e 92.499-92.512 92.516-92.524
A 92.982-92.995 93.000-93.008
2nd repair size+ 1.0 2 ) B 92.991-93.004 93.008-93.016
e 92.999-93.012 93.016-93.024
(I) Group identification stamped at top next to cylinder bore.
REPLACING PISTONRINGS- RA03001043170X(03-3170)
Replacing )liston rings - RA0300 1043170X(03-3170)
Preceding work:
Piston removed (03-3160).

Mercedes-Benz
POS · 5216 -17
1 Plam romp¡os SJoonng 3 Doltlle bevekd od C'Oilrolnnº

2 Tapef-mted hook s.craper nng 4 Oll codrol nng ~\l:h e~ spmg
Fig. 126: ldentifying Plain Compression Ring, Taper-Faced Hook Scraper Ring And Coil Spring
Gap and end clearance of piston rings measure, see table.

Piston rings remove with pliers (10) 000 589 51 37 OO.
Width of ring of pisten rings measure.
Piston rings ínstall only rings with ídentical ring width.
Installation position note, "Top" faces up.
Hook spring (8) in oil scraper ring (3) install offset 180° to joínt (arrow).
Special tool
Mercedes-Benz
000 589 5 1 37 00
TEST DATA
groove 1 0.20-0.40
Gap clearance of piston rings groove 2 0.20-0.40
groove 3 0.20-0.45
groove 1 0.015 - 0.050
End clearance of pisten rings groove 2 0.020- 0.040
groove 3 0.010 - 0.045
NOTE: When replacing the piston rings, determine which pistons are installed.
When performing repairs, fit pistons only with the matching piston rings.
Replacing piston rings- RA03001193170X(03-3170)
Preceding work:
Pistons removed (03-3160).

Mercedes-Benz
I'CS • 5216 -17
1 Plam ~cmpr&SsJOO rng 3 Oo!ble bewled rotl spnng loaded oi C!1lOÍ'olrl'lg

2 Tflj)11í-lac.ed hook Scrnpilf ITIQ 4 Coi Sllfl19
Fig. 128: ldentifying Plain Compression Ring, Taper-Faced Hook Scraper Ring And Coil Spring
End clearance of
piston rings
measure.
remove w itb pliers (1 0), insta11, special tool 000 589 51 36 OO.
Piston rings NOTE:

Pay attention to installation position, "Top" faces up. Hooked spring (8) in oil
scraper ring (3) is installed offset 180° to joint (arrow).
Special tool
Mercedes-Benz
ooo sa9 i t 37 oo
03
TEST DATA IN MM
Groove 1 0.05-0.08
End clearance of pistan rings Groove 2 0.01 - 0.03
Groove 3 0.01 - 0.04
EXAMINING AND REPAIRING CRANKSHAFT- RA03001043180X(03-3180)
DATA IN MM
Crankshaft, Tolerances, and Part number see (03-3190}
Permissible out-of-roundness of crankshaft and conrod bearing joumals 0,002
conrod bearing journals 0,010
Pennissible difference in cylinder shape over length of about
54 mm crankshaft bearing
0,010
journals
Permissible axial runout of fit bearing 0,02
crankshaft bearing
1,9 - 2,1
Fillet radii at the journals
conrod bearing joumals 1,9- 2,1
Bearingjournals ground and p recision-lapped, max. peak-to-valley-height Rz (!J.m) 0,15
Crankshaft journal 0 at front 31 ,98- 32,00
Permissible difference in concentricity of front crankshaft (l) (2) 0,05
~ ournal
92,874 -
Contact surface 0 for radial seal at rear
92,928
radial (l) 0,04
Permissible difference of rear crankshaft flange
axial (1) 0,015
Permissible difference in concentricity of crankshaft bearing journals 2, 6 0,07
lioumals (l) (3) journals 3, 4, 5 0,14
Scleroscopic hardness of crankshaft and conrod bearing when new 74-84
~oumals limit value 60 (4)
Mercedes-Benz
Pemússible imbalance of crankshaft when mounted in j oumals 2 and 6 l1oo gmm es)
(1) When crankshaft mounted on crankshaft bearing journals 1 and 7 and one full revolution.
(2) If measurement made when crankshaft installed, eliminate radial bearing play by applying pressure to
crankshaft joumal.
(3) When crankshaft mounted on the crankshaft bearing joumals in front of and behind the crankshaft
bearing journal to be measured and one full revolution, permissible difference 0.04.
(4) The limit value must exist at least 2/3 ofthe circumference ofthe journal.
(5) Related to l st and 12th baiancing weight at 550 rpm when mounted on 2nd and 6th crankshaft
bearing journals.
NOTE: Maximum wear limit of crankshaft and conrod bearing journals 0.02 mm. The
repair sizes listed in the table should be adhered to exactly. When re-grinding, it
is essential to maintain the fillet radii at the crankshaft and conrod bearing
journals.
All the radii of the conrod and crankshaft bearings are inductively suñace-
hardened, at the 2nd, 3rd, 4th, 5th and 6th crankshaft bearin gs.
The running surface for the rear radial seal ís ínductively hardened to a depth of about 1 - 2 mm.
SpeciaJ tool
000 589 20 21 00
NOTE: Proceed in the order stated in the diagram overleaf when examining and
servicing crankshafts.
A. Exarnining, grinding
Mercedes-Benz
Vísual lnspection
s~edamage
Y es
jscnp
J
Cr-ack test (see e~~ory note)
Cracks pruert
Yea
Hardness test {see explanatory note)

Al bearlng Journals
Scleroscopic hlrdness at lealt 60 scale values
on 2/3 of CÍ'Ct.mferev of joumal
Y es
E Harden~ (sectlon B)
j
Musurlng journlls
Mcas..-ements oerrcct
Yes
Exarnne whether IJilcing ls sbl

possble v.thln lhe spedfled repair slzes
Yes ]No
[E
IGrind crankshaft
1 1
1
¡
(;;ek tesl 1
Cfilcks presenl
Yes !No
~
l&rap
1
Fig. 131: Grinding E xamining Flow Chart (1 Of 2)

Mercedes-Benz
1990-2002 ENGINE Cran k Assembly - 129 Chassis
Lapping
Dimensional check
Dimensions oorrect
Y es
r---
see Examinlng/Grinding
Assemble cranl<shaft
1
1End of inspection
Fig. 132: Gr inding Examining Flow Chart (2 Of 2)
B. Hardening
Mercedes-Benz
Check whether grindlng is sUI possible wjhin the specified repalr sizes.
Yes
1~0
~
¡scrap
1
lnductlon ha rdening
S'ystem available
~S 1~0
¡sorap
llnductlon hardenlng
Test hardness by etching (see explanatory note)
Straightenilg by b1ending not permited

in the case of crarnkshaft bearing
'e>urnals with radus hardening
¡see Grinding crankshaft (secti on A)
Fig. 133: Hardening Examining Flow Chart

Mercedes-Benz
Explanatory notes of diagram
Crack testing
Clean crankshaft. The bearing journals must be free of oil and grease.
Magnetize crankshaft and apply fluorescent powder (flux).
It is also possible to use a dye penetration method (irnmersing in bath or using a spray can).
Aid: dye, UV oil or fluorescent powder, cleaning product, developer
Hardness testing
Test hardness with the d:rop hardness tester (scleroscopic hardness).
The mínimum hardness of 60 scale values must exist at 2/3 of the circumference of the joumaL
Fie. 134: Identifying Test Hardness With Drop Hardness Tester
Hardening
Always barden journals with hardened radii (arrows) inductively.
If this is not possible, scrap crankshaft.

Mercedes-Benz
P03-5357-1 3
Fig. 135: Locating Harden Journals With Hardened Radii
lnspecting hardening
The setting of the hardening system should be checked by taking metallographic sections in order to
achieve proper hardening. These sections can be taken from test hardenings on scrapped crankshafts.
Check hardening by etching the surface of the journal with a 2% alcoholic nitric acid (HNO 3 ).
No dark patches should appear on the surface of the journal.
The hardened radü must be just as bright as the surface of the journal.
The non-hardened radii darken in color.
As a comparison, it is recommended to perform etching on a journal which has been metallographically

checked.
Following this, carefully wash off the nitric acid with alcohol.
Corrosion protection
Crankshafts which are not re-installed immediately, must be oiled with a con osion protection oil.
CRANKSHAFT MACHINING DIMENSIONS AND IDENTIFICATIONS- RA03001043190X(03-3190)
CRANKSHAFT MACHINING DIMENSIONS AND IDENTIFICATIONS, RADIAL MOUNTING (l)

Machining stage Crankshaft bearing Colored identification oo Laser lettering oo front of
(2) journal0 counterweight crankshaft
Standard 57.960-57.965 blue B
Standard 57.955-57.960 yellow G
Standard 57.950-57.955 red R
Mercedes-Benz
Standard 1 57.945-57.950 white w

Standard 1 57.940-57.945 purple V
Rep. 1 57.705-57.715 - -
Rep. 2 57.450-57.465 - -
Rep. 3 57.205-57.215 - -
Rep. 4 56.955-56.965 - -
(1) New crankshafts are identified before shipping from the factory with the tolerance classification of
the crankshaft bearing journal 0 and fit bearing width either with a colored id!entification on the
counterweights or with laser lettering on the front of the crankshaft joumaL
(2) Standard síze 1 and repair size crankshafts are not supplied as replacement parts except in
reconditíoned engines.
CRANKSHAFT MACHINING DIMENSIONS AND IDENTIFICATIONS, AXIAL MOUNTING (l)

Machining stage Fit bearing Colored identification on Laser lettering on front of
(2) widtb (J) counterweight 8 a nd 9 crankshaft
Standard 24.500-24.533 none o
Standard 1 24.600-24.633 red 1
Standard 2 24.600-24.633 red 1
Rep. 1 24.700-24.733 - -
Rep. 2 24.900-24.933 - -
Rep. 3 25.000-25 .033 - -
Rep. 4 - - -
(l) New crankshafts are identiified before shipping from the factory with the tolerance classification of
the crankshaft bearing journal 0 and fit bearing width either with a colored id!entification on the
counterweights or with laser lettering on the front of the crankshaft journaL
(2) Standard size 1 and repair size crankshafts are not supplied as replacement parts except in
reconditioned engines.
(3) The thrust washers for axial bearing play are supplied in thícknesses of2.15, 2.20, 2.25, 2.35 and
2.40 mm, each with a thrust washer for the crankcase and the thrust washer for the bearing cap as a
parts kit (2 in total).
Laser lettering on front of crankshaft

Mercedes-Benz
1 2 S 4
1 1
•-311095
-- --·
.. - - ....
'
5 8
P03.2o.0245-55
1 C.Ofll)atlY emblem 4 lnsp.ecbon diQit ot m.tomallc measmng sr.;tem

2 MOOeldesiQllMon 5 Cralilshaft bilalingJOI.IIlBI e
3 tlsp{lc ton date 6 Ftt boaang wdlh
Fig. 136: ldentifying Laser Lettering On Front Of Cr ankshaft
MEASURING CRANKSHAFT, FITTING NEW BEARINGS - RA03001043200X(03-3200)
Measuring crankshaft, fitting new bearings- RA03001043200X(03-3200)
Preceding work:
Crankshaft removed
Engine disassembled, cleaned
Crankshaft inspected, cleaned
Mounting crankshaft radially in bearings

Mercedes-Benz
P03-5351l-53
Fig. 137: Measuring Bearing Bore Dia And Radial Bearing Play
Crankshaft bearing cap install, tighten (30 N m).

Bearing bore 0 measure, note.
Crankshaft bearing journal 0 measure, note (03-3190).
Bearing shells match, see table "Bearing shells for crankshaft".
EXAMPLE:
Bearing bore dia 0 62.51 mm
- 57.95 mm
Crankshaftjournal 0
4.55 mm
-0.04mm
Radial bearing play
4.51 mm: 2
Bearing shell thickness 2.25 mm
see table "Bearing shells for crankshaft"
Top bearing shell "blue"
Bottom bearing shell "blue"
When determining different bearing shells, match thicker bearing shell to the bearing cap.
Likely radial bearing play calculate.

Bolt holes blow clean.
Bearing shells insert into crankcase and bearing cap.
Bearing cap bolts tighten (30 Nm).
Bearing 0 measure.
Radial bearing play (real play)
calculate.
(Specification 0.035-0.045 mm)
Mercedes-Benz
Bearing cap remove.

Bearing shells in crankcase oil.
Crankshaft at bearing points oil.
Bearing caps with bearing shells oil, instan.
Thread and contact surface of bolts oil, install.
tighten to tightening torque and tightening angle (55
Nm+90° tightening angle).
Bolts Lt.
Rotate cran.kshaft while tightening the bolts in order to
detect any jamming in good time.
Mounting crankshaft axially in bearings
P03>-5359-57
Fig. 138: Measuring Bearing Width At Crankshaft And Thrust Washers
Fit bearing width at crankcase

measure, note.
and at fit bearing cap
Fit bearing width at crankshaft measure, note.
match.
Lt.
Thmc::t w::~c::hP-rc:: nf thP c::::~mP thir.knPsc:: mnc::t ::1 lwll\t<:: hP inc::P.rtP-il nn nnP
Mercedes-Benz
side in the crankcase and in the bearing cap.

The oil grooves must face toward the contact surface of the crankshaft
Thrust washers
and be oi1ed.
The anti-twist lock is on the thrust washer in the bearing cap.
Likely axial bearing play calculate.
Axial bearing play with
measure. (Specification 0.100-0.250 mm).
crankshaft installed
Bearing diagram of crankshaft
21 21 21 21 B
24 24 24
... - 24 A
A Baoong 5he s in aankcase

B Beooog shel s m beanng cep.s
Fig. 139: Identifying Bearing Shells In C rankcase An d Bearing Shells In Bearing Caps
Fll\TJ:SHING DIMENSIONS AND IDENTIFICATION OF BASIC BORES OF CRANKCASE

BoreO Bearing points Identification (l) Size Fit bearing width
62.500-62.506 1, 5, 7 1 chisel punch Standard 19.979-20.000
62.506-62.513 1, 5, 7 2 chisel ptmches Standard 19.979-20.000
62.513-62.519 1, 5, 7 3 chisel punches Standard 19.979-20.000
62.500-62.506 2, 3, 4, 6 2 chisel punches Standard 19.979-20.000
62.506-62.519 2, 3, 4, 6 3 chisel punches Standard 19.979-20.000
Mercedes-Benz
(1) The fmishing tolerance stages are indicated by punch marks in the contact surface of the oil sump, in
each case next to the crankshaft bearing.
Permissible difference of fit bearing contact surfaces laterally from rectangularity related to the
0.03
diameter ofthe 1st and 7th crankshaft bearing point
BEARING SHELLS FOR CRANKSHAFT BEARINGS (REPLACEMENT P ARTS) (l)

Size Bearing Color Replacement part Bearing shell wall Bearing shell wall
inner 0 coding additional index tbickness (2) in tbickness (2 ) in
crankcase bearing cap
Standard 58.00 blue 52 2.255-2.260 2.255-2.260
Standard 58.00 yellow 54 2.260-2.265 2.260-2.265
Standard 58.00 red 56 2.265-2.270 2.265-2.270
white-
Standard 1 58.00 57 2.263-2.268
blue
white-
Standard 1 58.00 58 2.268-2.273
yellow
Standard 1 58.00 white-red 60 2.273-2.278
Rep. 1 57.75 blue 52 2.375-2.380 2.375-2.380
Rep. 1 57.75 gelb 54 2.380-2.385 2.380-2.385
Rep. 2 57.50 blue 52 2.500-2.505 2.500-2.505
Rep. 2 57.50 yellow 54 2.505-2.510 2.505-2.510
Rep. 3 57.25 blue 52 2.625-2.630 2.625-2.630
Rep. 3 57.25 yellow 54 2.630-2.635 2.630-2.635
Rep 4 57.00 blue 52 2.750-2.755 2.750-2.755
Rep. 4 57.00 yellow 54 2.755-2.760 2.755-2.760
(1) A parts set with tbe replacement part additional indices 52, 54 and 56 consists in each case ofa
bearing shell for the crankcase and a bearing shell for the bearing cap. Parts with the replacement part
additional indices 57, 58 and 60 are supplied individually and should be used only for the bearing cap
(without oil groove).
(2) The thickest point measured in tbe middle of the bearing shell is the relevant thickness.
TEST DATA
radial 0.030- 0.045
Crankshaft bearing play
axial 0.100-0.250
Conrod bearing play radial 0.020- 0.050
TIGHTENING TORQUES IN NM OR TIGHTENING ANGLE

Tightening torque 55
Bolts (I) of crankshaft bearing caps
Tightening angle
(l) Re-use bolts up toa bolt length of max. 63.8 mm.
Mercedes-Benz
SpeciaJ tools
001 589 72 21 00
F ig. 140: ldentifying Special Tools (001 589 72 21 00}
001 589 53 21 00
363 589 02 21 00
F ig. 142: ldentifying Special Tools (363 589 02 21 00}
COMMERCTALLV AVATLABLE TOOLS

Quick-calipers for interna! measurements
0 20 -40 mm
0 40 -60 mm
0 60 -80 mm
Micrometer
O- 25 mm
Mercedes-Benz
lso- 75 mm
Mounting crankshaft in bearings - RA03001203200X(03-3200)
Preceding work:
Engine removed and disassembled.
Oil passages in crankcase and in crankshaft cleaned.
Crankshaft inspected for cracks, dimensional tolerance, hardness and concentricity.
Engine 120.980/981
1
(]Plll
11101·-·M
P03-5039-55
1 BoiM18 X 1.5X 45 rrm 11 CO!Tod boamg shels

2 01 sOOd s¡lfi1QS (4 fl total) 12 Wasllers 4 5 mm tllck
3 Bol pc.lle'¡tMbtaboo damper 13 Dllvonplato 15 rrm ltld< , 296mm e
4 Crankshat gear 14 Dllv en plato 1 rrm tlld<, 287 mm 2i
5 Cranksha2 15 streldl MI for <*IVen platas
6 Woodrufkoy M12 X 1 5X 23(8tnlotal)
7 Crookshal b9811ng sllol tn crankce;so
8 Crankshal boanng shel ln beanng cap 16 Rlng gear wlh segmerts
9 17 Ft bo11s M6X 12mm
Ttrust washers '" ctllllkcas e
10 Ttrust washors m beanng cap 18 Spiilgwasl)er 86
19 Nult.l6
20 Loceting Pfl
Fig. 143: ldentifving Crankshaft, Belt Pulley And Ring Gear
DATA
Crankshaft Crankshaft Fit bearing Crankshaft Conrod Conrod
standard size and bearing journal Matching journal width at bearing bearing
Mercedes-Benz
repair sizes dia. thickuess of thrust fit bearing journal dia. journal
washers wid th
57.960 (1) 2.15 24.042 47.955 24.225
57.965 or 23.958 47.965 24.287
57.955 (1) 2.20
57.960 or
Standard size 57.950 (1) 2.25
57.955 or
2.35
or
2.40
57.945 (1)
57.950
57.940 (1)
Standard size I
57.945
57.935 (1)
57.940
57.700 47.705
1st repair size
57.715 47.715
57.450 47.455
2nd repair síze
57.465 47.465
57.200 47.205
3rd repair size
57.215 47.215
56.950 46.955
4th repair size
56.965 46.965
(1) Dots ofpaint on cranks of counterweights next to crankshaft bearingjournals: blue, yellow, red,
white, violet
BASIC BORE AND BEARING PLAY

Crankshaft bearing Conrod bearing
62.500 61.600
Basic bore dia.
62.519 62.619
23.500
Basic bore width at fit bearíng
24.533 r22.000
Conrod width - 21.948
Pemussible out-of-rotmdness and conicity ofbasic bore 0.02 10.02
Radial bearing play 0.026- 0.050 0.020 - 0.058
Axial bearíng play 0.100 - 0.254 0.225 - 0.391
Mercedes-Benz
MATClllNG CONROD BEARING SHELLS TO CRANKCASE

Matching top bearing shell with color coding
Chisel points on crankcase
1 mark 2 marks 3 marks
Color dots on crankshaft bearing cap Blue Yellow Red
Color of top bearing shell Blue Yellow Red
Matching bottom bearing shell with color coding
Color coding on crankshaft Blue Yellow Red White Violet
Lettering on crankshaft bearing journal B G R w V
Actual dim. numbers on crankshaft journal 35-39 40 - 44 45-49 50-54 55 - 60
Color of bottom bearing shell Blue Yellow Red White Violet
The upper standard size crankshaft bearing shells are supplied as replacement parts witb the color codings blue,
yellow and red, the bottom standard size crankshaft bearing shells with the color codings blue, yellow, red,
white and violet. They should be matched according to the table. It is therefore no longer necessary to gauge the
bearing play.
Pmch mBiks for m Ett:ting

aankshal boañng shols
P0-3-5332-13
Fig. 144: Locating Punch Marks For Matching Crankshaft Bearing Shells
Nuts M8X 1: 30
Crankshaft bearing cap Nuts MlOX 1: 50
Side bolts M8X60: 30
Special tool
Mercedes-Benz
363 589 02 21 00
Fig. 145: ldentifyi ng Special Tool (363 589 02 21 00)
COMMffiR~LYAV~ABLETOOLS
Quick-calipers for interna] .40 - 60 Hahn und Kolb BorsigstraBe 50 D-7000 Stuttgart 30
measurements, dia mm eg. Order no. G 222 K
Quick-calipers for interna] .60- 80
Order no. G 322 K
measurements, día mm
Micrometer 25 - 50 mm Order no. 31346 025
Micrometer 50- 75 mm Order no. 31346 050
NOTE: Self-locking stud bolts are insertad into the crankcase for attaching the
crankshaft bearing caps. The stud bolts must be used only once as the locking
fluid which is applied to the thread overall length of about 8 mm is no longer
effective when the bolts are removed. Pay attention to different insertion depths
and collar dia. when replacing the stud bolts.
When performing repairs, it is not permitted to use HELI-COIL inserts for the self-locking stud bolts of the
crankshaft bearing caps.
POJ-5337-13
F i2. 146: Locatin2 Self-Lockin2 Stud Bolts

Mercedes-Benz
The 5 crankshaft bearing caps manufactured from malleable cast iron are fitted in. at the si de of the crankcase
(arrows).
The fít (arrows) is off-centered so that the bearing caps can be installed only in one position.
The three middle bearing caps are additionally bolted to the side walls of the housing.
The crankshaft bearing caps are machined together with the crankcase and are not available as a replacement
patt.
POJ-533.4-13
Fig. 147: Locating Crankshaft Bearing Caps Side Of Crankcase
Normal bearing shells and thrust washers are installed at crankshaft bearing 4 (fit bearing).
TI1e thrust washers absorb tbe axial forces of the crankshaft.
The thrust washers (9 and 1O) inserted in the crankcase and in the bearing cap on both sides are identical.
The thrust washers in the bearing cap each have two catches, the once being positioned off center, asan anti-
twist lock and to avoid installation errors. In addition, all the thrust washers are chamfered at one end. The two
oil grooves in the thrust washers must face toward the crank webs.
When servicing crankshafts, the fit bearingjournals must be re-ground in width to one ofthe dimension stated
in the table (section "Data").
If bearing damage has occurred, the conrods must be removed and any swarf present removed from the conrod
bores and the crankshaft oil passages.
Mercedes-Benz
11
at
POO-.SllS-13
Fi~. 148: Locatin~ Crankshaft And Crankshaft Bearine
Carefully clean the oil passages in the crankcase, crankshaft, tirning case cover, oil filter cover, end cover, oil
pump etc.
Examine crankshaft for cracks, dimensional tolerance and hardness.
Matching crankshaft bearings, installing crankshaft
l. Install crankshaft bearing caps; pay attention to the marking, 1 is at the front.
The fit is off-centered (arrows); the crankshaft bearing caps can therefore be installed in only one
position.
2. Oil contact surface ofnut and thread, nuts M8 X 1: tighten to 30 Nm, nuts MIO X 1: tighten to 50 Nm.
3. Oil the thread and the head contact surface ofthe side bolts (M8 X 60) and tighten to 30 Nm. (Use bolts
of quality 1O.9 for the side mounting of the bearing caps.)
4. Measure crankshaft bearing bore at two levels in the direction A, B and C (conicity) and note the
measurements obtained.
If a crankshaft bearing bore exceeds the specification or is conical, dress the bearing cap at its contact
surface on a dressing plate to not more than 0.02 mm.
Mercedes-Benz
P01-<1195-13
Fig. 149: Identifying Crankshaft Bearing Bore Direction A, B And C
5. Insert bearing shells and install crankshaft bearing caps.
Tightening torque:
Nuts M8 X 1:30 Nm
M10Xl:50Nm
Side bolts M8 X 60: 30 N m
P03-2019-13
Fig. 150: ldentifying Bearing Shells And Crankshaft Bearing Caps
6. Measure bearing diameter and note.

Mercedes-Benz
P03-2020- 13
Fig. 151: Measuring Bearing Diameter
7 _ Measure crankshaft bearing journal, determine the radial play of the crankshaft bearing_
NOTE: The bearing play can be corrected by replacing the bearing shells (see
table for matching crankshaft bearing shells to crankcase).
P03-2021-1 3
Fig. 152: Measuring Crankshaft Bearing Journal Radial Play Of Crankshaft Bearing
8. Measure width of fit bearing journal and of fit bearing. Detennine axial play of crankshaft bearing (see
table in section "Data")-
The fit bearing shells of the repair sizes are supplied over-sized.
9. Treat bearing shells in crankshaft with SAE 30 engine oil and insert crankshaft Install bearing shells with
Mercedes-Benz
oil bore into the cran.kcase.
P03-2097-13
Fig. 153: Measuring Width OfFit Bearing Journal And Fit Bearing
10. Oil thrust washers with engine oil and insert into the grooves at the fit bearing (crankcase).
o ,..._ 11m:r-1a
P03-20~ 1 3
Fig. 154: Inserting Bearing On Crankcase
11. Install fit bearing cap.
A
Hold both thrust washers tight when installing tbe fit bearing cap.
Mercedes-Benz
P0~201 8- 1 3
Fig. 155: Installing Bearing Cap
The two oil grooves (arrows) in the thrust washers must face toward the crank webs.
PQ3- 2058- 13
Fig. 156: Locating Thrust Washers Oil Grooves
12. Tnstall crankshaft bearing caps.

13. Tighten crankshaft bearing caps to the specified torque in the order ofthe tightening diagram. Oil the
thread and the bolt head and contact surface ofnut, respectively, for this step.
Tightening torque:
Nuts M8 X 1:30 Nm
Mercedes-Benz
Ml0Xl:50Nm
Side bolts M8 X 60: 30 N m
NOTE: Use bolts of quality 10.9 for the side mounting of the bearing caps.
:M. 12 .. •
...
~ $ ~
31 7 1 ~ 13
1
4
as 11
' 17
P03-5014-35
Fig. 157: ldentifying Crankshaft Bearing Caps Tightening Sequence
14. Meas ure axial play of crankshaft bearing.

15. Rotate cranksba:ft by band and check whetber it runs freely.
P03-2225-1 3
Fig. 158: Measuring Axial Plav Of Crankshaft Bearing
Matchin!J c.onrorl hParin~Js :mrl installin!J

Mercedes-Benz
16. Install pistons and conrod (03-3160).

17. Oil bearing shells, crankshafts, pistons and cylinders with SAE 30 engine oil. Install conrod together with
pístons (03-3160) .
Pay attention to marking!
Install the bearing shells, with the oil bore in the conrod otherwise the conrod bushes will not be
Jubrícated.
P03-5033-1 3
Fig. 159: Locating Marking On Conrod Bearing
18. Tighten conrod nuts and conrod bolts (03-3100).
P01-1591-1 3
Fig. 160: Tightening Conrod Nuts And Conrod Bolts

Mercedes-Benz
19. Measure axial play of conrod bearings.
Ensure that the bearings have proper clearance in the pisten.
Disassemble oil pump, clean, replace if necessary. Replace oil delivery val ve. Clean oil ftlter. Carefully
clean air-to-oil cooler or replace.
lnstall initial operation oil filter element. Change engine oil and oil filter element after 1000 - 1500 km.
POS-2219-1 3
Fig. 161: Measuring Axial Play Of Conrod Bearings
Mounting crankshaft in bearings - RA030A1193200X(03-3200)
Preceding work:
Oil galleries in crankcase and in crankshaft cleaned.
Crankshaft examined for cracks, dimension oftolerance, hardness and concentricity.
03-4700, 6401 , 7021
A. Engine 119.96/97 with fit bearing

Mercedes-Benz
1 Bol M 18x1.5x45 rrm 15 Conrod beamg shels

--·--...
2 Bele\11 a spnng wasi191S (4 ea.), 16 Drscs 4.5 nrn tuck
3 BoiM.SX22{6aa) 17 DnvenplalD 1 Smmtlld<, 296 rrm da.
4 Spmg lock wa'i19l AS 18 Dnven pi~ 1 mm tlitk, 287 mm di a.
5 Bel p¡ney 19 stretch boa ter dnven plales
6 V1brabond~ M 12x1.Sx23 (8 ea.)
7 Hub 20 Rmg gear 'Mth sogmerts
8 Crnnkstl ~ gear 21 Fi~M5x12mm
9 Ctankstla! 22 Spmgwasher B 6
10 Woodnl~ key
23 t-l.JtM6
11 Crnnkstl a: ooanng shel i n crenkcas e 24 Loca!Jngp11
12 Crnnksh~ beanng shel i n beanng cap
25 BolM5x10
13 Fi boanng sllelm crankcase w1h 011 26 Bracket
groove and dnln g 27 Ma;¡net
14 Ft boanng shel m b"!!anng cap 28 W&<iler A 5.3
29 t-l.JtMS
Fig. 162: ldentifying Crankshaft, Vibration Damper And Belt Pulley
DATA IN MM
Crankshaft Crankshaft journal Crankshaft Crankshaft
Crankshaft standard Color width at fit bearing
bearing journal bearing journal bearing journal
size and repair sizes Coding (2)
0 0 width
63 , 9601 (l ) 1--> blue 27,000 47,965 50,000
63,965 27,021 47,955 50,100
Standard size
63 955 (I )
• 1-->1 gelb
63,960
63 ,950 (l ) 1-->1 rot
63,955
63,715 47,715
1st repair size
63,700 47,705
63,465 max.27,50 47,465
2nd repair size
63,450 47,455
()1 2 1.S 47 21.S
Mercedes-Benz
3rd repair size 63,200 47,205

62,965 46,965 max.50,30
4th repair size
62,950 46,955
(l) Tolerance division for bottom bearing cap, colored dots on cran.k webs or counterweights next to
crankshaft bearing journals
(2) Crankshaft main bearings with fit bearing as of engine no. 119.96 as of start ofproduction up to
engine no. 119.970 12 036277 119.971 12 017447 119.972 12 004797 119.974 12 008072 119.975
12 010516
CRANKSHAFT BEARING BORE, CONROD BEARING BORE AND BEARING PLAY IN MM

Crankcase (2) Color coding Conrod
68.480( 1) --> blue
68.486 yellow
68.486(1) --> red
Crankshaft bearing bore -
68.492
68.492(!) 1-->1
68.500
Conrod bearing bore
- - 51.600
51.619
Permissible out-of-roundness and conicity ofbores 0.01 0.01
whennew 0.021-0.045(3) 0.030-0.055(3)
Radial bearing play
wear limit 0.090 0.080
whennew 0.10-0.22 0.22-0.38
Axial bearing play
(l) Tolerance division for top bearing cap, chisel punch points in contact surface of crankcase at oil
sump end.
(2) Macbined togetber with crankshaft bearing cap.
(3) Aimed for average value ofradial bearing play.
MATCHING CRANKSHAFT BEARING SHELLS TO CRANKCASE

Matching top bearing shell wíth color coding
Chisel punch points on crankcase 1 punch point 2 punch points 3 punch points
Colored dots on crankshaft bearing cap Blue Yellow Red
Color of top bearing shell Blue Yellow Red
Color coding on crankshaft Blue Yellow Red
Color of bottom bearing shell Blue Yellow Red
Stud holt in crankcaseCl) 30
Mercedes-Benz
MlOxl nut 50
Crankshaft bearing stud. bolt
Ml0x40 side bolts (10.9) 50
(1) The stud bolts lose their locking effect after being unscrewed and must therefore only be used once.
Special tools
001 589 72 21 00
001 589 66 21 00
363 589 02 21 ()0

Hahn nnci Kolh
Mercedes-Benz
BorsigstraB 50
Quick-callipers for interna! measurernents, dia. 40- 60 rnrne.g. D-7000 Stuttgart 30
Order no. G 222 K
Quick-callipers for interna! measurements, día. 60- 80 mm Order no. G 322 K
Micrometer 25-50 mm Order no. 31346 025
Micrometer 50-75 mm Order no. 31346 050
NOTE: Self-locking stud bolts are screwed into the crankcase for securing the
crankshaft bearing caps. These stud bolts may only be used once as the
locking adhesive applied over approx. 8 mm length of the thread is no
longer effective when they are removed.
Pay attention to the different insertion depth and collar dia. when replacing the stud bolts.
When performing repairs, no HELI-COIL inserts may be used for the self-locking stud bolts ofthe
crankshaft bearing caps.
P03-5337-13
Fig. 166: Locating Self-Locking Stud Bolts
The 5 crankshaft bearing caps manufactured from malleable cast iron are fitted into the side in the
crankcase (arrows).
The fitting face (arrows) is positioned off-centre so that the bearing caps can only be installed in one
position.
The three center bearing caps are additionally bolted to the housing side walls.
The crankshaft bearing caps are machined together with the crankcase and are not available as a
Mercedes-Benz
replacernent part.
Fig.167: Locating Crankshaft Bearing Caps From Crank Case Length
If bearing damage has occurred, the conrods must be removed and any swarf removed frorn the conrod
bores and the oil passages of the crankshaft.
Carefully clean the oil passages in the crankcase, crankshaft, timing case cover, oil filter housing, closing
cover, oíl pump etc.
Examine crankshaft for cracks, dimensional tolerance and hardness (03-3180).
l. Install crankshaft lbearing caps, pay attention to marking, 1 is to the front.
The fit face is asymmetrical (arrows); the crankshaft bearing caps can thus only be installed in one
position.
2. Oil thread and contact surface of nuts, tighten nuts to 50 N m.

3. Oil thread and head contact surface ofside bolts (M IO X 40), install with the washers and tighten to
50Nm.
Mercedes-Benz
Fig. 168: Locating Crankshaft Bearing Caps From Crank Case Length
4. Measure crankshaft bearing bore in direction A, B and C at two levels (conicity); note measured
values.
If a crankshaft bearing bore exceeds the specified value or is conical, dress bearing cap at its mating
surface on a dressing plate up to max. 0.02 mm.
Fig. 169: ldentifying Crankshaft Bearing Bore Dimensions
5. Insert bearing shelis, install crankshaft bearing cap.
Tighten nuts and side bolts to 50 N m.

Mercedes-Benz
P03-2019-13
Fig. 170: Identifying Bearing Shells And Crankshaft Bearing Cap
6. Measure bearing díameter and note.
POS-2020-13
7. Measure crankshaft bearing journals, determine radial play of crankshaft bearing.
NOTE: The bearing play can be connected by replacing the bearing shells
(see table Matching crankshaft bearing shells to crankcase); in this
case, aim for the average value of the bearing play stated.
Mercedes-Benz
P00-2021-13
Fig. 172: Measuring Crankshaft Bearing JournaJs
8. Measure width of fit bearing journal and of fit bearing. Determine axial play of crankshaft.
The fit bearing shells ofthe repair sizes are supplied oversized.
Pro. 2097~13
Fig. 173: Measuring Width Of Fit Bearing Journal And Fit Bearing
9. Moisten bearing shells and crankshaft with SAE 30 engine oil and insert crankshaft.
6
Install bearing shells with oil drilling into the crankcase.
Mercedes-Benz
e
n
1 2 3 4 5
P03-0192-57
A CraJi«:aso
B F1tbeanng
C CrM<sllaft
Fig. 174: Identifying Crankcase, Fit Bearing And Crankshaft
1O. Tighten crankshaft bearing caps to the specified torque in the order of the tightening diagram. Oil
the thread and the bolt head or nut contact surface for this step.
Nuts 50Nm.
Side bolts 50 Nm
NOTE: Bolts of quality 10.9 should be u sed for the si de bearing cap fixture.
Mercedes-Benz
2 3 4
•' :11
@
@
-
""•IHG• D
Fig. 175: ldentifying Crankshaft Bearing Caps Tightening Diagram
11. Measure axial play of crankshaft.

12. Rotate crankshaft by hand and check whether it runs freely.
POO- 2225-13
Fig. 176: Measuring Axial Play Of Crankshaft
Matching conrod bearings and installing
13. Examine conrod bolts (03-3100).

14. Repair and align conrod (03-3130).
Mercedes-Benz
P03.222Q..13
Fig. 177: Examining Conrod Bolts
15. Insert conrod bearing shells, install conrod bearing caps with conrod bearing shells and tighten
conrod nuts or bohs to 35 N m.
17. Measure conrod bearing journal. Determine radial play of conrod bearíng.
NOTE: The bearing play can be corrected by replacing the conrod bearing
shells; if this step is performed, aim for the average value of the
specified bearing play.
Crankshaft bearing shells without color coding are thicker than those with blue color coding,
although it should be noted that the wall thicknesses wíthout and wíth color codíng may overlap.
P03-1221-1 3
Fig. 178: Identifying Radial Play Of Conrod Bearing

Mercedes-Benz
18. Install pistons and conrod (03-3160).

19. Moisten bearing shells, crankshafts, pistons and cylinders with SAE 30 engine oil. Install conrod
with pistons (03-3160).
Pay attention to marking.
Install the bearing shells with the oil drilling in the conrod otherwise the conrod bushes will not be
lubricated.
Fig. 179: Locating Bearing Sbells
20. Tighten conrod nuts and conrod bolts (03-3100).
Fig. 180: Tightening Conrod Nuts And Conrod Bolts
21. Measure axial play of conrod bearings. Examine clearance of conrod in the piston.
Mercedes-Benz
Disassemble oil pump, clean, renew if necessary. Replace oil delivery valve. Clean oil filter,
carefully clean air-to-oil cooler or replace.
Install initial operation oil filter element. Change engine oil and oil filter element after 1000 - 1500
km.
P03-1219-13
Fi~. 181: Me a s urin~ Axial Play Of Conrod Bearin~s
Mounti.ng crankshaft in bearings- RA030B1193200X(03-3200)
Preceding work:
Oil galleries in cran.kcase and in cran.kshaft cleaned.
Crankshaft examined for cracks, dimension oftolerance, hardness and concentricity.
03-4700, 6401,7021
B. Engine 119.97/98 witb tbrust wasbers

Mercedes-Benz
P03.30-0253-56
1 Bcl M 18x1.5x45rnn 16 Orscs 4.5 rnn tnck

2 Soleva le spnng washors (4 ea.), 17 Onven pla~ 1.5 mm lllck, 296 rnn die
3 BciM8x22(6ea) 18 Onven pla:O 1 rnn tnck, 287 mm <ía
4 Spm g loe k wa;.hcr .ttS 19 Strctro bollor <nv'en platas
5 8elpt6e'¡ M 12x1.5x23 (8 ea,)
6 Vrbratlon dfll11ler 20 Rmg geer .,..th segmerts
7 1-t.ib 21 FtlxitsM 6X12mm
8 Cranksha4 gea 22 Spmg wasnerBS
9 Crankshal 23 NutM6
10 Woodrufkcy 24 l OC!!ting Plf1
11 Cranksha4 bllallng shel m crdlkcas e 25 BciM5x10
12 Crankshat beanng shel rn beanng cap 26 Bracket
13 Ft baanng sllel rnaankcasemh oll 27 Magnet
groove aod oofolg
28 Was11 er A 5.3
14 H beanng shelm beanng cap 19 Nu!M5
15 C<lll'o-d beanng shels 30 lrtegated \4brabon dl!l11)er wtil bel puloy
31 S!artor nng geamcremonl (as ot Motromc)
F ig. 182: Exploded View Of Cranksbaft C omponents
DATA M119.971/975/981/985
Crankshaft Crankshaft Thickness of Crankshaft Crankshaft Crankshaft
Color
standard size bearing thrust washers journal width at bearing bearing journal
coding
and repair sizes ~ourna l 0 at fit bearing fit bearing journal 0 width
63.96o(l ) 1-->blue 2
2.2oC ) 27.000 47.965 50.000
63.965 yellow or 27.033 47.955 50.100
63.955(1) 1 2
Standard size --> red 2.25( )
63.960 or
63.950(1) 1-->1 2. 30(2)
63.955
Mercedes-Benz
63.945
63.950
63.940
Standard size, I _
63 945
63.935
63.940
(1) Tolerance dívision for bottom bearing cap, colored dots on crank webs or counterweíghts next to
crankshaft bearing journals.
(2) Crankshaft main bearing with thrust washers as of engine no. 119.970 12 036277 119.971 12 017447
119.972 12 004797 119.974 12 008072 119.975 12 010516 119.98 as of start ofproduction
CRANKSHAFT BEARING BORE, CONROD BEARING BORE AND BEARING PLAY IN MM

Crankcase Color coding Conrod
68.480(1) 1--> blue -
68.486 yellow
68.486( ) 1
1 --> red
Crankshaft bearing bore
68.492
68.492(1) 1 -->
68.500
Conrod bearing bore
- 1-->1- 5 1.600
51.6 19
Permissible out-of-roundness and con:icity of bores 0.01 0.01
when new 2
0.021 -0.045( ) 0.030-0.055(2)
Radial bearing play
whennew 0.10-0.22 0.22-0.38
Axial bearing play
(l) Tolerance division for top bearing cap, chisel punch points in contact surface of crankcase at oil
sump end.
(2) Aim for the average value of radial bearing play.
MATCHING CRANKSHAFT BEARING SHELLS TO CRANKCASE

Matching top bearing shell with color coding
Ch:isel punch points on crankcase
1 chisel point 2 chisel points 3 chisel points
Colored dots on crankshaft bearing cap blue yellow red
Color of top bearing shell blue yellow red
Color coding on crankshaft blue yellow red
Color of bottom bearing shell blue yellow red
The top and bottom standard size crankshaft bearing shells are supplied as replacement parts with the
Mercedes-Benz
color codings blue, yellow and red. They should be matched according to the table. It is then no longer
necessary to gage the bearing clearances.
Chssl pwKh pollll.s for ma:Cb ng

cranks!ud beanng shol s
P 00-5.331-1 3
Fig. 183: Locating Crankshaft Bearing Shells
Stud bolt in crankcase (1) 30
Crankshaft bearing stud bolt MlOxl nut 50
Ml Ox40 side bolts (1 0.9) 50
(l) The stud bolts lose their locking effect after being unscrewed and should therefore be used only
once.
Special tools
001 589 72 21 00
Fig. 184: ldentifying Special Tools (001 589 72 .21 00)

Mercedes-Benz
001 589 66 21 00
363 589 02 21 00
Fig. 186: ldentifving Special T ools (363 589 02 21 00)

Hahn und Kolb
. . . BorsigstraBe 50
Qmck cahpers for mternal measurements, 0 40 -60 mm e.g. D_7000 Stuttgart 30
Order no. G 222 K
Quick calipers for internal measurements, 0 60 -80 mm Order no. G 322 K
NOTE: Self-locking stud bolts are inserted into the crankcase for attaching the
crankshatt bearing caps. The stud bolts should only be used once as the
locking fluid applied over a length of about 8 mm of the thread is rendered
ineffective when the bolts ar e unscrewed.
Pay attention to different insertion depth and collar 0 when replacing the stud bolts.
When performing repairs, do not use HELI-COIL inserts for the self-locking stud bolts of the crankshaft
bearing caps.
Mercedes-Benz
P03..5337-13
Fig. 187: Locating Self-Locking Stud Bolts
The 5 crankshaft bearing caps are manufactured from malleable cast iron and are interference fitted in the
síde ofthe crankcase (anows). The fit (arrows) is off-centered wíth the result that the bearing caps can
only be installed in one posítion.
The three center bearing caps are additionally bolted to the side walls of the housíng.
The crankshaft bearing caps are maclúned together with the crankcase and are not available as a
replacement part.
Standard bearing shells and thrust washers are ínstalJed at the 3rd crankshaft bearing (fit bearing).
The thrust washers absorb the axial forces of the crankshaft.
The thrust washers (13 and 14) inserted on both si des of the crankcase and the bearing cap, are identical.
Mercedes-Benz
The thrust washers in the bearing cap each have identical.
The thrust washers in the bearing cap each have two retaining lugs, the bottom lugs being positioned off-
center, asan anti-twist lock and to avoid incorrect installation. In addition, all the thrust washers are
chamfered at one end. The two oil grooves in the thrust washers must face towards the crank webs.
When repairing crankshafts, the fit bearing journals should be re-ground in width to one of the
dimensions stated in the table (section "Data").
After bearing damage has occurred, the conrod should be taken out and any swarfpresent in the conrod
bores and in the crankshaft oil galleries, removed.
Carefully clean oil galleries in crankcase, crankshaft, timing case cover, oil filter housing, end cover, oil
pump etc.
Inspect crankshafts for cracks, dimensional tolerance and hardness.
13 13
11~f\
P03.20-0225- 13
Fie. 189: Identifying Crankshaft And Crankshaft Bearine
l. InstaH crankshaft ibearing caps; pay attention to marking, 1 is at the front.
The fit is asymmetrical (arrows) with the result that the crankshaft bearíng caps can only be
installed in one position.
2. Oil contact surface of nut and thread and tighten nuts to 50 N m.

3. Oil the thread and the bolt head contact surface ofthe side bolts (M lO X 40), ínstall with the
washers and tighten to 50 Nm.
Mercedes-Benz
4. Measure crankshaft bearing bore in the direction A, B and C at two planes (conicity) and note the
measurements obtained.
If a crankshaft bearing bore exceeds the specified data or is conical in shape, dress the contact
surface ofthe bearing capona dressing plate to not more than 0.02 mm.
P01-0195-13
Fig. 191: ldentifving Crankshaft Bearing Bore Dimensions
5. Insert bearing shells and install crankshaft bearing cap.
Tighten nuts and side bolts to 50 N m.

Mercedes-Benz
P03-2019-13
Fig. 192: ldentifying Crankshaft Bearing
POJ..WW-13
7. Measure crankshaft bearing journal and determine radial crankshaft bearing play.
NOTE: The bearing play can be corrected by replac ing the bearing shells
(see table Matching crankshaft bearing shells to crankcase).
Mercedes-Benz
P03-2021-1l
Fig. 194: Measuring Crankshaft Bearing Journal And Determine Radial Crankshaft Bearing
Plav
8. Measure width of fit bearing journal and of fit bearing and determine axial crankshaft bearing play.
(See table ofData)
The repair size fit bearing shells are supplied oversized.
P OJ-2097-1 3
Fig. 195: Measuring Widtb Of Fit Bearing Journal
9. Moisten bearing shells and crankshaft with SAE 30 engine oil and insert crankshaft.
lnstall bearing shells with oil drilling in the crankcase.

Mercedes-Benz
10. Oil thrust washers with engine oil and push into the grooves at the fit bearing (crankcase).
P03-2023-13
Fig. 196: Installing Bearing Shells
11. Install fit bearing cap.
Hold both thrust washers tight when installing the fit bearing cap.
P03-2018-13
Fig. 197: Installing Bearing Cap
The two oil grooves (arrows) in the thrust washers must face toward the crank webs.
Mercedes-Benz
12. Install crankshaft lbearing caps.
P03-205.8-1 3
Fig. 198: Locating Crankshaft Bearing Caps
13. Tighten crankshaft bearing caps to the specified torque in the order of the tightening diagram. Oil
the thread and the bolt head and nut contact surface for this step.
Nuts 50Nm.
Side bolts 50 Nm
NOTE: Bolts of quality 10.9 should be used for the si de bearing cap
connection.
1 ~ 3 4
411 :11
@
@
-
...•IHIO•D
Fig. 199: Locating Crankshaft Bearing Caps Tightening Diagram
14. Measure crankshaft bearing axial play.

Mercedes-Benz
P03- 2225-13
Fig. 200: Measuring Crankshaft Bearing Axial Play
Matching conrod bearings and installing
16. Inspect conrod bolts (03-3100).

17. Repair conrod and align (03-3130).
Fig. 201: lnspecting Conrod Bolts
18. Insert conrod bearing shells, install conrod bearing caps with conrod bearing shells and tighten
conrod nuts and bolts to 35 Nm .
20. Measure conrod bearingjournals and determine comod bearing radial play.
NOTE: The bearing play can be corrected by replacing the conrod bearing
shells. Aim for the average value of the bearing play stated.
Mercedes-Benz
Conrod bearing shells without color coding are thicker than those with blue color coding; note,
however, that the wall thicknesses with and without color coding may overlap.
P03-2222-1 3
Fig. 202: ldentifying Bearing Diameter
21. Assemble pistons and conrod (03-3160).

22. Moisten bearing shells, crankshafts, pistons and cylinders with SAE 30 engine oil. lnstall conrod
wíth pístons (03-3160).
Pay attention to ídentification.
Install the bearing shells with the oil drilling in the conrod otherwise the conrod bushes wíll not be
lubricated.
P03-50l3-13
Mercedes-Benz
23. Tighten conrod bolts (03-3100).
Fig. 204: Tightening Conrod Bolts
24. Measure conrod bearing axial play. Inspect clearance of conrods in pistan.
Dísassemble oíl pump, clean, replace íf necessary. Replace oíl delívery val ve. Clean oíl filter,
carefully clean air-oil cooler or replace.
Install initial operation oil filter element. Change engine oil and oil filter element after 1000-1500
km.
P0.3-2219-13
Fig. 205: Measuring Conrod Bearing Axial Play
REPLACING FRONT CRANKSHAFT RADIAL SEAL- RA03001043240X(03-3240)

Mercedes-Benz
Replacing front craokshaft radial seal- RA03001043240X(03-3240)
Preceding work:
Belt pulley/vibration damper removed (03-3420).
03-3000
P03-5279-S7
Fig. 206: ldentifying Radial Sbaft Seal, lnsertion Sleeve And Radial Seal
Bearíng smface of hub of

belt pulley/ inspect.
NOTE:
vibration damper lf bearing surface has grooves, use repair radial shaft seal with sealing lip
offset 2 mm to inside or press in standard radial seal about 2 mm deeper.
prise out with screwdriver.
Lh
Do not damage crankshaft and mounting hole for radial shaft seal (8). Use
clean cloth as base.
FnPP of mmmtinP holP for
Mercedes-Benz
radial seal (8) de burr.

oil at sealing lip.
A
Do not use grease. Grease prevents the return swirl on the sealing lip of the
radial shaft seal (8) feeding back the engine oiL
Radial shaft seal (8) fit onto insertion sleeve (1) 60 1 589 03 14 00
Insertion sleeve (O 1) fit on so that groove in insertion sleeve (01) is aligned with woodruffkey (7).
pull in with bolt (5) and 4 dished washers (6) as far as stop.
Insertion sleeve (O 1) NOTE:

The radial shaft seal (8) must be positioned at righ1! angles to crankshaft
bearing journal otherwise it will not provide a proper seal.
Belt pulley/vibration
install (03-3420).
damper
Special tool
601 5B9 03 14 00
NOTE: An oil leak can be determined after spraying the cleaned and dried surround ing
area with Mercedes-Benz white contrast spray 000 989 03 59.
Replacing front crankshaft radial seal - RA03001193240X(03-3240)
Preceding work:
Belt pulley, vibration damper and hub removed (03-3420).
03-3000 - 01 -3112
Mercedes-Benz
asN;- 1 Al\\~ -
15
ll)f$1@¡~
, .
' . ~ 16
. ~' • 14
400I'Im
~ 12 13
"11
Fig. 208: ldentifying Belt Pullev, Vibration Damper And Radial Seal
Belt pulley (12), víbration damper (13) and · ( _ )

remove, msta11 _03 3420_.
remove, hub (14)
Radial sea] (16) remove (step 2).
Mounting bore clean, deburr.
Sealing lip of radial seal ( 16) oil (step 4).
insta Uwith insertion sleeve, special tool 119 589 O1 14 00
(step 5).
Radial sea] ( 16) Lt.
Pay attentíon to installation posítion in the case ofhubs (14)
with running marks (step 6).
Leaks check wíth engine nmning.
Special tool
Mercedes-Benz
, ' 9 589 01 14 00
03
NOTE: An oil leak can be determined after spraying the dried and cleaned surroun ding
l. Check hub ofbelt pulley for running marks.
If running marks are present, install radial seal offset 3 mm to the inside (see step 6).
Fig. 210: Identifving Running Marks In Hub Of Belt P ulley
2. Lever out radial seal with a screwdriver.
Do not damage crankshaft and mounting bore for the radial seal, use clean cloths as a base.
3. Deburr edge of mounting hole for the radial seal.

4. Oil sealing lip of the radial seal.
Mercedes-Benz
Do not use grease. Grease prevents the angled webs on the sealing lip transporting back the engine oil.
Fig. 211: Removing Radial Seal
5. Fit radial seal (16) onto the side a ofthe insertion sleeve 119 589 01 14 00 and draw in as far as the stop
with bolt (11) and 4 Belleville spring washers (11a).
The radial seal (16) must be at right angles to the hub otherwise it wiU not provide a proper seal.
6. If the hub has nmning scores, position radial seal (16) 3 mm offset to the inside.
Todo this, fit radial seal (16) onto the side b ofthe insertion sleeve 119 589 01 14 00 and draw in as far
as the stop.
Mercedes-Benz
A'!:$tanda;dposmoo ofradial se al
B=Repair poSibon ot radial seal
Fi~. 212: Identifyin~ Standard And Repair Position OfRadial Seal
7. Install belt pulley, vibration damper and hub (03-3420).

Replacing front crankshaft radial seal- RA03001203240X(03-3240)
Operation no . of operation texts and work units or standard texts and flat rates 03-3000 - O1-3112
Mercedes-Benz
Fig. 213: Identifying Vibration Damper And Crankshaft Radial Seal
Pulley/vibration damper (6) remove, install (03-3420).

Radial seal (8) remove (step 3).
lnstallation bore clean, deburr.
Sealing lip, crankshaft seal (8) oil (step 5).
install with installation sleeve 119 589 01 14 00 (step 6 and
Crankshaft radial seal (8)
step 7).
Lh
On pulley/vibration damper (6) with wear observe installation position of shaft sea! (8) (step 8).
grooves
Engine allow to nm. Check for leakage.
Special tool
Mercedes-Benz
, ' 9 589 01 14 00
03
NOTE: Oil leakage can be located by spraying the clean, dry surrounding area with
Mercedes-Benz white contrast spray 000 989 03 59.
l_ Remove pulley/vibratíon damper (03-3420)_

2. Check hub (3) ofvibration damper for wear grooves.
Ifwear grooves are present, install shaft seal (8) offset inward 3 mm (see step 8).
11
I~:Z:Z:::Z:::!:;-!--=t-- 16
__._- 15
~'[¡;::=±:::;::-;- - 14
. _ _,3
t=-.-<:::::- - - -12
Fig. 215: ldentifving Hub, Vibration Damper And Shaft Seal
3 _ Press shaft seal out with screwdriver.

Mercedes-Benz
Do not damage cranksbaft or mounting bore for sbaft seal, use clean rag for support.
4. Remove burrs on edge of mounting bore for shaft seal.

5. Oil sealing lip of shaft seal.
Do not use grease. Grease prevents the angled web on the sealing lip from returning the engine oil.
Fig. 216: Pressing Shaft Seal Out
6. Attach shaft seal (8) to side a ofinstallation sleeve 119 589 01 14 OO. Align Woodruffkey (7), slide on
installation sleeve and assure that W oodruff key (7) in crankshaft is engaged in groove in installation
sleeve by turning.
7. Tighten installation sleeve 119 589 01 14 00 against stop with bolt (1) and 4 plate springs (2).
The shaft seal (8) must be at right angles to the hub to assure a perfect seal.
8. lfwear grooves are present on the hub, install sbaft seal (8) offset 3 mm inward. For this purpose, attach
shaft seal (8) to side b of installation sleeve 119 589 O1 14 00 and tighten against stop in aligned position.
Mercedes-Benz
Fi~. 217: Identifyin~ Shaft Seal Standard And Repair Position
9. Install pulley/vibratíon damper (03-3420).

10. Allow engine to run, check for leakage.
REPLACING REAR CRANKSHAFT RADIAL SEAL- RA03001043270X(03-3270)
Replacing rear crankshaft radia~ seal- RA03001043270X(03-3270)
Preceding work:
Manual transmission : two-mass flywheel removed (03-4620)
Automatic transmission: driven plate removed (03-4100)
03-3063
Mercedes-Benz
P03.5291-57
Fig. 218: Identifying Radial Shaft Seal And Insertioo Tool
prise out wíth a screwdriver.

Lt
Do not damage crankshaft and mounting hole for radial shaft seal (93).
Use clean cloth as base.
inspect.
Bearing surface of crankshaft NOTE:

lf bearing suñace has grooves, use "repair version" radial shaft seal
with sealing lip offset 3 mm to inside.
Edge of mounting hole for
deburr.
radia l shaft seal (93)
Inner part of insertion tool (2)
bolt on to crankshaft.
601 589 03 43 00
coat with engine oí l.
Sealing líp of radial shaft seal Lt
(93) Do not use grease. Grease prevents the retum swirl on the sealing lip of
the radial shaft seal (93) feeding back the engine oíl.
fít onto inner part of insertíon tool (2) and press in wíth insertíon tool (1)
as far as stop.
Mercedes-Benz
IRear of engine check for leaks (01-2240) .
Special tool
601 589 03 43 00
NOTE: An oilleak can be determined after spraying the cleaned and dried surrounding
The end cover is sealed to crankcase with sealant and centered with 2 dowel
pins. In addition, it is bolted to the oil sump and sealed to the bottom by the oil
sump gasket.
There must not be any scoring or unevenness in the sealing surface of the end
cover and of the crankcase.
End cover with integrated radial shaft seal, see note (01-2220) .
Replacing rear crankshaft radiar seal - RA03001193270X(03-3270)
Preceding work:
Transmissíon removed (27-600) .
Driven plates removed (03-4100).
03-3063 - 03-3301
Mercedes-Benz
20 16
Fig. 220: Identifying Driven Plates And Crankshaft Radial Seal
Radial sea] (15) remove (step 1).

Sealing lip of radial seal (15) oil.
Radial seal (15) install witb insertion too!, special tool 117 589 00 43 00 (steps 3 to 6).
Dríven plates (20) install (03-4100).
Leaks check at rear of engine when runníng (01-2240) .
Special tools
117 589 00 43 00
03
Fig. 221: ldentifying SpeciaJ Tools (117 589 00 43 00 03)

Mercedes-Benz
\1 9' 589 00 4000

15
Fig. 222: ldentifying Special Tools (119 589 00 40 00 15)
6 Insertion tool
Use only insertion sleeve 117 589 00 43 00 (2nd version) with hole for locating pin.
lnsertion sleeve 117 589 00 43 00 (1st version) can be altered by a hole with the dimensions "A, B, C" as shown
in the drawing.
SizeA=38 mm
B= l 5.6 mm
C= lümm
Fig. 223: Identifying Inser tion Sleeve Dimensions A, B And C
NOTE: The end cover guides the engine oil from the main oil gallery (arrow) to the two
oil passages for the oil supply of the cylinder heads and is sealed with a sealing
compound.
For this reason, the radial seal should be replaced if possible without removing the end cover.
If a leak exists at the rear, flrst of aH clean engine and spray dried surrounding area with Mercedes-Benz white
contrast spray, Part No. 000 989 03 59. Support engine, run and determine leakage point .
Mercedes-Benz
The running surface for the rear radial seal on the crankshaft is hardened and ground without a spiral.
Fig. 224: Locating Cvlinder Head End Cover
l. Prise out radial seal with a screwdriver.
Do not damage crankshaft and mounting hole for the radial seal. Use clean cloth as a base.
Fig. 225: Prising Out Radial Seal
2. Examine running surface on crankshaft. Ifrunning surface has grooves, install repair size radial seal (15)
with sealing lip offset l. 7 5 mm to inside, and maintain offset repair position of radial seal.
Mercedes-Benz
Poso on of semnq i p
A=radíal SQ:el, stand&d posallon
B=ralfl!ll so al, repair posdl<lll
..__-8 - -
Fig. 226: ldentifving Radial Seal Standard And Repair Position
3. Bolt inner part of special tool 117 589 00 43 00 to crankshaft.

4. Coat radial seal between dust lip and sealing lip with engine oil.
Do not use grease! Grease prevents the sealing lip ofthe radial seal transporting back the engine oil.
5. Push radial seal onto inner part of special tool 117 589 00 43 OO.
Fig. 227: ldentifying Special Tool (117 58900 4300)

Mercedes-Benz
6. Press radial seal into the end cover wíth the inse1tion toolll7 589 00 43 OO.
NOTE: The dust lip must not touch the crankshaft otherwise leaks will occur as a
result of the pumping effect.
7. Check rear of engíne for leaks with engine mnníng (01-2240).
ARRANGEMENT OF BELT PULLEYNIBRATION DAMPER- RA03001043422X(03-3422)
1st version
Arrangement of vibratíon damper with íntegrated 6-groove belt pulley on secondary síde.
Engíne 104.98 up to 01/91

Mercedes-Benz
1 M18x1 .5x55 {10.9)

2 Disood wast.or
3 Vtbrelicn damper pommy part
4 Bastomer
5 Be pt¡le·¡ (C.gro~va)
6 Víbf:abcrl dampor Me onda;¡y
part
7 Woodruffk ey
8 Red al sha.ít se el
g Crricase
10 Crali< sflaft sprod< at (<nv'11 ol
como!)
10a Cranl<shBfi sprod< at{drrve of
oi pump)
11 Crarl< sh!ilft
~Zl:2::;::::::z:z::z::¡¡af-+--- te
12 Oi SU!ll> 1&
13 Oi SIJ!ll> gasl<m
14 BoU cr altath!ng cJ SUIT1> y::::::::::~~~ 14
WW'NY'\->. ....,........~ 13
l h ' - - - - - - 12
Fig. 229: ldentifying Arrangement Of Belt Pulley/Vibration Damper (1st Version)
2nd version
Arrangement of 8-groove belt pulley on primary side of vibration damper. Thus improving quiet running of
poly V-belt.
Engine 104.98 as ofOl/ 1991
Engine 104.94/99 as of start of production up to 8/ 1993

Mercedes-Benz
6b B 9 7 10a 10 7
3
5
1 M18X1 .5x55(10.9)
2 Dlshod wasner
3 Vibfation damper pnmBJY part
4 Elastomer
5 Be puley {8-goove)
Sa M8x48bol
5b Wa-shef 'lt
S Vibrabon damper secondery
part
Al JI='..:.:...::.~"" tZ:lzi!:ZZ.l~~--t-·18
~ locamg~n
6b Hlb
7 Woom.ffkey
8 Rad~s~
---13
9 Creri<case ~-------------12
10 Crñshalt sprod< et (drive cf 1'1)3-QIU ·15A
cormJI)
10a Cranl<shaft spro{i(et (drNe of
oi pt.ITip)
11 Croo\\~
12 CliSli!T1>
13 Cli SUIT1> gasl< et
14 Bo for attachng oi Sllrrp
Fig. 230: Identifying Arraogement Of Belt PulleyNibration Damper (2nd Version)
3rd version
Modified central bolt.
Material strength modified from 10.9 to 8.8.
Conical wasber replaces tbe 4 dished wasbers.
Modified tighterung torque.
The different parts of the 3 versions must not be interchanged.
Engine 104.94/99 as of09/1993

Mercedes-Benz
1 M18 X 1,5 X 55 {8.8)

2 COflcal wa><her
S Víbraboo d!lllllar
pnmarypart
4 El!J<sromer
5 Bel puley(ó-groove)
Sa M5, b~
5b Washor
6 Vlbmboo dflllll'Bl
~ll"COridmy part
6a l~ elingp;r~
6b Hub
7 woo.mu: k&y
8 Radial wal
9 Tirnng case coVilr P03.3()...{):!88--15
10 Cra.nksh~ ·spr~ ket
(ooveot
cootrol)
10a Ctanl<'sha.'t sprod<et(dnve otoil
pump
11 Cranksh~
Fig. 231: ldentifying Arrangement Of Belt PulleyNibration Damper (3rd Version)
4th version
Belt pulley/vibration damper reduced in weight.
Hub integrated in vibration damper.
Engine 104.945/995 as ofstart ofproduction

Mercedes-Benz
POS-5373.-13
Fig. 232: Locating Belt PulleyNibration Damper
CHECKING, CORRECTING SETTING OF TDC SENSOR- RA03001043450X(03-3450)
Checking, correcting setting of TDC sensor- RA03001043450X(03-3450)
Preceding work:
Viscous fan sbroud removed (20-3120).
Operatíon no. of operation texts and work units or standard texts and flat rates
03 -1101
Checking setting of TDC sensor

Mercedes-Benz
POJ - S11i18- 13
POS · 5232 · 57
Fig. 233: Checking Setting Of TDC Sensor
Piston of cylinder 1 tum to 10° before ignition TDC.

Spark plug of cylinder 1 remove, instan.
TDC sensor (Ll) unbolt, bolt on.
TDC sensor (L 1) remove from adjusting slide (3).
Dial gauge holder (02) 136
install.
589 04 21 00
Dial gauge (O 1) and
insert into dial gauge holder (02) with 4 mm preload.
extension (length 155 mm)
rotate in direction of rotation of engine and set TDC on cylinder 1 with dial
Crankshaft
gauge (01).
Large pointer of dial gauge
zero.
(01)
r otate in direction of rotation of engine until dial gauge has moved back by
Crankshaft
the value, see table "piston travel" (20° after TDC of cylinder 1).
Locating devíce (4) 119 589
00 insert into adjustíng slíde (3).
21 00
Locating device (4) 119 589 . . . .
must engage over measurmg pm on v1brat10n damper ( 6).
00 21 00
Correcting setting of TDC sensor

Mercedes-Benz
PG:I - 62Ul-13
Fig. 234: Correcting Setting OfTDC Sensor
Engine 104.98: open cap of cooling system (release pressure).

Engine 104.98: remove heating water return line (25), install; replace seal.
Engine 104.98: plug opening of coolant pump.
Bolt (5) of adjustíng slide
slacken.
(3)
move untillocating device engages o ver measuring pin (4) on vibration
Adjustíng slíde (3)
damper (6).
Bolt (5) tighten.
Engine 104.98: pour in coolant (20-0100) .
Engine 104.98: check cooling system for leaks (20-0 170) .
PISTON TRAVEL WITH CRANKSHAFT IN POSITION 20° AFTER TDC OF CYLINDER 1 IN MM

Encrine
o
(1) 104.94 104.98 104.99
Measurement vertícaUy on píston 2.75 3.07 3.25
(l) except AMG engines
SpeciaJ tooJs
Mercedes-Benz
119 589 00 21 00
136 589 04 21 00
001 589 53 21 00
Fig. 237: lden tifying Special Tools (001 589 53 21 00}
SHOP-MADE TOOL
IMeasuring pin extension for dial gau ge length 155 mm
NOTE: The TDC sensor (L 1) with bracket is attached to the timing case cover.
The measuring pin (arrow) in the vibration damper must be positioned in the middle below the TDC sensor (L 1)
at 20° after TDC in cylinder l.
The setting; of the TDC sensor must be checked and corrected. as necessarv:
Mercedes-Benz
• When replacing the crankshaft or the vibration damper.

• When replacing the timing case cover.
• When adding parts to short engines.
With the cylinder head removed, attach a dial gauge holder to the crankcase and place dial gauge pin vertically
onto the pisten crown.
Fig. 238: Locating Vibration Damper In TDC Sensor
Checking and correcting settiug of TDC sensor- RA03001193450X{03-3450)
03-1101, 1122
Mercedes-Benz
I'():)-Q201Hit
Fie. 239: Checkine And Correctin2 Settine Of TDC Sensor Usine Special Tools (116 589 17 2100)
Ground cable of battery disconnect, connect.

Poly V-belt tensioníng device remove, install {13-3450) .
Right cylinder head cover remove, instaU {01-0500) .
Piston ofno. 1 cylinder set to 10° before TDC.
Spark plug at no. 1 cylinder remove, install (25 Nm)
Measuring pin 11 6 589 17 21 00 screw into spark plug thread ofNo. 1 cylinder, unscrew (step 6).
TDC sensor remove, install (step 7).
CHECKING SETTING OF TDC SENSOR

Mercedes-Benz
Dial gauge (0 1) clamp tight in measuring pin with 4 mm preload, special tooll16 589 17 21 00 (step
8).
Crankshaft turn in direction ofrotation of engine and set TDC with dial gauge (01) (step 8).
Large point of
setto "O" (step 8).
dial gauge
rotate with wrench socket in direction of rotation of engine until dial gauge has moved
Engine
back by the value, see table "Data" (20° after TDC), special tool 001 589 65 09 OO.
Fixing device insert into adjusting slide, special toolll9 589 00 21 00 (step ] 0).
must engage in measuring cam on vibration damper, special tool119 589 00 21 00
Fixing device
(step 10).
CORRECTING SETTING OF TDC SENSOR

Nut of adjusting
slide slacken (step 11).
move until fixing device locks in place in measuring cam on vibration damper, special
Adjusting slide
tooll19 589 00 21 00 (step 11).
Nut of adjusting tighten (step 12).
slide
PISTON TRAVEL AT CRANKSHAFT SETTING OF 20° AFTER TDC

Engine 119.960 119.970/974 119.971
Measurement through spark plug bore 3.25 mm 3.28mm 2.99 mm
Vertical to pisten 3.27mm 3.30mm 3.01 mm
Special tools
1 11t3 589 17 21 00
00
Fie. 240: Identifying Special Tools (116 589 17 21 00 03)

Mercedes-Benz
1l9'389 00 2 1 00
03
001 580 65 09 00
03 07 32 ..)
Fig. 242: Identifying Special Tools (001 589 65 09 00 03 07 32)
t.
102 58'9 02 09 00
15
Mahr
Dial gauge A 1 DIN 878 e.g. D-7300 Esslingen
Order no. 311 000
NOTE: The TDC sensor (2) with bracket is attached to the timing case cover.
The m easuring cam (1) on the vibration damper must be positioned in the middle below the TDC sensor (2)
when the crankshaft is in the position 20° after TDC.
Mercedes-Benz
Fi~. 244: Identifying TDC Sensor With Bracket To Timing Case Cover
The setting of the TDC sensor must be checked and corrected:
• When repJacing the cran.kshaft ofthe vibration damper.

• When replacing the timing case cover.
• When fitting parts to basic engines.
With the cylinder head removed, attach the dial gauge holder to the crankcase and position dial gauge pin on the
piston crown.

2. Remove poly V-belt tensioning device (13-3450) .
3. Remove right cylinder head cover (01-0500).
4. Position piston ofNo. 1 cylinder to 10° before TDC.
5. Unscrew sparkp1ug ofNo. 1 cylinder.
6. Screw measuring pin (arrow), special tool116 589 17 21 00, into spark plug bore at No. 1 cylinder.
Mercedes-Benz
Fig. 245: Locating Screw Measuring Pin
7. Unscrew hexagon nut (arrow) and withdraw TDC sensor (2).
Fig. 246: Locating TDC Sensor Hexagon Nut
Checking
8. Clamp dial gauge (O1) tight into measuring pin, special too! 116 589 17 21 00, with 4 mm preload.
Rota te crankshaft in direction of rotation of engine and set TDC precisely with the dial gauge (O 1). Turn
scale of dial gauge untillarge pointer of gauge (O1) is set to "O".
Mercedes-Benz
Fig. 247: ldentifying Dial Gauge lostalled In Measuriog Pio
9 _ Rota te crankshaft further in direction of rotation until the dial gauge has moved back by the relevant value
(pisten travel).
lO_ Position fixing device (4) 119 589 00 21 00 into tlne setting slide (3)_
The groove ofthe fixing device (4) must engage in the measuring cam (1) on the vibration damper.
Ifthe fixing device (4) does not engage, correct position of setting slide (3).
Fig. 248: Identifviog Fixing Device (119 589 00 21 00) & Settiog Slide
Correcting
1 l. Slacken nut (arrow) of setting slide and move it until the fixing device (4), special tool119 589 00 21 00,
engages in the measuríng cam (1).
12. Screw on setting slide (3) and remove fixing device (4).
Mercedes-Benz
Fig. 249: Locating Setting Slide And Vibration Damper
13_ Insert TDC sensor (2) and screw on (arrow).

14. Remove dial gauge and measuring pin.
15. Install in the reverse order beginning from step 5.
Fig. 250: Locating TDC Sensor And Screw
Cbecking, correcting setting of TDC sensor - RA03001203450X(03-3450)
Preceding work:
Poly-V belt removed (13-3420) _
Radiator removed (20-4200) .

Mercedes-Benz
P03-&277-37
Fig. 251: Checking Setting OfTDC Sensor
CHECKING SETTING OF TDC SENSOR

Tensianing roller, tensianing
remave, install (step 1).
device
Spark plugs on cylinder 1 and
remave, install.
7
TDC sensors (Ll/1 and Ll/2) remave, install (step 3).
Pistan af cylinder 1 and 7 set ta 10° befare TDC ( step 4).
Dial gauge holder (02) 363 589
02 21 00 with threaded sleeve fit an val ve caver af cylinder 1 and 7 (step 5).
(04)
Dial ITau iTe (0 1) w ith extension clamn in dial ITa1we ho lde r (02)
Mercedes-Benz
(03) (300 mm) 363 589 02 21 00 with 4 mm preload (step 6).

rotate in dírection of rotation of engine with wrench socket 001 589 65
Crankshaft
09 00 and set TDC at cylinder 1 and 7 with dial gauge (O 1).
Large pointer of dial gauge
set to "0".
(01)
rotate with wrench socket 001 589 65 09 00 in direction ofrotation of
Crankshaft engine until dial gauge has moved back by the value in table "piston
travel" (20° after TDC cylinder 1 and 7).
Fixing device 119 5 89 00 21
insert into adjusting slide (step 10).
00
Fixing device 119 589 00 21
must engage in measuring pin on vibration damper.
00
CORRECTING SETTING OF TDC SENSORS

Nuts of adjusting slide slacken (step 11 ).
Adjusting slide move untíl fixing device 119 589 00 21 00 engages at vibration damper (step 11 ).
Nuts of adjusting slide tighten (step 12).
PISTON TRAVEL AT CRANKSHAFT SETTING 20° AFTER TDC CYLINDER 1, OR 20° AFTER
TDC CYLINDER 7
IMeasurement through spark plug hole or vertically on piston 2.33 mm
Special tools
11 9 539 00 21 00
03
Fie;. 252: Identifyine; Special Tools {119 589 00 21 00 03)

Mercedes-Benz
1
001 580 6.5 09 (10
03 07 3:2 .1
Fig. 253: ldentifying SpeciaJ Tools (001 589 65 09 00 03 07 32)
, 19581J 02 09 00
15
' ~
001 53953 21 00
00
Shop-made tool
Threaded sleeve (M8 to M6 reduction) for attaching dial gauge holder 363 589 02 21 00 to cylinder head cover.
Mercedes-Benz
N - 1014·11
F ig. 256: ldentifying T hreaded Sleeve Length
NOTE: The TDC sensors (L 1/2} and (L 1/1} with adjusting slides (3} and (7} are attached
to the timing case cover.
The measuring pin (arrow) on the vibration damper mus.t be centered below the TDC sensors (L l /2) and (L l/1)
at 20° after TDC at cylinder 1° and at 20° after TDC at cylinder 7 (TDC pointer reading 80°).
The setting ofthe TDC sensors must be checked and conected:
• ifthe crankshaft or the vibration darnper is replaced.

• if the timing case cover is replaced.
• if parts are added to part engines.
With the cylinder heads removed, attach a dial gauge holder to the crankcase and position dial gauge pin on the
piston crown.
Fig. 257: Locating TDC Sensors And Adj usting Slides
C h ~>r kin (J ~ Pttin (J of T nC ~ P.n ~or~ (J , 1/ 1) ~mil (J ,1/2)

Mercedes-Benz
L Unscrew bolt (1 ), remove tensioning pulley (8) of poly V -belt
Tightening torque 38 Nm_
2. Unscrew spark plugs at cylinder 1 and 7 _
Fig. 258: Locating Tensioning Pulley OfPoly V-Belt And Bolt
3_ Unscrew TDC sensors (Ll/2) and Llll) and remove from adjusting slides (3) and (7).
Fig. 259: Locating TDC Sensors And Adjusting Slides
4. Set pistons of cylinders l and 7 to 10° before TDC (reacling 50° CKA on vibration damper for cylinder
7).
5. Attach dial gauge holder (02) 363 589 02 21 00 with threaded sleeve (04) (shop-made) to cylinder head
cover of cylinders 1 and 7.
Mercedes-Benz
Unscrew cylinder head cover bolt for this step and install dial gauge holder (02) with threaded sleeve
(04).
Riglt b.ank ct c;liodors
Fig. 260: ldentifving Right Bank Of Cvlinders
6. Clamp dial gauge (01) with extension (03) (300 mm) into dial gauge holder (02) witb 4 mm preload.
7. Rotate crankshaft in directíon of rotation of engine with socket wrencb 001 589 65 09 00 and set TDC at
cylinders 1 and 7 with dial gauge (O 1).
8. Tum scale of dial gauge until the large pointer of gauge (01) ís at "0".
Fig. 261: ldentifying Crankshaft Direction With Dial Gauge
9. Tum on crankshaft in direction of rotation of engine until the clial gauge has moved back by the
respective amount (piston travel).
10. Insert fixing device (4) 119 589 00 21 00 into the adjusting slide (3) (right bank ofcylinders) or (7) (left
bank of cylinders).
The slot ofthe fixing; device (4) must eng;ag;e in the measuring; oin (arrow) on the vibration damoer (6).
Mercedes-Benz
If the fixing device (4) does not engage at the vibration darnper (6), correct the setting of the TDC
sensors.
Fig. 262: Locating Vibration Damper, Fixing Device And TDC Sensor
Correcting setting ofTDC sensors (Ll/1) and (Ll/2)
11. Slacken nut (5) or (9) and move adjusting slide (3) or (7) until fixing device (4) engages in the measuring
pin (arrow) at the vibration damper (6).
12. Tighten nut (5) or (9).
13. Install in the reverse order, beginning at step 3.
A$1smg side (7), leltbañ< of cytndllfS
Fig. 263: Correcting Setting Of TDC Sensors (Ll/1) And (Ll/2)
REMOVING AND INSTALLING DRIVEN PLATE WITH RING GEAR- RA03001044100X(03-4100)
Removing and installing driven plate with ring gear- RA03001044100X(03-4100)
Preceding work:
Mercedes-Benz
Automatic transmission removed (27-600) .
Retaining lock for crankshaft/ring gear installed (03-5000) .
03-800 1-8201
PO:l-5284-57
Fig. 264: ldentifying Driven Plate And Ring Gear Remove/lnstall Components
Stretch bolts (4) or intemal torx bolt unscrew, screw on.

Stretch bolts (4) inspect, see table.
Internal torx bolt replace.
replace if mínimum stretch shank shaft día. ( d) does not
Stretch shank bolt (4)
exist.
Driven plate with ring gear ( 11) and plate
remove, install.
(8)
Dowel pin ( 6) note.
BOLT ATTACHMENT OF DRIVEN PLATES

ITvpe ofbolt Interna! torx T55 (1) Stretch bolt
Mercedes-Benz
Thread D MIO X l M lO X 1
d - 8.5-0.2
Stretch sbank 0
when new minimum 0 - 8.0
Length of bolt Lwhennew 28.5 22±0.2 (max. 22.5)
Tightening torque(2) 145 Nm+90° tightening angle
(I) As ofMay 1995 instead ofstretch bolt
(2) Thread and bolt contact smface moistened with assembly oil
Special tools
001 589 66 21 00
000 5B9 01 10 00
Fig. 266: ldentifying Special Tools (000 589 0110 00)
NOTE: lf no tightening angle wrench is available, the stretch shank bolts can be
tightened further to the specified angle in a single operation with a wrench
socket and tommy bar. A flexi-rod torque wrench must not be used for
tightening according to degrees of angle in order to avoid angle errors.
Mercedes-Benz
P03-5285-13
Fi~. 267: Locatin~ Ti~btenin& A n ~le Stretcb Sbank Bolts
The interna! torx bolts installed as ofMay 1995 must be used only once and should be replaced after each
removal and installation operation.
- L .-
V
.--
11--
1J 1
·- -
\ 1
" '\t--
1--
L .-
P03.30-0Z33-13
Fig. 268: Identifying Interna} Torx Bolts Dimensions

Mercedes-Benz
15
Oil sunp
2 C{}V(lf 12
3 Raffiel shat se al
4 Bot 8.5Nm
5 Cfenkshefi
6 Oowel ptn 10
8 3.5 rrm t11ck we:sh9f
9 Washer
10 Bol
11 Orwen pla!o{2X2.4 rrm luck)
8
12 Ca1ner pla!B
13 Ri.tel
14 Segment &
15 R11ggear, welded
Fig. 269: ldentifying Oil Pump, Radial Shaft Seal And Driven Plate
Removing and installing driven plates- RA03001194100X(03-4100)
Preceding work:
03-8201 , 8211
A Engine 119.960/97
Mercedes-Benz
17
18
OrffenplateA=1 S mm
Orrvenp!ateB=1.0 mm
----
Fig. 270: ldentifying Driven Plates Remove/lnstall Components
Retaíning lock for crankshaft/ríng gear install, remove {03-5000).

Position sensor (3) of ignition control unit with bracket (l)unbolt, bolt on (step 2).
Stretch bolts (19) unbolt, replace
(steps 3 and 4).
Driven plates (17) and ( 18) take off, fit on.
Installation position and installation order note (steps 5 and 6).
Special tools
Mercedes-Benz
001 589 66 21 00
116 589 01 40 00
11 9 5890040 ():0
Thread 0 ( l ) M 12xl.5
Inítial torque 30-40
(l) Micro-encapsulated, use only once.
NOTE: Driven plates and ring gear are balanced individually and can be replaced
without balancina.
Mercedes-Benz
The tapped holes in the crankshaft flange are drilled through_ If the bolts are removed and the engine is
tilted, engine oil flows out ofthe tapped holes.
l. Remove retaining lock for crankshaft/ring gear, install {03-5000)_
Fig. 274: ldentifying Retaining Lock For Cranksbaft/Ring Gear
2. Unbolt position sensor (3) of ignition control unit together with bracket (1).
3_ Remove bolts (19). Take off driven plates together with ring gear (20).
Fig. 275: ldentifying Position Sensor Of Ignition Control Witb Bracket
4. Install driven plates at crankshaft flange. Install thicker driven plate (17), thickness 1.5 mm, on
inside. Insert stretch bolts ( 19)_
Mounting surface of driven plates, ofbolts and plate mounts must be free of damage and dirt.
Mercedes-Benz
Install bolts ( 19) without sealant otherwíse leaks may occur.
Fig. 276: Identifying Driven Plate, Crankshaft Flange And Stretch Bolts
5. Fít ring gear (20) onto driven plates (17 and 18) and tighten nut (23) 5 Nm.
The ring gear must be installed so that the 3.5 mm día. holes (arrows) in the ring gear and in the
driven plates have the same angular position, otherwise proper operation of the ignition is not
assured.
6. Fix crankshaft against rotation. (see step 1).

7. Tighten bolts of driver to initíal torque of 30 N m and tightening angle of 90°.
NOTE: Bolts are micro-encapsulated; use only once.
8. Screw on position. sensor of ignition control unit wíth bracket.

Mercedes-Benz
Fig. 277: Identifying Ring Gear In Driven PI ates Position
B. Engine 119.98
P03.30-024S..57
Fig. 278: Identifying Piston Sensor, Driven Plate And Plate Base
Retaining lock for crankshaft/ring

install, remove. (03-5000).
g:ear
Mercedes-Benz
Position sensor (3) of ignition control . b lt b lt

. w1t
unlt . h braek et ( 1) un o ' o on.
Stretch bolts (19) unscrew, replace.
take off, fit on.
~
Combined driven plate/starter ring
Mount of driven plate, of bolts and p late mount must be free of
gear (25)
damage and din.
Install bolts (19) without sealant otherwise leaks may occur.
NOTE:
Installation position and installation A
order The driven plate (25) and the plate base (16) must be installed
so that the dowel pin engages in the 0 8 mm hole.
001 589 66 21 00
11 6 589 01 40 00
Fig. 280: ldentifying Special Tools {116 589 01 40 00)

Mercedes-Benz
11 9 589 00 40 00
Thread 0 M 12xl.5
Initial torque 30-40
NOTE: The threaded holes in the crankshaft flange are drilled through. lf the bolts are
removed and the engine is inclinad, engine oil flows out of the threaded holes.
FUNCTION OF TWO-MASS FLYWHEEL- RA03001044600X(03-4600)

Mercedes-Benz
PriiTlar,r tyv,heel mass 7 Sjlacor~ of seconda¡y~el massldamper

2 Socon<:l!lfY lytAI'leel mass system
3 Wllf spmgdampef 8 Rmggoar
4 h'lllf spnng damPilf 9 Groúv&d balboamg
5 Fndion doVJce 10 Oowelpm
6 Sjl&elll pl'l el pomarylt/NMel massldBIT'pOl S~tl!m 11 Grocved balbeamg
12 Slrelch shark 001 Qr slralgl'tsh:Ch sllanl< bol!
Fig. 282: ldentifying Outer Spring Damper, lnner Spring Damper And Primary Flywheel Mass
Design
The two-mass flywheel consists of three principal parts:
Primary flywheel mass (1)
The primary flywheel mass (1) ís bolted to the crankshaft by eight MIO X 1 X 57 stretch shank bolt. The
grooved hall bearing (9) for mounting the transmission input shaft is placed in the primruy flywheel (1 ). The
statter ring gear (8) is shrink-fitted on the outside.
Damper system
Secondary flywheel mass (2)
The secondary flywheel mass (2) pivots on the primary flywheel mass ( 1) by means of a grooved ball bearing
(9). I'he clutch is installed on the secondary flywheel mass (2).
The damoer svstem is installed between the two flvwheel mas ses. It consists of an ümer and outer sori.ng
Mercedes-Benz
damper and friction devices. The slewing range ofthe flywheel masses to each other is lirnited by the damper
system to ± 15 and ± 40, respectively. Each flywheel mass is connected to the damper system with ríveted
spacer pins (6) and (7).
Function
The two-mass flywheel absorbs the rotational vibrations. of the crank assembly and reduces the transmission of
these vibrations to the gearbox-propeller shaft area.
Ride comfort is improved in the lower engine speed range.
Critica! vibrations do not become effective except below idling speed range as a result of the different
distribution of the moments of inertia of the primary and secondary flywheel masses.
The primary flywheel mass ( 1) is bolted to the crankshaft and connected by spacer pins (6) to the secondary
flywheel mass (2).
The torsion and friction system positioned between has a damping effect on residual vibrations.
The ring gear (8) is shrink-fitted onto the primary flywheel mass (1).
A two-mass flywheel cannot be repaired and is supplied as a replacement part.
REMOVING AND INSTALLING TWO-MASS FLYWHEEL- RA03001044620X(03-4620)
Preceding work:
Manual transrnission removed (26-020).
Clutch removed (25-050).
Retaining lock for crankshaft/ring gear installed (03-5000) .
03-8001, 03-8201
Mercedes-Benz
1"03-5286-57
Fig. 283: Identifying Two-Mass Flvwheel Remove!Install Components
Stretch bolts (12) (1st version) or straight stretch shank bolts

(2nd version) or torx bolts (with sheet steel two-mass unscrew, screw on.
flywheel)
inspect, see table.
Stretch bolts (12) NOTE:

lf the shank 0 is less than the mínimum
0 (d), replace stretch bolt (12).
Straight stretch shank bolts or torx bolts replace, see note.
remove, install.
Two-mass fl ywheel (1) or sheet steel two-mass fl ywheel NOTE:

The installation position of the flywheel
(1) is determined by the dowel pin (10).
STRETCH SHANK BOLTflST VERSIONJ

Thread D MIOX 1
Stretch 0 shank d whennew 8.5-0.2
1
Mercedes-Benz
1
mínimum 0 8.1
Bolt length L whennew 57±0.2
Part no. 103 032 00 71
Tightening torque 130 Nm+90° tightening angle
l) Thread and bolt head contact surface moistened with assembly oil
STRAIGHT STRETCH SHANK BOLT (2ND VERSION)

Thread D MlOX 1
Bolt length L 57±0.2
Part no. 111 032 00 71
Tightening torque 145 Nm+90° tightening angle
l) Thread and bolt head contact surface moistened with assembly oil
TORX BOLT (WITH SHEET STEEL TWO-MASS FLYWHEEL AS OF 05/1995)

Thread D MIOX 1
Bolt length L 28.5 ± 0.2
Tightening torque (l) 45 Nm+90° tíghtening angle
(1) Thread and bolt head contact surface moistened with assembly oil
NOTE: The straight stretch shank bolt should be replaced when performing repairs; it
must be used only once.
- ·-
~
.,.. __
~
::
~
- -- -- 11-·-------
~
::
- JI
P03-5365-13
Fig. 284: ldentifying Straight Stretcb Sbank Bolt Lengtb
As ofMay 1995 the bolts ofthe driven plate and two-mass flywheel (sheet steel two-mass flywheel) have been
standardized. The torx bolt (3rd version) should be replaced when performing repairs.
Mercedes-Benz
-- L .-
V
.--
11--
¡ ,--
11
\ 1
'
\1--
\ t--
L_
P03.30-0233-13
Fig. 285: ldentifying Torx Bolt Length
Special tools
001 569 66 21 00
000 589 01 10 00
Fig. 287: ldentifying Special Tools (000 589 0110 00)
NOTE: lf no tightening angle torque wrench is available, the stretch shank bolts or
straight stretch shank bolts can be torqued further to the specified angle in a
single operation with a wrench socket and tommy bar. A flexi-rod torque
Mercedes-Benz
wrench must not be used for tightening to tightening angles in order to avoid
any angle errors. For design of two-mass flywheel see "Function of two-mass
flywheel (03-4600)".
Fi~. 288: Ti~hte nin ~ An~le Stretch Shank Bolts
REMOVING AND I NSTALLING NEEDLE BUSH I N TW O-MASS FLYWHEEL- RA03001044640X

(03-4640)
Preceding work:
Two-mass flywheel removed (03-4620).
Mercedes-Benz
P0~2-57
Fig. 289: ldentifying Needle Bush, Primarv Flywheel And Nut
Puller (7) 000 589 33 33 00 with insert (15) 000

fit onto needle busb (11 ).
529 25 33 00
Nut (14) turn and spread taper apart.
Needle bush (11) pull out.
press in at outer race as far as the stop.
&
New needle bush (11) with 0 45 sleeve Press needle bush (11) in, do not strike.
Use 0 14.8 mm securing drift to prevent bearing rollers
dropp ing out.
must be tightly seated at outer race in the primary
N eedle bush ( 11)
flywheel (1).
DATAINMM
IMounting hole 0 in two-mass flywheel 46.96-49.98
Special tools
Mercedes-Benz
Fig. 290: ldentifying Special Tools (000 589 25 33 00}
000 589 25 33 00
Fig. 291: ldentüying Special Tools (000 589 25 33 00)
REMOVING AND INSTALLING RETAINING LOCKFOR CRANKSHAFTIRING GEAR-

RA03001045000X(03-5000)
Removing and installing retaining lock for crankshaft/ring gear- RA03001045000X(03-5000)

Mercedes-Benz
=>o:>-5287-57
Fig. 292: ldentifying Retaining Lock For Crankshaft/Ring Gear Remove/Install Components
Closing cover (2) on rear take off, fit on.

ofoil sump
M6 X 85 bolts (1) unscrew, screw on.
Retainin<dock (3) 601 589 . . .
02 40 00
° allow to engage m nng gear, rotate crankshaft tfnecessary (01-0120).
unbolt, bolt on (lO Nm).
Retaining lock (3)
Lh
Bolt on retaining lock (3) with M6 X 90 bolts (4) otherwise the threads in the
rear closing cover will be damaged.
Special tool
Mercedes-Benz
601 589 02 40 00
Removing and installing retaining lock for crankshaft/ring gear - RA03001195000X(03-5000)
A. Witb transmission installed
Fig. 294: Identifying Retaining Lock Position
Models 124, 129, 140: left front

exhaust cross pipe
Cover at left starter recess remove, ínstaU.
Retaining loe k ( 1) insert into rinQ' qe::~r until it e nqaqes . rot.ate cmnksh::~ft ifnecessarv.
Mercedes-Benz
special tool 116 589 O1 40 OO.
Special tool
116 589 01 40 00
B. With transmission removed
Preceding work:
Fig. 296: ldentifving Retaining Lock And Bracket

Mercedes-Benz
Brank.cket (2 ) 00 left side ofbolt on, unbolt, special toolll9 589 00 40 OO.
era case
insert into bracket (2) and insert into ring gear until it engages, rotate
Retaíning loe k ( 1)
crankshaft ífnecessary, special toolll6 589 01 40 OO.
Special tools
11 658901 4000
11 9589004000
REMOVING AND INSTALLING BELT PULLEY OF VIBRATION DAMPER AND HUB-

RA03001193420X(03-3420)
Removing and installing belt pullley of vibration dam¡>er and hub- RA03001193420X(03-3420)
Preceding work:
Model 124: radiator removed (20-4200) .
Tensioning device removed {13-3450) .
Reservoir witb coolant drain line removed (20-2120).

Mercedes-Benz
Retain:ing lock for crankshaft/ring gear installed (03-5000).
03-1320-1911
A. Engine 119.960
119.97 up to 8/1994
Fig. 299: ldentifving Vibration Damper, Belt Pulley And Hub
If AC fitted: guard plate attach to condenser.

mark relative to vibration damper ( 13) with colored marking (arrows).
Installation note
Belt pulley (12)
The belt pulley (12), the vibration damper (13) and the hub (14) must be bolted
together in a particular position as one ofthe 6 boles is positioned off-center.
Central bolt (11) with 4 lnstallation note
dished washers (lla) Oil bolt thread and the 4 Belleville spring washers (11a).
Fit on spring washers (lla) with curved side facing bolt head.
Mercedes-Benz
Belt pulley (12) and remove, install.

vibration damper (13)
Crankshaft and hub (14) mark relative to each other with chisel punch (arrow).
remove with puller, special tool 103 589 00 33 OO.
Installation note
Hub (14) Heat hub (14) to approx. 50 oc so that it slips easily onto the crankshaft.
Determine by turning whether the groove in the hu b (14) is aligned with the
woodruff key ( 15) in the craukshaft.
Belt pulley (12) exanune.
SpeciaJ tools
001 589 66 21 00
001 589 7 4 21 00

Mercedes-Benz
001 589 65 09 00
103 589 00 33 00
COMMERCULLYAVA~ABLETOOL
3/4 " mterna

.
1 square to
Hazet
D-42853 R h .d
" t d
112. ex ema1square a aptor e.g. emsc e1
Order no. 1058 RI
SHOP-MADE TOOL
lGuard plate for radiator at condenser Dimensions approx. 680 X 400 X 1 mml
DATA IN MM
. .bl d . . .b . d from radial runout0.3
PermiSSl e ev1atwn at v1 ratwn amper fr .
om axm1nmout 0 .5
Ml8 bolt ofvibration damper400
M8 bolts ofbelt pulley 35
NOTE: Engine 119.96/97: if the vibration damper is replaced, the TDC sensor
should be set (03-3450).
B. Engine 119.97/98 starting from 8/1994

Mercedes-Benz
Preceding work:
Viscous fan coupling removed (20-3120) _
Tensíoníng device removed (13-3450) _
03-1320-1911
P03.30-0254-57
Fig. 304: ldentifying Generator, Viscous Fan Coupling Bearing Bracket And Central Bolt
Ground cable at battery disconnect, connect (AR54.1 0-0003A).

Generator ( 1) remove, instalL
Guard plate attach at radiator, take off
Viscous fan coupling
bearing bracket (2)
Bracket of A/C
unbolt, bolt on.
compressor carrier (3)
Pisten of cylinder 1 turn to TDC so that W oodruff key ( 15) in crankshaft is facing vertically up _
R P.t~ in1 n P 1()1"k- f()r install, remove (03-5000) .
Mercedes-Benz
crankshaft/ring gear
unscrew, screw on (200 Nm+ Angle 90°).
Central bolt ( 19) with
NOTE:
tapered washer (20)
Conical washer (20) replaces dished washers; the different parts of the 2
versions must not be interchanged.
pull off, remove upward, fit on.
NOTE:
Vibration damper (18)
Align Woodruff key (15), fit on vibration damper (18) and turn in order to
determine whether the slot is aligned with the Woodruff key (15) in the
crankshaft.
Special tools
001 589 74 21 00
001 589 65 09 00
COMMERCIALLY A V AILABLE TOOL
314 , .flemde
al " Firma Hazet
to 112 ma 1e e.g. D-42853 Remscheid
4-pomt a apter Order no. 1058 RI
SHOP-MADE TOOL
Mercedes-Benz
IGuard plate for radiator and condenser Dímensíons: approx. 680 X 400 X l mml
. . . . Initial torque Nm 200
Ml8 Xl.5 X 44 bolt ofv1brat10n damper (w1th comcal washer)T. h . An o
1g terung ang 1e g1e 90
Removing and installing belt pullley/vibration damper- RA03001203420X(03-3420)
Preceding work:
Bottom engine compartrnent panel removed
(Maintenance Manual2, Op. no. 6190).
Operation no. of operation texts and work units or standard texts and flat rates 03-1320-1911
P03- 52:78-57
Fig. 307: Identifying Vibration Damper, Fan And Coolant Pump

Guard plate attach in front of radiator.
Crankshaft of cylinder 1 rotate to TDC (step 3).
Mercedes-Benz
Bolts ofbelt pulleys offan (lO) and of coolant pump (9) slacken, tighten ( 13 N m) (step 4).
Poly V-belt remove, install (13 -3420).
Tensioning pulley (8) of poly V-belt remove, install (38 Nm) (step 6).
Belt pulleys of fan ( 1O) and of coolant pump (9) remove, install (step 7).
Retaining lock for crankshaft/ring gear remove, install (03-5000).
Bolt of hub (1) unscrew, screw on (step 9).
Belt pulley/vibration damper (6) remo ve, install (step 10).
Woodruff key (7) note.
Belt pulley ( 6) check.
DATA IN MM
radialrunout (l)0.2
Pennissible deviation at vibration damper
lateral nmout <2) O. 3
(l) Measured at pulley, inside front.
(2) Measured at pulley, front.
Bolt at crankshaft 400
Bolt of belt pulley of fan and coolant pump 13
Bolt of tensioning device 38
Special tools
602 58.9 00 40 00
03

Mercedes-Benz
001 589 74 2.1 00 1

00 i.
001 589 72 21 00
00
001 580 65 00 00
03 07 32
Fig. 311: ldentifying Special Tools (001 589 65 09 00 03 07 32)
13/4" square socket to 1/2" externa! square connector eg.Hazet, D-5630 Remscheid Order no. 1058 RI
SHOP-MADE TOOL
IGuard plate for radiator/condensor Dimensions: approx. 680 X 400 X 1

2. Attach guard plate in front ofradiator.
3. Rotate crankshaft until cylínder 1 is at TDC (arrow) so that the Woodruffkey in the crankshaft is facing
Mercedes-Benz
vertically up.
----,-...l:.::=::=:==== POS· 5071 -13

Fig. 312: Locating Cyünder 1 At TDC Position
4. Slacken bolts (arrows) ofthe belt pulleys ofthe fan (10) and of the coolant purnp (9).
5. Remove poly V-belt (13 -3420).
Fie. 313: Locatine Fan & Coolant Pump Belt Pulleys Bolts
6. Unscrew bolt (1), remove tensioning pulJey (8) ofpoly V-belt.

Mercedes-Benz
Fig. 314: Locating Poly V-Belt Tensioning Pulley Bolt
7 _ Unbolt belt pulleys of fan ( 1O) and of coolant pump (9) and remove_
Fig. 315: Locating Belt Pulleys OfFan And Of Coolant Pump
8_ Insert retaining lock for crankshaft/ring gear (03-5000}_

Mercedes-Benz
Fig. 316: Locating Retaining Lock For Crankshaft/Ring Gear
9. Unscrew bolt ofhub.
Installation note
Oil bolt thread and 4 dished washers. Fit on dished washers with curved sí de facíng bolt head. Tighten
bolt to 400 N m.
PQ3-5006·13
Fig. 317: ldentifying Curved Side Facing Bolt Head
10. Remove belt pulley (5) together with vibration damper (6).
Installation note
Align Woodruff key (7), fit on vibration damper ( 6) and determine by tuming whether the slot of the hub
(3) is engaged with the Woodruffkey (7) in the crankshaft (11).
11. Check belt pulley.

Mercedes-Benz
400Nm
1
1100-~
Fig. 318: ldentifying Vibration Damper, Woodruff Key And Cranksbaft
Removing an<l installing belt pulley/vibration damJ>er - RA030A1043420X(03-3420)
Preceding work:
Models 124, 202: radiator removed (20-4200).
Model 129: fan shroud removed (20-3400).
03 -1320- 1901
A. Models 124, 129, 202 with belt pulley, vibration damper and hub
Mercedes-Benz
1
~
POS-5346-57
Fig. 319: ldentifying Fan Belt Pulley, Vibratioo Damper And Bolt
If AC fitted: attach guard plate at condenser.

Piston of cylinder 1 to TDC tum so that woodruffkey (7) in crankshaft is facing vertically up.
Bolts ( 15) of fan belt pulley
slacken, tighten (12 Nm).
(17)
Poly V-belt remove, install (13-1200) .
Belt pulley of fan ( 17) and
remove, install.
plate (16)
Retaining lock for
remove, install (03-5000).
crankshaft/ring gear
Bolts (Sa) unscrew, screw on (32 Nm).
Belt pulley (5) and vibration
remove, install.
damper (6)
unscrew, screw on.
NOTE:
Bolt ( 1) with dished washers
Oil bolt thread and 4 dished washers (2) or conical washer.
(2) or conical washer
Fit on dished wasber (2) with curved side facing vibration damper (6).
Mercedes-Benz
1990-2002 ENG INE Cran k Assembly - 129 Chassis
pull offwith puller (04) 103 589 00 33 00, p ush on.
NOTE:
Hub (6b)
Align woodruff key (7), push on hub (6b) and turn in order to
determine whether the slot in the crankshaft is aligned with the
woodruff key (7).
Special tools
001 589 74 21 00
001 589 65 09 00
Fie. 321: Identifying Special Tools (001 589 65 09 00)
103 589 00 33 00

Mercedes-Benz
COMMERCIALLY AVAILABLE TOOL

Hazet
Connector, 3/4" square socket to 1/2" externa! squaree.g.42853 Remscheid
Order no. 1058 RI
SHOP-MADE TOOL
lGuard plate for radiator and condensersizes: approx. 680 X 400 X 11
M18 bolt ofvibration damper (with four dished washers)400
Ml8 bolt ofvibration damper (with conical washer) 370
M8 bolts of belt pulley 32
REPLACING RING GEAR - RA03001194300X(03-4300)
Preceding work:
Transmission removed (27-600)
03-8312, 8321
Mercedes-Benz
20
Fi~. 323: Loca tin~ Rin ~ Gear An d Bracket
Engine rotate so that no segments (arrows) ofthe ríng gear (20) are touching the bracket (l)_
Ri ( 0) take off, fit on (5 Nm).
ng gear 2 Pay attention to installation position (see note).
Special tools
001 S81J 7 2 21 00
00
Fig. 324: ldentüying Special Tools (001 589 72 21 00 00)

Mercedes-Benz
001 580 6.5 09 (10

03 07 3:2 .)
Fig. 325: Identifying SpeciaJ Tools (001 589 65 09 00 03 07 32)
DATA
Permissible variation from concentricity at ring gear 0.3mm
Centering collar dia. for driven plate (1.5 mm thick) 296.00 - 296.05 mm
NOTE: Driven plates and ring gear are balanced individually; they may be replaced
without being balanced.
The ring gear must be installed so that the 3.5 mm dia. holes (arrows) in the ring gear (20) and in the driven
plates ( 18) ha ve the same angular position otherwise proper operation of the ignition is not assured.
Fig. 326: Locating Boles In Ring Gear And In Driven Plates
ADJUSTING CLEARANCE OF RING GEAR TO STARTER- RA03001194350X(03-4350)
Preceding work:
Starter removed (ARI5.30-7100?)

Mercedes-Benz
? 15-5024-57
Fig. 327: Identifying Starter, Ring Gear And Shims
adjust with shims (7, 8).
NOTE:
The specified positioning of the starter relative to ring gear is adjusted by
Clearance of starter to shims (7, 8).
ríng gear
The correct clearance ensures that the starter piníon engages and releases properly.
When performing removal and installation work, pay attention to shims (7, 8) and
adjust clearance of ring gear to starter, if necessary.
CLEARANCE OF RING GEAR TO STARTER IN MM

Clearance of rear edge of crankcase to front edge of ring gear No. of shims fitted at starter
14.3 to 15.2 o
13.3 to 14.2 1
12.3 to 13.2 2
TECHNICAL MODIFICATIONS ENGINE 119 MECHANICAL ll - RA0300119TAOOX

Mercedes-Benz
03 Crank assembly
Designation Nature and reason for modification Production Op. no.

breakpoints
In t Starter ring gear and dríven plate fmnly connected. 60-2 03-
cremen gear segments flor pos1t10n
· · sensor prov1·ded on nng
· gear. 9.95
4100
Pistons for Ml19.980/982 lighter weight and shape 03-
Pistons 09.95
optimized. 3160
03-
Cran.kshaft Modified crankshaft webs (in sbape of ship's bow). 09.95
3200
Vibration
Damper vulcanized on and weight-optimized. 08.94 03.3420
damper
TECHNICAL MODIFICATIONS ENGINE 120 MECHANICAL 1- RA0300120TAOOX
03 Crank assembly

breakpoints no.
Discontinuatíon of single-track bevel for starter
Starter ring gear 12.93
pinion
Vibration
Damper vulcanized and weight-optimized 04.95
damper
Mercedes-Benz
1990-99 ENGINE COOLING Orive Belt Routing- Mercedes-Benz
Orive Belt Routing- Mercedes-Benz
IDENTIFICATION
NOTE: To identify Mercedes-Benz model, chassis and engine codes, see MERCEDES-
BENZ MODEL IDENTIFICATION .

DIESEL ENGINES
Removal & Installation

Mercedes-Benz
1990-99 ENGINE COOLING Orive Belt Routing - Mercedes-Benz
• While cranking, press shut off lever (arrow) to

prevent the engine from starting.
Checklng poly-V-belt
• Mark poly-V-belt clearly using chalk.
• Crank engine in steps while checking the poly

-V-belt for damage.
• End the process when the marli< is visible

again (one full turn of the belt).
• The poly-V-belt must be replaced according to

SMS Job No. 13-342 (on separate order) if the
damage patterns on the following pages are
evident:
• On diesel engines, with 1st versi on

tensioning lever bearing. check the following
parts:
Check pivot shaft (30) of tensioning lever

(360) for tight seat (visual inspection)
• When the pivot shaft is loose, the shaft collar

no longar rests against the timing housing cover
(28). This is also recognized by misalignment of
tensioning pulley.
Check tensloning levar bearing for wear

(visual lnspectlon)
• Tensioning lever bearing bushings are wom

out, resulting in considerable play between pivot
shaft (30) and tensioning lever (360). Recognized
by tilted position of tensioning pulley.
G0004018 1
Fig. 1: Removal, Checking & Installation - Diesel Engine Polv-V-Belt

ENGINE 102
Mercedes-Benz
Removal & [nstallatioo
• Loosen screw (25) by 1/4-1/2 turn.
• Loosen tensioning device wlth tensioning nut

(24) (turn counterclockwise) until poly-V-belt (27)
can be removed.
• Check the pulley profiles and the tensioning

device for damage and dirt and replace if required
(e.g. worn out tensioning device bearing bushing,
dents In the pulleys, etc.).
• On vehicles produced up to the middle of
October 1986, slide adjusting poínter (22) to the
left until the tip of the pointer is above the first
dividing line of the adjusting scale (arrow).
• On vehicles produced as of the middle of

October 1986, slide adjusting pointer to the left
until the tip of the pointer is above the thin line (A)
of the adjusting scale.
lnstalling poly-V-belt:
• Start in numerical sequence of belt routing
diagrams at tensioning pulley (1) (for illustrations,
refer to following pages}.
Note:
• Check the seatlng of the poly-V-bell on the

belt pulleys.
• On vehícles produced up to the mlddle of

October 1986, turn the tensionlng nut (24) to the
right until the tip of the adjusting pointer (22) is
posltioned between the 8th and 9th index mark.
• On vehicles produced as of the middle of

October 1986, keep turning tensioning nut to the
rlght until the tip of the ad¡·usting pointer is
centered above the thick ine (E) of the adjusting
scale.
• Tíghten bolt (25) as follows:
Width between flats 19 mm 75Nm

Width between flats 17 mm
(shouldered boft) 80Nm
G00040183
Fig. 2: Removal & Installation- Engine 102 Poly-V-Belt

Courtesy of :MERCEDES-BENZ OF NORTH AMERICA.
Mercedes-Benz
Belt routing diagram on vehicles with power

steering and A/C compressor
Belt fength: 1980 mm

1 Tensioning pulley
2 Crankshaft
3 A/C compressor
5 Generator
7 Power steering pump
8 Coolant pump
G00040184
Fig. 3: Engine 102 Belt Routing Diagram

ENGINE 103

Mercedes-Benz
Engine 103
• Loosen fan cover and place on fan.
• On Model201 : remove radiator.
• On all models unscrew viscofan clutch with

fan. Remove tan cover.
• For loosening and tightening of hex. socket

screw, use special tool103 589 01 09 00 and
torque wrench 001 589 72 21 OO.
• Lock pulley by simultaneously engaging

counterhold 103 589 00 40 00 in bearing bracket
notch and in hub bore.
• Loosen screw (16) by about 1/4 to 1/2 turn.
• Release tensioning device with tensioning nut

(5) (turning counterclockwise) until bett can be
removed.
• Check pulley profiles and tensloning device

tor damage and contamination, replace if required
(e.g. worn out bearing points of tensioning devlce,
dents in pulleys etc.).
• Tum adjusting pointer (219) to the right (seen

from the front) and set adjacent to the 1st index
mark (arrow), on vehicles as of 02,1988, set on
the cast mark on the right (seen from the front).
• Start in numbering sequence of belt routing
diagrams, start with tens.ioning pulley (1 ).
• Do not use belt wax or similar products.
G00040185
Fig. 4: Removal & lnstallation- Engine 103 Polv-V-Belt (1 Of2)

Mercedes-Benz
• Turn clamping nut (231) to the right unt!l the

adjusting pointer is positioned over the 7th 1ndex
mark (arrow), on vehicles as of 2/88 over the left
mark accordingly (seen from the front).
• Tighten bolt (211) lo 75 Nm (reference value).
Note: Starting November 1986 the generator is

insta lled with a lower collar screw 13 mm. When
this collar screw is removed. the poly-V-belt can
be loosened by swiveling the generator and can
be te nsioned to its original condition without
loosening bolt (211 ).
• Check if belt is correctly seated on pulleys.
• lnsert and install viscofan clutch with fan

cover.
• When tightening hex. socket screw (tightening

torq ue 45 Nm) apply counterhold to pulley.
• Todo this, ínsert counterhold at back of hub

and engage simultaneously into holding groove of
bea ring bracket.
Then remove counterhold.

G00040186
Fig. 5: Removal & lnstallation- Engine 103 Polv-V-Belt (2 Of2)

Belt routing diagram on vehicles with air

conditioning compressor
Belt length: 2255 mm
1 Tensioning pulley
2 Crankshaft
3 Compressor
4 Fan
5 Generator
6 Deflector pulley
8 Coolant pump
G000401 87

Mercedes-Benz
ENGINE 104
• Pull out locking pin (1) on tan cover.
• Tum ring (2) to the left and remove.
• Loosen screw (16) for approx. 1/4 to 1/2 tum.
• Loosen tensioning unit with tensioning nut (5)

(tunn counterclockwlse) until the belt can be
removed.
• Check pulley profiles and tensioning device

for dama9e and contamination and replace, if
required (e.g. wom out bearing points of
tensioning device, dents in pulley etc.).
Inst an poly-V-belt:
• Starting in numerical sequence of belt routing
diagrams at tensioning pulley (1).
Note: Do not use belt wax or similar products.
• Set pointer (13) of tensioning unit to mark 2.
• Tum tensioning nut (5) downwards until

adjustlng pointer (13) is in alignment with mark 1
(arrow).
• Check seat of belt on pulleys.
• Tighten screw (16) to 75 Nm.
• llnstall ring of fan cover in reverse sequence.
G00040188
Fig. 7: Removal & Installation- Engine 104 Polv-V-Belt

Courtesy of :MERCEDES-BENZ OF NORTH AMERICA.
Mercedes-Benz
Engine 104 models 124, 129 up to 01 /91

Belt routing diagram veh~cles with air pump and
with air conditioning compressor,
Belt length: 2445 mm; 6 ribs .--...-:-=-.,.._..-~~~~
1 Tensioning pulley
2 Crankst1aft
3 Air conditioning compressor
5 Fan
7 Airpump
8 Generator
9 Guide pulley, upper
1O Power steering pump
11 Coolant pump
Belt length: 2440 mm

models 124, 129, 6 ribs; model140 8 ribs
800040189

ENGINE 112
NOTE: lncludes all models listed below.
• Engine 112.947 In Model170.465

• Engine 112.960 In Modell70.466
• Engine 112.912 InModel203.061
• Engine 112.946 In Model 203.064
Mercedes-Benz
1 Po/y V-be//
2 Tone bol/
3 Tensionlng pulley
lltil Removing
1 Slacl<en poly· V-belt (1) and take off Swivel torx bolt (2) at tensioníng pulley (3) in
anti-clockwise directlon for this step.
Lock tensíoníng pulley with pin or drlft
(5 mm diameter).
1~ lnspecting
2 lnspect belt pulley sections and tensioning
device for damage and dirt
3 lnspect poly V -belt (1) liJ For damage pattems refer to ¡
~AP lnspect condition of poly V-belt, replace if
necessary.
¡g¡' lnstalllng
4 Fit on poly V-belt (1 ), tension liJ Begln In numerlcal order or the relevan!
running diagram wlth the tensionlng pulley:
Runnlng dlagram of poly V-belt
@ Do not use belt wax or similar products.
000040190
Fig. 9: Removal, Inspection & lnstallation- Engine 112 Polv-V-Belt

Mercedes-Benz
6-groove single-belt drive, without AC compressor
1 Crankshaft
2 Guide pulley 2
4 Guide pulley 1
5 Generator
6 Coo/ant pump and fan
7 Tensioning pulley
6-groove singte-belt drive, with AC compressor
1 Crankshaft
2 AC compressor
4 Guide pulley 1
5 Generator
6 Cootant pump and fan
7 Tensioning pulley
G00040192
Fig. 10: 6-Groove Single-Belt Routing Diagrams

NOTE: lncludes all models listed below.
• Engi:ne 112 In Model210, 202, 163.154, 129

• Engine 113 In Model 21 O, 208, 202, 163.172, 129
• Engines 112, 113 In Model463
Mercedes-Benz
Shown on engine 112
1 ~ Counterholder
2 Belt pul/ey
3 Viscous fan
4 Torque wrench
1 (gJ lll1 Removlng, lnstalling

1 Position counterholder (1) against hexagon [I) Belt pulley of coolant pump
socket bolts of the belt pulley (2),
counterhold
~
2 Unscrew union nut at visocus tan (3) (!.1 Right-hand thread.
~
[ll lnstallatlon:
Use torque wrench with open-end wrench bi
~
3 Unbolt tan at viscous clutch rn lnstallation:
lnstallation position of tan is fixed by cast rib
on fan ring.
~[
8 Fan, fan clutch

112, 113
BA20.40· P· 1001..()18 Fan to viscous clutch Nm 10

BA20.40·P-1002·01B Vlscous clutch to bearing body Nm 45
G00040191
- ·-'-- -
Fig. 11: Removal, lnspection & lnstallation - E ngine 112 Fan & Fan Clutch
ENGINE 119
Mercedes-Benz
1990-99 ENGINE COOLING Orive Belt Routing- Mercedes- Benz
• Pull locklng pin from fan cover.
• Turn ring to the left and remove.
• Loasen screw (16) approx. 1/4 to 1/2 turn.
• Loasen tensioning device with tensioning nut

(12} (turning counterc lockwise) until the belt can
be r·emoved.
• Check pulley pretiles and tensioning device

for damage and contamination and replace, if
required (e.g . worn out bearing points of
tensíoning device, dents in pulleys etc.).
• In numerical sequence of belt routing
diagrams, start with tensioning pulley (1 ).
Note:
• Set pointer (13) of tensioning device to mark

1
• Turn tensioning nut (12) clockwise until

pointer (13) is In position 2.
• Check that belt is seated correctly on pulleys.
• Torque screw (16) to 100 Nm.
• lnstall fan cover in reverse arder.
G00040193
Fig. 12: Removal & lnstallation- Engine 119 Poly-V-Belt

Mercedes-Benz
Belt routing diagram

Belt length: 2523 mm; 6· ribs
1. Tensionlng pulley
2. Crankshaft
3. A/C compressor
5. Fan
7. Airpump
8. Generator
10. Power steering pump
11. Coolant pump
Engine 119.970 model140.051

119.971 model140.042
119.974 model124.036
119.975 model124.034
Belt length: 2460 mm; 8 ribs
1. Tensioning pulley
2. Crankshaft
3. AJC compressor
5. Fan
7. Airpump
8. Generator
11 . Coolant pump
G00040194

ENGINE 120

Mercedes-Benz
• Remove cooling tan (job no. 20-3129)
• Using 15 mm wrench, swing tensioning roller

(1) asid e in dlrection of arrow up to stop and no
iurther so that belt can be removed. Check pulley
profiles and tensioning device for damage and
contamlnatlon and replace, if required (e.g. worn
out bearing points of tensioning device, dents in
pulleys etc.)
lnstalllng poly-V-belt:
• In numerical sequence of belt routing
diagrams, start with tensioning pulley (1).
Note:
• Pretension tensionlng pulley (1) and install

belt over pulley (1). Check that belt is seated
correctly.
Note:
When the belt length and tension are· corree! the
positioning mark (P) will be within ra111ge (A).
• Reversa procedure to install.
G00040195
Fig. 14: Removal & Installation- Engine 120 Poly-V-Belt

Mercedes-Benz
Engine 120.980 Model140.056/57

Belt length 2585 mm 8 ribs
2. Crankshaft
3. A/C compressor
5. Fan
7. Airpump
B. Generator
9. Guide pulley, upper
1O. Power steering pump
11 . Coolant pump
G00040196
Fig. lS: Engine 120 Belt Routing Diagram

ENGINE 601,602,603 & 606
Removal & lnstallation

Mercedes-Benz
On engine 601 , loasen fan cover and place on

tan. Unscrew tan and remove with tan cover.
On engine 602.911 in model201 with one piece

tan cover. remove radiator.
On engine 602 in model 201 with two piece tan
shroud, pulllocking pin (1) and tum ring (2) to the
left. to open shroud and remove. Place rinQ on
tan. Pull out shroud body (3) and remove nng.
On e nglne 602 in model124, loasen tan cover

and place on tan. Unscrew viscofan clutch with
fan and remove with tan cover.
To loasen and tighten hex. socket screw of
viscotan clutch, use screwdriver insert 103 589 01
09 00 and counterhold 603 589 00 40 OO.
On e ngl ne 603.96 (TURBO), the viscofan clutch

cannot be removed without removing the radiator.
• Loasen tensioning device (vehicle tool or

conventional tool):
• Unscrew nut (378).

• lnsert a lever (12- 13 mm dia.• approx. 300
mm long) or wheel nut wrench trom vehicle tool
set into hole on spring tensioning lever (374).
Push lever slightly to the left untll screw (375) can
be pushed back in direction of intake manifold.
• Loasen draw spring (380) by swiveling lever
to the right.
• Push back tensioning pulley and remove poly-
V-belt.
• Check belt pulley profiles and tensioning
device for damage (such as wom out pivot points
of tensioning device, dents in pulleys, etc.) and
con'tamination and replace, if necessary.
G00040197
Fig.16: Removal & lnstallation- Engines 601,602 & 603 Poly-V-Belt (1 Of 2)

Mercedes-Benz
l:nstalling poly-V -belt:
• Do not use belt wax or similar products.
~ Slightly pull up ~ensionfng pulley. Make a loop

1n the poly-V-belt wtth the V-grooves facing
outwards. and slip between coolant pump pulley
a nd crankshaft pulley.
• Push poly-V-belt firmly agaínst coolant pump

pulley and turn pulley counterclockwise (arrow)
until the poly-V-belt is adjacent to tensioning
pulley.
• Posilfon pofy-V-belt on tensioning pulley and

on crankshaft pulley. Then tum free portion of poly
-V-belt around and positíon on air conditioning
compressor, power steering pump, coolant pump
and generator pulleys.
• Tension poly-V-belt and screw on tensioning

device.
• Check seat of poly-V-belt on bell pulleys.
• On engines 601, 602, 603.91 in model 124,

install fan or viscofan clutch with fan and fan
cover.
• On engine 601, torque fan mounting screw to
28Nm.
• Torque viscofan clutch mounting screw to 45
Nm. When tightening use counter hold 603 589 00
40 OO.
• On engine 602.911 in modal 201 without two
piece fan shroud, instan radiator.
<300040198
l?io _ 17 ! R4>mnv~l & Tn~t~IIMinn- F. noinf'~ 1\0L 1\0?. &- 1\01 Pnlv-V-R4>1t (?. Of?.)
Mercedes-Benz
Belt routing diagram for vehicles with power

steering and automatic climate control
Belt lengths:
Engine 601:2120 mm
Engine 602: 21 00 mm
Engine 603.96: 2145 mm
Engine 603.970: 2120 mm
2. Crankshaft
3. A/C compressor
5. Generator
8. Coolant pump
G00040199
F ig. 18: Engines 601, 602 & 603 Belt Routing Diagram
Mercedes-Benz
Engine 605.960 In model 202. Engines

602.982,605.962 in model210
Remove visc:oos tan clutch Engine 605, 606 in model124
Engine 606.961 In model 140
Englne 605 in model 202
Englnes 602.982. 605. 606 in model 210
Engioe 604 in modo! 202,210

Engioe 602.9831n modol461
Slad<en poly-V-ben
Lever for presslng sprlng tenslonlng lever ol
poly-V-bell tenslonlng clevioe
Take off poly-V-bell
CheCk poly-V-betls. damage pattems

lnstalling
Fit on poly-V·bell '' Do notuse bellwax or similar products.
Englne 602.9821983
m Layonpoly..V-belllnlhenumber
beginning wilh !he lenslonlng pulley ¡
poly-V-belt running dlagram
Tenslon poly..V-bell
Lever for presslng sprtng lenslonlng lever of ,
poly.V-be~ tensionlng devk:e
~
lnslall víscous fan dutch lnes605,606in model124
lne 606.961 1n model140
ine 6051n modal 202
Engines 602.982, 605. 606 in model210
Engine 604 in model s 202, 21 O
Engine 602.983 in model 461
Insta JI charge air pipe Engine 605.960 in modo! 202. engines
602.982. 605.962 in model210
G00393732
Fig. 19: Removal & lnstallation - Engine 606

Mercedes-Benz
6-groove single-belt drive,without AC compressor engine 604/605/606

1 Tensioning pulley
2 Crankshaft
5 Generator
@)
8 Coolant pump
6-groove single-belt drive,with AC compressor engine 602.982/604/605./606

1 Tensioning pulley
2 Crankshaft
3 AC compressor
5 Generator
8 Coolant pump
G00393733

Torque speclfications (Nm) Engine
Vis-cotan clutch on coolant pump or bearing 103-, 104, 602, 603 45

body
Tensioning device mounting bolt (M 12) 19mm 102, 103 75

17mm 102 80
Fan to viscofan clutch 103, 104 10
000040182
Fig. 21: Torgue Specifications

Mercedes-Benz
1990-2000 ENGINE COOLING Cooling Fans - All Models
Cooling Fans - All Models
IDENTIFICATION
NOTE: For Mercedes-Benz model, engine and chassis identitication, see MERCEDES-
BENZ MODEL IDENTIFICATION . Procedures are listed by engine and chassis
identitication.
TESTING
NOTE: Testing intormation is not available.

* PLEASE READ THIS FIRST*
NOTE: On models where it is necessary to counter-hold the tan bearing mounting hub
to loosen or tighten the tan mounting bolt, insert tool in hole on side ot bearing
bracket assembly to lock tan pulley.
COOLINGFAN
Engine 112.947 In Chassis 170.465 & E ngine 112.960 In C bassis 170.466

Mercedes-Benz
1990-2000 ENGINE COOLING Cooling Fans- All Models
1 Becttic tan connector

2 Coolant 1/ne
3 Braclcet
4 Clamps
S Relain/ng studs
6 Rubber mount
M4R Elétlrit fañ
Removal lnstallatlon
Separate connector (1) of electric fan (M4f7) Instan in the reverse order
Press coolant Hne (2) out or bracket (3) [I) tnstallatlon: The two retaín~ sluds (5)
Remove damps (4) of the etectric fan must be tocat at the
bottom in the rubber mounts (6).
Lift etectric fan (M4n) up and out Molsten lhe two re1alning studs lighlly wilh
lubricanl
G00042512
Fie. 1: Removal & Installation- E lectric Fan- En~:in e 112

Engine 113.981 In Cbassis 163.174

Mercedes-Benz
1 Connector
2 Electrical connections
3 Cable strap
4 Electtic fan
5 Scmws
6 Ptatenuts
7 Piste ctamps
8 Retaining platas
9 Protective caps
10 Bracket
S .~
8-~ t
Oisconnect elecltlcal connector (1) lnstall ln !he reverse order
Pull off protective caps (9). Ensure that the retaining plates (6) of !he
Unbolt electrical conneclions (2) eleclric tan are located in !he mounts of !he
Protect ends of cables with lnsulatlng tape radiator on rlght and lett.
from unintentional contact to ground.
Uncllp cable straps (3)

Press coolant hose out of bracket (10)
Remove englne compartment panellng
Unbolt electnc fan (4) at bottom
Remove bolts (5) and
remove plate nuts (6).
Remove plate clamps (7l

Remove eleclric fan (4)
G00042506
Fig. 2: Removal & Installation- Electric Fan- Engine 113.981

Courtesy of MERCEDES-BENZ OF NORTH AMERICA
Engine 611.960 In Chassis 202.133/134/193/194; Engine 611.961ln Cbassis 210.006/007/206/606 & Engine 612.961 In
Chassis 210.016/216/616
Mercedes-Benz
Shown on model 202:
1 Radiator
2 Eloctric tan
3 Coolant retum flow hose 1
4 Flat spring
Y3114 EGR pressure regulatlng flap
Y3115 Boo!l pr&ssum contfOIIer vacuum
transducer
Oisconnect battery ground cable lnstallln the reve!S'e ()(der
Remove ooolanl rei\Jm ftow hOse (3) from
fixture at radlator (1)
Oisconnéd eleetrlcal pfug eonnectlon al
elecltic tan l2l
On Model 202 dlsconnect boosl gressure tnsert retalnlng lugs (arrows) of elédñc tan
regulator vacuum ITansducer (Y 1/5) and lnto lhe mounts Or\ lhe radlator.
EGR pressure regulator ftap (Y3114) at
eteclric fan
Place components to Ule slde
Pull off flat sprlngs {4) en top of electtic fan
Uft electñc tan (2) up and out
G0004.2514
Fig. 3: Removal & Installation- Electric- Fan Engine 611 & 612
VISCOUS FAN CLUTCH
Engine 111ln Model 124, 170,202, 210,208 & 163

Mercedes-Benz
1 ~ Open-end wnmch insert

2 ~ Torque wrench
3 ~ Counterllofder (1st vorsion)
3a ~ Countemolder (2nd version)
Vlscous fan dutch with fan (25):
8
8lnstallation position of fan
UñScrew unlon nut (26a), (25) is fb<ed by casi rlb on tan ring.
rn left-hand thread! ~ 1st verslon: place countert'lolder (3l
against retaining ~late (33a) of belt pul ey
~ {33) and counter- .old.
Use torque wrench (2) with open-end ~ 2nd version: place counterholdcr (3a)
wrench insert (5) against hexagon socket bolls of belt pulley
(33) and counter-h<Jid.
~
Fan (25) to viscous tan clutch
Coolant pump belt puliey
G0004251S
Fig. 4: Removal & lustallation - Viscous Fan Clutch- Engine 111

E ugine 112 In M odels 129, 163.154, 202, 210 & 463; Engine 113 In M odels 129, 163.172, 202, 208 & 210
Mercedes-Benz
1 ~ Counterholder
2 Be/lpulley
3 Viscous tan
4 Torr¡ue wrench
Removal lnstallation
PosiUon counterholder (1) against hexagon Instan in lt'le reverse order
socket tlolts of lhe belt pulley (2).
countertlold
Unscrew unlon nu t at vlsocus fan (3) Use torque wrench with open.end wrench bit
[I) Right-hand lt'lread. ~To tlghten unlon nut at vlscous clutch.
lll
Unbolt fan at viscous clutch mlnstallation:

lnstallation positlon of fan is fixed by cast rib
on fan ring.
8
G00042507
Fig. 5: Removal & lnstallation - Viscous Fao Clutch - Engioe 112 & 113
Engine 120 In Models 129 & 140

Mercedes-Benz
IRemoval lnstallatlon
Remove tan shroud (5) Tighten bolt (1) with hexagon insert and
torque wrench, unsaew.
Fit on oounterholder (04)
Use screwdriver and attached torque
~ Torque wrench
wrench to unscrew bolt (1) ~ Hexagon insert
~
8
IRemove viscous tan clutch (3) from tan (2)
G00042508
Fig. 6: Removal & Installation - Viscous Fan Clutch - Engine 120

VISCOUS FAN COUPLING
Engine 601, 604 In Model202 & Engiue 604 In Model210

Mercedes-Benz
Counter-holder lnstall ln the reverse order of removal.
at belt pulley of coolant pump
Remove vfscous fan coupling together lnstallation position of fan is marked

wíth fan (1) by unscrewing unlon nut (2a); by a lug on tan ring and by the
by uslng torque wrench with open-end marklng "VORNE FRONT" (on fan ring In
wrench bit (5) direction of travel)
Caution: Left-hand thread! 8
Remove tan at vlscous tan coupllng (2)
G00042518
Fig. 7: Removal & lnstallation- Viscous Fan Coupling- Engine 601 & 604
Engine 602.982, 605, 606.912/962 In Model 210; Engine 605 & 606 In Model124; Engine 605 In Model 202 & Engine
606.961 In Model140
Mercedes-Benz
1 Fsn
2 Viscous fan coupling ~~..
6 ~ Screwdriver 8 mm ~
7 Fan shroud (engine 602.982, 605)
l)
7a Fan shroud ring (englne 606)
8 TotQue wrench
9 fiDCcunter.hofder
1!0 Chsrge air pipo, cnglno 602.982,
605.9601962
7a
Removal lnst.alfation
Remove charge alr pipe (110) lnstall in lile reverse oroer
Engine 602.962. 605.962 In model210
Remove fan shroud (7). place over the fan Adjust fan shroud
(1)
Engine 602.962, 605
Engine 606.9121n model210
Tum fan shroud ring (7a) lo release ll from Ensure lhe tan shroud r1ng
lhe engaging sluds on lile fan shroud, (7a) ls propelfy located in lhe engaglng
remove
studs of lile fan shroud (7)
Engíne 606.961 In model140
Remove fan shroud (7) :and lift up and out Ensure the engaging studs
~glne 606.9S21n model 210 of lhe fan shroud (7) are prooertv located
lnsert counter-holder (9) atlhe beH pulley or

the coolant pump
Unboll viscous fan clutch (2) together wilh
tan (1 ), remove
~ Use a screwdriver (6) and torque
wrench (6) lo slacken lile central bolt.
On engine 605 in models 124. 202, remove
viscous fan coupling together wllh tan
shroud (7)
Unbolt fan (1) at viscous tan clutch (2)
a lug on lhe fan ri,
lnstallation pesition of tan is marked by
and by lhe
martdng "VORNE RONT (on fan ring In
dtrection ol travel)
G00024519
Fig. 8: Removal & Installation - Viscous Fan Coupling- Engine 602, 605 & 606
FAN SHROUD ASSEMBLY
Eugin e 111 In Models 124, 170, 202, 208, 210 & 163; Eugines 602.982, 604, 605 & 606 In Model210; Engine 111, 604, &
605 In Model202; E ugine 111, 605, & 606 In Model 124 & Eugine 606 In Model140
Mercedes-Benz
A Englne11 1 except 111.9441975, 604,

605 In model 124, 202
IEnglne 111, 602.982,604,605.962 In
modal 21 0
Englne 111 In modal 163,208
B E ngine 606 in model 124
C Engine111.94319461973 1n model170
e xceptAC
Englne1 11.9441975 in model 202
E nglne 605.91 , 606 In m odal 21 O
1 VJscous fsn coupling

7 Fan shroud
7a Fan shroud ring
8 Coolant hose
9 Lockfng clip (engine 606)
15 Flat springs
18 Radiator
110 Chsrge sir pipe
Remove charge air pipe (110) lnstallln the reversa order
Engine 605.960 in modal 202, englne
602.982. 605.962 In modal 21 O
Release fan shrovd ring (7a) from the When lnstaHing, ensure that fan shroud
loeking studs by turning atthe tan shroud, ring ls proper1y located In the
remove locking studs of the fan shroud.
Engine 6061n model 124, 140
Remove viscous fan coupRng {1)

Englne 604 and 605 in m0del 124. 202
Engine 111 1n m0del163. 170. 208
Engine 111. 604. 605. 606 in mOdet 210 t
Englne 111
Engine 604
Englne 605, 606 in model 124
Engine 606.961ln model 140
Engine 605 In model 202
Englne 602.982, 605. 606.912 in model 210
Detach coolant expansion reservoir
ModeiHO
Remove tan shroud (7), take out upwards lnsert retainlng lugs (arrows)
m on engine 6041605 in models 124, 202
together with viscous fan coupling
of lhe fan shroud lnto the mounts
at the radiator.
Align fan shroud to the fan.
[i) Model 163: remove screws of llat
springs and take off ftat spñngs.
G00042517
Fig. 9 : Removal & lnstallation- F an Sbroud- Engine 111, 602.982, 604, 605 & 606
Engine 111.958 In Chassis 170.444 & Engine 111.983 In C hassis 170.449

Mercedes-Benz
1 Coolanl expansion resetvair

1a Bolts
2 Coolant fina
28 Clip
3 Clamps
4 Fanshroud
5 Radiator
Arrow E/ectrica/ conneclion
Unboll ooolanl expansion reservolr (1) al lnstall in the reverse order
fronl end crossmember
Unplug conneclor (arrow) :al suction fan
Uncllp coolant llne (2) al top and bottom at
fan shroud
Pull out damps (3)
Pull fan shroud (4) out of fiXture al bollom of
radiator (5)
Remove fan shroud (4)
G00042513
Fig. 10: Removal & l nstallation- Fan Shroud Assemblv - Engine 111
E ogine 1121o Models 215 & 220; Engine 112 In Model 220
Mercedes-Benz
Shown on model220 w ith M112

1 Fan shroud
2 Coolant lino
3 Mounting plate
4 Retelnlng lugs
Rlsk of ln)ury to skin and eyes from lnslall in lhe reverse order
scalding wilh hot coolant whlch sptashes ou
lnspect coolanttevel and cooting system for
Risk of poisoning fronn swallowing co<llant. leaks
Do not open cooling system unless coolant
temperatura ts betow 90 •c.
Open cap slowty and release lhe pressure.
Do not pour coolanl into beverage bottles.
Wear protective gtoves. protectlve dolhing
and eye proteclion.
UJ At radiator
t!j
Ora in coolant
Remove air intake pipes at air cleaner
Unscrew boUs of mountmg plates (3) at fan
shroud (1)
Separate etectric ptug connections of
suction tan
Disconnect cootant fine (2)
OJ Detach onlv at radiator.
Unscrew plate attaching ATF fine
(D At botlom at fan shroud (arrow).
Remove fan shroud (1)
!IJ Uft fan shroud together wtth retalning
plates (4) up and out of lugs at radiator.
G00024509
Fig. 11: Removal & Installation- Fan Shroud Assemblv - Engine 112
Engine 120 In Models 129 & 140

Mercedes-Benz
11
20
~ 1
Centeríng Fan Shroud

Model1 29:
'
Mode1140:
A 14-17mm A 22-25mm
8 23 • 26 mm B 25 • 28 mm
e 17-23mm e 17 - 23mm
Remove engine compartmenl panel al Instan in the reversa arder
botlom front
Remove tri m panel (20) at top of radiator
Modet129
Unbolt front end crossmember (2)
Model140
Pull out locking pln (18)
Turn fan shroud ring (6) lo lhe left and place when lnstalling, ensure the 4 engaging
over ran studs and the lugs of the ran
shroud rinJ' (6) are property located in the
ran shrou (5)
Pull flal springs (15) up and off
Remove fan shrouds (5) and tan shroud when installing, insert retaining straps
ring(6) (arrows) of fan shrO<Ud (S)
into !he mounts atltle radiator.
The air flap (17) of t:he ran shroud (5) should
be posítioned to the- ínside ot the engine
compartmenl
Instan tan shroud 2nd version for high
coolant temperatura and high speeds, see
AF.
Allgn fan Shroud (5) with fan shroud ring lO
ran (7) according to dimeosions (A). (B). (C)
lli.J Allgn fan shroud (5). pay attentlon to
dimensions
G00042S10
Fig. 12: Removal & Installation - Fa o Shroud Assem bly - E ngine 120
FLUID CAPACITIES
Mercedes-Benz
Oesignation Engine Engine

112.9221944 113.941/960
in model220 in model215,
220
Cooling system Total capacitty llter ao10.5 a 11.5
Capacity of
anticorrosion/antifreeze agent liter
down to -37 "C .. 5.0 "'5.75
Capacity of
anticorrosion/antifreeze agent liter
down to -45 "'C .. s.s ... 6.25
G00042511
F ig. 13: Fluid Capacity - Engine 112 & 113

TORQUE SPECIFICATI ONS
Application N.m
Fan-To-Viscous Clutch
Engine 11 1 10
Engine 112 & 113 10
Engine 120 10
F an-T o-Viscous Coupling
Engine 601 & 604 lO
Engine 602 & 603 Except 602.982 lO
Engine 605 & 606 10
Viscous Clutch-To-Bearing Body (With Special Tool)
Engine 111 40
Engine 112 & 113 45
Engine 120 45
Engine 604 45
Engine 601 , 602 & 603 Except 602.982 40
Engine 605 & 606 40
Viscous Clutch-To-Bearing Body (With Torque Wrench)
Engine 120 41
Engine 601 , 602 & 603 except 602.982 45
Engine 604 45
Engine 605 & 606 45
Mercedes-Benz
IUn ion Nut -T o-Bearing Body

Engine 601
WIRING DIAGRAMS
NOTE: For wiring diagrams, see appropriate wiring diagram in WIRING DIAGRAMS.
Mercedes-Benz
1990-2002 ENGINE Electrical System - Engine - 129 Chassis
1990-2002 ENGINE
Electrical System - Engine - 129 Chassis
GENERAL INFORMATION
NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM- AH15.10-P-0002
Notes on avoiding damage to ignition system - AHlS.lO-P-0002-0lD
Engine 104, 111, 112, 113, 119, 120, 156, 271
• T o avoid damage to control unit connect and disconnect the two connectors on control unit only when
ignition is switched off.
• Terminal 1 of ignition coils must not be short-circuited to GND, e.g. as anti-theft protection.
• lnstall only original ignition system components.
• Do not operate ignition system at starting speed unless all of the ignition cables are connected.
• No tests such as holding ígnition cable 4 ata dístance to GND, unplugging a spark plug connector or
pulling cable 4 out of the ignitíon coíls, may be performed at starting speed or when the engine ís
runmng.
• Every hígh voltage círcuít must be loaded with at least 2 kohms (spark plug connector).
• If it is necessary to test the ignition spark when providing roadside assistance, this must only be done with
a spark plug at a cylínder ígnition cable. Ensure that the spark plug has good contact to ground.
• Before working at cranking speed, e.g. checking compression pressure, switch off ignition and disconnect
connector "2" from control unit.
n:::r-GF Engine 120 has two fuel injectíon and ignitíon systems.
Use of testers
• Only connect and disconnect secondary measuring sensor to corresponding ignition cables when vertical
engine and ignition are switched off.
• Ifthe shot-circuit protectíon is operated (cylínder comparíson) and the engine stays upríght, ít is not
possible to conduct the test with this test instrument.
• Do not connect test lamp to ignitíon coíl termínals 1 and 15.
Notes on avoiding damage to the ignition system - AH15.10-P-0002-01E
Engines 103, 104, 119 with CFI continuous fuel injection system
• To avoid damage to the control module connect and disconnect the two connectors on the control module
only when the ignition is switched off.
• Terminal 1 of ígnition coils must not be short-círcuíted to GND, e.g. as anti-theft protectíon.
• Install only original ignition system components.
Mercedes-Benz
1990-2002 ENGINE Electrical System- Engine- 129 Chassis
• Do not operate ignition system at starting speed unless all of the ignition cables are connected.
• No tests such as holding ignition cable 4 at a distance to GND, unplugging a spark plug connector or
pulling cable 4 out ofthe ignition coils, may be performed at starting speed or when the engine is
running.
• A load of at least 2 k ohms must be applied to each high voltage circuit (spark plug connector).
• If it is necessary to test the ignition spark when providing breakdown assistance, this must only be done
with a spark plug ata cylinder ignition cable. Ensme that the spark plug has good contact to grotmd.
• Before commencing work at starting speed, for exarnple testíng compression, switch ignition off and
unplugthe socket(s) ofthe crankshaft position sensor at the DI control module.
• To ensure good heat dissipation, the DI control module is installed with heat-conducting paste at the
wheelhousing paneL When replaced, the protective sheet must not be removed; it does not impair heat
dissípation.
Use of testers
• Connect and disconnect secondary measuring sensors to corresponding ignition leads only when engine
and ígnition are shut off.
• If the shot-circuit protection is operated ( cylinder comparison) and the engine stops, it is not possible to
conduct the test with thís tester.
• Do not connect test lamp to ignition coil terminals 1 and 15.
Notes on avoiding damage to the ignition system - AHlS.lO-P-0002-0lF
Engine 104, 119, 120 with LH-SFI fuel injection system
• In order to avoid damage to the control module, the two connectors at the control module must not be
disconnected or connected unless the ignition is switched off
• Terminal 1 ofthe ignition coils must not be short-circuited to ground, e.g. anti-tbeft protection.
• Install only genuine components of the ignition system.
• Do not operate igniüon system at starter speed unless all of the ignition cables are completely connected.
• At starter speed or when the engine is running, it is not permitted to carry out any tests, for exarnple
holding tbe ignition cable 4 close to ground, tmplugging a spark plug connector or pulling cable 4 out of
the ignition coils.
• The load applied to each high voltage circuit must be at least 2 k ohms (spark plug connector).
• If it is necessary to test the ignition spark when providing breakdown assistance, this must only be done
with a spark plug ata cylinder ignition cable. Ensme good ground contact of the spark plug.
• Before carryíng out work at starter speed, e.g. testing compression pressure, switch off ignítion and
unplug connector(s) of crankshaft position sensor at the DI control module.
Jt:rGF Engíne 120 has two fuel injection and ignition systems.
• The DI control module is installed with heat conducting paste at the wbeel housing to improve heat
dissipation. If replaced, the protective sheeting must not be removed. It does not impair the heat
Mercedes-Benz
dissipation.
Use of test equipment
• Do not connect or disconnect a secondary measure d value pickup to the appropriate ignition cables unless
the engine is not running and the ignition is switched off.
• If the short-circuit protection ( cylinder comparison ) is operated and the engine stops, it is not possible to
carry out the test with this tester.
• Do not connect a test lamp to terminal! and 15 of the ignition coils.
GENERAL NOTES ON CONTACTLESS IDGH VOLTAGE DISTRIBUTION- AHlS.lO-P-1002
General notes on contactless higb voltage distribution - AHlS.lO-P-1002-01 WA
Engine 112, 113 with ME-SFI fuel injection and ignition system
The ignition system can be tested at the primary side and secondary side. It is only possible to test ignition
circuit a and ignition circuit b one after the other.
The ignition coils are fitted as standard with cast mounts for the secondary adapters (kV pickup C). The primary
ignition voltage curve can be plotted w ith a primary adapter cable (D).
A Secondory adap tw "<lb/o

B kVplcJurp
o Prinwy aditpler cable
T1 t¡nition col
• Ye//ow soclcet lgnilion circui r a
(t<>rnVto/1)
b Green sotlrolfgnl lfon clrcuH b
(ternllttal 1/
e To lgnllion cablo
d Conneello - V clamp
Arrow l'oclcet lor*V plclcup lgni~on
eircuil b (socondary 5/do))
P IS IG--31<0 08
Fig. 1: ldentifying Connection Cables OfDouble lgnition Coil
n:s=-GF Diagnosis with engine tester:
Connect green connector (terminal 1) of engine tester altemative ly to the yellow socket or green socket for
assessing an ignition circuit with the primary adapter cable.
Mercedes-Benz
Connectyellow connector (terminall5) ofengine tester to positive (tml. 30 /tml. 15).
General notes on contactless high voltage distribution- AHlS.lO-P-1002-0lWD
Engine 104, 111 with ME-SFI fuel injectioo and ignition system
The ignition system can be tested only at the primary side.
~GF No test facility by means of kV pickup at the ignition coil although kV pickup is present.
It is only possible to test the primary ignition circuit with adapter cable A.
Connection cables of optimized ignition coil
A Pt/marylld~or cable
Tt tgnl lfon col/
• YcllowJOcAotienltlon clrculr•
(!J:tmi>•t15)
b Gtee-n soc ,\at tgnition clrcuft b
(!J:tmiha/1)
' ro t¡¡ntlvn 'illlo
Atrow PocAottoriCVclomp(no test
fllcllltyj
1 ¡-
• b
P1 5 1D·20JHI!I
Fig. 2: ldentifyiog General Notes On Cootactless High Voltage Distribution
o:s==-GF Diagnosis with engine tester:
The ignition system can be tested only at the primary side.
General notes on contactless high voltage distribution- AH15.10-P-1002-01WE
Engine 119, 120 with ME-SFI fuel injectioo and ignition system
The ignition system can be tested at the primary and secondary si des.
Secondary adapter
Mercedes-Benz
1990-2002 ENGINE Electrical System - Engine- 129 Chassis
Thc IIV pl r:llup must bo

/nscrtr:d lnro me
mounting por;llct of tho
lgnltlon r:o H as f~r as~
stop.
Pll7 <6~·111267·0 1
Fig. 3: ldentifying Secondary Adapter
~GF Diagnosis with engine tester:
Connect green connector (terminal 1) of engine tes ter alternatively to yellow socket or green socket for
assessíng an ignítíon circuít with the primary adapter cable.
Primary adapter cable
The ignition coils are fitted as standard with cast mounts for the secondary adapters (kV pickup). The primary
ignition voltage curve can be p lotted by means of a primary adapter cable.
Grr:cn sor:llcr: tml. 1

Ycllossocitct: tml. tS
P15.10·2UHt1
Fig. 4: Identifying Primary Adapter Cable
Connect yellow connector (tenninal15) of engine tester to positive (tml. 30 /tml. 15).
GENERAL NOTES ON TESTING CONTACTLESS IDGH VOLTAGE DISTRIBUTION- AHlS.lO-P-

1003-0lW
~GF
If a complaint exists in the start or warming-up phase, do not condition engine to operating temperature but
proceed on a complaint-related basis.
Connectíons: set díagnostíc tester to cylínder number 1 p rimary or secondary (ífpossíble) and test through the
ígnítion círcuíts one after the other.
Mercedes-Benz
Diagnosis test oscilloscope 1good image contactless higb voltage distribution Secondary side (single
image) Engine idling
(shown on engine Ml19.981, cylinder 1 with Bosch ignition coil)
Measuring range: 40 kV
Time range: 5 ms
(llV)
D.cay
•
2 Docey 20
3 Deuy
4 Deuy
5 Deuy
o '
~--~~1~~5------------------------------
2..
o
P tS. tO 21l'Jil08
Fig. 5: Oscilloscope Wave Signal- Secondarv Side (Single lmage)
Diagnosis test oscilloscope 1good image contactless high voltage distribution Primary side (single image)
Engine idling
M
q
(tila,.. on ""~~""' M 119.981. c)tnder 1)
MN...-.g range: 40 V
Ttme ran¡¡e: 5 m&
•
P t5.1(},203Nl6
Mercedes-Benz
Fig. 6: Oscilloscope Wave Si~nal- Primary Side (Single Image)
SAFETY PRECAUTIONS
RISK OF DEATH CAUSED BY CONTACT WITH PARTS CONDUCTING IDGH VOLTAGES.-
AS15.10-Z-0001-01A
Do not touch parts which conduct high voltages. Persons who wear electronic implants (e.g. heart
pacemakers) must not carry out work on the ignition system
Risk of death cau sed by high voltages in the ignition system
Electronic ignition systems operate within a hazardous power range both on the low voltage side (primary
circuit) as well as on the high voltage side (secondary circuit). Contacts with such parts can result in burns,
heart flutter or cardiac arrest.
~~nungl
Ynldllllll AiMtllft u e1er
Dll'l•
Dlnlllfl Higb -.elige

a.M.aulllln.,... . . .
Clllhlgrlita .....
.............
Danglllt Mallll tMIMln
Aallcllloll ..... trwvaac-
P15.1 1..0001 0 1
Fig. 7: Risk OfDeath Caused By High Voltages In Ignition System
Safety instructions/precautions
o Persons with heart pacemakers must not perform any work on the ígnition system.
o Switch ígnítion off before commencing any work on the ígnítíon system.
o Do not touch or dísmantle components of ignítion. system when workíng on runníng or rotating engine
with cranking speed.
o Wear safety shoes (with rubber soles).
o Detach the crankshaft position sensor con.nection either at the control unit or at the position sensor.
o Do not install any electrically conducting, uninsulated adapters or installation sensors into the ignition
cable.
TESTING & REPAIR

TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM- ENGINE-
AR15.00-Z-91 04AB
ENGINE 104
Mercedes-Benz
Test rotorless ENGINE 104, lll... AR15.10-P-

high voltage 3000WD
distribution
Replacing ENGINE 104.94/99, 111 , 119.97 (except AR15.12-P-
ignition cables 104.990) 0512G
with M3 cable
screw
Remove/instaU ENGINE 104.996/94/99, AR15.12-P-
ignition coils 111.920/940/941 /944/960/961 (except, 104. 990) 2003G
Removing and ENGINE 104.941 /942/943/944/991 /992 /994, AR15.12-P-
installing 111.920 /940 /941 /942 /944 /960 /961 /975 2133G
crankshaft
position sensor
Remove, install ENGINE 104, 1ll ... AR15.12-P-
crankshaft 2133GA
position sensor
Removing and ENGINE 104, 1ll ... AR15.12-P-
installing, 2143G
adjustable
camshaft position
sensor
Replacing knock ENGINE 104.94/99, 111.920/940/941 /942 AR15.12-P-
sensor (except, 104_990), 111.960/961 upto 30.11.94 2183G
Removing and ENGINE 103, 104 ... AR15.30-P-
installing starter 7100C
Removing and ENGINE 104, 111... AR15.30-P-
installing starter 7100EA
Removing and ENGINE 104, 1ll ... AR15.30-P-
installing starter 7100F
Prerequisites for ENGINE 103, 104, 112, 113, 119, 120 in AR15.40-P-
testing altemator MODEL 129 5009C
Prerequisites for ENGINE 104, 111, 112, 113, 601,604,605, 611... AR15.40-P-
testing altemator 5009EA
Prerequisites for ENGINE 104, 111 , 112, 113, 119, 602, 604, 605, AR15.40-P-
testing altemator 606, 611 , 612, 613 ... 5009F
Checking ENGINES 103, 104, 112, ll3, 119, 120 in AR15.40-P-
regulation MODEL 129 SOl OC
voltage of
altemator
Checking ENGINE 104, ll1 , 112, 113, 601 , 604, 605, 611... AR15.40-P-
regulation 5010EA
voltage of
alternator
Checking ENGINE 104, 111 , 112, 113, 119, 602, 604, 605, AR15.40-P-
regulation 606, 611 , 612, 6 13 .. . 5010F
Mercedes-Benz
voltage of
alternater
Testing alternator ENGINES 103, 104, 112, 113, 119, 120 in AR15.40-P-
charging current MODEL 129 souc
Checking ENGINE 104, 111 , 112, 113, 601 , 604, 605, 611... AR15.40-P-
charging current 5011EA
of alternator
Checking ENGTNE 104, 111, 112, 113, 119, 602, 604, 605, AR 15.40-P-
charging current 606, 611, 612, 613 ... 5011F
of alternator
Removing and ENGINES 103, 104 in MODEL 129 AR15.40-P-
ínstalling 5032CA
generator
Remove and ENGINE 104, 111 , 601, 604, 605, 61 L. AR15.40-P-
install generator 5032EA
Remove and ENGINE 104, 111 , 602, 604,605, 606, 61L. AR15.40-P-
install generator 5032F
Removing and ENGINES 103, 104, 119, 120 in MODEL 129 AR15.40-P-
instaHing the 5710CS
generator poly-V-
pulley
Remove/install ENGINE 104,111, 112, 113, 119,601,602,604, AR15.40-P-
generator belt 605, 606 ... 5710EA
pulley
Removing and ENGINE 103, 104, 119, 120, 112, 113 in AR15.40-P-
installing MODEL 129 5760CS
regulator of
generator
Removing and ENGINE 104, 111, 112,113,601,604,605, 611... AR15.40-P-
installing 5760EA
regulator of
generator
Removing and ENGINE 104, 111 , 112, 113, 119, 602, 604, 605, AR15.40-P-
installing 606, 611... 5760F
regulator of
generator
TESTING AND REP AIR W ORK: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE-
AR15.00-Z-9113AB
ENGINE 113
Remove, instaU camshaft Hall ENGINE 112, 113 ... AR15.10-P-2000A

sensor
Remove/instaH camshaft Hall ENGINE 113.988 in AR15.10-P-2000AC
Mercedes-Benz
sensor MODEL 203.076/276

ENGINE 113.989 in
MODEL 171.473
Remove/install camsbaft Hall ENGINE 113.964 in AR15.10-P-2000GZ
sensor MODEL 164.175
Remove/install camshaft Hall ENGINE 113.971 in AR15.10-P-2000RT
sensor MODELS 251.075 / 175
Remove/install camshaft Hall ENGTNE 113.990 in AR 15.1 O-P-2000RVK
sensor tviODELS 211.076 /276
ENGINE 113.991 in
MODELS 215.374,
220.074/174
Remove/install camshaft Hall ENGINE 113.967 in AR15.l O-P-2000TY
ENGINE 113.990 in
MODEL 219.376
Test rotorless high voltage ENGINE 112, 113 ... AR15.10-P-3000WA
distribution
Remove/instaH spark p lugs ENGINE 113.964 in AR15.12-P-1010GZ
MODEL 164.175
Remove/install spark plugs ENGINE 113.971 in AR15.12-P-1010RT
MODELS 251.075/ 175
Remove/install ignition lines ENGINE 113.964 in AR15.12-P-1312GZ
MODEL 164.175
Remove/install ignition lines ENGINE 113.971 in AR15.12-P-1312RT
MODELS 251.075/ 175
Remove/install ignition coils ENGINE 112, 113 ... AR15.12-P-2003A
Remove/install ignition coils ENGINE 113.964 in AR15.12-P-2003GZ
MODEL 164.175
Remove/install ignition coils ENGINE 113.971 in AR15.12-P-2003RT
MODELS 251.075/ 175
Remove/install ignition coils ENGINE 113.967 in AR15.12-P-2003TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install crankshaft ENGINE 112, 113 ... AR15.12-P-2133A
position sensor
Remove/instaH crankshaft ENGINE 113.964 in AR15.12-P-2133GZ
position sensor MODEL 164.175
Remove/install crankshaft ENGINE 112, 113 ... AR15.12-P-2133Q
position sensor
Remove/install crankshaft ENGINE 113.971 in AR15.12-P-2133RT
position sensor MODEL 251.075/175
Remove/install knock sensors ENGINE 112, 113 ... AR15.12-P-2184A
Mercedes-Benz
Remove/install knock sensors ENGINE 113.964 in AR15.12-P-2184GZ

MODEL 164.175
Remove/install knock sensors ENGINE 113.97 1 in AR15.12-P-2 184RT
MODELS 251.075/175
Remove starter, install ENGINE 112, 113 ... AR15.30-P-7100CS
Remove starter, install ENGINE 112, 113 ... AR15 .30-P-71 OOED
Removing/installing the ENGINE 112, 113 ... AR15 .30-P-71 OOFF
starter
Remove and installing the ENGINE 112, 113 ... AR15.30-P-7100GH
starter
Removing/installing the ENGINE 113.964 in AR15.30-P-7100GZ
starter MODEL 164.1 75
Remove starter, install ENGINE 112, 113 ... AR15.30-P-7100I
Removing and installing the ENGINE 111 , 112, 113 ... AR15.30-P-71 00P
starter
Remove/install starter ENGINE 112, AR15.30-P-7100PW
113,272,273 ...
Remove/install starter ENGINE 112, 113 ... AR15.30-P-7100R
Removing and installing ENGINE 113.971 in AR15.30-P-7100RT
starter MODELS 251.075/ 175
Removing and installing the ENGINE 113.967 in AR15.30-P-7100TY
starter MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove starter, install ENGINE 113.989 in AR15.30-P-71 00VT
MODEL 171.473
Prereg¡uisites for testing ENGINE 103, 104, 112, AR15.40-P-5009C
altemator 113, 119, 120 in MODEL
129
Prereg¡uisites for testing E NGINE 104, 111 , 112, AR15.40-P-5009EA
alternator 113' 60 1' 604' 60 5' 611 ...
Prereg¡uisites for testing ENGINE 104, 111, 112, AR15.40-P-5009F
altemator 113, 119, 602, 604, 605,
606, 6 11 , 612, 613 ...
Prereg¡uisi tes for testing ENGINE 111.977, AR15.40-P-5009GH
generator 112.942/970,
113 .942/965 /981 ,
612.963, 628.963 in
MODEL 163
Prereg¡uisites for testing the ENGINE 113 in MODEL AR15.40-P-5009GZ
altemator 164, 25 1
Prerequisites for testing ENGINE 112, 113, 137, AR15.40-P-5009I
altemator 275 ...
Prereg¡uisites for testing the ENGINE 111, 112, 113, AR15.40-P-5009P
Mercedes-Benz
alternator 611 , 612, 646 ___

Prerequisites for testing the ENGINE 112, 113, 275 in AR15.40-P-5009R
alternator MODEL230
Prerequisites for testing the ENGINE 112, 113, 628, AR15.40-P-5009T
alternator 646.### ## up to 709556,
647 in MODEL 211
ENGINE 113 in MODEL
219
Cbecking regulation voltage ENGINES 103, 104, 112, AR15.40-P-5010C
of alternator 113, 119, 120 inMODEL
129
Checking regulation voltage ENGINE 104, 111, 112, AR15.40-P-5010EA
of alternator 113, 601 , 604,605, 61L.
Checking regulation voltage ENGINE 104, 111 , 112, AR15.40-P-5010F
of alternator 113, 119, 602, 604, 605,
606,611 , 612, 613 ___
Checking regulation voltage ENGINES 111.977, AR15.40-P-5010GH
of alternator 112.942/970,
113.942/965 /981 ,
612.963, 628.963 in
JYIODEL 163
Checking regulation voltage ENGINE 113 inMODELS AR15.40-P-5010GZ
of alternator 164, 251
Checking regulation voltage ENGINE 112, 113, 137, AR15.40-P-50101
of alternator 275 ___
Checking regulation voltage ENGINE 111, 112, 113, AR15.40-P-5010P
of alternator 611 ' 612 ___
Check regulation voltage of ENGINE 112, 113, 275 in AR15.40-P-5010R
alternator MODEL230
Check regulation voltage of ENGINE 112, 113, 628, AR15.40-P-5010T
alternator 646, 647 ___
Testing altemator charging ENGINES 103, 104, 112, AR15.40-P-5011C
current 113, 119, 120 in MODEL
129
Checking charging current of ENGINE 104, 111 , 112, AR15.40-P-5011EA
altemator 113, 601 , 604, 605, 61 L.
Checking charging current of ENGINE 104, 111 , 112, AR15.40-P-5011F
altemator 113, 119, 602, 604, 605,
606, 611, 612, 613 ___
Checking charging current of ENGINES 111.977, AR15.40-P-5011GH
altemator 112.942/970,
113.942/965 /981 ,
612.963, 628.963 in
MODEL 163
Test charging current of ENGINE 113 in MODEL AR15.40-P-5011GZ
Mercedes-Benz
alternator 164, 251

Checking charging current of ENGINE 112, 113, 137, AR15.40-P-5011I
alternator 275 ...
Checking charging current of ENGINE 111 , 112, 113, AR15.40-P-5011P
alternator 6 11 , 612 ...
Test Charging current for ENGINE 112, 113,275 in AR15.40-P-5011R
alternator MODEL230
Test charging current for ENGINE 112, 113, 628, AR15.40-P-5011T
alternator 646, 647 ...
Test backup fuse for ENGINE 111, 112, 113, AR15.40-P-5012P
alternator 271 , 6 11, 612 ...
Test altemator fuse ENGINE 112, 113, 271 , AR15.40-P-5012T
628, 646, 647, 648 ...
Remove and install generator ENGINE 113.991 in AR15.40-P-5032AM
MODEL 215.374,
2 20.074 / 174
Remove and install generator ENGINE 112, 113 in AR15.40-P-5032CT
MODEL 129
Remove and install generator ENGINE 112.910 /920 in AR15.40-P-5032EB
MODEL 202 ENGINE
112.940, 113.943/984 in
MODEL208
Remove and install generator ENGTNE 112.921 /94 1, AR15.40-P-5032ED
113.940/980, 119.985 in
MODEL210
Remove and install generator ENGINE 111.977, AR15.40-P-5032GH
112.942/970,
113.942/965 /981 in
MODEL 163
Remove and installing the ENGINE 113.964 in AR15.40-P-5032GZ
alternator MODEL 164.175
Remove/install altemator ENGINE 112, 113 ... AR15.40-P-5032I
Remove/install altemator ENGINE 111 , 112, 113 ... AR15.40-P-5032P
Remove, install altemator ENGINE 112, 113 in AR15.40-P-5032R
MODEL230
Removing and installing the ENGINE 113.971 in AR15 .40-P-5032RT
alternator MODELS 251.075/ 175
Remove/install alternator ENGTNE 112, 11 3... AR15.40-P-5032TC
Removing/installing the ENGINE 113.967 in AR15.40-P-5032TY
altemator MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install altemator ENGINE 113.989 in AR15.40-P-5032VT
MODEL 17 1.473
Mercedes-Benz
RemovelinstaH generator belt ENGINE 104, 111 , 112, AR15.40-P-5710EA

pulley 113, 119, 601 , 602, 604,
605, 606 ...
Remove/install generator belt ENGINE 111, 112, 113, AR15.40-P-5710GF
p ulley 166...
Remove/install generator belt ENGINE 113.964 in AR15.40-P-571 OGZ
pulley MODEL 164.175
Remove/install altemator belt ENGTNE 112, 113, 137 ... AR 15.40-P-571 OT
pulley
Remove/install altemator belt ENGINE 111, 112, 113, AR15.40-P-5710P
pulley 271...
Removing and install ing belt ENGINE 113.971 in AR15.40-P-5710RT
pulley for the alternator MODELS 251.0751175
Removing and installing ENGINE 103, 104, 119, AR15.40-P-5760CS
regulator of generator 120, 112, 113 in MODEL
129
Removing and installing ENGINE 104, 111, 112, AR15.40-P-5760EA
regulator of generator 113, 601, 604, 605, 61 L.
Removing and instaUing ENGINE 104, 111, 112, AR15.40-P-5760F
regulator of generator 113, 119, 602, 604, 605,
606, 61 L .
Remove/install regulator of ENGINE 11 1.977, AR15.40-P-5760GH
alternator 112.942!970,
113.942/965 /981 in
MODEL 163
Remove/install regulator of ENGINE 113.964 in AR15.40-P-5760GZ
generator MODEL 164.175
Removing/installing the ENGINE 112, 113 ... AR15.40-P-5760I
alternator regulator
Remove/install regulator for ENGINE 111 , 112, 113, AR15.40-P-5760P
alternator 271...
Removing/installing the ENGINE 112, 113 in AR15.40-P-5760R
altemator regulator MODEL230
Removing and installing the ENGINE 113.971 in AR15.40-P-5760RT
alternator regulator MODELS 251.0751175
Remove/installing regulator ENGINE 112, 113, 646, AR15.40-P-5760T
for alternator 647 ...
Removing/installing regulator ENGINE 113.967 in AR15.40-P-5760TY
for alternator MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM- ENGINE -

AR15.00-Z-9119AB
Mercedes-Benz
ENGINE 119
Test rotorless high ENGINE 119, 120... AR15.10-P-3000WE

voltage distribution
Replacing ignition ENGINE 104.94/99, 111, AR15.12-P-0512G
cables with M3 cable 119.97 (except 104.990)
screw
high voltage distributor
cap, high voltage
distributor rotor
Removing and installíng ENGINE 119.97 AR15.12-P-2003E
ignition coils
Removing and installing ENGINE 119.981/982/985 AR15.12-P-2003EA
ignition coils
crankshaft position
sensor
crankshaft position
sensor
Removing and installing, ENGINE 119.97 AR15.12-P-2143E
adjusting camshaft
position sensor
Remove/install knock ENGINE 119.97 AR15.12-P-2184E
sensors
Remove/install knock ENGINE 119.981 /982/985 AR15.12-P-2184EA
sensors
Removing and instaHing ENGINE 119, 120... AR15.30-P-7100EC
starter
Removing and installing ENGINE 119.985 in AR15.30-P-7100FAF
starter MODEL 210.072
Prerequisites for testing ENGINE 103, 104, 112, AR15.40-P-5009C
alternator 113, 119, 120 in MODEL
129
Prerequisites for testing ENGINE 104, lll, ll2, AR15.40-P-5009F
alternator 113.1 19,602,604,605,
606, 611, 612, 613 ...
Checking regulation ENGINES 103, 104, 112, AR15.40-P-5010C
voltage of alternator 113, 119, 120 in MODEL
129
Checking regulation ENGINE 104, 111, 112, AR15.40-P-5010F
voltage of alternator 113.1 19,602,604,605,
606. 611, 612, 613 ...
Testing altemator ENGINES 103, 104, 112, AR15.40-P-5011C
Mercedes-Benz
cbarging current 113, 119, 120 in MODEL

129
Checking charging ENGINE 104, 111 , 112, AR15.40-P-50 11F
current of altemator 113, 119, 602, 604, 605,
606, 611 , 612, 613 ...
Removing and installing ENGINE 119, 120 in AR15.40-P-5032CS
generator MODEL 129
Remove and insta11 ENGTNE 112.921 /941, AR 15.40-P-5032ED
generator 113.940/980, 119.985 in
MODEL 210
Removing and installing ENGINES 103, 104, 119, AR15.40-P-5710CS
the generator poiy-V- 120 in MODEL 129
pulley
Remove/install generator ENGINE 104, 111, 112, AR15.40-P-5710EA
belt pulley 113, 119, 60 l , 602, 604,
605, 606 ...
Removing and installing ENGINE 103, 104, 119, AR15.40-P-5760CS
regu1ator of generator 120, 112, 113 in MODEL
129
Removing and installing ENGINE 104, 111, 112, AR15.40-P-5760F
regulator of generator 113,119, 602, 604, 605,
606, 611...

AR15.00-Z-9120AB
ENGINE 120
ARlS.lO-P-
Test rotorless high voltage distribution ENGINE 119, 120...
3000WE
Removing and installing high voltage distributor AR15.12-P-
ENGINE 120.980/981
cap, high voltage distributor rotor 1928F
AR15.12-P-
Removing and installing ignition coils ENGINE 120.980/981
2003F
AR15.12-P-
Removing and installing ignition coils ENGINE 120.982/983
2003FA
Removing and installing crankshaft position AR15.12-P-
ENGINE 120.980 /981 /982
sensor 2133F
Removing and installing crankshaft position AR15.12-P-
ENGINE 120.983
sensor 2133FA
AR15.12-P-
Remove/install knock sensors ENGINE 120.98
2184F
AR15.30-P-
Removing and installing starter ENGINE 119, 120...
7100EC
Mercedes-Benz
1990-2002 ENGINE Electrical System- Engine - 129 Chassis
ENGINE 103, 104, 112, 113, 119, AR15.40-P-

Prerequisites for testing alternator
120 in MODEL 129 5009C
ENGINES 103, 104, 112, 113, 119, AR15.40-P-
Checking regulation voltage of altemator
120 in MODEL 129 5010C
ENGINES 103, 104, 112, 113, 119, AR15.40-P-
T esting altemator charging current
120 inMODEL 129 5011C
AR15.40-P-
Removing and installing generator ENGINE 119, 120 in MODEL 129
5032CS
Removing and installing the generator poly- ENGINES 103, 104, 119, 120 in AR15.40-P-
Vpulley MODEL 129 5710CS
ENGINE 103, 104, 119, 120, 112, AR15.40-P-
Removing and installing regulator of generator
113 in MODEL 129 5760CS

AR15.00-Z-9129AA
MODEL 129
Servicing wiring MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 208, AR15.18-P-
harness 210, 215, 220 0500A
REMOVE, INSTALL CAMSHAFT HALL SENSOR- AR15.10-P-2000A
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202,203,208, 209.361 /365/461 /465, 210,
211.061 /261 /065 /265 /080/082 /280 /282, 220, 230.467
ENGINE 113 (except 113.990/991) in MODEL 129, 163, 202, 208, 209.375/475/376/476, 210,
211.070 /270/083 /283, 215, 220, 230.472 /474 /475
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246

Mercedes-Benz
BM C.mshalt HdalliJScr
P15 . 10-il24111
Fig. 8: ldentifying Camshaft Hall Sensor- Sbown On Engine 112 In Model 2.20
Fig. itero etc. Work instructions

@ Camshaft Hall sensor to *BA15.10-P-1002-03A
cylinder head
B6/ 1 Camshaft Hall sensor n::r"GF Replace 0 -ring.
@ Position sensor
Number Designation Engines Engines Engine
112.910/911 / 113.940/941/ 113.987/
912/913/914/ 942/943/944/ 988/990/
915/916/9171 948/960/9611 991
920/921/922/ 962/963/964/
923/940/941/ 965/966/9671
942/943/944/ 968/969/971/
945/946/9471 980/981/982/
949/951/953/ 984/986/992/
954/955/960/ 993/995
961/970/972/
973/975/976
BA15.10-P- Camshaft Hall Nm8 8 8
1002-03A sensor to
cyl.inder head
TEST ROTORLESS IDGH VOLTAGE DISTRIBUTION- AR15.10-P-3000
Test rotorless high voltage distribution - AR15.10-P-3000WA
ENGINE 112.923 /943, 113.961 in MODEL 129
ME-SFI fuel injection and ignition system with engine diagnostic tester Dat.ascope D 980
Mercedes-Benz
ENGINE 112.942, 113.942/965/981 in MODEL 163
ME-SFI fuel injection and ignition system with engine diagnostic tester Datascope D 980
ENGINE 112.910/920,113.944 in MODEL 202
ENGINE 112.940, 113.943 in MODEL 208
ENGINE 112.911 /921 /941, 113.940/980 in MODEL 210
ENGINE 112.922 /944, 113.941 /960 in MODEL 220
~BT Risk of accident. Secure vehicle to prevent ASOO.OO-Z-0005-0lA

Accídents may result íf it from movíng. Wear
the vehicle starts off closed and snug-fitting
unintentionally with the work clothes. Do not
engíne running. Risk of grasp hot or rotating
injury as working around parts.
the engine during start-up
or while runníng may
result in contusions and
bums
~BT Risk of death. Death Do not touch parts AS15.10-Z-0001-01A
may result if contact is carrying high voltages.
made with parts carrying Persons who wear
high voltages. electronic implants (e.g.
heart pacemakers) must
not carry out work on the
ignition system.
1 Remove air cleaner
2 Remove trim panel of
cylinder head cover
3 Test ignition circuits IJJ Datascope engine *WH58.30-Z-1003-13A
diagnostic tester
~GF General information on AH15.10-P-1002-01 WA
rotorless high voltage
distribution
~GF General information on AH15.10-P-1003-01 W
Mercedes-Benz
testing rotorless high

if necessary:?
Test secondary side
IJ:S"GF Secondary
adapter cable in place of
kV clamp.
~GF kV clamp in
ignition coil recess
altemately at ignition coil
T l/1-Tl/6 or Tl /8
Test primary side
~GF Primary adapter
cable altematively at
ignition coil Tl/1 -Tl/6 or
Tl /8
e ommerc1a·uty ava1.•a ble too1s

Number Designation
WH58.30-Z-l 003-13A Engine tester
Test rotorless bigh voltage distribution- AR15.10-P-3000WD
ENGINE 104.943 /991 as of 1.6.96 in MODEL 129 ME-SFI fuel injection and igoition system with engine
diagnostic tester Datascope D 980
ENGINE 104.944/994 as of 1.6.96 in MODEL 140 ME-SFI fuel injection and ignition system with engine
ENGINE 111.943, 111.946 as of 1.6.98, 111.973 in MODEL 170 ME-SFI fuel injection and ignition system
with engine diagnostic tester Datascope D 980
ENGINE 104.941, 111.944 as of 1.8.96 in MODEL 202 ME-SFI fuel injectioo and ignition system with
engine diagnostic tester Datascope D 980
ENGINE 111.974 in MODEL 202 with CODE (491) U.S. version ME-SFI fuel injection and ignition
system with engine diagnostic Datascope D 980
ENGINE 111.975 as of 1.8.96 in M O DEL 202.024 ME-SFI fuel injection and ignitiou system with engine
ENGINE 111.975 in MODEL 202.085 ME-SFI fuel injection and ignition system with engine diagnostic
tester Datascope D 980
ENGINE 111.944 /975 in MODEL 208 ME-SFI fuel injection and ignition system witb engine diagoostic
Mercedes-Benz
ENGINE 111.945 as of 1.6.98 in MODEL 208.335 ME-SFI fuel injection and ignition system with engine
diagnostic tes ter Datascope D 980
ENGINE 111.945 in MODEL 208.435 ME-SFI fue) injection and ignition system with engine diagnostic
ENGINE 104.995 as of1.6.96 in MODEL 210 with CODE (491) U.S. version with CODE (498) Japanese
version ME-SFI fu el injection and ignition system with engine diagnostic tester Datascope D 980
ENGINE 111.977 in MODEL 163.136 ME-SFI fue) injection and ignition system with engine diagnostic
& Risk of accident. Secure vehicle to prevent ASOO. 00-Z-0005-0 lA

Accídents may result íf it from movíng. Wear
the vehicle starts off closed and snug-fittíng
uníntentionally with the work clothes.
engíne runníng. Risk of Do not grasp hot or
injury as working around rotatíng parts.
the engine during start-up
or while runníng may
burns
& Risk of death. Death Do not touch parts AS15.1 O-Z-0001-01A
high voltages. electroníc ímplants (e.g.
ignitíon system.
1 Remove intake
connection líne at hot
film mass air flow sensor
cylinder head cover
3 Test prímary ignition IT1 Datascope engíne * WH58.30-Z-1 003-13A
circuít diagnostic tester
n::3rGF General information on AH15.10-P-1002-01WD
rotorless high voltage
distribution
n::3rGF General information on AH15.10-P-1003-01W

Number jDesignation
WH58.30-Z-1 003-13A IEngine tester
Mercedes-Benz
Test rotorless higb voltage djstributloo - AR15.10-P-3000WE
ENGINE 119.982, 120.983 in MODEL 129 ME-SFI fuel injection and ignition system with engine
ENGINE 119.980 /981 in MODEL 140 ME-SFI fuel injection and ignition system witb engiue diagnostic
ENGINE 119.985 in MODEL 210 ME-SFI fuel injection and ignition system with engine diagnostic tester
Datascope D 980
& Risk of accident. Secure vehicle to prevent ASOO.OO-Z-0005-01A

Accidents may result if it from moving. Wear
the vehicle starts off closed and snug-fitting
unintentionally with the work clothes.
engine running. Risk of Do not grasp hot or
injury as working around rotating parts.
the engine during strut-up
or wlúle running may
bums
& Risk of death. Death Do not touch parts AS15.10-Z-0001-01A
ignition system.
1 Remove air cleaner,
instaU
IJ:S="GF Engine 119 AR09.10-P-1050E
cylinder head cover
3 Test ignition circuits
OJ Datascope engine * WH58.30-Z-1 003-13A
diagnostic tester
[!rGF General information 011 AH15.10-P-1002-01WE
rotorless high voJtage
distribution
[!rGF General information 011 AH15.10-P-1003-01W
if necessary: ?
Test secondary side
IJ:S="GF Secondary
adapter cable in place of
Mercedes-Benz
kV clamp.
~GF kV pickup in
ignition coil recess
altematively at ignition
coil Tl/1-Tl/8 or Tl/1 2
Test primary side
~GF Primary adapter
cable altematively at
ignition coil Tl/1-Tl /8 or
Tl/ 12
e ommerc1a·uty available t 001S

Number Designation
WH58.30-Z-1003-13A Engine tester
REPLACING IGNITION CABLES WITH M3 CABLE SCREW - AR15.12-P-0512G
ENGINE 104.94/99, lll, ll9.97 (except 104.990)
Left-hand illustration
Attach sleeve of cable screw to insulation.
Right-band illustration
Attach sleeve of cable screw to ignition cable core.
F ig. 9: ldentifying Sleeve Attachment Of Cable Screw To Insulation

Mercedes-Benz
P1S. 12:4201.01
Fig. 10: ldentifving Sleeve Attachment Of Cable Screw To lgnition Cable Core
Making up
1 Make up ignition cables n::!if"GF Ignition cables
to correspond to the are still only available on
cables removed the parts market in cut
length. Por this reason, fit
the connecting parts on
using cable pliers before
installing the ignition
cables.
2 s.trip the insulation off
the ends of the new
ignition cables over 6 mm
3 Fit on sleeve of cable First of all attach to the
screw insulation, then to the
core of the ignition cable
~GF Fig. 11
4 Fit on markings for the
individual cylinders
5 Screw on spark plug
connectors
Fig. 11: Jdentifying Cable Pliers (000 589 55 37 00)
REMOVING AND INST ALLING HIGH VOLTAGE DISTRffiUTOR CAP, HIGH VOLTAGE
DISTRmUTOR ROTOR- AR15.12-P-1928
Mercedes-Benz
Removing and installing b.igh voltage distributor cap, high voltage distributor rotor - AR15.12-P-1928E
ENGINE 119.97
IJ Hlgh voltilgo dls·trlburor rotor

14 FOi owor
14~ FOMowor s/or
1$
1e
17
Scrccnlng
Covcr
c.,
Hlgll vo/ragc dlstrlburor c~p
11 Hocd
Arrow La<dt lng pln
jl1f f142M-0 , P1tl ,,.1)2H.41
F ig. 12: Identifying High Voltage Distributor Cap An d Rotor Remove/Install Components CEngine
119.97)
Fig. item, Work inst ructions.

etc.
Hazard from contact Do not touch parts conducting high voltages. Persons
AS15.10-Z-
LÍi with parts conducting who wear electronic implants (e.g. heart pacemakers)
0001-0lA
high voltages must not carry out any work on the ignition system.
Engíne 104, 111 , 112, 113, 119, 120 with MESFI fue l AH15.10-P-
injection and ignition system 0002-0l D
Notes on avoiding
[[] AH15.10-P-
damage to the ignition Engíne 103, 104, 119 with CFI fuel injection system
0002-0l E
system
Engíne 104, 119, 120 with LH-SFI fuel injection AH15.10-P-
system 0002-0lF
install in the correct order at the high voltage
n::!irGF
distributor caps
Ignition cables
r ight : 1-4-6-7
left : 5-8-3-2
0 -ring
&oanQer! examine, replace if necessary
High voltage distributor
13 slacken screws and take off
rotor
~WF
High voltage distributor BT15.12-P-
rotor with stiffening ribs 0002-0lA
14 Follower n::!irGF Tnsta 11 atínn
. : nav attent1. on to 1oca.ttnQ
. nm.
Mercedes-Benz
(arrow) and follower slot (14a)

High voltage dístríbutor
15 slacken hexagon socket screws and take off
cap
Hood of high voltage
18
distributor
Removing and installing higb voltage distributor cap, high voltage distributor rotor - AR15.12-P-1928F
ENGINE 120.980/981
1J OIJtrlbutor roror
14 Orfvor
14.1 Orlvor slot
1$ OIJtrlbutor c;,p
17 C-ovot
17~ So¡/
11 Covor
AffOW L.oc~r!n¡¡pln
MI 12.a2'2r&OCI
Fig. 13: Identifying Higb Voltage Distributor Cap And Rotor Remove/Install Components (Engine
120.980/981)
Fig. item, Worl< instructions

etc.
Hazard from contact Do not touch parts conductíng high voltages. Persons
AS15.10-Z-
A with parts conducting who wear electronic implants (e.g. heart pacemakers)
0001-01A
Notes on avoiding
Engine 104, 111, 112, 113, 119, 120 with MESFI fuel AH15.10-P-
OJ damage to the ignition
injection and ignition system 0002-01D
system
Engine 104, 119, 120 with LH-SFI fuel injection AH15.10-P-
system 0002-0lF
Install the ignition cables at the distributor caps in the
~GF Ignition cables order l -5-3-6-2-4 o n the right and 12-8-10-7-11-9 on
the left.
u::rGF High voltage distributor No alteration to ignítion timing ís necessary after

removin!l anrl insta llin!l the hi llh volta!le di strihutor
Mercedes-Benz
The ignition timing is fixed by the DI ignition control

units .
When instalJing, pay attention to locating pin (arrow)
14 [Driver
and driver slot (14a)
High voltage distributor
15
cap
IHigh voltage distributor
BT15.12-P-
o:$"WF cap, high voltage
0001-01A
distributor rotor
l7a Seal examine, replace if necessary
Cover of high vo1tage
18 insert screwdriver into the catch (arrow) and release
distributor
REMOVING AND INSTALLING IGNITION COILS- AR15.12-P-2003
Remove/install ignition coils- AR15.12-P-2003A
ENGINE 112.910 in MODELS 202.026/086
ENGINE 112.920 in MODELS 202.029 /089
ENGINE 112.921 in MODELS 210.063 /081 /263 /281
ENGINE 112.922 in MODELS 220.063 /163
ENGINE 112.940 in MODELS 208.365 /465
ENGINE 112.941 in MODELS 210.065 /082 /265 /282
ENGINE 112.944 in MODELS 220.065 /165
ENGINE 113.940 in MODELS 210.070 /270
ENGINE 113.941 in MODELS 220.070 /170
ENGINE 113.960 in MODEL 215.375,220.075/175/875

Mercedes-Benz
ENGINE 113.962 /982 in MODEL 463
ENGINE 113.980 in MODELS 210.074 /274
ENGINE 113.944 in MODELS 202.033 /093
ENGINE 113.943 in MODELS 208.370 /470
ENGINE 113.984 in MODELS 208.374
ENGINE 112.912 in MODELS 203.061 /261, 209.361 /461
ENGINE 112.946 in MODELS 203.064 /264
ENGINE 113.986 in MODEL 215.373, 220.073 /173
ENGINE 112.961 in MODELS 203.065 /265
ENGINE 113.968 in MODEL 209.375 /475
ENGINE 112.913 in MODELS 211.061 /261
ENGINE 112.949 in MODELS 211.065 /265
ENGINE 113.967 in MODELS 211.070 /270
ENGINE 113.987 in MODELS 209.376 /476
ENGINE 112.955 in MODELS 209.365 /465
ENGINE 113.990 in MODELS 211.076 /276

Mercedes-Benz
ENGINE 113.991 in MODELS 215.374, 220.074/174
ENGINE 112.916 in MODELS 203.081 /281
ENGINE 112.953 in MODELS 203.084 /284
ENGINE 112.972 in MODELS 220.067 /167
ENGINE 112.975 in MODELS 220.087 /187
ENGINE 113.948 in MODELS 220.083 /183
ENGINE 113.966 in MODELS 220.084 /184
ENGINE 112.917 in MODELS 211.080/280
ENGINE 112.954 in MODELS 211.082 /282
ENGINE 113.969 in MODELS 211.083 /283
ENGINE 113.988 in MODEL 203.076/276
ENGINE 113.993 in MODELS 463.270/271
5/1 Sparlcpi((JJ eonn..,!or

M Bolt
T111 C:;fnd8r 1 /gnftlon .eolt
T112 Cyfnci8r 2/gnlrion col/
T113 C:;fnd8r31gnition col/
T11<1 Cyfnd8r4 1gnlrion coi/
rt/5 C:;fnder 5 /gnltion eo/1
Tf/6 C:;fnd8r6/gnltloo coi/
Nn Cyfnder T l gnttlon col/
T1t8 Cyfndor llgnltlon col/
ArrOI!N': tlentf6cadon of the c onnector
PIS . I :!-20<~.05
Fig. 14: ldentifying lgnition Coil Remove/lnstall Components - Shown On Engine 112
Mercedes-Benz
Modification notes
16.5.06 "Disconnect/connect grOlmd Model 203, 209,
line on battery" removed
~~ Remove/install
n:::r-sr Risk of death caused Do not touch parts which conduct high AS lS.l O-Z-0001-
by touching parts voltages. Persons who wear electronic OlA
which conduct high imp lants (e.g. heart pacemakers) should
voltages never perform any work on the ignition
system.
[JJ Notes on avoiding AH15.10-P-0002-
damage to ignition Ol D
system
1.1 Deactivate service rt:rGF Only on model 463.270 with AR82.95-P-0005-
mode in TELE AID code: Tele-Aid car phone emergency call 03GR
emergency call systemET2.
system
~GF Notes on TELE AID Model 463.243/244/245/247/248/250/ AH82.95-P-0001-
emergency call 254/270/309/322/323/332/333 TELE OIGA
system AID car telephone emergency call
systemET2
2 Discormect grOlmd Model463 except model463.241 /248 AR54.10-P-0003G
line from battery with code 979 special protection version
Model 463.241 with: special protection AR54.10-P-0003PV
version code 979, -special protection
version FB4 with code ZS4, -special
protection version FB6 with code ZS6, -
special protection version FB7 with code
ZS7, additional battery 100 Ah incl.
cutoffrelay code E26.
M odel 463.248 with: special protection AR54.10-P-0003PM
version, code 979, -special protection
version FB6>code ZS6, -special
protection version FB7, code ZS7,-
additional battery 100 Ah including
cutoffrelay, code E26.
3.1 Unclip cover on Model 211, 215, 220, 230.475/476
front side of engine
4.1 Remove engine Except model l70.466,
cover with integrated 203.065/076/265/276, 209.376/476 from
air filter 24.4.04, 211 .076/276, 215.374,
220.074/ 174, 230.474, 463.270/271
~GF The air fJJter is integrated in the
engine cover. Remove the engine cover
or the air filter housing by pulling it from
Mercedes-Benz
the cylinder head covers vertically in the

upward direction.
4.2 Remove air filter Model 170.466, 203.065/265, AR09.10-P-
housing 211.076/276, 215.374, 220.074/174, 1150SVK
230.474
Model 203.076/276, 209.376 /476 from AR09.10-P-1150AC
24.4.04, 171.473
Mode1463.270/271 AR09.10-P-1150GX
5 Unscrew screw (5/3) @ *BA15.10-P-1001-
04A
6 Detach spark plug ~GF Pry off spark plug connector
connector (5/1) from (5/ 1) using open-end wrench, double
the spark plugs over the cylinder head cover of the spark
plugs.
~GF Installation: Observe the
identification ofthe connector (arrow) on
the cylinder head cover and the ignition
coil of cylinders 1 to 6 or 1 to 8 for the
corresponding spark plug connector
(5/ 1).
~GF Double open-ended wrench Fig. 15
7 Separate electrical ~GF Installation: Install new cable
connector of ignition ties.
coil of cylinder 1 to
6 (Tl/1 to Tl/6) or 1
to 8 (T1/ 1 to Tl/8)
8 Remove ignition coi]
of cylindler 1 to 6
(Tl/1 to Tl/6)or 1 to
8(T1/ 1 to Tl/8)
order
10.1 Actívate Service ~GF Only on model463.270 with AR82.95-P-0005-
mode in Tele-Aid code: Tele-Aid car phone emergency call 03GR
emergency call system ET2.
system
~GF Notes on TELE AID Model 463.243/244/245/247/248/250/ AH82.95-P-0001-
emergency call 254/270/309/322/323/332/333 TELE OIGA
system AID car telephone emergency call
system ET2
@¡Lgm.ti on coil
Number Designation Engines 112,113
BA1 5. 10-P-1001-04A Bolt for ignition coil on Nm 8
cylinder head cover
Mercedes-Benz
Fig. 15: ldentifving Double Open-End Wrench (110 589 01 01 00)
Removing and installing ignition coils- AR15.12-P-2003E
ENGINE 119.97
Model 129 illustrated
2V COVIIr
Tl/1 ~Ilion co/11 (right I>Jn~ of
cyNndo~
Tl/2 /tlnltion collt (!Oft l>~nll ofcyNn<Jonj
Fig. 16: ldentifving lgnition Coils Remove/lnstaJI Componeuts (Engine 119.97)
Fig. Work instructions

item, etc.
AS15.10-Z-
& w ith parts conducting who wear electroni c implants (e_g_ heart pacemakers)
0001-01A
Notes on avoiding
E ngine 104, 111 , 112, 113, 119, 120 with MESFI fuel AH15.10-P-
ITJ damage to the ignition
system
AH15.10-P-
Engine 103, 104, 119 with CFI fuel injection system
0002-01E
Engine 104, 119, 120 with LH-SFI fuel injection AH15.10-P-
system 0002-0IF
Model124
Remove left intake scoon
Mercedes-Benz
Remo ve left alann system horn

Model 140
~GF
AR09.10-P-
Ignition coil (T1/2) Remove left headlamp, see Repair Instructions
8221EA
Electrical System II Model 140
Op. no. 82-4730
29 Cover of ignition coils take off
Tl/1, terminal 1: M5 connection thread
Ignition coils
Tl/2 terminall5: M6 connection thread
Removing and installing ignition coils - AR15.12-P-2003EA
ENGINE 119.981/982/985
1911 F~stcnfng c~<:mcnt
T111· T1l4 lgnltfon c-olls

(rlght bon~ ot cylindors)
T1JS·nlt lgnlrfon coils

(tcft l>~nK ct cytlndcrs)
A. 8 C·overs
Fig. 17: ldentifving Ignition C oils Components
Fig. ítem, etc. Work instr uctions

6 Hazard from contact Do not touch parts AS15.10-Z-0001-01A
with parts conducting conducting high voltages.
high voltages Persons who wear
electronic implants (e.g.
he art pacemakers) must
not cany out any work on
the ignition system.
[JJ iNotes on avoiding Engine 104, 111 , 112, AHl S.lO-P-0002-0l D
damage to the ignition 113, 119, 120withME-
system SFI fuel injection and
ignition system
Engine 103, 104, 119 AHl S.lO-P-0002-0lE
with CFI fuel injection
system
Engine 104, 119, 120 AHl S.lO-P-0002-0lF
with LH-SFI fuel
Mercedes-Benz
inj ection system

A,B Covers
29/ 1 Fastening element pay attention to
installation position
Tl/1-Tl/8 Ignüion coils pay attention to routing of
cables
Removing and installing ignition coils- AR15.12-P-2003F
ENGINE 120.980/981
Model129
TJ/1 Jgntr/on col/1 {ftght b¡n/1 ot cyllndus)

T112 lgnlf/on col/1 (lctt thlnK or c)lllndets)
111.11 124228-01
Fig. 18: Identifying Ignition Coils Removellnstall Components (Model129)
Model140
T111 lgntrlon ~ol/1 (rlghr b•nllllf ~linden)

1112 Jgntr/oncol/1 {Ioft thlnllllfc)lllndets)
P1! t2Q.!30.01
Fig. 19: ldentifving lgnition Coils Remove/lnstaU Components (Model140)

item, etc.
Hazard from contact Do not touch parts conducting hlgh voltages_Persons
ASIS.IO-Z-
Lh with parts conducting who wear electronic implants (e_g_heart pacemakers)
0001-01A
high voltages must not carry out any work on tbe ignition system_
Engine 104, 111 1 112, 113, 119, 120 with MESFI fuel AH15.10-P-
Notes on avoiding
DJ damage to the ignition
Engine 104, 119, 120 with LH-SFI fuel injectíon AH15.10-P-
system
system 0002-01F
Mercedes-Benz
n:!rGF Cover abo ve right or left Model140

headlight Remove, install
Tl/ 1, Ignition coils, polaríty Terminal 1: M5 thread
T1/2 (arrows) Terminal15: ~6tbread
Removing and installing ignition coils- AR15.12-P-2003FA
ENGINE 120.982/983
T lgnrllon ooíl
Arrow Clip
Fig. 20: ldentifving lgnition Coils Remove/Install Components (Engine 120.982/983)

item,
etc.
AS15.10-Z-
~ with parts conducting who wear electronic implants (e.g. heart pacemakers)
0001-0lA
high voltages must not carry out any work on the ignition system_
Engine 104, 111, 112, 113, 119, 120 with MESFI fuel AHlS.lO-P-
Instructions for avoiding
injection and iguitíon system 0002-0lD
DJ damage to the iguition
AH15.10-P-
system Engine 104, 119, 120 with LH-SFI fue! inj ection system
0002-01F
T Ignition coil Remove clip (arrow)
Remove/install ignition coils- AR15.12-P-2003G
ENGINE 104.996 /94/99, 111.920/940/941 /944/960 /961 (except, 104.990)
Engine 104
Mercedes-Benz
~~ lgnlrJon Nb/0 duct COVOI

12 c•blo diJct. IIJod<;.l 1:.1
Fig. 21: ldentifving lgnition Coils Components (engine 104)
Shown on Engine 111 Left graphic
X151U Connoctor
Englno!f¡nltion coll
Right tlgur•
T111 1Wo sporl< IIP'i lion col 2
2nd onrl Jrrlcylnrler(HFUPIIS}
Anows l~nltlon cobtcs
Fig. 22: ldentifying Ignition Coils Components (engine 111)
Sbown on Engine 111 Left graphic
T1t1 1Wo <porill~nllion col/ f

Ut Inri 4th cy/lnrlot (HFMPMS}
T111 tillO Sf»ril l~nltion <O N 1
2nd. ond Jrrl. cyNndor(HFUPMS}
Right figure
Arrow Connortor
P15.1~1 P1! t2>CY.M)d.01
Fig. 23: ldentifying Ignition Coils Components (Engine 111)
Connection schema ignition coil/ignition cables

Mercedes-Benz
Left graphic, Engine 104
Tl/1 lfll'll lfon colt 1 cyNndar 2 • nd 5

T112 /fll'lllfon coN 2 cyKnder J ~nd4
T1f 3 tgnllfon colt 3 cyHndar 1 •nd &
firlng ordor: 1-5-3·6·2·4
Right ¡¡nphic. Engino 111
Tlll lgnlrton coN 1 cyHndar 1 • nd 4
T112 lfll'lllton c oN 2 cyHndar 2 • nd J
firlng o rdar: 1·3-4·2
Fig. 24: Connection Schematic lgnition Coil/lgnition Cables

& Hazard from contact Do not touch parts which ASlS.l 0-Z-0001-0lA
with parts conducting conduct high voltages.
high voltages. Persons who wear
ignition system.
IIl N otes on avoiding Engine 111 with PEC AH15.10-P-0002-0 lB
damage to ignition fuel injection and ignition
system system
Engine 104, 111 with AH15.10-P-0002-0 lC
HFM-SFI fuel injection
and ignition system
Engine 104, 111 , 112, AHIS.lO-P-0002-0lD
113, 119, 120 with ME-
SFI fuel injection and
ignition system
Engine 103, 104, 119 AHlS.lO-P-0002-0lE
with CFI continuous fuel
inj ection system
Engine 104, 119, 120 AHlS.lO-P-0002-0lF
with LH-SFI fuel
inj ection system
T1/ l , T l /2 Unbolt Ignition coils for better assembly of
lines circuit 1 and 15
REMOVING AND INSTALLING CRANKSHAFT POSITION SENSOR- AR15.12-P-2133
Removelinstall crankshaJt position sensor - AR15.12-P-2133A
ENGINE 112.910 in MODEL 202.026 /086

Mercedes-Benz
ENGINE 112.920 in MODEL 202.029 /089
ENGINE 112.921 in MODEL 210.063 /081 /263 /281
ENGINE 112.940 in MODEL 208.365 /465
ENGINE 112.941 in MODEL 210.065/082/265/282
ENGINE 112.944 in MODEL 220.065/165
ENGINE 113.940 in MODEL 210.070 /270
ENGINE 113.941 in MODEL 220.070/170
ENGINE 113.960 in MODEL 215.375,220.075/175
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.944 in MODEL 202.033 /093
ENGINE 113.980 in MODEL 210.074/274
ENGINE 113.943 in MODEL 208.370 /470
ENGINE 112.912 in MODEL 203.061/261,209.361 /461
ENGINE 112.946 in MODEL 203.064 /264

Mercedes-Benz
ENGINE 112.961 in MODEL 203.065 /265
ENGINE 112.913 in MODEL 211.061 /261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243 /246
ENGINE 112.955 in MODEL 209.365 /465
ENGINE 112.916 in MODEL 203.081 /281
ENGINE 112.953 in MODEL 203.084 /284
ENGINE 112.972 in MODEL 220.067/167
ENGINE 112.975 in MODEL 220.087/187
ENGINE 113.948 in MODEL 220.083/183
ENGINE 113.966 in MODEL 220.084/184
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283

Mercedes-Benz
U CrriU..tt position u mor
P15 .12 0275 11
Fig. 25: Identifving Crankshaft Position Sensor - Shown On Engine 113 In Model 220
~tru Remove/install
l.l Remove engine cover All except Engine
with integrated air filter 112.960 in Model
170.466, Engine 112.961
in Model203.065 /265
n:::!?GF Remove air filter
housing by lifting
vertically up and off the
n:::!?GF InstaUation:
Slightly moisten rubber
retainers on cylinder bead
covers and sealing ring of
hot film mass air flow
sensor in the air filter
housing with lubricating
paste
Lubricating paste *·BR00.45-Z-1 002-06A
1.2 Remove air filter housing Engine 112.960 in model AR09.10-P-1150SVK
170.466
Engine 112.961 in model
203.065/ 265
2 Remove crankshaft @ *BA15.10-P-1001-03A
position sensor (L5)
4 Reinitialize crankshaft n:::!?GF If crankshaft
position sensor (L5) using ¡position sensor (L5)was
STAR DIAGNOSIS replaced, a re-
irutialization must be
carried out witb STAR-
Mercedes-Benz
DIAGNOSIS in the menu

ítem control unit
adaptations.
@ Position sensor
112.910/911/ 113.940/941/
912/913/914/ 942/943/944/
915/916/917/ 948/960/961/
920/921/922/ 962/963/964/
923/940/941/ 965/966/9671
942/943/944/ 968/969/971/
945/946/9471 980/981/982/
949/951/953/ 984/986/992/
954/955/960/ 993/995
9611970/972/
973/975/976
BA15.10-P-1001- Crankshaft position Nm8 8
03A sensor to engine
block
. 1s
R epatr matena
BR00.45-Z-1 002-06A lubricating paste A 000 989 01 60
Removing and installing crankshaft position sensor - AR15.12-P-2133E
ENGINE 119.97
L5 Croruuholf poshion sensor
L&
Fig. 26: ldentifving Crankshaft Position Sensor

etc.
Crankshaft position pull off cover and take cable to DIIKSS ignition control module
L5
sensor out of cable duct
Mercedes-Benz
Removing and installing cranksbaft position sensor- AR15.12-P-2133EA
ENGINE 119.981/982/985
Fig. 27: ldentifving Crankshaft Position Sensor Components

L5 Crankshaft position unplug coupling and
sensor remove crankshaft
position sensor
Removing and installing cranksbaft position sensor- AR15.12-P-2133F
ENGINE 120.980 /981 /982
Engine 120.980/981
z Cl"o»nllshilrt p oslrlon s~Mor control

co»olo co U/MpiUI/
1.!14 Lct't cranltshilrt poslr!on sensor
U /5 Ri¡¡ht cr.nl<shilh p0$ltlon sonsot
Nl'4 l.cft!JI,KSS control modulo
Fig. 28: Identifying Crankshaft Position Sensor Remove/Jnstall Components (Engine 120.980/981)
Engine 120.982
Mercedes-Benz
l..5i 4 l..cff er~nksh~tr posltlon semtu

L515 RJ¡¡ht e ronl<shott posftlon sensor
F ig. 29: Identifving Crankshaft Position Sensor R emove/Install Componen ts (E ngine 120.982)
~' Removing and installing

~
Engine AR07.03-P-
120.980/981 1452F
1 Removíng and installing fuel rail with injectíon valves
AR07.03-P-
Engine 120.982
1451F
AR09.10-P-
2 Removing and installing air filter
1050F
Engine AR09.20-P-
120.980/981 1310F
3 Removing and installing intake manifold
AR09.20-P-
Engine 120.982
1310FA
Disconnect control cable connector from crankshaft posítion
4
sensor (L5/4, L5/5)
Engine
5 Remove cable to D I control module (Nl/4) from cable duct
120.980/981
6 Remove crankshaft position sensors (L5/4, L5/5)
Removing and installing crankshaft position sensor - AR15.12-P-2133FA
ENGINE 120.983
l?io "O • ldPntifvin o rr!:~ nln: h :!:aft Pn~:i ti nn ~P n~:nr R P mnvp/Jnd!:~ ll rnmnnn P nt~: {l?.noin P 11.0 QR::\\
Mercedes-Benz

LS/4 , L5/5 Crankshaft sensors Unplug connector and remove crankshaft positíon sensors
Removing and installing crankshaft position sensor- AR15.12-P-2133G
ENGINE 104.941 /942/943 /944 /991 /992 /994, 111.920/940 /941 /942 /944 /960/961 /975
Englne to•
Loft-ttand flg.
U Cr'M!Iish•ft ¡xuiJJon sensor
Rignt-llland fil}.. modo! 124
111 Ctillllish• ft poJfJJon SCIUor
t:onnc:clllt (HFW.SFO
Fig. 31: Identifying Crankshaft Position Sensor Remove/Install Components (Engine 104)
Englno 104
Loft•hand flg._ modoJ 129
111 Cr•n-sh•ft positjon s<:~UM
connc:cror (HFW.SFO
Rlgllt-hand flgM modt1140
111 Cron-sh• ft poJfllon sensor
.. onr~c:cror (HFII-SFI}
Fig. 32: Identifving Crankshaft Position Sensor Remove/lnstall Components (Engine 104)
Englne 111
Loft·h•md flg.
L5 Cr.nlish•ft position sensor
Right•lilanCI fig.
111 cranlish• ft poJfllon sensor
t:onnccror (HFU-SFI)
Fig. 33: Identifying Crankshaft Position Sensor Remove/Install Components (Engine 111)
Mercedes-Benz
En gin• 11 1
112 Criltllrsho rt posltiotJ setuor
s.ocllcr (I'ECJ
Fig. 34: Identifying Cranksha ft Position Sensor Rem ove/Install Components (Engine 111)

etc.
AR15.30-P-
Engine 104 in M odel 129
7100C
¡GrGF AR15.30-P-
Remove starter, install Engine 104, 111 in model 202, 208
7100EA
AR1 5.30-P-
Engine 104, 11 1 in model210
7100F
Engine 111
¡GrGF Remove cruise control Refer to repair instructions cruise control
actuator, install systems
Op. no. 30-541
¡GrGF Windshield washer Engine 111 PEC
reservo ir Detach, place to the side
or socket
Model 124, 129, 202 on right in component
8/1 , 8/2 Separate plug connection
compartment behind battery
Model 140 on ríght in engine compartment
REMOVING AND INSTALLING, ADJUSTING CAMSHAFT POSITION SENSOR - AR15.12-P-2143
Removing and installing, adjusting camshaft position sensor - AR15.12-P-2143E
ENGINE 119.97
Mercedes-Benz
Scrow
10 Shfm
11 0-rihg
L51t C.amsh•ff posiflon nnsor
Arrow C.amsh•rrposiflonscnsor eoupllnll
Fig. 35: ldentifving Crankshaft Position Sensor Remove/Install Components (Engine 119.97)

etc.
it!rGF
Cover of coolant
remo ve
tbermostat housing
11 0-ring replace
LS/ 1 Camshaft position sensor ¡remove: ?
check clearance of camshaft position AR15.12-P-
sensor/camshaft sprocket segment, adjust 2143-0lA
Checking, adjusting clearance of camshaft position scnsor/camshaft sprocket segment- AR15.12-P-2143-0 lA
Adjusting
l. Position crankshaft to 25° CKA before ignition TDC of cylinder l.
Measuring
2. Use a deptb slide gauge to measure size "A" from tbe plane face ofthe camshaft position sensor (L511) at
the cylinder head to the segment (arrow) on the camshaft sprocket.
it!rGF Enter size "A" in table (see calculation example).

Mercedes-Benz
Fig. 36: Identifying Camshaft Position Sensor Segment On Camshaft Sprocket
3. Use depth slide gauge to measure size "B" at camshaft position sensor (L5/ l) without shim from the
contact surface to the position sensor.
IC!if"GF Enter size "B" in table (see calculation example).
4. Calculate difference "D 18 • D is the difference between A and B (D = A- B).
((!rGF Specification "W" is 0.4 -0.6 mm (airo for average of 0.5 mm).
5. Calculate thickness ofshims "S" (S = W- D).
f2l If the result for "D" is a negative value, the amount of "D" must be added to the specified value (0.5
mm) (S = W- (-D) = W + D). Otherwise, the camshaft position sensor would be damaged because ofits
projection.
Shims (10) are available as replacement parts in 1/10 graduations from 0.1 - 1.0 mm.
P15. 124Z4!-D1
Fig. 37: Measuring Size Camshaft Position Sensor Size
CALCULATION EXAMPLES
Example 1 Example 2
Size "A" > or = Size "B" Size "A" < Size "B"
Mercedes-Benz
Síze "A" 24.1 mm 23.8 mm

Síze "B" -23.8 mm -24.1 mm
Difference "D" 0.3mm -0.3 mm
Specíficatíon "W" 0.5mm 0.5mm
Difference "D" -0.3 mm + 0.3 mm
Thickness of shim "S" 0.2mm 0.8mm
Removing and installing, ad,justable camsbaft positioo sensor- AR15.12-P-2143G
ENGINE 104.941 /942 /943 /944 /991 /992 /994,

111.920 /921 /940 /941 /943 /944 /945 /946 /947 /960 /961 /973 /974/975 /977
1111 SoiOllng rlng

1111 Shlm
Ui' l C<>mshJfr posilfon sensor
Arrow CoupHng
Fig. 38: Identifving Crankshaft Position Sensor Remove/Install Components (Engine 119.92)
Loft•h ..,d lllustnl:lon

Shown o n tnglnt 111 ~77
LS'f CiiiiUI!.tr posllfon sensor
Rlght·hand lll uJtrallon
Solflng wlth hlc/cr SliSIC
, 16.12-1Qfli.01
Fig. 39: Identifying Crankshaft Position Sensor Remove/Install Components (Eogine 111.977)
Removing,
~~
= installing
Remove cylinder
1.1 ~GF Only engine 104 raO 1001 04c500x
head cover
AR61.20-P-
Remove engine Model 170/ 202/ 208
2 llOSA
compartment panel
AR61.20-P-
Mercedes-Benz
Model210.03/04/05/07/23/24/27 UOSAB
Remove camshaft ~GF Installation : Replace seal (1111)
3 position sensor 1JJ If camshaft position sensor is replaced, it is necessary
(L511) to set the clearance to the camshaft
Length of bolt for
~WF
attaching camshaft BT07.51-P-0002-
Engine 111 .961
posítion sensor OlA
modified
~GF Ro tate crankshaft untíl the camshaft sprocket
segment is opposite the camshaft position sensor (L5/1 ).
Set camshaft
Measure size of gap with feeler gage between camshaft *BE15.10-P-
4 positíon sensor
sprocket segment and camshaft position sensor (LS/1) 1001-04A
(L5/1)
~GF Shims (11/2) are available as replacement parts
in 1/10 graduations from 0.1 -1.0 mm
5
order
TEST DATA POSITIO N SENSOR

Number Desigoation Engine Engine
104 111
BE15.10-P-1001 - Síze of gap between camshaft sprocket segment and
mm 0.5 0.5
04A camshaft position sensor
REPLACING KNOCK SENSOR - AR15.12-P-2183G
ENGINE 104.94 /99, 111.920 /940 /941 /942 (except, 104.990), 111.960/961 up to 30.11.94
Engln. I04
Lelt-hand fig.
1411 Retoi nln¡¡ olomp
Arrow Connccto r
Flight· llond flg.

A28g1 K nociC sensor
A2Ugl Knotll scnsct
P11!12-G!t1741 P11! 1~01
Fig. 40: Identifying Knock Sensor (Engine 104)

Mercedes-Benz
Enalnt~ 111
L~ttt-handtia.
14!1 Rct•l nlng clomp
Arrow Connc cto r
Ria·ht·h"Ond fla.
AfiS Knock sensor
Fig. 41: ldentifving Knock Sensor (Engine 111)

~GF Remove sta11er, install Engine 104 in Model 129 AR15.30-P-7100C
Engine 104, 111 in model AR15.30-P-7 1OOEA
202
Engine 104, 111 in model AR15.30-P-7100F
210
~GF Windshield washer L1f t off, place to the side
reservo ir Model 202 with ENGINE
111
~GF Remove supporting engine 111
bracket of intake
manifold,
A16, A29gl , A29g2 Take off knock sensor open retainíng clamp
connector, ( 14/1) for this step.
[S="GF The cables of the
knock sensors are
combined in a protective
sheath (corrugated
sheath). They can only be
rep1aced as a unit
REMOVE/INST ALL KNOCK SENSORS - AR15.12-P-2184
Removelinstall knock sensors - AR15.12-P-2184A
ENGINE 112.910 in MODEL 202.026 /086
ENGINE 112.920 in MODEL 202.029 /089
ENGINE 112.921 in MODEL 210.063 /081/263 /281
ENGINE 112.922 in MODEL 220.063 /163

Mercedes-Benz
ENGINE 112.940 in MODEL 208.365 /465
ENGINE 112.941 in MODEL 210.065/082/265/282
ENGINE 112.944 in MODEL 220.065/165
ENGINE 113.940 in MODEL 210.070 /270
ENGINE 113.941 in MODEL 220.070 /170
ENGINE 113.960 in MODEL 215.375, 220.075/175
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.944 in MODEL 202.033 /093
ENGINE 113.980 in MODEL 210.074/274
ENGINE 113.943 in MODEL 208.370 /470
ENGINE 112.912 in MODEL 203.061 /261, 209.361 /461
ENGINE 112.946 in MODEL 203.064 /264
ENGINE 112.961 in MODEL 203.065 /265

Mercedes-Benz
ENGINE 113.968 in MODEL 209.375 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070 /270
ENGINE 113.987 in MODEL 209.376 /476
ENGINE 112.955 in MODEL 209.365 /465
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243 /246
ENGINE 112.953 in MODEL 203.084 /284
ENGINE 112.916 in MODEL 203.081 /281
ENGINE 112.972 in MODEL 220.067 /167
ENGINE 112.975 in MODEL 220.087 /187
ENGINE 113.948 in MODEL 220.083 /183
ENGINE 113.966 in MODEL 220.084/184
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082 /282
ENGINE 113.969 in MODEL 211.083/283
ENGINE 113.990 in MODEL 211.076 /276
ENGINE 113.988 in MODEL 203.076 /276
ENGINE 113.993 in MODEL 463.270 /271

Mercedes-Benz
P15 12 0278-11
F i2. 42: Identifyin& Left Knock Sensor 2 - Shown On En2ine 112 In Model 220
~t[j Remove/install
1.1 Remove intake manifold All except model, 463 with AR09.20-P-1310A
engine 113.962/982/993
Model463 with engine
112.945
Model170.466 with engine
112.960
Model203.065/265 with
engine 112.961
Model21 1.076/276 with
engine 113 _990
Model463 with Engine AR09.20-P-1310AG
112.945, 113.962/982
1.2 Remove compressor Model170.466 with AR09.50-P-4705SVK
engine, 112.960 model
203.065/265 with engine,
112.961 model
211.076/276 with engine
113.990
Model463.270/271 with AR09.50-P-4705GX
engine 113.993
2 Detach knock sensor 1, @ *BA15.10-P-1001-02A
right and knock sensor 2,
left (A16/2) from
cylinder block
order
@ Knock sensors
N umber Designation Engine Engine Engine
Mercedes-Benz
112.910/911/ 113.940/941/ 113.989

912/913/914/ 942/943/944/
915/916/917/ 945/946/948/
920/921/922/ 960/961/962/
923/940/941/ 963/964/965/
942/943/944/ 966/967/968/
945/946/9471 969/971/980/
949/951/953/ 981/982/984/
954/955/960/ 986/987/988/
961/970/972/ 990/991/992/
973/975/976 993/995
BA15.10-P- Bolt securing N m 20 20 20
1001-02A knock sensor to
cylinder block
Remove/install knock sensors - AR15.12-P-2184E
ENGINE 119.97
Fig. 43: Locating Knock Sensor Bolts
Fig. 44: Locating Knock Sensor Bolts
'Graphic- ¡work instructions¡

Mercedes-Benz
Item, etc.
Refer to Repaír manual Engíne
~GF
Remove/install
119.960/970/971/972/974/975 Mechaníc II Op-no ..22-
engine support
2500
(GrGF Clutch Detach switching unit
The línes of both knock sensors are joined together in a
~GF Knock sensors protective hose (shaft tube) . They can only be replaced
as one unit
@ *BA15.10-P-
Arrows Bolts
1001-02A
@KNOCK SENSORS
Number Designatioo Engine 112.910/911/912/ 913/914/915/ 916/917/920/ Eogine
921/922/923/ 940/941/942/ 943/944/945/ 946/947/949/ 119,120
951/953/954/ 955/960/961/ 970/972/973/975
Bolt securing
BA15.10-P-
knock sensor to Nm 20 20
1001 -02A
cylinder block
Remove/install knock sensors- AR15.12-P-2184EA
ENGINE 119.9811982/985
lllustrate left knock sensor
Fig. 45: Identifying Knock Sensors Components
Graphic Item, etc Work instructions

~GF Remove/install Refer to Repair manual Engine
engine support 119.960/970/971/972/974/97 5 Mechanic
II Opno. 22-2500
lfSGF Clutch Detach knock sensor
Arrow Bolts *BA15.10-P-1001-
@ 02A
Mercedes-Benz
@ Knock sensors
Number Designation Engine 112.910/911/912/ Engine 119, 120
913/914/915/916/917/920/
921/922/923/940/941/942/
943/944/945/ 946/947/949/
951/953/954/ 955/960/9611
970/972/973/975
BA15.10-P-100 1- Bolt securing N m 20 20
02A knock sensor to
cylinder block
Remove/instaU knock sensors - AR15.12-P-2184F
ENGINE 120.98
Al& Lclt ~nod scnsoo

A30 R~ htAnoc k sanso rs
A19gf Le lt ÁnoeÁ sensor 1
Al&gf t~lt .\noclf .sensor 2
A30gf RIQht knock sensor1
AJOgf RIQ htllnoc k scnso r Z
P111124:Z:»o08
Fig. 46: Identifying Knock Sensors

etc.
AR07.03-P-
Remove fuel Engine 120.980/981
1452F
o:::rGF clistributor with
AR07.03-P-
injection valves Engine 120.982/983
1451F
o:::rGF Remove air cleaner, AR09.10-P-
install 1050F
AR09.20-P-
Engine 120.980/981
Remove/install intake 1310F
o:::rGF
manifold AR09.20-P-
Engine 120.982/983
1310FA
Unbolt
A29gl , @
A29g2_ ~GF Both cahles ( A29_ A10) íoín together on
Mercedes-Benz
A30g l , the left and right the knock sensors in a protective *BA15.10_p_
A30g2 Knock sensors hose (shaft tube) They can only be replaced as one _ A
1001 02
device
@KNOCK SENSORS
Number Designation Engine 112.910/911/912/ 913/914/915/ 916/917/920/ Engine
921/922/923/ 940/941/942/943/944/945/ 946/947/949/ 119, 120
951/953/954/ 955/960/9611 970/972/973/975
Bolt securing
BA1 5.10-P-
knock sensor to N m 20 20
1001-02A
cylinder block
SERVICING WIRING HARNESS - AR15.18-P-OSOOA
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 208, 210, 215, 220
82 Cable c onnectron o·f mass alrnowsens or

811 Cabt. eonnf!clion of romporstuf& soiiSor
z r .,mtnaJ block
Fig. 47: Identifving Cable Connection Of Mass Air Flow Sensor And Terminal Block
~GF If a cable break or similar damage exists in the area of the p lug connection of the mass air flow sensor
(B2) or temperature sensor (B 11), it is possible to repair the wiring harness in order to avoid costly replacement
of a wiring harness.
Modification notes
27.9.99 Supersedes SI 54/76 Remove SI 54/76 from
dated 23.1.96 your file.
w~ Removing and installing

1 Remove air cleaner, n:::?GF Only on engine
install. 11 9
2 Expose wiring harness to ITJ Ignition switched off
mass air flow sensor or
Mercedes-Benz
temperature sensor.
3 Unplug socket from mass
air :flow sensor or
temperature sensor.
4 Plug in repair socket
together wíth cables at
mass air :flow sensor or
temperature sensor and
ínsert into cable duct.
5 Repair wíríng hamess ~GF Tum together AR54.18-P-0 100-02A
using end soldering cable of engine wiring
sleeves (Z). hamess and cable repair
socket of the same color
and insert into end
soldered sleeves (Z).
~GF Use end soldered
sleeves (Z)only in cross
sectíon area 0 0.7- 0 4.0
mm2
6 Insert cables into the
cable duct.
7 Connect HHT, read faults ~GF see Diagnosis
and erase Manual Engine Volume 2
Index 0: Connecting and
using test equipment
order
p arts ord enng

. no t es
Part no. Designation Quantity
140 540 00 36 Repair kit socket (B2) 1 acc. to condition
1) Consisting ofrepair socket (B2)
and 5 cable connectors
140 540 00 81 Repair socket (B2) acc. to condition
202 540 01 81 Repair socket (B 11) 3-pin acc. to condition
126 540 30 81 Repair socket (B 11) 4-pin acc. to condition
001 546 99 41 Cable connector acc. to condition
006 989 84 85 Fabríc tape acc. to condítion
REMOVING AND INSTALLING STARTER- AR15.30-P-7100
Removing and installing star ter- AR15.30-P-7100C

Mercedes-Benz
1 Elce ll'le e~l>lc cl reuft JO

Eloc trlr: c~blo ci rcuir 5I)
s erc•ws
181 St•t lor
P15_lQ-205H III
Fig. 48: Identifving Starter R emove/lnstall Components
~' Removing, installing

~
Risk of explosion from explosive gas. Risk of No ftre, sparks, naked flames or
poisoning and caustic burns from swallowing smoking. Wear acid-protective gloves,
AS54.10-Z-
~ battery electrolyte. Risk of injury from caustic clothing and eye protection. Pour
0001-01A
burns to eyes and skin from battery electrolyte battery electrolyte only into suítable
or from handling damaged! lead acid batteries. and appropriately marked containers.
ITl lnsulate cable lug of ground cable as
a protection against unintentional AR54.10-P-
1 Disconnect ground cable ofbattery
contact of the disconnected ground 0003A
cable with the ground point Wl O.
[[] Notes on battery AH54.10-P-
All models
0001-01A
AR61.20-P-
2 Remove bottom engine compartment panel
1105AB
*BA15.30-
@ Nut of connection circuit 30
P-1001-01A
3 Disconnect electric cables (1 , 2)
*BA15.30-
® Nut of connection circuit 50 P-1002-0IA
4 Unscrew screws (3) @ Bolt of starter *RA15.30-
Mercedes-Benz
P-1003-01A
5 'fake starter (Ml) down and out
7 Carry out operational check
AR00.19-P-
8 Render electrical system operational [!?'GF Perfom1 basic progranmring.
0200A
@sTARTER
Number Designation Engine 103, 104, 111, 120
BA15.30-P-l001-01A Nut of connection of circuit 30 Nm 14
BA15.30-P-1002-01A N ut of connection of circuit 50 Nm6
BA15.30-P-l 003-0lA Bolt of starter N m 42
Remove starter, instaU- AR15.30-P-7100CS
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070 /270
Shown on engine 112
1 Eloelrle ••t>lc elreult J()

E1oelrle •~blo elreult !SO
Bolts
4 Nuts
MI S t orter
PIS l0·200HIB
Mercedes-Benz
Fig. 49: Identifying Starter Remove/Install Components (Engine 112)
MODIFICATION NOTES
13.9.03 !check ring gear, newly recorded lstage 7 1 1
~
~ Remove/lnstall
Align vehicle between the ~~lumns of
the hydraulic hoist and pos1t1on the four
.&.Risk of deatb case~ b.y vehicle slipping or
support plates below the h~ist support
ASOO.OO-Z-
· toppling off of the hftmg platform. 0010-01A
points specífied by the veh1cle
manufacturer.
Risk of explosion caused by ~xplosive gas.No frre, sparks, open flames or sr.noking.
Risk of poisoning and caust1c bur~s causedWear acid-resistant gloves, clothing and AS54.10-Z-
.&. by swallowing battery electr~lyte. Risk ofglasses. Pour battery elec.trolyte only OOOl-OlA
· mjury caused by burns to skm and eyes frominto suitable and appropnately marked
battery acíd or when handling damaged lead- containers.
acid batteries
AHOO.OO-N-
[JJ Notes on self-locking nuts and bolts
0001-0lA
[!irGF Insulate ground line as a
Disconnect ground cable from battery protection against unint~ntio~al contact
of dismounted ground hne w1th ground
point ofbattery.
AR54.10-P-
1 Model129
0003A
AR54.10-P-
Model211.0
0003T
AR54.10-P-
Model211.2
0003TA
AH54.10-P-
[[] Notes on battery
0001-0lA
AR61.20-P-
Model129
1105AB
2 Detach lower engine compartrnent paneling
AR61.20-P-
Model211
1105T
*BA15.30-
@ Nut of terminal 30 connection P-1001-01A
3 Dismount electricallines (1 , 2)
*BA15.30-
@ Nut of connectíon circuít 50 P-1002-01A
[!irGF Unscrew bolt at engine mount,
lightly raise engine and place engine
Dismount right engine mount from engine
41 mount to the side.
· support
Model 211.270
Mercedes-Benz
AR22.10-P-
Model 211.070
llOOPV
@ *BA15.30-
5 Unscrew bolts (3)
P-1003-01A
6 Take out starter (Ml) to the síde
When replacing the starter on vehicles
Check ring gear at flywheel for wear and fitted with manual transmission
7.1
damage [S="'GF Rota te engine at the crankshaft
in direction of rotation.
When replacing the starter on vehicles
Check ring gear on the drive plate for wear fitted with automatic transrnission
7.2
and damage [!irGF Rotate engine at the crankshaft
in direction of rotation.
9 Perform function check
See?
AR00.19-P-
Modell29
10 Render electrical system operatjonal 0200A
AROO.l9-P-
Model211
0200T
[S="'GF When the work is complete
Read diagnostic trouble code memory and stored faults must be worked on in the
11
erase diagnostic trouble code memories and
erased.?
[Z] Connect STAR DIAGNOSIS, read out ADOO.OO-P-
fauJt memory 2000-04A
@sTARTER
Number Designation Eogine 112 except 112.951, 113.94/96/98
BA15.30-P-1001-01A Nut of connection of circuit 30 Nm 14
BA 15.30-P-1002-01A Nut of connection circuit 50 Nm6
BA15.30-P-1 003-0lA Bolt of starter to crankcase N m 42
Removing and installing starter·- AR15.30-P-7100EC
ENGINE 119.972 /982 in MODEL 129.067
ENGINE 120.981 /983 in MODEL 129.076
Shown on engine 119

Mercedes-Benz
1 Ero«tic: '~1>/c clteult Jo

2 Erc,ttll: uolo ''"ulr 50
l Sc:rcws
4 BfiXht
5 $p~CCI$
Spl~ll ~ter gu~rrl
Sl'llotd
Scrcws
Nut
Jl11!!1),~
Fig. 50: ldentifving Starter Remove/lnstall Components (Engine 119)
MODIFICATION NOTES
Figure modified from 16 Nm Figure inBA15.30-P-1001-0lA for engine *BA15.30-P-1001-
6.7.00
to 14 Nm 112, 113 modified OlA
Figure modified from 1O N m Figure in BA15.30-P- 1002-01A for engine *BA15.30-P-1002-
6.7.00
to6Nm 112, 113 modified OlA
Figure modified from 58 Nm Figure in BA15.30-P-1003-01A for engine *BA15.30-P-1003-
6.7.00
to42 Nm 112, 113 modified OlA
Figure modified from 42 Nm Figure in BA 15.30-P-1003-01A for engine 119 *BA15.30-P-1003-
6.7.00
to 58 Nm modified OlA
~~ Removing, installing
& Risk of explosion from No fue, sparks, naked AS54.10-Z-0001-0IA
explosive gas. Risk of flames or smoking. Wear
poisoning and caustic acid-resistant gloves,
burns from swallowing clothing and glasses. Pour
battery electrolyte. Risk of battery electrolyte only
injury from caustic burns into suitable and
to eyes and skín from appropriately marked
battery electrolyte or from containers.
handling damaged lead
acid batteries.
l Disconnect ground cable IIl Insulate cable lug of AR54.10-P-0003A
ofbattery ground cable to provide
protection from
unintentional contact
between disconnected
ground cable and ground
Mercedes-Benz
point WIO
OJ Notes on battery All models AH54.10-P-0001-0lA
2 Turn steering to full left Engine 120
lock
3 Remove bottom engine AR61.20-P-1105AB
compartment panel
4 Take off shield of right
pitman arm
5 Detach stiffener strut at
front right
6. 1 Unscrew bolts (8) and nut Engine 119
(9) and take out shield (7)
6.2 Remove shield at starter Engine 120
7 Remove bracket (4) Engine 119
8 Disconnect electric cables @ *BA15.30-P-1001-01A
(1/2) @ *BA15.30-P-1002-01A
9 Unscrew screws (3) @ *BA15.30-P-1003-01A
n:::!f"'GF Installation :
Connect ground lead.
10 Take starter (MI) down ~GF Installation: On
and out engine 119, ensure splash
water guar d (6) is
correctly positioned
(arrows) and spacer(s) (S)
are cor rectly installed in
the correct quantity .
12 Carry out operatíonal
check
13 Render electrical system ~GF Perform basic AR00.19-P-0200A
operational programrmng
@ ST ARTER
Number Designation Engine 103, 104, 111, 120 E ngine 119
BA15.30-P-1001-01A N ut of connection circuit 30 Nm 14 14
BA15.30-P-1002-01A Nut of connection of circuit 50 Nm6 6
BA15.30-P-1003-01A Bolt of starter to crankcase N m 42 58
PREREQUISITES FOR TESTING ALTERNATOR- AR15.40-P-5009C
ENGINE 103, 104, 112, 113, 119, 120 in MODE L 129
Connection schematic between battery and altero ato r

Mercedes-Benz
C2 Altornotortb.Jtrory l no o/oc rrolyrlc

c~dtot ;ntJJrfCf·cn.c.o supJNassion
Gl 8ilfte(y
Gl Alromotot
ll~'! --,
M7 St~rtcr
W10 GroiJnd (b• rtor»

l. ._j
W!6/Z Ground (componcnt comport moniJ
!lí4fl Connocro r tctmlnal J W
lnrorfor
!lí4Jl 0 Connocror rcrmJna/ JO. 6-p/n
bt brown
/)/ block
rd red
P1 S &0·2055-0íi
Fig. 51: Schematic Diagram Between Battery And Alternator
~GF Model129 with engine 119 up to Vehicle Ident. End No. 1F 032 589:
In the event ofproblems with the power supply, check battery voltage-dependent load swap (see engine
diagnostic manual volume 2 group 07 .3).
~ @:1 Removing, installing

Remo ve battery cover on right-hand
1
side in trunk
6.oanQert Testing
• Battery (G1/+)
• Connector terminal 30 (X4/ 1O)
• Connector terminal 30 (X4/ 1)
Check electrical line terminal 30 to
2 the following items for firm seat and • Altemator ( G2/B+)
flawless condition • Starter (Mll+)
• Alternator/battery ground electrolytic
capacitor interference suppression
(C2/+)
• Battery (G 1/-)
• Battery ground (WlO)
Check electricalline terminal 31 to
3 the following items for frrm seat and • Major assemblies compartment
flawless condition ground (W16/2)
• Ground strap between engine and
body
4 Check ribbed V-belt tension
Mercedes-Benz
Check function of the cbarge

*BES4.30-P-
5 indicator lamp in the instrument
1001-0lA
cluster
TEST V ALUES FOR ALTERNATOR CHARGE INDICATOR LAMP

Number Designation Model129,163,168,170,202,
203,208,210
Charge indicator
0/ 1
BE54.30-P-1001- Position of ignition 1 glow lamp Off
OlA start switch Charge indicator
2
lamp On
CHECKING REGULATION VOLTAGE OF ALTERNATOR- AR15.40-P-5010C
ENGINES 103, 104, 112, 113, 119, 120 in MODEL 129
Connection diagram
0111 el Vo/r ampero IDJtor

&> Cllarglng curronr conneclton
G1 Bottcty
C2 aliD motD r
M1 Srar!Dr
W10 Ground (bott.wy)
W10
l
1 ·---~
G1 G2
P1H0·2HHIII
Fig. 52: Checking Regulation Voltage Of Alternator
&oanQerl Checking
~GF Assess results, replace AR54.10-P-
1 Check condition of battery (G 1)
battery if required. G 1 1129Z
Check whether preconditions for alternator AR15.40-P-
2
testing have been fulfilled 5009C
DJ V olt ampere tester with load *WH58.30-
3 resistance Z-1002-09A
Attach volt amnere tester (079) accorciin!! to
Mercedes-Benz
connection plan OJ Volt ampere tester ETT *WH58.30-

011.00 Z-1003-09A
Risk of accident caused by vebicle starting off Secure vehicle to prevent it from
by itselfwhen engine is running. Risk ofinjury moving by itself.
ASOO.OO-Z-
.&. caused by contusions and burns during starting W ear elo sed and snug-fitting
0005-0lA
procedure or when working near tbe running work clothes.
engme Do not grasp hot or rotating parts.
4 Start engine
Check function of charge indicator lamp when
IJ:!?GF Charge indicator lamp
5 engine is idling and with increasing engine
must extinguish.
speed (up to 3000 rpm)
*BE15.40-P-
1001-02A
OJ Volt ampere tester with load *WH58.30-
resistance Z-1002-09A
OJ Volt ampere tester ETT
011.00 *WH58.30-
IJ:!?GF Regulation voltage > Z-1003-09A
15.0 V:?
• Replace regulator
IJ:!?GFRegulation voltage
< 13.0V:?
• Check electrical AR15.40-P-

connections for charging 5760CS
Load battery (G 1) using a permanent consumer system for transition
6 resistances; repair if
and check regulation voltage of altemator (G2)
necessary.
Electrical connections OK: ?

• Check alternator (G2) AR15.40-P-
diodes 9301-02EA
Engine tester with oscilloscope
If diodes are faulty: ? *WH58.30-
Z-1046-13A
• Replace alternator (G2)
AR15.40-P-
Engines 103, 104
5032CA
AR15.40-P-
Engines 112, 113
5032CT
AR15.40-P-
Engines 119, 120
5032CS
Mercedes-Benz
7 Tum off engine

ITl V olt ampere tester with load *WH58.30-
8 Disconnect volt ampere tester (079)
w Volt ampere tester ETT *WH58.30-
011.00 Z-1003-09A
CHECKVALUESFORREGULATOR
Number Designa tio u Eugines 103, 104, 111, 112, 113,
119, 120, 137,155, 166,275
Debit: only on
V 13 to 15
BE15.40-P- Regulating voltage permanent consumer
1001-02A ( at battery) Engine speed rpm 3000
Measured after mm approx. 2
CO~RCMLLYAV~ABLETOOLS
Number Designation
WH58.30-Z-l 002-09A Volt-amp(s) tester with load resistance (no longer available)
WH58.30-Z-l 003-09A Volt ampere tester
WH58.30-Z-l 046-13A Engine tester with oscílloscope
TESTING ALTERNATOR CHARGING CURRENT- AR15.40-P-5011C
ENGINES 103, 104, 112, 113, 119, 120 in MODEL 129
Connection diagram
08$ m Currant mctJ.suramcnt plicrs

01(1 m Volf Amp(s) fCSfw
&> Ch•rginJI curront connoct/Dn
G1 811ttcty
G1 Alfcrnoror
MI Sr•rhlr
W1D Ground (b• tter~
0$5
W10
G1 .,
l
P15 '0·Zl'Hiei
Fig. 53: Testing Alternator Charging Current

Mercedes-Benz
&oanacr! Checking
Risk of explosion caused by oxyhydrogen
N o fire, sparks, open :flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant gloves,
caused by swallowing battery acid. Risk of AS54.10-Z-
& injury caused by burns to skin and eyes from
clothíng and goggles. Only pour
0001-0IA
battery acíd into suitable and
battery acid or when handling damaged lead-
appropriately marked containers.
acid batteries
[JJ AH54.10-P-
Notes on battery
0001-01A
Check whether the preconditions for AR15.40-P-
1
alternator checking have been fulfilled 5009C
AR15.40-P-
2 Test regulation voltage of alternator (G2)
SOl OC
Connect up Volt amp(s) tester (079) wíth
current clamp (065) according to connecting ITJ Volt amp(s) tester with load
*WH58.30-
3
diagrarn
*WH58.30-
ITJ Volt amp(s) tester ETT 011.00 Z-1003-09A
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
ASOO.OO-Z-
& injury caused by contusions and burns Wear closed and snug-fitting work
0005-0lA
during starting procedure or when working clothes.
near the running engine Do not grasp hot or rotating parts.
4 Start engine
~GF Vary load resistance long
Load battery (Gl) with the volt amp(s) tester enough until the maximum load
5 (079) and check alternator charging current current is achieved; when this is
(G2) ata high engine speed done, the regulating voltage must not
drop below 12.7 V.
*BE15.40-P-
Engine 112, 113
1001-01K
*BE15.40-P-
Engines 103, 104, 119, 120
1001-01B
ITJ Volt amp(s) tester with load *WH58.30-
*WH58.30-
OJ Volt amp(s) tester ETT 011.00 Z-1003-09A
~GF Charging current below
desired value: ?
AR15.40-P-
• Check altemator diodes (G2) 9301-02EA
*WH58.30-
Engine tester with oscilloscope
Z-1046-13A
~GF In case of defective
diodes:?
Mercedes-Benz
• Replace altemator
AR15.40-P-
Engines 103, 104
5032CA
AR15.40-P-
Engines 112, 113
5032CT
AR15.40-P-
Engines 119, 120
5032CS
6 Tum off engine
7
Disconnect volt amp(s) tester (079) using a DJ Volt amp(s) tester with load *WH58.30-
current clamp (065) resistance Z-1002-09A
*WH58.30-
DJ Volt amp(s) tester ETT 011.00 Z-1003-09A
TEST V ALUES FOR ALTERNATOR

Number Designation Engine 103.984 up to 09/91 Engine 103.984 from
Nl --> 14 V 36/100 A 10/91 NC 14 V 60/110 A
A 100 110
BE15.40-P- Alternator Engine
rpm 2250 2250
1001-0lB charge current speed
Ratio I= 2.82 2.82

Number Designation Engine 104.943 NC Engine 104.981 up to 09/91
14 V 60/110 A Nl --> 14 V 36/100 A
A 110 lOO
BE15.40-P- Altemator charge Engine
rpm 2200 2200
1001-0 lB current speed
Ratio I= 2.93 2.93

Number Designation Engine 104.981 from 10/91 Engine 104.991 NC 14
NC 14 V 60/110 A V 60/110 A
A 110 110
BE15.40-P- Alternator charge Engine
rpm 2250 2200
1001-0IB current speed
Ratio I= 2.82 2.93
TESTVALUESFORALTERNATOR
Number Designation Engine 119.960 N1 -- Engine 119.972 6-grooved belt
> 14 V 36/100 A drive NC14 V 60/110 A
A 100 110
1001 -0lB current speed rpm 2200 1950
Mercedes-Benz
Ratio 1=12.93 13.26

Number Designation Engine 119.972 8-grooved belt Engine 120.981
drive NC14 V 60/110 A NC14 V 60/110 A
A 110 110
rpm 1950 1950
1001-0lB current speed
Ratio I= 2.93 3.26

N umber Designation Engine 112 in model Engioe 113 in models
129 Bosch 129, 202 Bosch
max. A 11 5 150
mm A 90 120
BE15.40-P- Altemator charge
1001 -0lK Engine
current rpm 2000 2000
speed
Ratio I= 2.93 2.93
CO~UMERCMLLYAVMLABLETOOLS
Number Designation
WH5 8.30-Z-1002-09A Volt-amp(s) tester with load resistance (no longer available)
WH58.30-Z-l 003-09A V olt ampere tester
WH58.30-Z-1046- 13A Engine tester with oscilloscope
REMOVING AND INSTALLING GENERATOR- AR15.40-P-5032
Removing and iustalling generator - AR15.40-P-5032CA
Shown on engine 104

Mercedes-Benz
1 Elcctrlt ~ •blo, cir~ulr JO (S•)

2 Efccttc c1blo, circuir 61 (D•J
J Sctows
ti Protcctlon ~~fnst ~ct:irlcntJicon~t
c;z c;onorator
P1UO-ll20iHI6
Fig. 54: Identifying Generator Remove/Install Compooents (Engine 104)
~' Removing, installiog

~
1 Disconnect ground cable of battery AR54.10-P-0003A
Slacken poly V-be lt and take it off at
2 Engíne 103 ral 3001033420x
generator
Engine 104 ra 13001 041200x
Engines 103, 104 in model
3 Remove bottom engine compartment panel AR61.20-P-1105AB
129
Remove protection against accidental contact
4
(4)
*BA15.40-P-1001-
5 Disconnect electric cables (1 , 2) @ Nut at circuit B+ OlA
*BA15.40-P-1002-
® Nut at circuit D+ OlA
@ *BA15.40-P-1003-
6 Unscrew screws (3)
OlA
7 Remove generator (G2) downwards
@GENERATOR
Number Designation Engine 103 Engine 104
BA15 .40-P-1 001-0 lA Nut of circuit B+ to generator N m 15 15
BA1 5 .40-P-1 002-0 lA N ut of circuit D+ to generator Nm4 4
BA15 .40-P-1 003-0 lA Bolt of generator N m 42 42
Mercedes-Benz
Shown on engine 119 with bowl-type generator
1 Etoctrlc c.tl>/o c/rcuft 30 (& )

2 E lec trie cal>lo clrcuft U (Oo)
1 Poli V-l>oltputloy
4 Bolts
5 Solts
6 BowHypo ¡¡cnor•tor
7 Compact gonor•tor
P1 5 • 0-20 1'-06
Fig. 55: ldentifying Generator Remove/lnstall Components (119 With Bowl-Type Generator)
~'
t[j Removing, installing
1 Disconnect ground cable at battery AR54.10-P-0003A

2.1 Release pressure from cooling system Engine 120
3 Remove bottom engine compartment panel AR61.20-P-1105AB
Engine 119 with bowl-type
4.1 Remove viscous fan clutch ra2000 1193120x
generator
*BA15.40-P-1001-
5 Disconnect electric cables ( 1, 2) @ Circuit 30
OlA
*BA15.40-P-1002-
@ Circuit 61
OlA
6 Remove poly V-belt ral3001193420x
Engine 120
Detach connecting rod at lever of level
7.1
controller
DJ lnstallation : replace self-
locking bolt
8.1 Unscrew bolts attaching the ATF line Engine 120
Engine 119 with bowl-type
9.1 Remo ve poly V-belt pulley (3) AR15.40-P-5710CS
generator
~GF Fig,. 56
Engine 119, 120 with compact
Remove spring leaf rockers of the left and
9.2 runerator
right torsion bar
Tn stallation : renlace self-
Mercedes-Benz
locking bolt
@ *BA15.40-P-1003-
10 Unscrew bolts (5) of the generator
OlA
Engine 119 w ith bowl-type
11.1 Lift bowl-type generator (6) up and out
generator
Engine 119, 120 with compact
11.2 Take out compact generator (7) downward
generator
@GENERATOR
BA15.40-P-1 001-0lA Nut of circuit B+ to generator Nm 15 15
BA15 .40-P-1 002-0 lA Nut of circuit D+ to generator Nm4 4
BA15.40-P-1003-01A Bolt of generator N m 42 42
126 589 00 40 00
Holder
Fig. 56: ldentifving Holder (126 589 00 40 00)
Remove aod install generator - AR15.40-P-5032CT
Shown on ENGINE 112

Mercedes-Benz
J!'c rmlml :#J N l>lc ¡B+)

2 "l'o rmln~ / 61 c•l>lc (D•)
J ao1rs
4 Covot sloc vo
c;z Gcnu.. ror
P1 5 •O-lOOHlil
Fig. 57: ldentifving Generator Remove/Install Components (Engine 112) (1 Of 2)
5 fnr•l<• pipe
6 F~n shroud
7 F in WIIOO I
P1 5 •il-l0 33-e•
Fig. 58: ldentifving Generator Remove/lnstall Cornponents (Engine 112) (2 Of 2)
MODIFICATION NOTES
Specification revised from 15 Specification in BA15.40-P-1001-01 A revised *BA15.40-P-
14.4_00
Nmto 18Nm for Series 112, 113 engines 1001-0lA
Value changed from 4 N m to Figure in BA15.40-P-1001-02A for engine 112, *BA15.40-P-
14.4_00
5Nm 113 modified 1002-0lA
~ ~
t:[J RemovaUinstallation
1JJ Insulate cable terminal of ground lead to AR54.10-P-
1 Disconnect battery ground line prevent unintentional contact between the
0003A
disconnected ground lead and ground point Wl6/4
2 Remove intake pipe (5)
3 Remove fan shroud ( 6)
n:::rGF Unbolt fan wheel from the viscous fan AR20.40-P-
4 Remove fan wheel (7)
clutch 5660C
Mercedes-Benz
AR13.22-P-
5 Slacken poly V -belt
1202B
Take off cover sleeve (4) and (GrGF
6
discollllect electric cables (1/2)
@ *BA15.40-P-
1001-01A
@ *BA15.40-P-
1002-0lA
@ *BA15.40-P-
7 Unscrew altemator screws (3)
1003-0lA
8 Take out generator (G2)
9 lnstall in the reverse sequence
10 Perform operational check
@GENERATOR
Number Designation Engine 112.91/92/94/ 953/954/955/96/97,
113.94/96/98
BA15 .40-P-1 001- Nut of circuit B+ to
N m 18
OlA generator
BA15.40-P-1002- Nut of circuit D+ to
Nm 5
OlA generator
BA15.40-P-1003-
Screw, alternator N m 42
OlA
REMOVE/INSTALL GENERATOR PULLEYS- AR15.40-P-5710
Removing and installing the generator poly-V-pulley- AR15.40-P-5710CS
ENGINES 103, 104, 119, 120 in MODEL 129
Sbown on pot generator

Mercedes-Benz
Coll•t<Jd nut
2 Sp~ts
1 ,.oly-V-puloy
4 Support 11/sl!
5 F •n wnccl
lnt•it• • lt hose
P15 <0-l01HI6
Fig. 59: ldentifving Generator Poly-V-Pulley Remove/Install Components (Pot Generator)
Sbown on compact generator
1 Coll•rfJd nut
1 ,.0/y-VjJUiey
6 Sh•rt
P15•o-2o u-n
Fig. 60: Identifying Generator Poly-V-PuUey Remove/l nstaU Components (Compact Generator)
~~ Removing, installing
Retrofit smaller poly-V -pulley and aluminum AN15.40-P-
~AN
fan wheel 5700CS
1 Disconnect ground cable of battery ARS4.10-P-0003A
2 Remo ve poly-V -belt ral300 1193420x
Engine 104 wíth compact AR61.20-P-
3.1 Remove engine compartment paneling
generator. I I OSAB
Engines 119, 120 with pot
3.2 Remove aspirator hose (8)
generator.
RnQ'ines 119. 120 with AR 15.40-P-
1 Mercedes-Benz
1
3.3 Remove generator compact generator. 5032CS

4 Unscrew collared nut ( 1) rr::rGF Counterhold shaft.
@ *BA15.40-P-1004-
OlA
n:::r-GF Fig. 56
rr::rGF Fig. 62
Remove spacer washers (2), poly-V-pulley Engines 119, 120 with pot
5.1
(3), support disk (4) and fan wheel (5) generator.
E ngines 104, 119, 120 with
5.2 Remove poly-V-pulley (3)
compact generator.
@GENERATOR
Number Designation Engine 103 Engine 104 Engine 119 Engine 120
BA15.40-P-1004-01 A Collar nut to poly V-pulley N m 80 80 80 80
/
'
~>;:f
126 §89 00 4.0 00
'- Bllltt:BI
/
Fig. 61: ldentifving Bracket (126 589 00 40 00)
' ~
'
~~
~
\.. 000 589 10 99 01

/
Torqlll WfBIJICI!
Fig. 62: Identifving Torgue Wrench (000 589 10 99 01)
RemovelinstaU generator belt pulley - AR15.40-P-5710GF
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
ENGINE 166.940/960 in MODEL 168
ENGINE 112.923 /943, 113.961 in MODEL 129

Mercedes-Benz
1 Collar IIU!
2 Alternaror shaft
J Poly-V-pt~ll&y
p ¡§_¿OeQ2:Q1.06
Fig. 63: Identifying Generator Belt Pulley Remove/Install Components
F ig. 64: Identüving Double Hexagon Wrench
~tm Remove/Install
1 Remove altemator Engine 112, 113 in AR15.40-P-5032CT
Modell29 _
Engine 166_940 /960 in AR15AO-P-5032GF
Model168_
Engine 111, 112, 113 in AR15AO-P-5032GH
mode1163_
2 Unscrew collar nut ( 1) ~GFToho1d
generator shaft (2), insert
screwdriver bit through
doub1e hexagon wrench
Mercedes-Benz
(4).
~AP Shorten double hexagon ~GF Modell63 only WF58.50-P-1540-0ll
wrench to remove the belt ~GF Engines 111,
pulley 112, 113:?
@ *BA15.40-P-1004-01A
~GF Engine 166: ?
® *BA15.40-P-1003-01B
3 Remove ribbed V -belt ~GF When replacing
pulley (3) generators after mileages
in excess of
100.000 km
simultaneously also
re place the poly-V-belt
pulley (3).
@GENERATOR
Number Designatioo Engine 166.940/960
BA15.40-P-1003-01B Collar nut to poly V-belt N m 80
puJley
@GENERATOR
Number Designation Engine 111 Engine 112.91/92/94/
953/954/955/ 96/97'
113.94/96/98
BA15.40-P-l 004- Collar nut to poly N m 80 80
OlA V-belt pulley
REMOVING AND INSTALLING REGULATOR OF GENERATOR- AR15.40-P-5760CS
ENGINE 103, 104, 119, 120, 112, 113 in MODEL 129
lllustration shows bowl-type generator

Mercedes-Benz
Fi2. 65: ldentifvin2 Re2ulator Of Generator Remove/lnstall Components (Bowl-Tvpe Generator)
DJustration shows compact generator
1 Bolts
Rcgu~ror
Elcc trie tilblcs.
4 Covor
5 Botts
e Rct•fntng /ugs
G2 Gcncr•ror
Fig. 66: ldentifving Regulator Of Generator Remove/lnstall Components (Compact Generator)
~ ~
llij Removing, installing

Disconnect ground cable at AR54.10-P-
1
battery 0003A
2.1 Unscrew bolts (5) Compact generator
Compact generator
3.1 Unclíp cover
~GF Press retaíníng lugs (6) apart
4 Unscrew bolts ( 1, 7)
OJ lnstallation : pay attention to installatíon position
of regulator (2, 8)
Take out regulator (2) to the
5.1 Compact generator
sí de
Tilt regulator (8) forward and
5.2 Bowl-type generato1·
take out
Mercedes-Benz
16 lrnstall in the reverse order
TEST DIODES OF GENERATOR- AR15.40-P-9301-02EA
eommerc1a·uty ava1'l a ble t001S

Number Designation
WH5 8.30-Z- l 046-13 A Engine tester with oscilloscope
OJO Enginotostf!rwllh osciloseope

085 O. c. clamp
C2 ElMitO!ytic CJJPlldtor (altomatotl
battel)' ham•os n<>i$• supprass""
G1 Sóiltal)'
G2 O.ne.ator
M1 Stllllor
W10 Oround (batt~)
WIM M~or IISSMJb/les competmelll
ground (t>Jeevolytfe C8pllcltor, noi$8
suppmsslon gonoratotlbattery 1/ne
X4/1 Tttmlnal bloel! (cb'eulr .'JO
, lrtlotlo"
X4110 TttmlfYI bloel< (clrcull
30/300r81ai371.J (8-pln)
ti sr......
tf Rad
&W S lee/e
Fig. 67: Generator Connection Diagram - Model129
n:!rGF Modell29 with engine 119 up to vehicle ident end no. IF 032 589: ProbJems with power supply
system - test battery voltage-dependent idle speed increase (refer to Diagnosis Manual Engine Volume 2 Group
07.3).
Mercedes-Benz
030
045
Engfiletosler wllh oscllosccpe
D. c. clamp
.-
·- ·- __ ..., Wl•
r----;====fJI;::::* 1__...,._
G1 8altOI)' · -¡¡.:..1
G2 Genentor
~¡rn-oiio b~ml
~36 Vdd lor ongines 1121113
Wl$14 Gtound(oulpuf gtOund · rnajor
assemb/les compartmenl · t/gh!/
r• .,
11 Red ! 1
sw Bl•clt 1
1 :
-
.1.._ __ .
P IS.<O 2000.06
030 Engne toslet wllh osclloac<>pe

065 D.c.clamp
45 Fuse45
F1 Fuse all(f reJay box
G1 B•trory
G1 Generstor
WIO Ground {batrery)
X4 Ternlnal blod< drcuit 30, tuse and
br
r&Jay b oxAnterlor, 2·pin
Brown []]liJII)
rl Red o.--- · """""1
SW Bt.ek
i
¡
i
i
!.1
i
P 15.40 206'l06

Mercedes-Benz
030
0116
En{lltto t estor wllh osclloscol'o
O.:. eiM>p
...
45
P1
Gt
Fose 46
Fase .ndreloy box
BoltMy
.lA~·-¡ l.-.~-
G2 Generelor
1 • •
·-· .J
WIO Ground, baltO/y contar como/o
(Interior) e--•
br
ti
Brown
Red •• [I]liJII]
sw Bt.ok Do._ ._
i
i
i
i
loa
1
!
Fig. 70: Generator Connection Diagram- Model414
030 Enfine toslorwlúr osclloscol'•

066 O.c. eiMnp
1 FUS4 1 (llllorn.lortormlna/ 30)
;
F31
G1
G2
K!5
MI
U160
Battory fusebox
Battory
Generelor
Crosh shut..off rel~ (go,...,atorl
baltMjiJ
Startsr
Va/Id ror •rv•ne n 2
- •1
US39 Va!Jd for ervlne 111 ME-SFI

Wl6 Ground(compotttnr compM1111<111Q
X<C/10 Tonni uJI block (cireulr 30 0t1d
clrcull81alb•ttof)'t fli>/111
SW 8/ack
PIS-"(1,2089~6

Mercedes-Benz
oso Etlgne teSierwilh oscllosc<>p-e

065 D.::. clamp
en Bartery
G2 Generator
MI Starter
U549 Valld for d excop f Mlf2
WIO Grcund (batteryJ
X4 Temlinal block (circuir 30, lofl
fo-otwel}
X1V3 Tem>lnal block e/ ro .JI 3Co'15
unfus.d, 3-p/n
rl Red
sw Bt.ck
PIS ..o 2089.08
Fig. 72: Geuerator Connection Diagram- Model 202
030
065
Erlgne tesrerwilh osclloscope
D.c. ecJamp
.-
G1 Bettery
G2 Generstor
M1 Starll!r
U5-A9
WIO
Valld l ord oxcop f Mlf2
Grcund (barteryJ [JJIIIIIJ
X4 Tonninal block (circuir 30, l efl
footwel)
X1113 Tem>lnal block (circuir 30)
rl Red
sw Black
P 15..40 2089 08
Fig. 73: Generator Connection Diagram - Model 208
n=:r-GF Model210: as of 1.6.99 a fuse for protection of generator is located in the terminal block circuit 30
(Xl2/3).
Mercedes-Benz
OJO Enfine test« w/th asüloscopce

0&5 D.c. clitmp
G1 Battery
G2 Genetstor
1.193 Valld lor ln./ble q lnas
W'IO Grocmd (batteryJ
)(,f Tem,.,al block (circuir .JO. Ioft
ft>otwoiJ
tl Red
5W Black
PIS,.<O '1!J71 08
l. Connect DC clip-on probe (065) from engine tester with oscilloscope (030) to positive pole of battery
(GI)
2. Start engine.
3. Switch on low beam.
4. Assess diode harmonics at 3000 rpm (engine speed).
o:::rGF In this test it is not possible to assess the exciter diodes.
PI 5.411.0002.01
HamJonics i f anegative dode isdefective

(example).
Fig. 75: Tdentifving Rarmonics- Negative Diode Defective

Mercedes-Benz
P 15AUl003 01
Harm onfcs N a positive dl Oide Js de!ectlve

(example).
Fig. 76: Identifying Harmonics - Positive Diode Defective
OJode hamJonfc s OK (voltage splkes

posslble but no t importanc) (example) .
F ig. 77: ldentifving Diode Harmonics OK
MAII NTENANCE
REPLACE SPARKPLUGS- AP15.10-P-1580
Replace spark plugs- AP15.10-P -1580AC

Mercedes-Benz
R4 Spu~plug
1'114 lgnllion co~
P15 10.022HMl
Fig. 78: ldentifying Spark Plugs
~~ Remove/install and replacing

Do not touch parts which conduct high
Risk of death caused by contact voltages Persons who wear electronic AS15.10-Z-
Lt with parts conducting high voltages. implants (e.g. heart pacemakers) should never 0001-0lA
perform alily work on the ignition system.
AH15.10-P-
ITl Notes on avoiding damage to
ignition system
Engines 104, 111 , 112, 113, 119, 120 with
ME-SFI fue] injection and ignition system 0002-0lD
1 Remove cover on face end of engine
AR15.12-P-
3 Remove ignition coils (Tl/4)
2003A
4 Disconnect spark plug connectors n:3f"GF L ever off over cylinder head cover Fig. 15
&oanqcr! Checking
Check spark plug connectors,

ignition coil connectors and ignition
5 n:3f"GF Replace, if necessary.
lines for damage, deformation and
crack formation
@ *BA15.10-P-
6 Remove spark plugs (R4)
1001-0lA
~GF Fig. 79
@SPARKPLUGS
Number Designation Engine 104, 110, 111, Engine 112.910/911/ 912/913/914/
113.940/941/942/943/ 915/916/917/920/921/922/
Mercedes-Benz
944/948/960/961/962/ 923/940/941/ 942/943/944/

963/964/965/966/9671 945/946/947/ 949/951/953/
968/969/971/980/981/ 954/955/960/961/970/972/
982/984/986/992/993/995, 115, 117, 119, 973/975/976
120
BA15. 10-
Spark
P-1001- N m 28 28
plugs
OlA
Fie. 79: Identifyine Spark Plu" Wrench (112 589 01 09 00)
110 5S9 0 1 Ot 00
Fig. 80: ldentifving Open-End Wrench, Double (110 589 01 01 00)
Replace spark plugs - AP15.10-P-1580CA
ENGINE 103, 104 from 1.10.93,

111.920 /921 /940 /941 /942/943 /944 /945 /946/947/952 /956 /957 /958 /960 /961 /970/973 /974 /975/977/91
120 from 1.10.93
Shown on engine HFM-SFI

Mercedes-Benz
5t1 lgnltfon ~blc

rcccss
512 Guldc ro1N
12 Cable rccc.ss
R4 sp~tl<plug
P1 5.00-00 31HI1
Fig. 81: ldentifving lgnition Cable Recess And Spark Plug (Sbown On Engine HFM-SFI)
Shown on engine HFM-SFI
T1 lgnition coll
T2 IJ1nlt.fo n t: olt
n lgnftion coll
P1 i iiD-'!l025·ll1
Fig. 82: Identifying Ignition Coil (Shown On Eogine HFM-SFI)
Pil7 6D-020 !J.01
Fig. 83: Identifving Cable Duct (Shown On Engine 120.982/983)

Mercedes-Benz
A DIS covcr
8 Wlrlng ll.amcss.
P1 5-0!HIIl 2B-01
F ig. 84: Identifving DIS Cover And Wiring Harness (Sbown On Engine 120.980/981)
~ R emoval:
"
Lh Risk of death Do not touch parts whích conduct hígh ASlS. lO-Z-0001-
caused by contact voltages. Persons who have electroníc OlA
with parts implants (e.g. pacemakers) must not
conducting hígh perform any work on the ignitíon system..
voltages.
[JJ Notes on avoídíng Engíne 111 wíth PEC fuel ínjectíon and AH15 .10-P-0002-
damage to ignitíon ignition system OlB
system
[JJ Notes on avoiding Engine 104, 111 with HFM-SFI fuel AH15.10-P-0002-
damage to ignition injection and ignition system 01C
system
[JJ Notes on avoiding Engines 104, 111, 112, 113, 119, 120 with AHlS.lO-P-0002-
damage to ignition ME-SFI fuel inj ection and ignition system OlD
system
[JJ Notes on avoiding Engines 103, 104, 119 with CFI fuel AHlS.lO-P-0002-
damage to ignitíon injectíon system OlE
system
[JJ Notes on avoiding Engine 104, 119, 120 with LH sequential AHlS.l O-P-0002-
damage to ignitíon multiport fuel ínjection system OlF
system
1 Ignítion: OFF
2.1 Loosen the cable Engine 120.980/981 ral500120 103lx
duct partially ~GF The cable duct must be loosened
partially in order to replace the spark plug at
cylinder 12.
Detach partial mbber seal, remove the cover
for the DI switching unit (A) and cable
harness (B).
Remo ve the mounting screws (arrows) for
the cable duct.
Detach the cable duct and press ít towards
the front.
Mercedes-Benz
3.1 Remove ignition

coils
[g]' Remove/install Engine 111.921/942/ AR15.12-P-2003GA
ignition coils 943/945/946/94 7/970/973/974/975/ 977
~GF Remove ignition coils (Tl/1, Tl/2)
with connected controllines and ignition
lines.
Engine 104, 111.920/940/941/944/960/961 AR15.12-P-2003G
n::!if"GF Remove ignition coils (Tl/1, Tl/2,
Tl/3) with connected controllines and
ignition lines.
Engine 120.982/983 AR15.12-P-2003FA
4 Release and ~GF Use pliers for straight spark plug
unplug spark plug connectors.
connector through
slight rotation
n::!if"GF Fig. 88
5.1 Check the spark Engines 104, 111
plug connectors on DJ The catalytic convetter can get damaged
the inside for any with spark plug connectors having
secondary spark secondary spark gaps.
gaps
(discoloration) and
the sealing for any
damage.
6oanqorl Checking
5.2 Check spark plug Only for engine lll
connectors, n::!if"GF Replace, if necessary.
ignition coil
connectors and
ignition lines for
damage,
deformation and
crack formation
w Installatiou
6 Blow out spark
plug stems and
recesses with
compressed air
7 Replace spark n::!if"GF Install only approved spark plugs.
plugs
@ *BA15.10-P-1001-
OlA
n::!if"GF Engine 103 with tapered seat (B) Fig. 85
n::!if"GF En{!ine 104. 111 with flat seat (C) Fie. 86
Mercedes-Benz
n:::rGF Engine 120 with flat seat (C), Fig. 87

cylinder 1 to 5 and 7 to 12
n:::rGF Engine 120 with flat seat (C), Fig. 86
cylinder 6
8 Connect spark ~GF Ensure that the ignition cables are
plug connector installed correctly.
9.1 Install ignition
coils
[g] Remove!install Engine 111.921/942/ AR15.12-P-2003GA
ignition coils 943/945/946/94 7/970/973/974/975/ 977
Engine 104, 111.920/940/941/944/960/961 AR15.12-P-2003G
Engine 120.982/983 AR15.12-P-2003FA
10.1 Assemble and Engine 120.980/981 ra15001201031x
fasten cable duct
@SPARKPLUGS
Number Designation Engine Engine 104, 110, 111,
103 113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/~
115, 117, 119, 120
BA15.10- Spark N m 20 28
P-1001- plugs
OlA
Fig. 85: Identifving Spark Plug Wrench (102 589 01 09 00)
11!l 589 02 og oo
Fig. 86: l dentifving Spark Plug Wrench (119 589 02 09 00)

Mercedes-Benz
Fig. 87: Identifying Spark Plug Wrench (120 589 02 09 00)
Pbrs
RETROFITTING & CONVERSION

RETROFITTING SMALLER POLY V-BELT PULLEY AND ALUMINUM FAN WHEEL- AN15.40-P-
5700CS
ENGINE 119 in MODEL 129.### ## up to 032598
1 Covor
2 Coll•r nur
J Sll•rt
4 Po/y V- bolr pulloy
$ Sp«or
5 Solr
7 lnf•~• •Ir Ileso
1 Solf
9 F~nwhacl
G1 Goncnror
P1 H0-201Hl!l
Fig. 89: Retrofitting Smaller Poly V-Belt Pullev And Aluminum Fan Wbeel
Mercedes-Benz
~' Removing
1 Remo ve poly V -belt ral3001193420x
2 Remove viscous fan clutch ra2000 1193120x
Disconnect ground cable at
3 AR54.10-P-0003A
battery
4 Remove intake air hose (7)
5 Remo ve cover ( 1)
[$»GF Use hexagon socket bit (8 mm) with
6 Unscrew collar nut (2)
reversible ratchet for holding the shaft (3)
@ *BA15.40-P-1004-
OlA
[$»GF Fig. 56
[$»GF F ig. 62
Take offpoly V-belt pulley (4)
7
together with spacer (5)
@ *BA15.40-P-1003-
8 Unscrew bolt (6)
OlA
S1acken bolt (8) and swivel out @ *BA15.40-P-1003-
9
generator (G2) OlA
[$»GF Refer to parts documentation (group 15)
10 Take offfan wheel (9)
for the parts required for conversion
wInstalling
11 Fit on fan wheel (9)
Fit on poly V-belt pulley (4)
12
together with spacer (5)
[$»GF Use hexagon socket bit (8 mm) with
13 Tighten collar nut (2)
reversible ratchet for holding the shaft (3)
@ *BA 15.40-P-1004-
OlA
IJ3"'GF F ig. 56
[$»GF F ig. 62
@GENERATOR
N umber Designation Engine 119
BA15.40-P-1003-01A Bolt of generator Nm 42
BA15 .40-P-1004-0 lA Collar nut on poly V -belt pulley N m 80
Mercedes-Benz
126 589 00 40 Ol)

Holder
Fig. 90: Identifying Holder (126 589 00 40 00)
000 589 10 99 01
Torqw wrantll
Fig. 91: Identifying Torque Wrencb (000 58910 99 01)

REPLACING IGNITION CABLES WITH M3 CABLE SCREW - RA15001040512X(15-0512)
Fig. 92: Identifving lgnition Cables With M3 Cable Screw
NOTE: The ignition cables are now only available on the parts market by the meter. For
this reason, the attached parts must be fitted with stop pliers before installing
the ignition cables.
Ignitíon cables cut to length.

Ends of cables strip 6 mm.
fit nn ::mil Mt:::~r.h fin:t tn thP in~nhtinn thAn tn thP ionitinn r.:::~hlP ron> with
Mercedes-Benz
Sleeve of cable screw the stop p liers.

Markings for individual
fit on. to ignition cables.
cylinders
Spark plug connector screw on.
Angle connector screw on.
Special tool
OCIO 589 55 -37 00

15
F ig. 93: Identifving Special Tool (000 589 55 37 00)
REPLACING SPARK PLUGS- RA15001041031X{l5-1031)
Replacing spark plugs - RA15001041031X(15-1031)
15-1031
A. Replacing
Mercedes-Benz
Fig. 94: Replacing Spark Plugs
Cover (21) detach, fit on.

slacken by turning to right and left, pull off, fít on. Blow out recesses with
Spark plug connector compressed air.
(arrow) l2l
When fitting on, ensure ignition cables are correctly routed.
Ignition cables clean.
unscrew, screw in; renew ifnecessary.
Tightening torque 20-30 Nm. For installing, use approved spark plug wrench
Spark plugs 119 569 01 09 OO.
Use only approved spark plugs with flat seat and seal. Check electrode gap.
Specification = 0.8 mm.
Special tool
Mercedes-Benz
l 1958!JO I 0900
15
NOTE: Since February 1991 the spark plug connectors are partially screened
(Beru and Bosch).
PRODUCTION BREAKPOINT: FEBRUARY 1991

Model Engine Engine end no. Manual transmission Engine end no. Automatic transmission
124.031104.980005464 023786
124.051
124.091
129.061104.981001046 010325
B. Table of spark plugs
Bosch or Beru spark plugs which are marked with a "O" have a center electrode with a larger diameter, e.
g.
BOSCHH7DCO
BERU 14K-7DUO
Since September 1989 Champion spark plugs have been installed which have a center electrode with a
copper core. These spark plugs are ídentífíed wíth a "C", e. g.
CHAMPION SlOYCC
. an d nationa1 verswns, excep1t ~BB &~ KOREA TAIWAN

B as1c
' '
Manufacturer BERU BOSCH CHAMPION
Spark plugs for normal compressíon 14F-8DUO F8DCO ClOYCC
Spark plugs for low compression 14F-9DUO F9DCO C12YCC
National version l) ~ea & ~, KOREA, TAIWAN

Spark plugs 14F-9DUO F9DCO C12YCC
Mercedes-Benz
l) The spark plugs are approved only for a max. speed of 160 km/h.
Spark plugs ofthe basic version must be installed on tourist cars and for sports competitíons.
Replacing Spark Plugs- RA15001191031X(15-1031)
15-1031
A. Replacing
,_
Fig. 96: Replacing Spark Plugs
Covers (21) remove, fit on.

slacken by turning to right and left, pull off, fit on. Blow out recesses with
compressed air.
Spark plug connector
(arrow)
121
When fitting on, ensure the ignition cables are correctly routed. Clean ignition
cables.
tmscrew, screw in; replace if necessary. Tightening torque 20-30 N m.
TJ~e annroved ~nark nhJQ wrench 119 5R9 02 09 00 for in~tallin!! lJ~e onlv
Mercedes-Benz
approved spark plugs with flat seat and seaL

Spark plugs Check electrode gap.
Specification = 0.8 mm.
Special tool
119589020900
15
B. Spark Plug Table
Since Aprill988 Bosch spark plugs, and since September 1988 spark plugs with a larger diameter ofthe
central electrode have been installed.
These spark plugs are identified with an "O" e.g.
BERU 14K-7DUO
BOSCHH7DCO
Since September 1989 Champion spark plugs have been instailed with a central electrode provided with a
copper core.
These spark plugs are identified with a "C" e.g.
CHAMPION S 1OYCC
. an d natrona versrons excep1t o::3"'ee Lh ~ KOREA TAIWAN

B asrc
' '
Spark plugs for normal compression 14F-8DUO F8DCO ClOYCC
14F-7DUO Cl) F7DCO (l) C9YCC (1)
Spark plugs for low compression 14F-7DUO F7DCO C9YCC
(1) Up to 06/91
National version 2) ~BB Lh [l), KOREA, TAIWAN

Mercedes-Benz

Spark plugs 14F-9DUO F9DCO Cl2YCC
2)The spark plugs are approved only for max. speed of 160 km/h.
Vehicles ofthe aforementioned national version should be equipped with spark plugs ofthe basic
version when used outside oftheir COlmtry (touríst vehicles).
Additionally approved spark plugs
The Beru silver spark plugs (Silverstone) are approved for retrofitting (refer to matching of standard spark
plugs and silver spark plugs).
The platinum spark plugs are no longer approved.
Standard Silver
14F-7DUOS3F
REMOVING AND INSTALLING IGNITION COIL- RA15001042001X(15-2001)
Removing and installing ignition coil- RA15001042001X(15-2001)
15-2001
Mercedes-Benz
~,...-------30
P1 S-5016-15
Fig. 98: Identifying Ignition Coil Remove!Iustall Components
Pay attention to instructions for working on the breakerless transistorized ignition system, see Diagnosis
Manual Engíne, Volume 2, Index 5 .l.

Cover (29) for ignition coi] (T 1), take off, fit on.
for electrical connections, unscrew, screw on.
Nuts ( arrows) NOTE:

Positive lead, MS connection thread. Negative lead, MG connection
thread.
Ignition cables at ignition
unplug, plug in.
coil
Nuts (30) unscrew, screw on.
Ignition coil (T 1) remove, insert.
Removing and Installing Ignition Coils- RA15001192001X(15-2001)
Mercedes-Benz
15-2001
29
T1/1
T1/2
.-30
Fig. 99: ldentifying Ignition Coils Remove/Install Components
Pay attention to instructions for work on the breakerless transistorized ignition system (15-0505).

Removing and installing ignition coil 1 (right
bank of cylinders, Tl/1)
Cover (29) for ignition coil (Tl/1) take off, fit on.
lgnition cable at ignition coil (T 111) pull off, fit on.
Nuts ( arrows) NOTE:

Terminal1: M5 connection thread. Terminal15:
M6 connection thread.
lgnition coil (Tl/ 1) remove, insert.
Removing and installing ignition coil 2 (left bank
of cylinders, Tl/2)
Mercedes-Benz
Cover above left headlamp remove, instalL

Cover (29) for ignition coil (Tl/2), take off, fit on.
Ignition cable at ignition coi] (T l/2) pull off, fit on.
Nuts (arrows) NOTE:

Terminal M5 connection thread. 1: Terminal M6
connection thread. 15:
Ignition coil (Tl/2) remove, insert.
REMOVING AND INSTALLING EZL/AKR CONTROL UNIT- RA15001042093X(15-2093)
Removing and installing EZL/AKR control unit - RA15001042093X(15-2093)
15 - 2093
Fig. 100: ldentifying EZL/AKR Control Unit
Vacuum connection (4) detach, fit on.

I
C:mn(i::~l r.nnnP.r.tnr fnr r.nntrnl r.::~hlP. fmm
Mercedes-Benz
crankshaft position sensor (2) unplug, plug in.

8-pin connector (A) unplug, plug in.
8-pin connector (B) unplug, plug in.
3-pin connector, knock sensors (1) unplug, plug in.
EZL/AKR trimming plug connector
tmplug, plug in.
(Rl6/2)
Fastening nuts for EZL/AKR control unit .
(Nl/ ) unscrew, screw on (3 nuts). Pay attentton to washers.
3
remove from stay bolt, fit on.
NOTE:
EZLIAKR control unit (Nl/3) Heat conducting paste has been applied to the rear of the
control unit and covered with heat-conducting protective
foil for improved heat dissipation. The protective foil must
not be removed.
read out, erase ifnecessary (see Diagnosis Manual Engine,
Volume 2, Index 0).
CIS-E controltmit fault memory NOTE:

Stored faults which may originate from test work resulting
from cables being disconnected or from a simulation, must
be erased in the fault memory after completing the work.
NOTE:
Since September 1989 a control unit
with modified map and fault memory
program part has been phased in. 76
of233
PRODUCTION BREAKPOINT
Model Vehicle ident end no. Implementation
124.031 B 092516 October 1989
124.051 B 089904 September 1989
Since October and November 1990, respectively, an ignition control unit witb new map has been used.
M odel Engine Vehicle ident end no. lmplementation
124.031 104.980 B 365990 October 1990
124.051 1 1
124.091 104.980 F 161750 October 1990
129.061 104.981 F 023200 N ovember 1990
Since April 1991 an EZL ignitíon control unit witb a modified map anda modified CIS-E control unit for tbe
adjustment range of the inlet camsha:ft have been installed in order to reduce combustion noises.
Mercedes-Benz
The total adjustment range ofthe inlet camshaft is reduced to 29 °CA (previousJy 34 °CA). The inlet camshaft
advance at part load above 5000 rpm has likewise been reduced from 17 °CA to 14.5 °CA.
The CIS-E control unit must only be instaJled together with the relevant EZL ignition control unit.
Pr oduction breakpoint: April 1991 (except )

Mod el E ngine E ngine end no. Manual transmission E ngine end no. Automatic t ransmission
124.031 104.980 005792 025654
124.051
124.091
129.061 104.981 001134 010894
Since August 1991 an EZL ignition control unit with modified software has been installed.
Reason: starting-off in 1st gear.
PRODUCTION BREAKPOINT: AUGUST 1991

Model Engine Vehicle ident end no.
124.051 104.980 B 600485
Removing and Installing EZL/AKR Control Unit - RA15001192093X(15-2093)
Operation no. of operatiou texts and work units or standard texts and flat rates:
15-2093
Mercedes-Benz
Fig. 101: Identifying EZL/AKR Control Unit Removellnstall Components
Vacuum connection (4) detach, fit on.

Coaxial connector for control lead from
unplug, plug in.
crankshaft position sensor (2)
8-pin connectors (A and B) unplug, plug in.
3-pin connector ofknock sensors (1) tmplug, plug in.
EZLIAKR resistance trimming coupling
unplug, plug in.
(Rl6/2)
Nuts ofEZL/AKR control unit (3 of) unscrew, screw on.
take off stay bolt, fit on.
NOTE:
EZLJAKR control unit (Nl/3) The control unit is coated on the rear with heat-
conducting paste for improved heat dissipation and
covered with a heat-conducting protective film. The
protective film must not be removed.
read out; erase, ifnecessary (see Diagnosis Manual Engine,
Volume 2, Register 0).
KE control unit fault memory NOTE:

Stored faults which may originate from test work as a
result of detached wiring or simulation, must be erased in
the fault memory after completion of work.
Mercedes-Benz
NOTE:
Modified EZL ignition control unit with
corrected altitude pressure transmission
(software modification) to KE control
unit.
PRODUCTION BREAKPOINT: 01/91

Modlel Engine Vehicle ident end no.
129.066 119.960 F 027983
Software ofEZL ignition control unit modified; reason: starting-off in first gear.

Modlel Engine Vehicle ident end no.
129.066 119.960 F 057 393
REMOVING AND INSTALLING CRANKSHAFT POSITION SENSOR- RA15001042133X(15-2133)
Removing and insta lling crankshaft p osition sensor - RA15001042133X(15-2133)
15-2133
P 15-5001 ~,._,......,...
Fig. 102: ldentifying Crankshaft Position Sensor
unscrew, screw in.

Screw (anow)
Tightening torque 1ONm as reference value.
remove, install. Take lead to EZLIAKR control unit out of cable shaft.
Crankshaft !21
position sensor On engines with two-mass flywheel (vehicles with manual transmission as of
(L5) September 1989) a spacer plate must be placed below the crankshaft position sensor
(L5) otherwise the segment will rub on the sensor.
Mercedes-Benz
CIS-E control unit . . . .

c. lt read out, erase 1fnecessary (see D1agnos1s Manual Engrne, Volume 2, Index 0).
1au memory
NOTE:
Stored faults which may originate from test work resulting from cables being
disconnected or from a simulation, must be erased in the fault memory after
Removing and InstaJling Crankshaft Position Sensor - RA15001192133X(15-2133)
15-2133
Fig. 103: ldentifying Cranksbaft Position Sensor
Fig. 104: ldentifying Cranksbaft Position Sensor
Connector at .
. tmplug, plug m.
EZL/AKR centro l urut
Cover at clntch hell remove from a hove. insert
Mercedes-Benz
unscrew, screw in.

Screw
Tightening torque 1ON m as reference value.
Crank.shaft position
remove, ínsert.
sensor (L5)
read out; erase, if necessary (see D iagnosis Manual Engine, Volume 2, Register
0).
KE control unit fault
NOTE:
memory
Stored faults which may originate from test work as a result of detached
wiring or simulation must be erased in t he fault memory after completion of
work.
NOTE: Bracket for crankshaft position sensor with improved cable routing (protection
against chafing).
PRODUCTION BREAKPOINT : 11/90

Mod!el Engine Engine end no.
129.066 11 9.960 0 13681
REM OVING AND I NSTALLING CAMSHAFT POSITION SENSOR- RA15001042143X(15-2143)
Removing a nd installing camsbaft position sensor- RA15001042143X(l 5-2143)
Operation No. of operation texts and work uníts or standard texts and flat rates:
15-2 143
Mercedes-Benz
1
~11
Fig. 106: ldentifving Camshaft Position Sensor Remove/lnstall Components
Connector of camshaft
unplug, plug in.
position sensor (arrow)
unscrew, screw m.
Screws (9)
Tightening torque 1O Nm as reference value.
Camshaft position sensor
(LS/ 1) remo ve, insert.
0 -ring (11) replace.
read out; erase, ifnecessary (see Diagnosis Manual Engine, Volume 2,
Register 0).
NOTE:
memory
wiring or simulation must be erased in the fault memory after completion
ofwork.
REMOVING AND INSTALLING EZL/AKR TRIMMING PLUG CONNECTOR- RA15001042153X

(15-2153)
Removing and installing EZL/AKR trimming plug connector- RA15001042153X(15-2153)

Mercedes-Benz
Operatíon No. of operatíon texts and work uníts or standard texts and flat rates:
15-2153
A. Removing and installing
Fig. 107: ldentifving EZL/AKR Trimming Plug Connector
B. Adapting ignition timing to available fuel with the EZL/AKR trimming plug connector
The ignitíon is set for unleaded premium grade fuel with an octane number ofRON 95.
lfregular grade fuel, e. g. wíth octane number ofRON 91 ís used, a suitable EZLIAKR trimmíng plug
connector (Rl6/2) must be fitted (see table).
Mercedes-Benz
Fig. 108: l dentifving EZL/AKR Trimming Plug Connector
[YGF
Ifregular grade fuel is u sed, the ignition is retarded by the anti-knock control, wruch increases the overall
temperature level of the engine.
It is therefore strongly recommended to use regular grade fuel only if, in exceptional circumstances, no
unleaded premium or premium plus fuel is available (see also Owner's Manual).
In su eh circumstances, the vehicle should not be driven at speeds in excess of 200 km/h.
Fig.109: l dentifving EZL/AKR Trimming Plug Connector
Version Fuel Trimming plug connector (l) Resistance ohms Ignition angle
RON DB PartNo. kohms correction °CA
KAT Premium 01 5 545 67 28 2.4 kohms o
Without
KAT
95 015 545 70 28 470 ohms o
KAT Regular 015 545 68 28 (2) 1.3 kohms -3
Without
91 015 545 71 28 220 ohms -5
KAT
(1) Ifno trimming plug connector is fitted, the ign ition timing is retarded by approx. 3 °CA at fullload.
(2) Ifthe engine still knocks, install trimming plu g connector 01 5545 69 28, resistance 750 ohms,
Mercedes-Benz
ignition ang1e correction approx. -6° CA.
NOTE: As only fuel with RON 92 is available in Indonesia, the standard trimming
plug connector EZLIAKR 015 545 70 28 must be replaced with the
connector 015 545 71 28.
REPLACING KNOCK SENSORS - RA15001042183X(15-2183)
Replacing knock sensors- RA15001042183X(15-2183)
Operatíon No. of operatíon texts and work tmits or standard texts and flat rates:
15-2183
P15-5002-53
Fig. 110: ldentifying Knock Sensors
unscrew, screw m.
Screws ( arrows)
Tightening torque 20 N m as reference value.
Connector at EZLIAKR .
.t unp1ug, p1ug m.
contro1 um
Protective hose for
unclip, clip in.
cables
NOTE:
The cables of both knock sensors (A16) are combined in the protective hose
(corrugated hose). They can only be replaced as a unit.
Replacing Knock Sensors- RA15001192183X(15-2183)
15-2183
Mercedes-Benz
Fig. 111: Locating Knock Sensors Bolt
Fig. 112: Locating Knock Sensors Bolt
Fig. 113: Locating Knock Sensors Lead
unscrew, screw m.
Bolts (arrows)
Tightening torque 20 Nm as reference value.
Mercedes-Benz
Knock sensors connector at

unplug, plug in.
EZL/AKR controllmit
Protective hose for cables unclip, clip in.
NOTE:
The cables of the two knock sensors (A 16) are combined in a
protective hose (corrugated hose). They can on ly be replaced as a unit.
Removing and InstaJling EZL/AKR Resistance Trimming Coupling- RA15001192153X(15-2153)
15-2153
A. Removal and Installation
R1812
--
...
Fig.114: Identifving EZL/AKR Resistance Trimming Coupling Remove/lnstall Components
B. Adapting Ignition Point to Available Fuel with the EZL/AKR Resistance Trimming Coupling
The ignition is set for unleaded premium grade fue] of an octane number of RON 95. If regular grade fu el
with e.g. an octane number ofRON 91 is used, a suitable EZLIAKRresistance trinuning coupling
(Rl6/2) must be fitted (see table).
Mercedes-Benz
Fig. 115: Identifying EZL/AKR Resistance Trimming Coupling
If regular grade fuel is u sed, the ignition is retarded by the anti-knock control. This increases the overall
temperature level of the engíne.
It is therefore urgently recommended to use regular grade fu el only if unleaded premiurn or premium plus
fuel is not available in exceptional circumstances (see also Owner's Manual). In such circumstances,
avoid speeds in excess of200 km/h.
Version Fuei RON Resistance trimming coupling(1) Resistance obms lgnition point
DB part no. kobms correction ° CA
Premium
KAT 015 545 67 28 2.4 k ohms O
95
Wíthout
Regular 91 015 545 71 28 220 ohms -5
KAT
(1) In the absence of a resistance trimming coupling, the ignition point is retarded by approx. 3° CA at
fullload.
REMOVING AND INSTALLING ENGINE SYSTEMS CONTROL UNIT (MAS) - RA15001042193X

(15-2193)
Removing and installing engine systems control unit (MAS) - RA15001042193X(15-2193)
15- 2193
Mercedes-Benz
Fig. 116: ldeotifying Engioe Systems Control Uoit (MAS)
REMOVAL
Locking handle (arrow) turn anti-clockwise from position "1" to position "O".
Engine systems control unit (N 16) pull offupward.
INSTALLATION
Engine systems . .
control unit (Nl 6) press vert1cally mto connector.
turn clockwise from position "O" to position "1 ".
Locking handle
arrow) Check that controltmit is correctly seated in the connector by tuming slightly back
(
and forward.
read out, erase if necessary (see Diagnosis Manual Engine, Volume 2, Index 0).
CIS-E control unit NOTE:

fault memory Stored faults which may originate from test work resulting from cables being
NOTE: Revision of software on engine systems control unit (MAS). Storage of fault
code 3 discontinued.
PRODUCTION BREAKPOINT: JULY 1990

Mercedes-Benz
Model Engine Vehide ident end no. Basic version National version
(Gres 1& lllJ
124.031 104.980 B 312083 X X X -
124.051 104.980 B 312703 X Jx X X
124.091 104.980 F 153839 X - - -
Removing an<l Installing Eogine Systems Control Unit (MAS)- RA15001192193X(15-2193)
15-2193
F ig. 117: ldentifying E ngine Systems Control Unit (MAS) Remove/lnstaU Components
REMOVAL
Cover of component compartment remove.
Tommy screw (arrow) tum counter-clockwíse from posítion "1" to posítion "0."
Engine systems control unit (NI6) pull upward.
INSTALLATION
Engine systems control
unit (Nl ) press vertícally ínto couplíng.
6
tum clockwise from position "O" to position "l." Check that control unit is
Tommy screw (arrow) correctlv seated in the couolíng bv turnin12: sli12:htlv back and forward.
Mercedes-Benz
KE control unit fault read out; erase, if necessary (see Diagnosis Manual Engine, Volume 2, Register
memory 0).
Cover of component
install.
compartment
REMOVING AND INSTALLING IDGH VOLTAGE DISTRIBUTOR- RAJL5001043010X(15-3010)
Removing and installing high voltage distributor- RA15001043010X(15-3010)
Operation No. of operation texts and work tmits or standard texts and flat rates:
15- 3010
1P15-5018-57
Fig. 118: Identifying High Voltage Distributor Removellnstall Components
Cover on cylinder head, pull off upward, fit on.

disconnect, plug in.
Ignition cables
The ignition cables at the distributor cap should be installed in the firing sequence 1 - 5 -
3 -6 -2 -4.
Distributor cap
(1 ) take off after slackening the hexagon socket screws, fit on.
5
Mercedes-Benz
Distributor
take off after slackening the screws, fit on.
rotor (13)
remove by slackening hexagon socket screw (19). When installing, pay attention to
Follower (14)
locating pin and follower slot ( 14a, ill.).
take off, insert, check 0-ring (17a).
Cover (17) NOTE:

After removing and installing the high voltage distributor, it is not necessary to set
the ignition timing. The ignition timing is fixed by the EZLI AKR control unit.
Ancw loc-amgpin
14a Folcwer s!ot
Fig. 119: Locating Pin And Follower Slot
13 Dstrilutorro~r
14 Fol cwer
15 DJs!ributnr cep
17 Cove1
P15-0449-13
Fig. 120: ldentüying Distributor Components
Removing and Installing High Voltage Distributor- RA15001193010X(15-3010)
Operation no. of operation texts and work units or standard texts aud flat rates:
Mercedes-Benz
15-3010
Fif:. 121: Identifying Higb Volta~:e Distributor Removellnstall Components
Pay attention to instructions regarding work on breakerless transistorized ignition system (15-0505)!
Cover of high
remove, install.
voltage distributor
unplug, plug in.
Installation note
Ignition cables Arrangement of ignition cables:
Right: 1-4-6-7
Left: 5-8-3-2
Distributor cap ( 15) after slackening screws, take off, fit on.
Distributor rotor
after slackening screw, take off, fit on.
(13)
after slackening the screw ( 19), take off, fit on. When installing, pay attention to
Driver (14)
locating pin and driver slot (14a, ill. ).
take off. ínsert check 0-rin!l
Mercedes-Benz
NOTE:
After removing and installing the high-voltage distributor, it is not necessary to
Cover (17) set the ignition point. The ignition point is specified by the EZLI AKR control
unit.
Arrcw Loca!ing Plfl

14a Dnvor s!ct
F ig. 122: Locating Pin And Driver Slot
13 OismWor retor
14 Dnver
15 Dlsmtru'tcr cap
17 C<JV!If
15 13 14
Fig. 123: Identifying Distributor Components
NOTE: Distributor rotor arm with stiffening ribs for reducing fractures and high voltage
arcing.
Mercedes-Benz
A B
A PreVIoos vergoo
IOOrüie-aboo (A)
8 Presertvers100
lderüicaboo (8)
F ig. 124: ldentifying Distributor Rotor Arm

Model Engine Engine end no.
129.066 119.960 023163
TECBNICAL MODIFICATIONS ENGINE 104 COM BUSTION CIS-E INJECTION -

RA15001045TAOOX
E lectrical system- engine (ignition system)
Designation Nature and reason for m odification Production Op. No.

breakpoint
Ignition cables Now only available by the meter - 15- 05 12
Mod. 124.03 1
Map and fau lt memory pwgram part 10/89
EZLIAKR control unit 15- 2093
modified Mod. 124.051
09/89
EZLIAKR trimming plug Trimming plug connecto.r for
08/90 15 - 2153
connector Indonesian vehicles modified
Software modification: storage of
Engine systems control unit 07/90 15- 2193
fault code 3 discontinued
10/90
EZL ignition control unit Ignition control unit with new map 15- 2093
11/90
Mod. 124.031
124.051
124.091
Mod. 129.061
Spark plug connectors partially
Spar k plug connector 02/91 15 - 1031
screened (Beru and Bosch)
15 - 2095
EZL ignition control
Combustion noises 04/91 except llJ Progranm1ed
unit/CIS-E control unit
Repairs
Software modification:
EZL ignition control unit 08/91 15 - 2093
Reason: starting-off in 1st gear
Mod. 124.051
Mercedes-Benz
REPLACING IGNITION CABLES WITH M3 CABLE SCREW- RA15001191476X(15-1476)
15-1476
Fig. 125: Identifying Ignition Cables With M3 Cable Screw (1 Of 2)
Fig. 126: l dentifying lgnition Cables With M3 Cable Screw (2 Of 2)
NOTE: The ignition cables are available in the parts market only by the running met er.
For this reason, t he connection parts must be attachedt with stripping pliers
before installing the ignition cables.
Ignition cables cut to 1ength.

Ends of ignition
strip 6 mm.
cables
fit on and attach first to the insulation with the pliers, then to the ignition cable
Sl eeve o f ca ble screw
core.
Ignition cable
fit on ( where provided).
marking
Spark plug connector screw on.
Angled connector screw on.
Mercedes-Benz
Special tool
000 589 5.5 37 00

15
TECHNICAL MODIFICATIONS ENGINE 119 COM-nUSTION KE INJECTION- RA1500119TAOOX
15 Electrical System Engine (Ignition System)
O p. Designation Nature and reason for modilication Production

no. breakpoint
15- Revised altitude pressure transmission (software
EZL control unit Ol/91
2093 modification) to KE control unit
15- Software of ignition control unit modified; reason:
EZL control unit 09/91
2093 starting-off in first gear
15- Crankshaft position
lmproved cable routing (as protection against chafing) ll/90
2133 sensor bracket
15- Distributor rotor arm with stiffening ribs; reason:
Distributor rotor arm 07/91
3010 reduction in fractures and high voltage arcing
NOTES REGARDING WORKING ON BREAKERLESS IGNITION SYSTEM- RA1500FLH0010X(15-

0010)
A. Safety precautions
Increased demands ofmodern engines in respect of the ignition systems and the desire for freedom of
maintenance have lead to standard introduction of electronic ignition systems.
As a rule, the ignit.ion capacities of electronic systems are higher than those of convent.ional systems.
Further increases in capacity are likely. Consequently, electronic ignition systems operate in a power
range which may be hazardous if contact is made with live parts or terminals (see warning sign).
Mercedes-Benz
Gefahr1iche Hochspannung!
Vorslcht bel Arbe41en andar
Zündanlage
Warríng si gn •n engine compar..ment
Dangerl High vQitC~ge
O~erve caution wMn worlcing
on the lgnlHon system
Danger! Haute tension

A1tention lorsde tnNeux au
systéme d'allumage
Fig. 128: ldentifying Engine Compartment Warning Sign
For this reason, when working on electronic ignition systems (EZL), pay attention to the following safety
precautions:
• When performing work at starting speed, e. g. testing compression pressure, switch off ignition and
unplug control cable (2) at the EZL ignition control unit or plug protective connector 102 589 02 21
00 into the diagnostic socket.
• Persons with a heart pacemaker should not operate on this type of ignition system.
• Do not grasp and/or unplug any component of the ignition system at startíng speed or when the
engine is running.
• Do not perform removal and installation work at the ignition system or disconnect and connect
sensors at ignition cables unless the engine is not running and the ignition is switched off
S!IO'Ml 011 tl.'l g !l B 119
Fig. 129: Identifying Ignition And Unplug Control Cable
B. Notes regarding avoiding damage to the ignition system

• The connectors of ignition control units must not be unplugged or plugged in unless the
ionition ¡~ ~wit.-h.Pd off to ~void il~m~oino th.P 1?.7.1. ionition c-ontrol nnit
Mercedes-Benz
• Do not connect a test lamp to terminal 1 of the ignítion coil.

• Terminals 1 and 15 of the ignition coil must not be short-circuited to ground, e. g. as an anti-theft
protection.
• The threaded pins of the ignition coil have different diameters (M5 and M6) to eliminate the risk of
incorrect polarity.
• lnstall only germine components ofthe ignitíon system.
• Do not operate the ignition system at starting speed unless all the ignition cables are completely
connected.
• To avoid damage to the EZL ignition control unit, the load applied to the high voltage side of the
ignition system must be at least 2 kohms (ctistributor rotor arm l k oh.ms, distributor cap per
terminal ! k ohrns ). Do not install 5 k ohms distributor rotor arms for interference suppression.
• The following operations must not be performed at starting speed or when the engine is mnning:
o Holding ignition cable (terminal4) close to ground,
o unplugging spark plug connectors,
o unplugging ignition cable (tenninal 4) at the ignítion coil.
• To improve heat dissipation, the EZL ignition control unit is provided with heat conducting paste
on the rear síde and covered with a heat-conducting protective film. This protective film must not
be removed.
• W hen performing the separate ignition coil test, the load applied to the ignition coil must not
exceed 28 kV to avoid damaging the ignition coíl.
• If it is necessary to test the ignítion spark when providing breakdown assistance, tbis must only be
performed with a spark plug at a cylinder ig nition cable.
Ensure good ground contact of the spark plug.
Pay attention to rísk of electrification!
C. Notes regarding use of engine testers

• Do not connect and disconnect voltage clamp to ignition cable (terminal4) and trigger clamp to
ignition cable of cylinder 1 unless the engine is not running and the ig nition is switched off.
• If the sbort-circuit protection (cylinder comparison) is operated and the engine stops, the test cannot
be performed wíth this tester.
ELECTRONIC IGNITION SYSTEM WITH VARIABLE IGNITION CHARACTERISTICS AND

ANTI-KNOCK CONTROL (EZL) - RA1500FLH0020X(15-0020)
Electronic ignition system witb variable ignition cbaracteristics ami anti-knock control (EZL)- RA1500FLH0020X(l5-
0020)
A. Basic function diagram of electronic ignition system (EZL)

a. Engine 104
Mercedes-Benz
N113
0~------------_.
865
A16 Knock soo sor R4 Spark ptlgs

B 11fl Coolart lsmporetura Sll!lSOf S513 Hgh vo!IBga <islnbdllr
LS Cranl<5tlal ~ion 5911SOC S65 TlllllsnusSicn O'wortoadprc!Ddon so.vtch, brake band
LSJ1 Camshaft po.sibcn sensor 81
M16/1 Ela~ionlc a~colera.:Or p.edal {EFP)sctu!rtcr T1 lgniboncoi
N113 EZL igntion con!rolurit X 11 Dlagnosllc socke.~ 9-ptn
Fig. 130: Basic Function Diagram Of Electronic lgnition System (EZL) (Engine 104)
b. Engine 119
Mercedes-Benz
113
0~------------·
865
A16 1<11 otk senSOf R4 Spat<pk¡gs

81112 Coolm ~perahre sensor S5,1<1 Hlgfl votage cismllltor wlh posltlon sensor
l5 Cranksllai pruaion sensor S65 TmnsmlsSion overload prolldon swt ch, brnke band
l511 Camshaftpos~on sensor 81
M 16/1 8ed·ooc acca!era!Ofpedai{EFP) actuator T1/2 lg!llion col 2 (le.'t bari< al cytnd«S)
N113 EZl igrnon roni"ol unt X 11 Oí !19f10stic sod< el, Q..pl n
Fig. 131: Basic Function Diagram OfElectronic lgnition System (EZL) (Engine 119)
Example, left bank of cylinders
c. Engine 120
Mercedes-Benz
T\12
N114
0~--------------·
566
0~--------------
Sl6f1
..
I"'S---...
A29 leftl<nock sensor R<l Sparl<pk¡gs

81 119 left roolal'lt!M!l* a~re ssns« S5J5 Lett hlgh vollage dismbU«
l512 Leltcamsha2 po51ion sensor 565 Tfll!lsmJSSion overkladllfc!IKion swtdl, bral<eband
LS/4 lelt aarilshalt IX>'>JbcO sensor 81
M1613 Beciomc acoolela~ ~edal {EFP) acruator 5651'1 TransmisSion o-.-erkladllfo»!ion s.vidl, brake band
lettE1l lgn¡too coo~olum, hct •.v1e (lH) 82
N1#1
T1f2 lglbon coi 2 (!elt blll"k ci C'l'iflders)
X 11fl Lelt di agnosllc sod<ot, '9-pln
X 1114 Tes! cOQ¡l6ng for diagt¡OSIS, pulse signal (38-pin)
Fi~. 132: Basic Function Dia~ram Of Electronic Ignition System (EZL) {En~ine 120)
Example, left bank of cylinders
B. Location of components
a. Engine 104
Mercedes-Benz
N1B EZl Jgntoncontolunt R1612 EZl rosrs!anco nnmngc~ng

N3/1 Hol wre (LH) comcltnt T1 lgriboncoi
N4/1 Elec..ooc Em:oloralor~dai{EFP)comolunt X1114 Test c~ng for cia1lf'IOSIS, pulse Signal {38-ptn)
N1611 Basemodlte(GM)
Fig. 133: ldentifying Electronic Ignition System (EZL) Components Location {Engine 104)
Components in engine compartment

Mercedes-Benz
A16g1 Knod< son sor 1 SS/3 Hí!PJ vol'ayn dstnbttCl

A16g2 Knod< sanSOf 2 S6.5 Transrmsstoo OV8(fcadpto~c•o11 SNldl , brake band
LS 81
LS/1 Camstla!tposiboo sensor
Fig. 134: lden tifying Electronic lgnition Svstem (EZL) Components Location (Components
In Engine Compartment)
Components on engine
b. Engine 119
Mercedes-Benz
N113 EZ1. ign¡ioo c,¡¡ntolullt R1612 EZ1. resJStance h nml!lgcoq¡ing

N311 Hot Wlre (LH) coltroltnt T1f1 9lt1011 tot11 (n!tt barl< ol q6ndors)
N411 Elnctooc actll'll!lralor poedal {EFP) c011ro1 uni T1f2 lgnibon cotl 2 (lelt b!lli< llll ctllnders)
N1611 Basemod!l.a {GM) X11.'4 Tost ooq>llng ror diagnosas, poulse sagnal {38-{lln)
N3011 ABS/A~ Gorlrollllt
Fig. 135: ldentifying Electronic Ignition System (EZL) Components On Engine (Engine 119)
Shown on model 140

Mercedes-Benz
.A.16 KflO~S!lOSOI" SS/5 Loltllghvo=ag.o diSI!iW:oc

L5 Crenkstla1 po51l0ll SOOSOI" SS/6 Rlgtt high YOlegil cb~t.or
lS/1 Camshel!posiibon sens« sas Transm¡ssaoo ovorloedp~o:&doo sWitch, brel<e b!md
81
Fi~. 136: Identifyin~ Electron.ic I~nition System (EZL) Components On En~ine
c. Engine 120
Mercedes-Benz
N1/4 laftEZl 1gr"doo control un~ hot wn {lH) T1/1 Rlglt 1Q11Jicn coil
N1.5 Rlgli EZl ignmon corirol Ulli, hot ~m {LH) T1/2 laft1gnlon cctl
N312 lefthot me (l.H) comol Ul'lt X1112 leftOI&gnosbc sod<e~ 9-ptn
N313 Rigli hotwJreflH) control u ni X11/3 Rlglt áa9fiOSÜC sod<et, 9-p.l
R16/a l eftEZl res•slllnce mm11g c~ng X111<1 Test c~ng for áagnoss, pulse Slgnal {3a.P11)
R16.14 Rlgtt EZl resrstanc e tnmmng <OUplllg
Fig. 137: ldentifying Electronic lgnition System (EZL) Components- Components In Engine
Compartment (Engine 120)

Mercedes-Benz
A29g1 Lelt Jq]ock sonSOOfS 1 L514 Lo:taari\sh&'lpoodlorl senSOf

A29g2 Loftla'iock !.SnSOfs 2 LS/5 Rlgrn uanksh~ poSitoo sen SOf
A30g1 RIQh! Jq]ocl< sensOfS 1 5515 Loa llgll vota~n dsinblior
A3()g2 RiQI1 la'iock sensOfS 2 55Al RIQI1 hlgll YOitage disrilulor
L5l1 Loft carnsh~ poSláoo son SOf 565 Transmr~on OVN!oadpro:odon s.Nidl , lxakeband
l51'3 Rlglt cemshaltposilon sensor 81
55511 TransmtsSton o\IOOoadpro:oclion s.Nich, bral<eband
B2
Fig. 138: Identifying Electronic lgnition System (EZL) Compartment On Engine Compartment
C. EZL block diagrams

a. Engine 104
Mercedes-Benz
lgnftlon termlnal15 Voltage supply (+) Dwell angle control

battery (+)
~ f----e>
te rmina l JO
Ground, left fronl Ground (·)

~
wheelhouse co nlro ls lgnftlon con
(lgnftlon coh W3)
f-e> (T1)
Crankshaft posltlon Englne speed In

sensor (L5)
f-e> crankshan poslllon Englne speed slgnal ror 1
f- o hot wlre (LH) control
unl (N311) l
Carnshan poslllon Recogritlon cyl. "1" ror
sensor (L5f1) ani ~knoc.k conl rol and
~ fuel lnjectlon Synchronlzallon slgnal
for lnjecllon sequence. 1
f----e> hot wlre (LH) control
unl (N3f1)
lnlake manifold Load siete of anglne
pressure
~ and altllude correctlon ...
EZL resistan ce Ada~atlon or EZL

ttlmmlng cou plng l¡ylltlon map ignítion
(R16/2) f-----t> KATIWitholA KAT end control
correcllons unit (N1 /3)
Transmlsslon overload Retardallon of lgnllon

protectlon sv.1tch. brake
band 8 1 (S65)
f----e> tlmlng dul'lng gearshlfts
Knock sensors (A16) Retardatlon of lgnllon

tlmlng with knocKing
f----t> combust lon Diagnosis fauJt output 1
-o
Hol v.1re (LH) control 1

Data lnterchange Via
Lllil (N3f1)
~ serial databus (CAN)
1
Vi a
Electronlc accelerator
~
pedal control unll
~ " V
(N4f1)
--------
test coupllng ror
Permanent diagnosis, pulse slgnal 1
ABS/ASR control unll fault (38-pln) (X1114)
(NJ0/1)
memory
fcJ-c>
1
Fig. 139: EZL Block Diagrams (Engine 104)
b. Engine 119
Mercedes-Benz
lgnHion terminal 15 Vollage supply (+) Dwell angla control

ba1tery (+) ~ ~
te rminal JO
Ground polnl (W3). lefl Ground (-) ó

co ntrols lgnHion coils
fro~ Whee lhouse
(lgnftlon coil)
r---e- (T1. T2)
Crankshaft posltlon Englne speed and

sensor (L5)
r---e- crenkshaft poslllon Englne speed slgnal fo r
LH control unft (N311)
~
Camshaft posltlon Recognltlon cyl. "1 " ror
sensor (L5f1) ani ~knock con! rol and
~ fue l lnjecllon SynchronlzaUon slgnal
for lnjectlon sequence.
f-e LH con! rol unH (N311)
lntake manlrold Load state of englne
pressure
r-e- and altltude correctlon
EZL reslslance Ada pi al ion oflgnltlon EZL

ignítion
tflmmlng coupYng
(R1612) f--------r>
map KAT!WIIhoi.A KAT
and correctlons - control
unit (N1 /3)
Transmlsslon overtoad Retardallon of lgnllon

proteclion s~tch (565) timing durlng gearshlfts
1--t>
Knock sensors (A16) Retardallon of lgnl lon

r---e- llming wlth knocklng
combustlon Diagnosis faull output
--t::
LH control unll (N3/1) Data lnterchange 111a

fr---D serial dalabus (CAN)
1
vi a
Electronlc accelerator
pedal control unlt .....
(N4/1) f:l--<> ¿
----------------- test coupllng ror
diagnosis. pulse slgnal
ABS/ASR control unll Permanent (38-pln) (X1 1/4)
(N30/1)
~ fault
memory
Fig. 140: EZL Block Diagrams (Engine 119)
c. Engine 120
Right bank of cylinders

Mercedes-Benz
lgnllon termlnal 15 Voltage supply (+) Owelt angle control

battery (+) ~ ---{>
terminal 3D
Grolll'ld polnt. rrorf léft Ground (-) ~

Ykleelhouse (lgniUon
col l. W3) f-i> ... ---{>
Conlrols lgnltlon
coll 1 (T111), rlght bank
of cylnders
Rlght crankshan En~ne speed and

posltlon sensor (L515) f-r> crankshaft poslllon
Englne s,peed slgnal for
---{> rlght hol wlre (LH)
control unll (N3/3)
Recognltlon cy'L •t• for
Rlght ca msh81'1 posft Ion
sensor (l5/3) anll-knock conlrol and
~ tllél njectlon
Synchronlsallon slgnal
for lnjectlon sequence.
rlg11 hot wlre (LH)
lntake man rold Load slate of englne -----D control unll (N3/3)
pressure and altltude correctlon
f-1>
Right EZL
Rlghl EZl reslstance ignltion
trfmmlng coupllng Adaptatlon oflgnlllon
control
(R16/4) ~ map KAT/wllhout KAT
and correctlons unit (N1/5}
Transmlsslon overload Ret ardatlon or lgnlllon

....
protectlon switch . brake
band 91, 92 (565), f-t> tlmlng durlng gearshlfts
(56511)
Rlghl knock sansors R&tardaUon or lgnllon

(A30)
f<J----t> tlmlng wlth knocklng
combusllon
Dlagnosl s rault outplA

Rlght hol wlre (LH) .... ,..., ----{::;:
contro l unlt (N3/3) f<i---t> Oat 11 lnterchange vla
señal databus (CAN)
Electronlc: accelerator 1
pedal (EFP) conlrol unft Vi a
(N4/t) ~
ABS/ASR control unll test COI.4)11ng for

diagnosis. pulse slgnal
(N3 011)
f<J----t> (38-pin) (X11/4)
Fig. 141: EZL Block Diagrams- Rigbt Bank Of Cylinders (Engine 120)
Left bank of cylinders

Mercedes-Benz
QnJ o, !Otn'dra' 16 >~O·~O <U>ply (~) - 10woll onglo carirol

banery (•• -l>
lem1111130
Ground. len no.-. Grcunc (·) &

\\t•thOUJt C.nnlrr.ls lpnll• n
(lgnr.lon c>U, 'IV3) f-t> coi 2 (TI/2).
Ioft b>nk d cylnd>r<
léft erank$haft po ~Uhn ~!jino<poedand

SI!'\!Of (L!>/4) "ll<snslt posiuon
En~ln• 1pood • •SJ~IIIol
---('> l•ft l'OI vAr~ (U1i
contro unl (N3/2!
Loft COlO$ ' ofl PO>IIOn Recognltion t)1. "1 2'

untot (1 Sn) n.w 3-ntH.not\ '-CJtll'iJl
f---i> anc ~Jtl ,...,uon
Synr11'oolu!llor. 51(1111
ror lnjc:cUon ~ c q.~ c n:o .
Rmunl1. 1eft ltn,- . Cndlno '"""'" hiW'k or ten tol vAre (lJ11
\'tt'e&house ( g1Hcn cylh do-o -----!> con·ho un• (Nl/2:!
col. \1'13) f---1> (cyts. 7· 12"
hts'o mo.1W
old L~td 5kt1,o of .n¡ho
Lelt EZ.L
pressure anc slttucJe corradllr' lgnltion
f-t:> ~ contrnl
~~ (11114)
Len EZL rest!ten:e

-llmliog COUFiMS Adap:a:Jon ort¡nll on
(R16/))
f---1> mop KAT....,Ihou KAT
81C COil'Uilons
Tr!lnsnlsllon overl,.d Reta~de~ on or lgnl lon

prolecllon sl'otch bl'lkl
bond 8 1, 32 (SG6, f-e' Ulllin9 llJrlng geanhlns -"
SE5i11
ten Knoc• sen!o"'S Relardnon or 1gn1 1on

(A29) kn cc~g
fr-i> Umlng vA:I>
COmbUSl b n
~ OIOQ10S'S t•ul O~olja.l
(.jft h!X Wh (\.H)

cnn'fnl u nit (I.On)
Eletlronlc ac::eleralor
pedal (EFP) conlrd urft
(N411l
Fig. 142: EZL Block Diagrams - Left Bank Of Cylinders
D. Ignition coil
Mercedes-Benz
In engine 104 one, in engines 119 and 120 one ignition coi l for each of the two banks of cylinders, is
used, with a separate ignition system being used in engine 120 for each bank of cylinders.
Locatjon, see Section "B".
E. Firing order
Enfllne104
Pltl---11
Fig. 143: ldentifving Firing Order (Engine 104)
t ,. t t
Engme 119
010 oo oo oo
Oro_:¡o 0 .~.,.0 o"o
..
Ot'\0
u u 11
. J"
i-15486372
1 12 5 a 3 10 e 7 2 n 4 e
o
oo o
o
o o o o o
o~~~
o o~o\..Jo\Jr
F. EZL ignition control uoit

Mercedes-Benz
a. General
An ignition map for vehicles with catalytic ·converter and an ignition map for vehicles without
catalytic converter is stored in the EZL ignition control unit (Nl/3, engine 120 Nl/4 and Nl /5}.
Faults which occur when the engine is running are counted by a fault counter.
Only if a fault occurs during more than 8 successive trips it is entered into the fault memory after
the engine is switched off and can be read with the pulse counter.
If the fault then no longer occurs, it is erased again after a certain number of starts.
Only faults which prevent the engine from starting or severely affect engine running are stored
immediately. The fault memory is not
Fig. 146: ldentifying EZL lgnition Control Unit
erased when the battery is disconnected. The stored faults can be read with the pulse counter at the
test coupling for diagnosis (Xll/4) (see Diagnosis Manual Engine Volume 2).
The fault memory should be read when the engine is not running and the ignition is switched on.
The idle speed and fullload signals are passed by the actuator at the throttle valve vía the electronic
accelerator pedal control unit (N4/ l) or idle speed control/Tempomat control unit (N4/3),
depending on the equipment, to the EZL ignition control unit.
b. Assignment of ignition control units ( engine 120)
The assignment (coding) of the two ignition control units to the corresponding bank of cylinders is
performed via coupling "A" contact "6".
Mercedes-Benz
If contact "6" is not assigned, this ignition control unit is assigned to the right bank of cylinders
( cylinders 1-6), viewed in direction of traveL If ground exists at contact "6", this ignition contro l
unit is assigned to the left bank of cylinders (cylinders 7-12).
Shc'MlOO leftEZliQJlibcn conlrol m (N114)
Fi~. 147: Identifyin~ Ignition Control Units (Engine 120)
c. Assignment of couplings
ASSIGNMENT OF COUPLINGS
Engine 104 Engine 119 Engine 120
3-pin coup ling knock sensors: 3-pin coupling knock sensors:
3-pin coupling knock sensors:
l. Common ground L Common ground
1 l. Common grOlmd 2. Knock sensor 1 (left 2 . Knock sensor 1 (left side of
2. Knock sensor 1 side of engine) engine)
3. Knock sensor 2 3. Knock sensor 2 (right 3. Knock sensor 2 (right side
side of engine) ofengine)
Coaxial connector for control Coaxial connector for control Coaxial connector for control
2 cable from crankshaft position cable from crankshaft position cable from crankshaft position
sensor sensor sensor
Left EZL resistance trimming
EZL resistance trimming EZL resistance trimming coupling (Rl6/3)
3
coup ling (Rl6/2) coup ling (RI6/2) Right EZL resistance trimming
coupling (R16/4)
4 Vacuum connection Vacuum connection Vacuum connection
8-pín coupling:
8-pin coup ling:
l. Ignition coil (Tl/1 , Tl/2)
8-nín counlin !l· 1 T!lnition coil (TI/2) te rminal 1
Mercedes-Benz
l. Ignition coil (Tl) terminal l 2. Ground temúnal 31

terminal! 2. Groundterminal31 3. Terminal 15
2. Ground terminal 3 1 3. Tenninall5 4. TN signal
3. Terminall5 4. TN signal 5. Negative, TN sígnal/
4. TN signa! 5. Negative, position cylinder recoguitionl
5. Negative, position sensor/ cylinder diagnostic output
A sensor/ cylinder recoguition 6. 6 left: ground (coding for
recognition 6. Ignition coil (Tl/1) left bank of cylinders,
6. Vacant terminal! cylinders 7-12), right:
7. Pulse output vacant
7. Pulse output
8. Camshaft position 7.. Pulse output and serial
8. Camshaft position diagnosis interface
sensor (L5/l) signa! sensor (L5/1) signal
output output 8. Camshaft position sensors
(L5/2, L5/3) signal output
8-pin coupling: 8-pin coupling:
8-pin coupling:
l. Camshaft position l. Camshaft position
l. Camshaft position sensors
sensor (L5/ l) signa! sens or (L511) signal
(L5/2, L5/3) signal input
input input
2. Transrnission overload
2. Transmission overload 2. Transmission overload
protection
protection protectiou
B 3. Data line
3. Data line 3. Dataline
4. Data line
4. Data line 4. Data line
5. Ground, camshaft position
5. Ground, camshaft 5. Ground, camshaft
sensor
position sensor position sensor
6. Ground, data line
6. Ground, data line 6. Ground, data line
7. Vacant
7. Vacant 7. Vacant
8. Terminal 30
8. Terminal30 8. Tenninal30
Engine 104
The EZL ignition control unit features a power output stage which actuates an 11 A ignition coi!
(Tl).
Mercedes-Benz
Fig. 148: Identifving EZL lgnition Control Unit (Engine 104)
The high voltage is distributed through the high voltage distributor (S5/3) in the firing order 1-5-3-
6-2-4.
The moving carbon in the distributor has been replaced by a fixed central electrode.
Fig. 149: ldentifying High Voltage Distributor In Firing Order

Mercedes-Benz
13 Olstnbulor ro!Of 81111

14 Folower
15 Oí stnbti.OH-ap
17 Cover
...._.,
Fig. 150: Identifying Distributor Components
Engine 119
The EZL ignition control unit features two separate power output stages each of which actuates an
11 A ignition coi] (T111, Tl/2).
Fig. 151: ldentifying EZL lgnition Control Unit ffingine 119)
The high voltage is likewise distributed through two separate high voltage distributors (SS/5, SS/6).
The high voltage distributor (S5/6) distributes the high voltage to cylinders 1, 4, 6 and 7, the hígh
voltage distributor (S5/5) to cylinders 5, 8, 3 and 2.
The moving carbon in the high voltage distributor has been replaced by a fiXed central electrode.
Mercedes-Benz
Fig. 152: Identifying IDgh Voltage Distributor Distributes High Voltage To Cvlinders
13 Dlstnbt!or rotor 8IIT1

14 Folcwer
15 Dlstnbt!or cap
17 Ccver
Fig. 153: ldeutifying Distributor Componeuts
Engine 120
The EZL ignition control múts each feature a power output stage which actuate an 11 A ignition
coil (Tl/1 , Tl /2).
T111 lgniloo cod 1 (nglltbarft o( ~dets)
Fig. 154: ldentifying lgnition Coil1 (Right Bank Of Cvlinders)

Mercedes-Benz
T1f2 lgnCJon c~l 2 (nghtboo!< of (yfrlclels)
Fig. 155: ldentifying lgnition Coil 2 (Rigbt Bank Of Cylinders)
The high voltage :iis dístríbuted through two separate hígh voltage dístríbutors (S5/5, S5/6). The
hígh voltage distributor (S5/5) distributes the high voltage to the left bank of cylinders (cylinders 7-
12) in the firing order 12-8-10-7-11-9, the hígh voltage dístributor (S5/6) to the right bank of
cylínders (cylinders 1-6) in the firing order 1-5-3-6-2-4.
The moving carbon in the high voltage distributor has been replaced by a ftxed central electrode.
Fig. 156: Identifying High Voltage Distributors
tl Olsmbúor r0ctor am1

14 Folawer
15 Olstnbu!or ~
17 Cover
.. ~,
Mercedes-Benz
Fig. 157: Identifving Distributor Components
d. EZL resistance trimming coupling
The ignition map for KA T or without KA T is activated vía the resistance trimming coupling
(Rl6/2, engine 120 Rl6/3 and R1 6/4).
The ignition is set for unleaded premium grade fuel with an octane rating ofRON 95.
Ifregular grade fuel with e. g. an octane rating ofRON 91 is used, a suitable resistance trimming
coupling (Rl6/2, engine 120 Rl6/3 and Rl6/4) must be installed (see Diagnosis Manual Engine,
Volume 1).
Fig. 158: Identifying Resistance Trimming Coupling
NOTE: lf regular grade fuel is used, the ignition timing is retarded by the
anti-knock control which increases the overall temperature level of
the engine. For this reason, regular grade fu el should only be used if,
in exceptional cases, no premium unleaded or premium plus is
available (see also Owner's Manual).
e. TN signaJ
The EZL ignition control unit converts the s inusoidal signal of the crankshaft position sensor into a
square wave signal - TN signaL
The conversion to the TN signal has become necessary as the ignition timing for each cylinder in
the knock control range may differ. The TN signal can be measured in exactly the same way as the
TD signaL
The signa) is passed by the EZL ignition control units to the respective LH control unit and from
there to the base module.
f Synchronization signal for fuel injection system
The injection sequence must be synchronized to ensure that the moment of injection is coiTectly
matched to the respective cylinder. The signa! ofthe camshaft position sensor (LS/1, engine 120
LS/2 and LS/3) is Tequired for this purpose.
The camshaft position sensor generates two altemating voltage signals during each rotation of the
Mercedes-Benz
camshaft. These are processed to square wave sígnals in the EZL ígnüion control unit and passed to
the LH control unit.
Fig. 159: ldentifying Camshaft Position Sensor
g. Coolant temperature signal
Thís signal is passed by the coolant temperature sensors (Bll/2, engine 120 Bll/9 and Bll/10) to
the respective LH control unit and from there via the CAN databus to the respective EZL ignition
control unit.
Bgno 104
Fig. 160: ldentifying Coolant Temperature Sensors (Engine 104)

Mercedes-Benz
Englne 1111
Fig. 161: Identifying Coolant Temperature Sensors {Engine 119)
En;wne 120
Fig. 162: ldentifying Coolant Temperature Sensors (Engine 120)
h. Safety measures
Should one ofthe coolant temperature sensors fail, a substitute temperature of 120 oc is selected. As this
temperature is within the boiling protection range> the ignition timing advance is retarded by 3.5° CA.
G. Anti-knock control (AKR)
Should the load sensor in the EZL ignition control unit fail, fullload is assumed to thus activate the anti-
knock control. Sbould the knock sensors, the analysis circuit in the EZL ignition control unit anci/or tbe
camshaft sensor fail, ignition timing is retarded 10° CA as a safety measure.
a. Block diagram
Mercedes-Benz
Wltrease 11 COfll)res~on as a causes -D Meochl!l1calllbratlcns

resol of coll'ÍltJ sbon residue'S
flcooect mll.ttn COill>GSilon 1

means a;e delactftdby
lllcortroled
rombuslion
11aeasedutal<o air
~peraturo
'7
EZl ign¡loo conrolunt (N113,
an;¡tne 120'N1f4 andN115) ~ otecncalsiQJle.ls
1
mls ?
ooaty¡os
~ loBd staio ol ong¡ne
1
C«Uoo cirrut IS
re~ated urd no fiJtlle( ~ C<ldentta~eral!lr&
l<n~clong JS detectod
1
wi:Jdl cyinder t1¡M SlgllaiS cf and
docKies knod<Jn gyes, no
~FII.IIoadfde speedcooálct
1
~ ~
Y es ]]No ~~ecognbonc)inder 1 or
c)ináar 12
1
c)indor no . !<roelOng
~ Eng¡ne speed
1 1
correds
~
byretaroog No d Hlnge 11 íQf111011 bmflQ or
1g111ion tmmg 1!11Jiion tining IKMlnce urnrl
map, aftnrcorrplobonotcon~ol
Fig. 163: Anti-Knock Control CAKR)- Block Diagram
b. Function
The ignition maps of the ignition system (EZL) are designed for optimal engine output. Should
knocking combustion occur under certain operating conditions, the knocking cylinder is detected in
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the respective EZL ignition control unit by the integrated anti-knock control and ignition tíming is
retarded accordingly.
Knocking combustion may occur, for example, as a result ofpoor fuel quality and deposits in tbe
combustion chambers.
The anti-knock control has been developed to avoid darnage as a result of knocking combustion.
The anti-knock control is integrated in the EZL ignition control unit
ft' rt ::li"
d• 1 ...
1.) Pmss11e an comoosbon chamhel

2.) lgmuon advanoe !lllgle
a I!Jliboo exces<.S~vcty'a~anced - modong
b lgmiJon •mllg corred
e lgnibon e>a:es5ivetyrotarded
d BTOC
e ATOC
Fig. 164: Fue) Ouality Graph
Pressure curve in combustion chamber during normal combustion

Mercedes-Benz
d BlOC
e
ATDC
Fig. 165: Combustion Chamber Pressure Graph
Pressure curve in combustion chamber during knocking combustion
d BTDC
o ATOC
Fig. 166: Combustion Chamber Pressure Graph
The "KAT" or "without KA T" ignition map in the EZL ignition control unít is activated by fitting
on an appropriate resistance trimming coupling (Rl6/2, engine 120 Rl6/3 and R16/4).
Should knocking combustion occur as a result, e. g. of fu el with a low octane number, the
mechanical vibrations produced are converted in the knock sensors into electrical signals and
passed to the respective EZL ignition control unít.
The EZL ignition control unit compares these incomíng signals with the specifications stored in the
integrated microcomputer.
If deviations exist, the ignition timing for the cylinder in which knocking combustion has taken
place is retarded by 3° CA as early as the next ignition.
Should the cylinder continue to knock, ígnitíon tirning is retarded by a further 3° CA.
This retardation of ignition timing may be repeated if knocking combustion continues to exist until
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a maximum retardation is reached, this bei.ng dependent on coolant temperature (e. g. 12 o CA at

80-90 oc coolant temperature).
Fig. 167: ldentifying Resistance Trimming Coupling
Several knocking combustions in a cylinder
a 1
1 lgnllOn anglo rel:ardedby

l'CA
2 lgrillOn angla allYanted by
0.35. CA
a lgnllOn angla BTOC

b Power slrol<es
P1 •-ota .........
~----------------------------------.-b
Fig. 168: Cylinder Knocking Combustions Chart
Should no further knocking combustion occur, the ignition timing of the cylinder in question is
restored to the map value by being advanced 0.35° CA per ignition.
An additional signal is required for detecting the cylinders for the anti-knock control. This
alternating voltage signal comes from the camshaft position sensor (LS/1 , engine 120 LS/2 and
LS/3).
Engines 104 and 119 each have a camshaft position sensor (LS/1) which detects cylinder l. Engine
120 has two camshaft position sensors (LS/2 and LS/3) which detect cylinders 1 and 7.
Should one of the followin~r comoonents fail. an í!rnition timin~r retardation deoendent on coolant
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temperature is activated for aU cylinders for safety reasons:
• Knock sensors,
• knock sensor analysis circuit of anti-knock control in EZL ignition control unit,
• camshaft position sensor (L5/ 1, engine 120 L5/2 and L5/3).
Examples for retardation of ignítion timing dependent on coolant temperature:
10° CA at l 00 oc coolant temperature

7° CA at 80 oc coolant temperature
To facilitate fault fmding, faults at certain components can be interrogated by means of a pulse
readout (flash code).
c. Knock sensor units
Piezo electric structure-bome sound sensors are used as knock sensors (Al6, engine 120 A 29 and A30).
The vibrations of the engine block are transmitted to the piezo ceramic and passed in the form of an
alternating voltage signal along a screened wire to the EZL ignition control unit.
A knock sensor unít consists of two knock sensors which are combined in a cable and can thus only be
replaced as a unit.
A 16 Kno:d< Sili1SOf un
Fig. 169: l dentifying K nock Sensor Cable
Engine 104, 119
NOTE: Piezo effect=generation of voltage as a result of pressure acting on a

Mercedes-Benz
certain ceramic.
A19 l eftlirlod< sensor uni

A30 Ri gtd linock sensor mt
Fig. 170: ldentifving Knock Sensor Cable- Right And Left
Engine 120
Engine 104
The knock sensors (arrows) are attached to the engine block below the intake manifold. This location
point has been selected as it is the best location to detect knocking combustion at aH cylinders.
Fig. 171: Locating Knock Sensor (Engine 104)
Engine 119
Mercedes-Benz
The knock sensors are attached to the engine block in each case below an engíne carrier. Thís installation
point has been selected as ít ís the best point to detect knocking combustíon at all cylinders.
Alrr:m Knock soosor, ng.ht stde c.f ongr1e
Fie. 172: Locatine Knock Sensor ffineine 119)
Fie. 173: Locatine Knock Sensor (Left Side Of Eneffie)
Engine 120
The knock sensors (A29) and (A30) are attached to the ínsides of the engíne block between the banks of
cylinders. This installation point has been selected as it is the best point to detect knocking combustion at
aH cylinders. The cables of the two knock sensors for each síde of the engine are combíned in a protectíve
sheath (flexible sheath).
Mercedes-Benz
Fig. 174: Locating Knock Sensor (Engine 120)
H. Camshaft position sensors
Two position pointers are arranged at the camshaft sprocket, offset relative to each other. This enables the
cylinders to be detected during each revolution of the crankshaft for synchronization of injection
sequence as well as for the anti-knock control.
The injection sequence for the cylinders is synchronized during the starting operation. In order to obtain a
strong signal already at starting speed, the air gap between position sensor and position pointer must only
be 0.4-0.6 mm. When performing repairs, the air gap must be checked and set, if necessary, with spacers
(see repair instructions).
l. Catalytic converter beating up
The exhaust temperature is increased in order to heat up the catalytic converter more rapidly to its
operating temperature.
For this purpose, the ignition timing, at idling speed and with selector lever in Por N, is continuously
retarded at a coolant temperature between approx. + 15 oc and +40 oc after each start for about 30
seconds depending on temperature, and idling speed is increased by the idle speed control to 1100-
1200/min. The idle speed increase is deactivated once a Drive mode has been engaged.
J. Transmission overload protection
GeneraJ
In order to protect the shift elements or the automatic transrnission from excessive thennal stresses during
power shifts in the top engine speed range, a transmission overload protection is integrated in the EZL
ignition control units.
As a result ofthe transmission overload protection, ignition timing is retarded to 5° CA before TDC for
about 400 ms (reduced em!:ine toraue) durimz 1 --> 2 and 2 --> 3 uoshifts (engine 120: 1 --> 2. 2 --> 3. 3-
Mercedes-Benz
-> 4).
As this retardation of ignition timing during the shifting phase also provides a smoother gearshift, this
measure is also used during 3 --> 2 fullload downshifts (engine 120: 4 --> 3 and 3 --> 2). Ignition timing
is retarded provided the following conditions are met sirnultaneously:
• Engine speed >4000/min (reference value)

• Vacuum in intake manifold <300 mbar (reference value)
• Shift signal from transmission overload protection switch, brake band Bl (S65) (engine 120: brake
band Bl (S65) or B2 (S65/ l)).
The transmission overload protection switch, brake band B 1 (S65) (engine 120: brake band B 1 (S65) and
B2 (S65/ l)) is designed as a hydraulic switch and linked to the operating pressure circuit ofbrake band
"Bl" and "B2", respectively, ofthe automatic transmission.
The opening and closing of the transrnission overload protection switch, brake band B 1 (S65) ( engine
120: brake band B1 (S65) and B2 (S65/ 1)) is detected as a shift signal by the appropriate EZL ignition
control unit. The shift function of the transmission overload protection switch, brake band B 1 (S65) is
dependent on the working pressure which exists at "B 1".
Working pressure < 1.8 bar: S65 opened.
Working pressure > 1.8 bar: S65 closed.
S65 Transmssioo oveooad protectlon S'Mtdl,

bJID<e band 8 1
Y3f2 Shftpout.retaidsofooOtdv.a.tve
Fig. 175: Identifying Brake Band
Engine 120
Mercedes-Benz
The shíft function of the transmissíon over load protection switch, brake band B2 (S65/ l) is dependent on
the working pressure which exists at "B2".
Working pressure <1.8 bar: S65/1 opened.
Working pressure > l. 8 bar: S65/2 closed.
The opening and closing ofthe transmission overload protection switch, brake band Bl (S65) and B2
(S65/ l) ís detected as a shift signa! by the appropriate EZL ignítion control unit.
SSS/1 Tremmtssaoo ovarloadprctadoo swt d1,

breke be.nd82
Fig. 176: Identifying Brake Band (Engine 120)
Emergency running mode transmission overload protection
If the EZL ignition control unit does not receive a shift signal from the automatic transmission when
driving, whether as a result of a fault at the transmission overload protection switch, brake band B 1 (S65)
or brake band B2 (S65/ l) or at the wiring, the appropriate EZL ignition control unit switches to
emergency runníng mode. The transmission overload protectíon ís active only to a restricted extent in the
emergency running mode.
If no shift signal is received from the automatic transmission, the EZL ignition control unit recognizes the
start of a gearshift as a result of a change in engine speed of a defmed magnitude. If the transmíssion
overload protection ís operating in the emergency nmning mode, this may make itself noticeable as a
result of a brief retardation of ignition timing at high speed. In the event of the complaint "misfiring at
hígh speed" the transmíssion overload protection switch, brake band Bl (S65) and brake band B2 (S65/ l)
as weU as the appropriate wiring should be checked.
K. Engine torque reduction in ASR control mode

Mercedes-Benz
GeneraJ
Ignition timing is briefly retarded if the vehicle speed is >20 km/h during the initial ASR control cycle in
order to achieve an immediate reduction in engine torque when the wheels begin spinning until the
throttle valve control is activated.
The signa! which is required to actívate the EZL ignition control unit in this case is supplied by the
electronic accelerator pedal control unít.
Electronic ignition system with variable characteristics EZL - RA1500KE3A020X(15-0020)
A. F unction diagram of ignition system (EZL)

a. Engine 102.910/962/963/982/985
X11
p 15..0214-35,>' 5·0% t 4~ 3 5
B11fl Coolan! !&mp.oralure sensor ( 2- Of 4..ptn) S29J2 TITo-~ votve S'.lllldl, trlloadlde -speed recogn~oo
G1 BattBJY T1 lgrlbonc~
l5 Cranksh~ posrjoo son sor X 11 Diag.noslíc sod<e~8lTTIJlalblo! k, temunal m
N1f2' EZl iQIIll~OO C'OI1JOIUI'Ill 1 Segmerts mdrrven plata
R4 Sparkptlgs 2 Vacwm lllo
R16 EZL res.smnco tl'imm~t~gpklg
S5f3 Hgh volage clístnbtiOt
Fig.177: Function Diagram Oflgnition System {EZL}
b. Engine 102.983/99
Mercedes-Benz
)(11
G1
P 15-0213-35A
Pt 5-0U3 · UA
811!2 Coolam mmp.eratue sensor f2· Of 4.ptn) S29/.2 llTolle \'!We S'Mich, ú lloa dllle speed rerogna on
81711 .-take au tomperatue sensorEZl. (electronlc) sss TmnsmJSSIOO cverloadprotecl!on SWIItn (autcma.5c
G1 8atte;y trensmss10n)
L5 Cranl<shS: pcsrton sonSOf T1 lg¡ttion coj
N1l2 EZl. tgn¡ion con~ol unt X 11 Otagnomc socke~lemmalblock, trurrunaiTO
R4 Sparkplugs 1 Segnem at~elldnv!lf1 pleta
R16 EZl.. r&Sis!B!'Ice mm~ngplug 2 Vat:U\JTlllrlO
S5f3 H. gtwolt!ge di Slllbttor
Fig. 178: Function Diagram Oflgnition System (EZL) (Engine 102.983/99)
c. Engine 103
Mercedes-Benz
T1
8 1112
G1
ffiüñP
Coolart lllmperalU!e s811S0f (2· or 4-pm) S29.'2
P1 5-S066-57
n.o~ wlve s·Mtdl, iJIIoadtdle spaed recogmnoo
G1 Batt91Y T1 lgrlboocot
L5 Cranksha1 poSiioo sensor X 11 Di agnosllc sodu~1letmilal bloc!-, tetmtnal ID
N112 EZL 1gn§on ronliolulllt 10 Segmarts atltfMleelldllven pla:e
R4 SparkpiUgs 12 V&UlJ:Tlliflo
R16 EZl. resiSiante rmm11g pllg
Ss.G Highvol:age dlslnbtlt<lr
F ig. 179: Function Diagram Oflgnition System (EZL) (Engine 103)
d. Engines 116, 117

Mercedes-Benz
2912
P1 5-5220-57
61112 C-oolaii lemperilble sensor (2- <X 4¡¡tn) S2912 ll'roll~ va've S'Mh:h, tlltoad.tde spfld rorog;~iicm
G1 Batter¡ T1 IQntJoncci
LS Cl8nksllat polillOO SllllSOf X 11 Dlagooslic sccke!ftellllllalblock, temunal ID
N1f2 EZL. 1gntoo conrolunt 2 Vactun lne
R4 Sparkptlgs 3 Se{Plerts atdnv1111 plata
R16 EZl rostStance flmmiJg~g
S513 Hlgll votago distnbúor
Fig. 180: Function Diagram Of Ignition System (EZL) (Eogine 116, 117)
Electroníc ignition system with variable characteristics EZL - RA1500KE3B020X(15-0020)
B. Location of components
a. Engine 102.910/96/982/985
Mercedes-Benz
61 1f2 Cwlart oompoo;lura s1111sor [2- cr 4-p¡n) S513 1-fgll vo\'.age distnWcr
61711 hal<e air tarnpcrelure sensor. ollQin& S 2912 fuo~ ..atve SMtch, ill loadlidle speed r&toQilboo
102.9&.98 KAT a<; ol OO!!l~ S2912x1 PkJQC0!'€19dOO, tl~ vaMl SWitCh
LS Cranksh~ poSI~on son sor T1 Jgnbon coi

N112 EZl i !Jilllion oon~ol urit
R16 EZl rssis!ance tmm.-.gpklg
Moáel 114 le:! otcornponontc.cmpartmert
Modal 201 etiEZl 1gnion con!Jolunt
Fig. 181 : Identifying Electronic Ignition System Location Of Components
b. Engine 102.983/99
Mercedes-Benz
..
,~
8 11/2 Coolart lBmpeiature sensor (2- or 4-pln) SS.G Hgh vc&age ástnbltcr
817ft EZl irtal<e ar temperalue sen sor S2Mlt1 Plugconnedcn, flrclt-il vaM! swich
817/2 KE ut el<e au tamptll"ature sensor S65 Tr!lll srms51on c'I'Ullooo prctecicn SNtch
l5 Cranksha= pasilon sensor T1 ~bonccl
N1/2 E.Zl agnton coowolu111
R16 E.Zl f!tSI$IenCO l'i'nmngpllg
Et1g11a 102.Sal Std nglt ol componert ocmplliÚl18lll
Fie. 182: ldentifyine Electronic Ienition Svstem Location Of Components (Eneine 102.983/99)
c. Engine 103
Mercedes-Benz
81112 C01llam tempemturo sensor 14-ptn) S5f3 Hlgn vomge <istnbúor

L5 Q¡¡¡¡¿¡k¡t¡~ S29lb..1
Crellksha! PQ"SI~on soos:or S2912X1 P\lgcomec~on. lhr~e va've swtdl, Mkladld:e
N112 EZL 1gmíon oonrolunt spe&d rocognttion
R16 EZL resismnc~ nnmW'lg pklg T1 lgnilloo c;ol
En911e 103.980" fl!1ll ol c;OfTl>O!len!corrpaJtnert
Fig. 183: ldentifving Electronic lgnition Svstem Location Of Components (Engine 103
d. Engines 116, 117

Mercedes-Benz
,...-oaza••
A1p8 Eloctont spoadomelnr •.v-llh mBJGmum spoadtmiler 5513 High v~ga dslnbttcr
(onty eng~ne 117.968) 52912 llTo!!le Vlllv& s·,\ltch, Llllo.a<Vl<te spe~drerogribon
81112 Coolart tempen;ttse SBilSOf (EZl/AKR, KE) 565 TransmtsSion owrloadprotsuoo swlch
(4-~) (onl{ engme 117 91>8)
LS Cra.nksllal po Sl~cn son ser T1 lgrclion coi
N1f2 EZI.. í!Jllion coorol ufllt
R 15 EZI.. re s•slallce nnm11g pl¡g
Fig. 184: Identifying Electronic Ignition System Location Of Components (Engine 116, 117)
Electronic ignition system with variable character·istics EZL - RA1500KE3C020X(15-0020)
C. EZL ignition control unit (Nl/2)
Intluencing parameters at EZL ignition control unit

Mercedes-Benz
Jgn~on startar swtcll Vot:ago supplyf+l

{S211)1911Tlllal 15 _llgnllon eol
--i> -[>
1
EZl tgttboll coctroh rot
(N1n)
GlOIIld p~nt W3 I!Jlbon mllllt;> C>
FrclileftwhoeroJso DNel 9!\1il conrol
4Clf0Uld(.)
1-{>: Prmasy currarA
l mlrlg
Prmasy rurrom
rui!Dfl
Crorl<shaftposmon soosor EO!Jina spoed af1d
(1.5) clllñ<shaft posilon
---t> -i>
- '- -
lrtel;e mantokl WC U!J11 Load ste!e PresstFe
f--t:. of Ofl!ll'no -{> soosor
C> C>
r-
Coo!Blll tomperattco
-
4Coolantt611llera~ro
~
sensor {81 1f2)
Thrott!e vat<a s>~lth

Fui b ad JlOSI•on Ofl!llnes
1161117
.l-o
(52912)
[> H~ll!Jno ~ad Signa! [>
-o~~o spelld pcstbon ong;no~-i>
{lD Sigllal)
102, 103
Ros•s!afoc.e tmmllg pllg

(R16)
lg¡libon map adapt¡Don !
---t:: -i> S4'lJIOS
cc;¡tols
Tmnsm ss10n overload

pro¡eeboll S'Mt:h {565) C> J
Ol!lgllcslic sockél
C>
{ody engznos 102 983.99
'Mfl oolomallt
ransrrusSioo and qne
117.006)
-o]Ga!Vstif!S
l-o X11
7
Tacllomotor, lllclpurrp
reley, AC COfllli.OSSOl
ruiDif cortrol Ull, KE
nake e;r t.emperat1Se coníolun~ 90!Jino
soosor {B1711) systoms cortrol Ulá o¡¡:_
[> [>
-oj~mkeer
~
{oriy engmas 102 91.9&9S
KATasoi09J89 aod tompom!tn
BO!JIOOS 102.983199)
ElearonK speedomeler Maxn:um sp&ed

{A1p8)(orifoog~~a •mbn~
117.968) ---1> -!> [> [>
Fig. 185: Communication Diagram - EZL Ignition Control Unit
The EZL ignítíon control unít ís located on the left wheelhouse paneL
It is installed with heat-conducting paste to dissipate the heat. When exchanging component, the
protective sheeting must not be removed. The sheeting does not impair heat dissipation. The EZL ignition
control unit contains a mícrocomputer, a pressure sensor and the power output stage.
Mercedes-Benz
The ignition characteristics for typicalload/ engine speed ranges anda fixed idle speed-ignition
characteristic curve (engines l 02, 103) or a fixed fullload-ignition characteristic curve (engines 116/ 117)
are stored in the microcomputer of the EZL ignition control unit. The EZL ignition control unit detects
the momentary operating state ofthe engine from different input signals. Engine speed in crank.shaft
position are detected by the crankshaft position sensor.
The optimal ignition timing point for the particular operating state is determined from the stored ignitíon
characteristic curves, taking into account all the input signals and the position of the resistance trimming
plug.
3 4
Vacuum cofl!ledJon
2 Coaxial connoctor for control i ne i"om posaban sensor
3 4·ptn c<~nnector, sensor
1 Cootoottefl1lera~rlt sllflSor
2 Thro~ e vatve S'llitdl
3 EZl resislance nnmlflgpklg

En gw1e 102.9-33/99wih atoma'!lc lrMsrrission
m addllon •ansmassaon oveooad protectioo stM!th
(r&sastaoce lnmmmg püg posai on -r no longar
perrmsSJble)
4 Vacarn (cable oods an hamess)
E.ng;r1e 102.9 1019M/8 KA T as of 09189 and
engme 102.!fa3J99: 111Bke an te~ra:ure ·seosor
E.ng:rHi1103.9R4 'llitil aJJ!omebc tmnsmtss.on:
~nd, (W3)
Eng¡ne 117.968" transmiSSJOfl oveñoad pro~cllo11

swidl
4 4-ptn conoortor, S'!..IPi>tf
15 : Tenn'l1al 15
16 : lgnion roil tnrmnal 1
TD : T0Stgllal
31 = GrOUld
Fig. 186: Identifying 4-Pin Counector Terminal, Sensor And Coolant Temperature Sensor
Thf' int~la~ m~nifnlil v~r.mrm i~ ::a m f'~~llrP. fnr thP. ln::ac! st::atf' nfthf' f'n!}"jnp ThP. int::akP. m~nifnlc! v::ar.m1m
Mercedes-Benz
passes along the vacuum hose to the pressure sensor in the EZL ignition control unit where a pressure-
dependent voltage signal is produced. As engine load increases, the ignition timing point is advanced
(higher engine torque).
The power output stage actuated by the microcomputer switches the primary current of the ignition coil
between terminals 16 and 31 (4-pin connector, supply).
The EZL ignition control unit also contains the functions of dwell angle control, primary current cutoff
and primary current limiiting.
The optimal performance of the ignition system is achieved by means of the dwell angle controL The
dwell angle is controlled within the control range in such a way that the same primary current is always
approximately achieved in any operating state, i. e. with different battery voltages and engine speeds.
Primary current limiting (effective up to approx. 2000/min) and primary current cutoff (when engine
stopped and ignition switched on) enable the series resistors in the primary circuit to be eliminated which
permits a higher ignition coil primary current and thus a higher ignition capacity.
The speed-dependent TD signal is produced in the EZL ignition control unit. The TD signal is passed via
the screw connection (arrow) at the diagnostic socket/terminal block, terminal TD (XII), to all the control
units with a TD terminal connection (tachometer, KE control unit, fuel pump relay and AC compressor
cutoff control unit etc.).
When the engine is started and running up to approx. 450/min, the ignition timing point is controlled only
via the segment edges ofthe flywheeL Only after a certain speed is reachedl (approx. 460/min) is a
transition made from the fixed ignition timing point to the timing point calculated accordingly for the
momentary operating state.
Fie. 187: Locatine Terminal TD
In the warrning-up range, various ignition characteristics are inhibited depending on the coolant
temperature in order to achieve operating temperature as rapidly as possible.
Mercedes-Benz
Idling speed engines 102, 103
A fixed ignition characterístic ís specífied ín idlíng speed and deceleratíon mode when the ídle speed
contact ofthe throttle valve switch is closed. This is ínfluenced neither by the temperature sensor, the
intake manifold vacuum nor by the EZL resistance trimming plug.
NOTE: In the event of an open circuit in the coolant temperature sensor

(resistance N t), the fixed id le speed characteristic curve is left in the case
of Bosch ignition control units and a certain ignition timing point in the
map is selected, i. e. the ignition timing point is advanced.
Idling speed engines 116, 117
The vacuum advance also operates in idling speed,
í.e. there ís no fixed ídle speed characterístic curve.
Ignítion timing advance also operates in ídling speed by means ofthe resistance trímming plug (without
vacuum).
Fullload
At fullload, the ignition timing point is determined by the fullload ignition characteristic curve. In this
case, the ígnition timíng poínt is advanced (higher engine torque), taking into account the knock limit.
Engines 102, 103 : The EZL ignítion control unit detects fullload from the intake manifold vacuum and
engine speed input signals.
Engines 116, 117 : The EZL ignition control unit switches to a fixed characteristic curve in the case of
fullload. Fullload is detected via the fullload contact in the throttle valve switch.
Eogine 102.983/99 : Two fullload ignition characteristic curves are stored in the EZL ignition control
unit.
Depending on the switching position of the EZL intake air temperature sensor (B 1711) the ignition timing
poínt is determined as follows:
o Below +25 oc íntake aír temperature by the advanced ignitíon characteristíc curve.
o Above +25 oc intake air temperature by the retarded ignition characteristic curve.
Mercedes-Benz
Fig. 188: ldentifying EZL lntake Air Temperature Sensor
Intake air temperature
Engine 102.96/98 KAT as of 09/89: On these engines with intake air temperature sensor (Bl7/ l) the
ignition timing point is retarded as the intake air temperature rises.
Transmissioo overload protectioo
On engines 102.983/99 and 117.968 with automatic transmission the function oftransmission overload
protection is additionally integrated in the EZL ignition control unit.
Manual/automatic transmission
On engines 102.96/98 KAT as of09/89 and engine 103.984 an ignition map for automatic transmission
and an ignition map for manual transmission are stored in order to further improve driving properties.
Engine 102: The respective map is activated by means ofthe EZL resistance trimming plug (R16) wilth
the inscription "AUTOMATISCH" or "MECHANISCH".
Fig. 189: ldentifying Distribution Cap (Engine 102.96/98)

Mercedes-Benz
Engine 103.984: Asan ídentíficatíon ofwhich ignítíon map is to be actívated, the cable from the EZL
ignition control unit, connector (B), contact 4, ís connected to ground W3 on vehicles with automatic
transmission.
On vehicles with manual transmission this cable ends in the wiring harness.
Fig. 190: ldentifying Distribution Cap (Engine 103.984)
Resistance trimming plug
The ignition timing points of certain ignition characteristic curves can be adjusted, depending on the
operating state, with the EZL resistance trimming plugs.
Two maps are stored in the EZL ignition control unit for the following operating modes:
l. Operation without catalytic converter (EZL-ECE or EZ ECE S resistance trimming plug).

2. Operatíon with catalytic converter (EZL-KAT resístance trimming plug).
The national versions n::s:=-ss , &. , OC! have reference resistors.

Mercedes-Benz
Fig. 191: ldentifving Resistance Trimming Plug
Fig. 192: Identifving Distributor Cap
NOTE: The EZL ignition control units of engines 102.983 Std., 103.980 Std. and
117.968 Std. (220 kW) have only one ignition m ap. The ignition timing point
is advanced for leaded and unleaded premium grade fuel with a special
resistance trimming plug (inscription EZL and figures 1-7).
Mercedes-Benz
Fig. 193: ldentifving Distributor Cap CEngine 102.983)
Safety measures at ignition control unit
In the event of a short-circuit or open circuit ofthe coolant temperature sensor, tbe EZL ignition control
tmit (depending on version) operates with a fixed value (substitute ternperature) and retards tbe ignition
timing point approx. 10° (safety retardation).
Boiling protection correction
If a coolant temperature of 90 oc to 100 oc (depending on version) is exceeded, certain ignition

characteristic curves are retarded in order to counteract any further rise in temperature.
The ignition timing point test must be performed ata coolant temperature between 75 oc and 90 oc
because of the boiling protection correction as the ignition timing point alters outside of tlús temperature
range.
In order to avoid incorrect rneasurement of tbe ignition tirning point, unplug connector for EZL coolant
temperature sensor and feed in a resistan ce of 320 ohms
(=80 oc coolant temperature) witb the resistance decade.

Mercedes-Benz
B11f2 Coolantterrpera~ct:J soosor

W11 Eo~neg~d
Fig. 194: Identifying Coolant Temperature Sensor
Example engine 102.99
Example engines 102.91/96/98 KAT
Activation of the boiling protection correction begins from a temperature of 100 °C. The ignition timing
is corrected by being retarded as follows:
l 00 oc --> KW retarded. 2° CA
11 O oc-->KW retard.ed. 4° CA
120 oc -->KW retarded 5° CA.
In addition, the correction of the boiling protection and of the intake air is added, i. e. 120 oc coolant
temperature and 50 oc intake air temperature result in a maximum retardation of 12° CA.
All engines with intake air temperature sensor for EZL ignition control unit:
To test ignition timing, unplug intake air temperature sensor connector.
Electronic ignition system with variable characteristics EZL - RA1500KE3D020X(15-0020)
D. Cranksbaft position sensor (LS)

Mercedes-Benz
In order to actuate the EZL ignítíon control unít, the crankshaft posítíon sensor (L5) detects the crankshaft
posítíon and engíne speed_
The position sensor is installed at the crankcase above the starter flange (arrow)_
The solenoíd body extends to just shortly in front of the segments on the flywheel or on the driven plate.
Segment posítíon and speed are detected by non-contactíng means.
Eng~nos 102, 10l , 104
Erqnes 116, 117
¡ o
.
i ----' '2
L ---------------------------- ---- - ------- -- - ---
Fig. 196: ldentifying Crankshaft Position Sensor {LS) {Engine 116,117)
When the engíne ís rotatíng, an alternatíng voltage is produced in the crankshaft positíon sensor (L5) as a
result of the induction. The peak value of the voltage CUu) is approx. 1.5 volts at starter speed. As engine
speed increases, the voltage rises (U8 approx. 3 volts at 1200/min).
NOTE:
Mercedes-Benz
Measure peak value of the voltage (U u ) with the oscilloscope.
Fig. 197: ldentifving Cranksbaft Position Sensor Cables
The crankshaft position is detected from the voltage as follows:
The front edge of the segment produces a negative voltage signaL
The rear edge of the segment produces a positive voltage sígnaL
Voltage signal, position sensor, engine 102
11 1 stsa~em
12 2rld segmen!
d Penodlor cn&crari<shal!revokt~on
Fig. 198: ldentifving Wave Form (Voltage Signal, Position Sensor, Engine 102)
Voltage signal, posítion sensor, engines 103, 104

Mercedes-Benz
t1 1sts'e"gmest
t2 2nd s&gment
t3 3ldsagment
d Ponodfor ooo aañ<shaftrovcii.CJoo
Fig. 199: Identifying Wave Form (Voltage Signal, Position Sensor, Engioe 103, 04)
Voltage signa} position sensor engines 116, 117, 119
t1 1SI segm!lrt
12 2nd S egnent
t3 3rdse~t
14 4th segrn!lrt
d Penodfor ooe aarf\shalt
ro\10\iion
t---------d-::--------~-1 P11J-QU4~:1
Fig. 200: Identifying Wave Form (Yoltage Signal, Position Sensor, Engine 116, 117, 119)
Engine speed is determined by measuring the period (d).
The alternating voltage ofthe position sensor is passed along the control cable (coaxial cable) to terminal
7 at the EZL ignition control unit. The cable is a single-core type. The screening is used as a second
cable.
lf the EZL ignition control unit does not receive a signal from the position sensor (e. g. open circuit of
sensor coíl), the complete ígnition system ís not operational.
The resístance of the position sensor between tennínal (7) and terminal (31 d) is 680-1200 ohms.
Mercedes-Benz
;--31d
P11-0240•13
Fig. 201: ldentifving Resistance OfPosition Sensor Between Terminal
Electronic ignition system with variable characteristics EZL - RA1500KE3E020X(15-0020)
E. Flywheel/driven plate with segments
As the segments rotate passed the position sensor, an altemating voltage is produced as a result of
induction.
Engine 102
Two segments offset by 180° (A) are fitted to the flywheel orto the dríven plate.
FtfMieel {manualtansmisSioo)
Fig. 202: ldentifying Flvwbeel (Manual Transmission)

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OnYI!tl plete 'Mil r11g gear

(81Jomalic transmssiOil)
Fig. 203: ldentifying Driven Plate With Ring Gear (Automatic Transmission)
Engines 103, 104
Three segments offset by 120° (arrows) are fitted to the flywbeel orto the driven plate.
A Onven plata wtil nng gear (aulcmabc transmission)

8 Ft¡...tleel (maruallrallsm~SSIOO)
A 8
Fig. 204: ldentifving Flvwheel And Driven Plate With Ring Gear
Engines 116, 117, 119
4 segments offset by 90° are fitted to the ring of the driven plate in order to actívate the ignition system.
Mercedes-Benz
Fig. 205: Identifying Positioning Sensor
Notes regarding damaged segments or mechanical damage to position sensor:
• Alternatíng voltage of position sensor below specification.

• Alternating voltage signals ofindividual segments differ greatly.
• No alternating voltage signaL
E lectronic ignition system with variable cbaracteristics EZL - RA1500KE3F020X(15-0020)
F. Coolant temperature sensor {Bll/2)
The coolant temperature is detected by a temperature sensor.
Temperature sensors with 2-pín or 4-pin connection (the latter as of approx. 09/89) are fitted. The
resistance of the coolant temperature sensor alters as a function of engine temperature ( see characteristic
curve). The characteristic curves of all the versions are identicaL
NOTE: NTC=Negative temperature coefficient, i. e. the resistance becomes less as

temperature increases.
Coolant temperature sensor (Bll/2), 2-pin
The coolant temperature sensor has two NTCs each with a one-pin connection. One NTC for the KE
injection system and one NTC for the EZL ignition system.
The temperature signal is passed along the green/black cable at the 4-pin connector, sensor (contact 1) to
the EZL ignition control unit.
Engines 102.96/982/985
Mercedes-Benz
rt-..
"'l
tClOOO ~
toCO
~
'tia~
4.01:10
~
.bOllO
a1ICIO
'' ~
~
1000
~~
ICID
~
~
-S
IX --
~
~
' ~...........
' ~ .......
.,
1 00
ICJ
~
~
tcl
10
- 30-10 o » 40 eo eo 100 t:ao <OC
"'a-on1-n
Fig. 206: Coolant Temperature Sensor Graph
B11f2 2- 01 4-pln coolart tempera!U'e senSOf

(atrrontlett on cytnder hoaá)
Fig. 207: Identifying 2- Or 4-Pin Coolant Temperature Sensor
Engínes 103, 104

Mercedes-Benz
6 11/2 2- Of 4-pmc'O"oiEirt wmperelUe SMWI
(et rear le! on cytnder head)
Fig. 208: Identifying 2- Or 4-Pin Coolant Temperature Sensor (Engines 103, 104)
Engines 116, 117
8 1112 Coo!Eirt temperatura sen sor
(etrear lc2 on cyfflder heaó t~Pb01 /Sll)
Fig. 209: Identifving Coolant Temperature Sensor (Engines 116, 117)
Engines 116, 117
8 11/2 2- cr 4-pln coo1ant tempcratue Se<l!>Cf
(lllfronloocylndorho.ad 65 of01/86)
Fig. 210: Identifying 2- Or 4-Pin Coolant Temperature Sensor (Engines 116, 1117)
Engine 102_ 983/99

Mercedes-Benz
811r2 2- oc 4..p~n roolatt !Bmperatl.re sensor

(atrrontoo ~nd8f haad)
Fig. 211: ldentifying 2- Or 4-Pin Coolant Temperature Sensor (Engines 102.983/99)
The sensor integrates two separate temperature sensors (NTC) wbich do not have any electrical
connection to the housing of the coolant ternperature sensor.
Fig. 212: Identifying Coolant Temperature Sensor 4-Pin
One temperature sensor is for the EZL ignition system (contacts 1 and 3) and one for the inj ection system
(contacts 2 and 4).
The connector of the coolant temperature sensor is designed in such a way that it can be plugged in any
desired position. The two temperature sensors are located diagonally.
e.g. engines 102/91/96/98

Mercedes-Benz
8 1112 4-pln ccolart tsm~rature sensor
Fig. 213: ldentifving 4-Pin Coolant Temperature Sensor
Pin assignment:
1=EZL temperature sensor
2=KE temperature sensor
3=Ground W3, front left wheelhouse
4=Ground, KE control unit
Notes regarding testing coolant temperature sensor (Bll/2)
When testíng the coolant temperature sensor, measure and compare the resistances 2 X diagonally.
_&_1,_12-.rr=w~l
KE
Fig. 214: ldentifving Connector Pin
Electronic ignition system with variable characteristics EZL - RA1500KE31020X(15-0020)
l. EZL resistance trimming plug
Two different types of resistance trimming plugs are fitted:

Mercedes-Benz
a. Variable resistance trimming plug (RI6).

b. Reference resistor (RI6/I) with fixed resistance (~BB , ~ , [l] ).
EZL resistance trimming plug {Rl6)
The ignition timing points of certain ignition characteristic curves can be adjusted with the EZL resistance
trimming plug, depending on the operating mode. This enables tbe ignition timing point to be adapted to
the available fuel (premium "S" and regular "N").
This setting to premium or regular grade fuel can also be performed by the customer (refer to Owner's
Manual).
Fig. 215: ldentifving EZL Resistance Trimming Plug
On engines 102.96/98 KAT as of09/89 an ignition map each for automatic and manual transmission is
stored in the EZL ignitíon control unit.
The ignitíon maps are activated by special resístance trimming plugs (RI6).
Fig. 216: ldentifying EZL Resistance Trimming Plug (Engines 102.96/98 KAT As Of 09/89)
NOTE: Optimal engine output and fuel consumption values are obtained when the
engine is operated with premium fuel.
Mercedes-Benz
Vehicles with the "EZL" resistance trimming plug must only be operated with leaded/unleaded premjum
fu eL
Models 107, 201
R16 EZL reSist!lOO! binmmg pklg
Fig. 217: IdentifvingEZL Resistance Trimming Plug (Models 107, 201)
Resistance trimmiog plug position "7"
On engines 102.983/99 with automatic transmissíon, resistance trimming plug position "7" ís assigned to
the transrnission overload protection signal.
On engine 117.968 it is assigned to the maximum speed limiting signa!. Thís position must therefore not
be used.
Model201.034
R16 E1l r&Sistante lnmmng ¡Wg
Fig. 218: Identifying EZL Resistance Trimmine Plug (Models 201.034)
Model 124
Mercedes-Benz
R16 EZl reSistanco tlim:ning pklg
Fig. 219: ldentifving EZL Resistance Trimming Plug (Models 124)
Model l24.030 with engine 103.980
R16 EZl res.starn:& lnmmng pkJg
Fig. 220: ldentifying EZL Resistance Trimming Plug (Models 124.030 With Engine 103.980)
The resistance network of all the EZL resistance trimming plugs is identical. The resistance trimming
plugs differ only in terms ofthe inscription.
ModeJ 126
R16 EZl rosastanco tlimning pkJg
Fiº. 221: Identifvinº EZL Resistance TrimminP Pltu! lModels 126)

Mercedes-Benz
The following resistances are assigned to the respective plug positions by meaus of the inscription:
RESISTANCES OF RESISTANCE TRIMMING PLUG (R16)

Position Resistan ce EZL r esistance trimming plug
"EZLECE" "EZLKAT" "EZL" "EZECE- "EZL-KAT "EZL-KAT
only S" only MECHANISCH" AUTOMATISCB
engines engine
102.983 102.983
Std. RUF
103.980
Std.
117.968
Std.
(220
kW)
iufmity
A
ohms
S 1 1 1 - -
B 2.4 kohms 2 2 2 S - S
e 1.3 kohms N 3 3 N S -
D 750 ohms 4 S 4 4 4 4
E 470 ohms 5 5 5 5 N N
F 220 ohms 6 N 6 6 6 6
G Oohms 7 7 7 7 - -
No resistances are positioned in the bottom part ofthe plug. The respective resistauce ofthe plug ís
tapped between the middle contact and tbe outer contact with which a contact is made.
IIU-It<l1•1l
Fig. 222: ldentifying Bottom Part Of Plug
The various resistors are located in the plug between the outer and inner pins.
The EZL iguition control uuit detects the resistance connected between resistance trimming plug and
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ground.
Perform resistance measurements for testing the resistance trimming plug at the ignition control unit
between sensor connector (contact 3) and ground.
NOTE: No pin is fitted in position A.
Fig. 223: ldentifying Trimming Plug Pins
EZL reference resistor (R16/1)
The EZL reference resistor (R16/1) has a fixed resistance. A certain ignition map in the EZL ignition
control unit is activated with the EZL reference resistor (Rl6/ l ). The ftxed resistances differ according to
the Part No. as follows:
Model201
Fig. 224: Identifying EZL Reference Resistor (Model 201)
PartNo. Resistan ce
000 540 22 81 220 ohms
000 540 23 81 470 ohms
Mercedes-Benz
000 540 24 81 750 ohms

000 540 25 81 1300 ohms
000 540 26 81 2400 ohms
Model 124
Fie,. 225: Identifying EZL Reference Resistor (Model124)
Mcdei 1ZS
Fig. 226: Identifying EZL Reference Resistor (Model 126)
Resistance measurement for testing the reference resistor (R16/ l) at the EZL ignition control unit
between sensor connector (contact 3) and ground.
PS-.IUI....¡II
Fig. 227: Identifying Resistance Between EZL lgnition Control Unit Between Sensor Connector
Anil r.ronnrl
Mercedes-Benz
Electa·onic ignition system with variable charactedstics EZL - RA1500KE3K020X(15-0020)
K. lgnition coil
Two windings are housed in the ignition coil. The primary winding between terminal! and terminal 15 is
low-impedance and consists of a small number of windings with thick copper wire. The secondary
winding between terminal 1 and temünal 4 is composed of a large number of windings with thin copper
wire. The resistance is 8 -13 k ohms.
If the primary circuit is closed vía the EZL ignition control unit, a high current flows through the primary
winding. A strong magnetic field is produced in the premagnetized iron core of the ignition coil.
In order to achieve a bigher ignition energy, tbe ignition coil is matcbed to the EZL ignition control1.mit.
As a result of the high switching capacity of the EZL ignition control unit, the primary current can be
further increased. The primary winding is designed as a very low-impedance of winding for this purpose
(engines 102, 103, 104, 119: 0.3- 0.6 ohms engines 116, 117: 0.2 -0.4 ohms).
Closed-circuit cutoff and primary current limiting enable the ignition coil to be operated without series
resistor. This eliminates the need for current linüting by means of the series resistor. If the maximum
primary current flows unlimited in the ignition coil (e. g. closed-circuit cutoff faulty), the ignition coi l is
damaged after a very short time as a result of the considerable heat which is developed.
Distinguishing features:
On 4- and 6-cylinder engines and engine 119 with EZL or EZLIAKR ignition systems the igtütion coils
are identical (identification: yellow rating plate). The ignition coils cannot be interchanged with the
ignition coils ofthe 8cylinder engines M116, 117 (identification: green rating plate). Pay attention to part
no. when replacing.
The primary current is interrupted in the ignition timing point by the EZL ignition control unit, the
magnetic field collapses abruptly producing the rugh ignition voltage in the secondary winding as a result
of induction.
The greater the primary current, all tbe greater is the magnetic field and thus the ignition voltage. A higb
ignition voltage is a prerequisite for bigh ignition energy.
Mercedes-Benz
e To EZl lgflillon cornrcl un (N112)

4-ptn suj:)ptf Cc()flnadcr, tormn~ 16
b To EZltg11illon rorrtroh m (N1/2)
4-pin suppt¡ ocnooctcr, mrmnal 15
Fig. 228: Identifying Ignition Coil
FUNCTION OF BREAKERLESS TRANSISTORIZED IGNITION SYSTEM WITHOUT SERIES

RESISTORS WITH HYBRID IGNITION CONTROL UNIT (TSZ) - RA1500KE20015X(15-0015)
Gl
G1 Ba ttery SS/2. Breakelless dlstrl butor

N1/1 Translstotlzed lgmtiol'l cont.tol unit {TSZ) T1 tgnltlon eoll
R4 Spa11< pltJ9s X11 Olagnostie soekeVtermlnal b4oek, term~nal TD
Fig. 229: Function Of Breakerless Transistorized Ignition System Without Series Resistors With Hybrid
Mercedes-Benz
Ignition Control Unit (TSZ)
The engines 102.96/982/985 in basic version Standard and national versions (KE l , KE 2) are equipped with a
breakerless transistorized ignition system (TSZ). Refer to Repair Instructions Engine 102 KE injection.
A TSZ ignition control unit (Nl/1)
l~nltion statter swlt:h Vollage supply (+) Owell angle control

(S21) Terminal 15 TSZ Closed oi nctilt OUI-{)ff
~ ignition Prirruuy curre:nt imlllng
control unít
(N1/1)
v
ClOniiOis
Gfoond point W3
Frort left wfleelhoose
-t> 1
Grou:nd ( • )
1-t> ~
l lgnti!On co~
1
lndlctille se:nSOf In Eng.lne 1.peed ln cmnkshal Englne speed slgnaJ (TD signa!)
dJStributor posIlion
-{> -t>
¿
supplles
~
l
controls
Olagnoatic socket
X11
Tachometer,
1
fue! pump relay,
AC oonnpressor
cut-{)ff control uJ\11,
KE control unlt, etc.
Fig. 230: Commuuicatiou Diagram- TSZ Ignition Control Unit
The TSZ ignitíon control unit is posítíoned on the left wheelhouse panel.
A 4-pin coupling and the control cable (coaxial connector) are plugged into the TSZ control unit.
Mercedes-Benz
1 lgnillon col
2 TSZ lgnitlon conltol unil
3 Tt!tmnal bloCk, terml'lal TO
4 DlagnostJc socket
Fig. 231: Identifying TSZ Ignition Control Unit Components
Contact assignment at TSZ ignition control unit
• Green control cable from inductive sensor in distributor (coaxial connector).

• 4-pin round connector with the terminals 15, 31 , 16 and TD.
Fig. 232: Contact Assignment At TSZ Ignition Control Unit
The electronic functions of primary current lirniting and closed circuit cut-off in the TSZ control unit
make it possible to elirninate the series resistors in the primary circuit. This makes possible a higher
ignition coil primary current and bigher ignition capacity.
The TSZ ignition control unit is actuated by the inductive sensor in the distributor.
Optimal performance of the ignition system is achieved by the dwell angle control in the TSZ ignition
control unit. Within the control range, the dwell angle is controlled in such a way that approximately the
same primary current is always achieved in any operating state, i.e. with different battery voltages and
engine speeds. As a result of elirninating the series resistors, the cut-off of the primary current is
performed by the TSZ ignition control unit when the engine is not running and the ignition is switched on
(closed circuit cut-off). The primary current is not connected until a certain pulse sequence ís generated
by the inductive sensor in the distributor.
Mercedes-Benz
The maximum prímary current of the ignition coi~ is determined by a current limiter in the TSZ ignition
control unit.
Current hmiting (e) can be recognized on the oscilloscope when the engine is idling. Current limiting is
no longer visible when the engine is running at approx. 2000/min or higher.
The power output stage switches the primary current of the ignition coil between terminals 16 and 31. In
addition, the power output stage performs a task of primary current limiting.
¡:·
1~
............
a Open¡ng a~1e
b 0\veUanglo
e Currenl limitlnQ
Fig. 233: Wave Form For Current
B. TD signal
The transistor speed (TD) signa! is produced in the TSZ ignition control unit. This is an engine speed-
dependent square wave signa!.
The engine speed is detected from the number of square wave signals per minute. When performing tests,
the cut-in time (t, e.g. 70%) ofthe individual square wave pulses is measured as dwell angle in degrees or
as on!off ratio in percent (related to period, d).
Mercedes-Benz
uf
- lli
d.
- t
Fig. 234: Identifving Blinking Pattern Of TD Siignal
The TD signal can be measured:
• With the dwell angle tes ter or on/off ratio tester in percentage and degrees.
• With the voltage tester 6 volts up to 12 volts direct voltage.
• With the oscilloscope - square wave signals..
NOTE: In the case of a short to ground at the connected equipment or at the

diagnostic socket/terminal block terminal TD (X11), no TD signal exists.
For troubleshooting, detach cable connection (arrow). Rectify short to
ground in the relevant circuit.
Fig. 235: Locating Block Terminal TD
The following electronic components have a TD connection, e.g.:
Tachometer, KE control unit, fuel pump relay and AC compressor cut-off control unit.
C. Distributor (SS/2)
Mercedes-Benz
• The inductive sensor is installed in the distributor and produces an alternating voltage up to approx.
100 volts for actuating the TSZ ignition control unit. The alternating voltage is fed along tbe green
control cable (coaxial cable) to the ignition control unit. The green cable is a single-core cable. The
screening is used as a second cable.
Fig. 236: ldentifying Distributor
• Engine speed-dependent ignition advance by means of flyweights. Load-dependent ignition

advance by means ofvacuum (above coolant temperature of approx. 60 °C).
• Interference suppression resistors: distributor rotor 1 k ohms ( code number Rl , on dístributor
rotor), distributor cap 1 kohms per cylinder.
D. lgnition coil (Tl)
The ignition coil is matched to the TSZ ignition control unit and designed for a higher ignitíon capacíty.
Identification: yellow sticker. The ignition coi! must on no account be replaced by one ofthe previous
ignition coils. Distinguishing features from previous ignition coils are:
• The anti-tamper plug in the cap of the ignition coiL

• A higher dome.
• Cable connection to terminal 1 with M5 thread.
• Cable connection to terminal 15 with M6 thread.
Mercedes-Benz
Fig. 237: ldentifying Ignition Coil Cable Connection To Terminal
A 5 _5 mm openiug ( arrow ), sealed with a plug, is provided in the cap of the iguítiou coiL Thís plug
detaches if an overpressure is produced as a result of production of considerable heat in the ignition coil
resulting from a faulty output stage in the ignition control unit The ignition coil is provided with a cover
in order to prevent the plug or the sealing compound coming out of the ignitíon coil in an uucontrolled
manner.
····1110-tl
Fig. 238: Locating Plug On Coil
E. Ignition cables
The partially screened spark plug and angled distributor connectors are designed for the higher ignition
voltage.
An interference suppression resistor of 1 kohms is installed in the spark plug connectors. They are of
screw-on type (M3 thread).
Mercedes-Benz
Fig. 239: Identifying lgnition Cables
F. Ignition advance in the warming-up phase, engine 102.961 Std _
2 1
WS 'J'I
Fig. 240: ldentifying Ignition Advance In Warming-Up Phase, Engine

Mercedes-Benz
The ignition timing point up to a coolant temperature of approx. +60 oc is advanced 8 - 12 ovia the
vacuum unit at the distributor, in addition to the centrifuga! force advance, in order to improve driving
characteristics in the warming-up phase.
Below a coolant temperature of approx. 60 oc

(thermovalve closed) the vacuum flows from the intake
manifold through the restriction (1) and non-retum valve (2) to the vacuum unit at the dístributor when
the engine is started. The maximum vacuum is retained at the distributor by the non-retum valve (2) (also
when accelerating), as a result of which the additional ignition advance is performed via the vacuum unit.
Above approx. 60 °C, the thermovalve (3) opens and the vacuum is dumped to the throttle valve body
when the engine is idling.
A restriction (1) is provided to prevent the vacuum for the other connected components being dun1ped
through the connection at the intake manifold when the thermovalve (3) is opened during idling.
G. TSZ wiring diagram
N1/ 1 Transls toriled lgnitlon contml unJt

SSI2 llstributor
T1 lgnition coll
W3 Ground, at front left wheellouse (igrutloncoi)
X11 lla9nosllc socket!ltomunal block, termonal T O
a Com.P(Hlen ts wdh term1na1TO
(e.g. tachometer. rua l pump relay, KE c:onttot unrt, X11
AC compressorcot-o ff control wut)
b Voltage supply temnnal ~

Mo do! 124 : To fuse 9 vla engllle plug c:onneotton (X26),
c:ontact 3
Modal 2!t1 . To lu$e 13 Vla e leotncal centre T1
cotJplng S, contaot 11
e Vollage supply termnal15, unfused

Modol124 . Engine p!ug connec\Jon ()(26), C011\act 1
Modol201 : Electrtcalcen lreOO!Jpti ng S,c:ontact4
!!
...
T
~
¡;: .
Fi~. 241: TSZ Wirin~ Dia~ram
ENGINE SYSTEMS CONTROL UNIT (MAS)- RA1500KE30030X(15-0030)
A. General
The engine systems control unit (N16) is installed on engines with KE injection
Mercedes-Benz
• in model129 with engines 103, 104, 119

• in modell24 with engine 104
Engine systems control unit (N16), model129
Located in front right of component compartment and eqtúpped with removal/ installation aid.
Modell29
N16 Eng111e systems codrol Ulit
Fig. 242: ldentifving Engine Systems Control Unit (Model129)
Model 124
N16 Engme ~em scGiiro!Ulil
Fig. 243: ldentifying Engine Systems Control Unit (Model124)
The engine systems control unit combines the previously known components of:
Mercedes-Benz
• Fuel pump relay

• AC compressor cutoff control unit and the following functions:
Function/Actuation Engine Designation on engine systems

control unit
Terminal Contact
103, 104,
Fuel pumps voltage supply 87 2
119
103, 104,
Oxygen sensor heater voltage supply 87SH 20
119
Diagnosis oxygen sensor heater current at KE
104, 119 SH 18
control unit
103, 104,
Air pump control sigual from KE control unit LP 17
119
103, 104,
Air pump magnetíc clutch voltage supply 87LP 19
119
103, 104,
Kickdown cutoff 87K 7
119
Reverse gear interlock 104(1) 87R 7
103, 104,
AC compres sor magnetic clutch voltage su¡pply 87M 22
119
AC compressor cutiu signal at KE control unit (idle 103, 104,
87Z 9
speed íncrease) 119
103, 104, Gk+ 5
Speed signal from AC compressor
119 Gk 6
AC compressor cutin signal from climate control 103, 104,
KL 3
push-button control unü 119
TD or TN signal 103 TD 16
Sigual input from EZL or EZLIAKR ignition
104, 119 TN 16
control unit
Engine speed signal (short-circuit-proof) 103 TDA 11
S igual output for consumers 104, 119 TNA 11
103, 104,
Pulse output for test coupling for diagnosis (X11/4) - orDi 14
119
Start valve actuation 103 87V 8
104 ( l)
Road speed signal frorn ABS control unit ' V 13
119
(1) only with manual transrnission
Function/Actuation Engine Design.ation on engine systems

control unit
Terminal [Contact
Mercedes-Benz
Coolant temperature signa! from KE

103 TF 13
control unit
Actuation terminal 15 103, 104, 119 15 21
103, 104, ll9with
ASR safety switch !Su 10
ASR
103, 104 without
Actuation terminal15 , unfused 15u 10
ASR
Actuation tenninal 50 103, 104, 119 50 12
Voltage supply terminal 30 103, 104, 119 30 1
Grotmd (Wl6) 103, 104, 119 31 4
B. Intluencing parameters at engine systems control unit (N16)
Engine 103.984
Mercedes-Benz
Volage supp ly (K111). Engine systems AC compressor

lermlnal 30
cont ro l unit
Ground (W16). Oxygen sensor heater
termina l 31
(N16)
Actuallon . Alrpump
termina l 15
Aciuallon . sta rt valva

termina l 50 ... ...
TD slgnal Klckdown swltch

rrom EZL lgnftlon
control unlt
Alr pump control slgnal Fu el pumps

rrom KE conlrot unlt
Coolant temperatura OutptA TOA slgnal for

sJgnal consumers . e . g.
tacho meter. KE control
ll'lil
AC compressor
ciJln slgnal rrom
,..,
pushbutton control unit AC compressor cutln
slgnal lo KE control
ll'lilldle speed lncrease
Speed slgnal rrom AC

compressor
GK+ and GK-
----------------------
Pulse oiJput. test
coupl ng ro r diagnosis
Fault memory
(Xl l/4) . contacl 14
Fig. 244: Communication Diagram Of Engine Systems Control Unit
Engine 104
Mercedes-Benz
Vohge supply AC compwessor

iermlnal 30
Engíne systems
control unl (N16)
Ground (W16). oxygen sensor heater
iermlnal 31
Aciuallon, Alr pump

terminal 15.
terminal 15 \.rln.Jsed
-e "
~
Diagnosis or oxygen
Actuallon. sensor heser curren!
terminal 50 lo KE control unlt
i N slgnat rrom EZL/ Klckdowrn switch

AKR lgnltlon control Reversa gear
unll ~le"rl'OCk"' ) ________
Alr pump control slgnal

fl'om KE conirol unlt
i'"' '"'"'
,-
1
Cutln signar fl'omAC OutpLi TNA slgnal for

compres sor consume.rs
.....
Control slgnal oxygen

sensor healer from KE AC comp:ressor culln
control unll .... slgnal to IKE control
unll
Speed signa! rrom AC

compressor GK+ and
GK-
Roed speed slgnel

1
fromABS control unft l'ulse oLtput. test
--------------- coupUng tor diagnosis
(X11/4). conlect 14
Fault memory
1) odf IMil mlll1lJ al tran srmsSioo
Fig. 245: Communication Diagram Of Engine Systems Control Unit (Engine 104)
Engine 119
Mercedes-Benz
Vo ftage supply, Engine systems AC compres sor

termina l 30 cont rol unít (N16)
Ground (W16). Oxygen s-ensor heater

terminal 31
Actuallon. Airpump
termlnal 15 ,...
Diagnosis. oxygen
Actuatlon. sensor heater curren!
termina l 50 .... lo KE control unll
TN slg nal rrom Klckdown switch

EZLIAKR lgnillon
control unlt .....
Alr pump contro l slgnal

ftom KE control unll
i'"' '"mp' 1
CuUn slgnal from Output. TNA slgnal for

AC compressor .. consumers. e. g.
tachometer, KE control
Ll'lll
Control slgnal. o.xygen

sensor heater from KE AC compres sor cutln
control unlt slgnal l o KE control
Ll'lil
Road speed slgnal

from ABS control unlt
Speed slgnal from AC

compres sor ....
GK+ and GK- ----------------------- Pulse out put.
tesl coupllng ror
Fault memory diagnosis (X11/4).
contact 14
Fi~. 246: Communication Dia~ram Of En~ine Systems Control Unit (En~ine 119)
C. Wiring diagram engine systems control unit

Mercedes-Benz
1990-2002 ENG INE Electrical System- Engine- 129 Chassis
rAGi·-·-·-·-·-·-·-·-·-·-
r
T
;.:;.
XS0/1
Al
WfT ,.
11
JX38
i
A1 mrunett d Jster X2212 PáJgcomedon, !lliomabc ransmtsSionfengtne 16-Pil)

F1 Fusa and relay box X224 PlJgconnedon, attomabc ransrrnsszonlangme {4-Pill
G3f2 H&ated oxygen sensor X26 Pllg eomocion, 11tanorioflg¡no ( 12~n)
G312x1 PáJgcOMGCion, hoated oxygan sensor ~n) X26J12 PlJgcomedon, WlfancdroosmJSSion (l>-pfl)
M1 Starter X27 Plllgcomodon, s181torhamess(~p111)
M3fm1 Fuelpump 1 X30J'1 Pklgconnecton, ITlllfuncton block
M3lm2 Fuel pt111p 2
N1/2 EZl tgn¡lion contol unt
N3 KE <:orool urtl X36 Pklgcomecion, ilolpurrp harnsss (1;Jin)

N16 En¡¡:Jle systams cootolu11t X3613 Pklgccmedon, l.lelpurrp harooss(2;J~n)
S211 9'Jboo Sl!il1m SOMII:h Y3 Au!Omallc transmJSston !Gcl<dcwn wlva
S1611 Starter lod<out andre110r51ng larrp sNtch Y4 2nd dnm g moda sv.ttchover valva
S1615 Dnmg mode SWitch (2nd me de) Y8 Slait va.Va
S16/7 Klcl<óoV4! SN«ch (2nd mode) Y32 Air pump S'~o~lchover vaN8
W3 Ground, at tcrt le:t whaal'louse ~gnli cn cotl) Y33 Air pump e Bctrom~ cktch
W11 Ground, eng:11e {c«<lectJon part lol ground wres) Y33x1 F'tlg come< loo, ~ pump electromagn~c. ckJ;;h
W16 Ground, corrpooort corrparmert AG Au!Omallc transmJSSlon
W17 Ground, ngilt raar seat MG Maooal transm sslOil
X4 Ternunal block, 1Brmnal30, fusa andrelayboxArienor
(2-ptll)
X4110 Te1Tll1nal block, lnrmlnai30/30LV61el87l. {5-¡>61)
X1114 Tos! C0!4Ji ng for deg¡lo5ls, pulse readout
(16-Pil)
Mercedes-Benz
F ig. 247: Wiring Diagram Engine Systems Control Unit
D _ Fuel pump actuation
The fuel pumps run as soon as the relay in the engine systems control unit has picked up and the terminals
30 and 87 are thus connected. The voltage supply is not fused.
The fuel pumps are actuated as follows:
• Brief voltage supply (approx. 1 second) to fu el pump when ignition switched on via terminal 15
(full running protection when engine not running and ignition switched on).
• Actuation offuel pump when engine started via terminal 50. Necessary because the pulse sequence
ofterminal TD/1N is only adequate from engine speeds above 80/min in order to constantly keep
contact terminal 30- 87 closed.
• Actuation of fu el pump when engine running via terminal TD/1N and terminal 15 _
• Fuel pump switched off as soon as no more pulses supplied vía terminal TD/TN of ignition control
unit
E. Governing engine speed
The fuel pumps are switched off via terminal TD/ 1N when a certain number of pulses is reached
(corresponding to maximum engine speed).
F _ Variable engine speed governing, only engine 119
Brief max. govemed speed 6300 ± 50/min
Continuous govemed speed 6000 ± 50/min
If an engine speed of n=6000/rnin is exceeded and remains above this level for longer than 1O seconds,
the govemed speed is lowered within 5 seconds from 6300 ± 50/min to 6000 ± 50/min_
The govemed speed is not raised again to n=6300 ± 50/min until after engine speed has dropped below
n=5500/rnin_
G. Kickdown cutoff with automatic transmission
The kickdown cutoff ensures that an upshift is performed before maximum engine speed is reached
(activation of engine speed goveming). In the kickdown position, the solenoid valve (Y3) at the automatic
transmission is actuated by terminal 15 via the engine systems control unit and the closed kickdown
switch (S16/7)_ This actuation is interrupted by the output stage in the engine systems control unit
(terminal87K) andan upshift initíated approximately 200/min before maximum engíne speed ís reached.
H. Vehicles with AC compressor

Mercedes-Benz
The electromagnetic clutch at the AC compressor (A9kl) is supplied with voltage via an output stage in
the engine systems control unit (terminal87M). The AC compressor cutin signal (terminal KL) is
supplied by the push-button control unit
lfthe AC compressor is not operating freely, it is switched off by the engine systems control unit. This is
done by analyzing the AC compressor speed (tenninals Gk+ and Gk).
Wiring diagram AC compressor model 129
N22
·--·(>--·
A9 A.C COOlPf&SSOf
A9k1 Eledromagnen c a.tdl
A911 RPM S911SOf
A9x1 Pllg coonecllon, AC COf11ll85SOI
N16 En!Jne sys.roms comolml
N22 A!Jom~c d mall c¡oorrol(l<l.A)
pushbtilon eortro1 mt
S31 A.C ClomPf&SSOf S"o~~tdl J
Of+ Z.ObadON2.6ba; 1
.xas PlJg ClOilll&cúon, ll'J IIlmallc he mar andlompoomro
{HAU, TAU)IIl!lllll\0 hamoss { 4-ptn)
con'"el ~ ~
;~,1•
•
1
L._._j
S31
P15-5208·'f1
Fig. 248: Wiring Diagram AC Compressor (Model129)
l. Oxygen sensor heater

a. Engines 104, 119
The KE control unit supplies a control signal (terminal SH) for the oxygen sensor heater to the
engine systems control tmit which then controls the oxygen sensor heater (terminal 87SH). The
engine systems control unit supplies an information signal regarding the oxygen sensor heater
current (feedback) to the KE control unit for diagnosis purposes.
b. Engine 103.984
The oxygen sensor is heated from a coolant temperature of 20 oc_ The voltage is supplied by the engine
systems control unit, terminal 87SH.
Mercedes-Benz
J. Air injection
The KE control unit supplies a control signal (terminal LP) to the engine systems control unit when air
injection is required (see Film II, 14-0030, section B). The engine systems control unit switches voltage
to the air pump switchover valve and to the electromagnetic clutch (termina187LP) via an output stage.
K. Road speed signa!
The ABS control unit on engine 104 with manual transmission and on engine 119 supplies a road speed
signal to the engine systems control unit (terminal V). The functions are: Engine 104 with manual
transmission : Reverse gear cannot be engaged unless vehicle stationary (reverse gear interlock).
Engine 119:
If the maximum speed control in the KE control unit fails as a result of a fault, the fuel pumps are
switched off vía the engine systems control unit.
L. Start valve actuation, engine 103.984
Actuation is performed when the starter is nmning (terminal 50) via the output stage in the engine
systems control unit (terminal 87V) up toa coolant temperature of 60 °C (terminal TF).
M. Voltage supply, terminal15/15u
V ehicles without ASR :
The engine systems control unit is supplied with voltage at terminal15 vía fuse B. Terminall5u is
supplied with voltage from fuse 5 (unfused side).
Vehicles with ASR : The voltage to terminal 15u is supplied via a protective circuit by the electro ni e
accelerator pedal control unit (N4/ l).
Voltage supply, terminall 5/15u
Example model129
Mercedes-Benz
N<l/1 Badromc a::celaratoc pedal (EFP) cornrol tnl

N16 E.ngma S)'Siems cornrolmit
X30/1 PlJQ connetboo, mtlhimctlcn blod<
F1 Fose and ralaybox
Fose B tomunal 15 ftls&d
Foso 5 loonllal 15 U!lfusod
a lgniton startm swich, termi1el15
Fig. 249: CircuitDiagram- Voltage Supply
N. TD/TN signal (engine speed signal)
The TD/TN signa! is passed directly by the EZL ignition control unit to the TD/TN input of the engine
systems control unít (MAS). The TD/TN signal ís processed by the engine systems control unít's (MAS)
own output stage and distributed via the TDA/TNA output to the other consumers. In the event of a short-
to-negative in the TDA/TNA cable, the fuel pump remains operational.
O. Diagnosis
The faults lísted below are recognized and stored in the engíne systems control unít (MAS). The stored
faults can be read with the pulse counter at the test coupling (Xll /4), contact 14.
FAULT TABLE PULSE READOUT ENGINE SYSTEMS CONTROL UNIT{MAS}

Pulse
Fault type/Components
readout
1 No fault in system
2 Fuel pump relay (terminal87) not operating
3 Interruption to TN or TD signal (n. a. as of 05/90)
4 Output stage of oxygen sensor heater (terminal87SH) faulty
5 Output stage of air pump (terminal 87LP) faulty
Mercedes-Benz
6 Output stage of kickdown switch (terminal 87K) faulty

8 Coolant temperature not withín tolerance (only engine 103)
9 Failure of terminal 50 (only engine 103)
10 Output stage of start valve faulty (only engine 103)
11 No AC compressor cutin signa! for idle speed control (terminal 87Z)
12 AC compressor output stage faulty (terminal87M)
13 Excessive slip of AC compressor
14 Road speed signal implausible (only engines 104, 119)
15 Short-circuit recognition in fuel pump circuit
Output stage of reverse gear interlock (terminal 87R) faulty (only engine 104 with manual
16
transmission)
ELECTRONIC IGNITION SYSTEM WITH VARIABLE CHARACTERISTICS AND ANTI-KNOCK

CONTROL (EZL/AKR)- RA1500KE3A025X{l5-0025)
E lectronic ignition system with variable characteristics and anti-knock control (EZL/AKR) - RA1500KE3A025X(15-
0025)
A. General
The electronic ignition system with variable characteristícs and anti-knock control (EZL/AKR) is fitted to
the following engines with KE injection:
• Engine 104
• Engine 116/ 117 with increased output in model 126 as of09/87 (compression ratio [epsis] = lO)
• Engine 119
The anti-knock control (EZLIAKR) has been integrated in the known EZL ignition system (see 15-0020).
Only components and functions which differ from the EZL ignition system are described below.
4-pin coolant temperature sensor, crankshaft position sensor (L5), ignition coil (TI) and flywheel/driven
plate with segments (except engine 119) are described under the EZL ignition system.
Distinguisbing feature ofEZL/AKR ignition system
Because of the comprehensive operating data recording, two 8-pin connectors (A) and (B) are fitted to the
EZLIAKR ignition control unit (two 4pin connectors for EZL system).
Mercedes-Benz
Fit:. 250: ldentifyint: EZL/AKR Ignition System
Electr·onic ignition system with variable characteristics and anti-knock control (EZL/AKR)- RA1500KE3B025X(15-
0025)
B. Function diagram of EZL/AKR ignition system

a. Engine 104
Mercedes-Benz
T1
4
,,........ ~
B 11fl Coolam !Bmpera!uie sensor (EZliKEI2 E-E) S65 Transmts51on overloadprolectJoil S'MII:h
G1 Baltery T1 lgnlbcnco:t
LS Cranl<91~ ~SI• en soosor X1114 Test cooplng fct magno SI S, pulsa road~
l511 Ca.msñalt~smon sens<X (16-Pil)
N1l3 EZI../AKR IQIIIIJon corno! uni
Verwmho-se
R4 Spail< I*Jgs
2 startar nng gear •~>~th se9fllerts
R 16fl EZl/AKR restSlMCe tnmmng coop;.ng
3 Dma l natoKE c011.Jol uni
SS/3 Hlgh vollaga dístnbut<X
4 Thl 5I g.Jlal to oogile SY$:Sms Cctlfiol urll
529.12 Throlle va.'ve sWJtch, i.ll lcadlide speedreroQllbon
Fig. 251: Function Diagram OfEZL/AKR lgnition Svstem (Engine 104)
b. Engines 116, 117

Mercedes-Benz
l\1p8
A16g1
Elec~onc speedome!llr •.vit! ma»mum speed i mimg
Knod< sensor 1
S5.t<l ligh volag& dismbtior wlh cyfi1der re1:o~ltlon
posaboo sensor
·-
l\16g2 Knod< sensor 2 52912 Thro!:le wlva swtch, illloadlídle spe.edrocognbon
8 1112 Cooart tomparalue sensor IEZliAKR KEf2 E-E) 565 Transmrssaon owrloadprot&cion swtch
G1 Batte¡y T1 lgrlbon cot
L5 Cra.nkshS: posiioo sons.or X 11 Dmgroslic sod<e.'it81TTlflalblock, tennmal TN
N1.G Ell./AKR lgn!IJon corirol 1111t 1 Flash code (áagnosls)
R4 Sparki*Jgs 2 Vacwmhoso
R 1612 EZUAI< R rosa stant e lnmmng coopf.ng 3 staltor nng gear w tn ssgmerts
Fig. 252: Function Diagram OfEZL/AKR Ignition Svstem (Engine 116, 117)
c. Engine 119
Mercedes-Benz
S515 X11
N1/3
P1 !1-5218-57
1>.1& l(nodc; SOOSOf S515 l efi!Jgll vollago <islnbttor

8 1112 Coolalt ternporaruro sensor {EZlllH, 4- Pill 529/2 ltrlliil& \'atio S'Mtch, illload.tO:o spood rorognilon
l5 Cranl<sl'l 811X>5ii on SOOSOf S65 TronsrrusSion owrloadjlfo!ec•on sWitch,
L511 Cemshalt posllion sensor bral<o tJ.andB1
N1/3 EZlJAl<R IQIIDOO Gorf.rol Ult T1/2 lg¡utJon coil 2 {loflbark of cylilders)
R4 Sparkpk.Jgs X11 Oiegnosbc sod<ot(9-JW~)
Fig. 253: Function Diagram Of EZL/AKR l gnition Svstem (Engine 119)
Function diagram engine 119, example of left bank of cylinders
Electronic ignition system with variable characteristics and anti-knock control (EZL/AKR) - RA1500KE3C025X(15-
0025)
C. Location of components
a. Engine 104
Mercedes-Benz
A16 f<nocl< SGilSOlS S513 Hgll vollage á slnbttor

8 11(2 Coolali blmperatu!e sonsor {E2l/AJ<RKE/2 E-E) S2912 Tholtle valva switch, tulload.tde spijed reco9fllbon
l5 Cnmkshat ¡>0"51•on sensor (S29.fll •Mttl a!Jtoma!Jc .5-spe!Hf transms510fl)
l511 Camshaft pos lb en sensor S65 TmnsrmsSion OYaooa.d p;otndon swtch
N 1/3 EZllAJ<R ~gr~!CJon cortro1 111t T1 lgnboncol
Fig. 254: ldentifying Electronic lgnition Svstem And Anti-Knock Control (EZL/AKR)(Engine
104)
b. Engines 116, 117

Mercedes-Benz
A1p8 Ele<tooc ~edome!sr will millQmtm sp88<l lm~nQ S514 Hlgll valage ástnWor •Mitl J>GSiion sensor
A16 Knod<sensors S29f2 Tnro~ \'&'Ve swit<h, ill loadltcfe speed ret·Oflillbotl
6 11/2 Coolart mmp&rehn sensor (EZl.JAXR, I<E) {4-pm) S 55 Transm;sgooovefloed pc-otedlcn Sl'.lll:h
l5 Crenl<stl~ po51t en sen sor T1 lgrlbcn coJ
N1f.3 EZlJAl< R IQI\DOO OOitrol uni
Fig. 255: ldentifying Electronic l gnition System And Anti-Knock Control (EZL/AKR)(Engine
116, 117)
c. Engine 119
Mercedes-Benz
3 2 1
~ S2912
7 8 9
LJL
....__...., .. ~
~~
A16 N1#3 S65
P15•0tU-ftt
A16 Knock senSOfS 5516 Rlgtt hgll dage Oisrilulof

8 111'1 Coolari !&mpor&Me sensor (E2lfAKR.f<E/2 E.E) S2Q/'l Th:olle YBive SJNid1, fu11oadAde speed ret0!1lilon
l5 Crnnksllai ~Silon som;.or (529.14 ....;111 eU!omalic !>.speed transmssion)
LS/1 Camsllalt~slllon sensor 565 TransmJSSion owrtaadprotecion swtd'i
N1t3 EZLIAKR ~g~~ilon cartrol ml T1f1 tgnboncoJ 1
SS-5 lill'lli~ vo\lago ástlbtl!or T1/2 lgnboncol2
Fig. 256: ldentifving Electronic lgnition Svstem And Anti-Knock Control (EZL/AKR)(Engine 119)
Electronic iguition system with variable characteristics and anti-knock control (EZL/AKR)- RA1500KE3D025X(15-
0025)
D. lnfluencing parameters at EZL/AKR ignition control unit

Mercedes-Benz
a. Engines 104, 119
lgnitlon startec switch Voltage s14Jply (+)

(521) terninai15Z
Gro111d point (W3)

front
left wheelhoose
En¡jne speed and
crankshaft position lgnition coil
Position sensor (l5) at ---e> M 119: ldentífication Engine 1 04: T1
starter ring gear cyinder bari< Engine 119·
T1/1 and T1/2
Load state of engne

and altlude correction
Coolant temperah.re
controls
Full throttle position
Engine systems control

unl (N16)
ldle speed positlon
EZLIAKR re sistance
trmming coopling Adaptation of S14Jplies
(R16/2) í~ítlon map KAT/
withoot KAT
Fuet pump set

Transmission overload Tachometer
proteolion switch (S65) KE control unit
~============~---c>~~G-e_a~-h_m_s--------~ Oxygen sensor heater

Air pump
Camshaft positlon
sensor (LS/1)
Knock senso~ (A16) Knocl<ing

combustion
KE control unit Data interchange over data

(N3) line
KEIEZL assignment. pressure interrogation via
conditions. intake air tempenture,
maximum speed contro~ ille
speed ernergency mode curve
coolart temperature . faul Test C014Jing
recogrition (X11 /4) with pulse
COllller
124 589 19 21 00
Fig. 257: Communication Diagram- Electronic Ignition System And Anti-Knock Control
{EZL/AKR) {Engine 104, 119)
Mercedes-Benz
b. Engines 116, 117
lgnbon S taller SWII:Il V~age~l~l N113 ONGI and I!Jltion 8l1g!e cortrol
(S21)1Dm1nal 15
f--1> --!>
""""" ""''""' ·~· ¡t-..

LJ G_round_f--~---....J~ EZl/AKR IO'JbOn
~
contols
!
.left'Atleoi1ouse CO!trOhlll
~
[>
Cranksllat po51ton Eng¡ne speed and
sensor(l5) crarllsl\alt poSition IIO'Jion coil
f--1> --!> 1
HEng¡r~e spead Stglai{TN &Jgnal)

~
H
l oad ste:e ol ong¡ne
lltel<a mantlld vacwm .
~
1
L________j
Coolart tomperatu-e sl.J)ples

sensor (8 1112) Coolarri llllllpera!ure
Flt loaopostlon
[> ~
DlagnoSilc sod<et
c"O!Ua!s
[>
lltotie Wilto swtdl (X11)
{S29fl)
EZlfAKR roSistanc a Adeptallon ol ¡gnbon ma¡: Tadlome!er, 1uol ¡xrnp

tnmmmgC()l.Jlllng
(R 16f2) f--1> KAT.RUF --!> rel3¡, AC COfllp(OSsot
Cttcll contoiUilll, KE
cortrol unt ele
TranSI'TliSSlon owcload
pratecbon swtcll (565)
[> [>
Elecrooc sp9edomelill rclFia~c006

wtlli'Tlillarrum spead
~
i mlllg(A1p8)
(ontfM1 17.968) Ma»mwnspe&d
f--1> --!> lltBrrogabon VIS
J
separa'.D adaptar cables wtll LEO
Hgh vlll:ago áslnbúor

'Aith poSlton sensor,
cytnder rocOj!l'lion
(5514)
Knod< sensors(A16)
Fig. 258: Communicatioo Diagram- Electronic Ignition System And Anti-Knock Control
(EZL/AKR) (Eogine 116, 117)
Mercedes-Benz
Electronic ignition system witb variable cbaracteristics and anti-knock control (EZLIAKR) - RA1500KE3E025X(15-
0025)
E. EZL/AKR ignition control unit (Nl/3)

a. Anti-knock control (AKR)
fncmBSlll!I C
- Omp¡:essoon causes
1>
as aresú! ol combusion
I05ldueS
me81lS
con.-91! 1rto
IEZl/AKR91iHl<l CilfÚolllli {N1t:l)
load ste:& of on~
IDSI!S
Cortrol loop IS
ropoa!ed urti no
illlhor lonodóng is
~!&d
FIAioed.lele speed coro!!!
Recogtllion el c.,._ndor 1
c·ooocts
No dlango lrl iQil,Oillmtng poli! Of
IQI111on • mJlg 1>0111! IS IICMIIlced to
map va\Je, elle< comple~on ol
eorlrol
Fig. 259: Communication Diagram - Electronic Ignition System And Anti-Knock Control
(EZL/AKR)
Mercedes-Benz
The ígnítion maps of the EZL ígnítíon system are desígned for optímal engíne output. Should
knocking combustíon occur under certain operating conditions, the knocking cylínder is detected
by the integrated anti-knock control in the appropriate EZL ignition control unit and the ignition
timing point is appropriately retarded.
Knocking combustion may occur, for example, as a result of poor qualíty fuel and deposíts in the
combustion chambers. The anti-knock control was developed in order to avoid damage caused by
knocking combustion. The anti-knock control has been integrated in the EZLIAKR ignition control
unít.
NOTE: lf regular grade fuel is used, the ignition timing point is retarded by
the anti-knock control. This results in an increase in the overall
temperature level of the engine. For this reason, regular grade fuel
should only be used in those exceptional cases where no unleaded
premium or premium plus fuel is available.
1.) PHl!'.'S'Ure 11 cooñusboo chambor

2.) lgntioo a<Waoce anglo
a tgntioo too actvanced - Mocl'lng
b lgritioo in COlrert im11g potnt
e lgnboo te-o reta;ded
d BTDC
e ATOC
Fig. 260: Fuel Quality Graph
Pressure pattem in combustíon chamber during normal combustion

Mercedes-Benz
d BTDC
e A.TOC
Fig. 261: Identifying Blinking Pattern Of Combustion Chamber Pressure
Pressure pattern in combustion chamber with knocking combustion
d BTOC
A.TOC
Fig. 262: ldentifying Blinking Pattern Of Combustion Chamber Pressure
Should knocking cornbustion occur, for exarnple as a result of fuel with a low octane number, the
mechanical vibrations produced are converted in the knock sensors into electric signals and passed
to the respective EZL/AKR ignition control unit. The EZL/AKR ignition control unit compares
these incoming signals with the specifications stored in the integrated microcomputer. If
differences exist, the ignition timíng point for the cylinder in which knocking combustion has taken
place, is retarded by 3° CA by the time the next ignition occurs.
Should the cylínder continue to knock, the ignition timíng point is retarded by a further 3° CA.
This retardation of the ignition timing point may be constantly repeated if knocking combustion
continues until a maximum retardation, dependent on coolant temperature, is reached (e. g. 12° CA
at coolant temperature of 80 - 90 °C, ata coolant temperature of +30 °C, for example, the
maximum retardation is then only 3.5° crank angle).
On engine 104 the knock control may retard the ignition timing point for each cylinder by between
2.5° crank angle and 5° crank angle per ignition, depending on the intensity ofthe knocking.
Several knocking combustions in a cylinder

Mercedes-Benz
a 1
lgllllon ang!e retardad by

3"CA
2 lgliloo angle advanco~ by
0.35"CA
e lglllon angla BTDC
b Pcwer slrokes
~--------------------------------------------------------------------------b
Fig. 263: ldentifying Pattero
If no further knocking combustion occurs, the ignition timing point of the cylinder in question is
restored to the ignition map value by being advanced by 0.35° CA per ignition.
The anti-knock control requires an additional signal in order to recognize the cylinder. This
alternating voltage signal on engines 104, 119 ís supplíed by the camshaft posítíon sensor (L5/l) or,
on engines 116, 117, by the high voltage distributor with cylínder recognition posítíon sensor
(inductive sensor). Cylinder 1 is the cylinder detected.
Safety measures
In the event of failure of the knock sensors, of the analysis circuir in the EZL/AKR ignition control
unit and of the camshaft sensor, the ignition is retarded by a safety retardation of 10° CA. In the
event of failure of the coolant temperature sensor, a substitute temperature of 120 oc is selected. As
this temperature ís within the range ofthe boíling protectíon, the ignitíon tíming point is retarded
by 3.5° CA.
In the event of the failure of the load sensor in the EZL/AKR ignition control unit, fullload is
assumed to thus actívate the anti-knock controL
Mercedes-Benz
High volage distnW.Of", en¡J~nes 116, 11 7
Fig. 265: Identifying High Voltage Distributor
b. Resistance trimming coupling!ignition maps
An ignition map for vehicles fitted with catalytic converter and an ignition map for vehicles
without catalytic converter (RUF for engines 116, 117) are stored in the EZLIAKR ignition control
unit.
The ignition maps are actívated by the resistance trimming coupling (Rl6/2) whích is plugged in
directly to the EZL/AKR ignition control unit, connection 3.
Fig. 266: Identifying Resistance Trimming Coupling/Ignition Maps

Mercedes-Benz
Fig. 267: ldentifving Resistance Trimming Coupling
ENGINES 104,119
Version DB part no. Resistan ce
WithKAT 015 545 67 28 2.4kobms
Without KAT Ol5 545 71 28 220 ohms
ENGINES 116,, 117

Version DB part no. Resistan ce
With KAT Ol5 545 66 28 infmity ohms
RUF 015 545 72 28 Oohms
Engine 104
An ignition map for automatic transrnission and an ignition map for manual transmission are stored
in the EZLIAKR ignition control unit.
The cable from the EZLIAKR ignition control unit, connector B, contact 6 is connected to ground
(W3) in order to actívate the ignition map for vehicles with automatic transmission.
This cable ends in the wiring harness on vehicles with manual transmission.
c. TN signal
The TD signal is replaced by the TN signa l. The EZLIAKR ignition control unit converts the
sinusoidal signal ofthe crankshaft position sensor into a square-wave signa! - TN signal.
Conversion to the TN signa! has become necessary as the ignition timing point for each cylinder
may differ within the knock control range. The TN signa! can be measured in exactly the same way
as the TD signa!.
d. Power output stage
Engines 116, 117
The TD signal is distributed to other components via the diagnostic socket/tenninal block, terminal
TD (see also 15-0015, section "TD signal").
Engines 104, 119

Mercedes-Benz
The TN signal is passed directly from the EZL/ AKR ignition control unit to input TN of the engine
systems control unit. The TN signal is processed by the engine systems control unit's own output
stage and distributed to other components via the output TNA. If a short-to-negative occurs in the
TNA cable, the fuel pump remains operacional.
Engines 104, 116, 117 : The power output stage in the EZL/AKR ignition control unit is actuated
by the rnicrocomputer and thus switches the primary current of the ignition coi l. The primary
current to the ignition coil (Tl) is connected between terrninal31 (ground) and connector A,
contact l .
E ngine 119 : The EZLIAKR ignition control unit features two separate power output stages, each
ofwhich actuates an ignition coil T l /1 and Tl/2. The primary current is connected between
terminal 31 (ground) aud connector A, contact 1 (T 1/2) or coutact 6 (TI/ l ).
Fi~. 268: Identifyin~ I~nition Coil Connector Terminal
e. Data interchange over data line, engines 104, 119
In order to further enhance operational reliability, a data line has been established between the
EZLIAK.R ignition control unit and the KE control unit. The following information is exchanged
over the data line.
• The intake air tempera tu re is analyzed in the KE control unit and passed to the EZL/AKR
ignition control unit.
• The pressure conditions in the intake manifold are passed by the pressure sensor in the
EZLIAKR iguitiou control unit to the KE control unit. Differences in absolute pressure, e. g.
for altitude correction, are also taken into account.
• The values supplied by the two coolant temperature sensors are compared. If implausible
differences occur, a substitute temperature is selected.
Ifminor differences exist between the one coolant temperature sensor and the other, e. g. K.E
90 oc and EZL 70 °C, the EZLIAK.R ignition control unit continues to operate with the
Mercedes-Benz
higher temperature reading.
• The "maximum speed control operating" signal is passed by the KE controltmit to the
EZLI AKR ignition control unit.
• Faults detected in the KE control unit and in the EZL/AKR ignition control unit are
exchanged.
• If the idle speed contact is closed and the idle speed adjuster is faulty (high engine speed), the
id le speed emergency mode line is selected in the EZLIAKR ignition control unit. As a
result, ignition timing is retarded to the maximum possible and any rise in engine speed
counteracted.
• Assigmnent ofEZLIAKR ignition control unit to KE control unit and vice versa. Incorrect
assigmnent is stored as a fault.
f. Maximum speed control
Engine 104
A road speed signal of 250 km/h in the KE control unit activates a leaner fuel/air mixture. At the
same time, the signa) is passed along the data line to the ignition control unit, which results in the
ignition tirning point being retarded to 15° crank angle before TDC.
Engine 117.968
Maximum speed governed via electronic speedometer (Alp8), (see 15-0020, section "M").
Engine 119
A road speed signal of 250 kmlh in the KE control unit activates a leaner fuel/air mixture. The
ignition tirning po int is not retarded.
g. Transmissiou overload protection
All engines with EZLI AKR and automatic transmission are equipped with the transmission
overload protection (see 15-0020, section "L").
h. Throttle valve switch, fullload/idle speed recognition (S29/2)
Both signals (idle speedlfullload recognition) are analyzed for the EZL/AKR.
1. Diagnosis
Fault recognition is integrated in the EZLIAKR ignition control unit. The test sequence must be
observed in order to read faults and test the ignition timing point. In addition, the engine must not
be switched off during the test procedure.
Engines 104, 119

Mercedes-Benz
The faults detected can be read with the pulse counter at the test coupling for diagnosis (Xll/4)
(see Diagnosis Manual Engine Volume 2).
...
<1
••
[11 11]
8tart
®@
013
X.4110 18f!Tlnal OIOd<, leiTTlll al :wt~UÜftS1 eJ1:lfL

X11/4 Tasi cciJplrlgfor diagnos¡s, ptl:se readout
(16-ptn)
013 Puso coortor
Fi2. 269: Identifyin~ Throttle Valve Switch, Full Loadlldle Speed Reco~nition
The following faults are detected:
Pulse Fault type/Component

readout
1 No fault
2 Maximum retardation of at least one cylinder reached
3 Coolant temperature sensor faulty (n. a. as of 05/90)
4 Load sensor in EZLIAKR ignition control unit faulty
5 Knock sensor 1 and/or 2 faulty
6 Camshaft positíon sensor faulty
7 Knock control analysis circuit in EZLIAKR ignition control unit faulty
8 Transmission overload protection switch does not elose
9 Trausmission overload protection switch does not open
10 Fault in elata interchan !!e hetween F.7T ,/A KR i!!nition controlnnit ano KF. control
Mercedes-Benz
unit
11 EZLIAKR resístance trimming coupling faulty
12 TN signal not within tolerance
13 Fullload contact does not open
14 Idle speed contact does not open
15 Output stage 1 of EZL/AKR ignition control unit faulty
16 Output stage 2 ofEZL/AKR ignition control unit faulty (only engine 119)
17 Crankshaft position sensor faulty
Engines 116, 117
Eight different faults can be detected. They are interrogated wíth a separate adapter cable with
LED. The adapter cable is plugged into connector A.
Fig. 270: ldentifying Adapter Cable Plugged Into Connector
The EZL/AKR ígnítíon control unít can output the following flash codes:
1 X flash No fault
2 X flash Maxímum retardation of at least one cylinder reached
Mercedes-Benz
3 X flash Coolant temperature sensor faulty

4 X flash Load sensor in EZL/AKR ígnítíon control unít faulty
5 X flash Knock sensor 1 or 2 or both faulty, or EZLIA.KR ignition control unit faulty
6 X flash No cylínder recognítíon
7 X flash Knock control analysís círcuit in EZL/AKR ígnítion control unit faulty
8 X flash Transrnission overload protection switch does not close, has open círcuit
9 X flash Transmission overload protection switch does not open, has short-to-ground
J. Connections on EZL/AKR ignition control unit (Nl/3)
1 Vacwm comedlofl 4 ~n c~nnect01 8

2 C'Oalllal coonedor ter cortrcl cabl& trcm <rall<shalt 1 Engmes 104, 119: camsha:t~s~on s!lflsor
posltlon s BI'IS<li" (t5f1), C)indOI
:> 8-pin eonnedor A rocc·gnlli oo
lgniion c;o¡f tsmmal1 Engmos 116, 11 7 Transmsston ovelload
1 protodlon sWJtt h
Eng¡nes 104, 116, 117 ig:n¡lioo coi T1
2 Engme 117.008 ma>CJrrum ~ed i mbng
Eng!oo 119 19flbon coi T1f2 3 Engme~ 104, 119: ~ansrms"Ston ovOOo.ad
2 Grcund(W3) llltmnal31 pro!oction SWJI!;h
3 Eng!oos 104, 119 posiwe, terminai 1S Eng~nes 116, 11 7 wcatt
Enplnes 116, 117 flasll cooe 4 Coolalltt&fl\:lerewe sensor (811/2) Slgnal
4 1N Signa! 5 Engmes 104, 11 ~ negeobvelscreenng
Eng!oos 104, 1W to e119Jne syS!ems cam slla.'l pcs~011 sons01
cornrol (t511)
Engmes 11 6, 11 7- gromd, c.oolant
Uflt lllmpoo;tu; e sensor
Eng!nes 116, 117. mdi agno,soc sod<o1 (81112)
!Brmnai blod< TD 6 Eng¡nes 104, 11 ~ gromd (W3) termnal31
5 Eng¡oos 104, 119" Engme~ 11 6, 11 7· wcaft
Negalf\lafsaeel'llng ror data C13ble mKE ecmol 7 kle spe&d cootacl, ~~e vat.e SNtdl
1.1111 an dpulse signa! m testcoq¡ing lor 8 FUlload cori!ect, throtle va.\re Sl'.tldl
á agi'IOSI S (X11(4)
Eng¡nes 116, 11 7
Neg!illvefsaee111ng.el poSibon sensor , cvtnd&f
rcccgnili on
5 3-pin conooctor, l<nock sansors
6 En!J.ne 1i04 wcartor aurom!illí 1 Common grou1d
~~ead transm ss1011 2 Knock s!lflsor 2
corirol uml 3 Knock sensor 1
Eng¡nes 116, 117 p~SiiV6, term.nal 15
En;;Jne 1:19 lgniJOIIC'OIIT1(1 6 EZlJAKR rc51stanr e tnmmng coo~g
7 Eng!oos 104, 119: da~ •ne lo KE coruot unit
Eng¡oos 116, 117 posilon son sor, cylnder
roc.og.rlló on
8 Englnes 104, 119. pUlse SJgnal totest
~ng fordiagn oSis
(X11/4)
~;b!M,:~~ ~
F iQ. 271: TdentifvinQ C:onnections On EZL/AKR JQnition C:on trol lJnit

Mercedes-Benz
NOTE: On engines 104, 119 contacts are led out in the ignition starter switch
(52/1) for terminal 15 and terminal 15Z. The voltage for the EZUAKR
ignition system is supplied by terminai15Z.
Electrooic ignition system with variable characteristics and anti-knock control (EZL/AKR)- RA1500KE3F025X(15-
0025)
F. High voltage distributor

a. Engine 104
The bigh voltage distributor (S5/3) is positioned on the front cover ofthe cylinder head in front of
the exhaust camshaft. The distributor rotor is driven by a follower arm directly by the exhaust
camshaft.
The moving carbon in the high voltage distributor has been replaced by a flxed central electrode.
Fig. 272: ldeutifying High Voltage Distributor (Engine 104)
13 Olstnbli01 rot01
14 Folo'Mlr
15 Olstnblior cap
17 Cover
.. ~,
Fig. 273: Identifying Distributor Componeuts
b. Engines 116, 117

Mercedes-Benz
The high voltage dístríbutor contaíns the cylínder recognítíon posítion sensor (ínductive sensor)
whích supplies an alternating voltage signal to the EZL/AKR ígnítíon control unít in the case of
continuity of the fust cylinder.
Fig. 274: Identifying Distributor Components (Engines 116, 117)
The cylinder recognition posítíon sensor (inductive sensor) opera tes on the same principie as the
sensor part in the distributor (inductive sensor) of the breakerless transistorized ignition system, the
stator (A) and rotor (B) being designed only for one cylinder (cylinder 1).
Fig. 275: Identifying Stator And Rotor
The cylínder recognitíon posítíon sensor (inductive sensor) can be tested wíth a multímeter set to
the ohms range and with an oscilloscope.
Resistance ( temperature range O - 100 °C)
R=900 -1600 t.
The first voltage ríse on the oscílloscope image is posítive.

Mercedes-Benz
t - ..
Fig. 276: Oscilloscope Wave Form
c. Engine 119
The high voltage is distributed tbrough two separate high voltage distributors (S5/5) and (S5/6).
The high voltage distributors are positioned on the front covers of the ey linder heads in front of the
exhaust camshafts. The distributor rotors are driven vía follower arrns directly by the exhaust camshaft.
Fig. 277: Identifying Higb Voltage Distributors (Engine 119)
The high voltage distributor (S5/5) distributes the high voltage to cylinders 1, 4, 6 and 7. The high voltage
distributor (S5/6) distributes the high voltage to cylinders 5, 8, 3 and 2.
Mercedes-Benz
The moving carbon in the high voltage distributor has been replaced by a fixed central electrode.
t 't t t
00 00 00 00
1
ono0;¡0 03~o o.•{J

1
.. t
u-
1 5 4 ae 3 7 2
o.[Jo orJo o[J.o o{j.o

0~0 oeo7 8
0 0 0 0
' " ' " lm,.fl!'3 -
Fig. 278: ldentifving High Voltage Distribution Seguence
The EZLIAKR ignition control unit features two separate power output stages, each ofwhich actuates an
8 A ignition coil Tl/1 and Tl/2. The ignition coil Tl/2 supplies high voltage to distributor S5/6, ignition
coi! Tl/2 high voltage to distributor S5/5.
Fig. 279: ldentifying Ignition Coil Supplies ffiflh Voltage To Distributor
Electronic ignition system with variable characteristics and anti-knock control (EZL/AKR)- RA1500KE3G025X(15-
0025)
G. Driven plate with segments and magnets, engine 119
The EZLIAKR ignition control unit recognizes the cylinder bank (cylinders 1 to 4 or cylinders 5 to 8) by
means ofthe voltage signa! from the crankshaft position sensor (L5). Magnets (1 , 2) are fitted to two
segments of the ring gear for this purpose. Recognition of the cylinder bank is necessary in order to be
able to actuate the respective ignition coil (Tl/ 1 or Tl/2).
Mercedes-Benz
LS
Fig. 280: ldentifying Driven Plate With Segments And Magnets
Voltage signal position sensor (L5) engine 119
l1 1st segmert wihout

mag;~al
t2 2nd segmert w.fl magnet

13 3rd S&Qfl'lert wtlw
magnal
4th segmert 'Nlh magne!
Penoo for one cranksh a1
revoiiAioo
Arrcw Magnet (nogalrv'e volage
slgnalltrougtlsegmert
frort edgo s~er)
Fig. 281: ldentifying Wave Form (Position Sensor Voltage Signa})
Electronic ignition system with variable characteristics and anti-knock control (EZL/AKR)- RA1500KE3H025X(15-
0025)
H. Camshaft position sensor (LS/1), engines 104, 119
Recognition of the cylinder for the anti-knock control is perforrned by the camshaft position sensor
(L5/ 1). The cylinder recognítíon position sensor in the high voltage distributor (engines 116, 117) ís thus
not fitted.
Mercedes-Benz
Fig. 282: Identifying Camshaft Position Sensor (Engine 104)
Fig. 283: ldentifying Camshaft Position Sensor (Engine 119)
E lectronic ignition system witb variable characteristics and anti-knock controJ (EZL/AKR)- RA1500KE3I025X(15-
0025)
l . Knock sensor unit (A16)
Two piezo electric structure-borne sound sensors are used as knock sensors .
The vibrations of the engine block are transmitted to the piezo ceramic and passed in the forro of an
alternating voltage signal along a screened cable to the EZLIAKR ignition control unit.
Engines 104, 119

Mercedes-Benz
A16 Kno<:k sensou nt
P1S-2181-13A
Fig. 284: ldentifving Knock Sensor Unit
The knock sensors are each attached to the engine block below an engine carrier. This installation point
has been selected as it is the best location to recognize knocking combustion at all cylinders.
Engine 119
Arrow Kno<:k sensor A16g1 , ngill Slde o1 engme
Fig. 285: ldentifying Knock Sensor Unit (Engine 119)
The cables oftbe two knock sensors are combined in a protective hose (corrugated hose) and can only be
replaced as a unit.
NOTE: Piezo effect=generation of voltage by pressure acting on a certain

ceramic.
Engine 119
Mercedes-Benz
Airow l<no.:k sensor A16g2, lell'sldoe al ong¡ne
Fig. 286: Locating Knock Sensor A16G2,Left Side OfEngine
Engine 104
Airo•m Knock sonso;s 00lcw 111lal<e mEilllfcld
Fig. 287: Locating Knock Sensor Below lntake Manifold
~15001CE3J025X
J. EZL/AKR wiring diagram

a. Engines 116.965, 117.965/968
Mercedes-Benz
....
..
JO
:1tltl ~·~
ri ._.,...
• ..,,, _..,_c__J
B11 2 ~ •l .fl,
S29, 2x~
1
'
1
Yo/1 X26
A1p8 Bec ~onc spe&dome:&I mn malOmiiTl speelUmimg W3 Ground, at lrOftloft wheemuse (ig;abon co4)
A 16 Knocl< se;¡sor Uflí! 'N9 Groond, atlel headampunt
A16g1 Knocl< se;¡sor 1 W11 Ground, engr¡a (C{)ITIBCbon part lor grollld •t.uas)
A16g2 Knock son sor 2 X11 Dlagnostlc sod<e1ttum.,alhlock, ltumlnal TN
81112 EZLJAKR oo1a1t tempooil.lre sen sor X22/1 Pl!gcomedon, ransrn1SS100 overioad protetllon
l1 TOC sensor sNich {2.ptn)
l5 CIBtlkshat poS!lon sensor X26 Pl!g comocion, 11!eoorlengJ1B
N113 EZllAKR '911tion colirol mi
R1612 EZl/AKR rGSI!il:anc o tnmmng cooping a To llso 7 {!ílrmnal15) \'la plug connedloo (X26){12-
pm), eng~ne hamoss, codact 1
To llse 7 (tarmnal 15)via plJg cooooálon (X26){12-
55.1<1 Higñ vol!aga distnhttor Wlll c"¡tnder rarogn¡bon pm), 8119100 hamess, ronact 1
poSibon S8JlSG( b To KE •l"!edlon sy&em cootoluro~ rortad 23
52912 Th"olle\/Bive SWitch, i.JI Ioadlidlespeedrecognbon e To i.Jse 2(1srmnal30)viapt.Jgconnedon (X26)(12-
529tlx Pl!g conoodon, flrctfa vllMl swtd'l pm), BI19ITMl hamess, c'Oftact 3
565 TransmJsSion ovarload PHl!IK•on swtch d To KE lll9álon systom oonlrolun~ cortad 7
T1 lgnboncoi o To KE •rl>Jction system coolroluro\ cortad 21
W1 M811 gromd (beh11d insJIITlerr. cklster) f To KE l fledlon systam Gonlrol UOI~ rortad 5
g To itle spead contolu11~ c;oriad 4
2 Connector 51oevo{soldor ronnectorm hamess)
Fig. 288: EZL/AKR Wiring Diagram

Mercedes-Benz
NOTE: A1p8 and cable via X26 only on engine 117.968 with maximum speed
limiting.
b. Engines 104, 119
See:
• Wiring Diagrams Model l29, Volume 1

• Wiring Diagrams Volume 4 (model 124 as of 09/89)
HIGH VOLTAGE DISTRIBUTOR CAP, IDGH VO LTAGE DISTRIBUTORROTOR -BT15.12-P-
0001-01A
MODEL 140.0## ## as of 080817,
129.076 ## as of 064184

World Model LHS P r od. V eh. Veh. P r oduction P r oduction Nature and Reference/Remarks
manuf. RHS plant ident ident period as period up r eason for
eo de end no. end of to modification
a s of no.
up to
140.0 080817 1.5.92
129.076 064184 1.3.92
l . High voltage dístríbutor cap and hígh voltage dístributor rotor have been converted to carbon to avoíd
cracking.
H IGH VOLTAGE DISTRIBUTOR ROTOR WITH STIFFENING RIBS- BT 15.12-P-0002-01A
ENGINE 119.974 ## as of 001475 as of 1.7.91,
119.971 ## as of 001537 as of 1.7.91,
119.970 ## as of 003625 as of1.7.91
STANDARD PRODUCTION BREAK POINTS/ MO DIFICATIONS/ NEW FEATURES

Engine LHS Transmission E ngine Engine Prod. P rod. Type and R efer ence/remarks
RHS end no. end no. period as per iod r eason for
as of up to of up to modification
119.974 001475 01.07.91
11 9.971 001537 01.07. 91
Mercedes-Benz
l u9.97ol 1003625 1 IOL07.91 1
Since 07/91 distributor rotors with stiffening ribs have been installed. This reduces fractures and high voltage
arcing.
A Pre~ous v.ston (ln.ntt~ 1) A B

8 PraMt ~rJ1411 (m• ldng Z)
Fig. 289: ldentifying Distributor Rotors With Stiffening Ribs

••
Mercedes-Benz
1990-2002 ENGINE Engine Cooling System- 129 Chassis
1990-2002 ENGINE
Engine Cooling System - 129 Chassis
GENERAL INFORMATION
NOTES ON COOLANT - AIDO.OO-N-2080-0lA
All engines
Coolant composition
passenger car and commercial vehicle engines (normally)
50 water in % by volume and 50 corrosion/antifreeze agent in % by volume.
Different coolant composition for CV engines, refer to MB Specifications for Operating Fluids
Tasks of corrosion and frost protection
• Corrosion and cavitation protection of all components in cooling system

• Antifreeze protection (frost protection)
• Increase the boiling point so that coolant does not evaporate so rapidly. Avoiding ejection of coolant at
high coolant temperatures.
Antifreeze protection
50 % by volume of anticorrosion/ antifreeze agent offers antifreeze protection down to approx. -37 °C . A
higher concentration is only necessary ifthe ambient temperatures are even lower. 55% by voh:m1e of
anticorrosion/antifreeze agent offers antifreeze protection down to approx. -45 °C
6 A concentration of more than 55 % by volume of anticorrosion/ antifreeze agent should not be used as the
maximum antifreeze protection is already reached. An even higher concentration once reduces antifreeze
protection and impairs heat dissipation. Reduced heat dissipation can lead to damage to components in the
cooling system or damage to the engine.
Water
Use water which is clean and not too hard. Drinking water often satisfies requirements, but not always the
contents of dissolved substances in the water may be of significauce for the occurrence of corros ion. If in doubt,
analyze the water.
For fresh water specifications refer to MB Specifications for Operating Fluids.
Period of use
Mercedes-Benz
The maximum permissible period of use of the coolant can be taken from the maintenance booklet; from the
applicable service/ maintenance sheet or the MB-Specifications for Operating Fluids respectively.
For the period ofuse for a varying coolant composition for CV engines, refer to MB Specifications for
Oper ating Fluids
.&. B efore pouring in fresh coolant, flush the used coolant out of the cooling system. In the event of high
pollution or oil fouling levels, clean the cooling system, otherwise damage can occur to the components of the
cooling system.
Disposing of coolants
Pay attention to legal provisions and local wastewater regulations.
For workshops located in the Federal Republic of Germany refer to: "Environmental Protection Manual for
Automotive Repair Workshops"
Publisher: Association of Automotive Industry e. V. (VDA)
60625 Frankfurt am Main, Westendstrab 61
NOTES ON COOLANT LEVEL- AIDO.OO-P-1142-01 V
Engine112,113,137,156,271,272,273,275,285,612,628,629,642
Model 171 with engine 271, 272
When tbe engine is cold, the engine coolant level must reacb up to tbe marking "MIN" on the coolant expansion
reservoir (arrow).
When coolant is warm: approx. 1 cm above this scribe mark.
Fig. 1: Locating Coolant Expansion Reservoir

Mercedes-Benz
Models 215, 220 with engines 113, 137
Model215, 220 with engine 275, main circuit
Model 461, 463 with engine 612
Model 463 with engine 112, 113, 628, 642
When engine is cold, the engine coolant level must reach up to the marking (arrow) at the coolant expansion
reservoir.
When coolant is warm: approx. 1 cm abo ve this scribe mark.
P 21lllll·211 15·01
Fig. 2: Locating Coolant Level- Model220,215,220,461,463
Model 210 with engine 112, H3
When engine is cold, the engíne coolant level must reach up to the maiking (arrow) at the coolant expansion
reservotr.
Fi~. 3: Locatin~ Coolant Level- Model210 With En~ine 112, 113
Model 202, 208 with engine ll12, 113

Mercedes-Benz
reservo u .
P2ll J0·2il09·01
Fig. 4: Locating Coolant Leve) - Model 202, 208 With Engine 112, 113
Model 129 with engines 112, 113
reservo u.
When coolant ís warm: approx_ 1 cm above this scríbe mark.
Fie. 5 : Locating Coolant Level - Model129 With Engines 112, 113
Model 230 engine 112, 113, 272, 273
Model230 with engine 275, main circuit
reservou.
When coolant is wam1: approx. 1 cm above this scribe mark.

Mercedes-Benz
Fig. 6: Locating Coolant Level- Model 230 Engine 112, 113, 272, 273,275
Model211 with engine 112, 113, 156, 271, 272, 273
Model 219 with engine 113, 156, 272, 273
When the engine is cold, the engine coolant level must reach up to the marking (arrow) in the coolant expansion
reservo ir.
When coolant is wann: approx. 1 cm above this scribe mark
Pl!Ulll·2 09!1·1D
Fig. 7: Locating Coolant Expansion Reservoir- Model 211,219
Model 216 with engine 156, 273,
Model 221 with engine 156, 272, 273, 629, 642
Model216, 221 with engine 275, main circuit
reservo u.
When coolant is wam1: approx. 1 cm above this scribe mark

Mercedes-Benz
P2U 0·2 H2·1Q
Fig. 8: Locating Coolant Expansion Reser"oir - Model 216,221
Model 240 with Engine 285, main circuit
reservo u .
When coolant is warm: approx. 1 cm abo ve this scribe mark.
P20 OO·lllil9·111
Fig. 9: Locating Coolant Expansion Resenoir - Model 240
Model 215, 216, 220, 221, 230 with engine 275, low temperature circuit
Model240 with engine 285, low temperature circuit
The engine coolant level must be placed, when coolant is warm or cold, in the cross-hatched illustrated area of
filler neck.
Mercedes-Benz
P 2ll.00·21 nH l4
Fig. 10: Locating Coolant Expansion Reservoir- Model215,216,220,221,230,240
NOTES ON VISCOUS FAN CLUTCH- AH20.40-P-0001-01AO
Transportation and storage
Temperature-controlled víscous fan clutches should be transported upright For short períods - for example for
ínstallatíon purposes - the clutch may be placed on the flange sí de, but never on the front The cast part number
ofthe fan should be positioned at the front (radiator side).
ITJ The bimetal strip must not be bent or damaged.

The 9-vane fan has been modífied toan 11-vaue fan.
Productiou breakpoint as of engine: 120.980-12-017 433
120.981-12-000 534
The 11-vane fanmust be used only together with the strengthened coolant pump 120 200 10 01.
BASIC KNOWLEDGE
RESERVOIR CAP, LOCATION/DESIGN/FUNCTION- GF20.30-P-1000A
ENGINE 112 in MODEL 129, 170,202,203,208,210,220
ENGINE 113 in MODEL 129, 202, 208, 209, 210, 220
ENGINE 111.951 in MODEL 203.035 /235 /735
ENGINE 111.955 in MODEL 203.045 /245 /745

Mercedes-Benz
ENGINE 112.912 in MODEL 203.061/261
ENGINE 112.946 in MODEL 203.064/264
ENGINE 611.962 in MODELS 203.004 /006 /204 /206 /706
ENGINE 112.961 in MODEL 203.065 /265
ENGINE 611.960
ENGINE 611.961
ENGINE 612.961
ENGINE 612.965
ENGINE 612.963
ENGINE 613.960
ENGINE 613.961
ENGINE 612.966
ENGINE 113.968 in MODEL 209.375 /475
ENGINE 271.940 in MODEL 203.042 /242 /742, 209.342
ENGINE 271.946 in MODEL 203.046 /246 /746
ENGINE 271.948 in MODEL 203.040 /740
ENGINE 612.962
ENGINE 271.941 in MODEL 211.042 /242
ENGINE 271.942 in MODEL 203.043 /243 /743, 209.343 /443

Mercedes-Benz
ENGINE 112.916 in MODEL 203.081/281
ENGINE 112.953 in MODEL 203.084 /284
ENGINE 612.990 in MODEL 203.018 /21 8 1718
ENGINE 646.962 in MODEL 203.007 /207 1707
ENGINE 646.963 in MODEL 203.008 /208 1708
&pansJon reurvo/r
Cap
Preuure tefe( valvesWJ1e 1
4 I"Yessure tellef vc.o/Vestage 2
5 Vacuum vca/ve
• V<t~~t dtlllngs
IJ AnnutM passage
e Outlet comectlon
P2ll.30.022< 06
F ig. 11: Identifying Expansion Reservoir, Cap And Pressur e ReliefVaJve Stage 1,2
Cap location The cap (2) is screwed

onto the expansion
reservoir in the engine
compartment.
Cap task During the engine off
heating phase (after
switching offthe engine)
the pressure in the
cooling system may rise.
So that no coolant
escapes, the cap (2) is
additionally built-in with
a compression stage.
Mercedes-Benz
Cap function Reservoir cap, function

- GF20.30-P-1000-01A
Reser·voir ca¡>, function- GF20.30-P-1000-01A
Expans/on ,.. • .,...,rr

2 c.,
3 Pronunl86oi..Wostage1
• Pressuruelel v~estage2
5 V.tcull'll vafve
" Vtlll t/Jf/llngs
b Artnular pessege
e Oudet connection
Fig. 12: Identifying Expansion Reservoir, Vacuum Valve And Cap
The cap (2) has two opening pressures.
1st stage
Ifthe pressure in the cooling system exceeds the first compression stage, the val ve opens and allows the
pressure to escape into the upper part of the cap (2)
2nd stage
Ifthe pressure continues to rise, the pressure reliefvalve of the 2nd stage (4) opens and allows the pressure to
escape through several ventilation bores (a) mounted at the cap of the expansion reservoir (1), along the annular
pon (b) into the outlet nipple (e) and a hose extension to atmosphere.
The 2nd stage cap (2) eliminates the need for the overflow tank
SAFETY PRECAUTIONS
RISK OF INJURY- AS20.00-Z-0001-01A
Do not open cooling system unJess cooJant temperature is below 90 °C. Open cap slowJy and release the
pressure. Do not pour coolant into beverage bottles.
Mercedes-Benz
Wear protective gloves, protective clothing and eye protection.
Possible hazards
Risk of injury
When the engine is wann, the cooling system is pressurized. If the cooling system is opened suddenly, there is a
risk of scalding from hot coolant which splashes out.
Danger of poisoning
If coolant is swallowed, this can result in manifestations of poisoning su eh as headaches, dizziness, stomach
pain, respíratory paralysis, unconsciousness, vomiting and cramps.
Safety precautions/instructions
o Allow cooling system to cool down to a coolant temperature of less than 90 °C.
o Open cap of cooling system slowly; turn a conventional coolant cap as far as the first detent and turn a
screwed coolant cap approx. 1/2 turn and release the pressure.
Wear protective gloves, protective clothing and eye protection.
Do not pour coolant into beverage bottles.
First aid measures
• Rinse affected skin with large quantities of cold water and cover with sterile bandages.
• Allow the person affected to drink: plenty ofwater with the addition ofmedicinal charcoal.
• If the person has suffered severe bums or has swallowed coolant, contact a doctor.
TESTING & REPAIR

INSPECT COOLING SYSTEM FOR LEAKS- AR20.00-P-1010HA
ENGINE 111
ENGINE 112 (except 112.961 /946 /953/947 /960 /916/955 /912)
ENGINE 112.945
ENGINE 113.962
ENGINE 113 (except 113.992 /987 /988/968 /991 /990/963 /995)
ENGINE 120
Mercedes-Benz
ENGINE 137
ENGINE601
ENGINE602
ENGINE 602.931
ENGINE603
ENGINE 603.931
ENGINE 603.972
ENGINE604
ENGINE605
ENGINE606
ENGINE 606.964
ENGINE611
ENGINE 612
ENGINE 612.965
ENGINE613
ENGINE 628
ENGINE 628.962
ENGINE 628.963
ENGINE 646.951
ENGINE 646.961
ENGINE 647.961
ENGINE 648.960/ 961
ENGINE 285.950
Mercedes-Benz
ENGINE 612.966
ENGINE 113.982
ENGINE 271.941/943
ENGINE 2751 (except 275.953 /982)
ENGINE 285.980
1 Ex~»n•üm "'.HtW>ir
2 Cop w/111 dtUI'II
%a 2'-.s~cop
3 res~"~'
4 Pross IIB pump
F ig. 13: ldentifving Cooling System Leakage Comp onents
~GF [g) Remove/install

~GF Risk of inj ury to skin Do not open coolíng system AS20.00-Z-0001-01A
1 and eyes caused by unless coolant temperature is
scalding from contact below 90°C. Open cap slowly
with hot coolant spray. and release the pressure. Do not
Risk of poisoning caused pour coolant into beverage
by swallowíng coolant. contaíners.
Open cap with detent (2) Wear protective gloves,
or 2-stage cap (2a) at protective clothing and safety
expansion reservoir (1) or glasses.
radiator. ITJ When closing cover with
detent (2): rotate closing cover
with detent carefully up to first
detent, release pressure relief,
then unscrew closíng cover with
detent (2).
ITJ For model 163 with 2-stage
cap (2a) or 1-stage cap: Rotate
cap half a revolution in
anticlockwíse direction, release
pressure, then unscrew 2-stage
Mercedes-Benz
1990-2002 ENGINE Engine Cooling System - 129 Chassis
cap (2a) or 1-stage cap.

2 Set heati.ng switches to OJ All model except model 163.
maximum heating Model 163 does not have any
capacity pulsed valve; the heater heat
exchanger has coolant
permanently flowing tbrough it.
[l] Checking
3 Check coolant level, if OJ Replace coolant against a
required adjust correctly. separate order if the antifreeze
protection is insufficient:
4 Fit test cap (3) on
. . OJ Model l24, 126, 129, 140, Fig. 15
expans10n reservmr or 170,201, 202,210,
radiator Model463.209 /232 /233 with
engine 112.945,
Model463.304 /324 /325 with
engine 602.931
Model463.307 /327 /328 with
engine 603 .931
Model 463.300 /320 /321 with
engine 603.972
Model463.308 /330 /331 with
engine 606.964
GJ Model 170, 202, 203, 208, Fig. 17
209, 21 0, 211
Model 215,
Model220 with engine 137, 275,
628,
Model230 with engine 112, 113,
275,
Model
461.302/331 /332 /342 /345 with
engine 612.966,
Model463.243 /246 with engine
113.982,
Model463.244 /245 /250 witb
engine 112.945,
Model463.247 /248 /249 /254
with engine 113.962,
Model463.322 /323 wíth engine
612.965,
Model463.309/ 332/ 333 with
engine 628.962
OJ Model 163 with engine 111, Fi~. 16
112, 113, 6 12, 628
5 Connect pressure pump [JJ Fig. 14
Mercedes-Benz
(4).
6 Apply pressure to cooling *BE20.30-P-1005-01A
system and check
leaktightness of cooling
system
7 Inspect cooling and
heating hoses as weU as
their connection points
for proper condition and
loss of coolant; replace
coolant hoses, if
necessary
8 Check hose clamps for !JJ Ifnecessary, retighten hose
condition and seating clamps and replace if required.
@ *WH58.30-Z-1001-
06A
@ *WH58.30-Z-1002-
06A
@ *WH58.30-Z-1019-
02A
order
R a d'tator or expanswn reserv01r cap

Number Designation Cap 2-stage cap
BE20.30-P-1005- Test pressure for bar gage 1.4 1.4
OlA pressure-testing
cooling system
Fig. 14: ldentifving Pressure Pump (124 589 24 21 00)

Mercedes-Benz
Te&! cap
Fig. 15: ldentifving Test Cap (124 589 00 91 00)
163 5&9 0191 00
Fig. 16: Ideotifying Test Cap {163 589 0191 00)
210589009100
Fig. 17: Identifying Test cap (210 589 00 91 00)
e ommerc1a·uty avat.•a bl e too1s

Number Designation
WH58.30-Z-l0 l9-02A Hose clamp pliers (length 21 O mm, clamping range
80 mm)
WH58.30-Z- l001-06A 6 mm socket hexagon on flexible shaft for hose
WH58.30-Z-l 002-06A 7 mm socket hexagon on flexible shaft for hose
CHECKING THE SHIFT POINT OF THE COOLING SYSTEM- AR20.00-P-1020AO
engine 120 in MODELS 129, 140

Mercedes-Benz
*BE20.10-P-1001-02A
ITJ Sbift points for coolant thermostat *BE20.10-P-1002-02A
*BE20.1 O-P-1003-02A
ITJ Shift points for fan clutch, additional fan *BE20.40-P-1001-01A
DJ Shift points for air conditioning *BE83.00-P-1001-01A
ITJ Cap switch points *BE20.30-P-1004-01A
IIl Shift points for transmission oil cooling Model 140 *BE27.55-P-1001-01A
COOLANT THERMOSTAT
Number Designation Engines 103, 104, 111, 120
BE20 .10-P-1 00 1-02A Start of opening oc 85 ... 89
oc 102
BE20.1 0-P- 1002-02A Mínimum stroke
mm 8
BE20.10-P- 1003-02A Thermostat bypass valve di a. mm 43
TEST V ALUES FOR FAN, FAN CLUTCH

BE20.40-P- Shift points Viscous fan Shift point for oc 96±4 96±4
1001-01A for cooling clutch cooling air
system temperature
Additional fan On switch "ON" Kmfh40 -
cut-in Cut-in "OFF" km/h 70 -
for outside a ir oc > or = 30 -
temperature
for outside air oc- < or = 5
temperature
"OFF"
for outside air oc- > or = 10
temperature
"ON"
for coolant oc 103/95 95/92
temperature
for pressure in bar 14/12 14/ 12
the refrigerant
circuit
Additional fan for coolant oc 11 5/110 110/ 107
fully switched temperature
on for pressure in bar20/14 20/ 17
the refrigerant
circuit (high
pressure side)
Mercedes-Benz
TEST VALUES FOR SWITCH POINTS FOR AIR CONDITIONING

Number Designation Models 129, 140
with engine 120
BE83.00-P-1001- Air conditioning Operating time cycles % 50
OlA Cycles "ON" S20
Cycle "OFF" S20
Cycle for coolant oc 123
temperature.
EMERGENCY STOP oc 127±1
CAP OF RADIATOR OR EXPANSION RESERVOIR
Number Designation 2-stage cap
BE20.30-P-1004- Pressure relief valve l st stage bar gage 1.4(±1)
OlA opens Coolant temp. > or = 130/134
2nd stage bar gage 2.0 (± 1)
Coolant temp. > or = 137/ 143
TEST V ALUES FOR TRANSMISSION OIL COOLING

Number Designation Transmissions
755.3/6
o
E-fan On for transmission oíl
BE27.55-P-1001- Swítching temperature e 105
OlA temperature o
E-fan Offfor transmíssion oíl
100
temperature e
DRAINIFILL IN COOLANT- AR20.00-P-1142HA
ENGINE 230.467 112 in MODEL 129, 163, 202, 208, 210, 211.061 /065 /261 /265 /080 /280 /082 /282, 220,
230.467
ENG INE 113 in MODEL 129, 163, 202, 208, 210, 211.070 /270 /083 /283, 215~ 220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 112.945 in MODEL 463.209/232 /233 /244/245 /250
ENGINE 113.982 in MODEL 463.241 /243 /246
Illustrated on model 202

Mercedes-Benz
Cool.n t Contfl"'IUtlon tank

2 Coolln¡¡ system e11p
J Radsator droin pllJ¡¡
38 Oraln hose
4 Oraln plug of eran-e"""
4a Oraln hose
F ig. 18: Identifying Cooling System Components - Model 202
C oolilll t oontfl"'JS<Otlon tanl<

Coollng 5 ystem Clip
J Radia tor drain pllJg
:ú Orllln hose
1'20..00 20<5.{16
Fig. 19: Identifying Cooling Compensation Tank Components - Shown On Model 215 With Engine 137
Modification notes
12.10.04 Fill coolant using vacuum Step 16
method added
Drain
tJ::rGF Risk of death caused by Align vehicle between columns of ASOO.OO-Z-0010-
Mercedes-Benz
vehicle slipping or toppling vehicle lift and position four support OlA
off the lifting platform. plates at vehicle lift support points
specified by vehicle manufacturer.
~GF Risk of injury to skin and Do not open cooling system unless AS20.00-Z-0001-
eyes caused by scalding coolant temperature ís below 90°C. OlA
from contact w ith hot Open cap slowly and release the
coolant spray. pressure. Do not pour coolant into
Risk of poilsoning caused beverage containers.
by swallow ing coolant. Wear protective gloves, protective
clothing and safety glasses.
& Notes on coolant AH20.00-N-
2080-0lA
1 Open engine hood
2 Disconnect ground cable of Only when draining coolant at
battery crankcase, right.
OJ Do not connect quiescent current
retention unit.
Modell29, 163,202,208,210 AR54.10-P-
0003A
Model211.0 AR54.10-P-
0003T
Model211.2 AR54.10-P-
0003TA
Model215, 220 AR54.10-P-0003I
Model230 AR54.10-P-
0003R
Model 463 without special protection AR54.10-P-
0003G
Model 463.241 with special protection, AR54.10-P-
code 979 0003PV
code 979 0003PM
3 Open cooling system cap (2) OJ Observe the different versions.
at coolant expansion Cooling system cap (2) with detent:
reservoir (1) Ro tate cooling system cap with detent
(2) carefully to frrst pre-detent, release
pressure, then unscrew cooling system
cap with detent (2).
1-stage and 2-stage cooling system cap
(2): turn cooling system cap (2) 1/2
revolution counterclockwise, release
pressure, then remove cooling system
cap (2).
4 Raise vehicle
5.1 Remove lower engine Modell29,202,208,2l0 AR61.20-P-
Mercedes-Benz
compartment panelíng llOSAB

Model163 with engíne 112
Model 163 with engíne 113 AR61.20-P-
1105GH
Model211 AR61 .20-P-
1105T
Model215, 220 AR61.20-P-
1105M
Model230 AR61.20-P-
1105R
5.2 Remove underride guard Model463
6 Remove air deflector shield Modell63 with engíne 113.942
Drain coolant from
radiator
7 Push siphon hose (3a) onto Model 129, 202,208,210,211,215,
radiator drain plug (3) 220, 230,463
8 Open radiator drain plug (3) Model 129, 202,208, 210,211,215,
and draín coolant 220, 230, 463
ITJ Catch coolant in a suitable vessel.
9 Tighten radiator drain plug Modell29, 202, 208, 210, 211, 215,
(3) and detach drain hose 220, 230, 463
(3a) from radiator drain plug
(3)
10 Detach lower coolant hose Model163
frorn radiator or coolant OJ Catch coolant in a suitable vessel.
pump and drain coolant
11 Attach lower coolant hose to Modell63 *BA20.20-P-
radiator or coolant pump ITJ Installation: Replace hose clamp. 1004-0lA
.&. DanQer!
Drain coolant at crankcase

12 Push siphon hose (4a) onto Model 129, 202, 208, 210, 211 , 215,
crankcase drain plug (4) 220, 230, 463
13 Open crankcase drain plug Model 129, 202, 208, 210, 211 , 215,
(4) and drain coolant 220, 230,463
OJ Catch coolant in a suitable vessel.
14 Tighten crankcase drain Model129, 202,208,210, 211 , 215,
plug (4) and detach drain 220, 230, 463
hose (4a) from crankcase .&. Oanaerl *BA01.40-P-
drain plug (4) 1003-0lC
.&. DanQer! *BA20.00-P-
1001-02B
15 Lower vehicle
Filling
16 Pour in coolant and bleed IJJ Reuse clean coolant. AR20.00-P-1142-
Mercedes-Benz
cooling system 04A

[[] Fig. 17
[JJ Fig. 21
iGrAP Coolant specifications Sheet 310.1 BB00.40-P-031 0-
Ol A
(!rAP Anticorrosi oniantifreeze Sheet 325.0 BB00.40-P-0325-
agents (Sheet 325.0) OOA
W Engme 112,113 *BF20.00-P-
1001-02K
W Engine 137 *BF20.00-P-
l00 1-02M
& Notes on coolant level Engine 112, 113, 137 AH20.00-P-
1142-0lV
[JJ Notes on coolant level Model 163 with engine 112, 113 AH20.00-P-1142-
01GH
17 Inspect cooling system for AR20.00-P-
leaks lOlOHA
18 Fit air deflector Model l 63 with engine 113.942
19.1 Install tmderride guard Model463
19.2 Installlower engine Model 129,202,208,210 AR61.20-P-
compartment paneling ll OSAB
Model l 63 with engine 112
Model 163 with engine 113 AR61.20-P-
ll05GH
Model2ll AR61.20-P-
1105T
Model215, 220 AR61.20-P-
!105M
1105R
20 Lower vehicle
21 Connect grOlmd cable to Only when coolant has been drained at
battery crankcase on the right.
Model 129, 163,202,208,210 AR54.10-P-
0003A
Model 2ll.O AR54.10-P-
0003T
Model 211.2 AR54.10-P-
0003TA
Model 215, 220 AR54.l0-P-0003l
Model230 AR54.10-P-
0003R
Model 463 without special protection AR54.10-P-
0003G
Mercedes-Benz

code 979 0003PM
Model463.248 with special protection, AR54.10-P-
code 979 0003PV
22 Perform basic programming Only if ground line for battery has
been disconnected.
Modell29 AR00.19-P-
0200A
Modell63 AROO.l9-P-
0200GH
Model202, 208 AROO. l9-P-
0200C
Model210 AROO.l9-P-
0200D
Model211 AROO.l9-P-
0200T
Model215, 220 AROO.l9-P-
0200M
Model230 AROO.l9-P-
0200R
Model 463 except AROO. l9-P-
463.206 /209 /232 /233 /240 /241 0200P
Model463.206/ 209/ 232/ 233/ 240/
241
23 Read out and erase the fault Only if the ground line of the battery
memory using STAR has been disconnected.
DIAGNOSIS.
24 Close engine hood
• DanQerl e ran kcase, tnmng case cover, end cover

Number Designation Engine 113.940/941/ Engine 137
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/995
BAO L40-P-1003 - Outlet connection Nm 12 12
OIC for crankcase
en er al
Designation Engine 112,
113.940/941/
Mercedes-Benz
942/943/944/
945/946/948/
960/9611963/
964/965/966/
967/968/971/
980/9811984/
986/987/988/
990/991/992/ 995
BA20.00-P-l 00 l-02B Coolant drain plug to Nm 12
crankcase
&.oancwl Radiator, coolant hoses

Number Designation E ngine 112.942/970,
113.942/965/981
BA20.20-P-1 004-0lA Hose clamp Nm 3
~e
- ooung system
Number Designation Engine Engine Engine
112.910/920 112.911/921/941 in 112.922/944/972 in
in Model 202, model210 model220
112.940 in
Model208
BF20.00- Cooling Total filling Liters approx.9.5 approx.lO.O approx.l O.5
P-1001- system capacity
02K Capacity of Liters approx.4. 7 5 approx.5 .0 approx.5.0
anticorrosionl
antifreeze agent
down to -37°C
Filhng capacity Liters approx.5.25 approx.5.5 approx.5.5
of anticonosionl
antifreeze down
to -45°C
Specifications Sheet BB00.40-P- BB00.40-P-0310- BB00.40-P-0310-
for Operating 0310-0lA OlA OlA
Fluids Sheet BB00.40-P- BB00.40-P-0325- BB00.40-P-0325-
0325-00A OOA OOA
~ e ooling system
N umber Designation Engine Engine 112.945 in Model Engine
112.923/943 463.209/232/233/244 /245/250 112.942 in
in model Modell63,
129 113.940/980
inModel
210,
113.943/984
Mercedes-Benz
in Model
208,
113.944 in
Model202
BF20.00- Cooling Total filling capacity Líters approx.ll.75 approx. ll.5 approx.ll. O
P-1001- system Capacity of Liters approx.6.0 approx.5.8 approx.5.5
02K anticorrosion/antifreeze
agent down to -37°C
Filling capacity of Liters approx.6.5 approx.6.4 approx.6.0
anticorrosion/antifreeze
down to -45°C
Specifications for Sheet BB00.40-P- BB00.40-P-0310-01A BB00.40-P-
Operating Fluids 0310-0lA 0310-0lA
Sheet BB00.40-P- BB00.40-P-0325-00A BB00.40-P-
0325-00A 0325-00A
I]Jc
= ooli ng syst em
Engine
112.913/9171 Engine
949/954 in Model 113.967/969 in
Number Designation 211 model211
BF20.00-P- Cooling Total filling Liters approx.9.5 approx. l0.75
1001-02K system capacity
Capacity of Liters approx.4.75 approx.5 .25
anticorrosionl
antifreeze agent
down to -37°C
Filling capacity of Lite rs approx.5.25 approx.6.0
anticorrosionl
antifreeze down to -
45°C
Specifications for Sheet BB00.40-P-0310- BB00.40-P-0310-
Operating Fluids OlA OlA
Sheet BB00.40-P-0325- BB00.40-P-0325-
OOA OOA
- oo ag system
Number Designation Engine Engine Engine 113.962 in
113.941/960 113.941/9601 in Model 463.206/
in model220 model129 240/241 /247/248
249/254
BF20.00- Cooling Total filling Liters approx.ll. 5 approx.l2.75 approx. l2
P-1001 - system capacity
02K Capacity of Liters approx.5. 7 5 approx.6.25 approx.6
1
Mercedes-Benz
anticorrosíon/
antifreeze agent
down to -37°C
Filhng capacity Liters approx.6.25 approx.7.0 approx.6.6
of anticorrosíon/
antífreeze down
to -45°C
Specífications Sheet BB00.40-P- BB00.40-P- BB00.40-P-0310-
for Operating 0310-0lA 0310-0lA OlA
Fluids Sheet BB00.40-P- BB00.40-P- BB00.40-P-0325-
0325-00A 0325-00A OOA
~e
- oorrng s vstem
Engioe E ngine Engine
113.991 in 113.960/ 986 in 113.960 1
Num ber Designation model215 model 215 model 230.467
BF20.00-P- Cooling Total fi llíng Liters approx.l4 .5 approx.ll .5 approx.l0.8
Capacity of Liters approx.7.3 approx.5.75 approx.5.4
anticonosionl
antifreeze agent
down to -37°C
Filling capacity of Liters approx.8 approx.6.25 approx.6
anticorrosíon/
antifreeze down to
-45°C
Specifications for Sheet BB00.40-P- BB00.40-P- BB00.40-P-
Operating Fluids 0310-01A 0310-0ll.A 0310-01A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0325-00A 0310-0lA
~e
- 00linlg system
Number Designation En gine E ngine Engine 113.982 in
112.970 113.942/981 in model
113.965 in model 163 463.2411243/246
M odel163
BF20 .00-P- Cooling Total filling Liters approx.l2. O approx.ll.5 approx.ll.9
1001 -02K system capacity
Capacity of Litersapprox.6.0 approx. 5.7 5 approx.5 .95
anticorrosion/
antífreeze agent
down to -37°C
Fillíng capacity Liters approx.6. 75 approx.6.25 approx.6.55
of anticorrosion/
antifreeze down
Mercedes-Benz
to -45°C
Specíficatíons Sheet BB00.40-P- BB00.40-P- BB00.40-P-0310-
for Operatíng 0310-0lA 0310-0IA OlA
Fluids Sheet BB00.40-P- BB00.40-P- BB00.40-P-0325-
03·25-00A 0325-00A OOA
~e
- oormg syst em
113.986/991 in 113.948/966 in 112.975 in
Model220 model220 model220
BF20.00-P- Coolíng Total fillíng Líters approx.l3.5 approx.ll.6 approx.l O. 4
Capacity of Liters approx.6.8 approx.5.8 approx.5,2
antícorrosion/
antifreeze agent
down to -37°C
Filling capacity of Liters approx.7.4 6.4 approx.5.7
anticorrosion/
antífreeze down to
-45°C
Specificatíons for Sheet BB00.40-P- BB00.40-P- BB00.40-P-
Operatíng Fluíds 0310-0lA 0310-0IA 0310-0lA
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0325-00A 0325-00A 0310-0lA
~e
- ooli ng system
BF20 .00-P-1001- Coolíng system Total fillíng capacíty Liters approx.l2
02M Fíllíng capacíty of Liters approx.6
anticorrosion/
antífreeze down to -
37°C
Filling capacity of Liters approx.6,6
anticorrosion/
antifreeze down to -
45°C
Specifications for Sheet BB00.40-P-031 0-
Operating Fluids OlA
Sheet BB00.40-P-0325-
OOA
Mercedes-Benz
210 589 ()() 91 00
Fig. 21: ldentifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Bleed cooling system -AR20.00-P-1142-06GA
l. Engínes 605, 606 in model 210: open drain plug at cylinder head at the front left, pour in coolant, close
drain plug when the coolant flows out.
2. Switch vehicle heating to maximum heating capacity and allow engine to wann up at average engine
speed.
3. Re:fill the coolant continuously until the coolant level reaches the marking on the radiator filler opening or
the coolant expansion reservoir.
4. At coolant temperature of about 60 to 70°C, close the filler opening on the radiator or coolant expansion
reservoir with the plug.
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE COOLING SYSTEM- AR20.00-Z-
9113AB
ENGINE 113
Inspect cooling system for leaks ENGINES 113, 272, 273 AR20.00-P-1010GZ
in MODEL 164
Inspect cooling system for leaks ENGINE 111 , 112, 113 , AR20.00-P-1 01 OHA
120, 137, 271 , 275, 285,
601 , 602, 603, 604, 605,
606, 611,612, 613, 628,
646, 647, 648 ...
Inspect cooling system for leaks ENGINE 111 , 112, 113 , AR20.00-P-1 O1OP
Mercedes-Benz
271, 611 , 612, 646 ...

Inspecting the coo1ing system for ENGINE 272.967 in AR20.00-P- 1010RT
leaks MODELS 251.065 / 165
ENGINE 113.971 in
MODELS 251.075/ 175
Inspect cooling system for leaks ENGINE 112, 113 ... AR20.00-P-
1010RVK
Tnspect cooling system for leaks ENGTNE 272.964 in AR20.00-P-1 01 OTX
MODEL 219.356
ENGINE 113.967 in
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Drain/fill in coolant ENGINE 113,272,273 AR20.00-P- 1142GZ
inMODEL 164
Drainlfill in coolant ENGINE 112, 113, 137 ... AR20.00-P-1142HA
Drain/fill in coolant ENGINE 112, 113 ... AR20.00-P-1142PV
Drain/fill in coolant ENGINE 272.967 in AR20.00-P-1142RT
MODELS 251.065 / 165
ENGINE 113.971 in
MODELS 251.0751175
Drainlfill in coolant ENGINE 112, 113 ... AR20.00-P-
1142RVK
Drain/fill in coolant ENGINE 113.967 in AR20.00-P-1142TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Venting air from the low ENGINE 112, 113 ... AR20.00-P-
temperature circuit 1145RVK
Remove/install coolant pump ENGINE 112, 113 ... AR20.10-P-1271B
Remove/install coolant pump ENGINE 113.964 in AR20.10-P-1271GZ
MODEL 164. 175
Remove/install coolant pump ENGINE 112, 113 ... AR20.10-P-1271R
Remove/install coolant pump ENGINE 113.971 in AR20. 10-P-1271RT
~ODELS 251.075 / 175
Remove/install coolant pump ENGINE 113 ... AR20.10-P-
1271RVK
Remove/install coolant pump ENGINE 113.967 in AR20.10-P-1271 TY
MODEL 219.375
Remove, install coolant pump ENGINE 113.990 in AR20. 10-P-1271 TZ
MODEL 219.376
Testing coolant thermostat ENGINE 112, 113 ... AR20.10-P-2455A V
Test coolant thermostat ENGINE 113.964 in AR20.10-P-2455GZ
MODEL 164.175
Mercedes-Benz
Test coo1ant thermostat ENGINE 113.971 in AR20.10-P-2455RT

MODEL 251.075/175
Testing coo1ant thermostat ENGINE 113.995 in AR20.10-P-
MODEL 230.472 2455RVK
Test coolant thermostat ENGINE 113.967 in AR20. 10-P-2455TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Test coolant thermostat ENGINE 113.989 in AR20.10-P-2455VT
MODEL 171.473
Remove/install coolant thermostat ENGINE 112, 113 ... AR20.10-P-2460B
Remove/install coolant tbennostat ENGINE 113.964 in AR20.10-P-2460GZ
MODEL 164.175
Remove/install coolant thermostat ENGINE 113.971 in AR20.10-P-2460RT
MODEL 251.075/175
Remove/install coolant thermostat ENGINE 113 ... AR20.10-P-
2460RVK
Remove/install coolant thermostat ENGINE 113.967 in AR20.10-P-2460TY
MODEL 219.375
Remove/install coolant thermosta t ENGINE 113.990 in AR20. 10-P-2460TZ
MODEL 219.376
Remove/install radiator ENGINE 112, 113 ... AR20.20-P-3865AB
Remove!install radiator ENGINES 112, 113 in AR20.20-P-3865A V
MODEL 129
Remove/install radiator ENGINE 113.964 in AR20.20-P-3865GZ
MODEL 164.175
Remove/install the radiator ENGINE 112, 113 .. . AR20.20-P-3865HC
Remove/install radiator ENGINE 112 in AR20.20-P-3865HD
MODELS 210,208,202
ENGINE 113 in
MODELS 21 O, 208, 202
Removing/installing the radiator ENGINE 112, 113 ... AR20.20-P-3865PV
Remove/install radiator ENGINE 112, 113, 275 .. . AR20.20-P-3865R
Remove/install radiator ENGINE 272.967 in AR20.20-P-3865RT
MODEL 251.065/165
ENGINE 113.971 in
MODEL 251.075/175
Remove/install radiator ENGINE 112, 113, 628 ... AR20.20-P-3865TV
Remove!install radiator ENGINE 113.967 in AR20.20-P-3865TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Test cooling system cap ENGINE 112, 113 ... AR20.30-P-4300FV
Testing the cooling system cap ENGINE 113.964 in AR20.30-P-4300GZ
Mercedes-Benz
MODEL 164.175
ENGINE 272.967 in
MODEL 164. 186
Check cooling system cap ENGINE 111, 112, 113, AR20.30-P-4300P
271, 611,612, 613, 628,
642 ...
Testing the cooling system cap ENGINE 272.967 in AR20.30-P-4300RT
MODELS 251.065 /165
ENGINE 113.971 in
MODELS 251.075/175
Test coolant gage ENGINE 111, 112, 113, AR20.30-P-4460A
156...
Testing the coolant gage ENGINE 113.964 in AR20.30-P-4460GZ
~ODEL 164.175
ENGINE 272.967 in
MODEL 164.186
Test coolant gage ENGINE 113.971 in AR20.30-P-4460RT
MODEL 251.075/ 175
Remove/install expansíon ENGINES 113, 272, 273 AR20.30-P-4950GZ
reservo ir inMODEL 164
Remove/ínstall expansion ENGINE 113, 156, 272, AR20.30-P-4950RT
reservoir 642 in MODEL 251
Remove/install expansion ENGINE 113.967 in AR20.30-P-4950TY
reservoir MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
ENGINE 156.983 in
MODEL 219.377
Remove/install electríc fan ENGINE 113.988 in AR20.40-P-5000AC
MODELS 203.076 /276
with TRANSMISSION
722.636
Remove/install electric fan ENGINE 113.965 in AR20.40-P-5000GH
MODEL 163.175
ENGINE 113.981 in
MODEL 163.174
Remove/install electríc fan ENGINE 113.964 in AR20.40-P-5000GZ
MODEL 164.175
Remove/install electríc fan ENGINE 112, 113 ... AR20.40-P-5000PV
Remove/install electric fan ENGINE 113.971 in AR20.40-P-5000RT
MODEL 251.075/175
Remove/install electric fan ENGINE 112, 113,646, AR20.40-P-5000T
647, 648 ...
Remove/install electric fan ENGINE 113.967 in AR20.40-P-5000TY
MODEL 219.375
Mercedes-Benz
ENGINE 113.990 in
MODEL 219.376
Remove/install electric fan ENGINE 113, 271, 272 ... AR20.40-P-5000V
Disassemble/reassemble fan ENGINE 111 , 112, 113 , AR20.40-P-5100PQ
271, 611 , 612, 646 ...
Disassemble fan and reassemble ENGINE 113.967 in AR20.40-P-5100TY
MODEL 219.375
ENGTNE 113.990 in
MODEL 219.376
Remove/install viscous fan clutch ENGINE 112, 113 .. . AR20.40-P-5660C
Remove/install fan shroud ENGINE 112, 113 ... AR20.40-P-6800AB
Remove/install fan shroud ENGINE 112, 113 ... AR20.40-P-6800TB
Remove, install fan shroud ENGINE 113.990 in AR20.40-P-6800TC
MODEL 211.076/276
ENGINE 156.983 in
MODEL 211.077/277
Removing and installing the fan ENGINE 113.967 in AR20.40-P-6800TY
shroud MODEL 219.375
Remove/install fan shroud ENGINE 113.990 in AR20.40-P-6800TZ
MODEL 219.376
ENGINE 156.983 in
MODEL 219.377
Remove/install fan shroud ENGTNE 113.989 in AR20.40-P-6800VT
MODEL 171.473
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE COOLING SYSTEM- AR20.00-Z-
9120AB
ENGINE 120
Inspect cooling system for ENGINE 111, 112, 113, 120, 137, 271, 275, 285, 601, 602, AR20.00-P-
leaks 603,604, 605, 606, 611,612,613,628,646,647, 648 ... lOlOHA
Checking the shift point of AR20.00-P-
engine 120 in MODELS 129, 140
the cooling system 1020AO
AR20.30-P-
Test coo1ing systern cap Engines 111 , 120, 601,602, 603, 604,605,606/
4300HA
Removing and installing AR20.30-P-
ENGINE 120 inMODEL 129
overflow tank 4540AO
ENGINE 120 inMODEL 140
overflow tank 4540AP
viscous fan clutch 5660AO
fan shroud 6800AO
Mercedes-Benz
REMOVE!INSTALL COOLANT PUMP- AR20.10-P-1271B
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODELS 129, 163, 170, 202, 203, 208, 209, 210, 220
ENGINE 113.962 in MODELS 463.206 /240 /241/247 /248 /249 /254
ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 220
ENGINE 113.982 in MODELS 463.243 /246
Shown on engíne 112
1 \.ffsc.o t1s fan

2 Poly-V-belt
3 Fansbroud
4 Co-olant h ose
5 CoOiant h ose
a Coolant h ose to o ii•Will f!T heat
~chMtger
7 Coolant pump beltpuhy
8 Coolant p ump
9 Coolantpump gasket
10 Shock ab.sotber
1f 80 ~$
Fig. 22: Identifying Coolant Pump Components - Shown On Engine 112
Modification notes
16.12.03 Value changed Value in BA20.10-P-1002-0 1M modified on *BA20.10-P-1002-
from 10 N m to 9 engine 112.910/9 11/912/913/914/915/916/ OIM
Nm 917/920/92 1 /922/923/940/941 /942/
943/944/945/946/947/949/953/954/
955/960/961 /970/972/973/975
fi3="GF [gj Remove/install

fi3="GF Risk of death caused by Align vehicle between the columns ASOO.OO-Z-0010-
vehicle slippíng or of the and position the four support OlA
toppling off the liftíng plates below the lifting platform
Mercedes-Benz
pJatform. support points specified by the

1 Lift/jack up vehicle Models 129, 170, 202, 208, 210, 220
Model163 AR00.60-P-1 OOOGH
Model1 7 1 AR00.60-P-1000V
Models 2 03, 209 AR00.60-P-1000P
Model 463 AR00.60-P-1000G
~GF Risk of injury caused When moving components, ensure ASOO.OO-Z-0011-
by ímgers being that no body parts or limbs are OlA
jammed or pinched within the operating range of
when removing, moving p arts.
installing or aligning
hoods, doors, trunk lid/
rear-end door or sliding
roof
2 Open engine hood Model 129
Model 163 .154/ 172 up to AR88.40-P-1000GH
VINA145272
Model163.154/ 172 up to
~7083181 5 4/ 172
Model 163 .154/ 172 from AR88.40-P-1000GI
VINA145273
Model 163.154/172 from
VINX708319
Models 163.157/1 74/ 175
Modell70 AR88.40-P-1 OOOG
Modell71.4 AR88.40-P-1OOOV
Model 202 AR88.40-P-l OOOE
Model 203 AR88.40-P-1000P
Models 208/210 AR88.40-P-1 OOOF
Model 209 AR88.40-P-1000Q
Model220 AR88.40-P-1 OOOM
Model 463 AR88.40-P-1000GG
3.1 Unclip cover on :front ITl Only modeJ 220.
síde of engine
4.1 Remove engine cover or ITJ All except models 170.466,
air filter 171.473, 203.065 /265,
203.076 /276, 209.376 /476 from
24.4.04.
5.1 Partially remove air Engine 112.960 in modell70.466 AR09.10-P-1150SVK
filter housing Engine 112.961 in models 203.065/
265
Engine 113.987 in models AR09.10-P-ll50AC
209.376 /476 as of24.4.04
Mercedes-Benz
ENGINE 113 .988 in Models

203.076/276
Engine 113.989 inmodel171.473
6.1 Remove viscous fan (1) All except models 163.174/175, AR20.40-P-5660C
170,171.473,203,208.365/465,
209, 220
1JJ Right-hand thread!
7.1 Remove fan shroud (3) IJJ On vehicles fitted with suction
fan, separate the plug connection of
the suction fan before removing the
fan shroud.
Model171.473 with engine 113.989 AR20.40-P-6800VT
Model463 with engines 112.945, AR20.40-P-6800V
113.962/982
Model 220 with engines 112, 113 AR20.40-P-6800AB
8.1 Remove electric fan Model 163 with engines AR20.40-P-5000GH
113.965/981
Model170 with engines 112.947/ AR20.40-P-5000SV
960
Modell71.473 with engine 113.989 AR20.40-P-5000V
Model203.076/ 276 AR20.40-P-5000AC
Model 203 with engines AR20.40-P-5000PV
112.912/9 16/ 946/953/96 1
Model 209 with engines
112.912 /95 5, 113.968 /987.
Models 208.365/ 465
[!irGF Risk of injury to skin Do not open cooling system unless AS20.00-Z-0001-
and eyes caused by coolant temperature is below 90°C. OlA
scalding from contact Open cap slowly and release the
with hot coolant spray. pressure. Do not pour coolant into
Risk of p,oisoning from beverage coutainers.
swallowing coolant. Wear protective gloves, protective
clothing and safety glasses.
9 Drain coolant from IJJ Model 163: For draining coolant,
radiator detach bottom coolant line at
radiator or at coolant pump.
& InstaiJation: On model 163
replace radiator connection of hose
clamps to coolant hose, otherwise
this can cause a damage to the bolt/
thread.
&.oanqorl Hose clamp *BA20.20-P-1004-
1JJ Collect coolant OlA
IJJ Disposal of coolants: observe
Mercedes-Benz
legal regulations or local wastewater

requirements! Refer to
Environmental Protection Catalog
issued by MBVD/PWU for
locations in Germany.
Models 129, 163, 202, 208, 210, 220 AR20.00-P-1142HA
with engi.ne 112
Models 220, 2l0, 208, 202, 163, 129
with engine 113
Model463.206 /240 /241 /247 /248 1
249 /254 with engine 113.962.
M odel
463.209 /232 /233 /244 /245 /250
with engi.ne 112.945.
Models 463.243 /246 with Engine
113.982
Model170.465 with engine 112.947 AR20.00-P-1142SV
Model 170.466 with engine 112.960
Model171.473 with engine 113.989 AR20.00-P-1142PV
112.912
Models 203.064 /264/764 with
Engine 112.946
112.961
113.988
Models 203 .081 /281 with Engine
112.916
Models 203.084/284 with Engine
112.953
112.912
112.955
113.968
113.987
10 Remove poly-V-belt (2) ITJ Lock tensioning pulley with drift
or pin (diameter 5 mm).
Model AR13.22-P-1202B
463.209 /232 /233 /244 /245 /250
with engi.ne 112.945.
Model463.206 /240 /241 /247 /248 1
Mercedes-Benz
249 /254 with engine 113.962.

113.982
Models 129, 163 with engine 112
Models 129, 202, 208.370 /470, 210
with engine 113
Model 163 with engine 113 except
113.965/981
Models 202, 208, 210, 220 with AR13.22-P-1202BA
engine 112
Model 220 with engine 113 except
220.074/174
Modell63.175 with engine 113.965
MODELS 208.374 /474 with Engine
113
Models 220.074/ 174 AR13.22-P-1202R
Model170.465 with engine 112.947 AR13.22-P-1202SV
Model 170.466 with engine 112.960 AR13.22-P-1202SVK
MODELS 203.065/265 with
ENGINE 112.961
Model 171.473 with engine 113.989 AR13.22-P-1202PV
112.912
Models 203.064/264/764 with
Engine 112.946
113.988
112.916
Models 203 .084 /284 with Engine
112.953
112.912
112.955
Models 209.375 /475 witb Engine
113.968
113.987
11.1 Remove shock absorber Models 210,203,209,202, 170, 129
(lO) with manual transmission
12 Re move poly-V-belt Model AR13.25-P-3200B
tensioning device 463.209 /232 /233 /244 /245 /250
with P.nO"i nP. 11 ?. 94 ')
Mercedes-Benz
Model463.206/240 /241 /247 /248 1

249 /254 with engine 113.962.
113.982
Models 129, 163 with engine 112
Models 129, 202, 208, 210 with
engine 113
Model 163 wíth engine 113 except
113.965/981
Model 163.174 with enginell3.981 AR13.25-P-3200BA
Mode1163.175 with engine 113 .965
Models 170, 202, 203, 208, 209,
210, 220 with engine 112
Model 171.473 with engine 113.989
Models 203, 209, 220 with engine
113
13 Disconnect coolant hose ITI Check condition of coolant hoses
(4, 5) and hose clamps, replace íf
necessary.
14.1 Disconnect coolant hose OJ All except model171.473.
(6) at oil-water heat ITI Check conditíon of coolant hose
exchanger and hose clamp, replace if
necessary.
15.1 Remove bolts from oil ITI Only model 171.473.
lines on oil filter
&0anoer1 Bolt of oilline to oil fLlter *BA18.20-P-1003-
housing OlD
16.1 Remove bolts from oil ITI Only model171.473. *BA18.20-P-1004-
lines brackets and lay oil &oanqer! Bolt, oilline bracket OlD
lines with brackets to
one side
17.1 Remove bracket with ITI Only model171.473
switchover valve and
pressure sensor and
place to one side
18 Take off belt pulley of ITI Engine 112: ?
coolant pump (7) &oanoor! Belt pulley to coolant pump *BA20.10-P-1002-
OlM
ITI Engine 113, except
113.987 /988 1 989 /991: ?
&oanqerl Belt pulley to coolant pump *BA20.1 0-P-1002-
OlC
ITI Engínes
113 .987 /988/989 /991: ?
Mercedes-Benz
Belt pulley to coolant pump *BA20.10-P-1002-

&oanQorl
OlL
III Engine 113.989:?
III Counterholder Fig. 24
19 Remove coolant pump 1JJ Installation: Replace gasket of
(8) coolant pump (9).
IJJ Engine 112: ?
&oanQerl Self-tapping screw, coolant *BA20.10-P-1001-
pump to timing case OlM
1JJ Engine 113 except 113.987 /988 1
989 /991:?
&oanQer! Self-tapping screw, coolant *BA20.10-P-1001-
pump to timíng case OlC
III Engines
113.987 /988/989 /991:?
&oanoor! Bolt, coolant pump to timing *BA20.10-P-1001-
case OlL
III Engine 112, 113: ?
Lt. oanoorl Alternator screw *BA15.40-P-1003-
OlA
III External T orx set Fig. 23
order
21 Inspect cooling system III All except models 170, 171.473, AR20.00-P-1010HA
for leaks 203, 209, 220.074/174
Models 170, 171.473, 203, 209 AR20.00-P-10 IOP
Models 220.074/174 AR20.00-P-
1010RVK
Alternator
&oan•w!
Number Designation Engines Engine 113.991 in

112.91192/94/ models 215, 220
953/954/955/96/97,
113.94/96/98
BA15.40-P-1003- Bolt for alternator N m 42 -
OlA
Oil filter
&oancoer!

BA 18.20-P-1003-01D Boh, oilline to oil filter Nm 9
housing
BA 18.20-P-1004-0 1D BoEt for oílline bracket Nm-
Mercedes-Benz
• Dan"QerJ eootant ~ump_, coo ant t hermosta t

N umber Designation E ngines
112.910/911/91
2/913/914/915/
916/917/920/
9211922/923/
940/9411942/
943/944/945/
946/947/949/
953/954/955/
960/9611970/
972/973/975
BA20.10-P- Self-tapping Thread not pre- M6 N m 14
1001-0lM screw, coolant tapped
pump to timing Thread not pre- M8 Nm35
case tapped
Threadpre- M6 NmlO
tapped
Thread pre- M8 Nm25
tapped
BA20.10-P- Belt pulley to coolant pump Nm9
1002-0lM
• Dan"QorJ eoo1ant ~u m p, coo1a n t ther m osta t

E ngines
113.940/9411
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992
N omber Designation 993/995
BA20.10-P- Self-tapping Thread not pre- M6 N m 14
1001-0 lC screw, coolant tapped
pump to timing Thread not pre- M8 Nm35
case tapped
Thread pre- M6 NmlO
tapped
Thread pre- M8 Nm25
tapped
BA20.10-P- Belt pulley to coolant pump NmlO
1002-0lC
Mercedes-Benz
• DanQerJ eoo1ant ~ump, coo1ant thermostat

Engine
113.987/988/
Number Designation 990/991 Engine 113.989
BA20.10-P- Bolt, coolant M6 N m 14 14
1001-01L pump to timing
case M8 Nm20 20
BA20.10-P- Belt pulley to coolant pump Nm9 9
1002-0lL
&oanQerJ Radiator, coolant hoses

Engines 112.942/970,
Number Designation 113.942/ 965/981
BA20.20-P-l 004-0 lA Hose clamp Nm3
,r.,,..,l Ton( SCjl
Fig. 23: Identifying External Torx Set (001 589 76 09 00)
113 589 00 4C 00
Fi~. 24: Identifyine Counterbolder {113 589 00 40 00)
TESTING COOLANT THERMOSTAT- AR20.10-P-2455AV
ENGINE 112
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243 /246

Mercedes-Benz
ENGINE 113 (except 113.995) in MODE LS 129, 163,. 202, 203, 208, 209, 210, 211, 215, 220, 230
1 C oolanttbelmoslat
2 Vd1e
PKLI O 2009~<
Fig. 25: Testing Coolant Tbermostat
o:::?'GF [g¡ R emove/install

n::!rGF Risk of injury to Do not open cooling system unless coolant AS20.00-Z-0001-
skin and eyes temperature is below 90°C. Open cap slowly OlA
caused by and release pressure. Do not pour coolant into
scalding from beverage containe rs.
contact with hot Wear protective gloves, protecti ve clothing and
coolant spray. safety glasses.
Risk of poisoning
from swallowing
coolant.
1 Remove coolant IIJ Installation:
thermostat ( 1)
o Install new sealing ring.
o The coolant thermostat (1) must not be
removed from housing. Otherwise it will
be destroyed. The housing is supplied
together with a coolant thermostat (1) for
repau purposes.
Engine 112 in models 170, 203,
2 11.080/280 /082/282/2611265 '
Engine 113 in models 211.083/283/270,
215.373/3 75
Engine 112 in models 211.061 /065 , 220, 129, AR20.10-P-
209.361/461 , 163 , 202, 208, 209.365/465, 210, 2460B
Engine 112.945 in models
463.245/233/209 /250/244/232,
Engine 113 in models 209, 210, 129, 208,
211.070, 220, 230.475, 163, 202,
Engine 113 .962 iu models
463.254/206/248 /240/247/241/249'
Engine 113.982 iu models 463.246/243
Engine 113.990 in models 211.076/276, AR20.10-P-
Engine 113 .991 iu mode1s 215.374, 220.074, 2460RVK
Mercedes-Benz

2460R
[l] C hecking
2 Heat coolant IJJ Suspend coolant thermostat (1) from a wire
thermostat (1) in a vessel ftlled wíth water and heat water.
6 F or heating up under no circumstance use a
welding torch ora soldering torch, otherwise
sudden heat penetration modifies the metal
structure!
3 Measure IJJ The heating-up rate should be not more than
temperature of 1oc to 2°C/minute from about 8°C below start
water of opening of coolant thermostat (1).
@ *WH58.30-Z-
1002-0SA
4 Warm up water to 1JJ Ifthe check values are not achieved, replace
full openíng coolant thermostat ( 1).
temperature of Check values for engine 113.969:
valve (2) and then Start of opening
measure hub of Mínimum stroke
valve (2) Check values engine 112, 113 except 113.969:
Start of opening *BE20.10-P-
1001-02A
Mínimum stroke *BE20.10-P-
1002-02A
5 Install in the
reverse order
6 Inspect cooling
system for leaks Engine 112.946 in model 209.764
Engine 112 (except AR20.00-P-
112.961/946/953/ 947 /960/916/955/9 12), 1010HA
Engine 113 (except
113.992/987/968/ 991 /990/963)
Engine 113.963/990/9911992 AR20.00-P-
lO lORVK
Engine 112.912/916/947/953/955/960/961 , AR20.00-P-
Engine 112.946 except in model209.764, 1010P
Engine 113.968/987
Coolant thermostat
Number Designation E ngine 112, engines
113.940/941/
942/943/944/
945/946/948/
Mercedes-Benz
960/961/962/
963/964/965/
966/967/968/
971/980/981/
9 82/984/986/
987/988/990/
991/992/993/995
BE20.1 0-P-1 00 l-02A Start of opening oc 85 to 89
BE20.1 0-P-1 002-02A Mínimum stroke oc 102
mm8
BE20.1 0-P-1 003-02A Thermostat bypass valve mm-
dia.
e ommerc1a·uty availa ble too s

Number Designation
WH58.30-Z-l 002-08A Digital temperature measuring instrument
(measuring range -20° to +70°
REMOVE/INSTALL COOLANT THERMOSTAT- AR20.10-P-2460B
ENGINE 112 in MODEL 129, 163, 202, 208, 209.361 /365/461 /465, 210,211.061 /261 /065 /265, 220
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113 in MODEL 129, 163, 202, 203, 208, 209, 210, 211.070 /270, 220, 230.475
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
Shown on engine 112

Mercedes-Benz
1 Coolanllherm<>sta t houslng
2 SINilng rlng
3 Solts
4 H..seetamp
5 Coolat>l hose
6 RMilaiOI'
Fig. 26: ldentifying Coolant Thermostat Components - Shown On Engine 112
Modification notes
1.9.04 Value changed V alue in row 100 3 changed for engine *BA20.10-P-
from 10 Nm to 14 112.910/911/912/913/914/915/916/9171 1003-0lM
Nm 920/921/922/923/ 940/941/942/943/944/
945/946/947/949/ 953/954/955/960/961 1
970/972/973/975
~GF [gj Remove/install

o::rGF Risk of injury Keep body parts and limbs well clear of moving ASOO.OO-Z-
caused by fmgers parts. 0011-0lA
being pinched or
crushed when
removmg,
installing or
aligning hoods,
doors, trunk lids,
tailgates or
sliding roof.
1 Open engine
hood
~GF Risk of injury to Do not open cooling system unless coolant AS20.00-Z-
skin and eyes temperature is below 90°C. Open cap slowly and 0001-0lA
caused by release the pressure . Do not pour coolant into
scalding from beverage containers.
contact with hot Wear protective gloves, protective clothing and
coolant spray. safety glasses.
Risk of
poisonin~ caused
Mercedes-Benz
by swaUowing
coolant.
2 Drain coolant at [I] Model163: For draining coolant, detach
radiator (6) bottom coolant line at radiator or at coolant pump.
Lt. Installation: On model163 replace radiator
connection of hose clamps to coolant hose,
otherwise this can cause a damage to the bolt/
thread.
&oanQerl Modell63 *BA20.20-P-
[I] Collect coolant 1004-0lA
[I] Disposal of coolants: observe legal regulations
or local wastewater requirernents! Refer to
Environmental Protection Catalog issued by
MBVD/PWU for locatíons ín Germany.
Engine 112 in model220, 208,211 , 163, 210, AR20.00-P-
129, 202 1142HA
Engine 113 in model211 , 163, 208, 202, 2W,
220, 129
463.240 /241 /248 /254 /206 /247 /249
463.233 /244 /209 /232 /245 /250
Engine 113.982 in model463.246 /243
1142RVK
Engine 112.912 in model209.361 /461 AR20.00-P-
Engine 112.955 in model209.365 /465 1 142PV
Engine 113.968 in model209.375 /475
Engine 113.987 in MODEL 209.376/476
Engine 113.988 in mode1203.076/ 276
Engíne 113.989 in model 171.473
& Notes on coolant AH20.00-N-
2080-0lA
3 Unclip cover on Model211, 220
front side of
engme
4 Remove engine Except model 211 , 230
cover with Model 171.473 AR09.10-P-
integrated a1r Model 203.076/ 276 1150AC
filter Model209.376/ 476 as of24.4.04
[I] For model463, 220, 210.074 /274,
208.370 /374 /470,
209.361 /365 /375 /376 /461 /465 /475 /476,
202.033 /093, 129, the air filter ís integrated in the
Mercedes-Benz
engine cover. Remove engíne cover or aír filter by

pulling it vertically up and off the cylinder head
covers.
5 Detach coo]ant OJ Inspect condition of coolant hose (5) and hose
hose (5) clamp (4), replace ifnecessary.
6 Remove poly-V Model 171.473 with engine 113.989 AR13.22-P-
belt from guide 1202PV
pulley
7 Unscrew bolts & The coolant thermostat must not be removed
(3), remove from the housing. Otherwise it will be destroyed.
coolant Re-ínstallatíon ís not possíble. The housíng ís
thermostat supplied together with the coolant thermostat for
housing (1) with repair purposes.
coolant OJ Installation: Install new sealíng ríng (2)_
therrnostat *BA20.10-P-
& oanQerl Engine 112
1003-0lM
&oanQer!Engine 113 except 113.987 /988/989/991 *BA20.10-P-
1003-01C
&oanQer! Engine 113.987 /988/989 /991 *BA20.10-P-
1003-0IL
8 Install in the
reverse order
9 Inspect cooling Modell29, 163, 202, 208, 210, 211, 463 AR20.00-P-
system for leaks 1010HA
Model220 except 220.074/174
Modell71.473 AR20.00-P-
lOlOP
Model 203.076/ 276
Model220.074/174 AR20.00-P-
1010RVK
Model230.475
&oanQerl Radiator, coolant hoses

Number Designation Engine 112.942/ 970,
113.942/ 965/981
BA20.20-P-1004-01A Hose clamp Nm3
&oanQerl Coolant pump, coolant thermostat

N umber Designation Engine 113.940/9411
942/943/944/
945/946/948/
960/961/962/
963/965/966/
Mercedes-Benz
967/968/969/
980/981/982/
984/986/992 993/995
BA20.10-P-1003- Bolt for coolant M6 N m 10
OlC thermostat housing
· Danaorl eoo1ant pump, coo ant t hermostat

Number Designation Engine 112.910/911/91
2/913/914/915/
916/917/920/
9211922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/961/970/
972/973/975
BA20.10-P-1003- Bolt for coolant M6 N m 14
OIM thermostat housing
• Oanaerl eoo1ant ~ump, coo1ant thermostat

Number Designation Engine E ngine 113.989
113.987/988/
990/991
BA20.10-P- Bolt for coolant M6 N m 14 14
1003-0IL thermostat
housing
REMOVE/INST ALL RADIA TOR - AR20.20-P-3865AV

Mercedes-Benz
V l.sc ou.sfm ; ATF lino

F • n shro tld 10 Blu~or ATF lino
Cavar 11 R•dl•to r
4 Coollnt Mno rodlltor-rhormostilt housl ng 12 CliM11p S
C ooU nt Mn a r.Jdútor-cool4nt p ump 13 Roldiatcr C' rossmombcr
c ool>nt Mno OJt~nslon rosorvot -~dl•tor 14 Br• c~o t suporcll• rgcr lino
Coololnr Mna u~m ion rcsGtvoli'- r• dl•tor tS SUplllt:ll•rgor lino
1 ATF l fnc
Fig. 27: ldentifving Radiator Remove/lnstall Components
n:::rGF
¡g¡ Remove/install
[JJ *WH58.30-
@ Wrench hexagon
Z-1001-06A
*WH58.30-
@ Wrench hexagon
Z-1002-06A
AR61.20-P-
1 Remove engine compartment paneling
UOSAB
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
~GF
scalding from contact with hot coolant AS20.00-Z-
pressure. Do not pour coolant into
spray. Risk of poisoning from swallowing 0001-0lA
coolant.
Wear protective gloves, protective
dothing and safety glasses.
AR20.00-P-
Drain coolant at radiator, pour it in
1142HA
AR20.40-P-
3 Remo ve viscous fan ( 1) IJJ Right-hand thread! 5660C
- On vehicles with suction fan, frrst
4 Remove fan shroud (2).
disconnect connector for suction fan.
5 Remove cover (3).
Mercedes-Benz
6 Detach coolant lines ( 4, 5)

7 Detach coolant línes ( 6, 7)
8 Remove ATF lines (8, 9) 1JJ Seal connectíons!
[JJ Fig. 28
*BA20.20-P-
Lt.oanaerl
1003-01A
Lt.oenqe.r!
*BA20.20-P-
1001-0lA
Remo ve bracket ( 1O) of ATF line (8) at
9
radiator ( 11)
10 Remove clamps (12)
11 Remove radiator crossmember (13)
Remove bracket (14) from supercharger line
12
(15)
13 Unbolt condenser at t·adiator IJJ Big 3 bolts on upper radiator.
lnstallation :
14 Unhinge capacitor Capacitor must be seated in the two
retainers (arrow) ofthe radiator (11).
Iostallation :
The studs on the radiator must be
15 Remo ve radiator ( 11)
located at the bottom ín the mbber
mounts on the crossmember.
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
¡GrGF injury caused by contusions and burns ASOO.OO-Z-
Wear closed and snug-fitting work
0005-0lA
during starting procedure or when working dothes.
near the running engine Do not grasp hot or rotating parts.
Check oillevel in automatic transmission AR27.00-P-
17
and correct ifnecessary. 0101A
AR20.00-P-
18 Inspect coolíng system for leaks
1010HA
& RADIATOR, COOLANT HOSE S

oanaer!
Number Designation Engine 112 except 112.942/970, engines

113.940/941/943/944/945/946/948/960/961/962/963/966/967/968/969/980
Union nut,
BA20.20- automatic
P- 1001- transmission N m 20
OlA oilline to
radiator
BA20.20-
P-1003- Banjo bolt Ml2Xl.5Nm 30
OlA
Mercedes-Benz
129 5B9 00 91 00
Fig. 28: ldentifving Set Of Stop Plugs (129 589 00 91 00)
CO~RCMLLYAV~ABLETOOLS
Number Designation
WH58.30-Z-1 00 1-06A 6 mm socket hexagon on flexible shaft for hose clamps with worrn drive
WH58.30-Z-1 002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
TEST COOLING SYSTEM CAP - AR20.30-P-4300
Test cooling system cap - AR20.30-P-4300FV
ENGINES 112,113
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243 /246
ENGINE 113.993 in MODELS 463.270 /271
A C h""k eap w lth d<tt..,t

2 Tostor
3 TeSI Clf'
4 Ad.ap ter
5 Cop w lth cMtem
6 Prossoto te6ol viJNo
8 Teat t and 2..uge co,p
2 T ester
3a Ad.ap te.r
S. Cap
P20..304!23 06
Mercedes-Benz
Fig. 29: Testing Cooling System Cap - Engines 112,113
~GF Remo ve
~GF Risk of injury to Do not open cooling system unless coolant AS20.00-Z-0001-
skin and eyes temperature is below 90°C. Open cap slowly mA
caused by and release the pressure. Do not pour coolant
scalding from into beverage bottles. Wear protective gloves,
contact with hot protective clothing and eye protection.
coolant spray.
Risk of poisoning
from swallowing
coolant.
1.1 Fit cap with detent [JJ For model 463.206/209/232/233/ 240/241
(5) with cap with notch (5).
[JJ Carefully rotate cap up to the ftrst detent,
release overpressure, then unscrew cap (5). If
corrosion present at cap with detent (5), the cap
must be replaced.
1.2 Remove 1 or 2- [JJ A 1-stage cap (5a) is installed in model 163.
stage cap (5a) In models 140, 170, 199, 202, 203, 208, 209,
210, 211 , 215, 220, 230, 463.243/244/245/
246/247/248/249/250/254/270/271 there are 2-
stage caps (5a) 1nstalleci
[JJ Turn 1 or 2-stage cap ( 5a) half a tum in an
anti-clockwise direction, release pressure and
then unscrew cap.
[tl Check cap with
detent
2.1.1 Attacb test cap (3) Only on model463.206/209/232/233/240/ 241
and adapter (4) to with cap with notcb (5).
tester (2)
[JJ Tester Fi!!. 14
[JJ Test cap Fig.lS
[JJ Adapter Fi2. 30
2.1 .2 Screw cap ( 5)
with detent onto
the adapter (4)
2.1.3 Inspect pressure Only on model463.206/209/232/233/240/ 241
relief val ve (6) with cap with notch (5).
[JJ The pressure reliefvalve (6) must be resting
against the mbber seal (arrow), it must be
possible to lift it easily and it must spring back
after being released.
Detennine the opening pressure of the cap with
notc.h (S) hv n11mn ::~no n~nl::~c.e c.::tn with notc.h
Mercedes-Benz
(5) if necessary_
Cap code number *BE20.30-P-
1001-01A
Pressure relief valve opens *BE20.30-P-
1002-01A
Pressure relief valve opens (Reference value) *BE20.30-P-
1003-01A
Test pressure *BE20.30-P-
1005-01A
[lJ Test the 1 or 2-
stage cap
2.2.1 Attach adapter Only on models 163, 140, 170, 199, 202, 203,
(3a) to tester (2)208, 209, 210, 211 , 215, 220, 230,
463.243/244/245/246/247/248/249/250/
254/270/271.
ITJ Tester Fig. 14
Adapter for models 140, 170, 199, 202, 203,
208, 209, 210, 211, 215, 220, 230,
463.243/244/245/246/247/248/249/250/
254/270/271:
ITJ Adapter F ig. 34
Test cap for Model 163: ?
ITJ Test cap F h!. 33
2.2.2 Screw 1 and 2- Only onmodels 163, 140, 170, 199, 202, 203,
stage cap (5a) 208, 209, 210, 211,215,220,230,
onto adapter (3a) 463.243/244/245/246/247/248/249/250/
254/270/27 1.
2.2.3 Inspect pressure Only on models 163, 140, 170, 199, 202, 203,
relief val ve 208, 209, 210, 21 1, 215, 220, 230,
463.243/244/245/246/247/248/249/250/
254/270/271.
ITJ Determine opening pressure ofthe cap (5a)
by pumping and replace cap (5) if necessary.
Cap code number *BE20.30-P-
1001-01A
1002-01A
Vacuum valve opens (reference value) *BE20.30-P-
1003-01A
1004-01A
Test pressure *BE20.30-P-
1005-01A
[g]... Installing
Mercedes-Benz
3. 1 Fit cap with detent OJ For model 463.206/209/232/233/240/241

(5) with cap with notch (5).
3.2 Install Remove 1 OJ For models 140, 163, 170, 199, 202, 203,
or 2-stage cap (5a) 208, 209, 210, 211 , 215, 220, 230,
463.243/244/245/246/247/248/249/250/
254/270/271 with 1 or 2-stage cap (5a).
eap or rad.ta tor or expanswn reservotr

Number Designation Cap 2-stage cap 1-stage cap
model163
BE20.30-P- Cap code number 140 140/200 -
1001-01A
BE20.30-P- Pressure relief New bar gage 1.4(+0.1) - 1.4 (+0.1)
1002-0lA valve opens U sed bar gage 1.4 (-0.1) - 1.4 (+0.1)
BE20.30-P- Vacuum valve opens bar vacuum 0. 1 0.1 0.5
1003-01A (reference valu e)
BE20.30-P- Pressure relief 1st stage bar gage - 1.4(± 1) -
1004-01A valve opens Coolant temp. - > or = -
130/ 134
2nd stage bar gage - 2.0 (± 1) -
Coolant temp. - > or = -
137/143
BE20.30-P- Test pressure for pressure- bar gage 1.4 1.4 -
1005-01A testing cooling system
eap or ra d.tator or expans10n reservou

Number Designation 2-stage cap 2-stage closing
engine 113.968 cover on model
in model209 211
BE20.30-P- Cap code number 140/200 -
1001-01A
BE20.30-P- Pressure relief New bar gage - 1.5 (-0.2)
1002-0lA valve opens U sed bar gage - 1.5 (-0.2)
BE20.30-P- Vacuum valve opens (reference barvacuum 0.1 0.1
1003-01 A value)
BE20.30-P- Pressure relief 1 st stage bar gage 1.4(±1) 1.5 (-0.2)
1004-01A valve opens Coolant temp. > or = 130/ 134 135 (+5)
2nd stage bar gage 2.0 (± 1) 1.5 (-0.2)
Coolant temp. > or = 137/ 143 145 (+5)
BE20.30-P- Test pressure for pressure-testing bar gage 1..4 1.4
1005-01A cooling system
Mercedes-Benz
Fig. 30: Identifying Adapter (000 589 77 63 00)
Fig. 32: Identifving Pressure Pump (124 589 24 21 00)
Tea:aap

Mercedes-Benz
210 589 03 S3 00
Test cooling system cap- AR20.30-P-4300HA
Engines 111, 120, 601, 602, 603, 604, 605, 606 1
A TUt C/IIIWim dloll::nt

a Cl>ce lr 2-s~(IO c•p
P20. l0.022J.il6
Fig. 35: Testing Cooling Svstem Cap - Engines 111, 120, 601, 602, 603, 604, 605, 606
~GF[gJ Removing/installing
[]] The cap in model 163 cannot be
checked; it must simply be
replaced.
1 Open cooling system cap (5, 5a) DJ Cap (5, 5a)
Cap with detent:
Carefully rotate cap up
to the fust detent,
release overpressure,
then unscrew cap.
2-stage cap: Tum cap
half a turn in anti-
clockwise direction_
Mercedes-Benz
release overpressure,
then unscrew cap.
[l] Test cap with detent
2.1 Check cap (5) for corrosion & Replace in case of
COITOSIOn
3.1 Attach test cap (3) and double OJ Tester (2) Fif!. 14
union (4) to tester (2)
OJ Test cap (3) Fi2. 15
OJ Double fitting (4) Fig. 30
4.1 Screw cap (5) with detent onto
the double union (4)
5.1 Inspect pressure relief valve Determine the opening *BE20.30-P-1001-01A
pressure of cap (5) by
pumping; replace cap
( 5) if necessary.
OJ From 02/ 1986 the
opening pressure of the
cap was increased from
the previous 1.2 bar to
1.4; this means that the
permissib1e coolant
temperature has been
raised from 125 to 129°
e for standard
antifreeze protection
down to -30°C
6.1 Test vacuum valve (6) For a cap (5) : The *BE20.30-P-1 003-0IA
vacuum val ve ( 6) must
be resting against the
rubber seal (arrow); it
must be easy to raise it
and must spring back
when released.
[l] C heck 2-stage cap
7.1 Attach test cap (3a) to tester (2) OJ Tester (2) Fi2.14
OJ Test cap (3a) Fig. 17
8.1 Screw 2-stage cap (5a) onto test
cap (3a)
9.1 Inspect pressure relief valve Determine the opening *BE20.30-P-1 004-0lA
pressure of cap (5) by
pumping, replace cap
(5) ifnecessary.
Function see ?
Function of 2-stage cap GF20.30-P-1000A
Mercedes-Benz
110 IInstaH in reverse order
eap or ra d.Ia tor or expans10n reservmr

Number Designation Cap 2-stage cap
BE20.30-P- Cap code number 140 140/200
1001-01A
BE20.30-P- Pressure relief New bar gage 1.4 (+0.1) -
1002-0IA valve opens U sed bar gage 1.4 (-0.1) -
BE20.30-P- Vacuum valve opens (reference barvacuum 0.1 0.1
1003-01A value)
BE20.30-P- Pressure relief 1st stage bar gage - 1.4 (± 1)
1004-0IA valve opens Coolant temp. - > or = 130/134
2nd stage bar gage - 2.0 (± 1)
Coolant temp. - > or = 137/ 143
BE20.30-P- Test pressure for pressure-testing bar gage 1.4 1.4
1005-0lA coolíng system
Tn!ar
Te!i:l c'llp
Fig. 37: Identifying Test Cap (124 589 00 91 00)

Mercedes-Benz
2 10 599 00 91 00
Fig. 38: ldentifying Test Cap (210 589 00 91 00)
2t0 599 03 S3 00
Mapt&s
Fig. 40: Identifving Adapter (000 589 77 63 00)
TEST COOLANT GAGE- AR20.30-P-4460A
ENGINE 111 in MODELS 170, 202, 208, 210
ENGINE 112 in MODELS 129, 202, 208, 209, 210
ENGINE 113 in MODELS 129, 171, 202, 203,208,209, 210

Mercedes-Benz
R!ng m01gnct
a AM-5 Mulltmote r
$41 C401M~t /evo/ lndfcaror switch
P2Cll0-(IH5-11
Fig. 41: Identifying Ring M agnet And Coolant Level Indica tor Switch
~GF Removing
1 Remove coolant leve! OJ The coolant level
indicator switch (S41) indicator switch (S41) is
not directly enveloped
directly with coolant and
can be removed from the
expansion reservo ir or
radiator without draining
the coolant
Model 209 with engine AR20.30-P-4392PI
156
Except model 209 witb
engine 156
[l] Checking
2 Connect multimeter OJ Electrical connection Fig. 42
(DMM-5) at coolant set
level indicator switch
(S41)
® Multimeter *WH58.30-Z-1001-09A
3 Test switching point of WUse float with ring
'maximum' coolant level magnet from expansion
reservoir ofmodels 129,
140,202,203,208,209,
21 0 _
OJ Check witbout using
the ring magnet (1) !
If the resistance indicated
lby tbe multimeter (DMM-
5) = infinity (infmite) ?
Re place coolant level
Mercedes-Benz
indicator switch (S41 ).

4 Test switching point of ITJ Guide the ring magnet
'mínimum' coolant level (1) along the coolant level
indicator switch (S41) to
do this until the contact
switches in the coolant
level indicator switch
(S41).
o Specified resistance
approx. 5 ohrns!
o If the contact is not

switched or if the
resistance indicated
is too high: ?
Replace coolant level

indicator switch (S41 ).
[gJ' InstaD
5 Fit coolant level indicator Model 209 with engine AR20.30-P-4392PI
switch (S41) 156
Except model 209 with
engine 156
Fig. 42: ldentifving Electrical Connection Kit (220 589 00 99 00)
e om mereJa· u1y avaiJ abl e t0 0 1S

Number Designation
WH58.30-Z-l 00 l -09A Ml.tltimeter
REMOVING AND INSTALLING OVERFLOW TANK- AR20.30-P-4540AO

Mercedes-Benz
--~.,.
-·
o-t..-4
1'2fl.l0<1l265·1Ml
Fig. 43: Identifying Overflow Tank Removellnstall C omponents
n:::rGF [g] Removing, installing

1 Drive car onto lift
p latform or over
inspection pit
2 Remove trim panel (7) at
front right
3 Detach overflow line ( 6)
from overflow tank ( 1)
4 Unscrew nuts (2)
5 Remo ve overflow tank ( 1) 1IJ When removing the
overflow tan.k ( 1),
protective cap (3) of air
admission connection (5)
remains positíoned next to
w indshield washer
reservoir (4).
The protective cap should

lbe fitted on agaín when
installing
The overflow tank is GF20.30-P-1000A
discontinued with
introduction of the 2-stage
cap, see ? Function of 2-
Mercedes-Benz
stage cooling system cap

REMOVING AND INSTALLING VISCOUS FAN CLUTCH- AR20.40-P-5660
Removing and iustalling viscous fao clutcb - AR20.40-P-5660AO
P 2 !U0-11 2 55·06
Fig. 44: Identifying Viscous Fan Clutch Removellnstall Components
~GF
[gj.. Removing, installing
AR20.40-P-
1 Remove fan shroud ( 5)
6800AO
2 Fit on counterholder (04) OJ Fig. 45
Use screwdriver and attached
3
torque wrench to unscrew bolt ( 1)
OJ Fig. 46
OJ
OJ Installation : tighten bolt ( 1) wíth Fig. 46
hexagon in sert and torque wrench,
unscrew.
OJ Torque wrench Fig. 47
OJ Hexagon insert Fig. 48
Mercedes-Benz
*BA20.40-P-
&oanQer!
1002-01A
&oanQcrl
*BA20.40-P-
1003-01A
Detacb viscous fan clutch (3) from *BA20.40-P-
4 &oanacrl
fan (2) 1001-0lA
Pay attention to general notes on viscous
fan clutch ?
AH20.40-P-
see
0001-01AO
&oanQcrl FAN, FAN CLUTCH

Number Designation Eogioe
120
BA20.40-P-1001-
Bolt of fan to viscous clutch N m lO
OlA
BA20.40-P-1002- Tightening bolt of viscous fan clutch to bearing body with approved
N m 45
OlA special tool
BA20.40-P-1003- Tightening bolt of viscous fan clutch to bearing body with screwdriver N m
41
OlA and torque wrench
120 589 02 Ot 00
Fig. 45: Identifving Open-End Wrench (120 589 02 O1 00)
120 sag 14 01 oo
Fig. 46: ldentifving Screwdriver (120 589 14 07 00)

Mercedes-Benz
OO t 5B9 72 2t 00
Fig. 47: ldentifving Torgue Wrench (001 589 72 21 00)
103 SB9 Ot 09 Oll
Fi¡:. 48: Identifyin¡: Screwdriver Bit (103 589 01 09 00)
Remove/install viscous fan clutch - AR20.40-P-5660C
ENGINE 112 in MODEL 210, 202, 163.154 /157, 129
ENGINE 113 in MODELS 210, 208, 202, 163.172, 129
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243 /246
Sbown on Engine 112

Mercedes-Benz
1 Countorhoid@l'
2 Sollpu.lley
3 vtscous fu
4 T on¡ue Wtwfch
5 0/Ufl·Md wreneh bit
Fig. 49: Identifving Viscous Fan Clutch Remove/Install Components - Sbown On Engine 112
~GF[gj Remove/lnstall
1 Fít counterholder (1) on ITJ Belt pulley of coolant
bolts ofbelt pulley (2), pump
counterhold
ITJ Fig. 24
2 Unscrew union nut at ITJ Right-hand thread.
viscous fan (3)
ITJ Installation: Use
torque wrench with open-
end wrench bit.
&oanqcrl *BA20.40-P-1002-01B
ITJ Fig. 50
3 Unbolt fan at viscous ITJ lnstallation: The
clutch installation posítion of
the fan is preset through
cast-on ribs at fan ring.
&oanQCrl *BA20.40-P-1001-01B
Fan, fan clutch

&oanqert
N umber Designation Engine 112.910/9111 Engine 113

912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
Mercedes-Benz
945/946/9471
949/9511953/
954/955/960/
9611970/972/
973/975/976
BA20.40-P-1001- Fau to viscous NmlO 10
OlB clutch
BA20.40-P-1002- Viscous clutch to Nm45 45
OlB bearing body
t13 589 00 01 00
Fig. 50: Identifving Open-End Wrench Bit (113 589 00 01 00)
' t13 sag 00 <10 00 _)

Cor.n'lelfidd!!o
Fig. 51: ldentifving Counterholder (113 589 00 40 00).)
REMOVING AND INSTALLING FAN SHROUD- AR20.40-P-6800AO

Mercedes-Benz
11
211
~ 1
Modol 125 :
' Modoii~O:
A l d-17mm A 22-25 mm
8 23-:ZSmm e 25 - 28mm
e 17-23mm e 17- 23 mm
Fig. 52: Identifying Fan Shroud Remove/Install Compooents
u::rGF
¡g¡ Removing, installing
Remove engine compartment panel at

1
bottom front
Remo ve trim panel (20) at top of
2 Model 129
radiator
3 Unbolt front end crossmember (2) Model 140
4 Pull out locking pin ( 18)
Tum fan shroud ring (6) to the left
!Il lnstaiJation : when installing, ensure the 4 engaging
5 studs and the lugs of the fan shroud ring ( 6) are
and place over fan
properly located in the fan shroud (5)
6 Pull flat springs ( 15) up and off
!Il InstaiJation : when installing, insert retaining straps
(arrows) of fan shroud (5) into the mounts at the
radiator.
Remove fan shrouds (5) and fan
7 The air flap (17) of the fan shroud ( 5) should be
shroud ring (6)
positioned to the inside of the engine compartment
Install fan shroud 2nd version for high coolant
temperature and high speeds, see AF.
Align fan shroud (5) with fan shroud
8 ring to fan (7) according to !Il Align fan shroud (5), pay attention to dimensions
dimensions (A), (B), (C)
Mercedes-Benz
MA~NTENANCE
ENGINE COOLING SYSTEM- CHECK FLUID LEVEL, ADJUST TO CORRECT LEVEL. INSPECT
ANTICORROSION/ ANTIFREEZE PROTECTION, ADJUST TO CORRECT CONCENTRATION-
AP20.00-P-2010Z
M O DEL
203.004 /006/016 /018 /020/035 /040 /042 /043 /045 /046 /061 /064 /065 /076/081 /084 /204 /206 /216 /218 /2:
M O DEL
211.004 /006/007 /008 /016/020 /022 /023 /026/028 /029 /041 /042 /052 /054 /056 /061 /065 /070 /072/076 /0'
MODEL414
M O DEL
209.308 /316 /320 /341 /342 /343 /354 /356 /361 /365 /375 /376 /420 /441 /442 /454 /456 /461 /465 /475 /476
MODEL 215 (except 215.376/379)
M O DEL 220 (except 220.176 /179)
MODEL 230 with ENGINES 112, 113
MODEL 124, 129, 140, 168, 170, 202, 208, 210
MODEL 209 with ENGINE 156.9
[l] Check
~GF Risk ofinjury to Do not open cooling system un1ess coolant AS20.00-Z-0001-
skin and eyes temperature is below 90°C. Open cap slowly OlA
caused by and release the pressure. Do not pour coolant
scalding from into beverage containers .
contact with hot Wear protective g loves, protective clothing
coolant spray. and safety glasses.
Risk of
poisoning caused
by swallowing
coolant.
Lt Notes on coolant AH20.00-N-2080-
OlA
1 Remove screw
cap of coolant
expansion
reservo u
2 Check cooEaut ITJ Coolant cold: E ngine coolant leve! up to
leve! marking "Cold water level".
Mercedes-Benz
ITJ Coolant wann: Engine coolant level approx.

1 cm abo ve marking "Cold water leve!".
3 Inspect cooling ITJ If loss of fluid is not due to normal
system for leaks consumption (against separate order)
Engine 103 ra2000102001 7x
Engine 119 ra20001190170x
~' Inspect cooling Engine 111 in model 203 AR20.00-P-
system for leaks Engine 112 except lOlOHA
112.9 12/9 16/946/947/953/955/960/96 1,
Engine 113 except
113.963/968/987/988/990/991/992/995
Engine 120, 137, 601, 602, 603, 604, 605, 606,
613, 628, 646 except 646.8, 647, 648,
Engine 611 except in model 203
Engine 612 except in model203 ,
~' Engine 156 in model209, 211 AR20.00-P-
1010TMG
~' Engine 272, 273 in model 211 AR20.00-P-1010TS
~ Engine 642 in model 211 AR20.00-P-1010TI
'
~' Engine 629 in model211 AR20.00-P-1010TJ
~' Engine 113.963/990/991/992/995 AR20.00-P-
Engine 112.960 in model170.466 lOlORVK
Engine 112.961 in model203.065/265
~' Engine 111 , 112, 113, 271, 611,612, 646 in AR20.00-P-1010P
model203
Engines 2 71, 646.8 in model 211
Engine 112 in Modell70
Engine 112, 113,271,612 in MODEL 209
~ Engine 642 in model 209 AR20.00-P-1010PI
~ Engine 272 in model 209 AR20.00-P-
'
1010QB
~ Engine 166, 668 in model 168 AR20.00-P-
1010GF
~' Engine 166, 668 in model 414 AR20.00-L-
lOIOVA
4 Inspect ITJ Use only approved anticorrosion and
anticorrosion and antifreeze agents.
antifreeze agent in ITJ lf the coolant composition is incorrect:
coolant and Correct the coolant composition (subject to
coolant separate repair order).
composition
5 Mount screw cap
for coolant
expans ion
reservoir
Mercedes-Benz
REPLACE COOLANT - AP20.00-P-2080A
ENGINE 103
ENGINE 104
ENGINE 111
ENGINE 112 in MODEL 210, 208, 202, 203, 209, 129
ENGINE 113 in MODEL 210, 208, 209, 202, 129, 203
ENGINE 119
ENGINE 120
ENGINE 166
Modification notes
110.3_05 lcooling system IE ngine 271 I*BF20.00-P-1001-02P
~GF Risk of injury to Do not open cooling system unless AS20.00-Z-0001-01A

skin and eyes coolant temperature is below 90 oc_
suffering scalding Open cap slowly and release the
from contact with pressure. Do not pour coolant into
hot coolant spray_ beverage bottles.
Risk of poisoning Wear protective gloves, protective
from swallowing clothing and eye protection.
coolant
OJ Notes on coolant All engines AH20.00-N-2080-
OlA
1 DrainlfiH with
coolant
& Notes on coolant Engine 112, 113, 137, 275, 285 AH20.00-P-1142-
level 01V
OJ Notes on coolant Model124, 129, 140, 163.113/128, 168, AH20.00-P-1142-01A
level 170, 202,208 , 210, 211 , 220
OJ Notes on coolant Model203withengine 111 , 112, 11 3, AH20.00-P-1142-01P
leve! 611, 612, 271' 646
Model209 with engine 112, 11 3, 27 1,
612.967
Model211.042 /242 with Engine
271.941
Mercedes-Benz
As a separate repair order:?

Engine 103 ra20001030100x
Engine 104 ra20001040100x
Engine 111 inModel124, 163, 170, AR20.00-P-1142HG
202, 208, 210
Engine 112 in Model 129, 163, 202, AR20.00-P-1142HA
208,210, 220
Engine 113 in Model129, 163, 202,
208, 210, 215 , 220
Engine 112.912 in Model203.061 /261, AR20.00-P-1142PV
209.361/461
Engine 112.946 in Model203.064/264
Engine 112.955 in Model209.365/465
Engine 112.961 in Model203.
Engine 113.968 in Model 209.375/475
Engine 113.987 in Model209.376/476
Engine 113.988 in Model203.076/276
Engine 111.951 /955 /981 in model203 AR20.00-P-1142PR
Engine 271 in Model203, 209
Engine 119 ra2000 11901 OOx
Engine 120 ra20001200100x
Engine 166 AR20.00-P-1142GF
ITl Only use approved
anticorrosion/ antifreeze agents.
l:ru Engine 104 *BF20.00-P-1001-
02A
~Engine 111 *BF20.00-P-1001-
02F
l:ru Engines 112, 113 *BF20.00-P-1001-
02K
l:ru Engine 119 *BF20.00-P-1001-
02B
l:ru Engine 120 *BF20.00-P-1001-
02C
l:ru Engine 271 *BF20.00-P-1001-
02P
l:ru Engine 166.940 /960 *BF20.00-P-1001-
ITJ Without separate coolant expansion 02L
reservo ir.
l:ru Engine 166.940 /960 *BF20.00-P-1002-
ITl With trailer hitch, automatic 02L
transmission, air conditioning without
separate coolant expansion reservo ir.
l:ru Engine 166.940/ 960/990/ 995 *BF20.00-P-1003-
ITJ With seoarate coolant exoansion 02L
Mercedes-Benz
reservoir.
WEngine 166.940/ 960/ 990/ 995 *BF20.00-P-1004-
WWith trailer hitch, automatic 02L
transmission, air conditioning without
separate coolant expansíon reservoir.
In case fluid loss not dueto normal
consumption
As a separate repair order: ?
Check radiator system for leaks
Engine 103 ra2000 10200 17x
Engine 119 ra20001190170x
Engine 104
Engíne 111 AR20.00-P-1010HA
Engine 112 (except 112.912 /946/
947/960/961)
Engine 113 (except
113.968/987/988/990/991/992)
Engine 120
Engine 111.951 in Model203.035/ AR20.00-P-1010P
235/735
Engine 111.955 in Models 203.045 1
245/745
Engine 112.912 in Model203 .061/261,
209.361
Engine 112.946 in Model 203.064/264,
209.365
Engine 112.947 in Modell70.465
Engine 112.960 in Model170.466
Engine 112.961 in Model 203 .
Engine 113 in Model 209
Engine 166 AR20.00-P-1010GF
wc
- oormg system
N umber Designation Engine Engine
104.941 in 104.942/980/992 in
Model 2 02 Model124
BF20.00- Cooling Total capacity without Liters 10.0 9.0
P-1001- system AC
02A withAC Liters 10.5 9.5
Capacity of without Liters 5.0 4.5
anticorrosion/antifreeze AC
down to -37 oc withAC Liters 5.25 4.75
Capacity of without Liters¡5 .5 ¡5.0
Mercedes-Benz
anticorrosion/antifreeze AC 1 1
agent down to -45 oc with AC Líters 5.75 5.25
Specificatíons for Operating Fluicls Sheet BB00.40- BB00.40-P-0310-
P-0310- OlA
OlA
Sheet BB00.40- BB00.40-P-0325-
P-0325- OOA
OOA
~e
= oorm~ syst em
Number Designation Engine E ngine
104.943/9811991 104.944/990/994
in modell29 in modell40
BF20 .00- Coolíng Total capacity without Líters 11.5 14.5
P-1001- system AC
02A wíth AC Líters 11.5 14.5
anticorrosíon/antifreeze AC
clown to -37 oc with AC Liters5.75 7.25
antícorrosion/antífreeze AC
agent down to -45 oc wíth AC Líters6.25 8.0
Specifications for Operating Fluicls Sheet BB00.40-P-0310- BB00.40-P-0310-
OlA OlA
Sheet BB00.40-P-0325- BB00.40-P-0325-
OOA OOA
~e
- oormg sys t em
N umber Designation Engine
104.945/995 in
Model210
BF20 .00-P- Cooling Total capacity without AC Liters 8.0
1001-02A system withAC Liters 8.0
Capacity of withoutAC Liters 4.0
anticorrosion/antifreeze clown
to -37 oc with AC Liters4.0
Capacity of without AC Liters 4.5
anticorrosion/antifreeze agent
clown to -45 oc withAC Liters4.5
Specifications for Operating Fluicls Sheet BB00.40-P-
0310-0lA
Sheet BB00.40-P-
0325-00A
Mercedes-Benz
t[Jc
- oormg system
111.920/921/941/944/945/961/974/975 111.943/958/97
in model202, 111.940/960 in model in model170
124, 111.942/947/970 in model210,
111.944/945/975 in model208,
111.946 in modell70
BF20.00- Cooling Total capacity without Liters 8.0 8.5
P-1001- system AC
02F with Liters8.5 9.0
AC
Capacity of wíthout Líters 4.0 4.25
anticorrosionlantifreeze AC
down to -37 oc with Liters4.25 4.5
AC
anticorrosionlantífreeze AC
agent down to -45°C with Liters4.75 5.0
AC
Specifications for Operating Sheet BB00.40-P-0310-0IA BB00.40-P-031
Fluids OlA
SheetBB00.40-P-0325-00A BB00.40-P-032
OOA
t[Jc
- oormg system
111.977 in 111.951/955/981 in
model163 Model203
BF20.00- Cooling Total capacity wíthout Liters approx. 10, approx. 8, 5
P-1001- system AC 5
02F with AC Liters approx. 1O, approx. 8, 5
5
Capacity of wíthout Liters approx. 5, approx. 4, 25
anticorrosion/antifreeze AC 25
down to -37 oc withAC Liters approx. 5, approx. 4, 25
25
Capacity of without Liters approx. 5, approx. 4, 7 5
anticorrosionlantifreeze AC 75
agent down to -45 oc wíthAC Liters approx. 5, approx. 4, 7 5
75
Specifications for Operating Fluids Sheet BB00.40- BB00.40-P-0310-
P-0310- OlA
OlA
Sheet BB00.40- BB00.40-P-0325-
Mercedes-Benz
P-0325-
00A
~e
- 00lin1~ syst em
Number Designation Engine Engines Engine
112.910/920 112.911/921/941 112.923/943
in Model in Model210 in Model129
202, 112.940
in Model208
BF20.00- Cooling Total capacity Lite rs approx. 9, 5 approx. 10, O approx. 11 ,
P-1001- system 75
02K Full capacity of Liters approx. 4, 7 5 approx. 5, O approx. 6, O
anticorrosionlantifreeze
agent down to -37 oc
Full capacity of Liters approx. 5, 25 approx. 5, 5 approx. 6, 5
anticorrosionlantifreeze
Specifications for Sheet BB00.40-P- BB00.40-P-0310- BB00.40-P-
Operating Fluids 0310-0lA OlA 0310-0lA
Sheet BB00.40-P- BB00.40-P-0325- BB00.40-P-
0325-00A OOA 0325-00A
~e
- ooling s_ystem
112.912/946 112.942 in 113.961 in
in Model203 Model163, model129
113.940/980
in Model210,
113.943/984
in Model208,
113.944 in
Model202
BF20.00- Cooling Total capacity Liters approx. 10, 5 approx. 11 , O approx. 12,
P-1001- system 75
02K Full capacity of Liters approx. 5, 25 approx. 5, 5 approx. 6,
anticorrosionlantifreeze 25
agent dlown to -37 oc
Full capacity of Liters approx. 5, 7 5 approx. 6, O approx. 7,
anticorrosion/antifreeze o
Specifications for Operating Sheet BB00.40-P- BB00.40-P- BB00.40-
Fluids 0310-0lA 0310-0lA P-0310-
OlA
Sheet BB00.40-P- BB00.40-P- BB00.40-
0325-00A 0325-00A P-0325-
Mercedes-Benz
looA
~e
- oormg system
112.912/946/955 112.916/953 113.968 in
in model209 M o del
209,211
Engine
113.969 in
Model211
BF20.00- Cooling Total capacity Liters approx. 10, 5 approx. 10, O approx.
P- 1001- system 11 , 5
02K Full capacity of Liters approx. 5, 25 approx_ 5, O approx. 5,
anticorrosion/antifreeze 75
agent down to -37°C
Full capacity of Liters approx. 5, 7 5 approx. 5, 5 approx. 6,
anticorrosion/antifreeze 25
Specifications for Sheet BB00.40-P-0310- BB00.40-P- BB00.40-
Operatíng Fluids OlA 0310-0IA P-0310-
OlA
Sheet BB00.40-P-0325- BB00.40-P- BB00.40-
OOA 0325-00A P-0325-
OOA
~e
- ooling system
113.987/988
BF20.00-P- l 001- Cooling system Total capacity Liters approx. 11 , 5
02K Full capacity of Litersapprox. 5, 8
anticorrosi on/antifreeze agent
down to -37°C
Full capacity of Liters approx. 6, 3
anticorrosion!antifreeze agent
down to -4 5 oc
Specifi cations for Operating Sheet BB00.40-P-
Fluids 0310-01A
Sheet BB00.40-P-
0325-00A
~e
- oorm !! system
119.960/972/982 119.970/971/980/981
Mercedes-Benz
BF20 .00- Cooling Total capacity without Litersl15 116.5

P-1001- system AC
02B with AC Liters 15.5 16.5
anticorrosíonlantifreeze AC
down to -37 oc with AC Liters 7.75 8.25
agent down to -45 oc with AC Liters 8.5 9.0
Specifications for Operating Sheet BB00.40-P- BB00.40-P-0310-01A
Fluids 0310-0lA
Sheet BB00.40-P- BB00.40-P-0325-00A
0325-00A
t:gjc
= oormg syst em
Number Designation E ngiue Engine
119.974/975 in 119.980/985 in
Model124 Model210
BF20 .00- Cooling Total capacity without Liters 15.5 11
P-1001 - system AC
02B Capacity of with AC Liters 15.5 11
anticorrosion/antifreeze
down to -37 oc
Speci:fications for Operating with AC Liters 7.75 5.5
Fluids without Liters8.5 6.0
AC
with AC Liters 8.5 6.0
Sheet BB00.40-P- BB00.40-P-
0310-0lA 0310-0lA
0325-00A 0325-00A
- oo ng s'stem
120.980/982 in 120.981/983 in
model140 model129
BF20 .00-P- Cooling Total capacity Liters 18.5 19
1001 -02C system Capacity of Liters9, 25 8,5
anticorrosionlantifreeze agent
down to -37 oc
1
Mercedes-Benz
F illing capacíty of Liters 10,25 9, 5

anticorrosion!antifreeze up to
-45 oc
Specifications for Operating Sheet BB00.40-P- BB00.40-P-
Fluids 0310-01A 0310-01A
0325-00A 0325-00A
~e
- oolinag s stem
Number Designation Engines Engine
166.940/960 166.990/995
BF20.00-P- Cooling system Total capacity Liters approx. 4, 9 -
1001-02L without Capacity of liter approx. 2, 5 -
separate antícorrosion/antífreeze agent
coolant down to -37 oc
expans10n Capacity of liter approx. 2, 7 -
reservou anticorrosion!antifreeze agent
down to -45 oc
Specifications for Operating Sheet BB00.40-P- -
Fluids 0310-0lA
Sheet BB00.40-P- -
0325-00A
BF20.00-P- Cooling system Total capacity Líters approx. 5, 1 -
1002-02L with trailer Capacity of literapprox. 2, 55 -
hitch or anticorrosionfantifreeze agent
automatic down to -37°C
transmission or Capacity of liter approx. 2, 8 -
air conditioning anticorrosion!antifreeze agent
without down to -45°C
separate
coolant
:Specifications for Operating Sheet BB00.40-P- -
Fluids 0310-0lA
expanswn
reservo ir Sheet BB00.40-P- -
0325-02A
BF20.00-P- Cooling system Total capacity Liters approx. 5, 5 approx. 5, 7
1003-02L with separate Capacity of literapprox. 2, 75 approx.2,85
coolant anticorrosion!antifreeze agent
expans10n down to -37 oc
reservou Capacity of liter approx. 3, 05 approx. 3, 15
anticorrosion!antifreeze agent
down to -45°C
:Specifications for Operating Sheet BB00.40-P- BB00.40-P-
Fluids 0310-0lA 0310-0lA
Sheet BBOO. 40-P- BB00.40-P-
0325-02A 0325-02A
Mercedes-Benz
BF20.00-P- Cooling system Total capacity 1 Literslapprox. 5, 7 -

1004-02L with trailer Capacity of literapprox. 2, 85 -
hitch or anticorrosionlantifreeze agent
automatic clown to -37 oc
transmission or Capacity of liter approx. 3, 15 -
air conditioning anticorrosionlantifreeze agent
without clown to -45 oc
separate
coolant
Specifications for Operating Sheet BB00.40-P- -
Fluids 0310-0lA
expansion
reservo ir SheetBB00.40-P- -
0325-00A
t[lc
- ooli ng syst em
BF20.00-P-1001- Cooling system Total filling capacity (first filling liter approx. 8
02P capacity)
Total filling capacity (workshop liter approx. 5, 6
change capacity)
Capacity of liter approx. 2, 8
anticorrosion/antifreeze agent
down to -37°C
Filling capacity of liter approx. 3, 3
anticorrosion/antifreeze up to-
45°C
Specifications for Operating Sheet BB00.40-P-
Fluids 0310-01A
Sheet BB00.40-P-
0325-00A

SWITCHING POINTS IN COOLING SYSTEM- RA20001040020X(20-0020)
Switching points in cooling system- RA20001040020X(20-0020)
DATA
Models 124 129 140 202 210
Thermostat at coolant temperature o C 85- 89 85-89 85- 89 85-89 85-89
Start of opening Max. opening 102 102 102 102 102
103 200 04 103 200 103 200 103 200 103 200
22(1) 06 22 02 22 05 22 03 22
Viscous fan clutch Cut-in temperature oc
92- 100 92- 100 102- 110 92- 100
Safety cutoff at engine speed fan speed in rpm 96- 104
4500 4500 4500 4500 4500
3250 3250 3420 3580 3420
Mercedes-Benz
Electric auxiliary fan 14/ 12 16/ 13 14

100/95
16/ 11 100/95 100/95 95
1st stage onfofi{2) 20/ 15
107/ 100 20/ 17 20/ 17 20
2nd stage onloff3) 107/ 100
11 5/ 107 115/ 107 115
AC at coolant temperature in oc 121-123 121- 123 121- 123 121 - 123 121-123
Start of pulseC5) Emergeney off 126-128 126-128 126-128 126- 128 126-128
Pressure cap opens at pressure in bar 1.3 - 1.5 1.3 - 1.5 1.3 - 1.5 1.3- 1.5 1.3- 1.5
1st stage 2nd stage - - - - 1.8- 2.2
Coolant temperature max. oc 130 130 130 130 130/ 137
(1) Engíne 103.980 viscous fan clutch 103 200 02 22
(2) at refrigerant pressure in bar. Cut-in 1st stage speed-responsive: compressor switched on <40 km/h
on >70 km/h off
(3) at coo1ant temperature in oe
(4) 2nd version 20/ 15 bar
(5) Pulse duration: 50% on time, 20 seconds on 20 seconds off
Switching points in cooling system- RA20001190020X(20-0020)
D AT A
Models 124 129 140 210
Thermostat at coolant temperature oC
78-82 78- 82 78-82 78 -82
Start of opening
94 94 94 94
Max. opening
92- 100 92- lOO 92- 100
Viscous fan coupling cut-in at airflow temperature oc Safety 4500 4500
92 - 100
4500
cutoff at engíne speed fan speed rpm 4500 3420
3250 3250 3420
100/95
Electríc auxilía1y fan(l) 100/95 14/ 12
107/ 100 95/ 115
1st stage onloff - 107/1 00 (3) (2)
16/ 11
2nd stage onloff 107/ 100 17/ 14
107/ 100 14/20 (l)
3rd stage onloff 20/ 15 115/ 107 (3)
20/ 17
A/C at coolant temperature in °C
121-123 121-123 121-123 121- 123
Start of cycle C4) 126-128 126-128 126-128 126-128
Emergency off
1.3 - 1.5 1.3 - 1.5
1.3 - 1.5 130 - 1.3 - 1.5(5) 130 -
System cap opens at pressure in bar or oc max.
130- 134 130- 134 134
1st stage
134 1.8 - 2.2 (5) 1.8 - 2.2
2nd stage
- 137 - - 137 -
143 143
(1) At coolant temperature in oc or refrigerant pressure in bar, 1st stage cuts in Iine with vehicle speed:
Mercedes-Benz
compressor switched on <40 km/h on >70km/h off

(2) Fully engaged
(3) USA circuit. NC off (EC button pressed), outside air> l5°C. 2nd stage of this version operates at
107/ 100°( or 17/14 bar, respectively
(4) Cycle: 50% ON period, 20 seconds on 20 seconds off
(5) From outside temperature of > 1ooc
COOLANT CIRCUIT- RA20001040050X(20-0050)
Coolant circuit - RA20001040050X(20-0050)

Mercedes-Benz
A B e
lt
13
12
19
P20.00-0233-57
1 Elcpansaon fOSOIVO. 11 Oi-to-coolart hoat Olrcilangor

2 PfesSllrecep 12 Cranl<caso
Mod91210 t.vo-stag11 prsssure cep 13 C~ndorha&d
3 lrtogra!od sl ce gol resEIMlir 14 Haamg systllrn leed p¡po
4 Fll qgp¡pe 15 Wr11isaoen 'Mperwater hoator
S Cross-llow ra:ie!of 16 Hoamg systnm hoat O)(ChMger
6 Thermoslat 17 Duo púsed vahte
7 Ventwe 18 C.rcuooon punp
8 From Sf1QIIl6 to red!elor 19 He.abng systern rotum PIJ>&
9 Frorn rediator lo 6flglno
10 Coolart purrp
Fig. 53: Coolant Circuit Diagram
A. Bypass mode
The coolant flows from the cylinder head through the coolant pump to the crankcase.
B. Mixed mode
The coolant flows partly through the radiator and partly through the coolant pump to the crankcase.
C. Cooling mode
Mercedes-Benz
The coolant flows through the radiator and the coolant pump to the crank:case.
Coolant circuit and engine cooling- RA20001200050X(20-0050)
ExpatiS!on tark S WJndstueld washel' resetv<Mr

1a OYerlow tari\ z Heaterte~d
2 Radía!cr R HeaterrottJrn
3 Thormostat A31 Heabn9 systom del wrywil
4 Coolaltpu~ A.31m1 C•raJiaíon punp
5 HeaOOg sy.¡tern hltat exch!lllg6f A.31y1 Lelt<lrov!!Ñe
A31y'2 Rlg!t du!lvaMI
Fig. 54: Engine Cooling Diagram
Engine off cooling
If the coolant temperature is < 100 oc after switching off the engine, the coolant temperature is monitored for a
period of 1.5 minutes. If the coolant temperature rises above 11 O oc during this time as a result ofbeing heated
by the engine, the heating water circulation pump of the coolant circuit is operated in order to avoid any local
overheating and the formation ofvapor bubbles.
The maximum duration of the engine off cooling is 1O minutes. The engine off cooling program is ended
prematurely if the coolant temperature is < 11 O oc.
Position of the components when engine off cooling operating.

Mercedes-Benz
• Power supply relay (K30) "On"

• Heating water circulation pump (A3lml) "On"
• Heater blower (A32ml) "Off''
• Pulsed va] ve (A31 y 1/2) closed, bypass circuit for engine off cooling open
THERMOSTAT
Engine Thermostat start of opening F ully open
120 102 oc
Coolant thermostat
The coolant thermostat (4) ís ínstalled in the cover (3) and prevented from turning, which produces a defined
position ofthe vent valve (5). The coolant thermostat housing (1) ís fitted together to the left coolant outlet
connection (6) and to the right connection (7) and sealed on each side by a 0 -ring (8).
3 9 4 2 10
7 8 5 1 6
1 Ccolam ll'lllllTlOsla! hotJs1119 S 0-nrtg

2 o.nng 9 Vonl p¡pe comedon
3 Cever 10 C«~~ectJon hling !o mcietor
4 C<Jolatt lllerrroslat !1 M 14X 1.5

5 Veftva.'ve b Ola. 7 rrrn
6 Le: coolaffi oullotconnecbon (cyindorhead) Ola. 4 3 rrrn
Rig:i coolari ouCet connectJon (cyklder head)
F ig. 55: Coolant Thermostat Diagram
OPERATION OF ENGINE OFF COOLING - RA20001040060X(20-0060)

Mercedes-Benz
P20 00.0234-55
S Wildsasoo washor reseri!Oil A31m1 crrrtla~~cn IMimP A31m1

z Heatrlg syslllm leed from en~ o A31y1 Ll!ftcilovalve A31y1
R Heaoog system r81Un to eoo1a1t punp A31y2 Rl!,fltciloviiM A31Y2
A31 Heat.>g system det>/or¡ Ult
Fig. 56: Engine Off Cooling Operation Diagram
If the coolant temperature after switcbing off tbe engine is > 11 O°C, tbe coolant temperature is tben monitored
for a period ofup to 1.5 min. Iftbe coolant temperature rises above 110 oc during this period as a result of
being heated up by the engine, the heating water circulation pump (A31 m 1) starts the coolant circuit flowing in
order to avoid local hot spots and the formation of vapor bubbles.
The maximum period of this engine off cooling is 1O minutes. The engine off cooling program is ended
prematurely ifthe coolant temperature drops to <110 °C.
Position of the components when engine off cooling operating:
• Power supply relay (K30) "On"

• Heating water circulation pump (A3lml) "On"
• Heater blower (A32ml) "Off'
• Pulsed valves (A3lyl/2) closed, bypass circuit for engine off cooling open.
DRAINING, POURING IN COOLANT- ANTI-FREEZE PROTECTION T ABLE - RA20001040100X

(20-0100)
Draining, pouring in coolant- aoti-freeze protection table - RA20001040100X(20-0100)
Preceding work:
Bottom engine compartment panel removed (Maintenance Manual 6190).
Mercedes-Benz
20-1142-115
P20-5304-57
Da19estell am T·,.p 202
Fig. 57: Identifving Draining, Pouring In Coolant - A nti-Freeze Protection Table
turn anti-clockwise as far as detent 1, turn 2-stage cap in model 21 O half a turn, to release
pressure.
Cap
n::rwF
(1)
Cap ( 1) must not be opened unless coolant temperature below 90 °C.
Risk of scalding!
Cap
turn further to detent 2, turn 2-stage cap in model 21 O further, and remove.
(1)
DRAINING COOLANT AT RADIATOR

Hose (inner día. 12 mm) fit onto connection (arrow).
Drain plug (3) open, close.
Coolant drain into suitable vessel.
DRAINING COOLANT AT CRANKCASE

Hose (inner dia. 14 mm) fit onto drain plug (4).
Drain plug (4) open. close (30 Nm).
Mercedes-Benz
lcoolant drain into a suitable vessel.
POURING IN COOLANT, BLEEDING SYSTEM

Model124: pour in coolant up to marking (arrow) on expansion reservoir (2).
pour in coolant up to separation between top part of expansion reservo ir
Models 129, 140, 202:
(black) and bottom part (transparent).
pour in coolant up to marking (cast lug, visible when cap open) on the floor of
Model210: . .
expanswn reservorr.
Heater switch on.
unscrew temperature sensor at coolant thermostat housing, screw in as soon as
Model210:
coolant flows out.
Engine warm up at modera te revs until coolant thermostat opens.
Models with auxiliary
bleed auxiliary heater (83-1165) .
heater:
Coolant level top up to marking orto separation line on expansion reservoir.
Filler neck on expansion elose from a coolant temperature of about 60 - 80 °C; model 210: pay attention
reservorr to note.
Coolant test for resistance to low temperatures.
Cooling system check for leaks (20-0170).
Special tool
001 589 72 21 00
Fie. 58: Identifvin¡: Torque Wrench (001 589 72 21 00)
Drain plug of radiator (reference valu e) 1.5
Drain plug of crankcase 30
Anticorrosion/antifreeze tester e.g. Leitenberger
BahnhofstraBe 23
FT 2020
7213 8 Kirchentell insfurt
NOTE: A 2-stage cap is fitted to m o del 21 O.

Mercedes-Benz
~WF
The 2-stage cap must be screwed in far enough until the lug engages in the notch on the coolant expansion
reservou.
The cap has au additional pressure stage to enable tbe system pressure to rise by up to 2 bar in tbe engine off
beating pbase wítbout coolant flowing out.
Fig. 59: Sectional View Of Coolant Expansion Reservoir Cap
CAPACITIES IN LITERS
M o del Engine Cooling sys.tem with heater Anticorrosion Antifreeze
-37 oc (50% by vol.) -45 oc (55% by vol.)
9 4.5 5
124 104 (l)
9.5 (2) 4.75 5.25
129 104 11.5 5.75 6.25
140 104 14.5 7.25 8.0
10 5.0 5.5
202 104
10.5 (2 ) 5.25 5.75
8.0 4.0 4.5
210 104
8.5(2 ) 4.25 4.75
(1) approx. 0.25 ltr. additional quantity with oíl-to-water beat exchanger
(2) with air conditioniug/air conditioning (automatic)
Mercedes-Benz
NOTE: Coolant composition for anti-freeze protection down to -37 oc

50% by vol. water (Mercedes-Benz Specifications for Service Products). 50% by vol. anticorrosion/anti-freeze
agent (Mercedes-Benz Specifications for Service Products).
A higher concentration is only of practica! use at lower ambient temperatures.
55 %by vol. anti-corrosion/anti-freeze agent offers anti-freeze protection down to approx. -45 oc.
More than 55 % by vol. anti-corrosion/anti-freeze agent reduces the anti-freeze protection and impairs heat
dissipation.
Operational monitoring of coolant
Check the coolant for its resistance to cold temperatures before the start of the cold season. In countries with
high outside temperatures, check anti-corrosion/anti-freeze agent concentration once ayear.
The corrosion protection of the coolant is degraded during operation. Sucb coolants have a severely corrosive
effect.
Tbe maximum period of use of a specified coolant in car engines is 3 years .
When topping up (after loss of coolant), jt must be ensured that an anti-corrosion/anti-freeze agent
concentration of 50 % by vol. exists in the coolant to provide anti-freeze protection down to -37 °C.
n::rwF
Befare pouring in fresh coolant, the cooling and heating system must be free ofused coolant and of corrosion
residues; for this reason, clean cooling and heating system.
Disposal of coolants
The anti-corrosion/anti-freeze agents approved in the Mercedes-Benz Specifications for Service Products are
biodegradable substances.
Observe nationallegislation and local waste water regulations.
For workshop locations in Germany refer to Environmental Protection Catalogue ofMBVD/PWU.
Anti-corrosion/anti-freeze agent
Anti-corrosion/anti-freeze agent performs the following tasks:
• ensuring adequate corrosion and cavitation protection for a U components

Mercedes-Benz
• providing anti-freeze protection

• increasing the boiling point
Use only approved anti-corrosionlanti-freeze agents (see Mercedes-Benz Specifications for Service Products).
Water
Use water which is clean and not too hard. Drínkíng water frequently, but not always, satisfies requirements.
The content of dissolved substances in the water may be of significance for the occurrence of corrosion. Ifthe
water quality is not known, distilled or fully desalinated water should be used. For water quality see Mercedes-
Benz Specifications for Service Products.
Dr aining, pouring in coolant- Amti-freeze protection table- RA20001190100X(20-0100)
Precedíng work:
Bottom engine compartment panel removed
(Maintenance Manual 6190).
20-1142-1151
Mercedes-Benz
5fl9
4~
A
T~ 140
A. 0r81'11*J9 1SIVOISIOil
B. Croo I*Jg 2ndVEII'SIOil
Fig. 60: Identifying Filler Cap And Drain Plugs
turn anticlockwise as far as 1st detent, tum 2-stage cap in model21 O balf a tum to releas e
pressure_
Filler cap ~WF
(1)
Cap (1) must not be opened unless coolant temperature is below 90 °C.
Risk of scalding!
Cap (1) tum on to 2nd detent, 2-stage cap in model 21 O and remove.
DRAINING COOLANT AT RADIATOR

Hose (12 mm inner dia.) fit onto tbe connection (arrow).
Coolant drain into a suítable vessel (about 6 liters).
DRAINING COOLANT AT CRANKCASE

lst versíon: drain plugs (4)
witb seals (5) next to left and unscrew, screw on (30 Nm).
rigbt engine carriers
Coolant draín into a suítable vessel (metal tray).
Mercedes-Benz
2nd version: drain plug (6)

(banjo bolt) next to left and slacken, tighten (10 Nm); see Note.
right engine carriers
Hose ( 15 mm inner dia.) fit onto drain plug (6).
Drain plug (6) open and drain coolant i-nto a suítable vessel.
Pouring in coolant, bleeding
pour in up to the marking on expansion reservoir (2).
auxiliary beater
pour in up to separation level between top part of expansion reservoir
(black) and bottom part of reservo ir (transparent).
Mod!ell24: coolant Note re model129
Mod!els 129, 140: coolant If expansion reservoir (2) does not have additional ventilation line (see
20-4500), detach ventilation line at expansion reservo ir (2), pour in
coolant, fit on ventilation line and add coolant up to the brim (arrow).
pour in up to marking (cast lug, visible when cap open) on bottom of
Mod!el 210: coolant
expansion reservoir.
Heater switch on.
Engine warm up by running at moderate speed until coolant them1ostat opens.
Vehicles with auxiliary heater: auxiliary heater bleed (83-1165).
Coolant in expansion reservoir top up.
Filler neck at expansion
sea! from a coolant temperature of approx. 60 - 70 oc.
reservo ir (2)
Coolant check resistance to low temperatures.
Coolíng system check for leaks (20-0170).
Special tool
001 589 72 21 00
Fig. 61: Identifving Torqu e Wrench (001 589 72 21 00)
TIGHTENING TOR QUES IN NM

Radiator drain plug (reference value) 1.5
l st version (A) 30
Crankcase drain plug
2nd version (B) 10 (l)
(1) Drain plug (2nd version) with fitting taper for drain hose, standard as of January 1993
Mercedes-Benz
Anticorrosion/antifreeze
e.g. Leitenberger
tester
BahnhofstraBe 23
73138 Kirchentellinsfurt
FT 2030
see also Workshop Equipment Manual Volume l , Chapter D, Group
13/20
M o del Engine Cooling system with heater Anti-corrosion Anti-freeze agent
-37 oc (50% by vol.) -45 oc (55% by vol.)
124 119.974/975 15.5 7.75 8.5
129 119.960 15 7.50 8.25
129 AMG 6,0 119.960 13 6.5 7.15
140 119.970/971 16.5 8.25 9.1
210 119.985 11 5.5 6.0
NOTE: Composition of coolant for antifreeze protection down to -37 oc

50% by vol. water (Mercedes-Benz Specification for Service Products).
55 %by vol. anticorrosion/antifreeze agent (Mercedes-Benz Specificat1ons for Service Products).
A higher concentration is only of sorne purpose at lower ambient temperatures.
A concentration of 55 % by vol. anticorrosion/antifreeze agent offers antifreeze protection down to -45 oc.
A concentration of more than 55 % by vol. anticorrosion/antifreeze agent reduces the antifreeze protection and
impairs the heat dissipation.
~WF
The anti-corrosion/anti-freeze agents approved in the Mercedes-Benz Specifications for Service Producís are
biodegradable substances.
Refer to the legal regulations or local waste-water regulations.
Refer to the Environmental Protection Catalog issued by MBVD/PWU for workshops in Germany.
Operational monitoring of coolant
Check the resistance of the coolant to low temperattues before the start of the cold season. In countries with
high amhient temneratures. check the anti-corrosion/anti-freeze agent concentration once a vear.
Mercedes-Benz
The corrosíon protection in the coolant ís reduced during operation of the vehicle. Such coolants have a sharply
corrosíve effect
The maximum permissible period ofuse ofthe specified coolant in car engines is 3 years. Iftopping up (after
loss of coolant) it is essential to ensure an anti-corrosionlanti-freeze agent concentration in the coolant of 50%
by voL (anti-freeze protection down to- 37 °C).
~WF
Before pouring in fresh coolant, the cooling and heating system must be free ofused coolant and of corrosion
residues. For thís reason, clean cooling and heating system.
Anti-corrosíon/anti-freeze agent performs the followíng tasks:
• provides adequate corrosion and cavitation protection for all components,

• provídes antí-freeze protectíon,
• increases the boiling point.
Use only approved anti-corrosion/anti-freeze agents (see Mercedes-Benz Specifications for Service Products).
Water
Use water whích ís clean and not too hard. Drinking water frequently, but not always, fulfills requírements. The
contents of díssolved substances in the water may be of importance for the occurrence of corrosion. Ifthe water
quality is not known, distilled or fully demineralized water should be used. See Mercedes-Benz Specifications
for Service Products for water quality.
r.t14x 1,5 M14x1 $
5 4
6
p 20-5339-53
Fig. 62: Sectional View Of Drain Plugs (1st And 2nd Version)
~WF
Mercedes-Benz
Drain plug (6) (2nd version) with fitting taper for drain hose and captive seal must not be used on the crankcase
with drain plug (4) (1st version).
Draining coolant, ffiling in - Anti-freeze table- RA20001200100X(20-0100)
Preceding work:
(Maintenance Manual6190).
20-1142-1151
Model 140
Fig. 63: Identifying Draining Coolant, Filling Components
ttm1 counter-clockwise to detent 1, release pressure.

[$""WF
Cap (1)
Cap (1) must not be opened unless coolant temperature below 90 oc. Risk
of scalding!
Mercedes-Benz
Cap (1) turn 011 to detent 2 a11d remove.

Draining coolant from
radiator
fit.
Hose (inner día. 12 mm)
onto the connection (arrow)
Coolant drain into a suitable vessel (approx. 10 liters).
Draining coolant from
eran k case
. p lug (4) wlt
D ram . h seal next NOTE: . . . . .
to left and right enoine Model129 for dram plug (4) on nght s1de of engme: unbolt sh1eld above
0
steering Model140 for drain plug (4) on left side of engine: remove
carner
exhaust system (49-0045 , 49-0170 ):
Coolaut draín í11to a suítable vessel (metal tray).
Pouring in coolant,
pour in up to separation level (arrow) on top
bleeding
part of expansion reservoir (black) and bottom
Coolant
part of expausion reservo ir (transparent).
Heater switch 011.
Engine warm up at moderate speed until coolant thermostat opens.
Vehicles with stationary
bleed (83-1165) .
heater: statíonary heater
top up to separation level (arrow) between top part of reservoir (black) aud
Coolant
bottom part of reservoir (transparent).
Filler neck of expansion
seal as of a coolant temperature of approx. 60 - 70 oc_
reservoír (2)
Coolant test for resistance to low te mperature.
Drain plug ofradiator (reference value) 1.5
Drain plug of crankcase 30
COMMrnRCMLLYAV~ABLETOOL
Anti-freeze tester e.g. Ph. Gather
Prestone-VV-Check (Union Carbide) 4020 Mettman
M odel Engine Cooling system witb heater Anti-corrosion Anti-freeze
-37 oc (50% by vol.) -45 °C (55% by vol.)
129 120.981 15.5 7.75 8.75
140 120.980 18.5 9.25 10.25
Mercedes-Benz
NOTE: Coolant composition, anti-freeze protection down to -37 oc

50% by vol. water (Mercedes-Benz Specifications for Service Products).
50% by vol. anti-corrosion/anti-freeze agent (Mercedes-Benz Specifications for Service Products).
A higher concentration is only of practica! benefit at lower ambient temperatures.
55 %by vol. anti-corrosion/anti-freeze agent offer anti-freeze protection down to approx. -45 oc.
More than 55 %by vol. anti-corrosion/anti-freeze agent reduces the anti-freeze protection and impairs heat
dissipation.
Checking coolant during operation
Before the start of the cold season the coolant should be checked for its resistance to low temperatures.
In countries with high outside temperatures, check the anti-corrosionlanti-freeze agent concentration once a
year.
Anti-corrosion protection in the coolant is reduced during operation. Such coolants have a strongly corrosive
effect.
The maximum pennissible period of use of the approved coolant in a car engine is 3 years . When topping up
(after loss of coolant) it is essential to ensure that the anti-corrosionlantifreeze agent concentration in the coolant
is 50% by vol. (anti-freeze protection down to -37 °C).
fi3F'wF
Before adding fresh coolant, the cooling and heating system must be free of used coolant and of corrosion
residues. For this reason, clean cooling and heating system.
n:s=-wF
The anti-corrosion/anti-freeze agents approved in the Mercedes-Benz Specifications for Service Products are
bio-degradable substances.
Observe legal provisions as well as local waste water regulations.
Workshops in Germany should refer to the Environmental Protection Catalogue availab]e from MBVD/PWU.
The anti-corrosion/anti-freeze agent perfonns the following tasks:

Mercedes-Benz
• provides adequate corrosion and cavitation protection for all components

• provides anti-freeze protection
• increases the boiling point
Use only approved anti-corrosion/anti-freeze agents (see Mercedes-Benz Specífications for Service Products).
Water
Use water which is clean and not too hard. Drinking water frequently, but not always, meets requirements. The
contents of resolved substances in the water maybe of ímportance for the occurreiDce of corrosion. If the water
quality is not known, distilled or dernineralized water should be used. For water quality see Mercedes-Benz
Specifications for Service Products.
FLUSHING COOLING AND HEATING SYSTEM- RA20001040150X(20-0150)
Flusbing cooling and heating system- RA20001040150X(20-<0150)
Preceding work:
Coolant drained (20-0100)
Mercedes-Benz
,~0083-51
P2{)..0083..57
Fig. 64: Identifying Cooling And Heating System Components
remove and install pressure-opened thermostat part no. 000 589 74 63 00,
Coolant thennostat
remove (step 1).
Flushing connection pipe
(0 ) install and connect tap water hose (steps 2 and 3).
1
Cooling system flush (steps 4 to 9).
Special tools
Mercedes-Benz
117 589 00 90 00
Fig. 65: ldentifving Flusbing Connection Pipe (11 7 589 00 90 00)
000 589 74 63 00
F ig. 66: Identifving Pressure-Opened Tbermostat (000 589 74 63 00)
WORKSHOP EQUIPMENT
IAnticorrosion /antifreeze agent 000 989 08 25
NOTE: High coolant temperatures and low heating capacity may be caused, for
example, by deposits of corrosion products in the radiator or in the heat
exchanger.
The deposits are recognizable as a j elly-like mass or, when the radiator is emptied and dry, from a grey layer on
the radiator connection pipes.
In this case, flush the cooling and heating system with water.
If the cooling pipes ofthe radiator are already completely or partially clogged by deposits, the radiator mus.t be
replaced.
Procedure
l . Remove coolant thermostat and install pressure-opened thermostat 000 589 74 63 00 with seal.
Mercedes-Benz
. . . n~n-1a
P20-2141-13
Fig. 67: Identifying Pressure-Opened Thermostat
2. Fit flushing connection pipe (O 1) 117 589 00 90 00 together with connection hose (02) between radiator
and coolant hose.
3. Fit a tap water hose (03) onto the flushing connection pipe (01).
P20-2142-131\
Fig. 68: Identifying Flushing Connection Pipe, Connection Hose And Water Hose
4. Open cap of expansion reservoir.

5. Set heater to "warm".
6. If model fitted with circulation pump, switch on circulation pump.
Todo this, switch on ignition and:
a. On models with automatic heater, set temperature selectors to "Max" position.

b. On models with air conditioning (automatic), press "Defrost" push-button.
Mercedes-Benz
7. Open bleeder valve of auxiliary heater.

8. Run engine at about 2500 rpm and flush cooling and heating system for about 15 minutes with flowing
water.
The cooling system must always be completely fi lled during the flus hing operation.
Regulate the quantity fed in accordingly.
9. Drain the flushing water completely in the radiator and crankcase; tighten drain plugs (17 and 82).
Replace seal (18).
10. Remove flushing connectiou pipe and connect coolant hose to the radiator.
11. Install normal coolant thermostat with new sea!.
12. On models fitted with stationary heater, connect plastic hose to bleeder valve and open valve.
13. Pour in fresh coolant (20-0100).
14. Check cooling system for leaks (20-0170).
Notes on coolant hoses- RA20001190150X(20-0150)
NOTE: The material quality of the coolant and heating hoses has been improved as of
10/1993.
Identification DBL 6254.12 (was DBL 6254.11). When performing repairs or rep1acing the engine etc., install
the improved hoses.
REMOVING OIL IN COOLING AND HEATING SYSTEM- RA20001040160X(20-0160)
R emoving oil in cooling and heating system- RA20001040160X(20-0160)
Preceding work:
Coolant drained (20-0100).
Cause of oilleak rectified.
Heating system or AC set to "warm".

Cooling and heating
fill with 3 % solution of water and alkaline cleaner part no. 00 l 986 2 1 71.
system
Engine warm up to normal operating temperature with flushing solution.
Engine run for about 1O minutes with flushing solution.
Flushing solution drain from crankcase and radiator (20-0100).
Heating system heat
flush thoroughly at reduced water pressure through the feed pipe.
exchanger
Mercedes-Benz
flush thoroughly with clear water with engine nmning.

fi3" wF
Cooling and heating
system Clear flushing is successful if no further solution residues are contained in the
cooling and beating system, in other words the flushing water which flows out
must no longer foam up.
Overflow reservoir (with
replace {20-4540).
oil residues)
Expansion reservoir, if
discolored by oil on replace {20-4500).
inside
Coolant and heating
examine for effects of oil; replace ifnecessary. pour in (20-0100).
hoses Fresh coolant
Removing oil in cooling and beating system- RA20001190160X(20-0160)
Preceding work:
Coolant drained (20-01 0).
Coolant thermostat removed (20-11 0).
Mercedes-Benz
:~
A
PW-5336-57
Fig. 69: Identifying Filler Cap And Drain Plugs
Heater
set to "warm" (step 1).
controls
Coolant drain (20-0100)
Cooling
fill with 5 % flushing solution (step 2).
system
Engine warm up to operating temperature and run for about 5 minutes (step 3).
Flushing drain and fill cooling system twice with fresh water, run engine each time for about 5
solution minutes, drain flushing solution complete ly (steps 5 and 6).
Cooling
check for leaks (20-017).
system
Special tool
Mercedes-Benz
124 5B915 21 00
NOTE: The oil in the cooling system has to be removed if, for example, engine oil, ATF
on models with automatic transmission or hydraulic fluid has got into the
cooling system.
Removing oil
l. Set heater controls to full capacity.
o::::rwF
On these models (light alloy radiator), do not use strongly alcalined cleaner such as P3 Standard
(supplier: Henkel).
2. Drain coolant (20-0100) .

3. Fill the cooling system witb a 5 % solution ofwater and neutral cleaner or with a cleaner sucb as
Neuproton 5226 (supplier: Henkel) which is suitable for cold spraying.
4. Warm up engine to about 80 oc by running at moderate revs and maintain at this temperature for about 5
minutes.
5. Switch off engine and allow cooling system to cool down to about 50 oc.
6. Drain solution completely.
7. Immediately after this, fill cooling system twice witb fresh water, run until warm (about 5 minutes) and
drain.
8. Pour in coolant (20-0100).
TESTING COOLING SYSTEM FOR LEAKS- RA20001040170X(20-0170)
Testiug cooling system for leaks- RA20001040170X(20-0170)
20-1010
Mercedes-Benz
SpeciaJ tools
124 589 00 91 00
Fi~:. 71: Identifyin~: Test Cap (124 589 00 91 00)
210 589 00 91 00
124 589 24 21 00
Fig. 73: ldentifving Attach To Tester (124 589 24 21 00)

Designation e.g. make, order no.
Hazet,
7 mm socket wrench hexagon on flexible sbaft for hose clips witb worm drive 42853 Remscbeid
Order no. 426-7
[$="WF
Mercedes-Benz
The cylinder head gasket is not watertight until the engine has reached operating temperature, in other words
until a swelling operation has taken place_ For this reaso n, the cooling system must be pressure-tested until after
the engine has reached operating temperature.
Testing system for leaks
l . Turn cap as far as detent 1 and release pressure, then turn on as far as detent 2 and remove cap.
Open 2-stage cap half a turn to release pressure and then unscrew_
2. Take off cap.
NOTE: The cap must not be opened unless the coolant temperature is below 90 o
c.
A 2-stage cap is installed in model 21 O; see note.
3. Check coolant level and adjust to correct leveL
NOTE: Model124: pour in coolant up to the marking on the expansion reservoir.
Models 129, 140, 202: pour in coolant up to the separation line between top part of expansion reservoir
(black) and bottom part ofreservoir (transparent)_
Model 210: pour in coolant up to the marking (cast lug) on the bottom ofthe expansion reservoir.
4. Pressurize cooling system to about 1.4 bar with the test cap and the tester.
5_ Examine all the cooling and heating water hoses and their connection points for loss of coolaut
6. Check conditiou of coolaut hoses and hose clips; replace or re-tighteu ifuecessary.
Fig. 74: Checking Condition Of Coolant Hoses And Hose Clips

Mercedes-Benz
NOTE: A 2-stage cap is installed in the expansion reservo ir of model 21 O.
The 2-stage cap eliminates the need for the overflow reservoir.
The pressure in the cooling system may rise during the engine offheating phase (after switching off
engine).
The first stage in the coolant cap opens at 1.4 bar; the cooling system remams closed, however.
It ís only ifthe 2nd stage in the coolant cap opens (at 2.0 bar) that coolant flows out to atmosphere along
several vent drillings (a), the ring duct (b) into the outlet connection (e) and P20-5407-13 along a hose
extension.
P W-5407-1:3
Fig. 75: ldentifying Vent Drillings, Ring Duct And Outlet Connection
Testing cooling system for leaks- RA20001190170X(20-0170)
20- 1010
Special tools
Mercedes-Benz
124 589 00 91 00
210 589 00 91 00
124 589 24 21 00

Designation e.g. Make, order No.
7 mm socket wrench hexagon on a flexible shaft for hose clips Hazet, 42853 Remscheid Order no.
with worm drive 426-7
(j$"WF
A newly installed cylinder head gasket is not watertight until the engine has reached its normal operating
temperature, in other words until swelling has occurred. For thís reason, do not pressure-test the cooling system
Mercedes-Benz
when performing repairs until after the engine has reached íts operating temperature.
Checking for leaks
~WF
The cap ofthe cooling system must not be opened unless the coolant temperature is below 90 °C.
A 2-stage cap is fitted to model 21 O; see note.
l. Tu m cap (detent loe k) to the 1st detent to release the pressure, then turn on to the 2nd detent.
Open 2-stage cap (screw lock) half a turn to release pressure, then unscrew.
2. Take offsystem cap.

3. Check coolant level and adjust to correct level ifnecessary.
NOTE: Model 124: pour in coolant up to the marking on the expansion reservoir.
Models 129, 140: pour in coolant up to the separation line between top part of expansion reservoir (black)
and bottom part ofreservoir (transparent).
Model210: pour in coolant up to the marking (cast lug) on the bottom ofthe expansion reservoir.
4. Use the test cap and the tester to pressurize cooling system to about 1.4 bar.
5. Inspect all the cooling and heating water hoses and the connection points for loss of coolant.
6. Inspect the conditíon of the coolant hoses and hose clíps; replace or re-tíghten if necessary.
Fig. 79: Checking Condition Of Coolant Hoses And Hose Clips
NOTE: A 2-stage cap is fitted to the expansion reservo ir of model 21 O.

Mercedes-Benz
The 2-stage cap eliminates the need for the overflow reservoir.
Dtuing the engine off heating phase, the pressure in the cooling system may rise.
The first stage in the coolant cap opens at 1.4 bar, the cooling system itself remains closed.
Only once the 2nd stage in the coolant cap opens (at 2 bar) does coolant flow through several vent
drillings (a), the annular gallery (b) into the outlet connection (e) through a hose extension to atmosphere.
PW-5407-1 -3
Fig. 80: Identifying Vent Drillings, Ring Duct And Outlet Connection
REMOVING AND INSTALLING COOLANT THERMOSTAT- RA20001041100X(20-1100)
Removing and installing coolant thermostat- RA20001041100X(20-1100)
20-2460-2482
Mercedes-Benz
P20-5310-57
Fig. 81: Identifying Coolant T hermostat Removellnstall Components
Coolant at radiator drain, pour in (20-0H)O).

C~tholant thermostat bousing cover unbolt, bolt on ( 9 N m).
Wl
coolant boses connected Model 202: pay attention to bracket (5).
remove, install.
Coolaut tbermostat ( 1) NOTE:

The ball valve (arrow) of the coolant thermostat (1) must be at the
highest point.
Seal (2) replace (20-0100).
Cooling system check for leaks (20-0 170).
Removing and installing coolant tbermostat- RA20001191100X(20-1100)
20-2460-2482
Mercedes-Benz
Fig. 82: Identifving Coolant Thermostat Remove/Install Components
Coolant at radiator drain (20-0100).

Modell29: dipstick guide tube from cylinder head unscrew, screw on.
Coolant hose (1) at thermostat bousin.g detach, attach.
Coolant thennostat housing cap (2) detach, attach (1 ON m).
Coolant thermostat (4) remove.
0-ring (3) replace.
install.
Coolant thermostat lostallation note
The ball valve (arrow) must be at the highest point.
Coolant pour in (20-0100).
Leaks check.
Removing ami installing coolant tbermostat- RA20001201100X(20-1100)
Preceding work:
20-2460-2482
Mercedes-Benz
10 MSX 85oolt+washor 'Mtll hexagoosoc:Xet

11 MSX 110bcl+wa$her wih hexagoowckot
Fig. 83: ldentifving Coolant Thermostat Removellnstall Components
Coolant draín from radíator (20-4200).

Fan shroud ríng take off, place over fan, fit on.
~WF The 4 catch studs of the fan shroud
ensure correctly located in the fan shroud when installíng.
rmg
Coolaut hoses ( 1 and 2) take off, fit on.
Coolant thermostat housíng cover (3) take off, fit on (9 N m).
Coolant thermostat housíng cover (3) swivel forward by 90°.
Temperature sensors (4 and 5) unscrew, screw on.
lnstallation note
replace accordíng to conditíon.
Seals (4a and 5a)
Holder (6) unscrew, screw on (21 Nm).
Coolant thermostat housíng cover (3) remove, install.
remove from coolant thermostat housing cover (3),
Coolant thermostat (7)
install.
lnstallation note
in the recesses (3a) on the coolant thermostat housing
The profile plate (7a) for the coolant must
cover (3).
catch
Mercedes-Benz
Sealing ring (8) replace.

Installation note
The ball valve (arrow) in the coolant should be positioned at the highest point.
thermostat (7)
Cooling system check for leakage (20-0170).
SpeciaJ tool
001 589 72 21 00
00
Fig. 84: Identifving Special Tool (001 589 72 21 00 00)
n::?'WF
The coolant thennostat housing (9) is sealed to the coolant pump (10) with an 0-ring (arrow). Replace 0 -ring
(arrow) in case of leakage.
Fig. 85: Locating Coolant Thermostat Housing 0-Ring
REPLACING CONNECTION PIPE FROM CYLINDER HEAD COOLANT PUMP- RA20001042110X

(20-2110)
PrecedtnQ work:
Mercedes-Benz
Coolant pump removed (20-2100).
Engine 104.98
P20 10-0216-57
d Fit driling 25,000 - 25,025 mm
Fig. 86: Identifying Connection Pipe From Cylinder Head Coolant Pump
Connectíon pipe (2) stríke on the si de with a punch, loosen in cylinder head (1 ).
pull out with locking pliers.
Connection pipe (2) n:::?'GF
Do not damage cylinder head.
Fit drilling clean.
Fit drillíng examine for concentricity and dimensional tolerance.
Collar ofnew connection
coat with Loctite 270 high strength 002 989 93 71 1O
pipe (2)
position at fit drilling and knock in with a plastic-headed hammer until it
New connectíon pipe (2)
projects 16 mm.
SEALING COOLANT PUMP - RA20001042250X(20-2250)
Preceding work:
Mercedes-Benz
Coolant pump removed (20-2100).
4 5
13 M6 X 20boi+Washer
Fig. 87: Identifving Coolant Pump Components
Spiral housing ( 6) unbolt, bolt on (10 Nm).

0-ring (7) replace.
Puller (14) 000 589 94 33
fit onto impeller ( 5).
00
Jaws ofpuller (14) tension with sleeve inner dia. 40 mm (shop made) or suitable hose-strap.
Impeller (5) pull off.
Mating ring (3) pull off with pliers.
press armmd circumference with screwdriver to remove from coolant pump
( Jl ).
Cassette-type seal (4) n::rwF
Do not damage coolant pump ( 1), use clean cloth as base.
Mercedes-Benz
7
~~!Ft--13
~~~- 10Nm
4 3 5 6
P»S21H7
Fi~. 88: Sectional View Of Coolant Pump Components
clean.
Mount for cassette-type seal (4) NOTE:

Sealing compound is applied to the circumference of the cassette-
type seal (4).
New cassette-type seal (4) press in with 40 mm diarneter sleeve as far as the stop
Mating ring (3) fit onto pump shaft with ground face toward seal (4a).
Impeller ( 5) heat to approx. 100 oc.
Impe ller ( 5) press on.
Size (a) (5.6- 5.8 mm) note.
T ight seat of impeller ( 5) on
check.
pump shaft
Special tool
Mercedes-Benz
000 589 94 33 00
Fig. 89: ldentifving Puller (000 589 94 33 00)
RETROFITTING COOLANT PUMP DRAIN PIPE - RA20001042255X(20-2255)
Preceding work:
Viscous fan coupling removed (20-3120).
Poly V -belt removed {13-3420) .
Belt pulley/vibration damper removed (03-3420) .
P20-5404-55
Fig. 90: Retrofitting Coolant Pump Drain Pipe
Belt pulleys at coolant pump and at fan

remove, install {13-3450) .
bearing pedestal
Shock absorber of tensioning device
Mercedes-Benz
1st version (coolant pump with 0 7.5 mm hole)

Connection fitting (1) coat with adhesive.
Connection fitting (1) knock in with insertion drift (shop-made tool).
fit onto connection fitting ( 1) and run between crankcase and
Drainage pipe (2)
power steering pump support.
2nd version (coolant pump 103 200 3 7 O1
with 0 9.9 mm hole)
Drainage pipe (2) coat with Loctite 648, 003 989 32 71.
insert into 0 9.9 mm hole and run between crankcase and
Drainage pipe (2)
power steering pump support.
Sbop-made tool
Insertion drift
Material: structural steel e.g. St.37-k
~------------- 340 --------------~
P2tM367-53
Fig. 91: ldentifving Sbop-Made Tool Dimensions
PARTS
Designation Part no.
Repair kit 0 7.5 mm hole 103 200 20 52
Repair kit 0 9.9 mm hole 104 203 08 02
REMOVING AND INSTALLING COOLANT PIPE FROM HEAT EXCHANGER TO COOLANT

PUMP- RA20001042300X(20-2300)
Preceding work :
Top part ofresonance intake manifold removed (AR09.20- 1310D)
Engines witb oil-coolant beat exchanger

Mercedes-Benz
P20-5l1 ~57
Fig. 92: Identifving Coolant Pipe Remove/lnstall Components From Heat Exchanger To Coolant Pump
Coolant at crankcase drain (20-0100).

unbolt, remove, install.
Coolant pipe (3) at coolant pump and at bottom part of NOTE·
resonance intake manifold ·
Replace 0-rings (3a) and (4a) at coolant pump
and at heat exchanger.
Top part ofresonance intake manifold (19) install (AR09.20-1310D).
TEMPERATURE-CONTROLLED VISCOUS FAN CLUTCH- RA20001043120X(20-3100)
Cut-in temperature
At a certain air flow temperature, see switching points of coolant system (20-0020), acting on the bimetal of the
viscous fan clutch, the bimetal alters its shape and causes the fan to cut in, whích can be clearly heard.
Safety cut-off
A second (intemal) bimetal switches off the fan in a smooth operation in the upper speed range above 4500
rpm, depending on the ambient temperature.
Mercedes-Benz
Repairs
A faulty viscous clutch cannot be repaired, and must be replaced.
Transportation and storage
Temperature-controlled viscous fan clutches must be transported upright
The viscous clutch may be placed down on its flange side for a short period, e.g. for assembly purposes, but it
should never be placed down on the front
REMOVING AND INSTALLING VISCOUS FAN CLUTCH- RA20001043120X(20-3120)
Removing and installing viscous fan clutch - RA20001043120X(20-3120)
Preceding work:
Fan shroud removed (20-3400).
20-6590
A. Model124
Mercedes-Benz
Fig. 93: ldentifying Viscous Fan Clutcb Removellnstall Components (Model l24)
rotate with hexagon insert (7) 103 589 O1 09 00 and torque wrench (8) 001 589
Viscous fan clutch (3)
72 21 OO.
Counter-holder (1) 103 engage from the rear of the belt pulley (21) in the retaining slot (20) of the fan
589 00 40 00 bearing bracket and simultaneously in the retaining hole of the belt pulley.
unbolt, remove, install ( 45 Nm).
together with fan (2)
unbolt, bolt on (1 ON m).
Viscous fan clutch (3) at lr$"WF
fan (2) The cast part number of the fan (2) must be positioned at the front (radiator
side).
B. Modell29
20-6590
Mercedes-Benz
' ----~18
Fig. 94: Identifying Viscous Fan Clutch Remove/Install Components (Model129)
Locking pin (18) remove, install.

turn to the left, place over fan (2), install (20-3400}.
~WF
Fan shroud ring (6)
When installing, ensure that the 4 engaging studs (arrows) of the fan shroud
ring (6) are correctly located in the fan shroud.
Counter-holder (1) 120
fit on, remove.
589 02 01 00
Viscous fan clutch (3) unbolt with hexagon insert (7) 103 589 O1 09 00 and torque wrench (8) 001
with fan (2) 589 72 21 00, remove, install (45 N m) .
Viscous fan clutcb (3) at ~ WF
fan (2) The cast part number ofthe fan (2) must be positioned at the front (radiator
side).
C. Model140
Preceding work:

Mercedes-Benz
20-6590
Cotmter-holder ( 1) 120
fit on.
589 02 01 00
Viscous fan clutch (3) unbolt with hexagon insert (7) 103 589 01 09 00 and torque wrench (8) 001
with fan (2) 589 72 21 00, remove~ install (45 Nm).
Viscous fan clutch (3) at ~WF
fan (2) The cast part number of the fan (2) must be positioned at the front (radiator
side).
D. Model202
Preceding work:
F an shroud removed (20-3400).
Mercedes-Benz
20-6590
10Nm
6~
-~ 45Nm
P2().5314-57
4 M&X 15blll+washer
5 M10X 45hexagonsockatbo!t
Fie. 96: Identifvine Viscous Fan Clutch Removellnstall Components (Model 202)
Wrench (7) 120 589 14 07 00 fit on at bolt ofviscous fan clutch.

Torque wrench (8) 001 589 72
21 00 with head in wrench (7) fit on and ro tate viscous fan.
removed
engage from the rear of the belt pulley (21) into the retaining slot (20)
Counter-holder ( 1) 103 589 00 of the fan bearing bracket and simultaneously into the retaining hole of
40 00
the belt pulley.
Bolt (4) ofviscous fan clutch (3) slacken, tighten (41 Nm).
Wrench (7) turn with handle (a).
Bolt (4) unscrew, screw on.
Viscous fan clutch (3) remove together with fan (2) and bolt (4), install.
unbolt, bolt on (1 O N m).
Viscous fan clutch (3) at fan (2) NOTE:

As a result of cast rib, fan (2) can only be installed on one side.
Mercedes-Benz
Viscous fan clutcb to bearing body 45 (41) (l)
Fan to viscous fan clutch 10
(l) Model202 tightened with wrench 120 589 14 07 00
E. Model210
Preceding work:
Operation no . of operation texts and work units or standard texts and flat rates:
20-6590
P20 40.0218-57
Fig. 97: ldentifying Viscous Fan Clutcb Remove/Install Components (Model210)
Wrench (7) 120 589 14 07 00 fit on at bolt ofviscous fan clutch.

Torque wrench (8) 001 589 72 21 00 with head in
fit 011.
wrench (7) removed
Mercedes-Benz
Counter-holder (1) 120 589 02 01 00 fit on.

Bolt (4) of viscous fan clutch (3) slacken, tighten (41 N m).
Wrench (7) tum witb handle (a).
Viscous fan clutch (3) remove together with fan (2)and bolt (4), install.
unbolt, bolt on ( 1ON m).
Viscous fan clutcb (3) at fan (2) NOTE:

As a result of cast rib, fan (2) can only be
installed on one side.
Viscous fan clutch to bearing body 45 (41)(l)
Fan to víscous fan clutch 10
(l) Model202 tíghtened wíth wrench 120 589 14 07 00
Special tools, model 124
103 589 01 09 ()0
Fig. 98: Identifying Hexagon Insert (103 589 01 09 00)
1 03 589 00 40 00
Fig. 99: ldentifying Counter-Holder (103 589 00 40 00)

Mercedes-Benz
001 589 72 21 00
Fig. 100: ldentifying Torque Wrench {001 589 72 21 00)
Special tools, models 129, 140
1 03 589 01 09 00
Fig. 101: ldentifving Hexagon lnsert (103 589 01 09 00)
1 20 589 02 01 00
Fig. 102: ldentifying Counter-Holder {120 589 02 01 00)

Mercedes-Benz
001 589 72 21 00
Fig. 103: Identifying Torque Wrench {001 589 72 21 00)
Special tools, model 202
120 589 14 07 ()0
Fig. 104: Identifying Wrench (120 589 14 07 00)
103 589 00 40 00
Fig. 105: ldentifying Counter-Holder (103 589 00 40 00)

Mercedes-Benz
001 589 72 21 00
Fig. 106: ldentifving Torque Wrench (001 589 72 21 00)
Special tools, model210
120 589 14 07 00
Fig. 107: ldentifving Wrench (120 589 14 07 00)
120 589 02 01 ()Q
Fig. 108: ldentifving Counter-Holder (120 589 02 01 00)

Mercedes-Benz
001 589 72 21 00
Fig. 109: Identifying Torque Wrench {001 589 72 21 00)
Removing an<l installing viscous fan clutch - RA20001193120X(20-3120)
Preceding work:
Radiator removed {20-4200).
20-5660, 20-6590
A. Model124
Mercedes-Benz
~Nm 2
Fig. 110: ldentifying Viscous Fan Clotch Removellnstall Components (Model124)
Counter-holder
fit on, remove, special tool 603 589 00 40 00_
(01)
slacken with hexagon socket and torque wrench, tighten (45 N m), special tools 103
Bolt(1)
589 01 09 00 and 001 589 72 21 OO.
Bolt (1) unscrew with key 120 589 14 07 00, screw on.
unbolt from fan (2), bolt on (1 O Nm).
Viscous fan o:::r-wF
clutch (3)
The cast part number of the fan (2) must be positioned at the front (radiator side)_
B. Model 129
Preceding work:
Fan shroud removed.
20-5660, 20-6590
Mercedes-Benz
'IONm
~-
1~-----
46Nm
Counter-holder
fit on, remove, special tool603 589 00 40 OO.
(1)
slacken with hexagon insert and torque wrench, tíghten ( 45 N m), specíal tools 103
Bolt (1)
589 01 09 00 and 00 1 589 72 21 OO.
unbolt from fan (2), bolt on (10 Nm).
Viscous fan ~WF
clutch (3)
The cast part number ofthe fan (2) must be positioned at the front (radiator side).
C. Modell40
20-5660, 20-6590
Mercedes-Benz
10Nm r.n.
~-'e
~N
1
m
Fig. 112: ldentifving V!iscous Fan Clutch Remove/lnstalJ Components (Model140)
Fan shroud ring (7 ) on take off, place over fan, fit on.
fan sbroud
Counter-holder (01) fit on, remove, special tool 603 589 00 40 OO.
slacken with hexagon insert and torque wrench, tighten (45 N m), special tools
Bolt (1)
103 589 01 09 00 and 001 589 72 21 OO.
tmbolt from fan (2), bolt on (lO Nm).
~WF
The cast part number of the fan (2) must be positioned at the front (radiator
side).
Viscous fan clutch to bearing body 45
Fan to viscous fan clutch 10
Special tools
Mercedes-Benz
\~______1_
W_~
__9 _14_0_7_oo___________)
001 589 72 21 00
603 589 00 40 00

Mercedes-Benz
103 589 01 09 00
Fig. 116: ldentifving Hexagon Insert (103 589 01 09 00)
D. Model210
20-5660, 20-6590
P20.4~7..S7
Fig. 117: ldentifving Viscous Fan Clutch Remove/lnstall Components CModel210)

Mercedes-Benz
fit onto belt pulley, remove, special toolll9 589 02 40 00 or 111 589 00 40
Counterholder (3)
00, see note.
slacken with torque wrench and open-jaw wrench bit (5), unscrew, tighten (40
Union nut (26a)
N m), specíal tools 001 589 72 21 00 and 111 589 02 O1 OO.
Viscous fan coupling (26) ~WF
of fan (25) The cast part number of the fan (2) must be positioned at the front (radiator
side).
Special tools
001 589 72 21 00
111 589 02 01 00
119 589 02 40 00
Mercedes-Benz
Fig. 120: ldentifying Counter Holder (119 589 02 40 00)
NOTE: Enlarge 0 ofthe holes from 10.5 mm to 11.5 mm in orderto fit

counterholder 111 589 00 40 00 over the hexagon bolts (arrows).
Change special tool number on too] from 111 589 00 40 00 to 119 589 02 40 OO.
P20.40-02:28-13
Fig. 121: Locating Counterholder Over Hexagon Bolts
REMOVING AND INSTALLING, ADJUSTING FAN SHROUD- RA20001043400X(20-3400)
Removing and installing, adjusting fan shroud - RA20001043400X(20-3400)
Preceding work:
Bottom engine compartrnent panel at front removed
20-6800
A. Models 124, 129, 202

Mercedes-Benz
p 20-5316-57
Fi~. 122: Id en tifyin~ Adjustin~ Fan Shroud Removellnstall Components (Models 124, 129, 202)
Modell29: remove trim panel (20) at top ofradiator, install.

Model202: detach coolant line at fan shroud, fit on.
Locking pin (18) remove, insert.
turn to the left, place over fan, install.
o:s=-wF
Fan shroud ring (6)
When installing, ensure the engaging studs are correctly located in the fan
shroud (5).
Flat shaped springs (15) pull offupward, install.
remove, install.
Fan shroud (5) and fan
NOTE:
shroud ring ( 6)
When installing, insert retaining plates (arrows) of fan shroud (5) into the
mounts on the radiator. Adjust fan shroud (5) relative to fan.
B. Model140
Preceding work:
Mercedes-Benz
Bottom engíne compartment panel at front removed
(Maintenance Manual6190)_
Operation no_ of operation texts and work units or standard texts and flat rates:
20-6800
p 20-5317-57
Fig. 123: ldentifving Adjusting Fan Shroud Remove/lnstall Components (Model140)
Upper frame cross member - t

( ) remove, ms a 11 _
2
Locking pin ( 18) remove, insert
turn to the left, place over fan, instalL
n:=:rwF
Fan shroud ríng (6)
When installing, ensure the engaging studs of the fan shroud ring (6) are
properly located in tbe fan shroud (5).
Flat shaped springs ( 15) pull off upward, install_
remove, ínstalL
Mercedes-Benz
NOTE:
When installing, insert retaining plates (arrows) of the fan shroud (5) into
Fan shroud (5) and fan the mounts on the radiator.
shroud ring ( 6)
Adjust fan shroud (5) relative to fan.
C. Model210
Preceding work:
Warning instructions when hood open
20-6800
B.l_.-15
\
B.l
P20.4()..()219-57
Fig. 124: Identifving Adjusting Fan Shroud Remove/Install Components (Model 210)
Mercedes-Benz
springs (15) pull off upward, install.

remove, install.
NOTE:
When installing, ensure the retaining plates (arrows) of the fan shroud (5) are
Fan shroud (5)
inserted into the mounts on the radiator.
Adjust fan shroud (5) relative to fan.
Models 124, 129
A. 16.5-J9.5mm
B. 25.5- 28.5 mm
C. 19.5 - 25 .5 mm
Model 140
A. 22-25 mm
B. 25 - 28 mm
C. 17-23 mm
Models 202, 21O
A. 19 - 22 mm
B. 28-31 mm
C. 17 - 23 mm
Mercedes-Benz
Fig. 125: Identifying Fan Adjustments
ADJUSTING
Flat sbaped springs ( 15) pull off upward_
Fan sbroud (5) with fan sbroud ríngadj ust relative to fan (7) according to the sízes (A), (B), (C).
Flat shaped springs ( 15) install.
Removing, installing and adj ustin g fan cowl - RA20001203400X(20-3400)
Preceding work:
Hood opened, raised to vertical position (01-0080) _
Engine compartment panelling at bottom front removed (Maintenance manual 6190)_
Mercedes-Benz
18
Fig. 126: ldentifying Fan Cowl Remove/Install Components
Modell29: top radiator trim panel (20) remove, install.

unscrew, screw on (9
Model 140: top front cross member (2)
N m) .
Fan cowl ring (6)
o::r"wF tum to the left, place over
When installing, ensure that the 4 locking studs of the fan cowl ring (6) are fan, install.
correctly located in the fan cowl (5).
Flat shaped springs (15) pull off upward, install.
Fan cowl (5) and fan cowl ring (6)
lnstallation note
When installing, introduce retaining lugs (arrows) ofthe fan cowl (5) into the
remove, install.
mounts on the radiator (4) (see "adjusting").
The air slots (17) ofthe fan cowl (5) must be to the inside ofthe engine
compartment.
Fan cowl (5) adjust.
Mercedes-Benz
Model 129
A 11 4- 17 mm
B 23-26 mm
e 17- 23 mm
Model 140
A 22 - 25 mm
B 25-28 mm
e 11 7 - 23 mm
Fig. 127: ldentifying Fan Adjustment
ADJUSTING
Flat shaped springs ( 15) pull off upward.
Fan cowl (5) with fan cowl ring adjust relative to fan (7) according to sizes (A), (B), (C).
Flat shaped springs ( 15) instaU.
TESTING COOLING SYSTEM PRESSURE CAP - RA2000104430X(20-4300)
Testing cooling system pressure cap- RA2000104430X(20-4300)
Mercedes-Benz
PW.40.0220-57
Fig. 128: Testing Cooling System Pressure Cap
PRESSURE CAP WITH DETENT

tum anti-clockwise as far as detent 1 to release pressure.
~WF
Cap (5)
Do not open cap (5) unless coolant temperature is below 90 °C.
Risk of scalding!
~~s~~ap (3) 124 589 00 attacb to tester (2) 124 589 24 21 00, take off
Double connection (4 ) attach to tester (2) 124 589 24 21 00, take off
124 589 53 63 00
Cap (5) attacb to double connection (4), take off
Opening pressure of
test. See table for opening pressure.
pressure relief valve
test. Raise vacuum valve (6) for this step.
Vacuum valve NOTE:

The vacuum valve (4) must be resting against the rubber seal (5) of the
sealing plate, it must be possible to raise it easily and it must spring back
when released.
Mercedes-Benz
The base for the sealing plate on the expansion tank must be flat.
Replace pressure cap if corroded. The part no. and the pressure cap code number
are stamped in the cap.
2-STAGE PRESSURE CAP IN MODEL 210

turn half a revolution anti-clockwise to release pressure.
IJ3"WF
Cap (5a)
Do not open cap (5a) unless coolant temperature is below 90 oc. Risk
of scalding!
Adapter (3a) 210 589 03 63 00 attach to tester (2) 124 589 24 21 00, take off.
2-stage cap (5a) screw onto adapter (3a), unscrew; pay attention to note.
test; see table for opening pressure.
Opening pressure of pressure
NOTE:
relief val ve
The cap code numbers are stamped in the cap. See note for design
of 2-stage cap.
TEST DATA OF CAP WITH DETENT

Cap code number Pressure reliefvalve opens at bar gauge Vacuum valve opens at
bar vacuum
whennew u sed
140 1.4 ± 0.1 1.4 -0.1 0.1
TEST DATA OF 2-STAGE CAP

Cap code number Pressure reliefvalve opens at bar gauge Vacuum val ve opens at
barvacuum
lst stage 2nd stage
140/200 1.4 ± 0.1 2.0 ± 0.1 0.1
Special tools
124 589 00 91 00
Fig. 129: ldentifying Test Cap (124 589 00 91 00)

Mercedes-Benz
~~---2_1_o_5B_9_0_3_63_o_o_____)
Fig. 131: ldentifying Tester (124 589 24 21 00)
124 589 53 63 00
Fig. 132: ldentifying Double Union (124 589 53 63 00)
NOTE: A 2-stage cap is installed in model 21 O.
ICSf'"wF
The 2-stage cap must be screwed in far enough until the lug engages in the notch on the coolant expansion
reservou.
The cap has an additional pressure stage so that the system pressure is able to rise by up to 2 bar in the engine
off heating phase without the coolant flowing out.
Mercedes-Benz
p 20-5400-35
F ig. 133: Sectional View Of Coolant Expansioo Reservoir Cap
Testing cooling system ca]l- RA20001194300X(20-4300)

Mercedes-Benz
020.4n..G220-57
Fig. 134: Testing Cooling System Pressure Cap
CAP WITH DETENT

tum anticlockwise to detent 1 to release pressure.
~WF
Cap (5)
Cap (5) must not be opened unless coolant temperature is below 90 °C.
Rísk of scalding!
Test cap ( 3) 124 589 00 attach to tester (2) 124 589 24 21 00, remove.
91 00
Double union (4) 124
attach to tester (2) 124 589 24 21 00, remove.
589 53 63 00
Cap (5) attach to double union (4), remove.
Opening pressure of
pressure relief val ve
test. Lift vacuum valve (6) for this step.
NOTE:
Vacuum valve The vacuum valve (6) must be making contact with the rubber seal of the
sealing plate. lt must be easy to lift and spring back when released.
Mercedes-Benz
The contact surface for the sealing plate at the expansion reservo ir must be flat.
Replace cap wbich is corroded.
The part no. and the cap code no. are stamped in the cap.
2-STAGE CAP IN MODEL 210

tum half a tum anticlockwise to release pressure.
o:::!?'wF
Cap (5a) Cap (5a) must not be opened unless coolant temperature is below 90 o
c.
Risk of scalding!
Adapter (3a) 210 589 03 63 00 attach to tester (2) 124 589 24 21 00, remove.
2-stage cap (5a) screw onto adapter (3a), remove. Pay attention to note.
Opening pressure of pressure
NOTE:
relief val ve
The cap code numbers are stamped in the cap. See note for design
of 2-stage cap.
TEST DATA OF CAP WITH DETENT

Cap code number P ressure r elief valve opens at bar gauge Vacuum valve opens at
bar vacuum
new used
140 1.4 ± 0.1 1.4 - 0.1 0.1
TEST DATA OF 2-STAGE CAP

Cap code number Pressure relief valve opens at bar gauge Vacu um valve opens at
bar vacuum
1st stage 2n d stage
140/200 1.4 ± 0.1 2.0 ± 0.1 0.1
Special tools
124 589 00 91 00
F ig. 135: l dentifying Test Cap (124 589 00 91 00)

Mercedes-Benz
\~___2_1_
o _5B_9_0_3_63_ o_o_____)
Fig. 137: ldentifying Attach To Tester (124 589 24 21 00)
124 589 53 63 00
Fig. 138: ldentifying Double Union (124 589 53 63 00)
NOTE: A 2-stage cap is fitted to model 210.
ICSf'"wF
The 2-stage cap must be screwed in sufficíently until the lug engages in the notch at the coolant expansíon
reservou.
The cap has an additional pressure stage witb tbe result that tbe system pressure may rise to 2 bar during tbe
engíne off heatíng phase wíthout coolant flowing out.
Mercedes-Benz
P20-5408-35
Fig. 139: SectionaJ View Of Coolant Expansion Reservoir Cap
FUNCTION OF ELECTRICAL COOLANT LEVEL INDICATOR- RA20001044450X(20-4450)
Model124
Mercedes-Benz
lil'2ó • 11211 · 57A
P20-521 1-57A
Expans100 rese1V01r A1e11 Coolart lewl warnng 1arr1>

51 Float a MKroproc essor (base pla!S)
52 0-mg F Fuse a.nd ro!ay bo>r
55 Cirdp S41 Coolart level sensor
A1 lnsrunortpooelunt w Gloond
Fig. 140: Function Of Electrical Coolant Level Indicator (Model124)
General
The coolant level indicator monitors the coolant level in the expansion reservo ir ( 1) when the engine is running.
When the ignition is switched on, the warning light (Alell) comes on weakly (check ftmction) and goes out if
the coolant is at the correct leve] as soon as the engine is started.
TI1e coolant level sensor (S41 ) has two retaining lugs of different width and can only be installed in one
position. It is sealed by means of an 0 -ring (52) and is fixed in place by a circlip (55).
Operatiou
Ifthe coolant is at the correct level, a permanent magnet (2) in the float (51 ) anda permanent magnet (3) in the
sensor (S41) keep a contact (arrow) open.
If the coolant level is too low, the float (51) moves clown and the permanent magnet (3) eloses the contact
Mercedes-Benz
(arrow) in the coolant level sensor (S41 ). A permanent input sígnal (vehícle ground) exists at the
microprocessor (a) in the electrical base plate ofthe ínstrument panel unit (Al) and the warning lamp (Alell)
comes on with a bright light.
Models 129, 140, 202, 210
F 52/ 1
A1e11
,.,. . . . . . 57
?20-5212-57
Soo'Ml 011 modol1 29 F Fuse and retay box

1 ExparlsiOll f8S91VOU S41 Coolalt l&vel sen sor
51 Floal W2 Gfoood attrort ng)t(elhe~glt Ulll)
54 Rmg magoot (pemHlllllré magnol) X24 H&a.d1gllt •nnng hamess tonnector
A1 lllsrume:i panel un1t
A1e11 Goolam le'Ylll wamng ~
a M1croproc ossor (base plall)
Fi2. 141: Function OfElectrical Coolant Level Indicator (Models 129. 140, 202, 210)
General
In models 129, 140, 202, 210, coolant does not flow directly around the coolant level sensor (S41) and the
sensor can be removed and installed without draining the coolant in the expansion reservoír (1).
Operation
Ifthe coolant level is too low, the ring magnet (54) in the float (1) closes the contact (arrow) in the coolant level
sensor (S41 ).
Mercedes-Benz
A pennanent input signal (vehicle grotmd) exists at microprocessor (a) in the electrical base plate ofthe
instrument panel unit (Al) and the warning light (A 1ell) comes on with a bright light.
TEST DATA
Resístance at coolant level sensor at "max" coolant infmíty ohms
level
Resistance at coolant level sensor at "min" coolant approx. 5 ohms
level
Battery voltage approx_ 12 V
IMultimeter e.g. SUN, DMM-5
REMOVING AND INSTALL ING COOLANT PUMP- RA20001192100X(20-2100)
Removing ami installing coolant pump- RA20001192100X(20-2100)
Preceding work:
Carrier ofviscous fan clutch removed (20-3140)
Belt pulley/vibration damper removed (03-3420) _
20-1270
Mercedes-Benz
P:!0-5299-57
Fig. 142: ldentifying Coolant Pump Remove/lnstall Components
Coolant hoses (4), (5) and (6) detach, attacb.

Connection cover at top (2) with engine lifting eye (1) unbolt, bolt on (21 Nm).
Gasket (2a) replace.
Model210 with secondary air injection: retaining plate with
unbolt at coolant pump (3), bolt on.
switchover valve for secondary air injection
unbolt.
Coolant pump (3) u::srwF
Coolant pump bousing, see Note.
fit on, bolt on (21 Nm).
u::srwF
Coolant pump (3)
Pay attention to different bolt
lengths, see bolt diagram.
Mercedes-Benz
A
11 10
a 10 12
10 11
......
P~300-55
A Engine 119.96 B Engine 119.97/98

10 MSxf!O OOlt +washer 10 MSX60 boi+Washor
11 M8ic65 bol+v.asher 11 MS~5 bol+v.a5her
13 M8Jd35 bol+washer 12 M8x7 5 bol+>Nashar
14 M8Jc90 bolt•washor 13 MBxB5 bol+v.ast~ar
{togethef 'Mih 11m d Jtch ~amor) 14 M8x90 bol+washar
15 M8x135 bol+washer (lo~ 'Mth tan cticncamar)
15 M8x135 bol•washer
Fig. 143: ldentifying Coolant Pump Bolt And Washers Location
Special tool
001 589 72 21 00
Fig. 144: Identifying Torque Wrench (001 589 72 21 00)
TIGHTENING TORQUE IN Nm
Bolts of cover at top to coolant pump 21
Bolts of coolant pump to crankcase 21
NOTE: Engine 119.97

Mercedes-Benz
The coolant pump must not touch the timing case cover at the bottom (arrows) otherwise the attaching hose and
the gasket may not be aligned and the top attaching eye may shear off Check position of coolant pump and
grind off coolant pump housing, if necessary, in the area of the arrows by about 1 mm.
P20-5l37-15
Fig. 145: Locating Timing Case Cover
Removing and installing coolant pump- RA20001202100X(20-2100)
Preceding work:
Radiator removed (20-4200).
Coolant temperature thermostat housing (4) removed (20-1120).

Mercedes-Benz
25
()~
-e-
Fig. 146: ldentifying Coolant Pump Removellnstall Components
Bolts (24) and (22) ofbelt pulleys slacken, tighten (step 1).
Poly V-belt (29) remove, install (13-3420) .
Viscous fan coupling belt pulley (21) and coolant pump belt pulley (23) remove, install (step 3).
Guide pulley (25) remove, install {13-3460) .
Coolant hose (15) detach, attach.
Coolant pump bolts (27) unscrew, screw on (step 6).
Coolant pump (26) with gasket (28) remove, install.
Cooling system check for lea.ks (20-0170).
M6 bolts ofviscous fan and coolant pump belt 10
pulleys
M8 bolts of coolant pump 21
SpeciaJ tooJ
Mercedes-Benz
001 589 72 21 00
00
l_ Slacken bolts (arrows) ofviscous fan coupling beJt pulley (21) and of coolant pump belt pulley (23).
Tightening torque 1O Nm_
2. Remove poly V-belt (13-3420) _

3_ Unscrew fan belt pulley (21) and coolant pump pulley (23), remove.
4. Remove guide pulley (25) at front right cover {13-3460) _
5_ Detach coolant hose at bottom of coolant pump.
Fig. 148: ldentifying Viscous Fan Coupling And Coolant Pump Belt Pulley Bolts
Mercedes-Benz
1 BaC+wBSherMSX 70
2 Boll+w asllarM8 X 85
3 Hoxagan sod<ot scrow 'Aitl
washe; M8 X 95
4 Model140 Bol+washe; M8X
6S Wlfl TDC sen sor jL1/2)
rnble holder
Fig. 149: Identifving Coolant Pump Bolts And Washer
6. Unscrew coolantpump (26) and take offto the front.
Installation note
Modell29: lead ignition cable 4 past behind coolant pump (26).
Modell40: lead cable ofTDC sensor (L1/2) past behind coolant pump (26).
Install screws and bolts according to diagram.

8. Replace gasket of coolant pump.
Removing and installing coolant pump- RA200A1042100X(20-2100)
20-1270-2351
A. Models 124, 129 with engine 104.98

Mercedes-Benz
..........,
Fig. 150: Identifying Coolant Pump Remove/Install Components

Coolant at engine and at radiatordrain, pour in (20-0100).
Intake air scoop remove, install.
Tensíoníng devíce remove, install {13-3200).
Power steering pump remove with pipes connected, install (25 N m).
Engine 104.98: unbolt return pipe (3), bolt on (step 7), replace seal.
Coolant hoses detach, attach.
Coolant pump (4) remove, install, replace sea! (step 9).
Leaktightness check.
Bolt of coolant pump to crankcase 25
Belt pulley of viscous fan to hub 15
Ml2 bolt oftensioning device for poly V-belt 75
Belt pulley to power steering pump 32
Belt pulley to coolaut pump shaft 32
Thermostat housing to coolant pump 9
COMMERCIALLY A VAILABLE TOOLS

Hexagon socket wrench with 6 mm joint, 3 /8"
Mercedes-Benz
7 mm socket wrench hexagon on fl exible shaft for hose clip Hazet 428530 Remscheid Order no.
with worm drive e.g. 426-7

2. Drain coolant at engine and at radiator (20-0100).
3. Pull air scoop off the a ir cleaner and remove .
4. Remove tensioning device for poly V-belt {13-3200).
5. Remove power steering pump with lines/wiring connected and place to the side.
Engine 104.98
6. Slacken bolt (29) ofbeating water return pipe. Pull beating water return pipe (25) out of coolant
pump and place to the síde. Detach coolant hoses. Pull ignitíon cable off bracket.
Installation note
Replace seal of heating water retum pipe.
Fig. 151: ldentifying Heating Water Return Pipe With Bolt
7. When replacing the coolant pump, switch over coolant thermostat {20-1100).
lnstallation note
The thermostat must be installed so that the ball valve ís at the highest point (20-1100). lnstall new
seaL
8. Unscrew bolts (263, 264) at the crankcase.

Mercedes-Benz
Remo ve coolant pump (265).
lnstallation note
Replace seal of coolant pump.

10. Check for leaks.
Fi~.152 : Identifyin ~ Coolant Pump With Bolts
REMOVING AND INSTALLING BEARING BRACKET OF VISCOUS FAN CLUTCH-

RA20001193140X(20-3140)
Removing and installing bearing bracket of viscous fan clutch - RA20001193140X(20-3140)
Preceding work:
Reservoir with coolant drain line removed (20-2120).
Alternator removed (15-51 0).
20-5996
A. Modell24
Mercedes-Benz
8 M~S bol+washor 12
11 M8x75 bol+washor 13
Fig. 153: ldentifving Viscous Fan Clutch Bearing Bracket Remove/lnstall Components (Model 124)
Coolant at radíator drain, pom in (20-0100).

Coolant hoses (4) and (5) at fan clutch d t h fit
. (2)
carner e ac , 1 on.
unbolt, place to the síde with lines connected, bolt on.
. . lnstallation note
Au pump (lO) w1th angle bracket (25) . . .
InstaD arr pump (10) wtth angle bracket (25) to fan clutch camer
(2) free of tensíon.
Fan clutch carrier (2) to crankcase unbolt, bolt on (25 Nm).
B. Model 129
Preceding work:
Operation no. of operatíon texts and work units or standard texts and flat rates
20-5996
Mercedes-Benz
Fig. 154: Identifying Viscous Fan Clutch Bearing Bracket Remove/Install Components (Model 129)
Coolant at radiator drain, pour in (20-0100).

Bolts ofbelt pulley- fan carrier (1) slacken, tighten (lO Nm) (step 2).
Poly V-belt remove, install (13-3420) .
Belt pulley - fan carrier ( l) unbolt, bolt on.
Coolant hoses (4) and (5) at fan clutch carrier (2) slacken, pul! off, fit on, tighten.
Altemator (3) swivel upward (step 6).
Fan clutch carrier (2) at angle bracket (25) and crankcase (7) unscrew, screw on (25 Nm) (Step 8).
Fan clutch carrier (2) take off, install.
Bolts (9 and 8) at angle bracket tighten free of tension (25 N m).
Special tools
Mercedes-Benz
001 589 72 21 ()0
6.03 589 00 40 00
Bolts of belt pulley 10
Angle bracket 25
Fan clutch carrier 21
l. Drain coolaut at rad.iator (20-0100).

2. Slacken bolts of belt pulley - fan clutch carrier; cotmter-hold with tool (1) 603 589 00 40 00 when
performing tills step.
3. Remove poly V-belt (13-3420).
Mercedes-Benz
Fig. 157: ldentifying Fan Clutch Carrier; Counter-Hold With Tool
4. Unscrew belt pulley on fan clutch carrier.

5. Unscrew coolant hoses from fan clutch carrier and detach.
6. Swivel altemator up by unscrewing the bottom bolt and slackening the top one.
7. Unscrew bolt, swivel angle bracket to the side and take off fan clutch carrier.
Install angle bracket free of tension.

C. Model210
Preceding work:
Viscous fan coupling removed (20-3120).
20-5996
Mercedes-Benz
P20 4(g)229-S7
Fig. 158: ldentifving Viscous Fan Clutch Bearing Bracket Remove/lnstall Components (Model 210)
Ground cable Installation note
Code radio.
Coolant and radiator drain, pour in (20-0100).
Bolts of belt pulley of fan carrier ( l) slacken, tíghten (15 Nrn)
Poly V-belt (8) remove, install (13-3420) .
Belt pulley of fan carrier (1) unbolt, bolt on.
Coolant hoses (4) and (5) of fan coupling
slacken, pull off, fit on, tighten.
carríer (2)
Front engine mount at front suspension
unbolt, bolt on (22-2110) .
carrter
Engine raise to enable generator (3) to be removed.
A TF pipe (lO) at front ríght at oil surnp unbolt, bolt on.
Generator (3) remove, install.
If secondary aír injection fitted: oil filter remove, install to enable air injection val ve (9) to be removed
(7) (18-1100).
If secondary a ir injection fitted: air
remove, install.
injection valve (9)
TPffi()Vf" inc::t::l Jl
Mercedes-Benz
Installation note
Angle bracket (25) Install angle bracket (25) to fan coupling support and
generator (3) free of stress.
Fan coupling support (2) unbolt, bolt on.
Special tools
001 589 72 21 00
Removing and installing bearing bracket of viscous fan clutch- RA200A1043140X(20-3140)
Preceding work:
Víscous fan clutch removed (20-3120).
Operation no. of operation texts and work uníts or standard texts and flat rates:
20-5996
A. Models 124, 129, 140

Mercedes-Benz
PL0-532~7
Dargestelit am Motor 104.98
M8 X 8llbol+washof 4 En g~ne104 .98MB X 67ft colar bol

2 MBX 65bol+washof Er!g:11 e104.99MB X 65ool+wasller
3 t.~ a X aooot 5 MB X 11 0~washor
Fig. 160: Identifying Viscous Fan Clutch Bearit1g Bracket Remove/Install Components
Cover (10) remove, install.

Ignition cable (4) and connector of
unplug, plug in.
camshaft adjuster
High voltage distributor (11) with
unbolt, place to the side, bolt on.
ignition cable connected
Holder of cover (1 Oa) unbolt, bolt on.
unbolt high pressure expansion hose at holder of front cover, bolt
Model 124, with leveJ control:
on.
unclip vacuum line at holder of bearing bracket, clip in place
Modell40:
(3X).
Bolts (19) of belt pulley (21) of fan slacken, tighten (15 Nm).
Po1y V -belt (8) remove, install (13-1200) .
Models 129, 140: remove plate (20), install.
Mercedes-Benz
Belt pulley (21) remove, install.

Models 124, 129 open expansion reservoir cap, release pressure.
unbolt heating water retum line (27) at coolant pump and bearing
Models 124, 129:
bracket (22), bolt on, replace seal (27a).
Models 124, 129: plug opening of coolant pump.
Bolts (1), (2), (3), (4) and (5) unscrew, screw on (21 Nm).
Models 124, 129: coat fit collar bolt (4) witb sealant 002 989 00 20 10.
Bearing bracket (22) remove, install.
Models 124, 129: replace seal (97) in timing case cover.
Models 124, 129: pour in coolant (20-0100).
Models 124, 129: check cooling system for leaks (20-0170).
Bolts ofhigh voltage distributor 10
Bolts ofbelt pulley of fan 15
Bolts ofbearing bracket ofviscous fan clutch 21
Special tool
001 589 72 21 00
A20-4200 REMOVING AND INSTALLING RADIATOR - RA20001194200X
Preceding work:
20-3865-4535
A. Model124
Mercedes-Benz
Fig. 162: ldentifying Radiator Remove/Install Components (Model124)
Coolant to radiator drain (20-0100).

Oillines (7) and (8) of automatic
transmission at radiator (4)
Oilljne (9) of automatic
remove, install.
transmission
Bracket (9a) of oiJ line of automatic
remove, install.
transmission
Coolant hoses (10), (11) and (12) detacb, attacb.
Flat springs (15) remove, install.
Bolts (l6) unscrew, screw on.
separate, remove, install.
IGif"wF
Fan shroud (5) and (5a)
The air flaps (17) ofthe fan shroud (5) and (5a) must face toward
the inside of the engine compartment.
Mercedes-Benz
Flat springs (18) remove, install.

remove up and out ofthe rubber pads (19) ofthe cross member,
instaU.
Radiator (4) Installation note
The securing studs of the radiator must be inserted into the rubber
pads (19) of the cross member or mounting bracket.
Cooling system fill, bleed (20-0100) .
Oil level of automatic transmission check, adjust to correct level.
Leaks check.
B. Model129
Preceding work:
20-3865-4535
P20-5327.S7
Fig. 163: ldentifving Radiator Remove/lnstall Components (Model129)

Mercedes-Benz
Coolant at radíator draín {20-0100).

Coolant hoses (9), (10), (11) and (12) detacb, attach.
If automatic transmission fitted: oillines
(7) and (8) unbolt, bolt on (20 N m).
Air scoop remove, ínstall.
Stmt ( 1) and cross member (2) unbolt, bolt on.
If AC fitted: bracket, line of air
slacken, bolt on.
condítíoner at bottom left
lf AC fitted: condenser (3) at radíator (4) unbolt, bolt on.
raíse, lift out of mountíngs (4b) at radíator (4 ).
Installation note
Fit on both rubber pads (4a) at bottom of condenser (3), stick
Condenser (3)
on.
When installíng radiator, raise condenser (3) and ínsert into
catches (4b) on radiator (4).
remove upward, install.
lnstallation note
Radiator (4)
The securing studs of the radiator must be ínserted ínto the
mbber pads ( 19) ofthe bottom cross member.
Cooling system fill (20-0100).
If automatic transmission fitted: oillevel
check, adjust to correct level.
of automatic transmission
Coolíng system check for leaks {20-0170).
C. Model140
Preceding work:
F ront engine compartment panel removed
20-3865-4535
Mercedes-Benz
Plll- 8001--
Fig. 164: ldentifving Radiator Remove!Install Components (Model 140)
Coolant at radiator (4) drain (20-0100).

Oillines (7) and (8) of
automatic transmission at unbolt, bolt on (20 N m).
radiator (4)
Coolant hoses (9), ( 1O) and tak ff fit
( 11 ) e o , 1 on.
Intake air scoops remove, install (09-0060) .
Radiator cross panel (2) unbolt, bolt on.
turn to the left, place over fan, install.
Fan shroud ring (6) ~ WF
When installing, ensure the 4 engaging points are correctly located.
Flat springs (15) pull off upward , install.
TP.lTI()VP im:t::tJJ
Mercedes-Benz
Installation note
Fan sbroud (5) When installing, insert retaining catches of fan sbroud ( 5) into the mmmting
points on the radiator (4).
Plastic strips (13) on
pull off, install.
radiator
Bowden cable of hood lock d t h tt
. tor (4)
at rad1a e ac , a ac11.
If AC fitted: radiator (4) unbolt from condenser (3), bolt on.
lnstallation note
Radiator (4)
The fastening studs of the radiator must engage in the mbber pads (19) of
the cross member.
Fan sbroud (5) install (20-3400). boh on.
Installation note
If new radiator (4), adjust positioning strip (20) by hand with adjusting bolt
Radiator cross panel (2) (21). Todo this, tum adjusting bolt (21) with radiator cross panel (2)
installed until adjusting stiip (20) is resting with slight tension against
radiator cross panel (2).
Coolíng system fill (20-01 00).
If automatic transmission
fitted: oil level of automatic check, adjust to conect level.
transmission
Cooling system check for leaks. (20-0170).
Transmission oil hose to radiator (union nut) 20.0
Hose clip (reference value) 2.5
Drain plug ofradiator (reference value) 1.5
COMMERCIALLY A VAILABLE TOOLS AND TESTERS

Designatíon e.g. Make, order No.
Hazet
7 mm wrench socket hexagon on flexible shaft for hose clip with worm drivee.g. D-5630 Remscl1eid
Order No. 426-7
D . Model210
20-3865-4535
Mercedes-Benz
~22
P20 20-()219-57
Fig. 165: ldentifying Radiator Remove/lnstall Components (Model 210)
Fan shroud (l) remove, ínstall.

Coolant hoses (lO, 11 , 12) disconnect, connect.
ATF pipes (7) and (8) of
automatic transmission NOTE:
Seal ATF pipes (7) and (8) with fitting, see note.
Fan grille (20) remove, install.
Flat springs (15) pull offupward, fit on.
Front member cross panel (2) unbolt, bolt on.
Cable of hood loe k at cross
detach, attach.
panel(2)
Intake air scoop (22) remove, install.
If A/C fitted: condenser at
unbolt, bolt on.
radíator (4)
lift out, install.
Radíator (4)
NOTE:
Mercedes-Benz
The securing studs of the radiator must engage in the rubber pads
(19) of the bottom cross member when installed.
ATF level of automatic
check, adjust to correct level.
transmission
TIGHTENING TORQUES IN 1\TM

ATF hose of automatic transmission to radiator 20
(union nut)
Hose clips (reference value) 2.5
Drain plug of radiator (reference value) 1.5
COMMERCIALLY A VAILABLE TOOL

Hazet
Socket hexagon 7 mm on flexible shaft for hose clip with worm drivee.g. 42853 Remscheid
Order no. 426-7
NOTE: Seal ATF pipes with fitting (01) (shop-made).
01
p 2().5.319-13
Fig. 166: ldentifving Seal ATF Pipes With Fitting
ELECTRICAL FUNCTION OF COOLANT LEVEL INDICATOR- RA2000119440X(20-4400)
A. Model124
Mercedes-Benz
P'20· 1211- ~A
El<pans1001 9S91VOII A1e1 1 C<tolart te·,¡e¡ •nttcator larrp

51 Floal a Baso plato
52 0-nng F Foso and reley box
55 C11cip S41 God!ll1! leval sen sor
A1 lnsnmero panelunt w Grcund
Fig. 167: Electrical Function Of Coolant Level l ndicator (Model l 24)
General
The coolant level indicator monitors the coolant level in the expansion reservo ir (1) when the engine is
running.
When the ignition is switched on, the indicator lamp (Alell) lights up weakly (check function) and goes
out as soon as the engine is started provided the coolant is at correct level.
The coolant level sensor (S41) has two retaining lugs of different width and can be installed only in one
position. It is sealed by means of an 0 -ring (52) and fixed in position by a circlip (55).
Function
If the coolant is at the correct leve! a permanent magnet (2) in the float (51) and a permanent magnet (3)
in the sensor (S41) hold a contact (arrow) open.
If the coolant level is too low the float (51) moves down and the permanent magnet (3) eloses the contact
Mercedes-Benz
(arrow) in the coolant level sensor (S41 ). A permanent input signal (vehicle ground) exists at the base
plate (a) ofthe instrument panel unit (Al) and the indicator lamp (Al e ll) lights up brightly.
B. Models 129, 140
F 5211
A1e11
1 Expanston raseNotr F Fuso reley box

51 Float S41 Coolalt level sensor
54 Rlng m~et(porrnanonl magnel) W2 G!oond, hont n!1t (at headlan'p Ull)
A1 lns tunoctpanolunt X24 R.lgcomadon heoclamp ~ring hamass
A1e11 Cool!llt levelmdicator I!Jnll
8 Base plata
Fig. 168: Electrical Function Of Coolant Level Indicator (Model129, 140)
General
The coolant leve! sensor (S41) is not directly enveloped in coolant and can be removed and installed
without draining the coolant in the expansion reservoir (1).
Function
Ifthe coolant level is too low the ring magnet (54) in the float (1) closes the contact (arrow) in the coolant
level sensor (S41 ).
The permanent input signal (vehicle ground) exists at the base plate (a) of the instrument panel unit (Al)
Mercedes-Benz
and the indicator lamp (A l e ll) lights up brightly.
REMOVING AND INSTALLING EXPANSION RESERVOIR- RA20001194500X(20-4500)
Removing and installing expansion reservoir - RA20001194SOOX(20-4500)
20-4950
A. Modell24
Fig. 169: ldentifying Expansion Reservoir Remove/lnstall Components (Model124)
open (release pressure).

Cap (2) on expansíon reservoír ~WF
(1) Do not open cap (2) unless coolant temperature is below 90 °C. Risk
of scalding!
Coolant drain (until expansion reservoir is empty), pour in (20-0100).
rnnnP.r.tnr nf nhw rnnnP.r.tinn
Mercedes-8enz
(S41) of unplug, plug in.

coolant level índicator
Coolant hoses (4), (5) detach, attach.
Line (6) to overflow reservoir detach, attach.
remove, install.
Expansion reservoir ( 1) IJ3rwF
Pay attentíon to rubber pad (9) of expansíon reservoir ( l ).
NOTE: As ofvehicle ident end no. 124.03418 786 454 and 124.03618 783 119,
respectively, an expansion reservoir 124 500 15 49 with integrated vent
valve has been installed. This prevents air getting into the cooling circuit
when the coolant level drops.
Detach coolant hose (4) for fílling.
B. Model129
20-4950
Mercedes-Benz
,...0011-·7
Fig. 170: ldentifying Expansion Reservoir Remove/lnstall Components (Model129)
Cap of expansion tank ( 1) open (release pressure).

drain (until expansion reservoir is empty), pour in (20-
Coolant 0100}.
Cover (2) unbolt, lift off, install.
Connector (3) of coolant level indicator
unplug, plug in.
switch
Coolant hoses (4), (5), (6) detach, attach.
Nuts (7) uns crew, screw on.
remove, ínstall.
Expansíon reservoir ( 1) ~WF
Pay attention to mbber pad (9) of expansion reservoir (1 ).
NOTE: As of vehicle ident end no. 001 950 an expansion tan k with the
identification 129 500 03 49 (was 129 500 01 49) has been installed.
ldentification on top side of reservoir.
This reservoir has a modífíed vent connection to ensure imoroved ventilation of the svstem. When
Mercedes-Benz
performing repairs, install this reservo ir.
As ofvehicle ident end no. 022 921 an expansion reservoir with a ventilation line to the heating system
has been installed.
C.Model140
20-4950
1120"'.-.17
Fig. 171: ldentifving Expansion Reservoir Remove/Install Components (Model140)
Cap of expansion reservo ir ( 1) open (release pressure).

drain (lmtil expansion reservoir is empty), pour in (20-
Coolant
0100).
Connector (3) of coolant level indicator
unplug, plug in.
switch
Coolant hoses (4), (5), (6) detach, attach.
Mercedes-Benz
Nuts (7) uns crew, screw on.

remove, install.
Expansion reservoir (1) n3f»wF
Pay attention to rubber pad (9) of expansion reservoir (1).
Removing and iustalling expansion tauk- RA20001204500X(20-4500)
Preceding work:
20-4950
A. Modell29
Fig. 172: ldentifying Expansion Tank Remove/Install Components (Model129)
Cap on expansion tank (1) open (release pressure).

Coolant drain (until expansion tank is empty), refill (20-0100).
Right air cleaner (2) remove, install (09-0015) .
Cover (12) remove, install.
Mercedes-Benz
Plug of coolant level indícator connector (S41) unplug, plug in.

Coolant hoses (4), (5), (10) take off, fit on.
Coolant hose (6) to overflow tank detach, fit on.
Expansion tank (1) remove, install.
[$='WF
do not lose.
Rubber pad (9) of expansion tank (1)
Operation no. of the operatíon texts and work uníts or standard texts and flat rates
20-4950
B. Model 140
Fig. 173: ldentifving Expansion Tan k Remove/lnstall Components (Model140)
Cap on expansion tank ( 1) open (release pressure).

dra.in from ra.diator (until expa.nsion tank is empty), refill (20-
Coolant
0100).
Cover above ríght wheelhouse tmclip, remove, install.
Air clea.ner (2), right remove, install (09-0015) .
Mercedes-Benz
Plug (3) disconnect from coolant level indicator switch, reconnect.

Coolant hoses (4, 5, 6) remove, install.
Expansion tank (1) remove, install.
[!?wF
Rubber pad (9) of expansion tank do not lose.
(1)
Removing and installing expansion reservoir- RA200B1044500X(20-4500)
B. Models 129, 140
Warning instmctions wh.en hood open (01-0085) .
20-4950
P2C) • 5253 • !!17
Model 129
Fig. 174: ldentifying Expansion Reservoir Removellnstall Components
Cap of expansion reservoir (1) open, release pressure (20-0100).

Mercedes-Benz
drain (until expansion reservoir is

Coolant
empty), pour in (20-0100).
Model129: unbolt cover (2), raise, install.
Plug of connector (S41) of coolant level indicator remove, insert.
Coolant hoses (4), ( 5) detach, fit on.
detach coolant hose (6) to overflow tank,
Model129:
install.
take offvent line (lO) (iffitted), fít on;
Modell29:
see note.
remove, install.
lt:rwF
Expansion reservoir ( 1)
Pay attention to mbber mount (9) of
expansion reservo ir ( 1).
Note re model. . 129 . . Wl1en peflormm
.e: · · · all this
0o- repaus mst
As ofvehicle tdent end no. 001 950 an expanston reserven . . . '
·th h ·d ·fi · O" (p · reservou. As ofvehiCle tdent end no .
wt t e 1 entt cat.Jon 129 500 _, 49 revtous1y 129 500 01 · · ·tl
022 921 1
49) on the top ofthe reservo ir has been installed. This reservoir t . ant ethxpahnstt~n reservt orrhwt b a
.fi d · · h· h . 1
f ven me o e ea mg sys em as een
11as a m od 1 te vent connect10n w111c tmproves t e ventmg o · t d
. ms a 11e .
l
t h e coo mg system.
REMOVING AND INSTALLING OVERFLOW RESERVOIR- RA20001194540X(20-4540)
Removing and installing overflow reservoir- RA20001194540X(20-4540)
20-5411
A. Model124
Mercedes-Benz
-·
_0---~
64
CEO
63
P20 . 5254. !5'1
Fig. 175: ldentifving Overflow Reservoir Removellnstall Components (Modell24)
Front right wheel (3) take off, fit on.

Partition panel (2) below front fender remove, install.
Bolts (61) unscrew, screw on.
V acuum hose (65) detach, fit on.
Vacuum reservoir (62) remove, install.
Nut (63) and bolts (64) unscrew, screw on.
Coolant hose (66) detacb, fit on.
Overflow reservoir (6) remove, install.
B. B. Model129
20-5411
Mercedes-Benz
Fig. 176: ldentifving Overflow Reservoir Remove/Install Components (Model129)
Car drive onto Iift platform or over inspection pit.

Overflow line ( 6) of
detach, install.
overflow reservo ir ( 1)
Nuts (2) unscrew from below, screw on.
take off downward, install.
~WF
Overflow reservo ir ( 1)
When removing overflow reservoir (1 ), protective cap (3) of air admission
connection ( 5) remains next to splash water reservo ir (4).
Protective cap (3) must be re-fitted when installing.
C. Model 140
20-5411
Mercedes-Benz
Fig. 177: ldentifying Overflow Reservoir Remove!lnstall Components (Model140)

--
Car drive onto lift platform or over inspection pit.
Front engine compartment panel (2) at bottomremove, install.
Front bumper (3) remove, install (88-2000).
Overflow line (6) of overflow reservoir ( 1) detach, attach.
Nuts (arrows) unscrew, screw on.
Overflow reservo ir (1) take off, insta U.
Removing and installing overflow reservoir- RA200B1044540X{20-4540)
B. Modell29
20-5411
Mercedes-Benz
P21J • 5133 • 57
Fi~. 178: ldentifving Overflow Reservoir Remove/Install Components
Vehicle drive onto lift platform or inspection pit.

Front right panel (7) remove, install.
pull off, install.
Coolant hose (6) at n=:rwF
overflow reservoir When removing the overflow reservoir ( 1), protective cap (3) of air admissi on
connection (5) remains lying at top next to spray water reservoir (4).
Overflow reservoir (1) remove, install.
Protective cap (3) fit on.
TECHNICAL MODIFICATIONS ENGINE 119 MECHANICAL lll- RA2000119TAOOX
20 Engine cooling, coolan t, radiator
Designation Nature aod reasoo for modification Production breakpoints Op. no.
Coolant pump Modified version 21-2100
Mercedes-Benz
REMOVING AND INSTALLING COOLANT THERMOSTAT HOUSING- RA20001201120X(20-1120)
Preceding work:
Viscous fan (20) removed (20-3120) .
Model 140: radiator removed (20-4200).
Operation no. of the operation texts and work units or standard texts and flat rates:
20-2710
P20 •$09S ·57
Fig. 179: Identifying Coolant Thermostat Housing Remove/Install Components
Modlel 129: coolant drain from radiator, pour in (20-0100) .

Shield caps (11), (14) and (15) remove, install.
disconnect from both high voltage distributors
Ignition cable 4
(12), plug in.
High voltage distributor (12) with holders (13) and
( 17), shield cap
lnstallation note
clip into holders (13) and (17).
Cables ofTDC sensors (Ll/1 ) and (Ll/2)
Mercedes-Benz
Modiel 129: ignition cable 4 clip into holders (13) and (17).
Oil lines of power steering pump clip into left holder (17).
p 20- 5~03-57"
Fig. 180: Identifying Coolant Thermostat Housing Remove/InstaU Components
Coolant boses (1) and (2) detacb from thermostat housing cover (3), fit on.
Electrical connector at thermostat housing (4) unplug, plug in.
Screws (6) and (7) in thermostat housing cover (3) unscrew, screw on.
M8 X 80 screws (5) in tbermostat housing (4) unscrew, screw on (21 Nm).
Thermostat housing (4) together with bousing cover (3) remove, install.
0-rings (8), (9) and (10) replace.
REMOVING AND INSTALLING RADIA TOR- RA20001204200X(20-4200)
Removing and installing radiator - RA20001204200X(20-4200)
Preceding work:
Fan cowl removed (20-3400).

Mercedes-Benz
20-3865
A. Modell29
• 5200· 13 P20 • 5266 • fiT
Fig. 181: Identifying Radiator Remove/Install Components (Model129)
Expansíon tank cap open (release pressure).

Coolant draín from radiator (arrow ).
fit hose (inner día. 12 mm) onto
To drain coolant
connection (arrow).
Drain plug (14) unscrew.
Coolant draín ínto suitable vessel (lO liters).
unscrew from radiator (4), screw
Oillines (7 and 8) of automatic transmission
on.
Coolanthoses (9, 10, 11 and 12) take off, fit on.
Flat springs (15) unclip upward, clip in.
Condenser (20) unbolt from radiator (4), bolt on.
Radiator (4) remove upward, ínstall.
Tn d~ ll ~tion no tP~
Mercedes-Benz
The securing studs of the radiator must be insetted into the mbber
pads (19) ofthe bottom cross member.
Cooling system fill, bleed (20-0100).
Oillevel of automatic transmission check, adjust to correct level.
Cooling system check for leaks {20-0170).
Gear oil hose of automatic transmission to radiato r 20
(union nut)
COMMERC~LYAVMLABLETOOL
7 mm socket wrench hexagon on fl exible shaft for hose clíps e.g. Hazet, D-5630 Remscheid Order
witb wonn drive no. 426-7
Preceding work:
Fan cowl removed (20-3400).
20-3 865-453 5
B. Model140
Mercedes-Benz
Fig. 182: Identifying Radiator Remove!lnstaU Components (Model140)
Expansion tank cap open (release pressure).

Coolant drain from radiator (arrow), refill.
NOTE:
to connection (arrow).
To drain, connect hose (ID 12 mm)
Drain plug (14) unscrew.
Coolant (approx. 1O liters) drain into suitable vessel.
unscrew from radiator (4), screw on
Oil lines (7 and 8) for automatic transmission
(20Nm).
Coolant hoses (9, 1Oand 11) remov e, install.
Plastic strips on radiator pull off, fit on.
Front air scoops (22) remove, install (09-0060) .
Bowden cable of hood catch at radiator (4) detach, attach.
Coolant hose (12) detach, attach.
Mercedes-Benz
unscrew from condenser (3), screw

Radiator (4)
on.
Radiator (4)
InstaUation notes
The securing studs of the radiator must be inserted into the rubber
grommets ( 19) of the bottom cross member when installing.
set acUusting bar (20) by hand with
With new radiator (4)
adjusting screw (21 ).
T o perform this step .. .
. . . . . . tum adJustmo0 screw (21) when front
The adjustmg bar (20) must be restmg shghtly pretens10ned agamst b ( ) · tall d
cross rnem er 2 ms e .
the front cross member (2).
Coolíng system fill, bleed (20-0100).
Oillevel of automatic transmission check, adjust to correct level.
Hose clamps (reference value) 2.5
Drain plug, radiator 1.5
Gear oiJ hose of automatic transrnission to radiator 20
(union nut)

7 mm socket wrench on flexible shaft for hose clamps with Hazet, D-5630 Remscheid Order no.
worm screw e.g. 426-7
Removing and installing radiator- RA200B1044200X(20-4200)
B. Model129
Mercedes-Benz
P 20-5327-57
Fig. 183: Identifying Radiator Remove/Install Components
Preceding work:
Operation no. of operation texts aud work units or standard texts and flat rates :
20-3865-4535

Coolant hoses (9), ( l 0), ( 11) tak ff fi
and ( 12) e o , 1t on.
unbolt oillines (7) and (8), bolt on (20 N m).
fitted:
Air scoop remove, install.
Strut (1) and cross member
uubolt, bolt on.
(2)
If AC fitted: detach bracket, air conditioner líne at front, bottom left, bolt on.
If AC fitted: unbolt condenser (3) at radiator (4), bolt on.
r~isP. lift ont ofmonnts (4h) ~t r~oiMor (4)

Mercedes-Benz
NOTE:
Push both rubber mounts (4a) onto condenser (3) at bottom (arrow),
stick on.
Condenser (3)
When installing radiator, raise condenser (3) and insert into mounting plate
(4b) at radiator (4).
remove upward, install .
Radiator (4) NOTE:

The securing studs of the radiator must be inserted into the rubber pads
(19) of the bottom cross member.
check oillevel, adjust to correct level.
fitted:
Hose of automatic transmission fluid to cooler (union 20
nut)

7 mm wrench socket hexagon on flexible shaft for hose clip Hazet, 42853 Remscheid Order no.
with worm drive e.g. 426-7
TECHNICAL MODIFICATIONS ENGINE 120 MECHANICAL ll- RA2000120TAOOX
20 ENGINE COOLING, COOLANT, RADIATOR

Designation Na tu re and reason for Production breakpoints Op. no.
modification
Waterpump Modified installation deptb and belt pulley
Central bolt of fan MIO 65 bolt (wasMlO X 01/93 20-3120
coupling 60) Reason: standardization
with Mll9
Mercedes-Benz
1990-2002 ENGINE Engine Lubrication , Engine Oil Cooling - 129 Chassis
1990-2002 ENGINE
Engine Lubrication, Engine Oil Cooling- 129 Chassis
TESTING & REPAIR

MEASURING OIL CONSUMPTION - ARlS.OO-P-0025
Measuring oil consumption- AR18.00-P-0025AO
ENGINE 120
01 ~ Dipsíiol<
02 l?ll Rol moll: thormomc ll:r
Fig. 1: Measuring Oil Consumption
~ Inspecting
Inspect engíne for externa! oil
1 Eliminate any leaks
loss
~ The oil consumption test run must only be carried
out with engine oil; an engine oil change should
therefore be carried out prior to the oil consumption test
run. AP18.00-P-
2 Engine oil and filter change
It is not necessary to change the engine if the last oil 0101AA
change was carried out less than one month before, or if
the vehicle has not been driven more than 1000 km
since the last engine oil change.
Park vehicle on a flat surface
3
and mark the parked position
4 Rrin Q' enQ'i ne oil temnerature to &oanQer! Mea~ure oi 1temnerature with the re mote Fig. 2
Mercedes-Benz
1990-2002 ENGINE Engine Lubricat ion, Engine Oil Cooling - 129 Chassis
80 oc thermometer (02)
5 Switch off engine
&. oanaer!
~ Insert dipstick (O 1) with the scale pointing toward

Measure oillevel with dipstick
engine side and remove after 3 seconds, read off oil
6 (O 1) after 5 minutes; adjust oil Fig. 3
level and note
level to maximum if necessary
IJJ A void over:filling oil; top up oillevel to
"max." (value "O" see table)
~...
Carry out test run o ver a measured distan ce of 250 km
(in the case of measurement by workshop personnel) or
7 Carry out test run 1000 km (in the case of measurement by customer).
If measurement made by workshop personnel, take into
account the operating conditions of the vehicle at the
customer's.
Park vehicle at the marked
8
position
&.oanaer! Measure oil temperature with remote
thermometer (02).
Bring engine oil temperature to CO If tbe engine is switcbed off to allow the engine oil
9 to cool down to 80 °C, the engine has to be n m for Fig. 2
80 oc
about 10 seconds before the measurement (step 5) and
the accelerator operated sharply during this time in
order to create identical measurement conditions.
10 Switch off engine
&.oanaorl
Measure oillevel with dipstick CO Withdraw dipstick after 3 seconds and read off oil
11 Fig. 3
(O 1) after 5 minutes level
Oil quantity consumed see ?
Calculate the oil consumption
in liters 1 1000 km from the oil AR18.00-P-
12 Matching oil consumption to dipstick indication
quantity consumed (cm3 and 0025-0lAO
the measured distance (km)
Depending on the oil
13 consumption, top up oil or
carry out a repair measure
Mercedes-Benz
1990-2002 ENGINE Engine Lubrication , Engine Oil Cooling- 129 Chassis
124 ssg 0 1 21 on
Fig. 2: ldentifying Remote Thermometer (124 589 07 21 00)
120 589 OS 21 OD
Fig. 3: ldentifying Dipstick (120 589 06 21 00)
MEASUREMENT SHEETS
Engine Print no. (German 1English) Print no. (French 1 Spanish)
120.980/982 B20.800.98.446.00.A B20.800.98.446.0 l.A
120.981/983 B20.800.98.439.00.A B20.800.98.439.01.A
Measurement sheet for weigbing method B20.650.05.002.00.A B20.650.05.002.01.A
Matching oil consumption to dipstick indication- AR18.00-P-0025-01AO
Oil consumption = Oil quantity consumed in cm3 /Measured distance in km = 1= liters 1 1000 km
Example:
Engine oil is topped up prior to the test mn to "max." = 141 mm (value "O" see table engine 120.980/982).
After the test run (measured distance 7 50 km) the indication read off on the dípstíck is 139 mm > results in a
difference of 500 cm3·
Oíl consumptíon = 500 cm3 /7 50 km= 0.67liters 1 1000 km
0 OIL CONSUMPTION MEASUREMENT

Number Designation Engi ne 120.980/982 in Engine 120.981/983 in
Mercedes-Benz
1990-2002 ENGINE Engine Lubrication, Engine Oil Cooling- 129 Chassis
model140 with dipstick model 129 with dipstick

12010 12011
149 Oil qty_
mm in cm3 - -
148 Oil qty.
mm in cm 3 --
147 Oil qty.
mm in cm 3 - -
147 Oil qty.
mm in cm 3 - -
146 Oil qty_
mm in cm 3 -
-
145 Oil qty.
mm in cm 3 -
-
144 Oil qty.
mm in cm 3 - -
Dipstíck indícation
BF18.00-P- 143 Oil qty_
1001-020
from 136 mm to 149
mm in cm 3 - -
mm
142 Oil qty.
mm in cm 3 - -
14 1 Oil qty.
mm in cm 3
0 -
140 Oil qty_
mm in cm 3
250 -
139 Oil qty.
mm ]n cm 3
500 -
138 Oil qty.
580 -
mm in cm 3
137 Oil qty.
mm in cm 3
670 -
136 Oil qty.
750 -
mm in cm 3
135 Oil qty.
830 o
mm in cm3
134 Oil qty.
920 100
mm in cm3
133 Oil qty.
1000 200
mm incm3
Oil qty_
132 1080 300
incm3
Mercedes-Benz
131 Oil qty.

1170 400
mm in cm 3
130 Oil qty.
1250 500
mm in cm 3
129 Oil qty.
1330 600
mm in cm 3
128 Oil qty.
1420 700
mm in cm 3
127 Oil qty.
1500 800
mm in cm 3
Dipstick indication Oil qty.
BF18.00-P- 126
from 121 mm to 135 1600 900
1002-02G
mm
mm in cm 3
125 Oil qty.
700 1000
mm in cm 3
124 Oil qty.
1800 1120
mm in cm 3
123 Oil qty.
1900 1240
mm in cm 3
122 Oil qty.
2000 1360
mm in cm 3
121 Oil qty.
2080 1480
mm in cm 3
120 Oil qty.
2170 1560
mm in cm 3
119 Oil qty.
2250 1640
mm in cm 3
118 Oil qty.
2330 1720
mm in cm 3
117 Oil qty.
2420 1800
mm in cm 3
Dipstick indication 116 Oil qty.
BF18.00-P- 2500 1880
from 106 mm to 120 mm in cm 3
1003-02G
mm
115 Oil qty.
1690
mm in cm 3 -
114 Oil qty.
2040
mm in cm 3 -
113 Oil qty.
2120
mm in cm 3 -
112 Oil qty.
2200
mm in cm 3 -
Mercedes-Benz
111 Oil qty. 2280

mm in cm 3 -
110 Oil qty.
2360
mm in cm 3 -
109 Oil qty.
in cm 3 -
2440
mm
108 Oil qty.
2520
mm in cm 3 -
107 Oil qty.
in cm 3 -
2600
mm
106 Oil qty.
mm in cm 3 - -
Measure oil consumption - AR18.00-P-0025AV
ENGINE 112, 113
Only for models without Star Diagnosis
1 Olagnostic sor:ket
cap
P 18.00 2033o01
Fig. 4: Identifying Diagnostic Socket Cap - Shown On Model 208 With Engine 113
087 HHTconner:úng
cable
P13..0~211l31 01
Mercedes-Benz
Fig. 5: ldentifying HHT Connecting Cable
~ lnspect
1 Inspect engine for Rectify any leaks.
extemal oi] loss
2 Changíng the engíne oíl ~
and filter
"
The oíl consumption
measurement run must
only be carried out with
fresh engine oil. For this
reason, carry out an
engíne oil change before
conducting the oil
consumption
measurement run.
This eliminates any
incorrect measurements,
as a result of fuel present
in the oil.
lt is not necessary to
carry out an engine oil
change if the distance
which the vehicle has
covered since the last oil
change is < 1000 km.
@) Engine 112 except AP18.00-P-0101AE
112.942
@) Engine 113 except AP18.00-P-0101AF
11 3.942
3 Conduct measurement ~ '
run Conduct measurement
run over a measured
distance
of250 km (if
measurement carried out
by workshop personnel)
or over 1000 km (if
measurement carried out
by customer).
If the measurements are
conducted by the
workshop personnel, take
into account operating
conditions of the vehicle
at the customer's.
4 Plug in connection cable
Mercedes-Benz
(087) ofHHT to the

diagnostic socket
5 Read off actual values ~ When analyzing the
actual values, the vehicle
must be parked on the
same place as when the
oil change was carried
out otherwíse errors may
occur when determining
the actual values.
~ Read off the
consumed oil quantity
with the HHT. F or this
purpose?
in the function main
groups open menu point
"Body" ,?
in the function main
group Body open "KI
(instrument cluster)" , ?
in the instrument cluster
functions open menu
poínt ''Actual values" , ?
in the ínstrument cluster
actual values open
"Active servíce system
since last oil change" , ?
in the active service
system menu poínt
"Distance driven since
last oil chaoge" , read
off dístance and note.
Example: 1123 km.?
in the active service
system menu point
"Quaotity of oil added
during oil change", read
off oil quantity and note.
Example: 6.3ltr.?
in the active servíce
system menu point "Last
and second last detected
actual oil quantity with
relevant km/miles
reading with engine
operation " , read off last
detected actual oil
Mercedes-Benz
quantíty and note.

Example: 5.6ltr.
6 Calculate oil ~
"
consumption lf an oil quantity has
been r eplenished in the
meantime, add tbis to
the calculation.
Example:
Oil quantity poured in 6.3
liters minus last detected
actual oíl quantity 5.6
liters and no oil
replenishment results in a
difference quantity of0.7
liters.
Oil consumption:
Difference quantity in
liters x 1000
-- -------------------
Distance measured in km
= liters/ 1000 km
O. 7 X 1000 = ---------------
---- = 0.62liters/1000 km
1123
7 Depending on the oil ~"
consumption, top up oil The oil consumption for
or carry out any engines M 112/ 113 may
necessary reparr measure be as much as 0.8 liter of
oil over 1000 km. Repaír
measures must only be
carried out if the oil
consumption is higher
than this.
TESTING OIL PRESSURE- ARlS.OO-P-1250
Testing oil pressure- AR18.00-P-1250AO
ENGINE 120
Mercedes-Benz
P1800-'0387-0l
A Tc$t o Nprcs.s urc lllrougllconnocrion ~rol/ fltc r • ., Connoctlo n f ttilltl fAt OX1. 5
A Test o Nprcssurolllrougllconnocf1on 1t oll rlter A/umfnjjm so~/
~ Prossuro ~110 0-10 ~' 10J 519 00 21 00

01/ fl/fC(
T-IIMVO Remoto tllonnomotor
01 0/1 fl/tcr Cl#p Wffl) ~t connoctlon (shop-marffl to00
J Prcssuro /lnc
Fig. 6: Testing Oil Pressure
~
Testing oil pressure at oil filter cap
A
*B.A18.20-P-
1 Unscrew oil filter cap ~
1002-0lB
&.oanaerl Fig. 8
2 Replace oil filter element
Fit on oil filter cap (O 1) with test
3
connection
Oil fllter cap witb test connection for WF58.50-P-
Lt measuring oil pressure 1800-0IA
Connect pressure line (3) to test
4
connection
5 Close T -valve (2) (turn closed)
6 Inspect oil level
7 Remove dipstick (10)
Insert temperature sensor of remo te
8 &. o ...naerf Fig. 2
them1ometer (9) into dipstick
Risk of accident from vehicle starting
Secure vehicle to prevent it moving off by
off by itself when engine running.
itself .ASOO.OO-Z-
® Risk of injury from bruises and bums
W ear closed and elose-fitting work clothes. 0005-0lA
if yo u bold your hand into engine
Do not grasp hot or rotating parts.
when it is started or when it is nmning.
~ Wann un enQ'ine to oneratinQ' t emnerat:ure
Mercedes-Benz
(approx. 90°C).
At the operating temperature ofthe engine
oil, the oil pressure at id le speed must not
Run engine and test oil pressure at the
9 drop below 0.3 bar. When the throttle is
stated engine speeds and temperatures
blipped, the oil pressure must rise without
any delay and reach at least 3 bar atan engine
speed of 3 000 rpm.
~ Testing oil pressure through
B connection hole at oil ftlter
Unscrew oil pressure sensor (B5) *BA18.40-P-
1
together with seal ( 6) at oil filter (7) ~ 1001-01A
Fit on connection fitting or union (5) *WH58.30-
2 ~
together with seal (6) at oil filter (7). Z-1013-0SA
*WH58.30-
~
Z-1011-0SA
Connect pressure line (3) to connection
3
fitting or union ( 5)
4 Close T -val ve (2)
5 Inspect oil leve!
6 Remove dipstick (10)
Insert temperature sensor of remo te
7 thermometer (9) into dipstick guide
tu be.
Risk of accident from vehicle starting
Secure vehicle to prevent it moving off by
off by itself when engine running.
@ Risk of injury from bruises and bums itself. ASOO.OO-Z-
Wear closed and close-fitting work clothes. 0005-01A
if you hold your hand into engine
Do not grasp hot or rotating parts.
when it is started or when it is running.
&oanaerl
~ Warm up engine to operating temperature

(approx. 90°C).
Run engine and test oil pressure at the At the operating temperature ofthe engine
8 oil, the oil pressure at idle speed must not Fig. 2
stated engine speeds and temperatures
drop below 0.3 bar. When the throttle is
blipped, the oil pressure must rise without
any delay and reach at least 3 bar at an engine
speed of3000 rpm.
~ OIL LEVEL/OIL PRESSURE SENSOR

BA18.40-P-IOO 1-0IA Oil pressure sensor to oil filter N m 15
~ ENGINE LUBRICATION SYSTEM, OIL FILTER

IN umber joesignation jEngine 120
Mercedes-Benz
IBA18.20-P-1002-01B lscrew cap of oil fílter
Fig. 7: ldeotifyiog Tester (103 589 00 21 00)
103 5 89 02 09 00
Fig. 8: ldeotifying Wrench Socket (103 589 02 09 00)
124 5B9 07 :u 00
Fig. 9: ldentifying Remote Thermometer (124 589 07 21 00)
CO~~RCMLLYAV~ABLETOOLS
Number Designation
WH58.30-Z-l011-05A Adapter fitting M 10xl-M12xl.5 915 007 004 001 (DIN)
for oil pressure gage
WH58.30-Z-l O13-05A Connection fitting Ml2xl.5 for oil 915 006 004 002 (DIN)
pressure gage
Check oil pressure- AR18.00-P-1250D
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250

Mercedes-Benz
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 210,208,202, 163, 129
ENGINE 113.982 in MODEL 463.243 /246
i!l Oil-prusure
m1110me1ar
~ Connoction lñtlng
J Soal 12x11
4 Screw pJug
5 Süllng fÍilQ
S íil! Romate thermometer
7 04;utick
8 Vlscous fill1
9 F111 $hroud
Fie. 10: Identifyine Oil Pressure Remove/Install Components- Shown On Eneine 112
[g] tr:::r er Remove/install

1 Remove engine cover or ~ Remo ve engíne trím
air filter panel or aír filter by
lifting vertically up and
off the cylinder head
covers.
2 Remove víscous fan (8) ~ Right-hand thread! AR20.40-P-5660C
3 Remove fan shroud (9) On model 163 unscrew
bolts at bottom offan
sh.roud.
Model463. AR20.40-P-6800V
4 Remove screw plug (4) ~ Installation: Replace
together with sea] (5) at sealing ring.
tirning case ~ *BA18.40-P-1 001-0lB
5 Connect oil-pressure .1:. Danoer! Tester Fü!. 7
mano meter ( 1) to
connecting pipe (2) on &.oanaorl Double union Fig.13
timing case
Mercedes-Benz
~ Checking
6 Inspect engine oillevel,
adjust to correct level if
necessary
7 Connect remote ~ lnserttemperature
thermometer (6) sensor through tbe oil-
dipstick's guide tube into
the engine oil.
A oanqorl Remote
them1ometer Fig. 2
@ Risk of accident caused Secure vehicle to prevent ASOO.OO-Z-0005-0 lA
by vehicle starting off by it from moving by itself.
itself when engine is W ear closed and snug-
procedure or when
engme
8 Start engine, measure oil ~ Bring engine up to *BE18.00-P-1001-01B
pressure operating temperature
(approx. 80°C).
~ When accelerator is *BE18.00-P-1001-01B
operated, oil pressure
must rise instantly.
T est v al u es tioroil pressure

Number Designation Engine 112, Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995
BElS.OO-P-1001- Oil pressure at bar > or =0,7
OIB operating at rpm 700
temperature bar > or =3 ,0
at rpm 3000
Mercedes-Benz
~
m 0'11
1 eve11 01'1 pressure sensor
Number Designation Engines Engine 112 except

113.940/941/ 112.916/951/95
942/943/944/ 3/975
945/946/960/
961/962/963/
965/967/968/
969/980/981/
982/984/986/
992/995
BA 18.40-P-1001- Screw plug to Nm 20 20
OlB crankcase
~ 1 eve 11oil pressure sensor

m 0'11
Number Designation Engine Engine 113.9911

113.987/ 993
988/990
BA 18.40-P-1001- Screw plug to Nm 20 20
OlB crankcase
Fig. 11: Identifying Tester (103 589 00 21 00)
124 500 07 21 00
Fig. 12: ldentifying Remote T hermometer (124 589 07 21 00)

Mercedes-Benz
166 sag 00 63 00
Fig. 13: Identifying Double Union (166 589 00 63 00)
CHECK OIL LEVEL - AR18.00-P-3035-01A
0 OIL LEVEL CHECK

Number Designation Engine 112.912/913/94
6/949/955/973
BF18.00-P- Maximum mm 171
Oillevel
1001-03B Mínimum mm 151
Replenished oil
140mm +2.2
quantity in liters
Replenished oil
142mm +2.1
quantity in liters
Replenished oil
144mm +2.0
quantity in liters
Replenished oil
146mm + 1.8
quantity in liters
Replenished oil
148mm + 1.7
quantity in liters
Replenished oil
150mm + 1.6
quantity in liters
Oil dipstick indication from 140 Replenished oil
BF18.00-P- 152mm +1.4
mm to 168 mm (oil level too quautity in liters
1002-03B
low) Replenished oil
154mm + 1.3
quantity in liters
Replenished oil
156mm + 1.1
quantity in liters
Replenished oil
158mm +0.9
quantity in liters
Replenished oil
160mm +0.8
quantity in liters
Replenished oil
162mm +0.6
quantity in liters
Replenished oil
164mm +0.5
quantity in liters
R enlenished oil
Mercedes-Benz
1990-2002 ENGINE Engine Lubrication, Engine Oil Cooling - 129 Chassis
166mm quantity in liters +0.4

168mm Repl~ni~he~ oil +0.2
quanttty m hters
170 mm Oil quantity in liters 0.0
BF18.00-P- Oil dipstick indication from 170 171 ·¡ tit · ¡· t
1003-03B mm to 172 mm ( oillevel correct) mm 0 1 quan Y m 1 ers 0.0
172 mm Oil quantity in líters 0.0
174 mm E~tra~te~ oil_02
quant1ty m hters
Extracted oil
176mm -0.4
quantity in liters
Oil dipstick indication from 174 _ _ _ __ ___,l;...._-----"---1---------~
BF18.00-P- mm to 182 mm (oillevel too 178 mm E~tra~te~ oil _O.S
1004-03B high) quanhty m hters
180mm E~tra~te~ oi1_0 _6
quant1ty m hters
E~tra~te~ oi1_0 _7
182mm
quant1ty m liters
120 5S9 0 7 2t 00
ltusldn grod
Fig. 14: ldentifving Measuring Rod (120 589 07 21 00)
l. Position vehicle with warm engine on an even surface.

2. Switch off engine and maintain a waiting time of approx. 5 minutes.
3. Unplug plug (1) of oil dipstick guide tube (2).
4. &o."""'' Lead dipstick (3) into the dipstick guide tube (2) until its tip hes in the engine oí] pan.
~ Leave there for at least 3 seconds dwell time.
~ The collar of the dipstick grip end sits close at the oil dipstick guide tube (2).
~ Do not kink &oanaerl the dipstick (3). The &oanaer! dipstick (3)must be pressed in and guided according
to the forro ofthe dipstick guide tube (2).

Mercedes-Benz
P U 00·211i15·12
Fig. 15: Identifying Lead Dipstick
5. Read off engine oillevel at &.oanQorl dipstick (3).

6. Establish oil replenishment amount from the oil level table.
7. Adjust engine oillevel correctly, ifrequired.
8. Place plug (1) onto oil dipstick guide tube (2).
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE LUBRICATION, ENGINE OIL
COOLING- AR18.00-Z-911.3AB
ENGINE 113
Measure oil consumption ENGINE 112, 113 Only AR18.00-P-0025AV

for models without Star
Diagnosis
Measure oil consumption ENGINE 112, 113, 611 , AR18.00-P-0025CB
612, 613, 628 ...
Measure oil consumption ENGINE 113.964 in AR18.00-P-0025GZ
MODEL 164.175 Oil
consumption measurement
w ith STAR-DIAGNOSIS
Measure oil consumption ENGINE 113.971 in AR18.00-P-0025RT
MODEL 251.075 / 175, oil
consumption measurement
Mercedes-Benz
with STAR-DIAGNOSIS
Measure oíl consumptíon ENGINE 113.967 in AR18.00-P-0025TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Check oil pressure ENGINE 113.988 in AR18.00-P-1250AC
MODEL 203.076/276
ENGINE 113.989 in
MODEL 171.473
Check oil pressure ENGINE 112, 113 ... AR18.00-P-1250D
Check oil pressure ENGINE 112, 113 ... AR18.00-P-1250DA
Check oíl pressure ENGINE 113.964 in AR18.00-P-1250GZ
MODEL 164.1 75
Check oil pressure ENGINE 113.995 in AR18.00-P-1250RKV
MODEL 230.472
Check oil pressure ENGINE 113.971 in AR18.00-P-1250RT
MODEL 251.075/175
Check oíl pressure ENGINE 113.990 in AR18.00-P-1250RVK
MODELS 211.076 /276
ENGINE 113.99 1 in
MODELS 215.374,
220.074/ 174
Check oil pressure ENGINE 113.967 in AR18.00-P-1250TY
MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install oil spray ENGINE 112, 113 ... AR18.00-P-4000DV
nozzles (pistons)
Remove/install oil spray ENGINE 113.964 in AR18.00-P-4000GZ
nozzles (pistons) MODEL 164. 175
Remove/install oil spray ENGINE 113.971 in AR18.00-P-4000RT
nozzles (pistons) MODELS 251.075/175
Remove, install oil spray ENGINE 113.995 in AR18.00-P-4000RVK
nozzles (pistons) MODEL 230.472
Remove/install oil spray ENGINE 113.967 in AR18.00-P-4000TY
nozzles (pistons) MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install oil spray ENGINE 113.989 in AR18.00-P-4000VT
nozz1es (pistons) MODEL 171.473
Replace oil pump chain ENGINE 113.964 in AR18.1 0-P-2140GZ
MODEL 164.175
Replace the oil pump chain ENGINE 113.971 in AR18.10-P-2140RT
MODEL 25 1.075/175
Mercedes-Benz
Replace oil pump chain ENGINE 113.967 in AR18.10-P-2140TY

MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Replace the oil pump chain ENGINE 112, 113 ... AR18.10-P-2140V
Replace oil pump chain ENGINE 113.989 in AR18.10-P-2140VT
MODEL 171.473
Remove, install oil pressure ENGTNE 112, 113 ... AR18.1 0-P-5031 GV
relief valve
Remove/install oil pressure ENGINE 113.964 in AR18.10-P-5031GZ
relief valve MODEL 164.175
Remove/install oi1 pressure ENGINE 113.971 in AR18.l 0-P-5031RT
relief val ve MODEL 251.075/ 175
Remove/install oil pressme ENGINE 113.967 in AR18.1 0-P-5031 TY
relief valve MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install oi1 pressure ENGINE 113.989 in AR18.10-P-5031VT
re1ief val ve MODEL 171.473
Remove/install oíl pump ENGINE 112, 113 ... AR18.10-P-6020B
Remove/install oil pump ENGINE 113.964 in AR18.1 0-P-6020GZ
MODEL 164.175
Remove/lnstall oil pump ENGTNE 111, 112, 113 ... AR 18.1 O-P-6020PV
Remove/instail oil pump ENGINE 112, 113 ... AR18.l0-P-6020PW
Remove/install oil pump ENGINE 113 ... AR18.10-P-6020R
Remove/install oil pump ENGINE 113.971 in AR18.10-P-6020R
MODEL 251.075/ 175
Remove/install oil pump ENGINE 113.967 in AR18.10-P-6020TY
MODEL 219.375
ENGINE 113.990 in
NIODEL 219.376
Removing/installing the oil ENGINE 112, 113 ... AR18.20-P-3471B
filter housing
Remove/install oil fi lter ENGINE 112, 113 ... AR18.20-P-3471B
housing
Remove/install oil filter ENGINE 113.964 in AR18.20-P-3471GZ
hous ing MODEL 164.175
Remove, install oil filter ENGINE 113 ... AR18.20-P-3471RKV
housing
Remove/install oil ftlter ENGINE 113.971 in AR18.20-P-3471RT
housing MODEL 251.075/175
Remove/install oil filter ENGINE 113.967 in AR18.20-P-3471 TY
hous ing MODEL 219.375
Remove/install oil filter ENGINE 113.990 in AR18.20-P-3471TZ
Mercedes-Benz
housing MODEL 219.376

Remove/install engine oil ENGINE 113.991 in AR18.30-P-l OOOM
cooler MODEL 220.074
Remove, install engine oil ENGINE 113.991 in AR18.30-P- 1000RKV
ENGINE 113.992 in
MODEL 230.474
ENGINE 113.995 in
MODEL 230.472
Remove, install engine oil ENGINE 113 ... AR18.30-P-1 OOORKY
cooler
Remove/install engine oil ENGINE 113.990 in AR18.30-P- l OOOT
cooler M ODELS 211.076/276
Remove/install engine oil ENGINE 113.990 in AR18.30-P-1000TY
Additional oil cooler
Remove/install engine oil ENGINE 113.990 in AR18.30-P- 1000TZ
cooler MODEL 219.376 Wheel
house oil cooler
Removing/installing the ENGINE 113.989 in AR18JO-P-1000VT
engine oil cooler MODEL 17 1.473
Remove/install engine oil ENGINE 113.990 in AR18.30-P-1010T
cooler fan MODEL 211.076/276
Remove/install engine oil ENGINE 113.990 in AR18.30-P-1010TZ
cooler fan MODEL 219.376
Remove/install oil/water heat ENGINE 112, 113 ... AR18.30-P-3481C
exchanger at oil filter
Remove, install oil/water heat ENGINE 112, 113 ... AR18.30-P-348 1CA
exchanger at oil filter
Remove/install oil/water heat ENGINE 113.964 in AR18.30-P-348 1GZ
exchanger at oil filter MODEL 164.175
Remove/install oil/water heat ENGINE 113.97 1 in AR18.30-P-3481RT
exchanger at oil filter MODEL 251.075/ 175
Remove/install oil/water heat ENGINE 113.967 in AR18.30-P-348 1TY
exchanger at oil filter MODEL 219.375
Remove/install oil dipstick ENGINE 112/, 113/ AR18.40-P-351OBV
guide tube ( except, 112.912/946 /961,
113.963/995)
Remove/install oil dipstick ENGINE 113.964 in AR18.40-P-35 1OGZ
guide tube MODEL 164.175
Remove/install oil dipstick ENGINE 113.971 in AR18.40-P-351 ORT
guide tube MODELS 251.075/ 175
Remove, install oil dipstick ENGINE 113.995 in AR18.40-P-3510RVK
guide tube MODEL 23 0.472
Mercedes-Benz
Remove oillevel sensor, ENGINE 112, 113 ... AR18.40-P-5111A

install
Remove oi11evel sensor, ENGINE 111 , 112, 113 ... AR18.40-P-5111PR
insta U
Remove/install oillevel ENGINE 112, 113 ... AR18.40-P-5111PW
sensor
Remove oil1evel sensor, ENGINE 113.967 in AR18.40-P-5111 TY
install MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install oil sensor ENGINE 113.964 in AR18.40-P-5112GZ
M ODEL 164.175
Remove/install oil sensor ENGINE 112, 113 ... AR18.40-P-5112R
Remove/install oil sensor ENGINE 113.971 in AR18.40-P-5112RT
MODEL 251.075/175
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE LUBRIC ATION, ENGINE OIL
COOLING- AR 18.00-Z-9120AB
ENGINE 120
Measuring oil consumption ENGINE 120 AR18.00-P-002SAO

Testing oil pressure ENGlNE 120 AR 18.00-P -1250AO
Replacing oil pump chain ENGINE 120 AR18.10-P-2140AO
REPLACING OIL PUMP CHAIN - ARlS.lO-P-2140
Replacing oiJ pump chajn- AR18.10-P-2140AO
ENGTNE 120
Mercedes-Benz
P1910-'ll211·05
Fie. 16: Replacine Oil Pump Chain
[gJ n=:rer Removing, installing

1 Remove oil pan Model129 AR01.45-P-7500AO
Model 140 AR01.45-lP-7500AP
2 Remove spark plugs
3 Separate oil pump chain AR18.10-P-2140-01AO
&.oanaerl Fil!.28
&.oanQer! Fi!!. 27
&oanQer! Fi!!. 25
&.oanQer! Fi!!. 26
4 Rivet oil pump chain AR18.10-P-2140-02AO
~ *BA18.10-P-1001-01A
&.oanaerl Fi2. 28
&. oanaer! Fi!!. 34
&.oanaer! Fig. 33
&oanaerl Fi!!. 31
&.oanacrl Fig. 32
~ OILPUMP
INumber ¡nesignation ¡Engine 120
Mercedes-Benz
BA18.10-P-1001-01A Cbain sprocket to oil Nm28

pump
Casa
Fig. 17: Identifying Case (602 589 00 98 00)
Sll2 589 0§ 63 00
Fig. 18: Identifying Thrust Spindle (602 589 05 63 00)
602 599 02 33 00
Fig. 19: Identifying Chain Separating Tool (602 589 02 33 00)
002 589 05 63 01
Fig. 20: Identifying Thrust Pins (602 589 05 63 01)

Mercedes-Benz
oot ssg 65 og on
Fig. 21: ldentifving Socket Wrench Bit (001 589 65 09 00)
Rtllliin g1001
Fig. 22: ldentifving Riveting Tool (602 589 00 39 00)
103 599 01 S3 00
Fig. 23: Identifving Assembly Inserts (103 589 01 63 00)
6i)2 ss9 0.2.toon
Fig. 24: Identifying Assembly Links (602 589 02 40 00)
Separating oil pump chain- AR18.10-P-2140-0IAO

Mercedes-Benz
Fig. 2S: ldentifving Chain Separating Tool (602 S89 02 33 00)
soo sag os 63 01
Fig. 26: Identifying Thrust Pins {602 S89 OS 63 01)
602 589 05 63 0 0
Ttnl!lhplll!lle
Fig. 27: Identifying Thrust Spindle (602 S89 OS 63 00)
Fig. 28: ldentifving Case (602 S89 00 98 00)
l. Unbolt oiJ pump gear (arrow).

Mercedes-Benz
Fig. 29: Locating Oil Pump Gear
2. Use chain separating tool (O 1) 602 589 02 33 00 to separate oil pump chain (2). Position thrust pin (03)
602 589 05 63 01 against chain pin (arrow) for this step, screw in thrust spindle (02) 602 589 05 63 00
and press out chain pin.
P18.14l'li 24H I1
Fig. 30: Identifying Chain Separating Tool, Oil Pump Chain And Thrust Pin
Riveting oil pump cbain- AR18.10-P-2140-02AO
~ OIL PUMP
BA18.10-P-100 1-0lA Chaín sprocket to oil N m 28
pump
002 SS9 02 4ll OD
F io. ~1 ~ Tflpn t ifvi no A ~~Pmhl v T.inh {6 02 ~RQ 02 40 Ofn

Mercedes-Benz
001 589 85 09 00
Fig. 32: Identifying Socket Wrench Bit (001589 65 09 00)
t 03 589 Ot S3 00
Fig. 33: ldentifving Assembly lnserts (103 589 01 63 00)
Fig. 34: Identifving Riveting Tool (602 589 00 39 00)
l. Connect new oil pump cbain to the old oil pump chain with tbe assembly link 602 589 02 40 OO.
2. Use socket wrench 001 589 65 09 00 to rotate cranksbaft in direction of rotation of engine until the ends
ofthe new oil pump cbain can be connected.
3. Insert riveted link (4) from the rear.
Mercedes-Benz
Fig. 35: ldentifying Riveting Link
4. Insert chain guíde (F2) 103 589 01 63 00 ínto the ríveting tooJ (04) 602 589 00 39 00 (was 000 589 58 43
00) and attach with screw (28).
Fig. 36: Locating Chain Guide, Riveting Tool And Screw
5. lnsert moving thrust piece (D2) 103 589 01 63 00 into the riveting tool (04).
Fig. 37: Locating Riveting T ool And Thrust Piece
6. Insert outer plate (5) into the moving thrust piece (D2).
Mercedes-Benz
P18JO.OH7·01
Fig. 38: Locating Outer Plate And Thrust Piece
7. Fit web (arrow) onto both rollers at the riveted link.

8. Screw in spindle (05) until a firm resistance is felt.
~ When screwing in, ensure that the pins ofthe riveted link are guided into the holes ofthe plate.
P1 a1 o-n us-o1
Fig. 39: Identifying Screw Spindle
9. Take offriveting tool (04) and n1rn over moving thrust piece (arrow) (riveting side).
Fig. 40: Identifying Riveting Tool

Mercedes-Benz
Rivet the pins ofthe riveted link indívidually; tighten the spindle (05) to 30 Nm (reference value) for this
step.
P1 !LHHllSD-tl1
Fig. 41: ldentifying Screw Spindle
11. Inspect riveting (arrows), rerivet ifnecessary.
P!l 51 0-1121J-01
Fig. 42: Locating Riveting
12. Tnstall oil pump gear (7) with timing chain titted on, with convex face (arrows) pointing toward oil pump
(1).
Pay attention to tíghteníng torque.
P1'!LHHI.251 ·01
Mercedes-Benz
Fig. 43: ldentifying Oill Pump Gear
Replace the oil pump chain- AR18.10-P-2140V
ENGINE 112
ENGINE 112.945 in MODEL 463.209/232/233/244/245/250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243 /246
ENGINE 113 in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Sbown on engine 112
1 Oil pan b<>tromseoeriatl

2 Oflpump
3 011 rewm sllltoff wllve
4 Solts ofollpump
Pi8_10:0231.08
Fig. 44: ldentifving Oil Pump Chain Remove/lnstall Components - Shown On Engine 112
[gJ tr:::rer Remove/install

@ Risk of death Align vehicle between the columns of the ASOO.OO-Z-00 10-
caused by vehicle lifting platfonn and position the four support OlA
slipping or plates at the lifting platfonn support points
toppling off of the specified by the vehicle manufactmer.
lifting platform.
1 Remove oil pan
bottom section ( 1) Engine 113.988 in model203.076/ 276 AROl.45-P-
Engine 113.989 in model171.473 7555AC
Engine 112.975, 113.948 /966 in model220, AR01.45-P-
engine 112.917 in model211.080 /280 7555IW
Mercedes-Benz
Engine 112.954 in model211.082 /282

Engine 113.969 in model211.083 /283
Engine 112.912 in model203.061 /261, AR01.45-P-
209.361 /461 with transmission 722.6, 716.6, 7555PV
engine 112.946 in model203.064 /264 with
transmission 722.6
Engine 112.955 in model 209.365/ 465 with
Engine 112.961 in model203.065/ 265 with
transmission 722.6
transmission 722.6
Engine 112.913 in model 211.061 with
transmission 716.6, 722.6
Engine 112.949 in mode1211.065 with
transmission 722.6
Engine 113.967 in model211.070 with
transmission 722.6
Engine 112 in model 203.081 /084 /281 /284 AR01.45-P-
7555PW
Engine 113.963 in model230.475 AR01.45-P-7555R
Engine 113.990 in rnodel211.076 /276
Engine 113.991 in rnodel215.374, 220.074/
174
Engine 112.973 in rnodel230 AR01.45-P-
7555RA
Engine 112.942 in model163.154 AR01.45-P-7555V
Engine 112.945 in model463.209/ 232/ 233/1 AR01.45-P-
250 7555VA
Engine 112 in model129, 170, 202, 208, 210,
engine 113.962 in model
463.206 /240 /241 /247 /248 /249 /254
Engine 113 in model129, 202, 208, 210
Engine 113.982 in model463.243/ 246
Engine 112 except 112.975 in model220
Engine 113 except 113.966 /948 in mode1220
Engine 113.993 in rnodel463.270/ 271
Engine 113.965 in modell63.175 AR01.45-P-
Engine 113 .981 in model163.174 7555VE
2.1 Remo ve oil pan model 211.061 /065/ 070 ARO 1.45-P-
Mercedes-Benz
top section 7500TV

3 Remove oil pump ~ Installation:
(2)
o Ensure oil return flow check valve (3) is
o Clean the oil pump strainer.
o Fill the oil pump with engine oil before
installing, so that oil is delivered at the
initial startup.
250 6020B
Engine 112 in model210, 208, 202, 170, 163,
129
Engine 113.962 in model463.///254
Engine 113 in model210, 208, 202, 163, 129
Engine 113.982 in model463.243/ 246
Engine 113 except 113.948 /966 in model220 AR18.10-P-
Engine 111.951 in model203.035 /235 /7 35, 6020PV
engine 111.955 in model203.045 /245 /745,
engine 112.912 in model203.061 /261,
209.361 /461
Engine 112.946 in model203.064/ 264
Engine 112.961 in model203.065/ 265
Engine 113.968 in model209.375 /475
Engine 113.987 in model209.376 /476
Engine 112.955 in model209.365 /465
Engine 112.917 in model 211.080 /280
Engine 112.954 in model211.082 /282
Engine 113.969 in model211.083 /283
Engine 113.988 in model203.076/ 276
Engine 112 in model203.081 /084 /281 /284, AR18.10-P-
220.087 /187 6020PW
Engine 113 in model220.083 /084/183 /184
Engine 113.990 in model211.076 /276
Engine 113.991 in model215.374, 220.074/
174
Engine 113.993 in model463.270/ 271
1
Mercedes-Benz
1
6020RA
4 Separate oil pump AR18.10-P-2140-
chain OlV
5 Draw in oil pump AR18.10-P-2140-
chain and rivet 02V
6 Install in the
reverse order
@ Risk of accident Secure vehicle to prevent it from moving by ASOO.OO-Z-0005-
7 caused by vehicle itself. OlA
starting off by Wear closed and snug-fitting work clothes.
itself when engine Do not grasp hot or rotating parts.
is running. Risk of
injury caused by
contusions. and
burns during
starting procedure
or when working
near the running
engine
Run engine and
inspect for leaks
Separate oil pump chain - ARIS.IO-P-2140-0IV
;;--
- '
~
;;:::.-
~
002 ssg 00 98 00
' Cutt
./
Fi~. 45: Identifyine Case (602 589 00 98 00)
......,
/
~
602 500 05 53 00
' Th iU~ sptndle

./
F ig. 46: Identifying T hrust Suindle (602 589 OS 63 00)

Mercedes-Benz
602 589 02 33 00
Fig. 47: ldentifving Chain Separating Tool (602 589 02 33 00)
602589056301
lluu s.1 pim
Fig. 48: Identifying Thrust Pins {602 589 OS 63 01)
l. &oanqorl Screw pressure screw (02) &o.nqcrl with pressure pin (02a) &o.nq••' into chain-separating tool (03).
2. &oanqorl Fit chain separating too! (03) onto oil pump chain.
3. Screw in pressure screw (02) as far as necessary untiJ the &oanQer! c1ose1y at the oil pump chain pin
&oanQer!
(arrow).
4. &oanqor! Screw in pressure pin (02a) and press out oiJ pump chain pin.
P llt1 0-2922 02
Fig. 49: ldentifying Pressure Screw, Pressure Pin And Chain Spring Tool
Mercedes-Benz
5. Unscrew &oana••' pressure screw (02) and remove &oanoort chain separating tool (03).
6. Remove oil pump chain pin (1) from &o""""'' chain separating tool (03).
PCI5.10,(l27Hl1
Fig. 50: ldentifying Pressure Screw And Chain Spring Tool
Rivet oil pump chain- AR18.10-P-2140-02V
Fig. 51: ldentifving Case (602 589 00 98 00)
Fig. 52: Identifying Riveting tool (602 589 00 39 00)

Mercedes-Benz
103 589 01 63 00
Fig. 53: ldentifving Assembly inserts (602 589 01 63 00)
602 589024000
Fig. 54: Ideotifying Assembly links {602 589 02 40 00)
l. Connect new oil pump cbain (2) and old oil pump chain (1) with &oanacrl assembly clip-type fastener (3)
2. Slowly ro tate crankshaft in direction of rotation of engine (arrow) until it is possible to connect the ends
of the new oil pump chaín (2).
3. Unbook old oil pump chain (1).
P 18.10 2lll23 0 1
Fig. 55: ldentifying Oill Pump Chain And Clip-Type Fastener
4. ~ Connect the ends ofthe new oil pump chain (2) with the riveted link (4) Insert riveted link (4) from the
front.
Mercedes-Benz
P18.10 2ll~ 01
Fig. 56: Identifying Oill Pump Chain And Riveted Link
5. &oanoerl Place guide piece with the digít F2 into the &oanQcrl press-on tool (arrow) and fix with bolt (28)
P 18. Hl02230 1
Fig. 57: Locating Guide Piece With Press-On Tool
6. Place moveable &oanQer! thrust piece with the digit 2 (arrow) into &oanQer! the press-on tooL
P 18 .10 !12~ 01
Fig. 58: Locating Thrust Piece And Press-On Tool
7. Place outer plate into the &oanoe•• thrust piece with the digit 2 (arrow).
Mercedes-Benz
P 18. 100225 01
Fig. 59: Locating Outer Plate And Thrust Piece
8. &o.na••' Fit on press-on tool in such a way, that the rollers of the riveted link (4) are resting on the distance
web (arrow).
9. &o""""'' Tighten spindle (6) up to solid resistance.
~ &0a"""'' When turning the spindle (6) ensure, that the pins of the riveted link (4) are inserted in the
boles ofthe outer plate (5).
10. &oanaer! Remove press-on tool.
PIS.I~&CI
Fig. 60: Locating Rollers OfRiveted Link
11 . & oanaer! Tum thrust piece with the digit 2 onto ri vet profile (arrow).
Mercedes-Benz
P 18.10-0226 O1
Fig. 61: Locating Thrust Piece With Digit 2 Onto Rivet Profile
12. &oanoerl Fit on press-on tool in such a way, that the pin is located exactly in the míddle ofthe V-type
support (arrow)_
13. &oanoe•' Tighten spindle (6).
~ The torque at the &oanqer! spíndle (6) amounts to approx. 30-35 Nm (reference value).
14. Rivet pins ofriveted link individually
P18.1 Oo:2026-tl 1
Fig. 62: Locating Spindle
15. ~Check rivets (arrows) ofpins, ífnecessary rivet píns agaín_
POS. Ul 02 111 0 1
Mercedes-Benz
Fig. 63: Locating Rivets Of Pins
REMOVE, INSTALL OIL PRESSURE RELIEF VALVE- AR18.10-P-5031GV
ENGINE 112
ENGINE 112.945 in model 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in model463.206 /240/241/247/248/249/254
ENGINE 113.982 in model463.243 /246
ENGINE 113 in model129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Sbown on engine 112
1 0/1 fJM1 bottom4<>erion

2 011 pump wl lh oH prouure reliel valvo
3 011 rolllm shutoff vlllvt>
4 Solls of oll ptmp
Fig. 64: Identifving Oil Pressure ReliefValve Remove/lnstall Components- Shown On Engine 112
¡g][$='BT Remove/install
@ Risk of deatb Align vehicle between the columns of the ASOO.OO-Z-0010-
caused by vehicle lifting platform and position the four support OlA
slipping or plates at the lifting platform support points
toppling off of the specified by the vehicle manufacturer.
lifting platform.
1 Remove oi1 pan
bottom section ( 1) Engine 113.988 in model203.076/ 276 AR01.45-P-
Engine 113.989 in model171.473 7555AC
Engine 112.975, 113.948 /966 in model220, AR01.45-P-
engine 112.917 inmodel211.080/280 7555IW
Mercedes-Benz
Engine 112.954 in model211.082 /282

Engine 113.969 in model211.083 /283
Engine 112.912 in model203.061 /261, AR01.45-P-
209.361 /461 with transmission 722.6, 716.6, 7555PV
engine 112.946 in model203.064 /264 with
transmission 722.6
Engine 112.955 in model 209.365/ 465 with
transmission 722.6
transmission 722.6
Engine 112.913 in model 211.061 with
transmission 716.6, 722.6
Engine 112.949 in mode1211.065 with
transmission 722.6
Engine 113.967 in model211.070 with
transmission 722.6
Engine 112 in model 203.081 /084 /281 /284 AR01.45-P-
7555PW
Engine 113.990 in rnodel211.076 /276
Engine 113.991 in rnodel215.374, 220.074/
174
Engine 112.973 in rnodel230 AR01.45-P-
7555RA
Engine 112.942 in model163.154 AR01.45-P-7555V
250 7555VA
Engine 112 in model129, 170, 202, 208, 210,
engine 113.962 in model
463.206 /240 /241 /247 /248 /249 /254
Engine 113 in model129, 202, 208, 210
Engine 113.982 in model463.243/ 246
Engine 113 except 113.966 /948 in mode1220
Engine 113.993 in rnodel463.270/ 271
Engine 113.965 in modell63.175 AR01.45-P-
Engine 113 .981 in model163.174 7555VE
2.1 Remove oil pan Model211.061 / 065/ 070 AR01.45-P-
Mercedes-Benz
top section Model230.472/ 474/ 475 7500TV

AR01.45-P-7500R
3 Remove oil pump ~ Installation:
(2)
o Ensure oil return flow check valve (3) is
o Clean the oil pump strainer.
o Fill the oil pump with engine oil before
installing, so that oil is delivered at the
initial startup.
Engine 112.945 in model463.209/ 232/ 233// AR18.10-P-
250 6020B
Engine 112 in model210, 208, 202, 170, 163,
129
Engine 113.962 in model463.///254
Engine 113 in model210, 208, 202, 163, 129,
engine 113.982 in model463.243 /246
Engine 113 except 113.948 /966 in model220
Engine 111.951 inmodel203.035 /235/735, AR18.10-P-
engine 111.955 in model203.045 /245 /745 , 6020PV
engine 112.912 in model203.061 /261 ,
209.361 /461
Engine 112.946 in model203.064/ 264
Engine 112.961 in model203.065/ 265
Engine 113.968 in model209.375 /475
Engine 112.913 in Model211.061
Engine 113.987 in model209.376 /476
Engine 112.955 in model209.365 /465
Engine 112.917 in model211.080 /280
Engine 112.954 in model211.082 /282
Engine 113.969 in model211.083 /283
Engine 113.988 in model203.076/ 276
Engine 113.989 in model 171.. 4 73
Engine 112 in model 203.081 /084 /281 /284, AR18.10-P-
220.087/ 187 6020PW
Engine 113 in mode1220.083 /084/183 / 184
Engine 113.963 in mode1230.475 AR18.10-P-6020R
Engine 113.990 in model211.076 /276
Engine 113.991 in model215.374, 220.074/
174
Engine 113.993 in model463.270/ 271
Mercedes-Benz

6020RA
4 Replace oil ~ The oil pressure relief valve is supplied
pressure relief together with the oil pump for repair purposes.
valve It is therefore not necessary to disassemble the
oil pump.
5 Install in the
reverse order
@ Risk of accident Secure vehicle to prevent it from moving by ASOO.OO-Z-0005-
6 caused by vehicle itself. OlA
starting off by Wear closed and snug-fitting work clothes.
itself when engine Do not grasp hot or rotating parts.
is running. Risk of
injury caused by
contusions and
burns during
starting procedure
or when working
near the running
engme
Run engine and
inspect for leaks
REMOVE/INSTALL OIL PUMP- AR18.10-P-6020B
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODELS 210, 208, 202, 170, 163, 129
ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODELS 210, 208, 202, 163, 129
ENGINE 113.982 in MODELS 463.243 /246
ENGINE 1131 (except 113.948 /966) in MODEL 220

Mercedes-Benz
1 Off pan boltom "'c!lon

2 0/Jpump
3 011 r&tum sturott vii/ve
4 Sollo of oll pump
PIB. IO 02~1<118
Fig. 65: Identifying Oil Pump Remove/Install Components- Shown On Engine 112
[g_J~BT Remove/install
1 Remove oíl pan bottom Models 163.154, 163.172 AR01.45-P-7555V
section (1) Models 163.174 ARO 1.45-P-7555VE
Models 463, 220, 210, AR01.45-P-7555VA
208, 202, 170, 129
2 Remove bolts (4) &.oenaer! Screwdriver Fig. 66
hinged bit
~ Bolt, oil pump to *BA18.10-P-1001-01B
crankcase
3 Turn back chain tensioner
and take off chain
4 Remove oil pump (2) 1JJ Installation:
o Ensure oil retum
flow check valve
(3) is correctly
ínstalled.
o Clean strainer of
oil pump (2)
o Fill oil pump (2)
with engine oil
before installing so
that it delivers oil
at the initial
startup.
o On engine 113.960
Mercedes-Benz
with code 479 an

oil pump with a
higher delivery is
installed; pay
attention to this
when replacing oil
pum p.
Pay attention to notes in

order to ensure proper
lubrication of engine!
m
pump
1
Number Designation Engines Engine Engine

112.910/911/914/915 1 112.912/ 112.913/
916/920/921/922/923 1 946/960 917/949/
940/941/942/943/944 1 954/955
945/947/953/973/975
BA 18. 10-P- Bolt, oil M8x30 Nm 20 20 20
1001 -01B pump to M7X40 Nm - - -
crankcase M6x 16 Nm - - -
, .. 0'11 pump
~
112.948 112.951/ 112.961
976 AMG
BA I 8.10-P- Bolt, oil pump M8x30 Nm 20 20 20
1001 -0l B to crankcase M7X40 Nm - - -
M6xl6 Nm - - -
m
pump
1
Number Designation Engines 113.962/940/941/ E ngine Engine
942/943/944/948/960/ 113.963/ 113.968
961/965/966/980/981/ 967/9691
982/984/986/992/995 987/988 1
990/991 1
993
BA I 8. 10-P- Bolt, oil M8x30 Nm 20 20 20
1001 -0lB pump to M7X40 Nm - - -
crank.case M6x16 Nm - - -
Mercedes-Benz
Fig. 66: ldentifving Screwdriver Hinged Bit (112 589 00 10 00)
REMOVING/INSTALLING THE OIL FILTER HOUSING- AR18.20-P-3471B
ENGINE 112.945 in MODELS 463.232 /233 /245 /244 /250 /209
ENGINE 113.962 in MODELS 463.206 /240 /254 /247 /248 /249 /241
ENGINE 113 (except 113.965 /981) in MODELS 163,202, 129, 210, 208
ENGINE 113.982 in MODELS 463.246 /243
1 ll'fSCOU$ fl>11
2 F11116/YOud
3 OILIN»tM heat &Xch.ng"'
4 Cover
5 011 flhr houslng
f Sealngñng
1
7 Ollfl~•rwernenr
3 Soll
9 Solts
'
,,.~
Fig. 67: ldentifving Oil Filter Housing Removellnstall Components- Shown On E ngine 112 Without Air
Pump
[g]I($"BT Removing/insta Uing

1 Remove engine cover or air ~ Remove engine trim
fllter panel or air filter by
Mercedes-Benz

offthe cylinder head
covers.
2.1 Remove viscous fan (1) Engine 113 AR20.40-P-5660C
~ Right-hand thread.
3.1 Remove fan shroud (2). Engine 113
~ On model 163
unscrew bolts at
bottom of fan shroud.
Model463 AR20.40-P-6800V
4 Unscrew cap (4) at oil filter ~ Screw cap at oil *BA18.20-P-1001-01D
housing (5) filter
5 Unscrew bolts (9) of oil-water ~ Do not pinch off AR18.30-P-3481C
heat exchanger (3) at oil filter coolant lines.
housing (5)
6 Remove bolt (8) at oil filter ~ Bolt for oil filter *BA18.20-P-1002-01D
housing (5) housing on timing case
7 Remove oil filter housing ( 5) ~ Installation:
Replace seal (6).
8 Instan in reverse order
9.1 Check engine oillevel ~ Of oil level
measurement is made
using a workshop oil
dipstick
Engine 112.923/943 in AR18.00-P-303 5-01G
model129
Engine 112.942/970 in
modell63
Engine 113.940 in AR18.00-P-3035-0ll
model 21 O witbout 4-
MATIC
Engine 113.943 in
model208
Engine 11 3.944 in
model202
Engine 113.961 in
model129
Engine 113.940 in AR18.00-P-3035-01N
model210 4 AMG
Engine 113.984 in AR18.00-P-3035-01 IA
model 208 AMG
Engine 113.980 in
model 21 O AMG
10.1 Check engine oillevel ~ Of oillevel
Mercedes-Benz
measurement is made
using the vehicle oil
dipstick.
Engines 112, 113 in
models 208, 210, 463
Engine 112.923/943 in
modell29
Engine 112.942/970,
113.942 in modell63
ITl The vehicle must be
positioned horizontally
on the wheels,
otherwise false
measurements can
occur.
~ Oil filter
Number Designation Engines Engines
112.910/911/912/ 113.940/941/
913/914/915/ 942/943/944/
916/917/920/ 945/946/948/
921/922/923/ 960/961/962/
940/941/942/ 963/965/966/
943/944/945/ 967/968/969/
946/947/949/ 980/981/982/
951/953/954/ 984/986
955/960/961/
970/972/973/975
BA18.20-P-100 1- Screw cap on oil N m 25 25
OlD filter
BA18.20-P-1002- Bolt for oil filter N m 70 70
OlD housing on timing
case
REMOVE/INSTALL OIL/WATER HEAT EXCHANGER AT OIL FILTER- AR18.30-P-3481C
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 (except 113.965 /981) in MODELS 210,208,202,163, 129
ENGINE 113.982 in MODELS 463.243 /246

Mercedes-Benz
Vl1scou.s fan
Fanstroud
J Csp ol o/1 fl~er housl~
4 Coo/ant 1/n e
5 Ct>olanttrne
6 OiMNilter h..at &xchanJJer
7 Sell1'ng lings
Fig. 68: Identifying Oil/Water Heat Exchanger At Oil Filter Components - Shown On Engine 112
Without Air Pump
[g] te:rer Remove/install

1 Remove engine cover or ~ Remo ve engine trím
air filter panel or aír filter by
off the cylinder head
covers.
2 Remove viscous fan (1) ~ Right-hand thread! AR20.40-P-5660C
3 Remove fan shroud (2). ~ On modell63 AR20.40-P-6800V
of fan shroud.
Model463
4.1 Remove oil pipes at oil- ~ Only models 463.243/ AR18.30-P-6840-03MG
water heat exchanger 246.
5 Unscrew oil ftlter housing ~ *BA18.20-P-1001-01D
cover (3) ~ oanaer! Socket Fig. 8
@ Risk of injury to skin and Do not open cooling AS20.00-Z-0001-01A
eyes caused by scaldíng system unless coolant
from contact with hot temperature ís below 90°
coolant spray. C. Open cap slowly and
Risk of poisoning from release the pressure. Do
swallowing coolant. not pour coolant into
W ear protectíve gloves,
protective clothing and
safety glasses.
Mercedes-Benz
6 Drain coolant from ~ model 163: For AR20.00-P-1142HA

radiator drain ing coolant, remove
bottom coolant line at
rad iator or at coolan:t
pump.
7 Remove coolant line (4,
5) at oil-water heat
exchanger (6)
8.1 Remove air pump ~ Only for engines wíth
air pump.
Models 163, 202, 208, AR14.30-P-7251A
210
Model 129 with engines AR14.30-P-7251AA
112, 113
Model463 with engine AR14.30-P-7251AG
112, 113
9 Detach oil-water heat ~ Installation: Install *BA18.30-P-1001-01B
exchanger ( 6) at oil filter new sealing rings (7).
housing ~
11 Inspect cooling system for AR20.00-P-1010HA
leaks
~ Oil filter
Number Designation Engines Engines
112.910/911/912/ 113.940/941/
913/914/915/ 942/943/944/
916/917/920/ 945/946/948/
921/922/923/ 960/961/962/
940/941/942/ 963/965/966/
943/944/945/ 967/968/969/
946/947/949/ 980/981/982/
951/953/954/ 984/986
955/960/961/
970/972/973/975
BA18.20-P-1001- Screw cap at oil Nm 25 25
01 D filter
~ Oil cooling system

Number Designation Engines Engines Engines
112.910/911/ 113.940/941/ 113.987/
912/913/914/ 942/943/944/ 988/991/
915/916/9171 945/946/948/ 995
920/921/922/ 960/961/962/ E ngine
923/940/941/ 963/964/965/ 113.992
Mercedes-Benz
942/943/944/ 966/967/968/ without code

945/946/9471 969/971/980/ 030
949/951/953/ 981/982/984/
954/955/960/ 986
9611970/972/
973/975/976
BA18.30-P- Oil-water heat N m 11 11 9
1001-01B exchangerto
oil filter
housing
~o·•
1 coo lin1g sys t em
Number Designati.on Engine 113.990 Engine 113.992
with code 030
BA18.30-P-1001- Oil-water heat Nm 9 9
OlB exchanger to oil
filter housing
103 589 02 09 00
Wrem:il.....:lu!!
Fig. 69: ldentifving Wrench socket (103 589 02 09 00)
REMOVE/INSTALL OIL DIPSTICK GUIDE TUBE- AR18.40-P-3510BV
ENGINE 112 /, 113 1(except, 112.912 /946 /961, 113.963 /995)
1 olt dpstlckguldo tube

2 o// dp•tickguldo tube bo/1
3 01p6tlck
' O.ring
5 Sea!
7 Tfutrap
PIS_,<O 2025-11
Mercedes-Benz
Fig. 70: Identifying Oil Dipstick Guide Tu be Components- Shown On Engine 112
1 oll clpsue/c gulde tube

ll Sol!
9 oll dp.s!lckgulde tube brocket
10 ol/ dfps!lckguld-. IIlbe brac/cel
n so•
PIIA1<2 17~1 P I8-"0 21 70-01
Fig. 71: ldentifving Oil Dipstick Guide Tube And Oil Dipstick Guide Tube Bracket- Shown On Engine
113.989
[g_J~BT Remove/install
@ Risk of death caused by Align vehicle between ASOO.OO-Z-0010-01A
vehicle slipping or the columns of the and
topp ling off the lifting position the four support
platform_ plates below the lifting
platform support points
specified by the vehicle
manufacturer _
1 Remove lower engine Models 210, 208, 202, AR61.20-P-11 OSAB
compartmentpaneling 129
Model230 AR61.20-P-1105R
Models 163.172/ 174/ AR61.20-P-1105GH
175
Model211 AR6L20-P-1105T
Model1 70 AR6L20-P-1105A
Model171.4 AR61.20-P-1105V
Model203, 209 AR6L20-P-1105P
Model215, 220 AR61.20-P-1105M
Model219.375 AR6L20-P-1105TX
Models 163.154/ 157
Model219.376
2.1 Remove engine cover or ~ Remove engine trim
air filter ¡panel or air filter by
lifting vertical!y up and
off the eylinder head
covers.
Model 170.466 AR09.10-P- 1150SVK
Models 203.065 1265
Models 211.076 1 276
Model215.374
Models 220.074/ 174
Mercedes-Benz
Model 230.474
Model219.375 AR09.10-P-1150TY
Modell71.473 AR09.10-P-1150AC
Models 203.076/ 276
Models 209.376/ 476 as
of24.4.04
3.1 Remove air ftlter housing ~ Only on vehicles with
air filter located on
vehicle side.
4.1 Remove bolt (8) on oil Model171.473
dipstick guide tu be (9)
Aoanqe,, Externa! Torx set Fig. 72
bracket
5.1 Remove bolt for oil Except model 171.473
dipstick guide tube (2) on ~ *BA01.20-P-1001-01E
cylinder head cover Aoanoer! External Torx set Fig. 72
5.2 Remove bolt (11) ou oil Model171.473

dípstick guide tu be ( 1O) ~ *BA01.45-P-1010-01B
bracket A Danaorl Externa! Torx set Fig. 72
6.1 Remove cable strap (7) at Except models

oil dipstick guide tube (1) 203.076 /276, 171.473
~ lnstallation: When
attaching the cable strap
(7) to the oil dipstick
guide tube (1 ), pay
attentiou to the routing of
the wiring 1oom.
6.2 Remove mounting clip for Models 203.076/ 276,
battery cable set to starter 171.473
and hook up cable set to
the side
7.1 Remove oil pan Models 203.076/ 276 AR01.45-P-7500PV
Model 171.473 AR01.45-P-7500VT
Models 211 061 / 065 AR01.45-P-7500TV
Models 211 261/ 265
8.1 Lift oil dipstick guide Except model 171.473
tube ( 1) up and out ~ Installation: Replace
se al (5) and 0-ring (4) of
oil dipstick guide tube (1)
and of dipstick (3).
8.2 Take oil dipstick guide Model 171.473
tube ( 1) down and out ~ lnstallation: Replace
seal (5) and 0 -ring (4) of
oil dipstick guide tube (1)
and of dipstick (3).
Mercedes-Benz
9 Insta U in the reverse order

@ Risk of accident caused Secure vehicle to prevent ASOO.OO-Z-0005-01A
10 by vehicle starting off by it from moving by itself
itself when engine is W ear elosed and snug-
procedure or when
engine
Run engine and inspect
for 1eaks
~ Crankcase ventilation, cylinder head cover

Number Designation Engines Engines 113.940/ Engines
112.910/911/ 9411942/943/ 113.987/988/
912/913/914/ 944/948/960/ 990/991/993
915/916/917/ 961/962/963/
920/921/922/ 964/965/966/
923/940/941/ 967/968/969/
942/943/944/ 971/980/981/
945/946/9471 982/984/986/
949/951/953/ 992/995
954/955/960/
961/970/972/
973/975/976
BA01.20-P- Bolt for Nm 8 10 8
1001-0 lE cylinder head
cover
~Oilpan
BA01.45-P-1010- Mounting bolt, oil M6 Nm
01B dipstick guide tube M
to crankcase 8
l 30
001 589 78 09 00 '

'~------------//
Fig. 72: Identifying External Torx set (001 589 76 09 00)

Mercedes-Benz
REMO VE OIL LEVEL SENSOR, INST ALL - AR18.40-P-5111A
ENGINE 112 (except 112.912 /946 /961)
ENGINE 112
ENGINE 113
ENGINE 113 (except 113.968 /963 /992)
1 Oif p iHI, b ono m pan

2 Olf4evel $tflsorserews
3 Ptug foroitleve! son sor
$43 Olfleve! sensor
P IB..<o~•• .oe
Fig. 73: Identifying Oil Level Sensor Components - Shown On Engine 112
Modification notes
20.12.04 Engine oil filling capacity Engine 113.967 *BF18.00-P-1001-01H
with oil filter modified.
[g]n=:rer Remove/install
@ Risk of deatb caused by A lign vebicle between ASOO.OO-Z-0010-0lA
vebicle slipping or the columns of the lifting
toppling off ofthe lifting platform and position the
platform. four support plates below
the lifting platform
support points specified
by the vebicle
manufacturer.
1 Evacuate engine oil, drain ~ *'BA01.45-P-1003-01B
0 *BF18.00-P-1001-01H
[l] *WE58.40-Z-1005-22A
Mercedes-Benz
2 Remo ve lower part of oil Models 129, 170, 202, AR01.45-P-7555VA

pan (1) 208,210, 220, 463
Models 163.154, 163.172 AR01.45-P-7555V
Model163.174 AR01.45-P-7555VE
3 Unplug connector (3) at
oillevel sensor
4 Unscrew bolts of oil level ~ *BA18.40-P-1002-01B
sensor (2)
5 Remove oil level switch
(S43)
m
• .pan
112.910/911/ 112.916/953/975,
912/913/914/ 113.948/966
915/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
951/954/955/
960/961/970/
972/973/976
BA01.45-P- Oil drain Ml4 Nm 30 30
1003-01B screw to oil
pan
pan
1

113.940/941/ 113.987/ 113.990
942/943/944/ 988/991
945/946/960/
961/962/963/
965/967/968/
969/980/9811
982/984/986/
992/995
BA01.45-P- Oil drain Ml4 Nm 30 30 30
1003-01B screw to oil
pan
~ Oillevelloil ressure sensor

N umber Designation Engine Engine 112 except
113.940/941/ 112.916/951/95 3/975
Mercedes-Benz
942/943/944/
945/946/960/
961/962/963/
965/967/968/
969/980/981/
982/984/986/
992/995
BA18.40-P-1002- Oillevel sensor on Nm 10 10
OlB oil pan top section
~ 0'11
1 eve11oil pressure sensor
Number Designation Engine 113.987/ Engine 113.991/

988/990 993
BA18.40-P-1 002- Oillevel sensor on N m 10 9
01B oil pan top section
CDE.
ngme lb'
u ncahon
Number Designation Engine 112 except Engine Engine
112.916/953/975 112.916/953 112.975
BF18.00-P- Engine oil Filling capacity Liters 8.0 7.5 8.0
1001-01H with oil filter
Filling capacity Liters 7.5 7.0 7.5
without oil filter
Specifications for Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
Operating Fluids OlA 0229-0lA 0229-0lA
Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
03A 0229-03A 0229-03A
Sheet BB00.40-P-0229- BB00.40-P- BB00.40-P-
OSA 0229-0SA 0229-0SA
CDE.
ngme lb'
u ncabon
113.948/966 113.940/941/ 113.944/980/98
942/943/960/ 1/984/986/991
961/962/969/
982
1001-0IH with oil filter
Filling capacity Liters 7.5 - -
without oil filter
Specifications Sheet BB00.40-P- BB00.40-P- -
for Operating 0229-0lA 0229-0lA
Fluids Sheet BB00.40-P- BB00.40-P- -
0229-03A 0229-03A
Mercedes-Benz
Sheet BB00.40-P- BB00.40-P- BB00.40-P-0229-

0229-0SA 0229-0SA OSA
0Engme
. lb.
u nca fIon
113.963/ 113.967 113.987/988/
963/96S 990/992/993/ 99S
1001 -01H with oil filter
Filling capacity Liters 7.0 - 8.0
without oil filter
Speci:fícations for Sheet BB00.40-P- BB00.40-P- -
Operating Fluids 0229-0lA 0229-0lA
Sheet BB00.40-P- BB00.40-P- -
0229-03A 0229-03A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-0229-
0229-0SA 0229-0SA OSA
Engine oil extractor
MA~ NTENANCE
ENGINE OIL AND FILTER CHANGE- AP18.00-P-0101
Engine oil and filter change- AP18.00-P-0101AA
ENGINE 601, 603, 103
ENGINE 602, 604, 60S, 606, 104, 111, 119, 120 witbout ASSYST
~BT¡gj Remove/install/replace
@ Risk of accident caused by Secure vehicle to prevent it ASOO.OO-Z-OOOS-0 lA
vehicle starting offby itself from moving by itself
when engine is running. Risk Wear closed and snug-fitting
of injury caused by work clothes.
contusions and burns during Do not grasp hot or rotating
starting procedure or when parts.
working near the nmning
engme
~ ~ Change the engine oil only
when the engine is at
1.1 Remove air filter Engine 104.990 in model ra09lh1 041051 x
Mercedes-Benz
140
L2 Remove air filter housing Engine 119.985 in model
210
L3 Detach air hose from air filter Engine 119 except engine
119.985
1.4 Remove left-hand air filter Engine 120 AP18.00-P-0101-0SF
housing
2.1 Replace oil filter element, ~ Engine 601 in model 124 AP 18.00-P-0 1O1-06EB
drain oil filter Engine 601 in Model 202 to
12/94
Engine 604 in Model 202 up
to 05/94
to 11/94
to 06/94
~ Engines 603, 606 in AP 18.00-P-0 1O1-06EC
model124
~ Engine 601 in Model 202 AP 18.00-P-0 1O1-06EE
as ofOl/95
from 06/94
Engine 605 in Model 124 as
of 12/94
Engine 605 in Model202 as
of07/94
Engine 602, 604, 605, 606 in
mode1210
& oanacrl ~ Engine 104, 111, AP18.00-P-0101-06ED
120
& oanQer! ~ Engine 119 AP18.00-P-0101-06EA
2.2 Replace spin-on filter ~ Engine l03
&oanacr! AP 18.00-P-0 1O1-01 BA
3.1 Install air filter Engine 104.990 in model ra09lh1 041 051x
140
Engine 119.985
3.2 Attach air hose to a ir filter Engine 119 except engine
119.985
3.3 Installleft-hand air filter Engine 120
housing
4.1 Suction off engine oil If the engine oil is not
drained by removing the oil
Mercedes-Benz
drain screw.
Engine 601 , 602, 603, 604, AP18.00-P-0101-02Z
605, 606
Engines 103, 104
Engine 111 except engines
111.943/944/973/975
Engines 119, 120
Engine AP 18.00-P -0 1O1-02ZA
111.943/944//973/975
5.1 Remove bottom section of After draining the engine oil
soundproofing by removing the oi1 drain
screw.
Vehicles with diesel engines
Model124.1 /3 wh9490pkw0000x
Modell40.1 ra94001405305x
Model202 AR94.30-P-5 300A
Model210 AR94.30-P-5300AB
5.2 Detach lower engine After draining the engine oil
cornpanmnentpanelll1g by removing the oil drain
screw.
Vehicles with gasoline
engmes
Model 124.0/2 wh6190pkw0000x
Model129 wh6190pkw0000x
Modell40.0 wh6190pkw0000x
Models 170,202 AR61.20-P-1105A
6.1 Drain engine oil After draining the engine oil
by removing the oil drain
screw.
Engine 601 , 602, 603, 604,
605, 606
Engine 103, 104, 111 , 119,
120
Model 124.3 (4MATIC) AP18.00-P-O 1O1-03CA
7.1 Screw in oil drain screw After draining the engine oil
by removing the oil drain
screw.
LGoanQerl Replace seal
~ Engines 103, 104, 111 , *BA01.45-P-1003-01A

119, 120, 601 , 602, 603,
604,605,606
Model 124.3 (4MATIC) AP18.00-P-O 1O1-03CA
8 Pour in engine oil ~ Use only approved
engine oils
Mercedes-Benz
~' Specifíed and approved AH engines AH18.00-P-1000-01BA

quality grades and viscosity
classes conforming to SAE at
enduring low outside
temperatures
~' Notes concerning extension AH18.00-P-0102-01A
of the oil change interval
Eng ine 103, 104, 111 , 11 9, *BE18.00-P-1001-02A
120
Engine 601, 602, 603, 604, *BE18.00-P-1001-02B
605, 606
Q) Engines 103, 104, 119, *BF18.00-P-1001-0IB
120
0 Engine 111 *BF18.00-P-1001-01L
Q) Engine 601, 602, 603, *BF18.00-P-1001-01A
604, 605, 606
0 Service lnformation: Engine SI18.00-P-0011 A
oil change
@ Specified engine oils (service) BB00.40-P-0223-02A
- survey
@ Approved engine oils Passenger cars engines BB00.40-P-0226A
(service)
9 Run engine and inspect for
leaks
10 Tum off engine
11.1 Instan bottom section of After draining the engine oil
soundproofing by removing the oil drain
screw.
Vehicles with diesel engines
Model124.1 /3 wh9490pkw0000x
Model140.1 ra94001405305x
Model 202 AR94.30-P-5300A
11.2 Jnstall lower engine After draining the engine oil
compartment paneling. by removing the oil drain
screw.
Vel::ticles with gasoline
engmes
Modell24.0/2 wh6190pkw0000x
Model l 29 wh6190pkw0000x
Model140.0 wh6190pkw0000x
Models 170,202 AR61.20-P- 1105A
12 Check oillevel approx. 2 min Engine 103, 104, 111 , 11 9, *BE18.00-P-1001-02A
Mercedes-Benz
after switching offwarm 120

engme
Engine 601, 602, 603, 604, *BE18.00-P-1001-02B
605, 606
~
Insert dipstick fully and
leave in this position for at
least 3 seconds
T est v a1 ues t or engme 1u b ncatwn

. - genera
Number Designation E ngine Engioe E ngine
103.985 104.941/94 2/943/945/980/98119911992/995 104.944/990/994
BE18.00- Oil Numbers.Number- 10407 60322
P-1001- dipstick on
02A marking handle
Color = >
red 1
Color ==>
gray 2 Rouncl Color - - -
handle
Bottle Color 1 1 1
opener-
shaped
handle
T est val ues t or engme lu b nca

. f 100 - general
Number Designation Engine E ngine Engine
111.92/94/952/956/957/958/96/97/98 111.95/955 119.96/97
BE18.00- Oil clipstick N umbers Number 11102 11107 -
P-1001 - marking on
02A handle
Color = > 1
red
Color >2
gray Round Color - - -
handle
Bottle Color 1 1 2
opener-
shaped
handle
Test val ues t or engme 1u b ncat10n

. - general
119.98 120.980/982 120.9811983
Mercedes-Benz
BE18.00-P- Oil dipstick marking Numbers on Number 11902 12010 12011

1001 -02A handle
Color red >1
Color >2
gray Round Color- - -
haudle
Bottle Color 1 1 1
opener-
shaped
handle
. fIon - general
Test va l ues tor engme lu bnca
Number Designation Engine 601 Engine Engine
602.96 603.960
603.962
BE18.00-P- Oil dipstick marking liumbers on Number - - -
1001 -02B handle
Color red ==> 1
Color black ==> 2
Color green ==> 3
Color ==> 4
gentian Round handle Color2 - -
blue Bottle Color - 3 2
opener-
shaped
handle
T est va1ues t or engme lu b ncatioo

. - general
Number Designation Engines Eogine Engine
603.913, 603.971 604 up to
603.963 09/95
BE18.00-P- Oil dipstick marking Numbers on Number - 60324 60400
1001 -02B handle
Color red > 1
Color black --> 2
Color ==> 3
green
Color blue = > 4
gentian Round handle Color - - -
Bottle Color4 1 1
opener-
shaped
handle
Mercedes-Benz
v ues t or engme lb
T estaJ u n"catwn - genera
Number Designation Engine 605 E ngine 606 Engine
up to 09/95 up to 09/95 602.982 up
to 04/97
BE18.00-P- Oil dipstick marking Numbers on Number 60500 60600 60214
1001-02B handle
Color red ==> 1
Colorblack = >2
Color green ==>3
Color ==> 4
blue Bottle Color 1 1 1
opener-
shaped
handle
E ngme u nca r1on, genera1

· lb.
Number Designation Engine E ngine 604 E ngine 605
602.982 as as of 10/95 as of 10/95
of05/97 up to 04/97
BE1.8.00-P- Oil dipstick marking Numbers on Number 60502 60402 60214
1001-02B handle
Color red ==> 1
Color black ==> 2
Color green ==>3
Color = >4
blue Bottle Color 1 1 1
opener-
shaped
handle
E ngme u nca r1on, genera1

· lb.
Number Designation E ngine 605 E ngine E ngine
as of OS/97 606.912 as 606.961
of 10/95
BE1.8.00-P- Oil dipstick marking Numbers on Number 60502 60604 60608
1001 -02B handle
Color red ==> 1
Color black = > 2
Color green = > 3
Color = >4
gentian Round handle Color- - -
blue Bottle Colorl1 ] 1
1
Mercedes-Benz
lopener-
shaped
handle
Test val ues f or engme lu brtcation

. - general
BE18.00-P- Oil dipstick marking Numbers on Number 60214
1001-02B handle
Color red = > 1
Color black ==> 2
Color green ==> 3
Color gentían ==> 4
blue Round handle Color-
Bottle opener- Color 1
shaped handle
Specified engine oil quality levels

Number Designation Eugine 103, 104,. Engine 601, 602,
111,112,119,120, 603,604,605,606
166
BE18.00-P-1001- Specified engine oil CCMC G4 D4
03A quality levels G5 D5
PD2
API ECU CE
CF-4
m
pan
1
Number Designation Engine 103 Engine 104 Engine 111 Engine 119
BA01.45-P- Oíl drain Ml2 N m 25 25 - 40
1003-0IA screw at oil M
pan
14 Nm25 30 30 -
1
m pan
1
Number Designation Engine 120 Engine 601, 602 Engine

except 602.982, 603.913/963
603 except
603.913/963
BA01.45-P- Oil drain M12 Nm 40 30 30
1003-0IA screw at oil
Ml4 N m- 25 25
pan 1
Designation Engine 604, 605,

Mercedes-Benz
606
BAOL45-P-1003- O il drain screw at Ml2 N m 30
OlA oil pan M14 1 Nm30
~E
m
·ngme 1u b ncation,
. 01·1 filt
1 'er
Number Designation Engine 601, Engines 604, Engine 603 Engine 606
602 except 605
602.982
BA18.20-P- Oil filter Nm 25 25 25 25
1001 -01 A cover fixing
nuts
BA18.20-P- Return tube in Nm - - 25 25
1002-0lA oil filter cover
BA18.20-P- Oil filter Nm 25 25 - 25
1003-0l A screw cap
BE ngme 1u b ncatwn,
m . 01.lfil
t ter
Nomber Designation Engine Engine Engine
103 104 111.920/921/940/941/942/943/944/945/946/947/951/952/955/956/957/9!
BA18.20- Spin- Nm 20 - -
P-1001- on
01B filter
BA18.20- Oil Nm- 25 25
P-1002- filter
Ol B screw
cap
BA18.20- Center Nm - - -
P- 1003- screw
OlB of oil
filter
cover
0 . 1u b n.ca f wn, oil filt er

E ngme
BA18.20-P-1001-01 B Spin-on fílter Nm-
BA18.20-P-1002-01 B Oil filter screw cap Nm 20
BA18.20-P-1003-01B Center screw of oil filter Nm-
cover
0 Engine lubrica tion system

N omber Designation Engine 601 Engine Engines
602.982 603.913/96/970
without
ASSYST
Mercedes-Benz
BFI8.00-P- Engine oíl Capacíty (oíl and Líters,6,0 6,5 7,5

1001-0lA filter change)
Specíficatíons for SheetBB00.40-P- BB00.40-P- BB00.40-P-0228-
Operating Fluids 0228-01A 0228-0lA OlA
Sheet BB00.40-P- BB00.40-P- BB00.40-P-0228-
0228-03A 0228-03A 03A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-0228-
0228-0SA 0228-0SA OSA
Sheet BB00.40-P- BB00.40-P- BB00.40-P-0229-
0229-0lA 0229-0lA OlA
Sheet B800.40-P- 8800.40-P- BB00.40-P-0229-
0229-03A 0229-03A 03A
Sheet 8B00.40-P- 8800.40-P- BB00.40-P-0229-
0229-0SA 0229-0SA OSA
Sheet BB00.40-P- BB00.40-P- BB00.40-P-0229-
0229-3 1A 0229-31A 31A
®E ngme
. 1u b.
ncation system
Number Designation Engine Engine 604 Engine 605
603.971 without without
ASSYST ASSYST
BF18.00-P- Engine oíl Filling capacity (oíl Liters 8,0 6,5 6,5
1001 -0IA and filter change)
Specifications for SheetBB00.40-P- BB00.40-P- BB00.40-P-
Operating Fluids 0228-0lA 0228-0lA 0228-0lA
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0228-03A 0228-03A 0228-03A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0228-05A 0228-05A 0228-05A
Sheet 8800.40-P- 8800.40-P- 8800.40-P-
0229-0lA 0229-0lA 0229-0lA
Sheet BB00.40-P- BB00.40-P- 8B00.40-P-
0229-03A 0229-03A 0229-03A
Sheet 8800.40-P- 8B00.40-P- BB00.40-P-
0229-0SA 0229-0SA 0229-0SA
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0229-31A 0229-31A 0229-3 1A
®E . lubnca
ngme ' f100 sys t em
Number Designa ti o u Engine 606.91
without ASSYST
BF18.00-P-1 001- Engine oil Filling capacity ( oil Liters 7,5
OlA and filter change)
Soecifications for 1 SheetBB00.40-P-0228-
Mercedes-Benz

Sheet BB00.40-P-0228-
03A
Sheet BB00.40-P-0228-
OSA
Sheet BB00.40-P-0229-
OlA
Sheet BB00.40-P-0229-
03A
Sheet BB00.40-P-0229-
OSA
Sheet BB00.40-P-0229-
31A
0E ngme
. lb.
u ncatJon system
Number Designation Engine Engine 104 Engine 119
103.98S
BF18.00-P- Engine oil Filling capacity (oil Liters 6,5 7,0 8,0
1001 -0lB and filter change)
Specifications for Sheet BB00.40-P- BB00.40-P- BB00.40-P-
Operating Fluids 0229-0lA 0229-0lA 0229-0lA
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0229-03A 0229-03A 0229-03A
Sheet BB00.40-P- BB00.40-P- BB00.40-P-
0229-0SA 0229-0SA 0229-0SA
0E ngme
. lb.
u ncabon system
BF18.00-P-1 001- Engine oil Filling capacity ( oil Liters 10,0
01B and filter change)
Specificatíons for Sbeet BB00.40-P-0229-
Sheet BB00.40-P-0229-
03A
Sheet BB00.40-P-0229-
OSA
CDc apac1hes of engme 1u b ncat1on

. system
Number Designation Engine Engines
111.92/94/9S2/956/957/958/96/97/982/983 111.951/951/95S
BF18.00- Engine Capacity Liters- 6.5
P-1001- oil without ftlter
01L Capacity withl Liters5.5 7.0
Mercedes-Benz
filter
Specifications Sheet BB00.40-P-0229-01A BB00.40-P-
for Operating 0229-0lA
Fluids Sheet BB00.40-P-0229-03A BB00.40-P-
0229-03A
Sheet BB00.40-P-0229-05A BB00.40-P-
0229-05A
11 1599 0 .2 01 on
Fig. 74: Box Wrench (117 589 02 07 00)
103 589 02 09 OD
Fig. 75: Wrencb Socket (103 589 02 09 00)
606 599 Ot 09 00
Fig. 76: Wrench Socket (606 589 01 09 00)

Mercedes-Benz
Fig. 77: Clamping Device {000 589 40 37 00)
Suction off engine oil- AP18.00-P-0101-02Z
l. Extract engine oil through oil dipstick guide tube.
~ Extract engine oil only when engine at normal operating temperature.
Fig. 78: ldentifying Suction OffEngine Oil- Sbown On Engine 104
Removing left air cleaner housing - AP18.00-P-0101-05F
Engine 120
l. Loosen clips (arrows).

2. Screw offnuts (1).
3. Pull off intake air temperature sensor (2) and purge val ve (3).
4. Remo ve air cleaner housing.
Mercedes-Benz
Fig. 79: ldentifying lntake Air Temperature Sensor, Purge Valve Aod Nut
Replacing oil fllter cartridge, draining oil fllter- AP18.00-P-0101-06EA
Eogioe 119
m ngme u b ncatwn,
. 01·•mter
BA18.20-P-1003-01B Center screw in oil filter Nm 20
cap
l. Loosen center screw (1) and remove together with oil filter cap (2).
2. Replace rubber sealing rings on oil filter cap.
3. Attach oil filter cap (2) and fasten with center screw (1).
Fig. 80: Identifying Oill F ilter Cap
Replacing oil filter cartridge, draining oil filter - AP18.00-P-0101 -06ED
Engines 104, 111, 120

Mercedes-Benz
BA18.20- Screw Nm25 25

P-1 002- cap on
OlB oil
filter
t03 SS!I 0 2 09 00
Fig. 81: Socket Wrench Attachment (103 589 02 09 00)
Engine 104 (plastic screw cap, new version)
Fig. 82: Identifving Plastic Screw Cap New Version
Engine 111
1'11Jl0.0017·01
Fig. 83: Identifying Aluminum Screw Cap Old Version
Enf.(ine 104 (oltl version, aluminum screw cap)

Mercedes-Benz
Fig. 84: ldentifving Plastic Screw Cap New Version (Engine 111)
Engine 120
Fig. 85: ldentifving Aluminum Screw Cap Old Version (Engine 120)
1.1 Engines 111.944/975 up to 08/96: remove boost air pipe, compressor, left.
2 Screw off screw cap (2) with socket wrench attachment 103 589 02 09 00 and remo ve oil filter cartridge
(4).
3 Replace sealing ring (3).
4 Insert new oil filter cartridge (4) into oil filter bousing (5).
5 Install screw cover, use socket wrench attacbment 103 589 02 09 OO.
Engine oil and filter change- AP18.00-P-0101AF
ENGINE 113.940 in MODEL 210 with 4-MATIC
ENGINE 113.943 /984 in MODEL 208

Mercedes-Benz
ENGINE 113.940/980 in MODEL 210 except 4-MATIC
ENGINE 113.941 /948 /960 /966 /986 in MODEL 220
Modification notes
20.12.04 Engine oil filling capacity Engine 113.967 *BF18.00-P-1001-01H
with oil filter modified.
26.6.06 Notes on operation step Engine 113.988 in model
3.1 and 3.2 added 203.076/276
[g].. Removal
@ Risk of death Align vehicle between the columns ofthe lifting ASOO.OO-Z-
caused by platform and position the four support plates at tbe 0010-01A
vehicle slipping lifting platfonn support points specified by the vebicle
or toppling off manufacturer.
of the lifting
platfom1.
1 Remove oil- ~ Only change engine oil and the oil filter on an AP18.00-P-
filter insert engine at a normal operating temperature. 0101-06EF
& Danacrl Socket wrench bit Fig. 8
2.1 Detacb lower ~ Only when draining the engine oil.
engme Model 211: Remove the rear section only.
compartment
paneling
~AP Removeand Model 129, 202, 208, 210 AR61.20-P-
install bottom UOSAB
engme
compartment
paneling
Model203, 209 AR61.20-P-
1105P
Model211 AR61.20-P-
l105T
Model215 , 220 AR61.20-P-
1105M
Model230 AR61.20-P-
1105R
3.1 Suction off 1JJ Model203.076/276: AP18.00-P-
engine oil Do not suction off en gioe oil The total quantity of 0101-02Z
Mercedes-Benz
engine oil cannot be suctioned off dueto the divided

oil sump. When refilling complete!y there is the threat
of engine damage due to overfilling
[l] *WE58.40-Z-
1005-22A
3.2 Drain engine oil OJ Model203.076/276: Always unscrew botb oil drain
screws, otherwise the total quantity of engine oil is not
drained. When refilling completely there is the threat
of engine damage due to overfilling
3.2 ~ Unscrew oil drain screw.
&oanaer! Fig. 74
I[3=' BT lnstall
4 Install oil ftlter AP18.00-P-
element 0101-06EF
~ *BA18.20-P-
1001-01D
&oanQer! Fig. 8
5 Pour in engine ~ Use only approved engine oils
oil
~' Specified and All engines AH18.00-P-
approved 1000-0lBA
quality grades
and viscosity
classes
conforming to
SAEat
enduring low
outside
temperatures
~' Notes AH18.00-P-
concerning 0102-0 lA
extension of the
oil change
interval
~ Oil drain screw to oil pan *BA01.45-P-
1003-01B
CD *BF18.00-P-
1001-0lH
.&. Danqer! Fig. 74
0 Service SI18.00-P-
Information: OOll A
Engine oil
change
<§) Specified BB00.40-P-
engine oils 0223-02A
Mercedes-Benz
(service)-
survey
<§) Approved Passenger cars engines BB00.40-P-
engine oils 0226A
(service)
@ Risk of Secure vehicle to prevent it from moving by itself ASOO.OO-Z-
accident caused Wear closed and snug-fitting work clothes. 0005-0lA
by vehicle Do not touch hot or rotating parts.
statting off by
itselfwhen
engme ts
running. Risk
of injury
caused by
contusions and
bums during
starting
procedure or
when working
near the engine
as it is running
6 Check for leaks
with engine
runnmg
7.1 Installlower ~ Only when the engine oil was drained out.
engme
compartment
paneling.
~AP Remove and 11odel 129,202,208,210 AR61.20-P-
install bottom UOSAB
engine
compartment
paneling
Model 203,209 AR61.20-P-
ll05P
11odel211 AR61.20-P-
ll05T
Model215, 220 AR6 1.20-P-
ll05M
11odel230 AR61.20-P-
1105R
~ Checking
8.1 Check oillevel ~ Checking the oil level using an oil dipstick with a
scale.
~AP Check oillevel Engine 113.968 in model 209 AR18.00-P-
Engine 113.967 in model211 3035-0 I ce
Mercedes-Benz
Engine 113.963 in Model230

Engine 113.941/960 in model 220 except 4-MATIC AR18.00-P-
3035-01D
Engine 113.960 in mode1215
Engine 113.940 in model210 except 4-MATIC AR18.00-P-
Engine 113.943 in model208 3035-011
Engine 113.944 in model202
Engine 113.940 in mode1210 4-MATIC AR18.00-P-
3035-01N
Engine 113.969 in mode1211 4-MATIC AR18.00-P-
3035-0liW
Engine 113.948/966 in model220 4-MA TIC
Engine 113.984 in model208 AMG AR18.00-P-
3035-0IIA
Engine 113.980 in mode1210 AMG
Engine 113.988 in model203 AMG AR18.00-P-
Engine 113.987 in model209 AMG 3035-01PA
Engine 113.986 in model215, 220 AMG AR18.00-P-
3035-0lCB
9.1 Check oillevel ~ Checking the oil level using au oil dipstick with a
number identification.
Engine
113.940/941/943/948/960/961 /966/944/980/984/986
Dipstick marking *BE18.00-P-
1001-02C
10.1 Check oillevel ~ Checking the oillevel over the control system.
~AP Perform Model211 AR54.30-P-
adjustmeuts to 1000-020PT
the control
system
Model220,230 AR54.30-P-
1000-020PM
11.1 Reset service Model211 up to 31.8.03 AP00.20-P-
iudicator 0042T
Model211 as of 1.9.03 AP00.20-P-
0042TA
Model220, 230 AP00.20-P-
0042M
~' Notes AH18.00-P-
concernmg 0102-0lA
extension of the
oil change
interval
0 Service SI18.00-P-
Mercedes-Benz
llnformation
Engine oil
cbange
Test val ues t or engme 1u br1cation

. - genera
113.940/9411942/943/948/960/961/966 113.962/982 113.944/964/980/9811984/986/9
BE1 8.00- Oil N umber 11300 11309 11304
P-1001- dipstick on grip
02C marking
m
1 pan
113.940/9411942/943/944/945/946/960/9611962/963/965/967/968/969/980/9811982/9~
BA01.45- Oil M14Nm 30

P-1003- drain
Ol B screw
to oil
pan
~ Oil filter
Number Designation
113.940/941/942/943/944/945/946/948/960/9611962/963/965/966/967/968/969/980/981/
BA18.20- Screw Nm
P-1001- cap at
OID oil
filter
0E ngme
. 1u b.
nca t"1on
113.948/966 113.940/941/942/943/960/961/962/969/982 113.944/980/981
BF18.00- Engine Filling Liters 8.0 8.0 7.5
P-1001- oil capacity with
OlH oil filter
Filling Liters 7.5 - -
capacity
without oil
filter
Specifications Sheet BB00.40-P- BB00.40-P-0229-01A -
for Operating 0229-01A
Fluids Sheet BB00.40-P- BB00.40-P-0229-03A -
0229-03A
Sheet BB00.40-P- BB00.40-P-0229-05A BB00.40-P-0225
1
Mercedes-Benz
1990-2002 ENGINE Engine Lubrication , Engine Oil Cool ing - 129 Chassis
10229-0SA
®E ngm e 1u bn.cation
113.963/965/968 113.987/988/990/992/993/995 113.967
BF18.00- Engine Filling Liters 7.5 8.5 7.5
P-1001 - oil capacity wíth
OlH oil filter
Filling Liters 7.0 8.0 -
capacity
without olil
fi lter
Specifications Sheet BB00.40-P- - BB00.40-
for Operating 0229-0lA P-0229-
Fluíds OlA
Sheet BB00.40-P- - BB00.40-
0229-03A P-0229-
03A
Sheet BB00.40-P- BB00.40-P-0229-0SA BB00.40-
0229-05A P-0229-
OSA
11 7 5S9 02 07 ()l)
Fig. 86: Box Wrencb (117 589 02 07 00)
103 589 02 09 OD
'M'an!ll sod:el
Fig. 87: W reo eh Socket (1 03 589 02 09 00)

Mercedes-Benz
Replace oil mter element, drain oil filter- AP18.00-P-0101-06EF
~ Oil filter
112.910/911/912/913/914/915/916/917/920/921/922/923/940/941/942/943/944/945/946/
BA18.20- Screw N m 25
P-1001- cap at
OlD oil
filter
~ Oil filter
Number Designation Engine Engine Engine Engine
113.987/988 113.992/995 113.990/991/993 113.964/971
BA18.20-P- Screw cap N m 25 25 25 25
1001-0lD at oil filter
t 03 5B9 02 09 00
Fig. 88: Wrench Socket (103 589 02 09 00)
Sbown on engine 112
l. Remove engine trim panel or air filter.

2. Use wrench socket L't.oanQorl to remo ve screw cap (2) and take off together with oil filter element (4).
3. Knock oil filter element (4) offthe screw cap (2) into a suitable vessel (for example oil drip tray) by
briefly knocking against the middle rod.
4. Replace compression ring (3).
5. Push new oil ftlter element (4) onto screw cap (2).
6. Fit on screw cap; use wrench socket L't.oanqcrl •
Mercedes-Benz
1990-2002 ENGINE Engine Lubrication , Engine Oil Cool ing- 129 Chassis
P18Jlll..() l OB·Q1
Fig. 89: Identifying Knock Oil Filter Element Off Screw Cap

CHANGING ENGINE OIL AND FILTER- RA18001040020X(18-0020)
Changing engine oil and filter- RA18001040020X(18-0020)
Preceding work:
Modell40: Air cleaner removed.
00-6200
Mercedes-Benz
~19
P 18-5254-57
Fig. 90: Identifying Engine Oil And Filter
tmscrew with wrench socket insett (05) 103 589 02 09 00 so that engine oil in oil
Screw cover (2)
filter flows off into sump.
Screw cover (2) and
remove.
oil filter element (4)
Engine oil extract through dipstick guide tube (5a) when engine at operating temperature.
drain out of sump if no extraction device available; remove bottom engine
Engine oil compartment panel for this operation (see Maintenance Manual6190). Unscrew oil
drain plug (arrow).
Seal on oil drain plug
1
repace.
(arrow)
Oil drain pluo-0
screw on (25 Nm).
( arrow)
Sea] (3) in screw

replace.
cover (2)
New oil filter element. rt. t . filt
(4 ) mse m o 01 1 er.
Screw cover (2) install, tighten (25 Nm).
Cap (19) open, pour in engine oil.
Engine nm, check for leaks.
Mercedes-Benz
1990-2002 ENGINE Engine Lubrication , Engine Oil Cool ing- 129 Chassis
loil level check at dípstick (5) approx. 2 minutes after switchíng off warm engíne.
Special tools
001 589 72 21 00
103 589 02 09 00
117589020700
Fie. 93: Identifvine Special Tool (117 589 02 07 00)
SAE specified viscosity classes at prolonged outside temperatures
Exact use of SAE classes on the basis of the outside air temperature would necessitate frequently changing the
engíne oil. The temperature limits for the SAE classes should therefore be regarded as a guideline which m ay be
transgressed for short períods.
Mercedes-Benz
P18-5179- 33A
Fig. 94: Identifying Viscosity Temperature Grapb
Reference should be made to the "Specifications for Service Products" for further information regarding
specified viscosity classes and approved engine oils.
Engine Model Capacity when changing oil and filter

104.980/981 104.941/942/943 104.992 124, 129, 202 7.0
104.944/990/991 /994 140 7.0
104.945/995 2l0 7.0
Oil drain plug to oil sump 25
Screw cover 25
NOTE: Dipstick identification see (18-3500).
Eugine oil aud filter chauge- RA1800l200020X(18-0020)
00-6200
Special tools
Mercedes-Benz
001 589 72 21 00
00
103 58Q 02 09 <JO

18 J
11 7 589020700
18 26 3S
Fig. 97: ldentifving Special Tool (117 589 02 07 00 18 26 35)
Specified viscosity classes according to SAE at lasting ambient temperatures
The SAE class (viscosity) must be selected according to the average air temperature according to the season of
the year.
Mercedes-Benz
Fig. 98: Identifving Viscosity Temperature Graph
Exact adherence to SAE classes according to ambient air temperatures would require frequent oil changes. For
thís reason the temperature limits for the SAE classes should be consídered to be guidelines whích can be
exceeded or dropped below for a short time.
See Mercedes-Benz Specifications for Service Products for additional infonnation on prescribed viscosity
classes and approved engíne oils.
OIL CAPACITY IN LITERS (USE APPROVED ENGINE OILS, SEE "SPECIFICATIONS FOR
SERVICE PRODUCTS")
Engine Model Capacity for oil and filter Oil dipstick marking
change
Color code, bottle opener Code number on handle
shaped handle (color red)
120.980 140 10 red 12010
120.981 129 10 red 12011
120.982 140 10 red 12010
120.983 129 10 red 12011
IOil drain plug in oil pan 40
Screw cover 20
Change oil only with engine at operating temperature
l. Remove left air cleaner housing (arrow) (09 0015).

Mercedes-Benz
Fig. 99: Locating Left Air Cleaner Housing
2_ Before evacuating or draining oil, screw off cap (2) with socket wrench 103 589 02 09 00_ Remove screw
cap (2) together with clipped-in oil filter cartridge (4).
Fig. 100: ldentifying Screw Cap And Oil Filter Cartridge
3 _ Suck out oil through dipstick guide tube with engine at operating temperature.
Mercedes-Benz
Fig. 101: Sucking Out Oil Through Dipstick Guide Tube With Engine At Operating Temperature
4. If oil evacuation unit is not available, drain engine oil from oil pan (arrow); for this purpose remove
engine compartment panelling at bottom (Maíntenance Manual 6190).
Installation note
Replace sealing ring on oil draín plug (arrow).
Tighten drain plug (arrow) to 40 Nm.
Fig. 102: Locating Sealing Ring On Oil Drain Plug
5. Replace sealing ring (3).

6. Insert oil fílter cartridge (4) into oil filter housing (5).
7. Install screw cap (2) and tighten to 20 N m.
8. lnstaU left air cleaner housíng (09 -00 15).
Mercedes-Benz
Fig. 103: ldentifving Sealing Ring, Oil Filter Cartridge And Screw Cap
9. Open cover (arrow), add engine oil. Allow engine to run and check for leakage.
1O. Check oillevel approx. 2 minutes after shutting off engine after warrning up to operating temperature
(arrow).
Fig. 104: Locating Open Cover
OIL CIRCUIT- RA18001040050X{l8-0050)

Mercedes-Benz
24 25
?1&5272-61
1
OtlpuJtll
Olllongtlllinal gale!y lo a l ~lllf
9
10
Clan'""""""'
Verrtforctant80Sloner
3 OllfiiiDr 11 Frortdos~ccver 17 nm áll. (otllot'IOllJ<Inol¡¡elel'f
4 Otlpcessure sonsor lO otlllot eod metn oll gaiOfW
5 M""'oll galo(y 12 Ollltansve<se Onlely
!> 011spnr¡ nozzlos (pis!on a""" coolng) 13 Bal6 nm cb.
IC)l0 12193 14 Tunng (han otiSfJf<tf nozzlo
1S Oilnser gale¡y to cy!rlder head
Ollnsergalkuyto dlain 10f15101l0f
OllnM<-.mvi!M
16 Bai 1Snm áa.(..,.,Otl galo;ypllg) 26 M10X 1 saow pllgwtl s&.al

17 Ollro!lttlwon omer cie 4 mm. tngjne 104 99 27 Cemshall...,ster
18 Ollleod f l h - . . d o""""'tternsMl 2$ Fttllt dosng rovor, l1lol carnshal
19 Oolfeod llholcw.drtod om.l camshaft 29 Frort lueooodbusll, e><llatlstcernsllal
20 011 supjliy ll<haust camshlltbeanngs 7X 30 BJdlolllll>l*
11 011st~pply utot tamsllal teanngs 7X 31 OtJ ¡>~p os to arr-tn-oi coolet on ongnes ,..,
8>f.!<><lil cool:n¡¡
n Ollgalery, buckiiCI81>1>ot5<>1$O.I)ply
Coxllaustsllle) 12X 32 ~dor hoao clo~ oover
a Oll longtuinal galer¡ t om OllpuJtlltooU UOf
Oilgalery, bud<ottaope!s "'' ~ b To metn algalery
r.mr•1 12X
Olnyalratl!ncmtno., o.1s1111p
24 Camstlaftd ostng cavar
25 BaiSnmao {buckott8llPtl>oiOaJervl
Fig. 105: Identifying Oil Circuit Components
Timing chain lubrication

Mercedes-Benz
Fig. 106: ldentifying Timing Chaio Lubrication
A. Engine 104.98
The timing chain is sprayed with oil through a connection in the oil transverse gallery (12) anda drilling
(arrow) in the guide raiL
Equíp engines wíth oíl dríllíng ( arrow) in crankcase with guide raíl 104 025 04 16 in place of 104 052 06
12 (without oil drilling), see (05-3350) .
B. Engine 104.94/99
The timing chain is sprayed with oil through a connection in the oil transverse gallery (12) andan oil
spray nozzle (14).
TESTING OIL PRESSURE - RA18001040070X(18-0070)
Testing oil pressure- RA18001040070X(18-0070)
A. Testing oil pressure through connection drilling at oil filter

Mercedes-Benz
p 18-5270-57
1 O- 1Otn. Pl e>sure gB\J;¡e 103 589 00 21 00 6 Ak.irnnlSTl seal

3 Pres>Urewe 7 Ollflller
S M1 2X 1 SQt,J connodlootlmg 8 ScrewpkJg
915006004 002,alomabwt{ M1 0 X 1- M12X 1 5 9 Remotelhormometer 124 589 07 21 00
01>1 ad~or iling fi15 007 004 001
Fig. 107: Testing Oil Pressure
Screw plug (8) with seal (6) detach from oil ftlter (7), attach (15 Nm).
(Connection
) . t ac h to 01·¡ fil
fitting or adaptor fitting ( 5) with seal at ( ) d
1 ter 7 , etac
h (l 5 N m) .
6
attach to connection fitting or adaptor fitting (5),
Pressure pipe (3)
detach.
T valve (2) close (turn to close).
Oillevel check, adjust to correct level.
Dipstick ( 1O) remove, install.
Temperature sensor of remete thennometer (9)
insert into dipstick guide tube.
124 589 07 21 00
run. Check oil pressure at stated engine speeds and
Engine
temperatures, see table.
B. Testing oil pressure through oil filter cap

Mercedes-Benz
P1 8 . ~26S- 57
Fig. 108: Testing Oil Pressure Through Oil Filter Cap
Oil filter cap unscrew, screw on. {18-0020).

Oil filter element replace.
Oil filter cap (O 1) screw onto test connection ( shop-made tool) (20
Nm).
Delivery pipe (3) fit onto test connection, disconnect
T valve (2) close.
Oillevel check, adjust to correct level
Dipstick (10) remove, instalL
Temperature sensor ofremote thermometer (9) 124 insert into dipstick guide tube.
589 07 21 00
Engine run and check oil pressure at stated engine speeds
and temperatures; see table.
Engíne speeds in rpm En gine oíl pressure in bar at oil temperature of about
80 oc (1)
600- 750 approx. 1.3
1000 approx. 2.2
2000 approx. 4.8
3000 approx. 5.1
Mercedes-Benz
4000 lapprox. 5.3

(1) Oil filter element replaced
SpeciaJ tools
1 03 589 00 21 00
Fig. 109: Identifying Special TooJ (103 589 00 21 00)
124 589 07 21 00
Fig. 110: ldentifying SpeciaJ Tool (124 589 07 21 00)
M12 X 1.5 connection fitting (5) 915 006 004 002 (DIN)
M10 X 1 - M12 X 1.5 adapter fitting (5) 915 007 004 001 (DIN)
Sbop-made tool
Oil filter cap with test connection
l . Drill 0 8 mm hole in center of oil fílter cap (1).

2. Hollow-drill hexagon socket bolt (4) 0 2 mm.
3. Tap M6 thread in connection fitting (2).
4. Screw connectíon fitting (2) wíth seals (3, 5) onto oil filter cap (1) wíth hexagon socket bolt (4).
Mercedes-Benz
.--2
~3
o
1
t
.
~.
k
o
1
o
•
1
'
P58.50-0205-35
1 Oilfibifcap,paltno. 104 184 oooa

2 ConnactJonfltingM12X 1.5 DIN no. 915005004002
3- Aklmnium sea112X 17
4 Hexe:gon socl<olbol MSX 12
5 Washer 6.5X 18
Fig. 111: Identifying Oil Filter Components
Testing oil pt·essure and oil pt·essure sensor- RA18001190070X(18-0070)
Model129
Mercedes-Benz
10
U'x11
o
.,,._oo•-s
1 Pfossuro gau¡¡e 0.10 bar 103589 00 21 01 7 Oll fitof
2 Tvatve 8 MapterlttrlgM10x1- M12x1.5
3 PrBSSU!lllnBA 9 Tlraaded<:omoc6oo M 12x1.5
4 Pf8SSIJI8 lne B {s~ad8)
5 Com8dloo fitmg M1 2x1.5 10 Tadlometer

6 Seal X 11 Dla!J1nSIS Sl>Cket
85 Otl¡xessure sensOf 003 Reststamce rmaslllngmsllurmnt
(mi.Jbmeter)
Fig. 112: ldentifying Oil Pressure And Oil Pressure Sensor Components
Coolant temperature approx. 80 oc

Oillevel in engine check, adjust to correct level.
Oil filter element with oil cap raise, introduce.
Oil filter cap tighten (20 N m) .
Pressure gauge (1) install in place of oil pressure sensor (B5).
T valve (2) at pressure gauge (1) elose.
Oil pressure at indicated engine speeds measure (Step 8).
Oil pressure sensor (B5) connect to pressure gauge (Steps 4 to 6).
Mercedes-Benz
T valve (2) at pressure gauge ( l) open.

Oil pressure sensor (B5) connect to multimeter (003).
Electrical resistance at engine speeds test (Step 12).
Special tools
001 589 72 2.1 00

00
103 589 00 21 00
07
COMMlliRCMLLYAV~ABLETOOLS
Connection fitting (5) Ml2xl ,5 9 15 006 004 002 (DIN)
Adapter fitting (8) Mlüxl - Ml2xl.5 9 15 007 004 001 (DIN)
Resistance measuring instrument (003) e.g. multimeter Sun DMM-5
Tachometer (1 0) e.g. engine tester or multimeter
Shop-made tools
Threaded connection (9) M l 2x l.5 for oil pressure sensor (B5) to pressure gauge ( 1).
Mercedes-Benz
Fig. 115: ldentifying Shop-Made Tools
Measuring oil pressure
Test condition: coolant ternperatme approx. 80 oc_
l. Check oillevel in engine; adjust to correct level, if necessary.

2. Raise oil filter cap together with oil filter element so that the engine oil flows out ofthe oil filter housing
into the sump_
3 _ Install oil filter cap with oil filter element
4. Detach plug connection at oil pressure sensor (B5)_ Unscrew oil pressme sensor (B5)_
5. Screw in connection fitting (5) together with seal (6) in place of oil pressure sensor (B5).
6. Connect pressure gauge (1) with pressure lineA (3).
7. Close T valve (2) at pressure gauge (1).
Fig. 116: ldentifving Oil Pressure Sensor

Mercedes-Benz
8. Measure oil pressure at the indicated engine speeds.
MODEL 129
Engine speed in rpm Oil pressure in bar
600-750 0.3-1.5
1000 0.7-3.0
2000 1.6-5.0
2500 2.0-5.5
3000 2.5-5.5
4000 2.7-5.5
5000 2.8-5.5
The readings obtained must reach the indicated mínimum oil pressure.
Ifthe oil pressure is lower than the indicated smaller figure (mínimum oil pressure), the oil pressure
warning lamp is activated and the oil pressure pointer is deflected to the bottom stop.
Testing oil pressure sensor
Perform Steps 1 to 6.
9. Connect oil pressure sensor (B5) together with threaded connection (9), seals (6) and adapter fitting (8) to
the pressure line B(4).
10. Open T valve (2) at the pressure gauge (1).
ll. Connect oil pressure sensor (B5) to resistance measuring instrument (003) (multimeter).
12. With engine running, test resistance (ohms) of oil pressure sensor (BS).
The readings obtained must agree with the figures indicated.
MODEL129
Engine oiJ pressure in bar (gauge pressure) Oil pressure sensor resistance in ohms
o 3-16
0.3 17-34
1.8 102-125
3.0 163-1 95
3.5 170-223
Ifthe resistance ofthe oil pressure sensor (B5) is outside ofthe tolerance ofthe indicated values, the oil
pressure sensor should be replaced.
For testing wiring from oillevel sensor and instrument cluster refer to Diagnosis Manual Chassis.
MEASURJNG OIL CONSUMPTION- RA18001040250X(18-0250)

Mercedes-Benz
18-1020
l. Check engine for signs of extemal oilloss.

2. Park vehicle on level ground and mark parking position.
3. Warm engine oíl up to temperature of 80 oc_ Measure oíl temperature with remote thermometer 124 589
07 21 OO.
4. Switch off engine.
Waít precisely 5 minutes, then measure oíllevel from bottom of oil sump wíth dipstíck 120 589 06 21 OO.
The millimeter scale of the dipstick must fa ce toward the fan. Remove dipstick after 3 seconds and read
off oillevel.
A void overfilling engine with oil. Max. oil level:
Engine 104.941/942/943/945/980/981/991/992/995 = 102 mm from bottom of oil sump.

Engine 104.944/990/994 = 118 mm from bottom of oil sump.
Adjust oíl to correct level íf necessary and repeat measurement as from step 3.
Read off the oíl quantíty from the diagram of the test sheet in accordance with the dipstíck reading and
enter in the test sheet.
5. Carry out test run over a distance of approx. 250 km. Take into account the operating conditions ofthe
vehicle at the customer's.
6. Park vebicle on tbe marked position. Repeat operations as from steps 3 and 4.
lf the engine ís swítched off to allow the engine oil to cool to 80 °C, the engíne must be run for about 1O
seconds before performing the measurement (step 3) and the accelerator blipped in order to assure the
same measurement conditions.
7. Cale u late the oil consumptíon in litres/ 1000 km from the quantity of oíl consumed (cm2) and the distance
covered (km).
Special tools
Mercedes-Benz
124 589 07 21 00
1205890621 00
Engine 104.941/942/943/945
Engine 104.980/981
Engine 104.991/992/995
Specímen test sheet

Mercedes-Benz
1
lmax-.
1 104.941
104.942
104.943
104.945
104.880
104.981
104.991
104.992
104.995
1
P 18.00.0264-61
Fig. 119: Specimen Test Sheet
Engine 104.944
Engine 104.990
Engine 104.994
Mercedes-Benz
104.944
104.990
104.994
P 18-5317-6 1
Fig. 120: Specimen Test Sheet
Order the forms by quoting the
Print no. B20.800.98.443.00.A - 41/1092.
OPERATION OF OIL FILTER- RA18001041000X(18-1000)

Mercedes-Benz
Engines with air-to-oil cooling
18 17 16 15 1.. 13 12 11 E
P18-5258-57
Oillllter E 011 e o oler feed thermoctat element

atfii!Br e•emert lloiOOf 11 Thermcslat element
2 Screwcap 12 CompressJOn spnng
3 Seal 13 Slamgsleeve
4 (Jjffil!er elemert F 011 fllter bypus valva
5 (Jjffiler housmg 7 VeNecooe
6 Gasket 8 Compress1011 spnng
o Non-retum valve 9 Spmgásc
14 Spmgóst 10 Ctrclp
15 Cncip
16 Compress100 spnng
17 Vflite cona
18 Vfli¡e seat (loci<Jog nng)
G Oll draln vatve A. Unliltered oi to en-11:>-oi cooler

19 Ctrdip lrllalfereote-lt B UnRered oi from 111r-ID-oi cool!lf
20 Compress1011 spnng a from oil punp
21 Vaive cona b robe~gp~ns
22 CompresslOO spnng Otlr-el.lm to sumpwhen thang¡119 ner
24 atfii:Bf vtew d Uliltered 011 to besmg polrts
BS atocessure.se.ns~.t24. 129. 140
Fig. 121: Identifying Engines With Air-To-Oil Cooling Components
D Noo-return valve
The non-retum val ve prevents the oil filter running dry when the engine is switched off.
Mercedes-Benz
Opening pressure 0.2 bar.
E Oil cooler feed thermostat element
The thermostat element opens from an oil temperature of 106 oc and feeds the engine oil through the air-to-oil
cooler into the filter chamber of the oil filter.
F Oil fllter bypass valve
The bypass val ve opens wheu the oil flow is 1 1/min. and 3±0.4 bar and uufiltered engine oil flows into the oil
circuit.
G Oil drain valve
When the oil filter element (4) is raised, the oil drain vaJve opens and the engine oil flows out ofthe filter
chamber of the oil filter into the sump.
REMOVING AND I NSTALLING OIL FILTER- RA18001041100X{l8-1100)
R emoving and installing oil filter- RA18001041100X(18-1100)
Preceding work:
Air cleaner removed (09-0015)
Starter removed (15-700)
18-3090-3800
A. Model124 with engine 104.980
Models 129, 140 on engines with air-to-oil cooling

Mercedes-Benz
Fig. 122: ldentifving Removing And lnstalling Oil Filter
Connector (28) unplug, plug in.

Oil pressure switch (27) at oil filter ( t )
( ) unscrew, screw on s ep 2 .
5
Intake manifold bracket at rear
tmbolt, bolt on (step 3).
(67)
Models 124, 129: if cruise control remove actuator of electroníc accelerator with linkage, install (cable
fitted remains connected).
Engine oil cooler pipes (25) at
detach, screw on (step 5).
fixtures
Engine oil cooler pipes (25) at oil
unscrew, screw on, replace seals (24).
filter (5)
Oil filter (5) remove, install.
Oillevel in engine check (18-0020).
Leakti ghtness perform check.
Oil filter to crankcase 25
Screw cover 20
Oil pressure sensor í.n oil filter housing 20
Mercedes-Benz
Special tools
103 589 02 09 00
Fi~. 123: Identifyine Special Tool (103 589 02 09 00)
001 589 72 21 00
l. Unplug connector from oil pressure sensor (4).

2. Unscrew oil pressure sensor from oil filter.
3. Unbolt rear intake manifold bracket (arrows).
Mercedes-Benz
Fig. 125: Locating Rear lntake Manifold Bracket
4. Models 124, 129: if cruise control fitted, remove actuator of electronic accelerator with linkage;
cable remains connected.
5. Detacb engine oil cooler pipes from fixtures (arrows).
6. Unscrew engine oil cooler pipes from oil filter.
Tnsta11ation note
Replace seals (7).
Fig. 126: Locatiug Engine Oil Cooler Pipes Fixtures
7. Unscrew bolts and take off oil fllter.
Installation note
Clean sealing surfaces and replace gasket.
8. Install in re verse order.

9. Check oillevel in engine.
10. Perform check for leaks.
B. Engines with oil-coolant beat exchanger
Preceding work:
Top part ofresonance intake manifold removed
(AR09.20-1310D).
Mercedes-Benz
18-3090-3800
? 18;.5259-57
Fi~. 127: Locatin~ En~ines With Oil-Coolant Heat Exch an~er
Screw cover (2) at oil unscrew, screw on so that the engine oil in the oil filter flows into the sump {18-
filter ( 5) 0020)
Coolant at crankcase drain (20-01 00).
Coolant hose (9) at take off, fit on.
rear of cylinder head
Coolant pipe (3) at unbolt, bolt on.
bottom part of
resonance intake NOTE:
manifold Replace 0-ring (3b) at heat exchanger.
Coolant hose (4) from
crankcase to heat take off, fit on.
exchanger
@ lnstallation models 124 and 129: It is essential to maintain clearance ofthe
hose clips to the solenoid switch of the starter! Install bottom single-ear hose clip
only when oil filter removed. Pay attention to position of top and bottom hose
clips so that accelerator control hnkage does not get jammed.
Oil filter (5) at
tmbolt, bolt on (21 Nm).
crankcase
Mercedes-Benz

Coolant pour in (20-0100) .
Cooling system check for leaks (20-0170) .
Oillevel of engine check, adjust to correct level (18-0020).
loil filter at crankcase 21
Special tools
001 589 72 21 00
103 589 02 09 00
7 mm wrench socket hexagon on f1 ex1'b] e sh af1t wr

e- hose e¡·1p Wit
· h wmm dnve
· e.g. H azet 42853
d Remscheid
0 r er no. 426- 7
Removing and installing oil filter bousing- RA18001201100X(18-1100)
Preceding work:
Rottom rmo-inP. r.omn::trtmP.nt n::tnP.I rf'! m ovP.rl

Mercedes-Benz
(Maint Man. 6 190).
Left air cleaner with mass air flow sensor removed (09-0015) .
Viscous fan clutch removed {20-3120) .
A. Model129
~ ~ L1M
Fi~. 130: ldentifyin~ Removin~ And Installin~ Oil Filter Housin~- Model129 (1 Of 3)
Coolant drain from radiator, pour in (20-0100) .

Coolant hose to coolant thermostat cap remove, insta!!.
Tensioning device remove, install (13-3450) .
Power steering pump remove, install (46-710).
unscrew, screw on, allow engine oil in sump to
Screw cap (2) of oil filter housing (1)
drain (20 N m) (18-0020).
F ront torsion bar ( 17) unbolt, lower, bolt on (32-300).
Electrical connector of AC compressor disconnect, connect.
TDC sensor (Ll / 1) at oiil filter housing (1) unbolt, bolt on.
Mercedes-Benz
Bolts (l6 and l8) tmscrew, screw on.

AC compressor (11) with piping connected and air- detach from oil filter housing (1), attach at the side,
to-oil cooler lines (19) install.
Seals at air-to-oil cooler lines (19) replace.
Dowel sleeves at front of oil filter housing (1) note.
15Nm
(@)@ 85
Fig. 131: ldentifving Removing And Installing Oil Filter Housing- Model129 (2 Of 3)
Oil pressure sensor (B5) unbolt, bolt on, replace seal (15 Nm).
Secondary air injection line detach, fit on.
Oil fllter housing (1) unbolt from crankcase.
Shaped mbber gasket (8) replace.
Mercedes-Benz
Ptl-1221-17
12 M8X 40hexegoosocketbcl•,\llih wash&

13 MS X SOOO:•washor
14 M8 X 9Sbol•wBSher
15 OctNel slea\9
Fig. 132: ldentifving Removing And Installing Oil Filter Housing- Model129 (3 Of 3)
Oil filter housing (1) instaH, pay attention to dowel sleeve ( 15).
install according to bolt diagram, screw on until they
Bolts
make contact.
align to gap size "A" (5 mm) relative to timing case
Oil filter housíng (1) cover (24) otherwise the power steering pump cannot
be installed.
Bolts of oil filter tighten (25 Nm).
Engine run, check for leaks (step 17).
NOTE:
The oil circulates in the air-to-oil cooler once see function of oíl filter housing (18-1000).
the thermostat valve in the oil filter housing (1)
opens
Engine oillevel check, adjust to correct leveL
lscrew cap of oil filter 20
Mercedes-Benz
Oil pressure sensor 15

Oil ftlter housing to crank:case 25
Preceding work:
Radiator removed (20-4200) .
Tensioning device removed (13-3450) .
Left air cleaner with mass air flow sensor removed (09-0015) .
Power steering pump removed (46-710).
Rear engine compartment panel removed (Maint. Man. 6190).
Operation no. ofthe operation texts and work units or standard texts and flat rates:
B. Model140
15Nm
~
Bs
P18·5086·57
Fig. 133: Identifying Removing And Installing Oil Filter Housing- Model140 (1 Of 2)
lconnector (A9xl) of AC compressor unplug, plug in.

Mercedes-Benz
TDC sensor (Ll/1) from adjusting slide (10) and oil unbolt, bolt on (step 2 ).
filter housiug (1)
unscrew, screw on, allow engine oil to drain into oil
Screw cap (2) of oil filter housiug (1)
pan, 20 Nm (step 3).
Oíl pressure sensor (B5) remove, install (step 4 ).
Torsion bar (3) unbolt from front axle, bolt on (32-300).
Oilline (5) of automatic transmission at air-to-oil
unbolt, bolt on (step 6).
cooler lines ( 6) and (7)
Oillines ofair-to-oil cooler (6) and (7) at oil pan unbolt, bolt on (step 7).
P11- 5087.51
Fig. 134: Identifying Removing And Installing Oil Filter Housing - Model 140 (2 Of 2)
unscrew from oil filter housing (1 ), screw on (83-530)

AC compressor (11)
(step 8).
unscrew from bottom of front axle, screw on (22-
Left and right engine mounts (20)
2110) .
Engine raise by front lifting lug.
Oillines (6 and 7) of air/oil cooler at oil filter
unscrew from above, screw on (step 11).
housing (1)
lnstallation note
install fust of all.
Oilline (6)
0-rings replace.
Mercedes-Benz
AC compressor (11) with piping group connected swivel outward to the front
Oil filter housing ( 1) at crankcase unscrew, align, screw on (step 13).
Profile rubber gasket (8) replace.
Engine run, check for leaks (step 17).
Engine oil leve] check, adjust to correct level.
Oil filter screw cap 20
Oil pressure switch (B5) 15
Front engine mounts to front axle 25
Oil filter housing to crankcase 25
Special tools
,/
001 589 72 21 00
00
Fig. 135: ldentifying Specia1 Tool (001 589 72 21 00 00)
\03 68Q 0209 00

18 .)
Fig. 136: ldentifying Specia1 TooJ {103 589 02 09 00 00)
Removing, inst.alling
l. Unplug air conditioning compressor connector (A9x1)

2. Unscrew TDC sensor (Ll/1) from adjusting slide (10) and oil filter housing (1).
Mercedes-Benz
Fig. 137: ldentifving TDC Sensor And Oil Filter Housing
3. Unscrew oil filter screw cap (2) witb wrencb 103 589 02 09 00 so tbat tbe engine oil in tbe filter bousing
flows off to tbe oil pan.
Fig. 138: Identifving Oil Filter Screw Cap
4. Disconnect oil pressure switch (B5) connector and unscrew oil pressure switch.
lnstallation note
Pay attention to seal. Tightening torque 15 Nm.
5. Unscrew torsion bar at front axle (32-300).

Mercedes-Benz
Fig. 139: ldentifying Oil Pressure Switch
6_ Remove screws (arrows) of automatic transmission oilline (5)_

7 _ Remo ve screw ( 17) of air/oil cooler lines (6) and (7) at oil pan.
Fig. 140: Locating Oil Pan, Air\Oil Cooler Lines, Transmission Oil Line Screws
8_ Detach air conditioning compres sor (11) with pipe group of air conditioner at engine; remove bolts (1) for
this purpose {83-530) _
Mercedes-Benz
Fig. 141: Identifying Air Conditioning Compressor Bolts
9_ Unscrew bolts (arrows) at left and right engine mounts from below (22-2110) _
10. Insert engine hoist into front lifting lug of engine and raise.
Fig. 142: Locating Engine Mount Bolts
11. Remove screw (arrow) from above. Detach oillines (6) and (7) of air/oil cooler at oil filter housing.
lnstallation note
Replace 0 -rings. Install bottom oilline (6) first
12. Swing air conditioníng compressor with connected pipe group outward to the front
Mercedes-Benz
12 Hexagon sod<et screw wth washer MaX 40

13 Bot+washer 1111SXao
14 Bot+washer MB X 95
15 Oowel sloove
Fig. 143: Locating Oil Lines And Air\Oil Cooler Of Oil Filter Screw
13. Remove bolts and screws (12, 13 and 14).
Remove oil tilter housing upward.
lustallatiou note
Install oil filter housing (1) with dowel sleeve (15) and align to dimension "A" (5 mm) between timing
case cover (24) and oil filter housing (1) so that the power steering pump holder can be installed.

15. Replace profile rubber gasket.
16. InstaU in the reverse order.
NOTE: The oil circulates in the air/oil cooler when the thermostat valve in the oil
filter housing opens.
Mercedes-Benz
Fig. 144: Identifying Dimension Between Oil Filter Housing And Timing Case Cover
See function of oil filter {18-1000)_
18_ Check engine oillevel, adjust to correct leveL
Removing and installing oil filter housing- RA180B1191100X(18-1100)
Preceding work:
Pay attention to hazard warnings when hood opened (01-0080) _
18-3090-3800
B. Model129
Mercedes-Benz
Fig. 145: ldentifving Removing And Installing Oil Filter Housing
Plug connection ( 1O) at oil pressure sensor ( 11) unplug, plug in.
Oil pressure sensor (11) witb seal (12) tmbolt, bolt on (15 Nm).
V acuum line disconnect, connect.
Oillines (7) and (8) of air-to-oil cooler at oil fílter (5)unbolt, bolt on (7 N m).
Seals (9) replace.
Oil fílter (5) at crankcase unbolt, bolt on (25 N m).
remove downward, install.
lnstallation note
Oil fílter (5)
Clean sealing surfaces.
Replace gasket (5a).
Oil level in engine check, adjust to correct level.
Engine nm.
Leaks check.
O i l filter to crankcase 25
Oil fílter cap 20
Bolts of oil Iines at air-to-oil cooler 7
Mercedes-Benz
lüil pressure switch to oil filter 15
Special tool
001 589 72 21 00
NOTE: When ~changing oil filter, ensure that the upright pipe (8) in the oil filter
housing is not inadvertently removed. Oil filter housings with loose
upright pipe must be replaced otherwise unfiltered engine oil may flow to
the bearing points.
Fig. 147: Identifying Upright Pipe
The oil filter housing is supplied in the parts sector only as a running-in oil filter which in this case should
be replaced with the normal oil filter element.
As ofvehicle ident end no. 129066 lF 005981 oil filter housings, part no. 119 180 07 10, have been
installed which are fitted with an upright pipe which cannot come loose.
REMOVING AND INSTALLING OIL PIPES (OIL FILTER - AIR-TO-OIL COOLER) -

RA1800104112X(18-1120)
Mercedes-Benz
Removing and installing oil pipes (oil filter- air-to-oil cooler)- RA1800104112X(18-1120)
Preceding work:
Starter removed.
18-8591
Model129 with air-to-oil cooling
Fig. 148: Identifying Removing And Installing Oil Pipes (Oil Filter- Air-To-Oil Cooler)
Intake manifold supports . t

(ó?) remove, ms a11 .
Models 124, 129: if cruise remo ve actuator (55) of electro ni e accelerator with linkage, install (cables
control fitted remain connected).
Bracket (33) of oil pipes unbolt, bolt on.
Mercedes-Benz
Oil pipe (25) at oil filter

unbolt, bolt on (1 ONm). Replace seals (24).
(5)
Oil pipes (25) at air-to-oil
cooler (29)
Right and left engine
unbolt, bolt on (22-2110) .
mounts at bottom
Engine raise, lower.
Left engine mount (8) remove, install (22-2110).
Engine carrier (9) remove, install (22-2500) .
Oil pipes (25) remove to the front, install.
Oil level adjust to correct level {18-0020).
Engine run and check for leaks.
NOTE:
The oil circulates in the oil pipes (25) once the thermostat valve in the oil
fill er opens; see function of oil filter (18-1 000).
Removing and installing oil retum check valve in oil filter- RA18001191120X(18-1120)
Preceding work:
Oil fi lter removed (18-1100).

Mercedes-Benz
Fig. 149: ldentifying Removing And Installing Oil Return Check Valve In Oil Filter
Circlip ( 17) prise out with a screwdriver, instan.

Valve seat (12), valve cone (14) and remo ve.
compression spring (15) insta! l.
@)
Standard set oil return check valve with improved
Valve seat (12) with extended guide with valve
sealing properties:
cone ( 14) and compression spring (15) (2nd
Engine no.: 119.970 12 029 923 119.971 12 015 069
version)
119.972 12 002 097 119.974 12 006 973 119.975 12
007 964
Removing and installing oillines (oil fllter housing - air-to-oil cooler)- RA18001201120X(18-1120)
Preceding work:
(Maint. Man. 6190)
Front bumper removed (88-200) .
18-8571
Model129
Mercedes-Benz
16
P16-5248-57
F ig. 150: ldentifying Removing And Installing Oil Lines (Oil F ilter Housing- Air-To-Oil Cooler)
unscrew, pull up, screw on so that the engine oil in

Screw cap (12) with oil filter element clipped in
the filter housing flows off into the sump (18-
place 0020)_
Oí! línes (9) and ( 11) at oíl filter housíng ( 1) and
unbolt, bolt on.
bracket (13) of AC compressor
lnstallation note
install first of alL
Top oilline (9)
0 -rings (8) replace.
Oillínes (9) and (11) at bracket (14) at front of cross b lt b 1t
member un o ' o on.
unbolt, bolt on (30 Nm); brace with wrench (W AF
Oillínes (9) and ( 11) of air-to-oil cooler (2)
27) at hexagon head (15).
Oil lines ( 11) and (9) remove to the front, ínstalL
Leaks check when engine warm.
NOTE:
The oil circulates in the air-to-oil cooler (2) once see 08-1000)_
the thermostat valve in the oil filter housing opens
Oillevel check, adjust to correct leveL
Mercedes-Benz
00\ 589 72 21 00
00
103 68Q 02 Q9 00
18 J
PRESSURE-TESTING OIL-TO-COOLANT HEAT EXCHANGER- RA18001041370X(18-1370)
Preceding work:
Oil-to-coolant heat exchanger removed (18-1320)
18-6841
Mercedes-Benz
P18-5319-37
Fig. 153: Identifying Pressure-Testing Oil-To-Coolant Heat Exchanger
Oil-to-coolant heat
clean.
exchanger
Opening (2) seal air-tight.
Tester (1) connect.
Oil-to-coolant heat
pressurize with tes ter ( 1) to about l. 3 bar.
exchanger
Oil-to-coolant heat
immerse in tank with warm water.
exchanger
inspect for any air bubbles flowing out.
NOTE:
Oil-to-coolant heat Air bubbles indicate a leak; pinpoint more accurately where the air
exchanger bubbles come from.
Mercedes-Benz
lf a leak exists, replace oil-to-coolant heat exchanger.
DATA
IT
est pressure 1.4 bar
SpeciaJ tools
124 5B9 15 21 00
Fie. 154: Identifyine Special Tool (124 589 15 21 00)
REMOVING AND INSTALLING OIL PUMP- RA18001042IOOX(l8-2100)
Removing ancl installing oilJ>UIDJl - RA18001042100X(18-2l00)
Preceding work:
Oil sump removed (01-3100)
18-6020-6025
Mercedes-Benz
? 18-5260-57
1 MB X :mc~ l M6X 25boll+washer

2 M8 X 35c~+wasoor (he)(ag:Oil sod<lll) 4 Do•ml S:eeve
F ig. 155: Identifying Removing And I nstalling Oil Pump
Bolt (1) of oíl pump 0aear

(6) unscrew ' screw on (32 Nm) .
pull off, fit on.
Oil pump drive gear (7) NOTE:

at oil pump ( 6) lnstall oil pump drive gear (7) with convex tace pointing toward oil pump (6)
(arrows). Pay attention to position of tensioning bar relative to oil pump
chain.
Bolts+washer (2) and (3) unscrew, screw on (M6 9 Nm; M8 21 N m).
remove to the front, install.
Oílpump (6) NOTE:
Fill oil pump with engine oil before installing.
Strainer in oil pump cleau .
loíl oumo drive gear to oil oumo 32
Mercedes-Benz
Oil pump to crankcase 25

Bolt of oil pump to oil deflector plate lO
Bolts to oil pump cover (M6) 10
SpeciaJ tool
~~---0_01_5_8_9_72_2_1_00_____)
NOTE: Oil pump with hollow gear shaft to prevent oil buzz after cold start up to about
2000 rpm.
As of engine number (November 1995)
104.941 10 006 361
104.941 12 068 532
104.942 10 006 914
104.942 12 062 914
104.943 10 001 343
104.943 12 005 453
104.945 10 000 014
104.945 12 000 024
104.991 12 017 802
104.992 10 005 537
104.995 12 lOO 782

Mercedes-Benz
104.995 12 01 o421
Removing and installing oil pump - RA18001192100X(18-2100)
Preceding work:
Engine oil drained (18-0020).
18-6020-6025
Models 124, 129
S 5
·~~e
28Mm
2 M8x20 bco~wih washer 6 M&65 b~••Nash er

5 M6ll35 beol:t+wesh er 7 ()oofiel sleeves
Fig. 157: ldentifying R emovi ng And lnstalling Oil Pump
!cable straps at bottom part of oil sump detach, attach.

Mercedes-Benz
Oil line (9) of automatic transmission at

bottom part of oil sump (1)
If level control fitted: high pressure flexible
hose (10) at bottom part of oil sump (I)
Bottom part of oil sump (1) unbolt, bolt on (9 Nm) .
Gasket (la) replace.
Balancing weight of 1st crank:shaft joumal place horizontally.
unbolt, bolt on (18-3300).
Oil level sensor (S43) at oil pump (4) ®
Engine 119.97, see 18-3300.
Bolt (2) of oil pump drive gear (3) slacken, tighten (28 Nm).
InstaUation note
Oil pump (4) at timing case cover Prevent tensioning spring ( 11) of tensioning bar from
turning by inserting a screwdriver when tightening the bolt
(6).
tilt to the rear, unscrew bolt (2) and take off oil pump drive
gear (3) from oil pump (4), fit on.
Oil pump (4) lnstallation note
Fit on oil pump drive gear (3) with curved side toward oil
ptmlp (4) (arrows).
Oil pump (4) remove, install.
fill with engine oil before installing.
Oil pump (4)
®
A newly installed oil pump (4) must be filled witb engine
oil to ensure it draws in oil after starting.
Balancing weight (4a) remove, install, clean strainer.
Special tool
001 589 72 21 00
00
NOTE: lf the tensioning bar for the drive chain has to be replaced, the timing case
cover should be removed (01-21 00) .
Mercedes-Benz
Removing and installing oil pump - RA18001202100X(18-2100)
Preceding work:
Oillevel sensor removed (18-3300).
18-6023
A. Modell29
P18 - ~28·13
Fi2. 159: Identifying Removing And I nstalling Oil Pump (Modell29)
Bolts+washers (8 and 9) unscrew, screw on (M6: 9 Nm; M8: 21 Nm).

Oil pump detach from front dowel sleeves (11), push to the rear.
Bolt (6) of oil pump drive gear (7)unscrew, screw on (28 N m).
Oil pump drive gear (7) pull offfrom oil pump (1), fit on.
Oil pump drive gear (7) install with curved side toward oil pump (1) (arrows).
Oil pump ( 1) remove, install.
Compensating element (1 O) remove, install, clean strainer.
Mercedes-Benz
Preceding work:
Oil pan removed (01-3100).
Oillevel sensor (S43) removed {18-3300).
B. Model140
P18 • 5073 ·57

Fig. 160: ldentifying Removing And Installing Oil Pump (Model140)
Bolt (6) of oil pump drive gear (7) unscrew, screw on (28 Nm).
Oil pump drive gear (7) pull off oil pump ( l ), fit on. (Pay attention to note.)
Screw+ washers (8 and 9) unscrew, screw on (M6: 9 Nm; M8: 21 Nm).
Oil pump (1) remove to the front, install.
Compensating element (10) remove, install. Clean strainer.
NOTE: The oil pump (1) is fixed at the two front screws (8) with a dowel sleeve.
Fill oil pump ( 1) with engine oil before installing. Compensating element ( 1O) 35 mm dja_(was 18 mm) fitted
as standard as of engine end no.
120980-12-002 610.
Mercedes-Benz
Use 35 mm dia. compensating element (10) when performing repairs.
NOTE: lnstall oil pump drive gear (7) with curved face toward oil pump (1) (arrows).
Fig. 161: Locating Oil Pump And Oil P ump Drive Gear
REPLACING AND RIVETING OIL PUMP CHAIN- RA18001042120X(18-2120)
Preceding work:
Oil sump removed (01-3100) .
Spark plugs removed (AP 15.00-1 580CA)

Mercedes-Benz
P11·1017 - 13
P11- 5213 - 57
Fig. 162: Replacing And Riveting Oil Pomp Chain (1 Of 3)
Bolt (1) of oil pump gear

slacken.
(7)
Chain pin of oil pump
grind open (arrows).
chain (2)
Plate of oil pump cbain (2) prise offwith a screwdriver.
N e~ separated oil pump
1
c1am
connect to old oil pump chain with riveted link (4) part no. 000 997 14 98.
rota te witb wrench socket insert in direction of rotation of engine, draw in

Crankshaft
new oil pump chain.
New oil pump chain connect to riveted link (4).
Oil pump gear (7) unbolt, remove.
Mercedes-Benz
Pi &. 50'79 - n
Fig. 163: Replacing And Riveting Oil Pump Chain (2 Of3)
insert into pressing-on tool 000 589 58 43 00 and screw on with screw (28)
Jaw with the digit 2
(Fig. A).
Moving thrust piece with , . . .
the digit 2 msert mto pressmg-on tool (F1g. B).
Outer plate (5) insert into moving thrust piece (Fig. C).
Web (arrow) fit onto both rollers at riveted link (Fig. D).
screw in until firrn resistance felt (Fig. D).
Spindle (04) NOTE:

When screwing in, ensure that the pins of the riveted link (4) are guided
into the holes of the plate (5) (arrow) (Fig. 0).
Pressing-on tool take off
Mercedes-Benz
P18- SOM-13
Fig. 164: Replacing And Riveting Oil Pump Chain (3 Of 3)
Moving thrust
turn over to riveting profile (arrow) (Fig. E).
piece
Pressing-on tool fit on exactly over middle of pin (Fig. F).
Spindle (04) tighten to 30 Nm (Fig. F).
Pins of riveted
link rivet individually.
Riveting check (arrows); re-rivet ifnecessary (Fig. G).
Oil pump gear install wíth oil pump chain fitted with convex side facing oil pump (arrows), bolt on,
(7) tightening torque 32 Nm (Fig. H).
Special tools
Mercedes-Benz
000 589 58 43 00
1 03 589 01 63 00
001 589 72 21 00
REMOVING AND INSTALLING OIL PRESSURE RELIEF VAL VE IN OIL PUMP-

RA18001042150X(18-2150)
Removing and installiog oil pressure reliefvalve in oil )lump - RA18001042150X(18-2150)
Preceding work:

Mercedes-Benz
18-5043
Fig. 168: Identifying Remove/lnstall Oil Pressure Relief Valve In Oil Pump
Screw plug (551) unscrew, tíghten, 50 Nm.

Compression spring (549) remove, install.
Guide pin (550) remove, install.
Plunger (548) remove, install.
Removing and iostalling oil pressure relief valve (oil pump) - RA18001192150X{l8-2150)
Preceding work:
Extractor drain engine oil (18-0020).
Model140. Oil sump removed (01-3100).
18-5042
Mercedes-Benz
40Nm
10Nm~
Fig. 169: l dentüying Removing And I nstalling Oil Pressure ReliefValve (Oil Pump)
Bottom part of oil sump (1) unbolt, sea!, bolt on (10 N m).
Screwplug (5) of oíl pressure reliefvalve ®
Screwplug (5) ís pressurized by spring (4).
Spring (4), guíde pío (3), control plunger (2) re move, ínstall.
Special tools
----~0~01 589 66.21- P~-----....-

Mercedes-Benz
Fig. 170: ldentifying Specia1 Tool (001 589 66 21 00)
-------·-··
\. 116 589 02.07 00
_.,____.... -- - --./
Fig. 171: Identifying Specia1 Tool (116 589 02 07 00)
Removing and installing oil pressure relief valve - RA1800 1202150X(18-2150)
Preceding work:
Bottorn engine compartment panel removed
(Maint. Man. 6190).
Operatíon no. of the operatíon texts and work units or standard texts and flat rates:
18-5043
A. Model129
Mercedes-Benz
ª
SÁ_-~
SONm\)J}J'
Fi~. 172: ldentifyin~ Removin~ And Installin~ Oil Pressure Relief Valve (Model 129)
drain, pour in, replace seal (40 Nm)

Engine oil
(18-0020).
Cable strap of electric cable of oil pressure sensor at bottom part tak .c:r fit
of oil pan (8) e Ol, ' 1 on.
Bottom part of oil pan (8) unbolt, bolt on (1 0 N m).
Gasket (6) replace according to condition.
Screw plug (5) of oil pressure reliefvalve, WAF 22 unscrew, screw on (50 Nm).
NOTE:
The screw plug seals with a tapered seat (arrows).
Spring (4), filler pin (3) and control piston (2) remove, instan.
NOTE:
The control piston (2) must move easily in the oil pump bore
(1 ).
Preceding work:
Mercedes-Benz
Oil pan removed (01-3100).
B. Model140
1
5~-
4
. . . .-(f
S
50Nm\J:J}))JJ'
P11·50B5·57
Fig. 173: Identifying Removing And Installing Oil Pressure Relief Valve (Model140)
Screw plug ( 5) of oil pressure relief valve WAF 22 unscrew, screw on (50 Nm).
NOTE:
Screw plug (5) seals with tapered seat (arrows).
remove, install.
Spring (4), filling pin (3) and control piston (2)

NOTE:
The control piston (2) must move freely in the oil pump bore (1 ).
REMOVING AND INSTALLING OIL SIDELD AT CRAN.KSHAFT- RA18001042180X(18-2180)
Preceding work:

Mercedes-Benz
P18i-5251-57
2 M8X ~Sbol+wa:sller (hex~nsod<~

3 M6 X 1601" M6 X 20bol.,NBsher
8 M6X 12bol (hexagonsod<et), 12 ea
Fig. 174: ldentifying Remove/lnstall Oil Shield At Crankshaft Components
positíon to TDC (arrow) so that the crank webs of cylinder 2 are

Piston of cylinder 1
facing up.
Bolts (2) of oíl pump and bolt (3) of
unscrew, screw on. M6 9 N m;
íntake
manifold support M8 21 Nm.
Bolts (8) unscrew, screw on (9 N m).
Oil shield (9) remove, insta!!.
FUNCTION OF ELECTRICAL OIL LEVEL INDICATOR- RA18001043100X(18-3100)
Function of electricaJ oillevel indicator- RA18001043100X(18-3100)

Mercedes-Benz
t.snxn ert pan 91 u!lit ¡;¡ M 1CroplOC9Ssor

3 lgnlion loc k e Olllavelllcic a:or Jamp
S43 Oillevel sensor
Fig. 175: Identifying Electrical Oil Level Indicator Components
General
The electrical oillevel indicator monitors the engine oil level in the sump when the engine is running and when
the engíne oil temperature is above 60 oc. If the ignition is switched on, the indicator lamp comes on and goes
out as soon as the engíne has started.
Function
The engíne oil in the engíne oillevel sensor (S43) is matched to the engine oillevel in the sump through the
drain drilling (e). Ifthe engine oil is at the correct level, the contact (arrow) is closed by the float (6) with a
solenoid (7) anda permanent input signal (vehicle ground) is supplied to microprocessor (a) in the electrical
base plate ofthe instrument panel unit (1).
max
------
·----·
--- -·
-----
---- -----------
------------
--
----
- ------
-----
------------..._......
- - - - --- -----~ ·
-- - --- - - ------- ___ _
Mercedes-Benz
Fig. 176: ldentifying Contact Connected
Ifthe engine oillevel is too low, the float (6) moves down and opens the contact (arrow). The input signa! is
thus interrupted and after 60 seconds (switching delay controlled by microprocessor (a) in instrument panel
unit) the oillevel indicator lamp (e) comes on. Ifthe engine oillevel is too low or ifthe wiring has an open
circuit, the oillevel indicator lamp (e) remains on after the engine has started.
The d.rain drilling (e) is opened by the bi-metal snap plate (8) as from an engine oil temperature of 60 °C and the
engine oillevel in the oillevel sensor is matched to that in the sump.
A delay circuit of about 60 seconds is integrated in the electrical base plate of the instrument panel unit (1) in
order to prevent the oillevel warning lamp lighting up briefly when the oil is at the correct leve! and e.g. when
comering fast
® Changing engine oil
Below 60 oc the engine oil is viscous and only flows back slowly into the sump; i_ e_ the oillevel measured
below 60 oc does not correspond to the actual quantity of oil in the system. When changing the engine oil, the
oillevel sensor (S43) is filled through the vent drilling (d) as the drain drilling (e) closes at approx. 30 oc as a
result of the cold engine oiL
Fig. 177: Identifying Contact Disconnected
Electrical function of oilleveJ indicator- RA18001193100X{l8-3100)
A. Model129
Mercedes-Benz
X27
mtumortcWer a MJCroprocesSOf
3 lgnlion starlsr S'Mith b Fuses 5and9
5 P\Jgcomedon, olkwelsensor e OtllevelcHliC a!Dr level
(OOttom nglt mCfliff«:ase) S43 Odlevel SllflSOJ
X27 Pllgcomoc~on. startM \'llnng hamess
Fig. 178: ldentifying Electrica1 Function Of Oil Level Indicator
General
The electric oillevel gauge monitors the engine oillevel in the sump when the engine is nmning and the
engine oil temperamre is above 60 oc.
When ignition is switched on, the indicator lamp lights up and
goes out as soon as the engine is started.
Function
The engine oil in the oillevel sensor (S43) is matched to the engine oíllevel in the sump through the
drain drilling (e). Wben the engíne oil is at the correct level, the contact (arrow) is closed by the tloat (6)
with a magnet (7) anda permanent input signal (vehicle ground) is supplied to the microprocessor (a) in
the electrical base plate ofthe instrument panel unit (1).
Mercedes-Benz
max
___ __
..·----
--- ._ ._
·---
-----.....
-----------
-----------
-----
------------ ------
------
---- ---------
--------·
-----------------
--- ----
Fi~. 179: Id entifyi n~ Contact Connected
Ifthe engine oillevel is too low, the float (6) moves down and opens the contact (arrow). The input signal
is thus interrupted and the oillevel indicator lamp (a) lights up after 60 sec. (switching lag controlled by
microprocessor (a) in instrument panel unit). Ifthe engine oillevel is too low or ifthere is an open circuit
in the wiring, the oillevel indicator lamp (e) remains on after the engine is running. The drain drilling (e)
is opened by the bimetal snap plate (a) from an engine oil temperature of 60 oc and the engine oillevel in
the oillevel sensor is matched to that in the sump.
Fi~. 180: Tdentifying Contact Disconnected
@ Engine oil change
Below 60 oc the engine oil is viscous and only flows back slowly into the sump; i. e. an oillevel
measured ata temperature below 60 oc does not correspond to the actual oil capacity. Wben changing the
engine oil, the oillevel sensor (S43) is fílled tbrough the vent passage (d) as the passage (e) is closed by
the cold engine oil at approx. 30 oc_
B. Model 210
Mercedes-Benz
P18 40..0230-57
Fig. 181: ldentifying Oil Level Indicator Monitors
GeneraJ
The electric oillevel indicator monitors the engine oillevel in the sump when the engine is running and
the engine oil temperature is above 60 °C.
Operation
The engine oil in the oillevel sensor (S43) is matched to the engine oillevel in the sump through the
drained drilling (e). Ifthe engine oil is at the correct level, the contact (arrow) is closed by the float (6)
with a magnet (7) anda permanent input signal (vehicle earth) is supplied to the ME-SFI control module.
Ifthe engine oillevel is too low, the float (6) moves down and opens the contact (arrow). This causes the
input signa! to be intermpted and the engine oillevel indicator in the instrument cluster comes on after 60
seconds (operating time lag) and, in addition, a warning signal sounds.
If the engine oillevel is too low or if there is an open circuit in the wiring, the oillevel indicator comes on
with an additional warning signal about 25 seconds after the engine has started. The warning indicator
remains on for a further 2 minutes or so after the engine is switched off.
The warning signal can be canceled when driving by pressing the R button.
Mercedes-Benz
Engine oil change
The drain drilling (e) is opened by the bi-metal snap plate (8) from an engine oil temperature of 60 oc and
the oil leve] in the oillevel sensor is adjusted to that in the sump.
At temperatures below 60 °C, the engine oil is viscous and flows back only slowly into the sump, i.e. a
capacity measured at temperatures below 60 oc does not correspond to the actual oil capac ity.
When the engine oil is changed, the oillevel sensor (S43) is filled through the vent drilling (d) as the
drilling (e) is closed at about 30 oc as a result ofthe cold engine oil.
REMOVING AND INSTALLING OIL LEVEL SENSOR- RA18001043300X(18-3300)
Removing and installing oillevel sensor- RA18001043300X(18-3300)
Preceding work:
Bottom engine compartment removed
(Maintenance Manual 6190) 18-4111, 4113
Pl8-5262-57
P 1&5261-57
Fig. 182: Identifying Removing And Installing Oil Level Sensor

Mercedes-Benz
Engine oil drain partially, pour in (18-0020).

Coupling (2) at oillevel
unplug, plug in.
sensor (S43)
remove and install.
NOTE:
From 01/95 the oillevel sensor (S43) is attached with self-tapping screws.
Oillevel sensor (S43)
If the oil sump is replaced, fit on oillevel sensor (S43) with self-tapping
screws (20 mm long, previously 25 mm long).
0-ring (1) replace according to condition.
nm, check for leaks.
Engine NOTE:
Function of oillevel indicator, see (18-3100).
Removing and installing oillevel sensor - RA18001193300X(18-3300)
Preceding work:
(Maintenance Manual 6190). 18-4111 , 4113
Engine oil drained (18-0020).
Mercedes-Benz
Fi2.183: ldentifying Removin2 And Installin2 Oil Leve) Sensor
Cable straps on bottom part of oil sump detach, attach.

Oilline of automatic transmission on bottom part of oil sump (8) unbolt, bolt on (9 Nm).
If level control fitted : high pressure flexible hose on bottom part of oil sump
(8)
Bottom part of oil sump (8) unbolt, bolt on (9 N m).
Sea1ing surfaces clean.
Gasket (6) replace.
Plug connection of oillevel sensor (S43) at crankcase unplug.
Locking element (3) at pin (2) ofplug connection pull off, fit on.
Oillevel sensor (S43) with connection cable (5) and pin (2) ofplug
remove, install.
connection
Modlel 140: spacer sleeves do not forget, see Note.
0-ring replace.
check with engine
Leaks
runmng.
Special tool
Mercedes-Benz
/
OOl 58Q 7 2 21 00
00
NOTE: Check length of spacer sleeves. Attach oil level sensor with 2 spacer sleeves,
length 12 mm, part no. 119 991 02 40 and 2 M6 X 25 hexagon socket bolts, part
no. 000 912 006 042, to oil pump. lf spacer sleeves are too long (20 mm), oil
warning lamp already lights up between Max. and Min. markings on dipstick.
Standard production break point of 12 mm long spacer sleeves (was 20 mm):
Engine no.
119.970 12 001 385
119.971 12 000 604
Removing ami installing oillevel sensor- RA18001203300X(l8-3300)
Preceding work:
Bottom engine compartrnent panel removed
(Maint. Man. 6190).
Drain engine oil (18-0020).
18-4111, 4113
Mercedes-Benz
Fig. 185: ldentifying Removing And Installing Oil Level Sensor
Model 140
Modlell40: line for secondary air injection unscrew below left engine support and oil pan bottom section
( l O) (8), screw on (lO Nm).
Cable connector for electrícal líne for oíl
disconnect from oil pan bottom section, reconnect
pressure sensor
Oil pan bottom sectíon (8) unscrew, remove, install (lO Nm).
Gasket (6) replace, if required.
Plug (1 ), oillevel sensor (S43) disconnect from oil pan, right, reconnect.
Snap ring (3) for pín (2) on plug connector pull off, attach.
Modlel 129: intake manifold support (7) remove, instaD.
remove together with connecting cable (5) and pin (2) for
Oillevel sensor (S43)
connector, install (5 Nm).
Installation note
clip ínto intake manifold support (7) and oil deflector plate.
Connection cable (5)
0 -ring (4) on pin (2) for connector replace.
Engine allow to run, check for leakage.
Leakage check.
Mercedes-Benz
/
oot 589 n 21 oo
00 J
TESTING OIL LEVEL SENSOR- RA18001043320X(18-3320)
Mercedes-Benz
klsnsn ert panel u11t a tvhc roprots~;sor

2 Comedor 2,•rntrumenl panei!J'lll b Fvses 5 antl9
3 lgrltJon Jet k e Olllevelruice~ lamp
S43 Olllsvel senscr
X27 C.omertor, stru1et wmgha:mess comector
Fig. 187: Testing Oil Level Sensor
IF FOLLOWING PROBLEMS EXIST

A: Key in position "2" indicator lamp (e) does not come on.
B: Engine oillevel "max" and engine running indicator lamp (e) comes on and remains on.
C: Engine oillevel "max" and engine running indicator lamp (e) comes on intermittently.
TEST DATA
Resistance of oillevel sensor at "max" oillevel < 0.10 ohms
Mercedes-Benz
IResistance of oillevel sensor at "ruin" oil level ínfinity ohms
TEST CONDITIONS
Engine oil temperature > 60 °C
Battery voltage 12 V
Special tool
201 589 00 99 00

Multimeter e.g. Sun DMM-5
Test in the case ofproblem "A"
Indicator lamp (e) does not come on when key in position "2" (requirement: voltage supply exists at instrument
cluster).
Mercedes-Benz
Bulb in order?
Yes No
\}
&
Re-place bulb
1
r:;
Re¡place electronic
board in instrument
cluster
IEnd of t est
Fi~. 189: Volta ~e Supply Flow Chart
Test in the case of problem "B"
When engine oil at "max" level and engine running, indicator lamp (e) comes on and remaíns on.
Mercedes-Benz
Test oillevel sensor
Remove ptug from oillevel sensor connector (5)

Use rra.dtíneter to test pin of comector lo
grounci.
Readol.t <0.10 n
Yes ro
IReplace oillevel sensor (18-3300)
lnsert pi.Jg of olllevel sensor, test cable with ol

leve! sensor lo instrument cluster. Remove
lnstnment ci.Jster for ttis step . Disconnect plug
(2) and use multlmeter to measLre reslstance
between contact 9 (oillevel sensor wirlng
hamess) and contact 11 (W1 main ground
betindl ínstrLrnent cluster).
ReadoLt: < 1 n
Yes jNo
Use multlmeter to test pin of oomector

(X27) lo ground
Readolt: < 1 n
Yes No
¿ ~
Wl'íng hamess to Starter wirng
lnstrument cluster hamess has open
has open clrcul clrcult.
Replace electronlc
board In instrument
cluster
IEnd of test
Fig. 190: Oil Level Flow Chart

Mercedes-Benz
Fig. 191: Testing Oil Level Sensor (1 Of 3)
Test in the case of problem "C"

Mercedes-Benz
Indicator lamp (e) comes on intermittently when engine mnníng and oil at correct level.
Test switching d·elay of electronlc board in

instr ument cluster.
Rurn engine, disconnect plug of oH level sensor.
Readout: indicator lamp (e) comes on after a

time lag < 60 sec.
1
Yes 'No
!
Replace electronic board of instrument
cluster.
7
Test oillevel sensor and wiring harness ,
see test B
IEnd of test
Fig. 194: Oil Level Flow Chart
CHECKING DIPSTICK AND GUIDE TUBE- RA18001043500X(18-3500)

Mercedes-Benz
12.0589062100
P11· ó2i4-i7
1 Dipsticl< 4 Crenkcase
2 DipSUCk 120 589 00 21 00 5 Bo:tom of oll sunp
3 Olpstíck gude ll.tlo
Fig. 195: Cbecking Dipstick And Guide Tube
Dipstick ( 1) remove.
Code number (arrow) on dipstick
( 1) check against table.
insert with míllirneter scale facing to front as far as flow of oil sump
Dipstick (2) 120 589 06 21 00
(5).
Size (D) check against tab1e.
DIPSTICK AND GUIDE TUBE

Engine Model A-B a e D Code no.
104.941 202.028 15 516 600 605 104 07
104.942 124.0 15 516 600 605 104 07
104.943 129.058 15 516 600 605 104 07
104.944 140.028 20 552 645 649 603 22
104.945 210.053 15 516 600 605 104 07
104.980 124.0 15 516 602 605 104 07
104.981 129.061 15 516 602 605 104 07
104.990 140.03 20 552 645 649 603 22
Mercedes-Benz
REMOVING AND INSTALLING OIL SPRAY NOZZLES FOR PISTONS- RA1800104400X(18-4000)
Precedjng work:
Oil sump removed (01-3100) _
Oil shield removed (18-2180)_

Mercedes-Benz
1 - - -......
~~----~~~------~
2---~~
3- - -
4 - --.L
5---j~IIB
6 -_,.,;».1--~~
7
8---·t-f')7r;~
~~~~~=~
11 12
1 Crankcase· 6 Dram dill ng lor leal< oll

2 MMI oíl gale¡y 9 Rolpm
3 Oilfeed dilfng 10 No:ule open11g
4 Piston 11 M SX 22mm OOI+W¡¡sher
5 Compression spling 12 Ball, 2.5 mm dia
6 BaJ, 4 mm dta.
7 011spray nozzle
Fig. 197: ldentifying Removing And Installing Oil Spray Nozzles For Piston Components
Piston of oil spray nozzle to be

position to TDC.
removed (7)
Bolt (11) unscrew, screw on (1 ONm).
remove with suitable pliers, install.
®
Oil spray nozzle (7) The oil spray nozzles are discontinued as of 1/94.
The piston crowns are cooled through optimized drillings in the
conrods and conrod bearings.
REMOVING AND INSTALLING OIL SPRAY NOZZLE FOR TIMING CHAIN, ENGINE 104.94/99-
RA18001044100X(18-4100)
Preceding work:
Timing case cover removed (01-2100).

Mercedes-Benz
Guide raíl removed (05-3350) .
1 14
Fig. 198: ldentifying Rernoving And Installing Oil Spray Nozzle For Tirning Chain, Engine Components
T iming chain ( 6) at camshaft

lift off, fit on, pay attention to colored marking.
sprockets (3 and 5)
Crankshaft sprocket and oil
cover over with clean cloth.
sump
M5 thread (arrow) tap on oil nozzle (14) approx. 8 mm deep.
Oil nozzle ( 14) remove with irnpact extractor (1) 116 589 20 33 OO.
New oiJ nozzle (14) knock in with plastic-headed hammer, proj ection = 31 mm
Both drillings (14a) (oil spray must be positioned in oil nozzle (14) vertical to timing chain (6) (flat face
direction) on oil nozzle (14) at front parallel to tirning chain).
Note re engine 104.98
The timing chain is sprayed with oil through a connection in the oil transverse gallery (12) anda drilling
(arrow) in the guide raíl.
Mercedes-Benz
Fig. 199: Locating Drilling In G uide Rail And Oil Transverse Gallery
PRODUCTION BREAKPOINT: JlJL Y 1990

Modlel Engine Engine end no. manual Engine end no. automatic
transmission transmission
124.031 104.980 002876 012945
124.051
124.091
129.061 104.981 000562 005460
REPLACING OIL NON-RETURN VAL VE OF CHAIN TENSIONER - RA18001044150X(18-4150)
Preceding work:
Timing case cover removed (01-2100)
Tensioning rail removed {05-3300)
Mercedes-Benz
PH!-52"tl4-57
Fig. 200: Replacing Oil Non-Return Valve Of Cbain Tensioner
Oil non-return valve

( )
8
pull off witb suitable pliers.
install by hand.
Fuoction
New oil non-retum
The oil non-return valve (8)
valve (8)
prevents the oil reservoir for the chain tensioner in the timing case cover nmning
dry when the engine is not operating.
OPERATION OF OIL PRESSURE GAUGE - RA1800104A090X(18-0090)
Operatioo of oil pressure gauge- RA1800104A090X(18-0090)
A. Models 129, 140

Mercedes-Benz
X27
P'lt - 5113 - 57
Fig. 201: ldentifying Operatioo Of Oil Pressure Gauge
The two-pin oil pressure sensor (B5) in the oil filter ( 1O) converts the engine oil pressure which exists
into a resistance. As the oil pressure increases, the resistance increases also. The resistauce and engine
speed are supplied as input signals to the microprocessor (a) in the electrical base plate of the instrument
panel unit (Al).
If the oil pressure drops at a certain engiue speed with the result that the resistance drops below a certaiu
level, the oil pressure pointer moves to the bottom stop (O) and the warning lamp (8) comes on.
The oil pressure gauge also moves to the bottom stop (O) in the event of an open circuit in the wiring, but
without the warning light (8) being operated.
The microprocessor (a) analyzes the two input signals relative to the stored characteristic curve from an
engine speed of > 1200 rpm. Depending on the relevant evaluation, the angle position of the pointer of the
oil pressure gauge (A1p3) is controlled across the scale with the readings O, 1, 2 and 3.
The oil pressure sensor (B5) is connected to ground at the base plate and to the microprocessor (a) by
means of the connector (X27)_Voltage is supplied to the base plate through the ignition loe k (S2/ l ), the
fuses (5 and 9) in the fuse box (F1).
Function of oil pressure indicator- RA18001190090X{l8-0090)

Mercedes-Benz
Model129
10
X27
Fig. 202: Identifying Function Of Oil Pressure Indicator
The two-pin oil pressure sensor (B5) in the oil filter (lO) converts the engine oil pressure into an ohmic
resistance. As the oil pressure rises, the ohmic resistance increases. Resistance and engine speed are supphed as
input signals to the rnicroprocessor (a) in the electrical base plate ofthe instrument panel unit (1).
If the oil pressure drops ata certain engine speed so that the resistance falls below a certain level, the oil
pressure pointer moves to the bottom stop (O) and the warning lamp (8) lights up.
The oil pressure pointer also drops to the bottom stop (O) if the wiring has an open circuit, although the warning
lamp (8) is not activated.
The rnicroprocessor (a) analyzes the two input signals relative to the stored characteristic curve as from an
engine speed of > 1000 ± 60 rpm. Depending on the respective analyses, the angle position of the oil pressure
pointer in the instrument cluster (6) is controlled over the scale (7) with the figures O, 1, 2, and 3.
The oil pressure sensor (B5) is connected to ground at the base plate and to the microprocessor (a) vía the plug
connection (X27).
Voltage is supplied for the base plate via the ignition lock (3), the fuse and relay box (b) and fuses 5 and 9.
Mercedes-Benz
TECBNICAL MODIFICATIONS ENGINE 104 MECHANICAL lll- RA1800104TAOOX
18 Oil spray nozzles, oil non-retoro valve

breakpoint no.
Oil spray Elimination of oil spray nozzles; piston crowns cooled 18-
01/94
nozzles through optimízed drilling in the conrods. 4000
FUNCTION OF OIL FILTER- RA18001191110X(18-1110)

Mercedes-Benz
""~
Ollfilter E Temperatura t hermostat lnsert,
Certralbol oil eooler fe-ed
2 Saal 10 Tempei'Wa thenno~at ínsert
2B Seal 11 Sil:if\!1 sleeve
2b Ci rclp 16 CornpresSIOO spnng
3 Cap
4 IOO&Iseal
o 0 11 retum check vaJve
12 VIWesaat
4a Racial se al 12a 0-mg
5 Otl fillsr housing
13 01 s.hlld washer
6 Otl fii:Dr alomarA
14 Vll/ive cona
8 t..poght prpe
9 OtlpresgJro sensor 111111 seal
15 e ornpressoo spnng·
17 Ordp
18 EnQiile od i l ng \'lllve
{new ~. rtilber pljg)
19 M14saowpklg
20 Seal
A Urttered oilto ar-t<Hlll cooler
8 Urftered ocl ltom ar-t<Hlll c ooler
6 from oipunp
b to beanng poots
e Otl retun to sunp 'l'otloo chenging lilt!lf
d lo beanng pllflls andto oj punp
a Urftered angma ocl to ot rtter bypass vat,¡¡¡ tn
cl'al'l<case
Fig. 203: ldentifying Function Of Oil Filter Components
D Return check valve
The r eturn check valve prevents the oil filter running dry when the engine is switched off
Mercedes-Benz
Opening pressure 0.2 bar.
E Oil cooler feed temperature thermostat element
The temperature thermostat element opens from an oil temperature of approx. 11 O oc and feeds the engine oíl
through the air-to-oil cooler into the filter chamber of the oil filter.
REMOVING AND INSTALLING AIR-TO-OIL COOLER- RA18001191300X(18-1300)
Removing and installing air-to-oil cooler - RA18001191300X(18-1300)
Preceding work:
18-6820
A. Model124.036
Mercedes-Benz
Fig. 204: ldentifying Removing And Installing Air-To-Oil Cooler (Modell24.036)
Oillines (1) and (9) at air- NOTE:

to-oil cooler (2)
Counter-hold with wrench at air-to-oil cooler (2) when performing this
step.
Springs (5) detach from left and right mounting plates, attach.
Brackets (10) and (11) unbolt, bolt on.
Air-to-oil cooler (2) remove with brackets (12) and (13) and mbber bushes (14) and (15), install.
check when engine warm.
Leaks NOTE:
The oil circulates in the air-to-oil cooler (2) once the temperature
thermostat element in the oil filter opens (see 18-1110).
B. Model129
Preceding work:

Mercedes-Benz
(Maintenance Mauual6190) .
Operatiou no. of operation texts and work units or standard texts and flat rates
18-6820
F i2. 205: Identifying Removing An d Installing Air-To-Oil Cooler (Mod el l 29)
Bumper detach from mounting of radiator carrier, attach.

Oillines (1 ) of air-to-oil cooler unbolt, bolt on (3 0 Nm).
Locking pins (5) of air-to-oil
pull off, fit on.
cooler mountings
Air-to-oil cooler (2) remove from mouutings (3), fit on.
Air-to-oil cooler between
remove, install.
bumper and radiator carrier
Leaks NOTE:
The oil circulates in the air-to-oil cooler (2) once the temperature
thermostat element in the oil filter opens (see 18-1110).
Removing and installing air-to-oil cooler - RA18001201300X(18-1300)
PrPrPrlin o w ()rlc
Mercedes-Benz
(Maint Man. 6190).
Front bumper removed (88-200).
18-6820
A. Model129
P18-5250-57
Fig. 206: ldentifying Removing And Installing Air-To-Oil Cooler (Modell29)
A ir scoop (4) at front take off, fit on.

unbolt, bolt on (30 Nm) ; brace with wrench
Oillines (11) and (9) ofair-to-oil cooler (2)
(WAF 22) at hexagon head ( 14).
Clips (5) out of left and right mounting brackets (8) take off, fit on
detach from mmmting brackets (8), remove,
Air-to-oil cooler (2) with rubber bushes (6)
instalL
Leaks
r.hPrk whPn P:no-ÍnP: w~m1
Mercedes-Benz
NOTE: see (18-1000).

The oil circulates in the air-to-oil cooler (2) once the
thermostat valve in the oil filter housing opens
Operation no. of the operation texts and work
Preceding work:
units or standard texts and flat rates
18-6820
B. Model140
l,.
i
1
" 1 1
.~.J
,·.:o,..
, .
1
~o(....... '
....... ...... ~..
15 11~· ... . 'Os
Fig. 207: ldentifying Removing And Iustalling Air-To-Oil Cooler (Modell40)
Front bottom engine compartment panel (7) take off, fit on (Maintenance Manual6190).
unbolt, bolt on (30 Nm); brace with wrench
Oillines (9 and 11) of air-to-oil cooler (2)
(WAF 27) at hexagon head ( 14).
Bolts (5) unscrew, screw on.
Bracket (4) with rubber bushes (6) pull off, fit on.
lnstallation note
Tbe retaining lug (arrow) on the bracket (4) must engage in t k ff fít
a e0 '
1
the recess (anow) at the mounting bracket (8). on.
Air-to-oil cooler (2) at mounting brackets (8)
Leaks check when engine warm.
Mercedes-Benz
NOTE:
The oil circulates in the air-to-oil cooler (2) once the see function of oil filter (18-1000).
thermostat valve in the oil filter housing opens
lüillines to air-to-oil cooler 30
Removing and instaUing air-to-oiJ cooler- RA180Bl041300X(18-1300)
Model 129 with air-to-oil cooling
Precedíng work:
(Maintenance Manual 6190)
18-6820
Fig. 208: Identifying Removing And Installing Air-To-Oil Cooler

Mercedes-Benz
Bumper detach from cooler supporting brackets (7), attach.

Oil pipes (1) at air-to-oil cooler (2) unbolt, bolt on (30 Nm).
Locking elements ( 5) pull off from bearing pins (3), fit on.
Air-to-oil cooler (2) disconnect at mounting brackets (8), fit on.
A ir-to-oil cooler (2) between bumper
remove, instan_
and cooler support
Leaks NOTE:
The air circulates in the air-to-oil cooler (2) once the
thermostat valve in the oil filter opens.
Oillevel check, adjust to correct level (18-0020) _
TECHNICAL MODIFICATIONS ENGINE 119 MECHANICAL lll- RA1800119TAOOX
18 Engine lubrication, engine oil cooling
Designation Nature and reason for Production breakpoints. Op. no.

modification
Main oil gallery Offset as of open-deck 04.93
Dipstick Modified version for 9.95 18-0023
engines 119.98.
REMOVING AND INSTALLING DIPSTICK GUIDE TUBE - RA18001200023X(18-0023)
Preceding work:
(Maint_ Man. 6190)
Right air cleaner removed (09-0015) _
Operation no. of the operatiou texts and work units or standard texts and flat rates
Model129
Mercedes-Benz
Fig. 209: ldentifying Removing And Installing Dipstick Guide Tube
Air cleaner of secondary air pump ( 1) at engine and

unbolt, swivel to the side, bolt on.
combination carrier
unbolt from oil pan and cylinder head cover,
Dípstick guíde tube (3)
bolt on.
0-ring (2) replace.
FUNCTION OF OIL PUMP (COMPOUND OIL PUMP) - RA1800120200X(18-2000)

Mercedes-Benz
P18 -0198-611
18
1 Ollpurrp housaog ¡pnma¡y stage) 12 Oll purrp cover With ·stramer

2 Onvo sha.'t Wllh ixod gaar (1a) 13 CcmpreSSIOO SPflllg
2a Ge¡¡¡ {Jlmlllol'f ste¡¡e) 14 FAogpm
2b Woo®" key 15 Oemp9f bofe ~como! PfSÚlll
3 011purrp shS: Wll'l flxed gnar {3a) 1Sa Oll passage ío worl<lng chamber
:le Gaar (prllla¡y o;tega) 1S WOII<1ng chamher
4 Ollpurrp hou smg (setoodar¡ stage) 17 A.tt:ochmert bore •Mtl rolptll
5 Pla!o \I!JNe 18 Onve gaar wth rola.r scrow
6 Fored gear (secoodar¡ st¡:ge) on dnve 5ha1 o SUdlon etl from etl p:a.n
7 looscO gea.r (sacoodarystege) en etlpulll> shat) E Sudlon chBmbor
8 Bear~gcap F Pressure oi tommn ol ga!e¡y
g Ttmogcese p Pnma¡y olllow pressure dlaJTber
10 corool pistoo S S&eooda.ry oi llow prossure dla.rrber
11 8oi1ed COITI&ctlon G Pressure roiel boro
Fig. 2 10: Identifying Oil Pump Components
General
Using the compound oil pump in place of the conventional gear oil pump reduces. the hydraulic power losses
caused by the bypass operation and also improves noise characteristics while offering the same delivery
capacity. The compound oil pump channels sorne ofthe oil under zero pressure via parallel pump chambers.
Only the oil quantity required for the particular oil pressure is pumped (see oil pressure operating curves).
Mercedes-Benz
Oil pressure operating curves

A Requr-edm1n mum ollpressuro
B Compoond oilpuiTJl
C Corrvenbooal ge er oi pump
Fig. 211: ldentifying Oil Pressure Operating Curves
Design and function
The compound oil pump consists of a primary and secondary stage each having a pair of extemally toothed
gears (2a and 3a) and also (6 and 7). The gears (2a) and (6) are fixed on the drive shaft (2). The gear (3a) is
fixed and the gear (7) sits loose on the oil pump shaft (3). The primary oil flow passes directly into the main oil
gallery (arrow), while the secondary oil flow passes through the timing case (9) before entering the main oil
gallery.
Fig. 212: ldentifying Externally Toothed Gears, Oil Pump Shaft, Timing Case And Oil Gallerv
Primary and secondary stages have a common suction chamber (E) and separate pressure chan1bers (primary
stage P), (secondary stage S).
Mercedes-Benz
E 8 S P 4 S58 7 E 1
Fig. 213: Identifying Suction Chamber And Pressure Chambers
Primary and secondary oil flow are led to the control piston (10) separately.
Fig. 214: ldentifying Co ntro~ Piston
The pressure reliefbore (G) enables the control piston (10) to operate in the piston guide without oil back-
press.ure.
Mercedes-Benz
Fig. 215: ldentifying Pressure Relief Bore And Control Piston
Control piston in rest position
TI1e primary oil flow (P) is passed directly into the main oil gallery (F) while the secondary oil flow (S) passes
through the timing case (9) before entering the main oil gallery.
Benefit:
Greater delivery during startíng and hot idling.
Fig. 216: Identifying Primary Oil Flow In OiJ Gallery And Secondary Oil Flow In Timing Case
Control piston in blow-off position
The pressurized oil is passed through the damper bore (15) in the control pisten ( 1O) ínto the working chamber
(16) and moves the control pisten (10). The secondary flow (S) is led back into the suction chamber (E) (only
flow losses). All of the primary oil flow (P) passes into the main oil gallery.
Benefit:
Mercedes-Benz
Low hydraulic losses at high engine speeds.
Fig. 217: ldentifying Damper Bore, Control Piston And Working Chamber
NOTE: The plate valve (5) ensures a pressure balance between primary and secondary
flows when the control piston (10) is moving from the rest into the blow-off
position.
Control piston in bypass position
The secondary oil flow (S) is passed completely into the suction chamber (E).
Part of the primary oil flow (P) is passed via the front piston edge of the control piston into the suction chamber
(E) (bypass control).
Fig. 218: ldentifving Suction Chamber And Secondary Oil Flow
TECBNICAL MODIFICATIONS ENGINE 120 MECHANICAL ll - RA1800120TAOOX
1 R F,noinP lnhrir~ tion. PnoinP roolino

Mercedes-Benz

breakpoints no.
Elimination of oil nozzle in oil feed bore in rear of
Elimination of oilnozzle in
cylinder bead (new, oil nozzle is cast with oil feed 09.93
right and left cylinder bead
drilling).
Dipstick Modified version for improving use. 10/93
Conversion to less expensive single-pin oil pressure
Oil pressure sensor 0 1194
sensor.
Mercedes-Benz
1990-2002 ENGINE Engine Suspension - 129 Chassis
1990-2002 ENGINE
Engine Suspension - 129 Chassis
TESTING & REPAIR

TESTING AND REP AIR WORK: PASSENGER CARS: ENGINE SUSPENSION - AR22.00-Z-9113AB
ENGINE 113
Removelinstall engine ENGINE 113.989 in MODEL AR22.10-P-1100AC

mount 171.473 ENGINE 113 .988 in
MODEL 203.076/276
Remove/install engine ENGINE 112, 113 .. . AR22.10-P-1100AV
mount
Remove/install engine ENGINE 113 in MODEL AR22.10-P-1100DV
mount 210.070 /270 /074 /274
Removing and installing ENGINE 112, 113 in MODEL AR22.10-P-1100EV
engine mount 129
Removing/installing the ENGINE 113.964 in MODEL AR22.10-P-1100GZ
engine mount 164.175
Remove/install engine ENGINE 112.975, 113.948 /966 AR22.10-P-1100IW
mount inMODEL220
Removing and installing ENGINE 113.943 in MODEL AR22.10-P-1100MV
engine mount 208.370/470 ENGINE 113.984
in MODEL 208.374
Remove/install engine ENGINE 112, 113 .. . AR22.10-P-1100PV
mount
Remove/install engine ENGINE 112, 113 .. . AR22.10-P-1100R
mount
Removing/installing the ENGINE 113.971 in MODELS AR22.10-P-1100RT
engine mount 251.075 / 175
Remove/install engine ENGINE 113.967 in MODEL AR22.10-P-1100TY
mount 219.375
Remove/install engine ENGINE 113.990 in MODEL AR22.10-P-1100TZ
mount 219.376 ENGINE 156.983 in
MODEL 211.077 /277, 219.377
Remove, insta11 engine ENGINE 112, 113,272, 273 .. . AR22.10-P-1100VM
mount
Removelinstall rear engine ENGINE 112, 113, 137, 275, AR22.10-P-1160AB
mount 613, 628 ...
Remove/install rear engine ENGINE 113.9, 272.9 in AR22.10-P-1160GZ
mount MODEL 164.1 ENGINE 642.9,
629 in MODEL 164
Mercedes-Benz
1990-2002 ENGINE Engine Suspension- 129 Chassis
Removing/instaUing the ENGINE 111, 112, 113, 612, AR22.10-P-1160HG

rear engine mount 628 ...
Removing and installing ENGINE 112, 113 ... AR22.10-P-1160HV
rear engine mount
Remove/install rear engine ENGINE 112 in MODEL AR22.10-P-1160IW
mount 220.087/187 ENGINE 113 in
M ODEL
220.083 /084 /183 /184
Remove/install rear engine ENGINE 111, 112, 113, 271, AR22.10-P-1160PR
mount 646 ...
Remove/install rear engine ENGINE 113, 272, 642 ... AR22.10-P-1160RT
mount
Remove/install rear engine ENGINE 112, 113,271,646, AR22.10-P-1160T
mount 647, 648 ...
Remove, install rear engine ENGINE 112, 113, 272, 273 ... AR22.10-P-11 60TW
mount
Remove/install rear engine ENGINE 112, 113 ... AR22.10-P-1160V
mount
Remove/install rear engine ENGINE 113.989 in MODEL AR22.10-P-1160VA
mount 171.473 ENGINE 272.942 in
272.963 in MODEL 171.456
Remove/install rear engine ENGINE 113.9, 272.9 in AR22.1 0-P-
cross member MODEL 164.1 ENGINE 642.9, 1170GZA
629 in MODEL 164
Remove/install rear engine ENGINE 113, 272, 642 ... AR22.10-P- 1170RT
cross member
Remove/install engine ENGINE 112, 113 .. . AR22.10-P-1200R
support
Remove/install front engine ENGINE 112, 1131 (except AR22.10-P-1260A
mounts and/or engine 112.975, 113.948 /966) in
support MODEL220
Removing/installing front ENGINE 113.942 in MODEL AR22.10-P-1260MV
engine mounts and/or 163.172 ENGINE 113 .965 in
engine support MODEL 163.175 ENGINE
113.981 inMODEL 163.174
Removing, installíng right ENGINE 112, 113 ... AR22.10-P-4340AV
engine support
Remove/install right engine ENGINE 113 in MODEL AR22.1 0-P-4340DV
support 210.070/270 ENGINE 113.980
in M ODEL 210.074 /274
Remove/install rigbt engine ENGINE 112, 113 in MODEL AR22.10-P-4340EV
support 129
Removing/installing the ENGINE 113.964 in MODEL AR22.10-P-4340GZ
ri!!ht enmne sunnort 164.175
Mercedes-Benz
RemovelinstaU right engine ENGINE 112, 113 .. . AR22.10-P-4340PV

support
Removelinstall right engine ENGINE 112, 113, 272 ... AR22. 10-P-4340PW
support
Remove, install right engine ENGINE 112, 113 ... AR22.10-P-4340R
support
Removing/installing right ENGINE 113.971 in MODELS AR22.1 O-P-4340RT
engine support 251.075/175
Remove, install right engine ENGINE 112, 113, 272, 273 ... AR22. 10-P-4340TW
support
Removelinstall right engine ENGINE 113, 156... AR22.10-P-4340TY
support
Remo ve, installleft engine ENGINE 112, 1 13 .. . AR22.10-P-4350AV
support
Removelinstall left engine ENGINE 113 in MODEL AR22.10-P-4350DV
support 210.070/270ENGINE 113.980
in MODEL 210.074 /274
Removing, installing left ENGINE 112, 113 in MODEL AR22.10-P-4350EV
engine support 129
Remove/install left engine ENGINE 113.964 in MODEL AR22.10-P-4350GZ
support 164.175
Removelinstall left engine ENGINE 112.975, 113 .948 /966 AR22.10-P-4350IW
support in MODEL 220
Remove/install left engine ENGINE 112, 113 ... AR22. 10-P-4350PV
support
Removelinstall left engine ENGINE 112, 113 ... AR22.1 0-P-4350R
support
Removing/installing the left ENGINE 113.971 in MODELS AR22.1 O-P-4350RT
engine support 251.075 / 175
Remove, installleft engine ENG INE 112, 113, 272, 273 .. . AR22.10-P-4350TW
support
Removelinstall left engine ENGINE 113, 156... AR22.1 0-P-4350TY
support
TESTING AND REP AIR WORK: PASSENGER CARS: ENGINE SUSPENSION- AR22.00-Z-9120AB
ENGINE 120
I IRemoving and installing rear engine mount IENGINE 120 in MODEL 129, 140 IAR22.10-P-1160AO 1
REMOVING AND INSTALLING ENGINE MOUNT- AR22. 10-P-1100EV

Mercedes-Benz
Englno comp•rtm#nt ~nofn¡¡

U Shlo/11
14 Ro/Qylt:Var
W10 & tfluyground coblo
PHJO·lOJHIII
Fig. 1: Identifying Engine Mount Remove!lnstall Components {Shown On Model129 With Engine 112)
Shown on engine 112
Scrc.w
Ens~hc mounr
4 A frflftr;r
! 1/ls<:OCIS ton
Hot fi1m IAAF sensor
A Ir lntoAo pipo
• F•nshroud
Fig. 2: ldentifying Engine Mount Remove!lnstall Components (Shown On Engine 112)
@
m Remove!Install
Only necessary if the right engine mount is
&oanqnrl
removed.
Disconnect Qfounrl cabl e Tnstallation · A fter connectinrr. read out fault memorv. AR54.10-P-
Mercedes-Benz
(Wl 0), connect encode radío and normalize power wíndows. 0003A
1 Vebicles with stationary heater: adjust time display on
stationary heater.
AR61.20-P-
2 Remove engine compartment panel ( 1)
1105AB
Remove the shíeld (13) at the & Danaer! W ith Engine 112
3.1
relay lever (14) Only necessary íf the right engíne mount ís removed.
Unscrew bolts (2) ofthe
*BA22.10-P-
4 engíne mount (3) at the front ~
1001-01L
axle carrier
&oanaerl Remove aír cleaner by líftíng vertícally up and
5 Remove the air cleaner (4)
off the cylinder head covers.
AR20.40-P-
6 Remove viscous fan ( 5)
5660C
Remove the hot film MAF
AR07.07-P-
7 sensor ( 6) together with air
1454AG
intake pipe (7)
8.1 Remove fan shroud (8) &oanaer! With Engine 112
Unscrew bolts (9) ofthe
*BA22.10-P-
9 engine mount (3) at the ~
1004-0lL
engíne support
Fit on engine supporting
10
frame
Lift engine by the front
fll Ensure that the rear of the engíne does not touch the
11 body!
lifting eye
Do not over-tension coolant hoses!
l nstallation :
12 Remove shíelds (10) fll The notches in the shields (10) must be located in the
anti-twist locks ofthe engíne mounts (3).
Installation :
IIl The antí-twist locks (arrows) at the engíne mounts
13 Remove engine motmts (3) (3) must be located in the retaining grooves (arrows) of
the engíne supports.
&oanao.rl Dispose engine mounts into mixed scrap.

Stored faults occurríng due to cables dísconnected
duríng assembly or test work or due to símulation must
be processed and erased in the fault memories after the
15 Read fault memory, erase
work is completed. ?
Diagnosis Manual Volume 2, Index 0: Connectíng and
using test equipment.
~ ENGINE M OUNTS, ENGINE SUPPORTS

IN umber lnesignatio n IEngine 112.923/ 943, 113.961 in model
Mercedes-Benz
129.059/064/068
BA22.1 0-P-1 001- Bolt of front engine mounts to front N
OlL ax l e carner
. m 25
BA22.10-P-1004- Bolt of front engine mount to
OlL engine support
Nm 55
REMOVING AND INSTALLING REAR ENGINE MOUNT- AR22.10-P-1160
Removing ami installing rear engine mount- AR22.10-P-1160AO
Et>glnt: 120 wth trltl$llllsslon 7 2Z.'

11 Ensthc mount
12 BriJC~Ilt
U Et~ghc c•rrfcr
P 22.10-41217·06
Fig. 3: ldentifying Rear Engine Mount Remove!Install Components (Engine 120 With Transmission
722.3)
Mercedes-Benz
1990-2002 ENG INE Engine Suspension- 129 Chassis
Enfinc 120 wlh tnons.mlssion 7 22.e p.IAG)

11 Enginc mounr
U E.ngfnc . .rricr
Fig. 4: ldentifying Rear Engine Mount Removellnstall Components (Engine 120 With Transmission
722.6 (NAG))
@
OJ
1 Support transmissíon
Detacb cable straps of the
2.1 kickdown electric cable from Model129 with transmíssion 722.3
engine carrier (13)
Detach cable straps of the
3.1 kickdown and O 2 sensor electríc Model 140 with transmíssion 722.3
cables from engine carrier ( 13)
4 Remove engine carrier (13)
L:hoanoer! Engíne mounts with transmission 722.3: the
installation positi.on is frxed by a slot (arrow) on the
engíne mount ( 11) and by a notch (arrow) on the
bracket
*BA22.10-P-
5 Remo ve engine mount (11) ~
1002-0IB
*BA22.10-P-
B 1003-0lB
*BA22.10-P-
B 1008-0lB
B ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE CARRIER

Number Designation Engine 120 in model 129, 140 Engine 120 in model 129,
with transmission 722.6 (NAG) 140 with transmission 722.3
Mercedes-Benz
Bolt of rear engine

BA22.1 0-P-
mount to engine N m 25 30
1002-0lB
carrier
BA22.10-P- Bolt of rear engine
N m 40 40
1003-0lB carríer to body
BA22.10-P- Bolt of rear engine
N m 40 50
1008-0lB mount to bracket
Remove/install rear engine mount- AR22.10-P-1160V
ENGINE 112 in MODEL 210.06 /26, 208, 202, 129 with transmission 722.6
ENGINE 113 in MODEL 210.07/27,208, 202,129 with transmission 722.6
r Engfnc mo unr
z aotrs
J aotrs
4 C~~rrlor
! aotrs
P22 10·2037·0S
Fig. 5: ldentifying Rear Engine Mount Remove/Install Components (Shown On Engine 112 In Model
210)
@[IJ Remove/install
1 Suppott transmission
2 Remove bolts (3) ~ *BA22.10-P-1002-01L
3 Remove bolts (5) ~ *BA22.10-P-1003-0IL
4 Remove support (4)
5 Unscrew bolt (2) ~ *BA22.10-P-1006-01L
6 Remo ve engine mount ( l)

Number Designation Engines 112.910/920, Engine 112.911/914/921/941, 113.940/980 in n
113.944 in models 21 o.061/062/063/065/070/074/261/262/263/265
Mercedes-Benz
1990-2002 ENG INE Engine Suspension - 129 Chassis
202.026/029/033/086/089/093
Bolt, rear
BA22. 10- engíne
P-1002- mount to N m 30 30
OlL rear engine
crossmember
Bolt, rear
BA22. 10-
engme
P-1003- N m 40 40
crossmember
01L
to body
Bolt or nut,
BA22.10-
rear engme
M8 Nm - -
P-1006-
mount to
OIL MlONm 40 40
transmission

Number Designation Engine 112.923/943, Engine 112.940, 113.943/984 in
113.961 in model model208.365/370/374/465/470
129.059/064/068
Bolt, rear engine
A22. 10-P-
mount to rear engíne N m 30 30
1002-01L
crossmember
BA22. 10-P- Bolt, rear engine
N m 40 40
1003-01L crossmember to body
Bolt or nut, rear M8 Nm - -
BA22.10-P-
engine mount to
1006-01L MIO N m 40 40
transmission
REMOVE/INSTALL RIGHT ENGINE SUPPORT - AR22.10-P-4340EV
Sbown on engine 112

Mercedes-Benz
1 Gcnc10110r
2 en¡¡lno supp ort
J S:crow
@
PH-1 0· 2035·12
Fig. 6: ldentifyi.ng Right Engine Support Remove/Install Components (Shown On Engine 112)
@
Remove/lnstall
m
AR22.10-P-
1 Remove engine mounts
1100EV
AR13.22-P-
2.1 Take offpoly V-belt &oanqcrl With Engln.e 112
1202B
&oanoerl With Engln.e 112
&oanqerl Place to the side with línes connected.
3.1 Unscrew generator ( l)
*BA15.40-P-
B 1003-01A
&o""""'' Screws (3) must be used only once.
Unbolt engine support (2) *BA22.10-P-
4 ~
at crankcase 1005-01L
~ F ig. 7
Installation :
Remove engine supports
5
(2)
[[! There must not be any electric cables jammed in
between engine support and crankcase.
6 Insta U in the reverse order
~GENERATOR
Number Designation Engine 112.91/92/94/953/954/955/96/97, 113.94/96/98
BA15.40-P-1003-01A Screw, alternator N m 42

Number Designation E ngine 112.923/943, 113.961 in Model
Mercedes-Benz
129.059/064/068
BA22.10-P-1005- Bolt of engine support to l stNm 20
stage
OlL crankcase
Step 2 Angle 90
~; El El El El rl
Ei;L1 LJ LJ LJ [j
~o r1 r1 \:1 r1 EJ EH:!
1
OO t 59!1 76 09 00
Fig. 7: ldentifying Externa! Torx Set (001 589 76 09 00)
REMOVING, INSTALLING LEFT ENGINE SUPPORT- AR22.10-P-4350EV
Sbown on engine 112
1 AC com¡Kcs.sor
2 En11lno support
J Solt
Fi2. 8: ldentifyin2 Left En2ine Support Removellnstall Components (Sbown On En2ine 112)
@
[JJ Removing, installing
AR22.10-P-
1 Remove engine mounts
llOOEV
Mercedes-Benz
AR13.22-P-
2 Take offpoly V-belt
1202B
Attach AC compressor at bottom ín engine
&oanQcrl
compartment with lines connected

3 U n b o lt Ac compressor ( 1)
*BA83.55-P-
~ 1001-01A
[l] Bolts (3) must only be used once
Unbolt engíne support (2) ~ *BA22.10-P-
4
at crankcase 1005-01L
Fig. 7
Remove engíne support
5
(2)
~ ENGINE MOUNTS, ENGINE SUPPORTS

Nomber Desigoation Eogine 112.923/943, 113.961 in model
129.059/064/068
lstNm 20
BA22.1 0-P-1 005- Bolt of eng ine support to stage
OlL crankcase 2nd
Angle 0 90
stage
AC COMPRESSOR
Nomber Designation Engine 112.923/943, 113.961 in model
129
BA83.55-P-1001- Bolt ofNm AC compressor to
Nm20
0lA bracket
OOt 5S9 76 09 00 ,
''-------------~/
EX!IIl DfiOilt sal
Fig. 9: ldentifying Externa! Torx Set (001 589 76 09 00)

REMOVING AND INSTALLING REAR ENGINE MOUNT- RA22001042120X(22-2120)
Removing and installing rear engine mount- RA22001042120X(22-2120)

Mercedes-Benz
22-1160,1168
A. Models 124, 129, 140
Models 124, 129manu.eflulllsmiSS!On
Fig. 10: Identifying Rear Engine Mount Remove/Install Components (Models 124, 129 Manual
Transmission)
Mercedes-Benz
G 6
Modots 124, 129 ooiDmatic transmíssion
Fig. 11: ldentifying Rear Engine Mount Removellnstall Components (Models 124, 129 Automatic
Transmission)
Mercedes-Benz
~ 1B
40Nm @) ~ 25Nm
12b
~12a
Mod!!l 140 automabc 4-speoo lrnnsmssioo
Fig. 12: ldentifying Rear Engine Mount Remove/lnstall Components (Model140 Automatic 4-
Speed Transmission)
Mercedes-Benz
25Nm
MtHfel 140 manual5-spee~ troosmssmn
Fig. 13: ldentifying Rear Engine Mount Remove!Install Components (Mode1 140 ManualS-Speed
Transmissioo)
Mercedes-Benz
1
17
~1& ~25 Nm
40N~· JJJd
Mo{iol 140 attomatic ~spooo lnmsmsstoo
Fig. 14: l dentifying Rear Engine Mou nt Removellnstall Components (Model 140 Automatic 5-
Speed Transmission)
Cable straps of wiring of kickdown switch and
slacken, tie.
oxygen sensor at engine carrier ( 13)
remove, instail (M8 25 Nm,
Engine carrier (13)
M10 40 Nm).
remove engine mounts (11 or 12), instaU (70 Nm). Pay
attention to washer (9) or backing plate (lO)
Models 124, 129:
NOTE:
The engine mounts differ depending on whether a
manual or automatíc transmíssíon ís fítted.
s lacken securing bolt ( 16) of engine mount, tighten ( 40
Model140:
Nm), pay attention to note.
Special tools
Mercedes-Benz
001 589 66 21 00
001 589 72 21 00
Note re modell40
The installation position ofthe engine motmt (12a) is fixed by a slot (arrow) on the mount anda recess (6)
on the bracket (12b).
JGrGF
Rear engine mounts of engine 104 in model 140 di ffer in their load bearing capacity from the engine
mounts of engines 119 and 120 and must not be interchanged.
Automatic 4-speed transmission

Mercedes-Benz
Fig. 17: Identifying Engine Mount And Bracket
B. Models 202, 210
Operation no. of operation texts and work units or standard texts and tlat rates:
01-1 260
Mercedes-Benz
P22-5060-S7
A MarualtrammJSSion
B Aliomabt tBilSilli SSIOO
Fig. 18: ldentifying Manual And Automatic Transmission Engine Mount Remove/Install
Components
Transmissíon support.
unscrew, screw on (M8 25 Nm,
Bolts (7) and (1 0)
MIO 40Nm).
Engine carrier (2) remove, install.
Manual transmíssion: unscrew bolts (9) together with nuts ( 13), screw on (40 N m).
Automatic transmíssion: tmscrew bolts (9), screw on (40 N m).
Engine mounts (1) remove, install.
Removing and installing rear engine mount- RA2200119212X(22-2120)
Preceding work:
22-1160, 1168
Mercedes-Benz
A. Models 124, 140
2Stn
1
40Nm& ! 25Nm
P22. so.& -&7
Fig. 19: Identifying Rear Engine Mount Remove!lnstall Components (Models 124, 140)
Cable straps of electric cable of
detach, attach.
kickdown at engine carrier (13)
Engine carrier (13) remove, install (M8: 25 Nm; M lO: 40 Nm).
remove, install (40 Nm).
Engine mount ( 11) NOTE:

The installation position is fixed by a slot (arrow) on the engine
mount (11) and by a recess (arrow) on the mounting plat (12).
B. Model129
22-1160, 1168
Mercedes-Benz
Fig. 20: ldentifying Rear Engine Mount Removellnstall Compooents (Model 129)
Transmission support
Cable straps of wiring of kickdown switch and oxygen sensor at
detach, attach.
engine carrier ( 13)
remove, install (M8: 25 Nm; MlO:
Engine carrier (13)
40Nm).
Engine mount ( 11) remove, install (70 Nm).
Baclcing plate (10) note.
Special tool
Mercedes-Benz
001 589 66 21 00
C. Model210
22-1160, 1168
P22.10-0217--37
Fig. 22: Identifying Rear Engine Mount Removellnstall Components (Model210)
. (l )remove, install (M8 25 Nm)
E ngme mount 1 (MIO 40 N m)
Mercedes-Benz
REMOVING AND INSTALLING ENGINE CARRIER- RA22001042500X(22-2500)
Removing and installing engine carrier- RA22001042500X(22-2500)
Preceding work:
Bottom engine compartment panel removed (Maintenance Manual 6190).
A Models 124, 129, 140
22-4320
55Nm
P22. 5044 • $7
Fig. 23: ldentifying Engine Carrier Remove/Install Components {Typ 129)
Fan shroud ring remove, place over fan, install (20-3400) .

Air intake scoop remove, install (09-0060) .
. t b lt unscrew, screw on (55 Nm).
Engme moun o s In . d
( 6) t . stallation note re m o el 140
a top Also bolt holder of high pressure expansion hose to engine carrier (7).
Engine raise at front lifting lug.
Mercedes-Benz
Models 129, 140: take off shield (4) from engine carrier (5) on right, fit on.
Bolts (9 and 1O) unscrew, screw on (25 Nm).
Engine carriers ( 5
remove, install
and 7)
unbolt shield (4) at engine carrier (5) on right, bolt on.
Notes
Models 129, 140 with secondary air injection: also bolt mounting bracket of
secondary air inj ection pipe onto eugine carrier (5) on Iight.
Models 124, 129 with electronic accelerator: also bolt :motmting bracket of actuator
Model124:
to engine carrier (7) on left.
Model 140: also bolt mounting bracket of generator wiring harness to engine carrier
( 5) on ríght.
The anti-twist lock (arrow) in the engine mount (3) must engage in the opening in
the shield (4) and in the retaining slot in the engine carrier.
Bolt of engine carrier to crankcase 25
Bolt of engine carrier to engine mount55
SpeciaJ tool
001 589 72 21 00
B. Models 202,210
Preceding work:
Engine motmts removed! (22-2110).
22-4320
Mercedes-Benz
?22-5061-57
Fig. 25: ldentifying Engine Carrier Remove/Install Components (Models 202, 210)
Engine raised at front lifting lug.

Right engine carrier: unbolt shield ( 15a) at engine carrier ( 15), bolt on.
Bolts (12) and (13) unscrew, screw on (21 Nm)
remove, install.
Engine carriers (14)
NOTE:
and (15)
Model 202: Also bolt bracket (12a) to engine carrier (15) on right and bracket
(13a) to engine carrier (14) on left.
Removing and installing engine carrier - RA22001192500X{22-2500)
Front engine compartrnent panel at bottom removed (Maintenance Manua16190)
22-2031-4670
Mode1129 (Model 124

Mercedes-Benz
corresponds to Removing and installing front engine mounts 22-2110)
Fig. 26: Identifying Engine Carrier Remove/InstaU Components
Left or right engine carrier ( 5) remove, install.

F an shroud ring detach, attach.
Bottom engine compartment panel unbolt, bolt on.
Top engine mount bolt (2) unscrew, screw on (55 N m).
Bottom engine mount bolt (1) unscrew, screw on (25 N m).
Engine at left or right raise (about 30 mm).
take off, install
Shie1d (4)
(pay attention to installation note).
Engine carrier bolts ( 6) unscrew, screw on.
Engine carrier (5) take off, install (M8: 25 Nm; MIO: 40 Nm).
Special tool
Mercedes-Benz
Installation note
The anti-twíst lock (pin) in the engine mount must engage in the openíng in the shield (4) and in the retaining
slot in the engine carrier.
Removing and installing engi:ne carrier - RA22001202500X(22-2500)
Preceding work:
Engine compartment panel at bottom front removed (Maintenance Manual6190).
Engine mounts (3) removed (22-2110).
Secondary aír injectíon lines (10) removed.
22-4320
Modell29 corresponds to Removing and installing engine mounts (22-2110)
Model140
Mercedes-Benz
Fig. 28: Identifying Engine Carrier RemovellnstaU Components
Engine raised at front lifting eye (22-2110).

Left or ríght engine carríer remove, ínstall.
Right engine carrier (6): air cleaner of air unbolt at engíne carríer (6) and at bracket of air
pump (7) pump/generator, bolt on.
Right engine carrier ( 6): altemator wiring
unbolt at engine carrier (6), bolt on.
hamess (8)
Engine carriers (5) and (6) Take off downward, install.
REMOVING AND INSTALLING FRONT ENGINE MOUNTS- RA22001202110X(22-2110)
Removing and installing fro nt engine mounts - RA22001202110X{22-2110)
Preceding work:
Air cleaner with mass air flow sensor removed (09-0015) .
Fan cowl removed (20-3400)
Oneratíon no. ofthe oner:üíon texts and work unítc; or sta ndard texts and fl:ü rates
Mercedes-Benz
22-1260-1700
A_ Model129
Ground cable at battery disconnect, connect

Exhaust at exhaust manifold and transmission intermediate bearing unbolt, bolt on (49-5531 ).
Left engine mount: front exhaust pipe remove, install (49-5531).
Ríght engine mount: shield above steeríng ann remove, instalL
Rear engine mount at engine carrier unbolt, bolt on (22-2120)_
unscrew with suitable wrench,
Bolts of engine motmt at top
screw on (55 Nm).
Bolts of engine mount at the bottom unscrew, screw on (25 Nm).
Shields remove, instalL
Ríght engine mount to front and left engine mount to the rear remove, 1nsta1L
Installatiou note
Rotation locks in engine mounts into the openíngs in the shields and must engage_
into the retaining slots of the engine carriers
Jt!rGF
Pay attention to environmental protection regulations when disposing of engine motmts. Dispose of
engine mounts with mixed scrap.
M8 hexagon bolts for engine mounts to body 25
MlO hexagon bolts for engine mount to engine carrier55
Shop-made tool
Fig. 29: Identifying Shop-Made Tool With Specification

Mercedes-Benz
Preceding work:
Air cleaner with mass air flow sensor removed (09-0015) _
Operation no_of the operation texts and work units or standard texts and flat rates
22-1 260-1700
B. Model140
PZZ- 5017 • ~7A
Fig. 30: Identifying Front Engine Mounts Remove/Install Components
Ground cable at battery disconnect, connect

Fan cowl ring remove, place over fan, fit on (20-3400) _
lnstallation note
ensure correctly located.
4 catchpoints
remove, install (Maintenance Manual
Bottom engine compartment panel (2)
6190).
Bolts ( 1) at front axle unscrew, screw on (25 Nm).
Drag link remove, install (46-5500).
Right engine oil cooler line at cooler cross member detach.
Engine at front lifting eye raise, lower.
Mercedes-Benz
~GF
pay attention to coolant hoses.
When raising engine
unbolt at cylinder head and at crankcase,
Left engine mount: secondary air injection line
bolt on.
Installation note
note.
Gasket
1mbolt at cylinder head and at engine
Right engine mmmt: secondary air injection line
carrier (5), bolt on.
unbolt at cylinder head cover and at oil
Right engine mount: dipstlck guide tube
pan, bolt on.
lnstallation note
note, replace according to condition.
0 -ring
unscrew from above with suitable wrench,
Bolts (6)
tighten (55 Nm).
Engine mo1mt (3) with shield (4) remove downward, install (step 9).
engage in the opening in the shield (4) and
lnstallation notes
in the retaining groove in the engine
The rotation lock (arrow) in the engine mount (3) must
carrier.
Shields (4) on left and right
!G?'GF
Pay attention to envirornnental protection regulations when are identicaL
disposing of engine mounts. Dispose of engine mounts with
mixed scrap.
Hexagon bolts for engine mount to front axle 25
Hexagon bolts for engine mount to engine carrier 55
Special tool
001 589 66 21 00
00
Removing ami installing fl·ont engine mounts- RA220A1042110X(22-2110)
Mercedes-Benz
22- 1260-1700
A. Models 124, 129, 140
10Ñm88
G G
~10
........ . . .
Fig. 32: ldentifying Front Engine Mounts Remove/lnstall Components

Intake aír scoop remove, install (09-0060) .
Models 124, 129: take offfan shroud ring and fan shroud, fit on (20-3400).
Bottom engine compartment panelremove, install.
Bolts (1) unscrew, screw on, tightening torque 25 Nm.
Bolts (7) unscrew, screw on, tightening torque 55 Nm.
Engine mounts (2) and shield (3) remove, install, pay attention to installation note.
SpeciaJ tools
Mercedes-Benz
001 589 66 21 ()0
001 589 72 21 00
Installation note
Engine motmts (2) and shields (3) on the left and right are identical.
The anti-twist lock (pin) in the engine mount (2) must be inserted into the hole in the shield (3) and into
the retaining slot in the engine carriers (4 or 5).
Model 140
Remove left engine mount together with engine carrier. Unscrew securing bolts (1 ). Push high pressure
hose of tandem pump up and out.
Mercedes-Benz
Fig. 35: ldentifying Engine Mount With Bolts
R emoving an<l installing front engine mounts- RA220Bl192110X(22-2110)
Preceding work:
Intake aír scoops removed (09-0015) _
22-1260-1700
B.Model129
Mercedes-Benz
Fig. 36: Identifying Front Engine Mounts Remove/lnstall Components

remove, place over fan, attach_
Fan shroud ring Installation note
Ensure the 4 engaging points are correctly located.
Bottom engine
remove, install (Maintenance Manual6190).
compartment panel
raise, lower.
Engine at front lifting o:::rGF
eye
When raising, pay attention to accelerator control at rear and coolant hoses.
Bolts (2) unscrew, tighten (55 Nm).
Engine mount (3) with -
shield (4 ) remove, mstall (step 9).
NOTE:
lf vehicle fitted with AC. remove draa link. install (46-5500).
Mercedes-Benz
Instanation note The anti-twist lock in the engíne mount (3) must engage in the
opening in the shield (4) and in the retaining slot in the engine carrier.
Shields (4) on left and right are identical.
TIGHTENING TOR QUES IN NM

Hexagon bolts for engine mounts to frame cross member 25
Hexagon bolts for engine mounts to engine carrier 55
Special tool
001 589 66 21 00

Mercedes-Benz
1990-2002 ENGINE Engine Timing- REPAIR & ADJUSTMENTS- 129 Chassis
1990-2002 ENGINE
Engine Timing- REPAIR & ADJUSTMENTS -129 Chassis

CHECKING AND REPLACING HYDRAULIC VAL VE CLEARANCE COMPENSATING
ELEMENTS (BUCKET TAPPETS)- RA05001042110X(05-2110)
Checlüng aud replacing bydraulic valve clearance compensatiug elements (bucket tappets)- RA05001042110X(05-2110)
05-2010-2500
A 8
POs-5400-55
A &icketta¡¡pet 1st ve~>~on 8 Bud<elteppet 2nd v01>1on
a" 34.965 - 34.975mm a" 34.965 - 34.975 mm
Wetght 81g Woígt 67g 1.4> to 09/94
52 g as <ll 10194
Fig. 1: Hydraulic Valve Clearance Compensating Elements- System Diagram
VALVE CLEARANCE
Cylinder head cover remove, install (01-0500) _
Cam on respective bucket tappet position to base circle (lobe ofcam must face up).
Bucket tappet press with suitable tool (not steel tool).
Bucket tappets if one tappet can be pressed more easily in
comparison to the others, replace tbjs bucket tappet
BUCKET TAPPET CLEARANCE

Mercedes-Benz
Relevant camshaft remove, install {05-2200).

Bucket tappet of respective cylinder E!! U up with mbber sucker and remove.
~
Install bucket tappet 1st version, 82 g, only together
with double valve spring. Bucket tappet 2nd version,
67 g, and 3rd version, 52 g, can be installed with the
folllowing valve springs,
• cyl. double valve spring,

• cyL single valve spring,
• conical valve spring.
Magnets must not be used as minute iron swarf may

gather on the magnetized surfaces of the bucket
tappet and produces damage to buckets and cams.
The bucket tappets must be re-installed at the same
poínt.
Basic bore inspect visually.
COMMffiRCULLYAVAaABLETOOL
IRubber sucker 0 30 mm e.g. Hazet, no. 735-2
Examiuing aud replacing hydraulic valve clearance compeusatiug elemeuts (bucket tappets) - RA05001192110X(05-
2110)
05-2010-2500
Mercedes-Benz
A B
POS-5400-55
A. B1.11cket tappet 1st version B. Bucket tap pet 2nd version

a 34 965 . 34.9 75 mm a 34.965 · 34.975 mm
b 25.5 . 26.5 mm b 25.5 . 26.5 mm
( (stroke) =mil. 2J).1 mm e (strok.8) =m11 2.04 mm
d (pr.;ton extended)= 20.1 mm d (¡listen extended)= 20.1 mm
Worgtt. 82 g Wergit 64g
Fig. 2: Operation Diagram- Hydraulic Valve Clearance Compensating Elements
EXAMINING VAL VE CLEARANCE

Cylinder head cover remove, install (01-0500) .
Cam at relevant bucket tappet position to base círcle (lobe of cam must face up).
Bucket tappet press with suitable tool (not steel tool).
If one bucket tappet can be pressed more easily in replace this bucket tappet.
comparison to the others
COMPARISON BUCKET T APPET

Relevant camshaft remove, install (05-2200).
Bucket tappet of respective cylinder ~11 up with rubber suction cup and remove.
Install the first version of bucket tappet only

together with double valve springs. Do not use
magnets as minute íron particles collect at the
magnetized contact surfaces of the bucket tappet and
cause damage to the buckets and cams. The bucket
tappets must be re-installed at the same point.
The contact surface must not have any pitting
caused by the cam lobe so that the rotational
movement of the bucket tappet is not obstructed.
Basic bore perform visual inspection.
Mercedes-Benz
COMMffiR~LYAV~ABLETOOL
l3o mm dia. rubber suction cup e.g. Hazet, no. 735-2
Checking and replacing hydraulic valve clearance compensation elements (bucket tappets)- RA05001202110X(05-2110)
Operation no. of the operation texts and work units or standard texts and flat rates: 05-2010-2500
1-----1N
~------------~==~~
--·
Fig. 3: ldentifying Hydraulic Valve Clearance Compensation Elements - 1St Version
F ig. 4: ldentifying Hvdraulic Valve Clearance Compensation Elements - 2Nd Version
1st version
a= 34.96- 34.97 mm dia.
b= 26.5 - 27 .O mm
e= Minímum stroke 2.3 mm

Mercedes-Benz
2nd version
a= 34.96-34.97 mm dia.
b= 25.5- 26.5 mm
e= Minimum stroke 2.0 mm
Checking
l. Remove cylinder head cover, install (01-0500) .

2. Turn cam so that bucket tappet in question is against base circle (cam lobe should point up).
2 Press on bucket tappet with suitable tool (no steel tool). If one bucket tappet is easier to push than the
others, replace it.
Replacing
3 Remove camshaft affected, install (05-2200).

4 Pull bucket tappet on affected cylinder up with suction cup and remove. Visually check basic bore.
Do not use magnets, because extremely small iron particles collect on the magnetized sliding surfaces of
the bucket tappet leading to damage on the tappet and cam.
Assure that the bucket tappets are reinstalled in the same position.
COMMERC~LYAVA~ABLETOOL
IRubber suction cup dia. 30 mm e.g. Hazet no. 735-2
FUNCTION OF CAMSHAFT ADJUSTER- RA05001042160X(05-2160)
Function of camshaft adjuster - RA05001042160X(OS-2 160)

Mercedes-Benz
65Nm
~~
3 4 5
P0~01-59
1 M6ll18b-ol 15 Bol..washer (so e os. 2180)

2 Se/Vo magn el 'Mth 2-Pín comoctor 158 Colal OOI ( see 05-2180)
3 Bo!l 16 Flal'lged Sha.'t {1 S!VOISIOO d wihratOSS)
4 Atmetue (2Mv&ISloo· dwiÚlOUireces-s)
5 3)(22 rol pm 11 armature 17 ComiJ{8ssJCn sp¡¡n¡:¡
6 r.l20x1.5nUl, WAF 30 18 CO!trol plunger
7 Frortcollllr 19 18x1 círdp
8 Seal 20 End<OV'I!f A 180tl dnlirlg
9 g-¡lioo cootrolma<Mo poS!bon senSOf 21 S!Jai gtt pin m camsha2
10 M6x16 bol'.+wa-shef 22 lrtct oeamShalt
11 Seal (sae e see os. 2180)
12 C-over wih seal
13 Csmshaft Slll:od<a1 ~~dita!Dl{b)
14 PoSibonilg
p¡s!on (1stversooo S>ze e= 25.45-mm)
(2ndV8CSIOO SIZBC: 25-Qmm)
Fig. 5: Exploded View Of Camshaft Adjuster
Function
Wllen the en~Iine is runnin!l. the camshaft ad1uster rotates the 1nlet camshaft hvdraulicallv/ mechan1callv re1at1ve
Mercedes-Benz
to the camshaft sprocket by 34° (29°) 1 ) (engine 104.98) or 32° (engine 104.99) crank angle, respectively, to the
"advanced" position and back to the "retarded" position. The camshaft adjuster is actuated electromechanically
by the CFI or LH-SFI control module. The positioning time of approx. 1 second is dependent on the engine oil
pressure at the camshaft adjuster and on the oil viscosity and oil temperature, respectively. The position
indicator on the camshaft sprocket (13) provides the camshaft rotational speed to the position sensor (9) as an
input parameter for the ignition control module or, on engine 104.99, for the LH-SFI control module.
1 ) As of approx. 04/91 except ~
Engine switched off ("retarded")
The compression spring ( 17) pushes the control plunger ( 18) against the circlip (19). The engine oil pressure in
the camshaft adjuster is eliminated.
From Oto 1000 --> 2000/min ("retarded")
The torque ofthe intemally helically toothed camshaft sprocket (13) acting in the direction of rotation ofthe
engine pushes the externally helically toothed positioning pisten (14) against the cover ( 12) as a result of the
screw action. Consequently, the likewise intemally helically toothed positioning pisten (14) holds the externally
helically toothed flanged shaft (16) together with the bolted-on camshaft (22) in the "retarded position". The
compression spring ( 17) pushes the control pltmger (18) against the circlip ( 19). 'fhe engine oil flows through
two oblique drillings in the camshaft flange and in the flanged shaft (16) into the working chamber (A) and
holds the positioning pisten (14) additionally in the "retarded" position with the available engine oil pressure.
Leak oil flows off over control and positioning pisten surface, through the control pltmger drilling and 2
drillings (23) in the camshaft flange.
"Retarded" position
Servo magnet (Y 49) not energized.
Control plunger (18) against rear stop.
Positioning pisten (14) against front stop. Oil pressure in working chan1ber (A).
Mercedes-Benz
14 A
A. Worlong dlamb.er
12 Ccv& wth nog
13 Camshe: 5PJC)Ckel
14 PcSij onng Ptston
16 F lang&d shS:
17 C001pces Slon spnng
1·8 Ccn~olpkmgllf
19 18x1 drclíp
22 Camsha~
23 Oil oúle! dlllog
Y49 SONomag.net 'M~
2-pl'l eomec!of
18 19
POS - 5323 • 37
Fig. 6: Oil Pressure - Function Diagram
From 1000 --> 2000 to 5000/min ("advanced")
The control plunger ( 18) is puhled forward as far as the stop in the flanged shaft ( 16) by the servo magnet (Y49)
against the force ofthe compression spring (17).
The control plunger (18) closes the oil feed to the working chamber "A" and at the same time allows oil to flow
to the working chamber "B" through 2 drillings each in the flanged shaft (16) and adjusting piston (14). The
engine oil pressure moves the adjusting piston (14) as far as the stop on the flanged shaft (16).
As a result ofthe axial movement ofthe adjustíng piston (14), the camshaft (22) bolted to the flanged shaft (16)
is turned into the "advanced" position. The turning action is achieved as a result of the effect of the helical teeth
on the camshaft sprocket (13), positioning piston (14) and flanged shaft (16). The engine oil in working
chamber "A" flows off, assisted by the pushing action ofthe adjusting piston (14), over the flanged shaft (16)
and through 2 drillings (23) in the camshaft flange.
"Advanced" position
Servo magnet (Y49) energized.
Control plunger (18) against front stop.
Positioning piston (14) against rear stop. Oil pressure in workíng chamber (B).
Mercedes-Benz
V 9 12
A. Wcrtóng cham!}or
8 Worlong dlamoor
12 Cover 'Mitl ñng
13 Cemshal sprocl<et
14 POSitoring piston
18 Rangod shat
17 Compres sion spong
18 Con\-olpkJnge;
19 1& 1 arctp
22 Camsha:
23 011 oúlet <DI1ng
Y49 S!IIVomagoot w.~
2-~Gom&Cior
P05 -5322 • 37
Fig. 7: Oil Pressure At Advanced Position- Function Diagram
From 5000/min ("retarded")
The electromagnetic actuator (Y 49) is not energized and allows the control plunger to move. The compression
spring (17) pushes the control plunger (18) against the circlip (19). The oil feed to the working chamber "B" is
closed offand oil is able to flow to working chamber "A" along 2 drillings in the flanged shaft (16). As a result
ofthe engine oil pressure the control plunger (18) is moved as far as the cover (12).
This axial movement of the adjusting piston (14) rotates the camshaft (22) bolted to the flanged shaft (16) into
the "retarded" position.
The rotational movement is a result ofthe screw effect ofthe helical teeth on the camshaft sprocket (13),
positioning pisten (14) and flanged shaft (16). The engin e oil in the working chamber (B) flows off, assisted by
the pushing actíon ofthe adjusting píston (14), through 2 dríllings each in the adjustíng piston (14), flanged
shaft ( 16) and control phmger {18) through the control phmger ( 18) and 2 drillings in the camshaft flange (23).
Leak oil flows off over the control plunger and adjusting piston surfaces through the control plunger drilling
and 2 drillings in the camshaft flange (23).
Function of camshaft adjuster- RA05001202160X(05-2160)

Mercedes-Benz
~ @~
85¡--t 8 12
3 4 5
POS-5540-57
1 SaewM6 X 18 15 Colar screw M7 X 13 5(1Df) so<ke~

3 Bol+washerMSX 12 15 FllmgQ shalt
4 Amlwe 17 Comjlfessoo spnn¡;¡
S Rol p¡n 3 X 22m arma!ur e 18 Conlrol PI ston
19 Cncl p 1sX 1
6 NltM20X 1 5WAf 30
20 EndcO'YI'lr A18 oll bore
Froli!co-
21 Slralgill pcn m cemsh~
12 CowrwJhnng
22 Wake cemshal
13 e amshalt sprorl<et Y49 So!e.notd wlh 2-ptn connector
14 AdjiJs~n¡;¡ p¡ston
F ig. 8: Exploded View Of Camshaft Adjuster
CAMSHAFT ADJUSTMENT (SELECTOR LEVER IN DRIVE POSITION AND MEDIUM LOAD)

E ngine speed Adjustment of camshafts Effect on combustion cycle
up to approx. 2000 rpm retarded Idlíng improved, lower residual
gas quantity, smaller valve overlap
from 2000 to 4400 rpm advanced More torque, fewer fresh gas
losses
as of 4400 rpm retarded Intake valves open and close later,
cylínder charge improved (turbo
effect)
Engine switched off retarded
above 250 kmlh advanced
In selector lever oosition P/N the shift ooint in retarded direction is at 2500/min.
Mercedes-Benz
NOTE: The left and right camshaft adjusters are identical. Direction of rotation
modified compared to engine 104.
Function
When the engine is running, the camshaft adjuster hydraulically/mechanically advances and retards the intake
camshaft by 32° crank angle relative to the camshaft sprocket. The camshaft adjuster ís controlled
electromagnetically by the LH -SFI control module. The adjustment time of approx. 1 second is dependent on
the engine oil pressure at the camshaft adjuster and on the oil viscosity and oil temperature.
The intake camshaft is rotated as a result of the screw effect of the helical gearing on the camshaft sprocket
( 13), adjusting piston (14) and flange shaft ( 16). At the same time the engine oil in working chamber (B) is
pushed by the adjusting píston (14) and flows through 2 bores in the adjustíng píston (14), flange shaft (16) and
control piston (18) through tbe control piston (18) and 2 bore in the camshaft t1ange (23).
Leak oil flows off o ver control and adjusting piston surfaces through the control píston bores and 2 bores in the
camsbaft flange (23).
Engine switched off ("retarded")
The control piston (18) is pushed by the compression spring (17) against the circlip (19). The engine oil
pressure in the camshaft adjuster ís reduced. The engine oíllevel is fixed by the o il return lock in the cylinder
head.
Up to approx. 2000 rpm ("re tarded")
The torque of the intemally helícally geared camshaft sprocket (13) acting in the direction of rotation of the
camshaft, applies a pressure to the cover (12) as a result of the screw effect of the extemally helically geared
adjusting píston (14). As a result, the internally helícally toothed adjusting píston (14) also holds the externally
helically toothed flange shaft (16) witb the bolted carnshaft (22) in the "retarded" position. The compression
spring (17) pushes the control piston (18) against the circlip (19). The engine oil flows through 2 sloping bores
in the camshaft flange and in the flange shaft (16) into the working chamber (A) and, as the engine oil pressure
drops, additionaUy holds the adjusting piston ( 14) in the "retarded" position.
Leak oil flows off through the control and adjusting piston surfaces through the control piston bores and 2 bores
(23) in the camshaft flange.
"Retarded" position
Solenoid (2) de-energized .
Control piston (18) at rear stop.
Adjusting piston (14) at front stop. Oil pressure in working chamber (A).
Mercedes-Benz
14 A
A Worlong dlambflr
12 COVOf •~\4th nng
13 Camstla1 sprockcl
14 Ad)ustlng pisllrl
16 Flange sha:
17 Compression spnng
18 Cootclprslon
19 Cuclp 1eX 1
22 Camshal
23 Otl disdlarge be« e
Y4S Scl0001dwith 2-¡Hn coonodor
18 19
POS - 5323 • 37
Fig. 9: Camshaft Adjustment (Selector Lever In Drive Position And Medium Load) At Retarded Position
From 2000 to 4400 rpm ("advanced")
The control piston (18) is pulled forward by the actuator (2) against the compression spríng (17) as far as the
stop in the flange shaft ( 16).
The control piston (18) closes the oil feed to the working chamber "A" and at the same time allows oil to flow
to the working chamber "B" through 2 bores in the flange sha:ft (16) and in the adjusting píston (14). The engine
oil pressure moves the adjusting piston (14) up to the stop on the flange sha:ft (16).
As a result of the axial movement of the adjusting píston (14), the camshaft (22) bolted to the flange sha:ft ( 16)
is rotated into the "advanced" position. The rotation is the result ofthe effect ofthe helical gearing on the
camshaft sprocket (13), adjusting piston (14) and flange shaft (16).
The engíne oil in working chamber "A", pushed by the adjusting píston (14), flows offthrough the flange shaft
(16) and 2 bores (23) in the camshaft flange _
"Advanced" position
Solenoid (2) energized.
Control piston (18) at front stop.

Mercedes-Benz
Adjusting pisten (14) at rear stop. Oil pressure in working chamber (B).
V49 12
A WCflong dlamber
B WCflong dlamoor
12 Cover wlh nng
13 Camshat sprocket
14 AcfJ¡slmg JXSIDn
16 Flange shat
17 Compres-s~on !;JM1ng
18 Con~olprslon
19 Clrclip 18X 1
22 Camsh~
23 Otl <bcharge bOJe
Y49 Solonoldwllh 2.p~n connectOJ
P05 -5322 • 37
Fig. 10: Camsbaft Adjustment (Selector Lever In Drive Position And Medium Load) At Advanced
Position
From 4400 rpm (" retarded ")
The actuator (2) is de-energized and releases the control pisten. The compression spring (17) pushes the control
pisten (18) against the circlip (19). The oil supply to working chamber "B" is closed off and oil is allowed to
flow to working chamber "A" through 2 bores in the flange shaft (16). The engine oil pressure moves the
adjusting pisten (14) up to the cover (12).
Tiüs axial movement of the adjusting pisten ( 14) ro tates the camshaft (22) bolted to the flange shaft (16) into
the "retarded" position.
REMOVING AND INSTALLING CAMSHAFT ADJUSTER- RA05001042170X(05-2170)
Removing and installing camsbatt: adjuster- RA05001042170X(05-2170)
05-7201
Mercedes-Benz
P0>5401-59
F ig. 11: Exploded View Of Camshaft Adjuster
Piston of cylinder 1 position to ignition TDC (step 1).

Front cover (7) remove (01-2120) _
Timing chain mark relative to exhaust and inlet camshaft sprocket
(step 3).
Bolt (3), armature (4) unscrew, pull off (step 4).
Nut ( 6) of camshaft adjuster and cover with ring unscrew, take off (step 5).
(12)
Engine 104.98: remove guide sprocket, bearing body (left-hand
thread, step 6).
Engine 104.99: remove camshaft sprocket of exhaust camshaft,
instaH (step 7).
Camshaft adjuster (parts 13, 14, 16) take off, remove (step 8).
Flanged shaft (16) at inlet camshaft install (step 9).
Mercedes-Benz
Positioning piston (14) and camshaft sprocket (13) fít onto flanged shaft ( 16) (steps 1O, 11 ).
Cover with ring (12) and nut (6) instan (step 12).
Engine 104.99: install camshaft sprocket of exhaust camshaft (step
13).
Timing chain fít onto camshaft sprocket; pay attention to marking
(step 14).
Engine 104.98: install guide sprocket with bearingjoumals (35 Nm,
step 15).
Nut (6) tighten (65 Nm, step 16).
Armature (4) install (step 17).
Front cover (7) instan (01-2120) .

Bolt of armature to control plunger 1st version 0) bolt+washer 7
2nd version (2 ) collar bolt angle of 5+
rotation 90°
M20 X 1.5 nut 65
Flanged shaft to camshaft (see 05-2180)
Bolt of guide sprocket (left-hand thread, engine 104.98) 35
(1) When performing repaírs, replace by 2nd version
(2) Use only once
SpeciaJ tools
001 5B9 72 21 00

Mercedes-Benz
001 589 66 21 00
Removing
l. Position pis ton of cylinder 1 to ignition TDC.

2. Remove front cover at top, instan (01-2120) .
Fig. 14: Locating Front Cover
3. Mark timing chain relative to exhaust and inlet camshaft sprockets (arrows).
Mercedes-Benz
Fig. 15: Marking Timing Chain Relative To Exhaust And Inlet Camshaft Sprockets
4. Unscrew bolt (3); counter-hold armature (4) at flat (arrow) for this step. Pull off annature (4).
5. Unscrew nut (6), take off cover with ring (12).
P05-54D2-1 3
Fig. 16: Exploded View Of Counter-Hold Armature
Engine 104.98
6. Remove guide sprocket (1) together with bearingjournal (2).
Left-hand thread
Mark guide sprocket on front before removing so that the direction of rotation is maintained wben re-
installing.
Mercedes-Benz
Fig. 17: ldentifying Guide Sprocket Together With Bearing Journal
Engine 104.99
7 _ Unbolt camshaft sprocket of exhaust camshaft

8. Take off camshaft sprocket (13) and positioning piston (14). Unscrew bolts. (15 and 15a) and take flanged
shaft (16) of inlet camshaft (22)_
POS-5403-13
Fig. 18: Exploded View Of Exhaust Camshaft Sprocket
lnstalling
9 _ Fit flanged shaft ( 16) onto camshaft (22). Pay attention to locating pin (21 ), screw on.
Matching of securing bolt of flanged shaft to camshaft flange ( see table 05-2180)_
Mercedes-Benz
10. Fit positioning pisten (14) onto flanged shaft (16) into specified position, turning to the left; hold up
timing chain when performing this step.
Fig. 19: Identifying Piston And Flanged Shaft
11. Fit camshaft sprocket (13) onto positioning pisten ( 14) in specified position, turning to the right; hold up
timing chain when performing this step.
Fig. 20: ldentifying Camshaft Sprocket And Positioning Piston
12. Fit on cover with ring (12) and screw on nut (6), but do not tighten finally at this stage.
13. Engine 104.99: install camshaft sprocket of exhaust camshaft.
For tighteníng torques see (05-2180).

Mercedes-Benz
18
~~¡;~~. .
3 4 8 12
POS-5402-13
Fig. 21: Exploded View Of Exhaust Camshaft Sprocket
14. Fit timing chain onto both camshaft sprockets, pay attention to markings.
Fig. 22: Fitting Timing Chain Onto Both Camshaft Sprockets
Engine 104.98
15. Insert guide sprocket (1) together with bearingjoumal (2) and bolt (3), screw on.
The timing chain must be fitted on centrally on the tensioning rail.
Bolt (3) of guide pulley "left-hand thread" .

Mercedes-Benz
Fig. 23: ldentifying Guide Sprocket And Bearing Journa1
16_ Tighten nut (6) on camshaft adjuster.
Tíghtening torque 65 N m_
17. Fit armature (4) onto control plunger (18).
Tighten bolt (3).
Tightening torque (see table)-
The roll pin (arrow) in the arrnature (4) must be atiigned with the flat face on the control plunger (18)_
18_ Install front cover at top (01-2120) _
POS--5402-13
Fig. 24: Exploded View Of Control Plunger
Removi.n{! and installin{! camsbaft adiuster- RA05001192170X(05-2170)

Mercedes-Benz
1
t):1'
10NM
Fig. 25: l dentifying Camshaft Adjuster Remove/Install Components
Both front covers remove, install (01-2120) .
NOTE:
For left camshaft adjuster remove only left cover,
for right camshaft adjuster only right cover.
Piston of cylinder 1 set to 45° before ignition TDC (step 2).
All four camshafts secure with pins, special toollll 589 03 15 00 (step
3).
Tíming chain witb all four camshaft sprockets mark re latí ve to each other (check marking when
installing) (step 4).
Chain tensioner remove, install (05-3100).
Top guide rails remove, install (05-3350).
NOTE:
Remove only right guide raíl for right camshaft
adjuster.
Left exhaust camshaft sprocket unbolt, bolt on (18 Nm) .
Armature (4), nut (6), cover (12), right camshaft unbolt, take off, fit on, bolt on (steps 8 and 9).
sprocket (13) with adjusting piston (14), conica] NOTE:
spring (14a) and flanged shaft ( 16) lf only the left camshaft adjuster is removed, the
right one remains installed.
Armature (4), nut (6), cover (12), left camshaft take off, unscrew, screw on and fit on (steps 10 to
sprocket (13) with adjusting piston (14), conical 19).
Mercedes-Benz
lspring ( 14a) and flanged sbaft (16)
Special tools
119 589 00 01 00
111 589 03 15 00
111 589 01 40 00

Mercedes-Benz
1990-2002 ENGINE Engine Timing - REPAIR & ADJUSTMENTS - 129 Chassis
. . . .T
V$ $ ~m:saaaz
T~B O~ BO ~~
iiiJQJCLJ~8
000 589 0110 00
Fig. 29: ldentifying Special T ool (000 589 0110 00)
001 589 72 21 00
Fig. 30: Identifving 001 589 72 21 00
001 569 66 21 00
Fig. 31: Identifying Special T ool (001 589 66 21 00)
TIGHTENING TORQUE S IN NM AND TIGHTENING ANGLE

Bolt of armature to lst version bolt+washerCl) 7
control piste n
2nd version collar bolt(2) 1
Initial torque 5
Angle of rotation 90°
M 20xl,5 nut 65
Flange shafts to camshaft 1st version bolt+washer(l) 18
Torx T 40
2nd version collar bolt<2) 1
Mercedes-Benz
Initial torque 20
Angle of rotation 60°
(1) Replace with 2nd version when performing repairs
(2) Use only once
P01.10-0164-15
Fig. 32: ldentifving Tightening Torques And Angle Of Rotation
TIGHTENING TORQUES
Conical spring Size (d) Size (D)
Engine 119.96 2.1 mm 51.7 mm
Engine 119.97 1st versionCl) 2.1 mm 51.7 mm
2nd version(l) 2.9 mm 53.3 mm
3rd version<2) 3.0mm 53.3 mm
Engine 119.98 3.0mm 53.5 mm
(1) On engines 119.97 replace 1st and 2nd version by 3rd version when performing repairs
(2) Standard as of 12/ 1992
Mercedes-Benz
PDS-6 0 02 -t~
POS-5002-13
F ig. 33: ldentifving Conical Spring Size
Removal
L Remove both front covers (01-2120).
(Remove only left-hand cover for left-hand camshaft adjuster, right-hand cover for right-hand camshaft
adjuster.)
2. Set pisten ofNo. 1 cylinder to 45° before ignition TDC.
Fig. 34: Identifying Cylinder Piston Position
3. Secure all four camshafts with pins ( 1) 11 1 589 03 15 00.

Mercedes-Benz
Fig. 35: ldentifying Camshaft Pins
4. Mark timing chain with all four camshaft timing gears together (arrows).
Fit on the timing chain in the opposite direction of rotation of engine, beginning at the left exhaust
camshaft gear. The markings made previously must again agree.
Fig. 36: ldentifying Camshaft Timing Gears
6. Remove top guide rails (05-3350). Remove only right guide raíl for right camshaft adjuster.
7. Remo ve right exhaust camshaft sprocket.
8. Unscrew bolt (3) holding armature (4) in position on face (arrow). Pull off armature (4). Tightening
torque 7 Nm.
Mercedes-Benz
13
Fig. 37: Exploded View Of Armature (1 Of 2)
12
Fi~. 38: Exploded View Of Armature (2 Of 2)
9. Take offnut (6), cover (12), left-hand camshaft gear (13) with adjusting piston (1 4) and conical spring
( l4a). U nscrew bolts ( 15) and take flange shaft off intake camshaft.
Mercedes-Benz
21
o
Fig. 39: Exploded View Of lntake Camshaft
lnstalling
1O. Bolt flange shaft (16) onto inlet camshaft (22); pay attention to dowel pin.
NOTE: Replace collar bolts (15); use only once.
P05.20-02S7-13
Fig. 40: Identifying lnlet Camshaft Components
11. Insert spherical spring (14a) and push adjusting pisten (14) onto flange shaft (16) in fixed position (block
tooth B).
12. Screw on thrust nut (02) , special tool 111 589 01 40 OO.
13 . Push inlet camshaft sprocket (13) into fixed position (block tooth B) onto splines of adjusting pisten (14);
hold timing chain up for this step.
Mercedes-Benz
POS. 2:0-02'BB-15
Fig. 41: ldentifying Spherical Spring And Camshaft Sprocket
14. Unscrew thrust nut; hold camshaft adjuster together for this step.
15. Fit on cover (12).
16. Screw on nut (6) with its flat face pointing towards camshaft adjuster (securing slot at front).
?05.20.0289-1 3
Fig. 42: Holding Camshaft Adjuster
'
Mercedes-Benz
18. Fit on armatme (4) in fixed position.
Pay attention to operation 05-2175.
P05.W-02S-9- 13
Fig. 43: Identifying Armature And Nut
ARMATURE AND SERVO MAGNET AT CAMSHAFT ADJUSTER- RA05001042175X(05-2175)
Armature and servo magnet at camshaft adjuster- RA05001042175X(05-2175)
POS.20-0249-55
Fig. 44: Exploded View Of Armature And Servo Magnet At Camshaft Adjuster
Mercedes-Benz
Servo magnet (Y49) unbolt, bolt on.

Solenoid coat with sealan+t 002 989 00 20.
M6 X 16 bolts (1) tighten.
Front cover (7) remove, install (05-2170).
Annature (4) with M5 X 11 bolt (3) unbolt, bolt on; counter-hold armature (4) at the flat
(arrow). See table for tightening torque. Armature
(4) can be fitted onto control plunger (18) only in
the specified position (arrow).
D It is not permitted to re-use the bolt (3).
NOTE:
The armature (4) with the control plunger (18)
must move freely from stop to stop after the nut
(6) has been tightened to the specified torque of
65Nm.
~
The different versions of the armature (4) and of the
solenoid (2) must only be installed in the specified
matching for operational reasons (see table for
matching).
2
Mercedes-Benz
Fig. 45: Identifying Armature And Solenoid
MATCHING ARMATURE AND SERVO MAGNET

1st version Part no. Size A in mm Size B in mm Identification
Armattue (4) 104 051 04 43 - 21 see arrow X
Servo magnet (2) 104 050 01 77 27.1 - -
2nd version
Armattue (4) 119 051 00 43 - 23 see arrow Y
Servo magnet (2) 119 05100 77 29.1 - -
Bolt of armature to control plunger 1st versíon (l) bolt+washer 7
2nd versionC2) collar bolt 5+
tightening angle 90°
Bolts of solenoid to front cover lO
(1) Replace with 2nd versíon when performing repairs.
(2) Use only once.
Armature and solenoid at camshaft adjuster- RA05001192175X(05-2175)
P05.2().()249-55
Fig. 46: Locating Armature And Solenoid At Camshaft Adjuster
So1enoid (Y49) unbolt, bolt on.

Solenoid (Y49) coat sealing surface with sealant 002 989 47 20 1O.
M6 X 16 bolts (1) tighten.
Front cover (7) remove, install (05-2170).
Mercedes-Benz
Armature (4) wíth M5 X 11 bolt (3) unscrew, screw on; counter-hold armature (4) at
flats (arrow) for this step; see table for tightening
torque; armature (4) can be :fitted onto control
,Q!.unger (18) only in fixed position (arrow)_
U It is not permitted to re-use the bolt (3)_
NOTE:
The armature (4) together with the control
pi unger (18) must move freely from stop to stop
after the nut (6) has been tightened to the
specified torque of 65 Nm.
~
For operational reasons, the different versions of the
armature (4) and ofthe solenoíd (2) must only be
installed in the specified combination (see table for
matching)_
Fi2. 47: ldentifyin& Matchin¡ Armature And Solenoid
MATCHING ARMATURE AND SOLENOID

Mercedes-Benz
lst versíon Part no. Síze A in mm Size B in mm ldentíficatíon

Armature (4) 104 051 04 43 - 21 see arrow X
Solenoid (2) 104 050 01 77 27.1 - -
2nd versíon
Armature (4) 119 051 00 43 - 23 see arrow Y
Solenoid (2) 1190510077 29.1 - -
TIGHTENING TORQUES JlN NM AND TIGHTENING ANGLE
Bolt of armature to control plunger lst versíon(l) bolt+wasber 7
2nd version<2) collar bolt 5+
Tightening angle 90°
Bolts of solenoid to front cover 10
(1) Replace wíth 2nd version when performing repairs
(2) Use only once
REMOVING AND INSTALLING FOLLOWER AT CAMSHAFT- RA05001042178X(OS-2178)
Preceding work:
Warning ínstructions when hood open (01-0085)
Engine 104.980/9811990
Mercedes-Benz
0 01-585&57
Fig. 48: Identifying Follower At Camshaft Remove!lnstaJI Components
Model 124: remove viscous fan clutch, install (20-3120) .

Modell40: take off fan shroud ring at fan shroud, place over
fan, install (20-3400) .
Shielding cap ( 11 ) tmclip on both sides, take off, fit on.
Ignition cable 1 at HT distributor (12) unplug, plug in.
High tension distributor (12) unbolt, tilt up, install.
Distributor rotor (6) and foUower (4) remove, install.
NOTE:
The slot of the follower (4) must engage in the
Jocating pin (arrow) in the camshaft, (16 Nm).
Protective cap (2) and sea! (3) take off, fit on.
Distributor rotor to follower (reference value) 2,5
Follower to camshaft (Torx) 16
Special tools
Mercedes-Benz
001 5B9 72 21 00
1129oT
u~*mmsaaaaa
JIM.T
DnB B~ ~~ ~~
iiiJc:D c:¿]c:!J(1]
000 589 0 1 10 00
Fig. 50: Identifving SpeciaJ Too) (000 589 0110 00)
MATCHING BOLTS TO CAMSHAFT- RA05001042180X(05-2180)
Bolts of flanged shaft to inlet camshaft

Mercedes-Benz
1990-2002 ENGINE Engine Timing - REPAIR & ADJUSTMENTS- 129 Chassis
ToncT40
~ ~
D
Ptli . 5318 • 55
POS.5S18-55
A M7x11:6 mm hexa.gon bot+washer d Recass

8 M7x12.4 mm colarbo1Tooc- T30 e 68mm
e M7x13 5 mm cola~ bol T0/X - T30 &1 7 8mm
o M7x13. 3 mm cola~ bol 'Mih suotch shanl< 16 Flanged sha!t
Tooc - T40 22 Cam!>halt
18 C<l!t:rol pblger
Fig. 51 : ldentifying Bolts Of Flanged Shaft To Inlet Camshaft
Bolt Tightening torque Engine

Part number Part number as of up to
standard repa1rs
A A 18Nm 980 10/50, 20/60
005422
104 990 03 22 104 990 03 22 980 12/52, 22/62
023613
981 10/50, 20/60
001035
98 1 12/52, 22/62
010154
B B 22Nm 980 10/50, 20/60 980 10/50, 20/60
005423 005791
120 990 05 04 104 990 05 04 980 12/52, 22/62 980 12/52, 22/62
023614 025653
98 1 l 0/50, 20/60 98 1 10/50, 20/60
001036 001133
981 12/52, 22/62 981 12/52, 22/62
010155 010893
e e 22Nm 980 10/50, 20/60 980 10/50, 20/60
Mercedes-Benz
005792 007619
120 990 01 04 120 990 01 04 20 Nm+6oo(l) 980 12/52, 22/62 980 12/52, 22/62
025654 035763
D 981 10/50, 20/60 981 10/50, 20/60
001134 001913
120 990 02 04 981 12/52, 22/62 981 12/52, 22/62
010894 016058
990 10/50, 20/60
000567
990 12/52, 22/62
022721
D (2) D (2) 20 Nm+60° (1) 980 10/50, 20/60
007620
120 990 02 04 120 990 02 04 980 12/52, 22/62
035764
981 10/50, 20/60
001914
981 12/52, 22/62
016059
990 10/50, 20/60
000568
990 12/52, 22/62
022722
(1 ) It is not permitted to re-use bolt
(2) Engines 104.941/942/943/944/945/991 /992/994/99 5/996 as of start of production
Bolts of camshaft sprocket to exhaust camshaft

Mercedes-Benz
e1
TOrx Tao
T<Wx T 30
14
Torx T40
e M7x13.5mmc olllíbo1Too: - T30 e 6-.S mm

o M7~ 1 3.3 mm cola;bol!Too: -T40 o1 7 8 mm
E M7x13 nrn bol 'Mth lllnsionng washer 3 Camsheft sprod<et
Tooc-T30 14 Exhau st eamshaft
Fi¡:. 52: Identifyin¡: Bolts Of Camshaft Sprocket To Exhaust Camshaft
Bolt Tightening torque Engine

Part number Part number as of up to
standard repairs
E E 18Nm 980 10/50, 20/60
005731
103 990 00 22 103 990 00 22 980 12/52, 22/62
025192
98 1 10/50, 20/60
001111
981 12/52, 22/62
010734
990 10/50, 20/60
000080
990 12/52, 22/62
001015
e e 22Nm 980 10/50, 20/60 980 10/50, 20/60
005732 007619
120 990 01 04 120 990 01 04 20 Nm+6oo(l) 980 12/52, 22/62 980 12/52, 22/62
025193 035763
D 98 1 10/50, 20/60 98 1 10/50, 20/60
001112 001913
120 990 02 04 9R1 12/.S2 22/ñ2 9R 1 12/:)2 22/ó2
Mercedes-Benz
010735 016058
990 10/50, 20/60 990 10/50, 20/60
000081 000567
990 12/52, 22/62 990 12/52, 22/62
001016 022721
nC2) nC2) 20 Nm+6()o(l) 980 10/50, 20/60
007620
120 990 02 04 120 990 02 04 980 12/52, 22/62
035764
981 10/50, 20/60
001914
981 12/52, 22/62
016059
990 10/50, 20/60
000568
990 12/52, 22/62
022722
(l ) It is not permitted to re-use the bolt
(2) Engines 104.941/942/943/944/945/991 /992/994/995/996 as of start of production
MATCHING CAMSHAFT ADJUSTER PARTS- RA05001042190X(05-2190)
Matching camshaft adjuster parts- RA05001042190X(05-2190)
Flange shaft
Mercedes-Benz
~
~ -
\
....,...... ---~
;. . ~-
'
~
~
G
,.
- -- - r---- - - CD
CD
&
'"'~~
1 x 45 ~»
32,6
~~
2,8
6,8
40.4
58
P05.20-0251-35
Fig. 53: Matching Camshaft Adjuster Parts - Flange Shaft (1 Of 2)
Flange shaft 104 051 03 84

Mercedes-Benz
~~ ........
~~
~
~
-n·
'-:'loo. :.. looj
P' ~ -· - ·
N
¡;;; ·-· ~ - - -- co
4N• ~ ~
co
11¡ G -.....~"-."\:~ ••
1 X45°
32,6
~~
~ ¡...- 8,8
40,4
58
P05.20-0252-35
Fig. 54: Matchiug Camshaft Adjuster Parts - FJange Shaft (2 Of 2)
Flange shaft 104 051 04 84
Positioning piston
Mercedes-Benz
198
259
005.20-0 253-55
Fi2. 55: Identifyin2 Positionin2 Piston
Positioning piston 104 051 06 37

Mercedes-Benz
16,7
194
259
~5. 20-0 254-55
Fig. 56: Identifying Positioning Piston 104 051 06 37
Positioning piston 104 051 09 37

Mercedes-Benz
16,7
194
255
~.20-0255- 55
Fig. 57: ldentifving Positioning Piston 104 051 09 37
Positioning pisten 104 051 07 37
Camshaft sprocket
Mercedes-Benz
38
4
POS.2(}-625fi-55
Fig. 58: Identifving C amshaft Sprocket Position
Camshaft sprocket 104 050 10 49
38
4
P05. 20-0257-55
Fig. 59: ldentifying Camshaft Sprocket Position {104 050 10 49)

Mercedes-Benz
38
454
POS. 20-025.8-55
F ig. 60: Identifying Camshaft Sprocket Position (104 OSO 11 49)
POS. 20-0260-55
Mercedes-Benz
Fig. 61: Identifying Camshaft Sprocket Position (104 050 12 49)
Cover
0,6
-
~ ._,o
•
os
Fig. 62: Identifying Camshaft Sprocket Position (104 050 13 49)
104 051 39 03 104 051 16 03 119 051 47 03

Engine 104.98 Engine 104.94 Engine 111
1 1 Engine 104.99
Engine 111
Engine 104.99 Engine 119
Engine 120 Engine 120
Engine 104 104.941/942/ 104.980 104.990 103.943/944/ 012.458/ 12/22
except AMG 943/944/9911 945/991/994/
engines 992/994 995/996
Camshaft 104 050 09 47 104 050 10 47 104 050 07 47 104 050 08 47 104 050 12 47
adjuster 1040501147
Positioning 104 051 06 37 104 051 07 37 104 051 09 37
pis ton
104 050 09 37 104 051 09 37
Flange shaft 104 051 03 84 104 051 04 84
Camshaft 104 050 12 49 104 050 1149 104 050 10 49 104 050 11 49 104 050 11 49
sprocket 104 050 13 49
Cover 104 051 1603 1040513903 104 051 16 03
Mercedes-Benz
¡sensor at 1
camshaft
sprocket
Matching parts of camshaft adjusters- RA05001192190X(05-2190)
Flanged shaft
1,5x45°
42 e; 42,.5
59,3 59,3
........
Fig. 63: Matching Parts Of Camshaft Adjusters- Flanged Shaft
IEngine 119.96 Engine 119.97
Adjusting piston
Mercedes-Benz
"7:
=
1 ~
11~
\
~
. ~ -·-
F:
~
...
- ...-
lf)
""'
>-
15,3
18.4 18,4
22.6 2.2,6
Fig. 64: Matching Parts Of Camshaft Adjusters- Adjustiug Piston
IEngine 119.96 Engine 119.97
Camshaft sprocket
Fig. 65: Matching Parts Of Camshaft Adjusters - Camshaft Sprocket

Mercedes-Benz
Engine 119.96 on left and right
36.6
475
Fig. 66: Matching Parts Of Camshaft Adjusters- Engine 119.96 On Left And Right
Engine 119.97 on left
47,5
Mercedes-Benz
Fig. 67: Matching Parts Of Camshaft Adjusters- Engine 119.97 On Left
Engine 119.97 on right
Cover
....,
o
05 1
Fig. 68: Matching Parts Of Camshaft Adjusters - Engine 119.97 On Rigbt
Engine 104.98 Engine 104.99 Engine 111

Engine 120 Engine119
Engine 120
Engine 119.960 lt and rt 119.97 left 119.97 right Difference

Camshaft adjuster<1) 119 050 03 47 war 119 050 06 47 119 050 07 47 Part no.
1190500147
Flanged shaft 119 051 01 84 war 119 051 02 84 Oblique angle
(chamfer at 3 holes) 119 050 00 89
Oblique angle ll 0 20' 21 o 39' Flanged shaft and
adjusting piston
Adjusting piston 119 051 02 37 119 051 04 37 Obbque angle
Oblique angle 11 o 20' 21 o 39' Flanged shaft and
adjusting piston
Camshaft sprocket 119 050 03 49 119 050 os 49 119 051 09 28 Sensor
(2)
Cover 119 051 47 03 Dimensions

1
Mercedes-Benz
Adjusting angle o 20 25 -
CA
Sensor at camshaft 1 1 2 o Qty.
2 O Qty _sprocket
(1) For repair measures to eliminate knocking noises from the camshaft adjuster in hot countries,
camshaft adjusters with 11 ° 20' inclined angle are supplied for engines 119.97 _Part no. right 119 050
1O 4 7 (without sensor), left 119 050 O11 4 7 (2 sensors)
(2) T he camshaft gear for engines 119.98 has a modífied sensor position.
REMOVING AND INSTALLING CAMSHAFTS- RA05001042200X(OS-2200)
Removing an<l installing camshafts- RA05001042200X(05-2200)
Preceding work:
Cylínder head cover removed (01-0500)
Removing camshafts
Dargostoll am Motor 104.98
Fig. 69: Identifying Camshafts Remove/Install Components

Mercedes-Benz
Crankshaft rotate to 30° before ignition TDC of cylinder 1

(arrow).
NOTE:
At 30° before ignition TDC of cylinder 1 the
camshafts can be rotated without the valves
touching the piston crowns.
Chain tensioner (1) remove (05-3100).
Front cover (30) and top guide rail (42) remove (01-2120).
Camshaft sprockets (3) and (5) mark together with timing chain (6) (arrows).
Exhaust camshaft sprocket (3) unbolt.
Timing chain ( 6) lift off at inlet camshaft sprocket (5).
Camshafts tum with wrench (25) 104 589 00 01 00 (WAF 27)
or 104 589 O1 O1 00 (WAF 29) so that the lo bes of
the cams of cylinder 2 press on the middle ofthe
bucket tappets.
4 i 21Nm
~
8 7
fj tl
Fig. 70: Locating Camshaft Sprockets
Camshaft bearing caps ( 1), (4), (6) and (7) of unbolt (arrows).
exhaust camshaft (14) and bearing caps (8), (11),
(13) and (14) ofinlet camshaft (13)
Mercedes-Benz
Engine 104.98: remo ve thrust washers of camshaft bearing caps ( 1)

and (8), respectively (4) and (11), see (05-2210) .
Bolts of remaining camshaft bearing caps slacken in steps of one turn 1mtil counter-pressure is
e1iminated.
~
Camshafts (13) and (14) must not be twisted when
slackening or belting on the camshaft bearing caps.
lnlet camshaft (13) and ex:haust camshaft (14) take off
Insta lling camshafts
14
13
9 10 12 P05 - 5305 - ó7
Fig. 7 1: Locating Exhaust Camshaft Sprockets
B ucket tappets check ease of movement

All bearing points and bucket tappets oiL
lnlet camshaft (13) and exhaust camshaft (14) insert into bearing points at 30° BTDC of cylinder 1,
align axially_
The lo bes of the cams must be facing down centered
at cylinder 2 (arrows).
Camshaft bearing caps (2), (3) and (5) of exhaust instalL
camshaft (14) and bearing caps (9), (10) and (12) of llJ
inlet camshaft (13) Since 01.93 the camshaft bearing caps are no longer
fixed in position with dowel sleeves but bearing
caps are centered automatically over the bearing
points of the camshafts when the securing bolts are
tightened as specified.
Bolts of camshaft bearing caos screw on in steos each of one turn alternatelv,
Mercedes-Benz
&5hten (21 Nm).
Camshafts (13) and (14) must not be twisted when

bo lting on the camshaft bearing caps.
Camshafts hold with wrench (25) 119 589 00 01 00 or 104 589
01 01 00 when bolting on camshaft bearing caps so
that the lo bes of the cams at cylinder 2 are facing
down centered (arrows).
Engine 104.98: instaH thrust washers of camshaft bearing caps 1 and
8, r espectively 4 and 11 , see {05-2210).
Remaining camshaft bearing caps install, tighten (21 Nm).
Exhaust camshaft sprocket install, bolt on.
Timing chain fit onto camshaft sprockets; pay attention to colored
markings.
NOTE:
lf no colored markings are provided, adjust to
basic position of camshafts (05-2240).
Front cover and top guide raíl install {01-2120) .
Chain tensioner install {05-3100).
Basic position of carnshafts check {05-2230).
Camshaft sprocket or flanged shaft to camshaft (see 05-2180)
Camshaft bearing caps to cylinder head 21
Special tools
001 5B9 72 21 00

Mercedes-Benz
~~---1_19_5_~__
00_0_1_
00_____ )
1 04 5 89 o1 01 00
F ig. 74: Identifving Special Tool (104 589 01 01 00)
000 589 01 10 00
Fig. 75: Identifying Special Tool (000 589 0110 00)
NOTE: When the crankshaft is in the position 30° BTDC at cylinder 1 the camshafts can
be rotated without the valves touching the pistan crowns.
Mercedes-Benz
Fig. 76: Identifying Crankshaft At Position 30°
The camshaft code numbers are afflxed in each caseto the third camshaft bearing journal at the rear (arrows)
(behind the camsbaft beaóng caps) or stamped witb paint on the camshaft flanges (arrows).
Tbe camshafts are sensitive to fracturing and must not be subjected to stresses when being removed and
installed.
Fig. 77: Locating Camshaft Code Numbers
Tbe camshaft bearing caps are identified with numbers (arrows).
Tbe numbering (arrows) ofthe camshaft bearing caps are also cast in tbe cylinder heads.
The camshaft bearing caps must re-installed at the same point.

Mercedes-Benz
Fig. 78: Identifying Camshaft Bearing Caps Numbers
Removing an<l installing camshafts - RA05001192200X(05-2200)
Operation no. of operation texts and work units or standard texts and flat rates 05-5521, 5541, 6292-7050
Fig. 79: Identifying Camshafts Remove/Install Components

Mercedes-Benz
Pisten ofNo. 1 cylinder set to 45° before ignition TDC (arrow), (step 1).
Front covers (10 and 12) at top remove, install (01-2120) .
Camshaft timing gears mark relative to timing chain (step 3).
Chain tensioner (13) remove, install (05-3100).
Top slide rails (1 , la, 2, 2a) remove, install (05-3350).
Camshaft bearing caps ( 14) mark (step 6).
Camshafts (5), (6), (7) and (8) turn in direction of arrow with wrench (slacken),
special tool119 589 00 01 00 (step 7).
Camshaft bearing caps ( 14) unscrew, take off(lO Nm) (steps 8 and 9).
Camshafts with camshaft adjuster and camshaft take off, install. Special tool 119 589 00 05 00 (steps
timing gear 9 to 20).
~
Since 1993 the carnshaft bearing caps are no longer
fixed in position with dowel sleeves but the bearing
caps are centered by means of the bearing points of
the camshafts when the securing bolts are tightened
to specification.
Basic setting check (05-2230).
Camshaft bearing cap bolts 12
Camshaft gear to camshaft 18
Flanged shaft to camshaft T orx Initial torque 20
T40 Tightening angle 60
l) Replace when performing repairs; use only once.
Special tools
119 589 00 01 00

Mercedes-Benz
001 589 72 21 00
111 58903 1500
F ig. 82: I dentifving Special T ool (111 589 03 15 00)
TEST VALUE
When new
Camshaft bearing dia. in cylinder Standard size 28.000
headl 28,021
Repair size 28.500
28.521
Camshaft bearing dia. at camshaft Standard size 27.960
27.947
Repair size 28.447
28.460
Permissíble variation in Camshaft gear seat 0.02
concentricity of middle bearing
point and of camshaft timing gear
seat when mounted in outer Bearing points 2, 3, 4
bearing points
Camshaft bearing play Radial 0.053-0.06 1
Axial 0.050-0.150
NOTE: The camshaft bearing caps are numbered consecutively (arrows), beginning at
the right exhaust camshaft at the front.
Mercedes-Benz
The numbers (arrows) are cast in the cylinder heads.
The camshaft bearing caps must be re-installed at the same point.
The camshafts are sensitive to fracturing and must not be twisted when removing and installing camshaft
bearing caps. If a camshaft is removed, aU the others must be secured with fixing pins to prevent them turning.
Fig. 83: Locating Camshaft Bearing Cap Numbers
l. Set pisten ofNo. 1 cylinder to 45° before TDC (anow).

Fig. 84: Identifying No. 1 Cylinder Piston Position
3. Mark position of camshaft tíming gears (arrows) relative to tíming chain.

Mercedes-Benz
NOTE: lf the camshaft timing gear is removed, the color marking must be
transferred to the corresponding point on the new camshaft timing gear.
4. Remove and install chain tensioner (05-3100).

5. Remove top slide rails (05-3350).
Fig. 85: Locating Camshaft Timing Gears
6. Lift timing chain off camshaft sprockets. Rotate camshafts witb wrencb 119 589 00 01 00 so that only the
base círcle of the cams is touchíng the bucket tappets in each case.
NOTE: The timing chain is secured on the camshaft sprocket to prevent it turning
when t he timing case cover is installed.
Removal note
Ro tate camshafts free of tension: rotate right exhaust camshaft and right inlet camshaft approx. 6 teeth in
direction of rotation of engine.
Mercedes-Benz
Fig. 86: ldentifying Wrencb 119 589 00 01 00
Rota te left inlet camshaft approx_ 10 teeth in opp()site direction of rotation of engine_
Rotate left exhaust camshaft approx. 14 teetb in direction of rotation of engine.
7. Slacken camshaft bearing caps altemately so asto prevent any one-sided residual stress acting on the
camshaft
8. Take off camshaft bearing caps and camshafts together with camshaft sprockets and camshaft adjusters.
lnstalling
9 _ Oil bucket tappets and camshaft bearing points.

10. Insert left inlet and exhaust camshafts with timing chain fitted, free oftension. Pay attention to guide
bearing at bearing point 3 _
l L Oil bearing caps, install and tighten uniformly tolO Nm_ Camshaft must not be overtensioned on the one
side.
12. Rotate camshaft with wrench (3) 119 589 00 O1 00 and check for ease of movement
13_ Rotate left exhaust camshaft into position with wrench (3). Fit timing chain onto the marking affiXed
previously to the exhaust camshaft sprocket and pin with pin (1), special toollll 589 03 15 OO.
Mercedes-Benz
Fi2. 87: Identifyin2 Wrench (119 589 00 01 00) And Special Tool (111 589 03 15 00)
14. Rotate left inlet camshaft into position with wrench (3). Fit tirning chain onto the previously affixed
marking on the inlet camshaft sprocket and secure with pin (1). Camshafts in "retarded" position (arrow).
15. Insert right inlet and exhaust camshafts free of tension, with tirning chain fitted. Pay attention to guide
bearing at bearing point 3.
16. Oil bearing caps, install and tighten uniformly to 12 Nm. Camshaft must not be overtensioned on the one
side.
17. Ro tate camshafts and check for ease of movement.
Fi2. 88: ldentifyin2 Pio And Wrench

Mercedes-Benz
18. Rotate right inlet camshaft into position with wrench 119 589 00 01 OO. Fit timing chain onto the marking
afflxed previously to the inlet camshaft sprocket and pin with pin 111 589 03 15 OO. Camshafts in
"retarded" position (arrow).
19. Ro tate right exhaust camsbaft into position with wrench 119 589 00 O1 OO. Fit timing chain onto the
marking afflxed previously to the exhaust camshaft sprocket and pin with pin 111 589 03 15 OO.
20. lnstall in reverse order, beginning with step 5.
21. Check basic setting (05-2230).
MATCHING CAMSHAFTS AND MOUNTING- RA05001042210X(OS-2210)
Timing in degrees crank angle (°C.KA) at 2 mm valve lift (l) and new timing chain
Camshaft code Inlet opens ATDC Inlet eloses ABDC Exhaust opens Exhaust closes
number (2 ) (3) (5) (3) BBDC BTDC (5)
21 , 23 (6) 36° 36° - -
43 (7 )) 45 (8)
33 (9), (34 (4)
19 24 (6) - - 30° uo
'
41 (7 ), 47 (8)
35 (9), (36)<4 )
57 ílQ}
59 <11 ) (60) (4) 34° 34° - -
57 (58)(4) - - 31° 14°
65 (66) (4)
(1) Permissible difference: ± 2.0 °CKA.
(2) Camshaft code number on 3rd camshaft bearing or stamped on camshaft flange from rear with paint.
(3) Camshaft adjuster in "retarded" position.
(4) Repair size camshaft with 0.5 mm larger bearing diameter.
(5) These readings can be obtained at the vibration damper.

(6) Shaft diameter 30 mm since 8/89 (only USA; Japan).
(7) Modified cam shape with steel bucket tappet since 8/89.
(8) Centre axial location since 11/89.
(9) Modified cam shape since 2/90.
(1 O) since 04/91
(1 1) since 03/91
TEST DATA
Mercedes-Benz
Whennew
Camshaft bearing dia. Standard size 29.947- 29.960
Repair size 29.434 - 29.450
Camshaft bearing play Radial 0.040- 0.074
Axial 0.060 - 0.210
Camshaft axial mounting
POI -13:10 ·17
Fig. 89: ldentifving Camshaft Axial Mountings
2a Bottom thrust 1040510173

washer
2b Top thrust 104 051 00 73
washer
2c Bottom thrust 120 051 00 73
washer
A Thrust washer at bearings 1 and 8 in bearing halves Up to engine end
of cylinder head no.
Rnttnm thmo::t 1040<:i 1 0171 1049RO 1O
Mercedes-Benz
washer 000060
Front bearing Inlet 104 051 13 03 104980 12
cap 000053
Front bearing Exhaust 104 051 11 03 104981 10
cap 000019
104981 12
000074
B Two thrust washers each at bearings 1 and 8 in the As of engine no. Up to engine end
bearing halves of cylinder head and in tbe camshaft no.
bearing caps
Bottom thrust 104 051 01 73 104980 10 104980 10
washer 000061 000718
Top thrust 104 051 00 73 104980 12 104980 12
washer 000054 003032
Front bearing Inlet 104 051 20 03 104981 10 104981 10
cap 000020 000157
Front bearing Exhaust 104 051 18 03 104981 12 104981 12
cap 000075 000915
e Two thrust washers each at bearings 4 and 11 in As of engine no. Up to engine end
bearing halves of cylinder head no.
Thrust washer 120 051 00 73 104980 10 104980 10
000719 004091
Front bearing Inlet 104 051 13 03 104980 12 104980 12
cap 003033 017952
Front bearing Exhaust 104 051 11 03 104981 10 104981 10
cap 000158 000789
104981 12 104981 12
000916 007762
D Without thrust washers at bearings 4 and 11 in As of engine no. Engine 104990
bearing halves of cylinder head
Front bearing Inlet 104 051 37 03 104980 10
cap 004092
Front bearing Exhaust 104 051 35 03 104980 12
cap 017953
104981 10
000790
104981 12
007763
DECISION TABLE
Camshaft axial mounting
Bucket tappet A(l) B(2) - 1-
earbide metal - B e D
Steel 1 1 1
1 1
Mercedes-Benz
Camshafts A l- I-
Standard 21/19 -c(2) D(3)
Repair 33/35 1
Camshafts B
Standard 23/24, c<3)
43/41
Repair 33/35 1 1 1
Camshafts D
Standard 45/47 e D(4)
Repair 33/35 1 1 1
Camshafts D
Standard 33/35, D
57/59 (5)
Repair 33/35(6)
57/59 65
(1) May only be fitted with camshafts with code numbers 21119.
(2) May only be fitted with camshafts with code numbers 23/24.
(3) Together with cylinder head 104 010 10 20
(4) Together with cylinder head 104 010 21 20
(5) As of engine 980 10/50, 20/60 005792 980 12/52, 22/62 025654 981 10/50, 20/60 001134 981 12/52,
22/62 010894
(6) Up to engine 980 10/50, 20/60 005791 980 12/52, 22/62 025653 981 10/50, 20/60 001133 981 12/52,
22/62 010893
Note
Mercedes-Benz
Fi¡. 90: ldentifvin~ Cvlinder Head With Thrust Shoulder For AxiaJ Mountin~ Of Camshafts At Front
Engine 104.98 up to 11/90
Cylinder head with tbrust shoulder for axial mounting of camshafts at front (arrows).
Mercedes-Benz
Fi2. 91: ldentifyin& Cylinder Head Without Thrust Shoulder For Axial Mountin& Of Camshafts At Front
Engine 104.98 as of 11/90
Engine 104.99
Cylinder head without thrust shoulder for axial mounting of camshaft at front (arrows).
REPLACING THREADED BUSH IN FRONT OF CAMSHAFT- RAOS001042218X(OS-2218)
Preceding work:
Camshaft removed (05-2200)
Exhaust camshaft
Mercedes-Benz
--..,1\
-- ~..
,..
111(
l
. ,..
N
--;
-~
1
1
:e
-
P05.20-0259-57
Fig. 92: Identifying Threaded Bush In Front Of Camshaft
Threaded bush (1) unscrew (torx).

Hollow-drilled camshaft (26) clean.
Thread at front of camshaft (26) clean, remove grease.
Threaded bush (1) (microencapsulated) part no. 103 replace, tighten (45 Nm).
997 00 15
Special tool
000 589 01 10 00
Mercedes-Benz
Fig. 93: Identifying Special Tool (000 589 0110 00)
REPLACING END COVER IN CAMSHAFTS- RA05001042220X(05-2220)
Preceding work:
Camshafts removed (05-2200)
- -+-=E- t _
P05.20-0261-57
Fig. 94: ldentifving End Cover In Camshafts
Cover (1) prise out with a screwdriver.

Hollow-drilled camshaft (26) clean.
Bore (B) inspect (see table for dimensions).
End cover ( 1) knock in with drift (2) (shop-made tool).
[l]
U se new end cover (1).
The end cover must not be seated on the end of the
bore.
It is essential to maintain the insertion depth (size
E).
Mercedes-Benz
DATA IN MM
Camshaft (26) Inlet, exhaust at rear
Bore (B) 14.00- 14.04
End cover DIN 443 (1) A14
Insertion depth size (E) 9.3
Insertion drift (2) dimensions d 11.7
(shop-made) D 13.7
H 4,3
r 1
rl 35
CHECKING BASIC POSITION OF CAMSHAFTS - RA05001042230X(05-2230)
Checking basic position of camshafts - RA05001042230X(05-2230)
Preceding work:
Cylinder head cover removed (01-0500) .
Fan shroud and fan shroud ring removed (20-3400)
POS:.539:>57
Mercedes-Benz
F ig. 95: Identifying Basic Position Of Camsbafts
Cylinder 1 position to ignition TDC.

Todo this rotate crankshaft until the TDC marking on the
vibration damper and the TDC pointer (arrow) are
aligned (01-0120) .
4 mm 0 holes in the camshaft flanges (arrows) must touch the top edge ofthe cylinder head, except
at AMG engines.
Insert pins (1) into boles (arrows) for this step.
~
Camshaft adjuster must be in "retarded" position.
Inlet camshaft rotated in opposite directíon of
rotation of engine.
Inlet camshaft sprocket rotated in direction of
rotation of engine as far as the stop!
Checking, adjusting basic setting of camshafts - RA05001192230X(05-2230)
Preceding work:
Cylinder head covers removed (01-0500)

Mercedes-Benz
Fig. 96: Identifving Basic Setting Of Camshafts
ROTATION DEGREE
Engine rotate to 45° before ignition TDC with socket
wrench, special tool 001 589 65 09 00 (step 1).
It must be possible to pin the camshafts with the specíal toollll 589 03 15 00 (step 2).
pins (1)
ADJUSTING AT 45° BEFORE TDC

Guide rails (2) remove, install {05-3350).
Chain tensioner remove, install (05-3100).
Camshafts, beginning at right exhaust camshaft ro tate with wrench in direction of rotation of engine,
Camshafts, beginning at left exhaust camshaft rotate into position with wrench, special tool 111
589 03 15 00 (step 6).
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Timing chain fit on.

Camshafts pin with pins (1 ), beginning at left exhaust camshaft,
special tool 111 589 03 15 00 (steps 6 to 9).
Special tools
001 589 65 09 00
111 5B9 03 15 00
119 589 00 01 00
NOTE: The 45° before TDC marking on the vibration damper is an assembly marking.
The camshafts can be rotated in this position with the wrench 119 589 00 01 00
without the valves coming into contact with the piston.
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Checking
L Position engine to 45° before ignition TDC at No. l cylinder by cranking engine at crankshaft in direction
ofrotatjon of engine using special tool 001 589 65 09 OO.
Fig. 100: ldentifving No. 1 Cylinder Position
2. It must be possible to pin all4 camshafts with the pins (1), special tool111 589 03 15 00, through the 6.5
mm di a. holes in the flrst camshaft bearing caps.
Fig. 101: Identifying Pins And Special Tool (111 589 03 15 00)
Adjusting (at 45° before TDC)
3. Remove, install top slide raíl (2a) (05-3350).

4. Remove, install chain tensioner (05-3100).
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Fig. 102: ldentifying Top Slide Rail And Chain Tensioner
5. Ro tate camshafts in dírectíon of rotatíon of engíne with wrench, specíal tool 119 589 00 O1 00, begínníng
at right exhaust camsbaft (1).
To make it possible to start the adjustment at the left-hand exhaust camshaft (4), the slack section
(arrows) ofthe timing chain (at chain tensioner) must be transferred by rotating the camshafts {1 , 2, and
3).
Engme 119.9.00
Fig. 103: Identifving Camshafts Rotation
6. Rotate left-hand exhaust carnshaft into position with wrench (3) 119 589 00 O1 OO. Fit tíming chain onto
exhaust camshaft timing gear and pin with pin (1) 111 589 03 15 OO.
Mercedes-Benz
Fi~. 104: ldentifvin~ Pin 111 589 03 15 00 And Wrench (3) 119 589 00 01 00
7. Rotate 1eft-hand inlet camshaft into position with wrench (3). Fit timing chain onto inlet camshaft timing
gear and pin with pin (1). Camshafts in "retarded" position (arrow).
Fig. 105: ldentifying Wrench And Pin
8. Rotate right-hand inlet camshaft into position with wrench 119 589 00 01 OO.
Fit timing chain onto inlet camshaft timing gear and pin with pin 111 589 03 15 OO.
Camshafts in "retarded" position (arrow).

Mercedes-Benz
9. Rotate right-hand exhaust camshaft into posítion wíth wrench 119 589 00 01 OO.
Fit timíng chain onto exhaust camshaft tíming gear and pin wíth pin 111 589 03 15 OO.
Installation is perforn1ed in the reverse order, beginning from step 4.

Checking basic setting of camshafts- RA05001202230X(05-2230)
Preceding work:
Cylinder head covers removed (01-0500) .
Viscodrive fan removed (20-3120) .
Operation no. of the operation texts and work units or standard texts and flat rates: 05-601 O
Fig. 106: ldentifying Basic Setting Of Camshafts
CAMSHAFTFLANGESREFERENCE
Pistan of cylinder 1 rotate to ignition TDC with wrench socket 001 589
65 09 00 (steps 1 and 2).
The 4 mm dia. holes in the camshaft flanges are touching the top edge ofthe cylinder heads (step
(arrows) 2).
Mercedes-Benz
Pins (l) insert into the boles (arrows) (step 3). Camsbaft
adjuster against retarded stop.
Special tools
001 589 65 09 00
111 58903 1500
Checking
l. Rota te pisten of cylinder 1 to ignition TDC position.
To do this, ro tate crankshaft in direction of rotation of engine with wrench 001 589 65 09 00 until the
TDC marking (arrow) on the vibration damper (8) is aligned with the TDC pointer (7) on the timing case
cover.
Mercedes-Benz
---"""T"--..2::.::=:::=:=== = POi ·15011 - 13

Fig.109: Locating Vibration Damper TDC Markings (1 Of2)
POI5 • ! 015 • 5!1
Fig. 110: Locating Vibration Damper TDC Markings (2 Of2)
2. The piston of cylinder 1 is in ignition TDC when the base circles of the right hand intake/ exhaust
camshaft at cylinder 1 are resting against the bucket tappets (6).
Camshaft adjuster of intake camshafts against retard stop (mechanical stop in direction of rotation of
camshaft).
The 4 mm holes (arrows) in the camshaft flanges are touching the top edge ofthe cylinder heads (arrows).
3. As a check, insert4 mm dia. pins (111 589 03 15 00) into the holes (arrows) in the camshaft flanges at the
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left and right cylinder head.
Fig. 111: Inserting Pins Into Boles In Camshaft Flanges
4. Adjust basic setting (05-2240).
ADJUSTING BASIC POSITION OF CAMSHAFTS - RA05001042240X(OS-.2240)
Adjusting basic position of camshafts - RA05001042240X(05-2240)
Preceding work:
Basic position of camshaft cbecked (05-2230).

Mercedes-Benz
PQS-53~-57
Fig. 112: Adjusting Basic Position Of Camshafts
Crankshaft position to 30° BTDC of cylinder 1 (arrow) (01-

01 20) .
NOTE:
At 30° BTDC of cylinder 1 the camshafts can be
ro tated without the valves touching the piston
crowns.
Front cover (30) and top guide raíl (42) remove (01-2120).
Exhaust camshaft sprocket (3) unbolt, remove.
Camshafts rotate with wrench (25) 119 589 00 01 00 (WAF 27)
or 104 589 O1 O1 00 (WAF 29) until the 4 mm holes
in the camshaft flanges are touchíng top edge of
cylínder head.
Pins (1) insert ínto holes (arrows).
Crankshaft rotate with wrench socket insert in direction of
rotatíon of engine to TDC posítíon of cylínder l;
raise timing chain for this step.
Camshaft adjuster ro tate by hand in direction of rotation of camshaft to
"retarded" oosition stoo.
Mercedes-Benz
Timing chain fít onto inlet camshaft sprocket and check whether
timing chain is resting correctly against guide rail in
timing case cover.
Exhaust camshaft sprocket (3) insta U in base position of camshaft, bolt on.
Front cover (30) and top guide raíl (42) instali (01-2120) .
Chain tensioner (5) install (05-31 00).
Basic position of camshafts check (05-2230).
lcamsbaft sprocket to camshaft (see 05-2180)
Special tools
119 589 00 01 00
104 589 0 1 01 00
Ad.justing basic settiug of camshafts- RA05001202240X(05-2240)
Preceding work:
Front covers (30) and (30a) removed {01-2120) .
Spark plugs removed (15-1031).

Mercedes-Benz
Operation no. of the operation texts and work units or standard texts and flat rates: 05-6020
P05 - f006 - 67
Fig. 115: ldentifying Basic Setting Of Camshafts
Crankshaft rottate to 30° after ignition TDC at cylinder 1 with

wrench (11) 001 589 65 09 00 (step l).
Right exhaust camshaft sprocket (5) unscrew, remove (step 3).
Right and left guide raíl (4) and ( 6) at cylínder head remo ve (05-3450).
All four camshafts (7), (8), (9) and (10) rotate with wrench 104 589 01 01 00 into basic
position (step 5).
Crankshaft ro tate against direction of rotation of engine with
wrench (11) 001 589 65 09 00 into TDC position of
pisten at cylinder 1 (step 6).
Timing adjust, beginning at left exhaust camshaft (10) (steps
7 to 19).
Chain tensíoner instaH (05-3100).
Screws (15) of left exhaust camshaft sprocket (5) tíghten. Pay attention to tightening torque.
Basíc settíng of camshaft check (05-2230).
1 _T_or_x_T_4_o_C1_) ________________
2o_____________________,
Mercedes-Benz
1990-2002 ENGINE Engine Timing- REPAIR & ADJUSTMENTS - 129 Chassis
Exhaust camshaft sprocket to Initial torque

camshaft Tightening angle
Torx T30(2) 22
(1) Do not re-use bolt after tightening to correct angle.
(2) Replace lst version by Torx T40 when performing repairs.
Special tools
104 589 01 01 00
Fig. 116: Identifying Special TooJ (104 589 01 01 00)
001 589 72 21 00
001 589650900

Mercedes-Benz
/ ""\
112SoT
v~ *mm :aaaaa
112+T
un~ noo~ H ~
i(i]QJr::¿J ~8
00058"9 01 1000
'
\. 111 55903 1500
Fig. 120: l dentüying Special Tool (104 111 589 03 15 00)
Adjusting
L Rotate crankshaft into 30° position after TDC at cylinder 1 with wrench 001 589 65 09 00 ( arrow).
In this position, the camshafts can be rotated without the val ves corning into contact with the píston
crown.

Mercedes-Benz
Fig.121 : Locating Chain Tensioner Mark Numbers
3_ Unscrew right exhaust camshaft sprocket (5), remove_

4_ Remove right guiding blade (4) and left guide rail of cylinder head (05-3450)_
Fig. 122: Locating Rigbt Exhaust Camsbaft Sprocket And Rigbt Guiding Blade
5. Rotate camshafts with wrench 104 589 01 01 00 until the 4 mm holes in the camshaft flanges (arrows) are
at the top edge of the cylinder edge_
Lift timing chain off camshaft sprockets for perfonning this step.
Check with 4 mm dia_pins (1) (111 589 03 15 00).

Mercedes-Benz
r----------------------------------------------------------,
1
1
1
1
1
1
1
1
1
1
LO: cytlldor head
Fig. 123: Locating Carnshaft Flanges
6_ Rotate crankshaft back in opposite direction ofrotation of engine to TDC position (arrow) with wrench
001 589 65 09 00_
Lift timing chain off camshaft sprockets for this step.
Fig. 124: Locating TDC Position
7 _ Ro tate left exhaust camshaft ( 1O) half a tooth in direction of rotation of camshaft out of basic position
with wrench (25) 104 589 01 01 oo_
8. Place timing chain onto exhaust camshaft sprocket (3) and rotate exhaust camshaft against direction of
rotation of carnshaft back into basic position (timing chain tensioned).
Mercedes-Benz
Fig. 125: Rotating Left Exhaust Camshaft
9. Ro tate left intake camshaft (9) half a tooth in direction of rotation of camshaft out of basic position with
wrench (25).
10. Rotate camshaft adjusteT by hand in direction ofrotation of camshaft to "retarded" stop.
11. Fit timing chain onto intake camshaft sprocket (13).
12. Install guide rail (6).
13. Rota te intake camshaft (9) in opposite direction of rotation of camshaft back into basic position (timing
chain tensioned).
Fig. 126: Rotating Camshaft Adjuster
14. Rotate right intake camshaft (8) half a tooth in direction ofrotation of camshaft out ofbasic position with
wrench (25).
15. Rota te camshaft adjusteT by hand in direction of rotation of camshaft to "retarded" stop.
16. Fit timing chain onto intake camshaft sprocket (12).
17. Install guide rail (4).
1R R otMP int~lcP r~m<:h~ft (R) in onno<:ÍtP riirPr.tion of' rotMion of r~ m<:h~ft h~ rlc into h~.::ir. no<:ition (ti mi n a
Mercedes-Benz
chaín tensíoned).
Fig. 127: Fitting Timing Chain Onto Intake Camshaft Sprocket
19. Install exhaust carnshaft sprocket (5) with carnshaft in basic position and screw on.
20. Install chaín tensíoner (05-3100).
21. T ighten screws (arrows) of exhaust camshaft spro cket
Pay attention to tighteníng torque.
22. Check basic posítion of camshafts (05-2230).
Fi~. 128: Locatin~ Exhaust Camshaft Sprocket Screws
REMOVING AND INSTALLING VALVE SPRINGS- RA05001042500X(05-2500)
Removing and installing valve springs- RA05001042500X(05-2500)

Mercedes-Benz
Preceding work:
Spark plugs removed (15-1031).
Fan shroud removed (20-3400) .
Model 202: air cleaner top part removed (09-1 051 ).
05-3500
P~539S.57
Fig. 129: Identifying Valve Springs Remove!Install Components
Modiel 124: remove cover at component compa1tment panel,

install.
Model140: remove fresh air blower housing, install.
Modell40: unbolt cable duct at component compartment panel,
bolt on.
Modell40: pull off center partition, fit on.
Mercedes-Benz
If automatic transmissíon fitted: unbolt dípstick guíde tube at rear of cylinder head,
bolt on.
Supporting bar (2) 111 589 O1 59 00 install with slide (7), bolt on with bolts of camshaft
bearing caps (21 Nm).
Piston of cylinder to be machined turn with wrench socket to TDC; to do this, hold up
timing chain so that it does notjam when tuming
flJl-0120) .
~1
If the crankshaft is rotated, it must be ensured that
the startíng position is restored so that the colored
markings on the timing chain for setting the timing
of the camshafts can be reused. On no account ro tate
crankshaft back otherwise the guide rail will be
damaged by the tírning chaín.
The relevant piston is in TDC position if the
marking number on the víbratíon damper shown in
the drawing on the page before is aligned with the
TDC pointer.
Marking number Piston at TDC

TDC 1 and 6
2 and4
3 and5
Mercedes-Benz
Fig. 130: ldentifying Marking Numbers On Vibration Damper
Bucket tappet (3) ofrelevant cylinder remove, install (05-2110) .

(iJ
On no account may a heavy bucket tappet (82 g) be
installed together with the conical spring (yellow).
Connection hose (4) of cylinder leak tester screw into spark plug hole.
Crankshaft fix in position to prevent rotating (03-5000) .
Compression chamber pressurize.
Lever pusher (9) 111 589 18 61 00 with thrust piece attacb to slide (7).
(5) 111 589 25 63 00
Thrust piece (5) at valve spring retainer (15) fit vertically.
Thrust piece (5) and slide (7) align relative to each other.
Slide (7) fix in position with bolt (8).
Valve springs ( 17) and ( 18) compress.
rr:l
Valves must not sit on the piston crown otherwise
they wilJ be bent.
Valve coliets (14) remove with tweezers (6) or magnetic finger 116
589 06 63 00, install.
Valve spring retainer (15) with valve springs (17) remove, install.
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and ( 18)
Valve stem seal (19) remove, install (05-2700).
fi]
Valve stem seals (19) with bent metal casing must
be replaced.
Bottom valve spring retainer (20) remove and check for pitting, install.
Special tools
001 589 65 09 00
Fig. 131: ldentifying Special Tool (001 589 65 09 00}
111 5 89 o1 59 00
111 589 18 61 00

Mercedes-Benz
111 58:9 25 63 00
116 589 06 63 00
Fig. 135: ldentifying 116 589 06 63 00
NOTE: Valve springs, top and bottom valve spring retainers with pittings must be
replaced. The valve springs of the inlet and exhaust valves are identical.
NOTE: As of 11/93 conical valve springs version (8) have been installed in place of the
cylindrical double valve springs (A).
Pay attention to matching ofbucket tappets, see (05-211 O)

Mercedes-Benz
POS-549-9-1 3
F ig. 136: Identifying Conical Valve Springs Version And Cylindr ical Double Valve Springs
Cy linder leak tester e.g. Bosch E FA W 21 O A
Firma Sun, CLT 228
Rubber sucker 0 30 mm e.g. Hazet No. 735-2
Tweezers, straight 160 mm with e.g. Stahlwille
rounded tips
42349 Wuppertal
Removing and installing valve S[>rings - RA05001192500X(OS-2500)
Preceding work:
Camshafts removed (05-2200).
Spark plugs removed (1 5-1031) .
Operation no. of operation texts and work units or standard texts and flat rates 05-3500
A. Models 124, 129, 140

Mercedes-Benz
Fig. 137: ldentifving Valve Springs Remove/lnstall Components
Right cylinder head: engine wiring harness disconnect, connect.

Supporting bar (2) with slide (7) attach off-center (facing toward outside ofvehicle)
to relevant cylinder head, take off, special tool 1 11
589 01 59 OO.
Supporting bar (2) bolt on X with two M7 35 bolts (bolts of camshaft
bearing caps), tmbolt.
Timing chain raise and turn pistan of cylinder to be machined
with wrench socket to TDC.
[lJ
If turning at the crankshaft, ensu re that the starting
position is restored so that the colored markings
affixed to the timing chain can be reused for setting
the timing of the camshafts. The respective pistan is
in the TDC position ifthe marking numbers on the
vibration damper, shown in the drawing above, are
aligned with the TDC pointer.
MARKING NUMBER PISTON IN TDC

1 and 6
5 and3
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4 and 7
8 and 2
Fig. 138: Identifying Valve Springs Removellnstall Components
Bucket tappet (3) of relevant cylinder remove, install (05-2110).

Crankshaft fix in position with retaining lock to prevent it
rotating (03-5000) .
Compression chamber pressunze.
Lever presser (9) with thrust piece (5) insert into slide (7), special tools 111 589 18 61 00
and 119 589 06 63 OO.
Thrust piece (5) attach to valve spring retaíner (15) vertícally.
Valve spring (17) compress.
~
Valves must not touch the piston crown otherwise
they will be bent.
Valve collets (14) remove with tweezers (6) or magnetic finger,
install, special tool 116 589 06 63 OO.
lnstallation note
Coat valve snrÍn Q' retainer (15) for fixi nQ' valve
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collets (14) with grease.

Valve spring retainer (15) with valve spring (17) remove, install.
Valve stem seal (19) replace (05-2700).
Bottom valve spring retainer (20) remove and examine for scoring, install.
Special tools
1 11 589 1 B 61 00
Fig. 139: Identifying Special Tool {111 589 18 61 00)
111 589 01 59 00
119 589 06 63 o.o
Fig. 141: Identifying Special Tool {119 589 06 63 00)

Mercedes-Benz
11 6 589 06 63 00
F ig. 142: Identifying Special Tool (116 589 06 63 00)
COMMERCIALLY AV AILABLE TO OLS

Cylinder leak tester e.g. Bosch E FA W 210 A Sun, CLT
228
Rubber suction cup 0 30 mm e.g. Hazet Nr. 735-2
Straight tweezers 160 mm with e.g. Stahlwille
rounded tips D-42331 Wuppertal 12
NOTE: Valve springs, upper and lower valve spring retainers with scoring must
be replaced. The valve springs of the inlet and exhaust valves are
identical.
As ofOl/1993 corucal-shaped valve springs are installed together wíth modified valve spring retainers
and lighter bucket tappets. The inner valve spring is no longer fitted.
CONICAL-SHAPED VALVE SPRINGS

Valve spring wir e dia. (round) Valve spring wire dia. (ov.a l)
Engine 119.971/975 3.5mm -
Engine 119.970/972/ 974 - 3.4 - 4.2 mm
Preceding work:
Camshafts removed (05-2200).
Spark plugs removed {15-1031) .
B. Model 210
Mercedes-Benz
POS 2()..()2'90. 57
Fig. 143: ldentifying Conical-Shaped Valve Springs
Lift up timing chain and rotate piston of cylinder to be machined to TDC with wrench bit see table for
piston in TDC.
MARKING INDEX PISTON IN TDC

o 1 and 6
90 5 and 3
180 4and 7
270 8 and 2
Bucket tappet (3) ofthe relevant cylinder remove, install (05-2110).

Crankshaft fix in position with retaining lock to prevent it
turning (03-5000) .
Compression chamber pressunze.
Hinged clevis (7a) insert into appropriate hole of the camshaft bearing
cap in cylinder head.
Lever depressor (9) attach with thrust piece (5) to hinged clevis (7a) in
the appropriate hole, special tools 111 589 18 61 00,
119 589 10 63 00 and 119 589 06 63 OO.
Mercedes-Benz
Thrust piece (5) position vertically onto valve spring retaíner (15).
rfJ
The valves must not strike the piston crown
otherwise they will be bent.
Valve collets (14) remove, install with tweezers (6), magnetic finger,
special tool 116 589 06 63 00
lnstallation note
Coat valve spring retaíner (15) with grease for
fixing the collets (14) in position.
Valve spring retainer (15) together with valve remove, install.
spring (17)
Valve stem seal (19) replace (05-2700).
Bottom valve spring retainer (20) remove and ínspect for pitting, install.
Special tools
111 589 18 61 00
~~---1_19__
58_9_1_0 _63_ 0_0_____)

Mercedes-Benz
~~---1_19__
58_9_0_6 _63_ 0_0_____)
116 589 06 63 00
COMMERCIALLY A V AILABLE TOOLS

Cylinder leak tester e.g. Bosch E FA W 21 OA
Sun, CLT 228
Straight tweezers 160 mm with e.g. Stah.lwille
rounded tips D-42331 W uppertal 12
EXAMINING V AL VE SPRJNGS - RA05001042600X(05-2600)
Examining valve springs- RA05001042600X(05-2600)
Preceding work:
Valve springs removed {05-2500)
Operation no. of operation texts and work lmits or standard texts and flat rates
Mercedes-Benz
P OS-5506-55
Fig. 148: Examining Valve Springs
Valve springs clean.

lll
Replace valve spríngs wbich are not to dimensional
tolerance, which are corroded, have surface rust,
mechanical damage or are worn at the ends.
Color codíng (F) on valve springs check, match up, see table.
Spring force when pretensioned measure.
If the val ve springs do not reach the specified spring
force, they cause a loss of positive contact at high
speeds and must be replaced.
VALVE DATA
Valve Color Ou ter 0 Wire 0 (d) Lengtb Lengtb Ll and L 2
spring part cod ing (F) (D) mm mm untensioned p retensioned spring
no. (l) (L) mm force in N
Ll N IL2 N
Outer spring 104 053 03 yelnow- 29.8 4.0 46.8 36.9 285 27.5 665 ±
20 silvergrey or ± 14 33
purple-
silvergrey
Outer spring 104 053 05 yellow blue-
20 yeUow or
purple blue-
yelEow
Inner sorin!! 104 053 01 ourole- 20.5 2.5 47.6 33.9 125 ± 7124.5 258 ±
Mercedes-Benz
22 silvergrey or 13
yellow-
silvergrey
Conical 111 053 00 purple- 23.4 3.7 47.3 36.7 290 ± 27.3 600 ±
springC2) 20 yeJlow or 29.3 15 30
yellow-
yellow
(1) Not AMG engines
(2) As of 11/93
Inspecting valve springs- RA05001192600X(05-2600)
Preceding work:
Valve springs removed {05-2500)
.....J
POs-5506-55
Fig. 149: Inspecting Valve Springs
Valve springs clean.

[l]
Replace valve springs which are not to dimensional
tolerance, are corroded, have surface mst,
mechanical damage or wom at the ends.
Color coding on valve springs check, match, see table.
Mercedes-Benz
Spring force measure at pretensioned length.

If the valve springs do not achieve the specified
spring force, they cause a loss of frictional
connection at high engine speeds and should be
replaced.
DATA FOR M 119

Valve Color Outer 0 W ir e 0 (d) Length Length Ll a nd L2
spring p art coding (F) (D)mm mm untensioned initially tensioned
no. (L)mm spring for ce in N
L l /N L2/N
1st version 11905301 yellow/blue 29.6 3.9 40 33 1 225 23 1575
cylindrical- 20 (outer)
shaped
1st version 11905301 yellow/blue 20.7 2.4 41.6 30 1 100 20 1205
cylindrical- 22 (ínner)
shaped
2nd version 119 053 02 p urple or 24.42 oval 40.8 33 1 250 23.5 1 630
conical- 20
shaped
yellow/blue 30.22
2nd version 119 053 08 purple/blue 23.40 3.7 40.1 33 1250 24.1 1 600
conical- 20
shaped
29.20
2nd version 119 053 04 purple or 23.76 oval 41.9 33 1 210 24.5 1465
conical- 20
shaped
yellow/red 29.56
2nd version 119 053 09 yellow1green 23.00 28.80 3.5 41.7 331220 24.5 1 475
conical- 20
shaped
2nd version 119 053 07 purple/white 22.80 3.4 41.9 33 1210 24.51465
conical- 20
shaped
28.60
REPLACING VAL VE STEM SEALS- RA05001042 700X(05-2700)
Replacing valve stem seals - RA05001042700X(05-2700)
Preceding work:
Valve springs removed (05-3500).

Mercedes-Benz
05-3510
Fig. 150: ldentifying Valve Stem Seals
Valve stem sea1 (19) pull offwíth pliers (1) 606 589 00 37 OO.
Valve stems deburr, íf necessary.
Protective sleeve (2) fit onto valve stem, remove.
Valve stem seals (19) oil.
Valve stem seals (19) press on by hand with suitable installation dríft (3)
119 589 00 43 00 or 104 589 01 43 OO.
Special tools
Mercedes-Benz
606 589 00 37 00
1 04 589 o1 43 00
Fig. 152: ldentüying Special Tool (104 589 01 43 00)
119 569 00 43 00
NOTE: Exhaust and inlet valve stem seals and assembly sleeves are supplied as a
repair kit.
The assembly sleeves must be used to ensure that the val ve stem seals are not damaged.
Valve guides whích are worn at the retaíning groove for valve stem seals and valves with damaged valve ends
or va.lve stems must be replaced.
Valve stem seals with bent metal casing must be replaced.

Mercedes-Benz
Replacing valve stem seals - RA05001192700X(05-2700)
Preceding work:
Operation no. of operation texts and work units or standard texts and flat rates 05-351 O
Fig. 154: ldentifying Valve Stem Sea1s
Valve stem seals (16) remove withpliers (1) 104 589 00 37 OO.
Valve stems debur, if necessary.
Protective sleeve (2) fit onto valve stem, remove.
Valve stem seals ( 16) oiL
Val ve stem seals ( 16) press on by hand with the assembly drift (3).
Assembly drift 104 589 01 43 00 (día. 8 and 9 mm)
Assembly drift 119 589 00 43 00 ( dia. 7 mm)
Special tools
Mercedes-Benz
____
\\..__ 606 589 00 37 00 _..,.)
104 589 01 43 00
Fig. 156: l dentüying Special Tool (104 589 01 43 00)
119 589 00 43 00
NOTE: Valve stems and assembly sleeves are supplied as a repair kit.
Valve guides whicb are wom at tbe retaining groove for the valve stem seals and valves with damaged valve
ends or valve stem must be replaced.
Val ve stem seals witb bent metal sbe ll must be replaced_
DISTINGUISHING FEATURES OF VAL VE STEM SEALS

IEngine IEngine No. lrdentification Valve stem dia. IAssembly drift
Mercedes-Benz
PartNo. Inlet Exhaust (special too!)

119.96 (1st up to 011 930 104 053 02 58 8mm 1- 104 053 01 43
version) 104 01 43 00 - 9mm 00
119.96 (2nd as ofOll 931 000 053 42 58 or 7mm 7mm 119 589 00 43
version) 000 053 43 58 00
119.97 as of start of
series production
CHECKING VAL VE GUIDES - RA05001042845X(05-2845)
Checking valve guides- RA05001042845X(05-2845)
Preceding work:
Cylinder head removed.
Valves removed.
Inlet and exhaust valve guides inspect with gauge in 1ongihidinal and in transverse
direction.
For this purpose, check whether the NO GO end
with the wear limit size (+220) can be inserted into
the valve guides over its entire height (5 mm). Ifthe
gauge can be inserted over its entire heigbt, replace
valve guide.
Seat ofvalve stem seal on inlet and exhaust examine.
valve guides If seat worn so that val ve stem seal is no 1onger
tightly located, replace valve guide.
VAL VE GUIDES
Engine Valve guide ID Inlet Exhaust Gauge ( special too1)
104.980/981 (lst version) 8 mm - 102 589 00 23 00
9mm 117 589 03 23 00
104.980/981 (2nd version) 7 mm 102 589 01 23 00
104.990 (1st version) - S mm 102 589 00 23 00
104.980/981 (3rd version) 7 mm - 102 589 01 23 00
104.990 (2nd version) - 7mm
104.940/941/942/943/944/
104.945/992/994/99 5/996 1 1
SpeciaJ tooJs
Mercedes-Benz
c~--~10~2~5~~~0~0~23~0~0--~J
102 5 B9 O1 23 00
117 589 03 23 00
Checking valve guides - RA0500l192845X(05-2845)
Preceding work:
Valves removed.
Mercedes-Benz
I.Ill<er Zy\.ndo~cp: Motor 119.960
Fig. 161: Inspecting Valve Guides
Inlet, exhaust valve guide (54) and (56) i.n check with gauging drift (4).
longitudinal and transverse direction Gauging drift 102 589 00 23 00 inJet valve guide
dia. 8 mm.
Gauging drift 117 589 03 23 00 exhaust valve guide
dia. 9 mm .
Gauging drift 102 589 O1 23 00 inlet, exhaust valve
guide día. 7 mm.
When perfonning this step, check whether the "no go" stud (5) with the wear limit (+220) can be inserted
into the valve guides (54) and (56) over its entire length (5 mm). If the gauging drift (5) can be inserted
over its entire length, replace valve guide {05-2850}.
Retaining groove (arrows) ofvalve stem seal on check.
valve guides (54) and (56) Ifthe retaining groove is wom (arrows) with result
that the valve stem seal is no longer tightly seated,
replace valve guide {05-2850).
Special tools
Mercedes-Benz
102 589 00 2J 00
05
n7 589 03 23 oo
os
102 589 01 23 00
05
Fig. 164: ldentifying Special Tool (102 589 01 23 00 OS)
NOTE: Engine 119.96: as of engine end no. 011931 inlet and exhaust valve guides with
ID 7 mm have been fitted.
Engine 119.97: as of start of production inlet and exhaust valve guides with ID 7 mm have been fitted.
Cbecking valve guides - RA0500l202845X(05-2845)
Preceding work:

Mercedes-Benz
Valves removed.
Inlet and exhaust valve gttides check with gauge in lengthwise and transverse
direction.
Check whether the no-go stud with the wear limit
size (+220) can be inserted into the valve guides
over its entire height (5 mm).
lf the gauge can be inserted o ver its entire height,
replace valve gttide.
Seat ofvalve stem seal at inlet and exhaust valve check.
guides If seat is wom so that val ve stem sea] is no longer
properly seated, replace valve gttíde.
V ALVE GUIDES REFERENCE

Engine Up to engine Valve guide Valve guide inner dia. Gauge (special
end no. outer dia. Inlet Exhaust ltool)
120.980 016 879 13.50 mm 7 mm 102 589 01 23
00
8mm 102 589 00 23
00
120.981 000 346 13.50 mm 7mm 102 589 01 23
00
8 mm 102 589 00 23
00
Engine As of engine end no.
120.980 016 880 12.50 mm 7mm 102 589 01 23
00
7mm 102 589 01 23
00
120.981 000 347 12.50 mm 7mm 102 589 01 23
00
7mm 102 589 01 23
00
Special tools
Mercedes-Benz
102 589 00 23 00
102 589 01 23 00
REPLACING VAL VE GUIDES- RA05001042850X(05-2850)
Replacing valve guides- RA05001042850X(OS-2850)
Preceding work:
Valve guides inspected (05-2845).
A. Non-ferrous metal valve guides, engine 104.980/981 (1st and 2nd version) and engine 104.990 (1st
version)
Mercedes-Benz
PGS-5372-13
Fig. 167: Identifying Non-Ferrous Metal Valve Guides Bores
VALVE GUIDES AND BASIC BORES

Standard size Standard size I Repair size I
Basic bore in cylinder head 13.50- 13.51 13.53 13.70
Valve guide outer 0 and color 13.52 - 13.53 I 3.54- 13.55 13.7 1- 13.72
coding grey-brown red
Overlap 0.012- 0.031
Inlet Exhaust
Val ve guides 1st version inner 8.000 - 8.015 9.000 - 9.015
0
Valve guides 2nd version 7.000 - 7.015 8.000- 8.015
inner 0
Length (L) 35.5 37.9
Dim. (e) 10.8- 11.2 8.2- 8.6
B. Sintered metal valve guides engine 104.980/981 (3rd version) engine 104.990 (2nd version) engines
104.940/9411942/943/944/945/ 992/994/995/996 as of start of production
Mercedes-Benz
P05.30-0296-13
Fig. 168: Identifying Non-Ferrous Metal Valve Guides Bores

Standard size Standard size I Repair size I
Valve guide outer 0 and color coding 12.54 - 12.55 12.56 - 12.57 grey 12.74- 12.75 red
Overlap 0.029 - 0.051
Inlet/Exhaust
Valve guide inner 0 7. 000 - 7. o15
Length (L) 37.5
Dim. (e) 10.2- 10.4
Replacing non-ferrous metal and sintered metal valve guides
Knocking out valve guide

Mercedes-Benz
I'SCI'I'Soll
PQ5.5373-55
A Knodmg out '{ eNe g~~de
B MoasunngvaN& gt.Jde OIJ:I!l 0
Fig. 169: Measuring Valve Guide
Valve guide (54) knock out with drift ( 1) from the combustion
chamber side.
Drift 111 589 02 15 00 for valve guide inner 0 7
mm.
Drift 103 589 03 15 for valve guide inner 0 8 mm.
Drift 103 589 02 15 for valve guide inner 0 9 mm.
VALVE GUIDE VALUES

Outer 0 measure with micrometer.
Determine which valve guide was installed; match
up next larger valve guide, see table.
Basic bore in cylinder head rearo standard size I or broach repair size I
according to matched valve guide.
Standard size 1
(reaming basic bore with reamer)

Mercedes-Benz
POS-5374-1 5
Fig. 170: Reaming Through With Reamer
Basic bore ream through with reamer (3).

Use reamer 104 589 00 53 00 for basic bore 0
13.53 mm
Use reamer 119 589 00 53 00 for basíc bore 0
12.53 mm
NOTE:
Lubricate with petrol when reaming. Apply only
slight pressure and do not tilt reamer (3). Clean
blades of reamer before each reaming operation.
Repair size 1
(broaching basic bore with broaching tool)

Mercedes-Benz
POS-5375-15
Fig. 171: ldentifving Guide Sleeve And Broaching Tool
Guide sleeve (9) and broacbing tool (8) insert into bucket tappet basic bore.
Use guide s1eeve 104 589 01 63 00 and broaching
tooll04 589 01 53 00 for basic bore 0 13.7 mm.
tool 119 589 O1 53 00 for basic bore 0 12.7 mm.
Broacbing tool (8) press through.
NOTE:
Lubricate with petroleum when broaching. Clean
broaching tool (8) with compressed air before
and after each broaching operation.
Inserting valve guide

Mercedes-Benz
4 5
54
Fig. 172: Locating Valve Guides
Non-ferrous metal valve guides: supercool valve guides (54) in liquid nitrogen (for
about 3 minutes). If no líquíd nitrogen avaílable,
heat cylínder head in water bath to about 80 oc.
Sintered metal valve guides: moisten valve guide (54) on outside with oil.
NOTE:
lt is not necessary to heat the cylinder head orto
cool the valve guides (54).
Valve guide (54) knock in as far as the stop ( arrows) with drift (7).
Insertion drift 119 5 89 02 15 00 ínlet 0 7 mm for
basic bore 13.5 and 13.7.
Insertion drift 606 589 02 15 00 inlet/exhaust 0 7
mm for basic bore 12.5 and 12.7.
Insertiou drift 104 589 00 15 00 ínlet 0 8 mm.
Insertion drift 104 589 02 15 00 exhaust 0 8 mm.
Insertion dríft 104 589 O1 15 00 exhaust 0 9 mm.
NOTE:
The circlip is not fitted to the sintered metal valve
guides. The insertion depth is determined by the
insertion drift.
Valve guide (54) inspect that it is tight once cylinder head is cooled
down.
Inner 0 ofvalve guíde (54) inspect with gauging d ríft (4).
Gauge 102 589 00 23 00 inlet 0 8 mm.
Mercedes-Benz
Gauge 117 589 03 23 00 exbaust 0 9 mm.

Gauge 102 589 O1 23 00 inlet 0 7 mm.
NOTE:
lt must be possible to fully insert the GO side (6)
of the gauge (4).
Noo-ferrous metal valve guides : ream inner 0

with reamer, ifnecessaty.
Reamer 000 589 21 53 00 inlet 0 8 mm.
Reamer 000 589 10 53 00 exbaust 0 9 mm.
Reamer 102 589 01 53 00 inlet, exbaust 0 7 mm.
Sintered metal val ve guides : if the gauge cannot
be inserted, the valve guide should be replaced as
the material of the sintered metal guides too hard for
reammg.
Special tools
103 589 0315 00
103 589 02 15 00
Fi2. 174: Identifyin2 Special Tool (103 589 02 15 00)

Mercedes-Benz
111 589 02 15 00
Fig.175: Identifying Special Tool (111 589 0215 00)
606 589 02 15 00
1 04 589 01 63 00

Mercedes-Benz
11 9 589 05 63 00
104 589 00 15 00
Fig.l79: ldentifving Special Tool (104 589 00 15 00)
104 589 0115 00
Fig. 180: ldentifying Special Tool {104 589 0115 00)

Mercedes-Benz
11 958902 1500
1 02 589 00 23 ()0
11 7589032300

Mercedes-Benz
102 589 0 1 23 ()0
000 589 21 53 00
o
000 589 1 53 00

Mercedes-Benz
~~---1_02_5_8_
9_0 1_5_3_0_
0 __~)
Special tools
1 04 589 01 53 00
11 9 589 01 53 00

Mercedes-Benz
104 589 02 1 5 00
119 589 00 53 00

Mercedes-Benz
103 589 01 98 00
COMMERCIALLY AV AILABLE TOOLS

Cylinder head clamping device e.g.Hunger
D-8000 Munich 70
Order no. 221.60.000
Micrometer 0.25 mm
Replacing valve guides- RA05001192850X(05-2850)
Preceding work:
Valve guides cbecked (05-2845).
A. Engine 119.960/97 with nonferrous metal valve guides
P00-5372-13
Fig. 194: Inspecting Valve Guides And Basic Bores
VAL VE GUIDES AND BASIC BORES

IEngine 119.960(1)
Mercedes-Benz
Standard size ~~tandard size Repair size 1

Valve guide OD and color 13.52- 13.53 13.52- 13.53 13.71- 13.72
e ode grey- green red
13.54- 13.55
grey - brown
Overlap 0.012-0.031
Inlet Exhaust
Valve guide(l) ID 8.000 - 8.015 9.000 - 9.015
Length I 35.5 37.9
Dimension a 2.7 - 2.9 2.7 - 2.9
b 5.4 - 5.6 5.4 - 5.6
e 10.8- 11.2 8.2 - 8.6
(l) Valve guides witb ID inlet 8 mm and exbaust 9 mm up to engine end no.
119.960 12 011 930
Valve guides and basic bores

Engine 119.960(1)
Engine 119.97(1)
Standard size Standard size Repair size 1
1
Valve guide OD and color 13.52 - 13.53 13 .52- 13.53 13.71 - 13.72
e ode grey - green red
13.54- 13.55
grey - brown
Overlap 0.012-0.031
Inlet Exbaust
Valve guide(l) ID 7.000 - 7.o15 7.000 - 7.0 15
Length 1 35.5 40.5
Dimension a 2.7 - 2.9 2.7 - 2.9
b 5.4 - 5.6 5.4 - 5.6
e 10.8- 11.2 10.8- 11.2
(l) Valve gu.ide with ID 7 mm, as ofengine end no. 119.960 12 011 931 up
to 119.960 12 035 320 119.970 12 021 286 119.971 12 010 034 119.974
12 004 781 119.975 12 004 281
Knocking out valve guide

Mercedes-Benz
-.-...
?{}5.5373-55
A Knod< out VatY9 glllda
8 Me~re 'laNa gude 00
Fig. 195: Knocking O ut Valve Guide
Valve guide (54) knock out with drift ( 1) from combustion chamber
side.
Removal drift 103 589 03 15 inlet dia. 8 mm
Remo val drift 103 589 02 15 inlet, exhaust dia. 7
mm and 9 mm with basic bore 13.5 mm
MEASURING V AL VE GUIDE
OD measure with micrometer.
Determine which valve guide is installed. Match up
next larger valve guide, see table.
Basic bore in cylínder head ream to standard size 1 or to repair size I dependíng
on matched valve guide.
Standar d size 1
(Ream basic bore with reamer)

Mercedes-Benz
POIS-~!IF.I. t5
P05-5374-1 5
Fig. 196: lnspecting Valve Guide

Use reamer 104 589 00 53 00 for basic bore of
13.53 mm.
NOTE:
Lubricate with petroleum. Ream with only a slight
pressure and do not twist reamer (3). Clean
Repair size 1
(Ream basic bore with broaching tool)

Mercedes-Benz
Fi~. 197: Identifyin~ Guide Sleeve And Broachin~ Tool
B1ades of broaching tool (8) clean with compressed air or p1astic brush before
each broaching operation.
Guide sleeve (9) and broaching tool (8) insert into bucket tappet basic bore.
tool104 589 01 53 00 for basic bore 13.7 mm.
Broaching tool (8) press through.
NOTE:
Lubricate with petroleum. Clean broaching tool
(8) with compressed air after each broaching
operation.
lnserting valve guide, chec.king ID

Mercedes-Benz
4 5
54
POS-5389-55
Fig. 198: lnspecting Valve Guide
Valve guide (54) supercool in liquid nitrogen (about 3 minutes) .

If no liquid nitrogen is available heat cylinder head in water bath to approx. 80 °C.
Valve guide (54) knock in as far as stop (arrows) with insertion drift
(7).
Insertion drift 104 589 00 15 00 inlet 0 8 mm.
Insertion drift 104 589 01 15 00 exhaust 0 9 mm.
Insertion drift 119 589 02 15 00 inlet, exhaust 0 7
mm.
Valve guide (54) check if tightly seated if cylinder cool.
ID of valve guide (54) check wíth gauging drift (4).
Gauging drift 102 589 00 23 00 inlet día. 8 mm.
Gauging drift 117 589 03 23 00 exhaust día. 9 mm.
Gauging drift 102 589 O1 23 00 inlet, exhaust dia.
7mm.
Go side ( 6) of gauging drift (4) ID must be possible to insert fully.
ream with reamer, ifnecessary.
Reamer 000 589 21 53 00 inlet día. 8 mm.
Reamer 000 589 10 53 00 exhaust día. 9 mm.
Reamer 102 589 01 53 00 inlet, exhaust día. 7 mm.
Special tools
Mercedes-Benz
103 589 03 15 00
103 589 02 15 00
104 589 00 53 00

Mercedes-Benz
000 589 1o 68 ()0
104 589 01 63 00
104 589 01 53 00

Mercedes-Benz
104 589 00 15 00
1 04 589 01 15 00
11 9 589 02 15 00

Mercedes-Benz
102 589 00 23 ()0
117 589 03 23 00
102 589 01 23 00

Mercedes-Benz
000 589 21 53 00
o
000 589 1 53 00
102 589 01 53 00
Special tools
Mercedes-Benz
~~--~1~03~58~9~0~1~98~0~0_____)
11 9 589 01 53 00
11 9589056300

Cylinder head tensioning device e.g.Hunger
D-8000 Munchen 70
Order no. 221.60.000
Micrometer 0.25 mm
B. Engines 119.960/97/98 with sintered metal valve guides

Mercedes-Benz
P05-5372-13
Fig. 217: Inspecting Valve G uides And Basic B()res
VAL VE GUIDES l) AND BASIC BORES

Standard size Standard size 1 Repair size 1
Valve guide OD and color code 12.54- 12.55 12.56 - 12.57 grey 1 12.74- 12.75 red
Overlap 0.029- 0.051
ln1et 1Exhaust
Valve guide ID 7.000- 7.015
Length I 37.5
Dimension a -
b 5.4- 5.6
e 10.2- 10.4
1)Sintered metal valve guides, without circlip and groove, as of engine no. 119.960 12 035 331 119.970
12 021 287 119.971 12 010 035 119.972 as ofstart ofproduction 119.974 12 004 782 119.975 12 004
282 119.98 as of start of production
Mercedes-Benz
P0>5373-55
Fig. 218: Inspecting Valve Guide
Valve guide (54) knock out with drift ( 1) from combustion chamber
si de.
Removal drift 111 589 02 15 00 inlet, exhaust 0 7
mm with basic bore of 12.5 mm.
VALVEGUIDE
OD measure with micrometer.
Determine which valve guide is installed. Match up
next larger valve guide, see table.
Basic bore in cylinder head ream to standard size I according to matched valve
guide.
or broach repair size l.
Standard size 1
(Ream basic bore with reamer)

Mercedes-Benz
POS-5374-1 5
Fig. 219: lnspecting Ream Basic Bore

Use reamer 119 589 00 53 00 for basic bore of
12.53 mm.
NOTE:
Lubricate with petroleum. Ream with only a slight
pressure and do not twist reamer (3). Clean
Repair size 1
(Ream basic bore with broaching tool)

Mercedes-Benz
POS-5375-15
Fig. 220: Inspecting Ream Basic Bore With Broaching Tool
Blades ofbroaching tool (8) clean with compressed air or plastic brush before
each broaching operation.
Guide sleeve (9) and broaching tool (8) insert into bucket tappet basic bore.
Use guide sleeve 119 589 05 63 00 and broaching
toolll9 589 01 53 00 for basic bore 12.7 mm.
Broaching tool (8) press through.
NOTE:
Lubricate with petroleum. Clean broaching tool
(8) with compressed air after each broaching
operation.
Inserting valve guide, checking ID

Mercedes-Benz
4 5
54
Fig. 221: Inspecting Valve Guide
Valve guide (54) moisten on outside with oil.
NOT E:
lt is not necessary to heat the cylinder head orto
cool the valve guide (54).
Valve guide (54) knock in as far as stop ( arrows) with insertion dlrift
(7).
Insertion drift 606 589 02 15 00 inlet, exhaust 0 7
mm.
NOTE:
The circlip is not fitted to the sintered metal valve
guides. The insertion depth is fixed by the
insertion drift.
Installation depth (e) ofvalve guide (54) check, correct if necessary.
Valve guide (54) clean.
Cylinder brush 000 589 1O 68 00
Valve guide (54) check to ensure tight.
ID of valve guide (54) check with inspection drift (4).
Inspection drift 102 589 01 23 00 inlet, exhaust 0
7mm.
Go side (6) of gauging drift (4) must be possible to insert fully.
[l]
If it is not possible to insert the gauge, the valve
guide should be replaced as the material of the
Mercedes-Benz
sintered metal versions is too hard for reaming.
COMMERCIALLY A VAILABLE TOOLS

D-8000 Munchen 70
Order no. 221.60.000
Micrometer 0.25 mm
Special tools
o
000 589 1 68 00
11 9 589 05 63 00
1 03 589 01 98 00

Mercedes-Benz
111 58902 1500
11 9 589 00 53 00
11 9 589 01 53 00

Mercedes-Benz
606 589 02 15 ()0
102 589 01 23 00
REPLACING V ALVE SEAT RINGS- RA05001042900X(05-2900)
Replacing valve seat rings - RA05001042900X(05-2900)
Preceding work:
Valve guides examined (05-2845)
Mercedes-Benz
P<rS-5500-57
Fig. 230: Operation Of Valve Seat Rings
V alve seat rings (20 and 21) remo ve with ring seat turning tool.
Operating instructions of tool manufacturer observe.
Basic bore diameter (D 1) measure with interna! measuring instrument.
Valve seat rings (standard size or repair size) select according to overlap.
If repair size machine basic bore.
If repair size, seat ring bore matching valve seat ring pay attention to overlap.
Val ve seat ring cool with liquid nitrogen and insert with a suitable
drift.
Valve seats machine {05-2910).
DATA IN MM
Bore of valve seat ring Inlet Exhaust
DI cylinder head standard 36 H6 32 H6
size
D valve seat ring standard 36.1 to 36.12 32.1 to 32.12
size
Repair size 1
DI cylinder head repair size 37.2 H6 33.2H6
D valve seat ring repair size 37 .3 32.3
t 5.6 to 5.9
Mercedes-Benz
30 25.6

81375 Munchen
Order no. 221.60.000
Ring seat turning tool e.g.Hunger
81375 Munchen
size 2, order no. 220.03.110
Valve seat tuming tool (size 2) e.g.Hunger
81375 Munchen
Model VDSN 1145/30
Order no. 236.03.308
lnspection set for val ve seats e.g.Hunger
81375 Munchen
Order no. 216.93.300
Interna] measuring instrument e.g.Mahr,
(range 35- 100 mm) 73730 Esslingen
Order no. 844 N
Externa! micrometer (range 25- e.g.Mahr,
50 mm) 73730 Esslingen
Order no. 40 S H
Replacing vaJve seat rings- RA05001192900X(05-2900)
Preceding work:
Valve guides inspected (05-2845)
Operation no. of operation texts and work tmits or standard texts and flat rates
Mercedes-Benz
P<rS-5500-57
Fig. 231: Inspecting Valve Seat Rings
V alve seat rings (20 and 21) turn out with ring seat turning tool.
Operating instructions of tool manufacturer note.
Basic bore diameter (D 1) measure with interna! measuring instrument.
Valve seat rings (standard size or repair size) select according to overlap.
If repair size machine basic bore.
If repair size seat ring bore matching valve seat ring, pay
attention to overlap.
Valve seat ring cool with liquid nitrogen and insert with a suitable
drift.
Valve seats machine (05-2910).
VALVE SEAT RING REFERENCE

Dl Standard size 39H6 34H6
cy linder head
D Standard size valve 39.1 to 39.09 34.1 to 34.09
seat ring
Repair size
Dl Repair size cylinder 40.2 H6 35.2 H6
head
Mercedes-Benz
D Repair size valve 40.3 35.3

seat ring
t 7.8 to 7.9
D2 38.47 25.6
VALVE SEAT RING BORE

DI Standard size 36H6 34H6
cylinder head
D Standard size valve 36.1 to 36.09 34.1 to 34.09
seat ring
Repair size
Dl Repair size cylinder 37.2 H6 35.2 H6
head
D Repair size valve 37.3 35.3
seat ring
t 7.8 to 7.9
D2 35.47 33.47
Cylinder head clampíng device e.g.Hunger
81375 Munchen
Order no. 221.60.000
Ring seat turning tool e.g.Hunger
813 7 5 Munchen
Size 2, order no. 220.03.110
Valve seat tuming tool (size 2) e.g.Hunger
81375 Munchen
Type VDSN l/45/30
Order no. 236.03.308
Test kit for valve seats e.g.Hunger
81375 Munchen
Order no. 216.93.300
Interna! measuring instrument e.g. Mahr, 73 730 Esslingen
(range 35 - 100 mm) Order no. 844 N
Extemal micrometer (range 25- e.g.Mahr, 73730 Esslingen
50 mm) Order no. 40 S H
MACIDNING VALVE SEAT RINGS- RA05001042910X(05-2910)
Machining valve seat rings- RA05001042910X(OS-2910)
Preceding work:
Mercedes-Benz
PQ5..545S-57
Fig. 232: Machining Valve Seat Rings
Valve seats machíne.
NOTE:
Pay attention to operating instructions of tool
manufacturer.
Use SERDI shape tuming tool number 41196. Use

Hunger tuming tool number 23m or 24m.
D imensions maintain as stated in table.
Leaktigh tness check with valve installed.
Val ve seat width (b) measure.
NOTE:
lf necessary, correct valve seat width (b) with
Mercedes-Benz
correction angles (Hunger) 23m and 24m (angles

a and B).
Valves insert and measure clearance from valve stem end to
camshaft bearing base (see 01-480).
Data Inlet valve, exhaust valve

Valve seat widtb (b) 0.90- 1.10 mm
Valve seat angle (a)
Correction angle at top (13)
Correction angle at bottom (13)
Perrnissible radial runout of valve seat 0.03mm
V al ve seat tuming tool e.g. SERDI GmbH
Bregenzstr. 69
88131 Lindau
Shape turning tool e.g. SERDI GmbH
Bregenzstr. 69
88131 Lindau
Order no. 41196
81375 Munchen 70
Order no. 221.60.000
Valve seat turning tool e.g.Hunger
81375 Munchen 70
Model VS DN 1/45/30
Order no. 236.03.308
Test set for valve seats e.g.Hunger
81375 Munchen 70
Order no. 216.93.300
Turning tools for val ve seat and e.g.Hunger
correction angles (B) and (gamma) 81375 Munchen 70
23m Order no. 216.64.235
24m Order no. 216.62.170
Machining valve seat rings - RA05001192910X(05-2910)
Preceding work:
Mercedes-Benz
P0.~ 56-57
Fig. 233: ldentifying Macbining Valve Seat Rings
Valve seats machine.
NOTE:
Pa y attention to operating instructions of tool
manufacturer.
Use SERDI fom1 turning tool no. 41196.

Use Hunger turning tool no. 23m or 24m.
Reference size (T) between valve stem end and measure (see Inspecting, facing cylinder head
base of camshaft bearing contact surface 01 -4180).
IIl
If size "T" is not achíeved, no further correct valve
clearance compensation exists. In this case, the
valve seat or the cylinder head should be replaced.
Dimensions maintain according to table.
Leaktightness with valve installed check.
Valve seat width (b) measure.
Mercedes-Benz
NOTE:
lf necessary, correct valve seat width (b) with
correction tools 23m and 24m (Hunger) (angles a
and B).
Valves insert and measure clearance from valve stem end to
base of camshaft bearing (T), see (01-4180) .
~
The valves should always be replaced when
performing facing work on cylinder head and
resetting the valve seats.
DATAINLET, EXHAUST VAL VE

Valve seat width (b) Inlet 0.80-l.lOmm
Valve seat widtb (b) Exhaust 1.00- 1.20 mm
Valve seat angle (a)
T op correction angle (13)
Bottom correction angle (Y)
Perrnissible concentricity of val ve seat 0.03 mm
COMMmRCMLLYAV~ABLETOOLS
Valve seat tuming tool e.g. SERDI GmbH
Bregenzstr. 69
88131 Lindau
Form tum.ing tool e.g.SERDI GmbH
Bregenzstr. 69
88131 Lindau
Order no. 41196
81375 Muncben 70
Order no. 221.60.000
Valve seat turning tool e.g.Hunger
81375 Muncl1en 70
Type VSDN 1/45/30
Order no. 236.03.308
Test kit for valve seats e.g.Hunger
81375 Munchen 70
Order no. 216.93.300
Turn.ing tools for valve seat and e.g.Hunger
correction angle (13) and (Y) 23m 81375 Munchen 70
24m Order no. 216.64.235
Order no. 216.62.170
Machining valve seat rings- RA05001202910X(05-2910)
Prf>r.P.rl in o- wnrlc
Mercedes-Benz
Valve guides checked (05-2845)
POS-5456-57
F ig. 234: Macbining Valve Seat Rings
Valve seats machine.
NOTE:
Pay attention to operating instructions of tool
manufacturer.
Use SERDI fom1 cutting tool number 41196.

Use Hunger cutting tool number 23m or 24m.
Dimensions maintain as specified in table
Leaktightness with valve installed check
Valve seat width (b) measure.
NOTE:
Correct valve seat width (b) with correction tools
(Hunger) 23m and 24m, if necessary (angle and
B).
Mercedes-Benz
Valves insert and measure distance from valve stem end to

base of camshaft bearing.
DATA INLET, EXHAUST VAL VE

Valve seat width (b) 0.90- 1.10 mm
Valve seat angle (a) 45°
Upper correction angle (J3) 35°
Lower correction angle (Y) 58°
Permissible radial runout of valve seat 0.03 mm
CO~RCULLYAV~ABLETOOLS
Valve seat tumíng tool eg. SERDI GmbH
Bregenzstr. 69
D-88131 Lindau
Form cuttíng tool eg. SERDI GmbH
Bregenzstr. 69
D-88131 Lindau
Order no. 41196
Cylinder head clampíng device eg.Hunger
D-80000 Munchen 70
Order no. 221.60.000
Valve seat tuming tool eg.Hunger
D-85356 Mtmchen
Typ VSDN 1/45/3 0
Order no. 236.03.308
Test set for valve seats eg.Hunger
D-85356 Munchen
Order no. 216.93.300
Cutting tools for valve seats and eg.Hunger
correction angle (J3) and (Y) 23m D-85356 Munchen
24m Order no. 216.64.235
Order no. 216.62.170
REMOVING AND INSTALLING CHAIN TENSIONER- RA05001043100X(OS-3100)
Removing and installing chain tensioner- RA05001043100X(05-3100)
Preceding work:
Poly V -belt removed (13-3200) .
Mercedes-Benz
05-7800, 7801
Fig. 235: ldentifying Chain Tensioner Remove/Install Components
CHAIN TENSIONER OPERATION TEXTS

Modlels 124, 129, 140: unbolt air pump (22), swivel to the side with
lines/wiring connected, bolt on (14-7251) .
Modlels 124, 129, 140: cover over generator with cleaning cloth.
Modlel202: disconnect ground cable at battery, connect.
Modlel202: remo ve air cleaner top part, install (09-1051 ).
Modlel202: unbolt generator, place to side with wiring
connected, bolt on (15-5032).
Screw plug (1) slacken approx. one turn.
Chain tensioner complete unbolt.
~
Ifthe chain tensioner housing (14) has been
slackened, it must be taken off as the thrust pin (1 O)
is locked with the detent spring (9) in the pressure
direction.
Screw plug (1) with seal (5) unscrew.
Filler pin (7) and compression spring (8) remove.
Mercedes-Benz
Thrust pin (10) with detent spring (9) in chain press out in pressure direction.
tensioner housing (14)
@--15
bt-10
(J--9
tg----7
@--5
~40Nm
®-1
P05-5533-57
Fig. 236: ldentifying Screw Plug And Compression Spring
COMPRESSION SPRING
Air cleaner remove, install.
Generator unscrew top bolt, screw on, slacken bottom bolt,
swivel generator down.
Screw plug ( 1) slacken about one tum.
Chain tensioner complete unscrew.
~
Ifthe chain tensioner housing (14) was slackened, it
must be removed as the thmst pin (1 O) is locked in
the pressure direction by the detent spring (9).
Screw plug (1) with seal (5) remo ve.
Filler pin (7) and compression spring (8) remove.
Thrust pin (1 O) with detent spring (9) press out of chain tensioner housing (14) in pressure
direction.
Mercedes-Benz
Fig. 237: ldentifying Chain Tensioner Housing
CHAIN TENSIONER HOUSING

Chain tensíoner housing (14) wíth seal (15) install, tíghten (80 Nm).
TI1rust pin (lO) with detent spríng (9), Compressíon insert.
spring (8) and filler pin (7)
Screwplug (1) with new seal (5) screw in, tighten (40 Nm).
NOTE:
Stick seal (5) onto screwplug (1) with grease.
Screw plug of chain tensíoner 40
Chaín tensioner housing in timing case cover 80
Special tool
001 589 66 21 00

Mercedes-Benz
4~m 1 5 15 17 9 8 7 14 16
P05.54G5-55
1 Screwplug 10 1lrust pKl

2 Bal {rllilm flow sh.l!oífvalve) 11 Bal
3 Comprosston spnng 12 Cornpross1011 spnng
4 Bal QllldO 13 1lrust p¡ece(press-Meó)
5 Allmmm seal 14 Cilam lo1151oner housmg
7 Flerpin 15 AA!mraum seal
8 Compressron spnng 16 Tmang casecovor
9 Detert spnng
Fig. 239: SectionaJ View Of Cbain Tensioner Housing
Removing and installing chaÍil tensioner - RA05001193100X(05-3100)
Preceding work:
Right cylinder head cover removed (01-0500).
Operatíon no. of operation texts and work units or standard texts and flat rates 05-7800, 7801
Mercedes-Benz
POS-5376-57
Fig. 240: ldentifying Chain Tensioner Remove/Install Components
Mod!el 210: air cleaner housing remove, install.

Pisten of cylínder 1 position to 45° before ignition TDC (arrow).
Right outlet camshaft fix in position with pin (01) (arrow) so that the
exhaust camshaft does not jump across when timing
chain relieved.
Special tool 111 589 03 15 OO.
With mechanical secondary air injection: slacken poly V-belt and take offfrom air pump (6)
or model129 with engine 119.960, from generator,
fit on {13-3420) .
Mod!el129 with engine 119.960: generator unbolt, bolt on (15-510).
With mechanical secondary air injection: unbolt air pump (6) and place to the side with piping
connected.
Mod!els 124, 140 wíth mechanical secondary air unbolt bracket (7) of air pump or generator, bolt on
1njecrion: (25 Nm).
Mod!el 21 O with electric secondary air injection: remove electric air pump together with bracket,
install.
NOTE:
Unbolt guide pulley and EGR valve at bracket for
this step.
Mercedes-Benz
Bolt (8) and nut (9) slacken, tíghten evenly (25 Nm).
[l]
Engíne oil which flows out must not get ínto the
generator.
Chain tensioner (4) must not be tilted.
Chain tensioner (4) together with gasket (5) remo ve, fit on.
Gasket (5) replace.
Engine nm a:nd check for leaks.
Bolt and nut of chain tensioner M8 25
Bolts of air pump bracket 25
Guide pulley to air pump bracket ( with electric 30
secondary air injection)
Special tools
001 589 72 21 00
001 589 65 09 00

Mercedes-Benz
111 58903 15 00
1 Housmg a 4 mm ba!
2 O.shed washnr S Ccmpros51011 spnng
3 Ttrust pin 10 Ba.l guK!a
4 Flerp¡n 11 Bel seatnng
5 Compress1011 spnng 12 Pres"S!Jised oll feed
6 Cap 13 M10x14seal
7 Compress1011 spnng 14 M10x1 sa a•.vpklg
Fig. 244: Sectional View Of Chain T ensioner
Removing and installing chain tensioner - RA05001203100X(05-3100)
Preceding work:
Air cleaner with mass air flow sensor, right, removed (09-0015).
Intake air scoop, right, removed (09-0060) .
Secondary air pump removed {14-7251) .
Operation no. of the operation texts and work units or standard texts and flat rates 05-7800, 780 1
Mercedes-Benz
Fig. 245: Identifying Chain Tensioner Remove/Install Components
Crankshaft tum to 30° after TDC on 1st cylinder.

Plug (1) loosen approx. one turn.
Chain tensioner unscrew completely, remove.
~ has engaged in the locking spring (9) in the thrust
Ifthe chain tensioner housing (14) has been direction.
loosened, it must be removed, because the thrust
bolt (10)
Filler pin (7) and pressure spring (8) unscrew, remove (step 4).
Thrust bolt (1 O) press out of chain tensioner housing (14) in thrust
direction together with catch spring (9) (item 5).
Chain tensioner housing ( 14) instali with sealing ring (15), tighten to 50 Nm (item
6).
Thrust bolt (10) slide in together with catch spring (9), pressure
spcing (8) and filler pin (7) (item 7).
Plug (1) install with sealing ring (5), tighten to 40 Nm (item
R)
Mercedes-Benz
ILeakage check.
Plug, chain tensioner 40
Chain tensíoner housing in timíng case cover 80
Special tools
/
001 589 66 21 00
00
Fie. 246: Identifyine Special Tool (001 589 66 21 oo 00)
001 sao 65 no oo
03 07 ~2 ~
Fig. 247: ldentifying Special Tool (001 589 65 09 00 03 07 32)
COMMrnRCMLLYAV~ABLETOOL
Pin wrench insert 1Omm, 1/2" e.g. Hazet
drive D 5630 Remscheid
Order no. 985/ 1O
NOTE: lmproved noise characteristics in engine speed range 900 - 1200 rpm when
engine is at normal operating temperature as a result of modified chain
tensioner.
Pressure pío (lO) 1.1 mm día. control bore (ídentified by 3 grooves on 14.2 día.).
Cornpressíon pin (8) wíre gauge 0.7 mm (was 0.6 mm).

Mercedes-Benz
Standard as of August 1991.
Engine 120.980-12-003 128
120.981-12-000 068
1 PkJQ
2 Ba2(dleck va1Vo)
3 Prossu-e spmg
4 Bldgtude
5 ALmruum seaing nng 2 3 4 10 13
7 Rlerptn
8 Thrust spmg
9 Catdl spriog
10 Thrustbol
11 Ba5
12 PresstEe spmg
13 Thrust pi ece (p(es sed 11)
14 Chan tonstonerhousl1g
15 Aknl11tnl seálgmg
16 1im11gcase cover
17 0 11 raed passaga
1 5 17 15 9 8 7 14 16
POS· 5125 • 35
Fig. 248: Sectional View Of Chain Tensioner Housing
Removal, installation
l. Turn crankshaft to 30° after ignition TDC on 1st cylinder (arrow).

2. Loosen plug (1) approx. 1 turn.
3. Completely unscrew chain tensioner and remove.
Fig. 249: Locating 1st Cylinder Position

Mercedes-Benz
4. Remove plug (1) wíth sealíng ring (5). Remove thrust spríng (8) together with filler pin (7).
5. Press out tbrust bolt (10) together with catch spring (9) in thmst direction. Clean parts.
6. Screw in chain tensioner housíng (14) with new sealing ríng (15) and tighten to 50 Nm.
lnstallation note
Stick sea] (15) with grease to the chain tensioner housing (14) so that it remaíns centered on the guide
shoulder.
Tíghtening torque 80 Nm.
PO!J-!1211·13
Fig. 250: Exploded View Of Chain Tensioner Housing
7. Insert thrust bolt ( 1O) into installed chain tensioner housing together with installed catch spring (9) and
pressure spring (8) wíth filler pín (7).
Fig. 251: lnserting Thrust Bolt Into lnstalled Cbain Tensioner Housing
Mercedes-Benz
8. Screw plug (1) into installed chaín tensioner housing (14) with new sealing ring (5) and tíghten to 40 Nm.
9. Allow engine to run and check for leakage.
Fig. 252: ldentifying Sealing Ring And Chain Tensioner Housing
REPLACING AND RIVETING TIMING CHAIN - RA05001043200X(05-3200)
Replacing and riveting timing chain - RA0500l043200X(05-3200)
Preceding work:
Spark plugs removed (AP15.00-l580CA)

Mercedes-Benz
9 4
Fig. 253: Riveting Timing Chain (1 Of 2)
Chain tensíoner remove (05-3100)_

Engines with HT distributor: remove front cover and top guide raíl (01-2120) _
Engines without HT distributor: remove top guide raíl (05-3400).
Chain box cover over with a clean cloth.
Chain pín (arrows) oftíming chain (4) at exhaust grind open (arrows), separate with chain
camshaft sprocket (9) separatíng tool 602 589 02 33 00 and thrust spíndle
602 589 04 63 00 (0 2.9 mm).
Plate (8) oftiming chaín (4) prise offwith screwdriver.
Ground-open double link press out
Mercedes-Benz
P05 • 5312 - 57
Fig. 254: Riveting Timing Cbain (2 Of 2)
New timing chain (5) connect to old timing chain (4) with 1iveted link (6)
and center plate (7) (thickness 1.6 mm) and ground-
open outer plate (8).
Crankshaft rotate with wrench socket insert in direction of
rotation of engine.
Pay attention to different lengths of timing chains:
Engine 104.980/98 1 130 links
Engine 104.94/99 126links
N ew separated timing chain ( 5) pull in.
T iming chain ho ld meshed at exhaust camshaft sprocket (9) by
hand when pullíng in.
Bottom free end (4) oftiming chain pull out of chain box.
Crankshaft ro tate sufficiently until the end of the new timing
chain can be connected with. the riveted link.
New timing chain (5) connect to inserted link (6) and center plate (7).
NOTE:
Riveted links of the IWIS version part no. 000 997
22 98 should be matched to the IWIS timing chain
and riveted links of the Renold version should be
Mercedes-Benz
1990-2002 ENGINE Engine Timing - REPAIR & ADJUSTMENTS - 129 Chassis
matched to the Renold timing chain. The

identifications are stamped in each case on the
outer plates of the timing chain.
A B
P05 • 5111·13.
1'05-5112 -1 5
Fi~. 255: Identifyin~ Link An d Centre Plate
Jaw for duplex roller chain with digit 1 insert into pressing-on tool and screw on with screw
(28) (Fig. A).
Moving thrust piece for simplex roller chain with insert into pressing-on tool (Fig. B).
the digit 2
Outer plate (8) of 1.2 mm thickness insert into moving thrust piece (Fig. C).
Webs ( arrows) fit onto rollers at riveted link (Fig. D).
Spíndle (04) screw in until tíght resístance felt (Fig. D). When
screwing in, ensure that the pins of the riveted link
are inserted ínto the holes ofthe outer plate (8).
Pressíng-on tool take off.
Mercedes-Benz
POS- 5116 · 13 f'05 • 53H- 57
Fig. 256: Tdentifving Spindle And Outer Plate
Moving thrust piece with the digit 2 turn over (ríveting profile) (Fíg. E).
Pressing-on tool posítion exactly over middle of pin (Fig. F).
Spindle (04) to 30 N m tighten (Fig. F).
Pins of inserted link ( 6) rivet individually.
Riveting inspect, re-rivet if necessary (Fig. G).
Basic position of camshafts adjust (05-2240).
Front cover and top guide raíl install (01-2120) .
Chain tensioner install (05-3100).
Special tools
Mercedes-Benz
602 589 00 39 00
112 589 09 63 00
001 589 72 21 00

Mercedes-Benz
602 5B9 02 33 00
602 589 05 63 00
Replacing aod rivetiog timing chain- RA05001193200X(05-3200)
Preceding work:
Spark plugs removed {15-1031).
Mercedes-Benz
Fig. 262: ldentifying Operation For T iming Cb ain {1 Of 4)
Piston of cylinder 1 set to 45° before ignition TDC.

Right cylinder head: inlet, exhaust camshafts fix with pins (O 1) (Fig. A), special tool 111 589 O1
15 OO.
Chain tensioner remove (05-3100).
Right guide rail (2) at top remove, install (05-3350) (Fig. A).
Timing chain to camshaft sprockets lock with wedges (04) and (05) at right cylinder
head (Fig. B), special toolllO 589 03 59 OO.
Chain housing cover over with clean cloth.
Chain pin of timing chain (4) between inlet and grind open (Fig. C).
exhaust camshaft sprockets
P1ate (8) oftiming chain (4) prise offwith a screwdriver (Fig. D).
Ground-open double link push out.
Mercedes-Benz
Fig. 263: Identifying Operatiion For Timing Cbain (2 Of 4)
New timing chain (5) connect to old timing chain (4) with riveted link (6)
and middle plate (7) (tbickness 1.6 mm) and ground
open outer plate (8).
Pins (01) remo ve.
VVedge(5)atinletcamshaft remove, holding timing cbain meshed at inlet and
exhaust camshaft sprockets by hand when
performing tbis step.
VVed!ge (04) at exbaust camshaft sprocket slacken slightly.
Crankshaft rotate in direction of rotation of engine with wrench
socket (10); hold timing chain (4) or (5) mesbed at
inlet and exhaust camshaft sprockets when
fijforming this step.
Ensure that tirning chain (4) or (5) does not jump off
when tumed.
New timing chain (5) pull in.
End (4) oftiming chain which has become free pu 11 out of chain housing.
Crankshaft rotate sufficiently until the ends of the new tirning
cbain (5) can be connected with the riveted link
Tirning chain to camshaft sprockets flx with wedges (04) and (05).
N ew timing chain ( 5) connect with link (6) and center plate (7).
Mercedes-Benz
Fig. 264: Identifying Operatiion For Timing Chain (3 Of 4)
Jaws for duplex roller chain with number 1 insert into fitting tool and screw on with screw (28)
(Fig. E).
Moving thrust piece (arrow) for simplex roller chain insert into fitting tool (Fig. F).
with nwnber 2
Outer plate (8) (thickness 1.2mm) insert into moving thrust piece (Fig. G).
Webs ( arrows) tit onto roller at riveted link.
Spindle (06) screw in until tight resistance.
NOTE:
When screwing in, ensure that the pins of the
riveted link are inserted into the holes of the
outer plate (8).
Insertion tool remo ve.
Mercedes-Benz
POS· 5114 - 13
POS - 5116·13
Fig. 265: Identifyiog Operatiioo For Timing Chain (4 Of 4)
Moving tbrust piece (arrow) with number 2 tum over (riveted section) (Fig. I).
Fitting tool position exactly over center ofpin (Fig. J).
Spindle (06) tighten to 30 Nm (Fig. J).
Pins of riveted link ( 6) rivet indivídually (Fig. J).
Riveting ( arrows) examine, re-rivet if necessary (Fig. K).
Basic position of camshafts set (05-2240).
Chain tensioner install (05-3100) .
Special tools
Mercedes-Benz
000 589 SS 43 00
os
103 589 01 63 00
05
REMOVING AND INSTALLING TENSIONING RAIL- RA05001043300X(05-3300)
Removing ancl installiog tensioning rail- RA05001043300X('05-3300)
Preceding work:
Tinung case cover removed (01-2100).

Mercedes-Benz
Fig. 269: ldentifying Tensioning Rail Remove/lnstaD Components
A Motor 104.98 B Motor 104 _94/99

Cran.k:shaft sprocket mark relative to timing chain with colored marking.
Tensioning raíl (2) pull offbearing pin (20).
Tensioning raíl (2) instalL Pay attention to colored markings_ Check
basic position of camshaft, if necessary (05-2230).
NOTE:
The plastic guide (19) (running surface) is clipped
into the tensioning rail (2) and can be replaced
separately.
The bearing pin (20) is knocked into the crankcase.

Projection 28 mm.
The all-plastic tensioning rail (2nd version) can be
used in place of the 1st version.
Removing and installing tensioning rail- RA05001193300X('05-3300)
Preceding work:
Mercedes-Benz
Right camshaft adjuster removed (05-2170)_
Belt pulley/vibration damper removed (03-3420) _
Operationno. of operation texts and work units or standard texts and flat rates 05-8126
Fig. 270: ldentifying Tensioning Rail Removellnstall Components
Screwplug (35) with seal (36) unscrew, screw on (lO N m).

lnstallation note
Replace seal (36) according to condition.
Tensioning raíl pin (2) pull offwith impact extractor (02) and threaded
insert (03), special tools 116 589 20 33 00 and 116
589 02 34 OO.
Tensioning raíl (3) pull out of chain housing, ínsert
Tensioning rail pin (2) push in.
NOTE:
lnsertion size: pin to sealing ring contact (timing
case cover), maintain 10 mm.
Removing and installing tensioning rail - RA05001203300X('05-3300)

Mercedes-Benz
Preceding work:
18-----
-------13
- - ---21
~m!a----=+-----14
----15
~JJY.------18
POS- 5117-57
Fig. 271: ldentifying Tensioning Rail Remove/lnstaD Components
Crankshaft sprocket ( 1) mark with colored dot relative to timing chain (4).
Tensioning raíl (2) at bearing pin (17) pull off
Tensioning raíl (2) install, pay attention to colored marking.
NOTE: The plastic Iining (18) (sliding surface) is clipped into the tensioning rail (2) and
can be replaced individually.
The bearing pin (17) is knocked into the crankcase.
Projection 40 mm.
REMOVING AND INSTALLING GUIDE RAIL IN CRANKCASE- RA05001043350X(OS-3350)
Removing and installing guide raiJ in crankcase- RA05001043350X(05-3350)

Mercedes-Benz
Preceding work:
Tirning case cover removed (01-2100) .
Engine 104.98
~ t\l\!i
35Nm
P05 . $316 • 51
Fig. 272: ldentifying Guide Rail In Crankcase Remove/Install Components
Crankshaft sprocket ( 11) mark relative to timing chain (6) with colored
marking (arrows).
Guide sprocket (8) remove, install (05-4400).
Timing chain (6) lift off at inlet camshaft sprocket (5), fit on. Pay
attention to colored marking.
Retaining lugs (arrows) guide raíl outer part (9a) unclip, remove, install.
Guide rail inner part (9) on guide rail pins (21) and pull off, instalL Pay attention to colored marking
(22) ( arrows) on crankshaft sprocket ( 11 ); check basic
setting of camshafts if necessary (05-2230).
NOTE: The guide rail 104 052 02 16 (2nd version) with mounting pin and oil drilling
(arrow) should be used on crankcases with mounting drilling.
The guide rail104 052 06 16 (1st version) without mounting (arrow) must only be used on crankcases without a
Mercedes-Benz
P05.10.0150-35
Fig. 273: ldentifying Mounting Pin And Oil Drilling
Removing and installing guide rails at top of cylinder bead- RA05001193350X(05-3350)
Preceding work:
Valve covers removed (01-0500) .

Mercedes-Benz
Fig. 274: ldentifying Guide Rails At Top Of Cylinder Head
Release device (B) insert into top detents, special tool119 589 01 63 03
(step 1).
Pusher (A) fit onto the raíl, specíal tool 119 589 01 63 00 (steps
2 to 3).
Pusher (A) push down (step 4).
Front part of guíde raíl (2) take off
Guíde raíl (2a) with rubber gasket unbolt, bolt on (9 N m)_
Special tools
t19 S89 0 1 6300

05

Mercedes-Benz
OOl 58Q 7 2 21 00
00
l. Release top detent of rail by inserting the release tool (B) in direction of arrow between bottom part of
slide rail (2a) and top part (2).
Fig. 277: ldentifving Sllide Rail And Top Part
2. Raise rubber gasket (2b) so that pusher (A) can be inserted at the slide rail (2a).
Mercedes-Benz
Fig. 278: ldentifying Rubber Gasket And Pusher
3. Guide the metal tabs (6) of the pusher (A) through between the bottom detent (7) and the locking tabs (8)
(arrows).
Fig. 279: ldentifving M etal Tabs And Locking Tabs
4. Introduce pusher (A) into the slots (arrows) ofthe raíl and press down vertically at the handle until front
part of slide rail can be removed.
lnstaUation instructioo
Ensure engaging points are correctly positioned.
5. Unscrew bottom part of slide rail (2a), tightening torque 9 Nm.

Mercedes-Benz
Fig. 280: Locating Slots And Pusher
REMOVING AND INSTALLING FRICTION RAIL IN CRANKCASE- RA05001043360X(05-3360)
Preceding work:
Engine 104.94/104.99
17 5 6
21
Mercedes-Benz
Fig. 281: ldentifying Friction Rail In Crankcase Remove/Install Components
Crankshaft sprocket (11) mark relative to tíming chain (6) with a colored
marking (arrows).
Tensioning rail (2) remove, ínstall {05-3300).
Timing chain (6) at camshaft sprockets (3) and (5) lift off, fit on. Pay attention to colored marking
(arrows).
Guíde raíl (18) at bearing pins (17) and (21) pull off, fit on. Pay attentíon to colored marking
(arrows) on crankshaft sprocket (1 1); check basic
position of camshafts ifnecessary (05-2230).
NOTE:
The plastic guide (sliding suñace) is clipped into
the guide raíl (18) and can be replaced separately.
Projection of guíde raíl pin (17) at top with female

thread 21 mm.
Projection of guide rail pin (21) at bottom 34 mm.
REMOVING AND INSTALLING GUIDE RAIL IN CYLINDER HEAD - RAOS001043400X(OS-3400)
Removing and installing guide rail in cylinder bead- RA050 01043400X(05-3400)
Preceding work:

Mercedes-Benz
P05 - 6321 • 57
Fig. 282: ldentifying Guide Rail In Cvlinder Head Removellnstall Components
Chain tensioner ( 1) remove (05-3100).

Exhaust camshaft rotate with wrench (25) 119 589 00 01 00 (WAF 27)
or 104 589 01 01 00 (W AF 29) in direction of
rotation of camshaft, slacken timing chain at guide
rail (42).
[l] If the curved guide raíl (42) is taken out of its
mounting, the thrust pin in the chain tensioner is
moved in the pressure direction by one detent. The
chain tensioner must then be removed to avoid the
timing chain being overtensioned.
Guide rail (42) at bearing pin pull off, fit on.
Exhaust camshaft turn back with wrench (25) in opposite direction of
rotation of camshaft.
Chain tensioner ( 1) install (05-3100).
Guide rail with three bearing points replaces guide rail with two bearing points.
Standardization with engines 104.942/992.

Mercedes-Benz
B. 2nd version
Fig. 283: ldentifving Guide Rail With Bearing Points
PRODUCTION BREAKPOINT- JUNE 1991

Mocilel Engine Engine end no. manual Engine end no. automatic
transrnission transrnission
124.031 104.980 006321 028147
124.051
124.091
129.061 104.981 001311 o11953
140.032/03 3 104.990 000096 005054
Special tools
119 589 00 01 00
F ig. 284: ldentifying Special Tool (119 589 00 01 00)

Mercedes-Benz
104 589 01 01 00
Removing and installing guide rail in crankcase - RA05001193400X(05-3400)
Preceding work:
Timing case cover removed (01-2100) .
Engine 119.97
Mercedes-Benz
Fig. 286: ldentifying Guide Rails
Crankshaft sprocket (1) mark relative to tirning chain (25) with colored
marking (arrow).
Guide raíl (29) pull off from bearing pin (30) and (31 ).
Guide rail (29) instail, pay attention to colored markings; check
basic position of camshaft if necessary (05-2230).
Removing and installing crankcase guide raíl- RA05001203400X(05-3400)
Preceding work:
Timing case cover (24) removed (01-2100).
POS • 5118 ·57'
F ig. 287: ldentifving Crankcase Guide Rail Remove/Install Components
Crankshaft sprocket ( 1) mark with colored dot relative to timing chain (4).
AH carnshafts (5), (6), (lO) and (12) rotate with wrench (25) 104 589 01 01 00 in
direction of rotation of camshaft, beginning at right
exhaust camshaft (5) (slacken timing chain) (4).
Mercedes-Benz
Fig. 288: ldentifying Pump Chain And Guiding Rail
Tensioning spring (19), tensioning rail, oil pump remove from guiding raíl (13), insert (arrow).
chain (14)
Guiding rail (13) pull off guiding rail pins (20 and 21).
Guiding rail (13) install, pay attention to colo red marking.
NOTE: The plastic liner (sliding surface) is clipped into the guiding rail (13) and can be
replaced individually. The bearing pin (21) is knocked into the crankcase.
Projection 40 mm.
Special tool
104 58901 01 00
os
Mercedes-Benz
REMOVING AND INSTALLING GUIDE SPROCKET, ENGINE 104.98- RA05001044400X(05-4400)
05-8051 -8052
Fig. 290: ldentifying Guide Sprocket Remove/lnstall Components
Front cover remove, install (01-2120) .

Inlet camshaft rotate in opposite direction of rotation until timing
chain slackened.
Front side of guide sprocket mark because of direction of rotation.
Bolt (3) "left-hand thread" unscrew, screw in, tighten 35 N m (step 3).
Guide sprocket ( 1) with bearing journal (2) take off, fit on (step 4).
IBolt (left-hand thread) 35
Removing and installing
l. Rota te in1et camshaft in opposite direction of rotation until timing chain at guide sprocket is slackened.
2. Mark front side guide sprocket. A used guide sprocket should rotate in the same direction.
Mercedes-Benz
3. Unscrew bolt (3) "left-band thread" , screw in and tighten. Tightening torque 35 N m.
4. Take off guide sprocket (1) together with bearing journal (2). Oil bearing bush and fit on.
Fig. 291: ldentifying Guide Sprocket And Oil Bearing Bush
REMOVING AND INSTALLING CRANKSHAFT SPROCKET- RA05001044600X(05-4600)
Preceding work:
Oil sump removed (01-3100) .
Tensioning raíl removed (05-3300).
Guide raíl removed (05-3350).

Mercedes-Benz
06
32Nm
6
1
POs:-.5406-57
F i¡:. 292: ldentifyin¡: Crankshaft Sp rocket Removellnstall Components
Oil pump drive gear (6) at oil pump (7) unbolt, bolt on (32 Nm).
Oil pump chain (8) and oil ptmlp drive gear (6) remove, install.
NOTE:
Pay attention to installation of oil pump drive
gear (6) (18-21 00) .
Tensioning bar (9), bush (10) and spring (13) pull off, fit on.
T iming chain (14) remove, install.
Crankshaft sprocket (11) pull offwith puller (06) 615 589 01 33 OO.
Parallel keys (12) note.
Crankshaft sprocket (11) heat, fi t on.
Special tool
1 Mercedes-Benz
1
/'
~
t;
~
~
~
-
~ ]~-
f
~~-
11.:
~
.,.
\. 615 589 01 33 00 .J
TECH1\1JCAL MODIFICATIONS ENGINE 104 MECHANICAL 11- RA0500104TAOOX
CRANK ASSEMBLY TECHNICAL MODIFICATIONS

Designation Nature and reason for Production breakpoint Op. no.
modification
Bolts of two-mass Bott for attaching driven 05/95 03-4100
flywheel, driven plate plate and two-mass 03-4620
flywheel standardized
ENGINE TIMING, VAL VES

Desi gnation Nature and reason for Production breakpoint Op. no.
modificatíon
Camshaft bearing caps Elimination of dowel 01/93 05-2200
sleeves, bearing cap
centers itself over the
bearing points of the
camshaft.
Valve springs Conversion from 11/93 05-2500
cylindrical to conical
shape
Valve guides Sintered material
Valve guides Outer 0 12.5 was 13.5
BELTDRIVE
Designation Nature and reason for Production breakpoint Op. no.
modification
T ensioning pulley Diameter modified 01/96 13-1 200
13-1240
CHECKING TIMING OF CAMSHAFTS- RA05001192150X(05-2150)
Checking timing of camshafts - RA05001192150X(05-2150)

Mercedes-Benz
Preceding work:
Cylinder head covers removed (01-0500) _
05-6010, 6020
Fig. 294: Checking Camsbafts Timing
lcamshaft code numbers check (step 1).
TIMING OF INLET CAMSHAFTS

Mercedes-Benz
Position inlet camshaft of cylinder No. l or No. 6 so

that only the base circles are resting against the
bucket tappets (step 2).
Dial gauge holder (02) instali wíth threaded sleeve (04) at cylinder l or 6,
Dial gauge (01) install in dial gauge holder (02) with tracer pin (03)
on left side of camshafts to be checked (step 4).
Preload of 3 mm and angular posítion of 90° of set (step 5).
tracer pin to bucket tappet
Crankshaft ro tate with wrench socket in direction of rotation of
engine, special tool 001 589 65 09 OO.
At 2 mm valve lift, the reading on vibration damper
must agree wítb the readíng in table "Inlet valve
opens".
TESTING TIMING OF EXHAUST CAMSHAFTS

Position exhaust camshaft of cylinder No. 1 or No. 6
so that only the base circles are resting against the
bucket tappets (Step 7).
Dial gauge holder (02) 363 589 02 21 00 with insta U at cylinder No. 1 or No. 6 (step 8).
threaded sleeve (04)
Dial gauge (01) with tracer pu'l (03) install at cylinder No. 1 on left side at cylinder No. 6
on rigbt síde of camshaft to be tested.
Preload of 3 mm and angular position of 90° of set (step 9).
tracer pin (03) to bucket tappet
Crankshaft crank witb wrench socket 001 589 65 09 00 in
direction of rotation of engíne.
At 2 mm valve lift, the reading on vibration damper
must agree with tbe reading in table "Exhaust valve
opens"
TIMING IN CRANK ANGLE DEGREES (°CA) AT 2 MM VAL VE LIFT 1) WITH NEW TIMING
CHAIN
Engine Code numbers of camshafts (1) Inlet valve (2) 1
Exhaust valve
Inlet camshaft Exhaust camshaft opens el oses opens eloses
ATDC ABDC BBDC BTDC
rt lt rt lt 1 1
119.960 58 56 62(3) 60(3) 25.0° 35.0° 13.0° 13.0°
59(4) 57(4) 63(4) 61 (4) 1 1
119.970 74 72 78(4) 76(4) 30.0° 40.0° 13 .0° 13.0°
972/974 75(4) 73(4) 79 (4) 77(4)
1 1
119.971 82 80 86 84 30.0° 35.0° 8.0° 13.0°
83(4) 81 (4) 87(4) 85(4)
1 1 l
Mercedes-Benz
119.970/ 98 96 02 00 33_0° 42.0° 10.0° 1L0°

972/974
(5)¡
980/982
119.97 1/ 90 88 94 92 30_0° - 8_oo -
975 (5)¡
981 /985
l) Permissible variation: ± 2.0°CA Perform test only when cam ascending (in direction ofrotation of
engine)_
( l) Camshaft code number inscribed on camshaft bearing joumal at front
(2) Camshaft adjuster retarded.
(3) replaced by 78 or 76, respectívely
(4) repair camshaft with 0.5 mm larger bearing diameter
(5) as of model year 1993
SpeciaJ tools
363 589 02 21 00
001 589 65 09 00

Mercedes-Benz
001 589 53 21 00
Shop-made tool
Threaded sleeve (reduction M8 to M6) for attaching dial gauge holder 363 589 02 21 00 to cylinder head cover
sealing surface.
Fig. 298: ldentifying Cvlinder Head Cover Sealing Surface Dimensions
NOTE: lf performing installation work, it is sufficient to check the basic setting of the
camshafts (see 05-2230).
The timing is measured with the hydraulic bucket tappets.
Check "inlet valve opens" at No. 1 and No. 6 cylinder with 2 mm val ve lift and camshaft adjuster retarded.
Check "exhaust valve closes" at No. 1 and No. 6 cylinder at 2 mm valve residuallift.
l. Check camshaft code numbers. The camshaft code numbers are insciibed on the 3rd camshaft beaiing
joumal (fitted bearing) (arrows) and stamped on the camshaft flange from behind with colored ink.
Mercedes-Benz
Checking timing of inlet camshafts
2. Rotate crankshaft in direction ofrotation of engine until the lobes ofthe inlet cams to be tested are facing
up (arrows) and only the base circles are resting against the bucket tappets.
Fig. 300: ldentifying In.let Camshafts Timing
3. Install dial gauge, special tool (02) 363 589 02 21 00 with threaded sleeve (04) at sealing surface of
cylinder head cover at the camshaft to be tested.
Mercedes-Benz
Fig. 301: ldentifving Special Tool And Threaded Sleeve
4. Clamp dial gauge (01) with tracer pin (03) (80 mm) in the dial gauge holder (02) so that the tracer pin
(03) is resting vertically on the bucket tappet (arrow) with a preload of3 mm (small pointer of dial
gauge).
NOTE: Check freedom of movement of tracer pin (03).
5. Turn sea le of dial gauge until large pointer of gauge (O 1) is at "O".
Fig. 302: Clamping Dial Gauge With Tracer Pin In Dial Gauge Holder
6. Ro tate crankshaft in direct1on of rotation of engine with wrench socket, special tool 001 589 65 09 00
until the dial gauge indicates a valve lift of 2 mm. In this position, the reading obtained at the vibration
damper must agree with the reading "inlet valve opens ATDC".
Testing timing of exhaust camsbafts

Mercedes-Benz
7. Ro tate crankshaft in direction of rotation of engine until the lo bes of the inlet cams to be tested are facing
up (arrows) and only the base circles are resting against the bucket tappets.
Fig. 303: Locating InJet Cam L obs
8. Install dial gauge, special tool (02) 363 589 02 21 00 with threaded sleeve (04) at sealing surface of
cylinder head cover at the camshaft to be tested.
Fig. 304: l dentifying Dial Gauge And Threaded Sleeve
9. Clamp dial gauge (01) with tracer pin (03) (80 mm) in the dial gauge holder (02) so that the tracer pin
(03) is resting vertically on the bucket tappet (arrow) with a preload of 3 mm (small pointer of dial
gauge).
NOTE: Check freedom of movement of t racer pin (03). lnstall tracer pin (03) at No.
6 cylinder on right of camshaft.
Mercedes-Benz
Fig. 305: Clamping Dial Gauge With Tracer Pin In Dial Gauge Holder
lO_ Turn scale of dial gauge untillarge pointer of gauge (01) is at "O"_
1l. Use wrench bit, special tool 001 589 65 09 00, to rotate crankshaft in direction ofrotation of engine until
dial gauge índicates a valve lift of 2 mm.
In this position, the reading obtained at the vibration damper must agree with the reading "exhaust valve
closes BTDC'' _
Cbecking camshaft timing- RA05001202150X(05-2150)
Precedíng work:
Cylinder head covers removed (01-0500) _
Sparkplugs removed (15-1031) _

Mercedes-Benz
P05·H'7G·57
Fig. 306: Inspecting Camshaft Timing
Camshaft code numbers check (step l ).

Cbecking timing of intake camsbafts
Intake cams at cy linders 1 or 7 position so that only the base circles are resting
against the bucket tappets (5) (step 2).
Dial gauge holder (2) 363 589 02 21 00 with install at cylinder l or 7 (step 3).
threaded sleeve (4)
Dial gauge (1) fit into dial gauge holder (2) with tracer pin (3) on
the inside ofthe camshaft to be checked (steps 4 to
6)_
Preload of 3 mm and angle of approx. 90° of tracer set: (step 4).
pin (3) on bucket tappet (5)
Crankshaft rottate with wrench socket 001 589 65 09 00 in
At valve lift of 2 mm the reading at the vibration damper must agree with the figure in the table "intake
valve opens after TDC" (step 7).
Checking exhaust camshaft timing
Mercedes-Benz
lntake cams at cylinders 1 or 7 position so that only the base circles are resting
against the bucket tappets (5) (step 8).
Dial gauge holder (2) 363 589 02 21 00 with install at cylinder 1 or 7 (step 9).
threaded sleeve (4)
Dial gauge ( 1) fit into dial gauge holder (2) with tracer pin (3) on
the inside of the camshaft to be checked (steps 1O to
12).
Preload of 3 mm and angle of approx. 90° of tracer set (step 10).
pin (3) on bucket tappet (5)
Crankshaft ro tate with wrench socket 001 589 65 09 00 in
At valve lift of 2 mm the reading at the vibration damper must agree with the figure in the table "exhaust
val ve opens before BDC" (step 13).
TIMlNG IN DEGREES CRANKSHAFT ANGLE (°CA) AT 2 MM VAL VE LIFT l) AND NEW

TIMING CHAIN
Engine Code numbers of camshafts (I) Intake valve (Z) Exhaust valve
Iotake camshaft Exhaust camshaft opens eloses opens eloses
Rt Lt IRt Lt ATDC ABDC BBDC BTDC
120.980 29 30 27 28 34.0° 34.0° 17.0° 12.0°
33(3) 34(3) 31 (3) 32(3)
120.981 33(3) 34(3) 31 (3) 32(3)
1)Permissible deviation: ± 2.0° CKA. Perform check only with rising cam (in direction of rotation of
engine).
(1) Camshaft code number inscribed on front of 3rd camshaft bearing jo·urnal or stamped with paint from
the rear on camshaft flange.
(2) Camshaft adjuster in "retarded" position.
(3) Noise-optimized, engine 120.980 12 as ofengine end no. 010 823, engine 120.981 as ofstart ofseries
production.
SpeciaJ tooJs
,.
f ' ; . --- - -
- - - -.....,
1
001 589 SS U9 00
03 07 32 .)
Fig. 307: Identifying Special Tool (001 589 65 09 00 03 07 32)

Mercedes-Benz
001 589 S3 21 00
00
Shop-made tool
Threaded sleeve (M8 to M6 reduction) for attaching dial gauge holder 363 589 02 21 00 to sealing surface of
20
---
¡ •i-S ~ - - lt-----t •
~
r-1L
M
!O
F ig. 309: Identifying Sbop-Made Tool Dimensions
NOTE: Up to February 1992 the marking numbers are stamped on the vibration damper
(8) only within the range from 4S0 before TDC up to 20° after TDC in so
graduation lfor cylinders 1 and 6. As of February 1992 the marking numbers are
stamped on the vibration damper (8) from ooto 360° in graduations of so.
The are size for 5 °CKA at the vibration damper is 9.3 mm.
When performing remo val and installation work, it is su.fficient if the basic setting of the camshafts is checked
(see 05-2230).
Mercedes-Benz
Fig. 310: ldentifying Vibration Damper Marking Numbers
Pisten in TDC or BDC position at 0 crank angle reading on vibration damper.
Piston in cylinder TDC at °CKA BDC at °CK.A

1 and 6 TDC 180
7 and 12 60 240
2 and 5 120 300
8 and 11 180 TDC
3 and4 240 60
9 and 10 300 120
l. Check camshaft code numbers. The camshaft code numbers are applied in each caseto the 3rd camshaft
bearingjoumal (arrows) (behínd the camshaft bearing caps) or stamped wíth paínt on the camshaft
flanges (arrows).
'11
1
'11
: ..,.P06 -6012·13 ¡
L---- -----•----- - ----------------------------- - -------------~

Mercedes-Benz
Checking timing of intake camsbafts
2. Rotate crankshaft with socket wrench 001 589 65 09 00 until the tips ofthe intake cams to be checked are
pointing up (arrows) and only the base circles are srill resting on the bucket tappets.
Rigff¡ q6ndor he:ad
Fig. 312: Locating Intake Camshaft Points
3. Fit on dial gauge holder (2) 363 589 02 21 00 with threaded sleeve (4) at the sealing surface ofthe
cylinder head cover for the camshaft to be checked at cylinder 1 or 7.
r---------------------------------- ... -----------·-----------:_-1

1 1
1
1
1
1
1
1
1
1
1
Ri!ttt <:.¡lindar head
Fig. 313: l dentifving Dial Gauge Holder And Threaded Sleeve
4. Clamp dial gauge (1) 001 589 53 21 00 with tracer pin (3) (80 mm) in the dial gauge holder (2) so that the
tracer pin (3) is resting vertically on the bucket tappet (arrow) with a preload of3 mm (small pointer of
dial gauge).
5. Check ease ofmovement oftracer pin (3).
6. Rotate dial gauge scale until the large pointer ofthe gauge (1) is at "0".
Mercedes-Benz
Fig. 314: ldentifving Dial Gauge And Tracer Pin
7. Ro tate crankshaft with wrench socket 001 589 65 09 00 in direction of rotation of engine until the dial
gauge ( 1) índicates a valve lift of 2 mm.
In this position the figure on the vibration damper must agree with the figure " intake valve opens after
TDC" .
NOTE: 1st cylinder in TDC at O °CKA
7th cylinder in TDC at 60 °CKA
Checking timing of exhaust camshafts
8. Crank. camshaft with socket wrench 001 589 65 09 00 in direction of rotation of engine until the tips of
the exhaust caros to be checked are facing up (arrows) and only the base circles are still resting on the
bucket tappets.
r----------------------------------------------------------,
1 1
1 1
'
'
1
1
'
1
1
P05-i1ZI-13 :
-----------------~
Mercedes-Benz
Fig. 315: Locating Exhaust Camshaft Facing Position
9_ Fit on dial gauge holder (2) 363 589 02 21 00 with threaded sleeve (4) at the sealing surface ofthe
cylinder head cover for the camshaft to be checked at cylinder 1 or 7.
LO: cyflldor head
Fig. 316: Fitting On Dial Gauge Holder 363 589 02 21 00 With Threaded Sleeve
10. Clamp dial gauge (1) 001 589 53 21 00 with tracer pin (3) (80 mm) in the dial gauge holder (2) so that the
tracer pin (3) is resting vertically on the bucket tappet (arrow) witb a preload of 3 mm (small pointer of
dial gauge).
11. Check ease of movement of tracer pin (3).
12. Turn dial gauge scale until the large pointer ofthe gauge (1) is at "O"_
13 _ Ro tate crankshaft with wrench socket 001 589 65 09 00 in direction of rotation of engine until the dial
gauge (1) indicates a valve lift of2 mm at cylinder 1 or 7_
In this position, the figure on the vibration damper must agree with the figure " exhaust valve opens
before BDC " _
NOTE: 1st cylinder in BDC at 180 °CKA
7th cylinder in BDC at 240 °CKA

Mercedes-Benz
r----------------------
1
'
1
1
'
1
1
'
1
Fig. 317: Clamping Dia1 Gauge With Tracer Pin In Dial Gauge Holder
REMOVING AND INST ALLING VAL VES- RA05001192550X(05-2550)
Precedíng work:
Mercedes-Benz
P05 3{).()293- 59
Fig. 318: ldentifying Valves R emove/InstaU Compon~nts
Cylinder head (87) place on assembly base (24), special tool 111 589 02
59 00_
NOTE:
Place insert (25) 111 589 02 59 09 into assembly
base (24) with the direction of travel arrow (26)
facing forward and with the appropriate side.
Cylinder head (87) bolt on to assembly base (24)_
NOTE:
Bolt cylinder head (87) ont:o the assembly base
(24) with a cylinder head bolt (23) at the front and
rear and with its front end facing toward the
Mercedes-Benz
direction of travel arrow (26).
The cylinder head (87) can be installed with the

exhaust manifold.
Suppotting bar (2) with slide (7) fit onto the relevant cylinder head off-centered, take
off, special tool111 589 01 59 OO.
Supporting bar (2) bolt on with two M7 X 35 bolts (camshaft bearing
cap bolts), unbolt.
Bucket tappet (3) ofthe relevant cylinder rem ove, install {05-2110).
Lever depressor (9) with thrust piece (5) attach to slide (7), special tools 111 589 18 61 00
and 111 589 25 63 OO.
Thrust piece (5) attach vertically to valve spring retainer (15).
Valve collets (14) remove, install with tweezers (6), magnetic finger,
special tool116 589 06 63 OO.
lnstallation note
Coat valve spring retainer (15) with grease in order
to fix collets (14) in position.
Valve spring retainer (15) together with valve spring remove, instalL
(17)
Valve stem seal (19) replace {05-2700).
Bottom valve spring retainer (20) remove and inspect for pitting, install.
Cylinder head (87) remove from assembly base (24), remove valves
(21).
Special tools
111 5 89 18 61 00
Fig. 319: ldentifying Specia1 Tool (111 589 18 61 00)

Mercedes-Benz
111 5 89 o1 59 00
111 589 25 63 00
116 569 06 63 00

Mercedes-Benz
COMMffiRCMLLYAVMLABLETOOLS
Cylinder leak tester e.g.Bosch E FA W 210 A
Slm, CLT 228
Straight tweezers 160 mm witb e.g. Stahlwi lle
rounded tips D-42331 Wuppertall2
NOTE: Valve springs, top and bottom valve spring retainers with pitting must be
replaced. The valve springs of the inlet and exhaust valves are identical.
As of O111993 conical-shaped val ve springs have been installed together with modified val ve spring retainers
and weight-optimized bucket tappets. The inner valve spring is eliminated.
INSPECTING AND MACHINING VAL VES - RA05001192800X(05-2800)
Preceding work:
Valves removed
Mercedes-Benz
01..,, 1~
a> ! J
....,
,_
l.... D
P05.3.0-0151-1 5
Fig. 324: Inspecting Valve
Valves clean, inspect visually.

Valve stem inspect for nmout (max. 0.03 mm).
Valve seat inspect for runout (max. 0.05 mm), grind.
Dimensions and angle inspect (table).
DIMENSIONS AND ANGLE DATA

Engine up to 119.960 12 011930 as of 119.960 12 011 931
Inlet valve Exb. valve Inlet valve Exh. valve
Valve disc 0 (D) 37.90 32.90 37.90 32.90
38.10 33.10 38.10 33.10
Height (h) of when new 1.1 5- 1.45 1.55- 1.65 1.1 5-1.45 1.4- 1. 7
valve disc limit val. 1.05 1.3 1.05 1.3
Setting angle (a) for machining 45° + 15' 45° + 15' 45° + 15' 45° + 15'
valve
Valve stem 0 (D 1) 7.970 8.960 6.975 6.970
7.955 8.938 6.960 6.950
Sodium fllling without with without with
Valve length (L) 95.8 102.6 95.8 102.6
Width ofvalve seat min. 1.4 min. 1.4 min. 1.4 min. 1.4
max. 2.0 max. 2.0 max. 2.0 max. 2.0
Mercedes-Benz
Maximum pennissible runout at 0.05 0.05 0.05 0.05

valve stem and valve seat
Grooves for wedges on stem 1 1 3 3
VALVE STEMAND VALVE SEAT DATA

Engine up to 119.970 12 049 738 as of 119.970 12 049 739
up to 119.972 12 010 751 as of 119.972 12 010 752
up to 119.974 12 009 281 as of 119.974 12 009 282
lnlet valve Exb. valve Inlet valve Exb. valve
Valve disc 0 (D) 37.90 32.90 37.90 32.90
38.10 33.10 38.10 33.10
Height (h) of whennew 1.15-1.45 1.4-1.7 1.05-1.35 1.4-1. 7
val ve disc limit vaL 1.05 1.3 0.95 1.3
Setting angle (a) for machining 45° + 15' 45°+ 15' 45° + 15' 45° + 15'
valve
Valve stem 0 (D 1) 6.975 6.970 6.970 6.970
6.960 6.950 6.950 6.950
Sodium filling without with without wid1
Valve length (L) 95.8 102.6 95.7 102.6
Width of val ve seat min. 1.4 min. 1.4 min. 1.4 min. 1.4
max. 2.0 max. 2.0 max. 2.0 max. 2.0
Maximum permissible runout at 0.05 0.05 0.05 0.05
val ve stem and valve seat
VALVE STEM AND VALVESEAT DATA

Engine up to 119.97112 023 158 as of 119.97112 023 159
up to 119.97512 018 412 as of 119.975 12 018 413
as of 119.98 start of prod.
Inlet valve Exh. valve Inlet valve Exb. valve
Valve disc 0 (D) 34.90 32.90 34.90 32.90
35.10 33.10 35.10 33.10
Height (h) of whennew 1.15-1.45 1.4-1. 7 1.05-1.35 1.4-1. 7
valve disc limit vaL 1.05 1.3 0.95 1.3
Setting angle (a) for machining 45° + 15' 45°+ 15' 45° + 15' 45° + 15'
valve
Valve stem 0 (D 1) 6.975 6.970 6.970 6.970
6.960 6.950 6.950 6.950
Sodi um filling without with without with
Valve length (L) 95.8 102.6 95.8 102.6
Width of val ve seat min. 1.4 min. 1.4 min. 1.4 min. 1.4
max. 2.0 max. 2.0 max. 2.0 max. 2.0
Mercedes-Benz
Maximum pennissible runout at 0.05 0.05 0.05 0.05

valve stem and valve seat
NOTE: The stem of the exhaust valve is filled with sodium.
Unusable valves filled with sodium should be neutralized before scrapping. They should therefore be gathered
by the relevant workshop sector foreman and returned to:
Mercedes-Benz AG
Werk Marienfelde
DaimlerstraJ3e 145
Anlieferstelle KST 3153
Arbeitsvorbereitung TAl
P05.J0..0256-15
Exha.ust m'&
Fig. 325: ldentifying Valve

Mercedes-Benz
Special tools
001 589 53 21 00
Fig. 326: Ideotifying Specia1 Tool (001 589 53 21 00)
COMMERCIALLY A VAILABLE TOOLS AND TESTERS

Desigoatioo e.g. make Order no.
Valve cone grinding machine or Hunger, D-81375 Munchen TypeVKM 1 A
valve cone tuming tool Graflingerstr. Order no. 146 231 00 001
Inspecting and machining
l . Clean valves and conduct a visual mspection.
Valves with scorched valve disc, insufficient height (h) of valve disc or with wom or scored valve stem
should be replaced.
POS-0035-13
Fig. 327: Inspecting Scorched Valve Disc And Insufficient Height
2. Measure runout at valve stem. If a runout of more than 0.03 mm is measured, replace valve.
Mercedes-Benz
POS-2130-H
Fig. 328: Measuring Runout At Valve Stem
3. Macbine valve seat.
Pay attention to operating instructions ofmachining equipment and setting angle (a) 45°+15'.
If conducting facing work on cylinder head and re-setting ofvalve seats, always replace valves.
The valve seats ofvalves as ofmodel designation M119.98 must not be remachined; these should be
replaced when perforrning repairs.
4. Measure runout at valve seat and height (h) ofthe val ve disc.
Ifthe runout is greater than 0.05 mm or the height (h) is less than the specification in the table, replace the
valve.
Mercedes-Benz
POS-2126-13
Fig. 329: Measuring Runout At Valve Seat And Height Of Valve Disc
REMOVING AND INSTALLING SLIDE RAILS (ARRANGEMENT)- RA05001193330X(OS-3330)
A. Engine 119.96
Mercedes-Benz
9 17
...____ 20
3 - - -----
'--- - - :21
- - - - -22
------23
-- - - - - -24
1 Cmnksh~ ~mll'lggea¡¡ 14 Sido red, 1ns1do le: of cytnder hollld

2 Beamgpm<ia 12 rrm a "S.1 rrm
3 TenstOOII'Igrai b=9mm
4 Cllmn IBilSiooer
15 ttot cam shalt bmng 9Bili
5 Exheusl camshaltbrmng gear
16 Top side ral
6 Topsideral 17 Exhaustcamshaftmnng gear
1 ttet camshattbmng gear
18 SI de rell, OliSidole! cymder head
8 Sida rall, tnstde n!t( ol cyfrlder hoed a = 8.1 rrm
a=8 1 rrm
b=9mm
b=9mm
19 Stde lllll !lln
9 Stcfe rml pm
20 Sido mil pin
10 Stde retlpm
21 klergllBf
11 Gude pu'Joy
22 Beamg!llnbolod
12 Sida rml !lln
23 &lamg PIO bolied
13 Sido tetlllln 24 Sido lllll, aatl1<case
25 Ttmng ch1m, 228 double links
Fig. 330: l dentifying Sllide Rails Remove/Install Components - Engine 119.96
B. Engine 119.97/98
Mercedes-Benz
- - IIGU·Sl
1 Crankshlll•mfl g gear 14 Sida red,illSide lal of<:~nderhe&d

2 Beanogpcn a=8.1 mn
3 TensiOilflg ru b-9mm
4 Cham ta1151ooor
15 ln!at cam stlaft l!mng gaar
5 Exhau st e amshaft llmmg gaar
16 Top stcfu rai
6 Top stderal
17 Exhaust e amshaftt.Tung gear
7 lita! c.amshaft bmng ge:ar 25 Timng me:n, 216 dotbla inks
8 Sida re~l, nglll of cylnder head
26 Sida red, oúslda lel of cytnder haad
a=8.1 mn 8"'8.1 mn
b"'9mm
b=9mm
9 Sida rallpcn
27 Slld& re~l pcn
10 Si de rall ptn 28 Sida rallpin
11 GuciapUiey
29 Sida rell, aarl<case
12 Sido reJiptn -a =8.1 mn
13 Sida re~l pcn b,.9mm
30 Beamg pcn boled

31 8ear111gptn bolod
Fig. 331: Identifying Slide Rails Remove/lnstall Components- Engine 119.97/98
TECHNICAL MODIFICATIONS ENGINE 119 MECHANICAL ll- RA0500119TAOOX
05 Engine timing, valves
Designation Nature and reason for Production breakpoints Op. no.

modification
Dowel sleeves of Elimination of dowel sleeves and holes in camshaft 05-2200
camshaft bearing caps bearing caps and cylinder head.
Camshaft adjuster Modified version, weight- 09/95 05-2170
Mercedes-Benz
optimized and with

segment for detecting
cylinder l .
Securing bolts of Attached with stretch shank bolt. Modified 01 -2170
camshaft adjuster to tightening torque.
camshaft
V alve conical spring Weight-optimized and modified characteristic. 05-2500
Valve guides Sintered metal valve phased-in 1993
guides.
Exhaust camshaft Without journal for 04.95
distributor rotor.
Bucket tappets Weight-reduced, must be 04 .95
fitted only with conical-
shaped valve springs.
REMOVING AND INSTALLING GUIDE RAILS IN CYLINDER HEADS - RA05001203450X(OS-3450)
Preceding work:
P05. 5121-51
Fig. 332: ldentifying Guide Rails In Cylinder Heads Remove/lnstall Components
Mercedes-Benz
Crankshaft rotate to 30° after ígnitíon TDC at cylinder 1 (step

1).
Camshaft sprockets mark relative to timing chain (step 2).
Chain tensioner ( 1) remove, install {05-3100).
Right exhaust camshaft sprocket unscrew, screw on (step 4).
Right intake camshaft (8) rotate with wrench 104 589 01 01 00, slacken timing
chain, tension (step 5).
R.ight guide raíl (4) remove, install (step 6).
Left intake camshaft (9) rotate with wrench 104 589 O1 O1 00, slacken timing
cbain, tension (step 7).
Left guide raíl ( 6) remove, ínstall (step 8).
Torx T40 (1) 20
Exhaust camshaft sprocket to lnitial torque Tightening angle 90°
camshaft Torx T30 (2 ) 22
( 1) Do not re-use bolt after tíghtening to correct angle.
(2) Replace lst version by Torx T40 when performing repairs.
SpeciaJ tooJs
104 58901 01 00
05
001 589 72 21 00
00
Mercedes-Benz
1
001 sao 65 IUJ oo
03 07 :32 /
Fig. 335: ldentifyiog Special Tool (001 589 65 09 00 03 07 32)
000 589 01 10 00
00
Fig. 336: ldeotifyiog Special Tool (000 589 0110 00 00)
NOTE: Take off right cylinder head cover (01-0500) and right front cover (01-2120) in
order to remove the right guide rail.
Fig. 337: ldeotifyiog Rigbt Guide Rail
Removing and installiog

Mercedes-Benz
l. Rotate crankshaft to 30° after ignition TDC at cylinder l.
NOTE: In this position the camshafts can be rotated without the valves coming
into contact with the piston crown.
Fig. 338: ldentifying Cylinder Position
2. Mark all four camshaft sprockets and the timing chain with dots ofpaint (arrows).
3. Remove cbain tensioner (05-3100).
Fig. 339: Locating Camshaft Sprockets And Timing Chain Marks
4. Unscrew right guide raíl (4): unscrew right exhaust camshaft sprocket ( 5), remove.
Installation note
InstaU exhaust camsbaft sprocket (5) with timing cbain fitted, pay attentíon to colored marking and to
tightening torque.
Mercedes-Benz
Fig. 340: ldentifving Right Guide Rail And Right Exhaust Camshaft Sprocket Screws
5. Right guide rail (4): rotate right intake camshaft (8) in direction ofrotation of camshaft with wrench (25)
104 589 01 01 OO. Slacken timing chain.
6. Pull right guide rail (4) offbearing pin, remove.
Installation note
Fit timing chain onto intake camshaft sprocket (12) (pay attention to colored marking), tension and install
guide rail (4).
Fig. 341: Locating Right Guide Raíl And Right Intake Camshaft
7. Left guide raü (6): rotate left intake camshaft (9) in direction ofrotation of camshaft with wrench (25)
104 589 01 01 OO. Slacken timing chain.
8. Pullleft guide rail (6) offbearing pin (6a).
lnstallation note
Mercedes-Benz
Fit timing chain onto intake camshaft sprocket (13) and exhaust camshaft sprocket (3) (pay attention to
colored markings), insta ll guide rail (6).
Rotate exhaust and intake camshafts in opposite direction ofrotatjon of camshaft with wrencb (25) 104
589 01 01 OO. Tension timing chain.
Fig. 342: Rotating Exhaust And Intake Camshafts In Opposite Direction Of Rotation Of Camshaft
With Wrencb
REMOVING, INSTALLING AND SEALING TIMING CASE GUIDE RAIL- RA05001203500X(OS-

3500)
Preceding work:
Both front covers removed (01-2120).
Mercedes-Benz
120589 063100
a::::~---1
o--~
22Nm L1\\.----
1
----
-----
~--::-
_.: ---
--~
Fig. 343: ldentifying Sealing Timing Case Guide Raíl Remove/Install Components
Intake manifold gaskets (1) remove, install (14-1310) .

Guard plate 120 589 06 31 00 attach to intake ports.
Crankshaft turn to 30° after ignition TDC on cy1inder 1 (step 3).
Timing chain mark in relation to camshaft sprockets (step 4).
Chain tensioner (2) remove, install (05-3100).
Right exhaust camshaft sprocket (3) unscrew (step 6).
Guide raíl (4) remove (step 7).
Proftle gasket with cover (13) remove, replace (step 8).
Guide raíl bridge (15) unscrew, remove (step 9).
Contact surface of guide rail bridge (15) coat with sealant 002 989 00 20 10 (step 10).
Guide rail bridge ( 15) install (step 11 ).
Fitted bolts (1 6) install with washers downward, tighten (21 Nm)
(step 11).
Bolts (17) install, tighten (21 Nm) (step 11).
Timing chain po sition on marks on camshaft sprockets (step 12).
Guide raíl (4) install (step 13).
Right exhaust camshaft sprocket (3) install with timing chain positioned on mark, tighten
Mercedes-Benz
(16 Nm)(step 14).

Profile gasket install together with cover ( 13) without sealant (step
15).
Torx T40(l) 20
Exhaust camshaft sprocket to lnitial torque Tightening angle 90°
camshaft Torx T30(2) 22
Guide raíl bridge to cylinder head 21
(I) Do not re-use bolt after tightening to correct angle.
(2) Replace 1st version by Torx T40 when performing repairs.
Special tools
001 5S9 72 2.1 00

00
120 S89 06 31 00
01

Mercedes-Benz
104 58901 01 00
05
000 589 0 1 10 00
00
F ig. 347: Identifying Special Tool (000 589 0110 00 00)
l. Remove intake manifold gaskets {14-1310).

2. Attach guard plate 120 589 06 31 00 to intake ports.
3. Tum crankshaft to 30° after ignition TDC on cylinder 1 in engine direction ofrotation (arrow).
NOTE: In the position 30° before TDC the camshafts can be turned without the
valves coming into contact with the piston crowns.
Mercedes-Benz
Fig. 348: Locating Piston Position
4. Marking timing chain relative to camshaft sprockets (arrows).

5. Remove chain tensioner {05-3100).
Fig. 349: Locating Timing Chain Relative To Camshaft Sprockets Marks
6. Unscrew right exhaust camshaft sprocket (3), remove.

7. Pull guide rail (4) off of bearing bolt (4a).
Mercedes-Benz
Fig. 350: Identifying Right Exhaust Camshaft Sprocket And Guide Rail
8. Pull offprofile gasket (arrows) together with cover (13).
Fig. 351: Locating Profile Gasket With Cover
9. U nscrew guide raíl bridge ( 15) at rear, remove.

10. Clean sealing surfaces and contact surfaces on guide rail bridge (15) and coat with sealant 002 989 00 20
10.
Mercedes-Benz
Fig. 352: Identifying Guide Rail Bridge
11. Insta U guíde rail bridge ( 15), screw in fitted bolts ( 16) with ground washers at bottom and bolts ( 17) at
top.
Tighten fitted bolts (16) fírst, tightening torque 21 Nm.
12. Position timing chain on paint marks on camshaft sprockets.
NOTE: Turn camshafts with wrench 104 589 01 01 OO.
Fig. 353: ldentifving Guide Rail Bridge And Fitted Bolts
13. Slide guide raíl (4) onto bearing bolt (4a).

14. Install ríght exhaust camshaft sprocket (3) with timing chain posítioned on paint mark (arrows) and pay
attention to tightening torque.
Mercedes-Benz
Fig. 354: Locating Right Exhaust Camshaft Sprocket Paint Marks
15. Install profile gasket (anows) with cover (13) on guide rail bridge (15).
NOTE: lnstall profile rubber gasket (arrows) without sealant.
16. Install in opposite order.
Fig. 355: Locating Profile Rubber Gasket With Cover
TECHNICAL .MODIFICATIONS ENGINE 120 MECHANICAL II- RA0500120TAOOX
05 Engine timing, valves
Designation Nature and reason for Production breakpoints Op.no.

modification
Dowel sleeves of Elimínation of dowel 01 /93 05-2200
camshaft bearinl! caos sleeves and holes in
Mercedes-Benz
camshaft bearing caps

and cylinder head
Camshaft adjuster Control plunger with 03/93 05-2160
inner dia. 7 mm bore 05-2170
(was 5 mm) Flange shaft
with inclined dia. 5.4 mm
bore (was 4 mm) Inlet
camshaft with inclined
dia. 5.5 mm bore (was 4
mm)
Bracket of distributor Attached with torx 40 05/93 01-2120
rotor to camshaft bolt+washer (was torx
30)
Valve spring and valve Valve spring modified to 10/93 05-2500
spring retainer volute spring (was
conical valve spring).
Top and bottom valve
spring retainers adapted.
Reason: reduced friction
V al ve guides Valve guides made of Phased-in 1993
sintered metal
Exhaust camshaft Without stud for 04.95
distributor rotor
Bucket tappets Weight-reduced; may 04.95
only be fitted with volute-
shaped valve springs
Exhaust camshaft gear With segments for 04.95
camshaft position sensor
MISCELLANEOUS NOTES
DISPOSAL OF SODIUM-FILLED VALVES- OSOS.30-P-0001-01A
Exhaust valves filled with sodium
Collecting and storing
The sodium-cooled val ves must be inspected for leaks and neutralized if any leakage exists. Neutralizing should
be performed in the open in a vessel containing a 2: 1 mixture of spirit and water. After this, the cleaned valves
can be gathered together with other scrap items, in a closed removable open container for scrapping.
Disposal
The parts are scrapped by the scrap trade. Documentary proof of disposal, accompanying or delivery documents
as well as other disposal documents are not necessary.
Mercedes-Benz
Legal right in respect of information
The competent authority is obliged to provide information regarding waste disposal installations on request.
National or locallegislation determines which authority is responsible for providing such information.
Disposal of larger quantities of leaktight valves is possible through:
Mercedes-Benz AG
Werk Marienfelde
Dairnlerstrasse 145
Anlieferstelle KST 3153
Arbeitsvorbereitung TAl
Mercedes-Benz
1990-2002 ENGINE Exhaust Manifolds, Emission Control- 129 Chassis
1990-2002 ENGINE
Exhaust Manifolds, Emission Control - 129 Chassis
TESTING & REPAIR

REMOVE/INSTALL THE OXYGEN SENSOR- AR14.00-P-5303
Removelinstall an oxygen sensor- AR14.00-P-5303AB
Dlagnm lalt
GJ/3 L olt o sonsor upnro •m ot 1WC
1
Dlagram rlght
GJ-"1 RlghtO 1 scnsor upsrre.tmot1WC
P 1• 00.2007.01
Fig. 1: Identifying Oxygen Sensor Remove/InstaU Components (1 Of 4)
Dlagnm ltlt
GJ/:S Lolt d/agtiO$/S sensor lfOWnsrrc.am
ot1WC
Oiagnm right
GJ/4 Rlght dl~nosis sensor
downslroam of 1WC
,.,. 00.20<Jli.01
Fig. 2: ldentifying Oxygen Sensor Remove/lnstall Components (2 Of 4)

Mercedes-Benz
Flg. A
GJ/ 4.t 1 COIIIIOCIO r tor riQht 0
1
scmor
upsttc•m of TWC
Flg.B
G:Zt3.t1 Connecrorforlotr o scnsot
1
upst re•m or TWC
1'1 UIO·l OO!l-lló
F ig. 3: ldentifying Oxygen Sensor Remove/Install Components (3 Of 4)
Flg. A
GJISJt 1 COIIIIOCIO ro 1 ri¡¡hr df~IIO st/1:
sonsot ctownsrrc•mor rwc
Flg. B
Gl!ISX1 Connocroror Ioft dlo¡¡nostic
scns<>t do wnsrrumofTWC
1'1 tJIO·l005· 05
Fig. 4: Identifying Oxygen Sensor Remove/Install Components ( 4 Of 4)
MODIFICATION NOTES
Value
changed Value in Series 1001 for engine
10 1 04 55
· 1. Nfrom 112.910/911 /912/91 3/914/915/916/920/921/922/923/940/941/942/943/944/945/946/94 7/949/5
mto
45Nm
IFig. ítem lwork instructions 1

Mercedes-Benz
etc.
03/3, G3/4 Oxygen sensor !Il lnstallation : Coat thread on oxygen sensor and *BR00.45-Z-
G3/5, G3/6 Diagnostic sensor diagnostic sensor with heat-resistant lubricant. 1005-06A
*BA14.00-P-
8 1001-01A
[l] Fig. 5
G3/3xl , Oxygen sensor
left 1 right upstream ofTWC
G3/4x l connector
G3/5xl, Diagnostic sensor
left 1right downstream of TWC
G3/6xl connector
~02SENSOR
N umber Designation Engines
112.910/911/912/913/914/915/916/920/921/922/923/940/941/942/943/944/945/946/947
02
sensor
BA14.00-on
P-1001- exhaust Nm 45
OlA pipe/
exhaust
manifold
REPAIR MATERIALS
BR00.45-Z-1005-06A Paste A 000 989 76 51
'
~
000 5S9 71 03 00
'- Boxwrentn 11• Oitto R• and HJ
./
Fig. 5: ldentifying Box Wrench Bit, Delco R4 And A6 (000 589 71 03 00)
RemovelinstaU an oxygen sensor- AR14.00-P-5303D
ENGINES 104.94/99, 111.920/921 /94/96/970 /973/974 /975/977 (except, 104.990)

Mercedes-Benz
Ola~raln Ioft
Shown o n Englno 104. Modo1124
tst v•nion
Gl/2 O2
nnsor
Attow ContJC-dDr forO .sctuDt
2
Rlgilt pletUJt
Shown o n ong1no 104, modol124
2.n d version
Arrow Conm:cmr toro .seMDr
2
Fig. 6: ldentifying Oxygen Sensor Components (1 Of 4)
~tft and rl ght dlagrams
Shown on Eng1no 11 1, Modol124

2n d "erslon
Anows Conncctor fOrO 2 sensor
Gl/2 O 2 sensor
,, . ~,
Fig. 7: ldentifying Oxygen Sensor Components (2 Of 4)
Shown o n <~,n gino 111 ln modol163

c;l/2 o 2 sensor
Right dlagram
Shown o n onglno11 1 In modols 170, .
2()8
c;l/2 O sensor
2
Fi2. 8: ldentifyin2 Oxy2en Sensor Components (3 Of 4)
~tft dlagram
Shown o n onglno 11 1 In model 21 O
Gl/2 o 2 sensor
Dl•gr•m rlght
Shown o n onglno 104 In modol 21 O
c;l/2 O senior
2
Artow:· Conncetor tor o sensor
2
Fig. 9: ldentifying Oxy2en Sensor Components (4 Of 4)
Figure/ítem, etc. Work instr uctions

G3/2 Oxygen sensor lnstallation : Coat thread * BR00.45-Z-1 005-06A
on oxygen sensor with
Mercedes-Benz
heat-resistant lubricant
[lJ Fig.lO
[lJ Fig. 5
[l] Fig. 12
~ *BA14.00-P-1001-01A
~02 sensor
Number Designation Engines 104, 111, 119,
120, 137, engine 166 in
model168
BA14.00-P-l 001-0 lA 0 2 sensor on exhaust Nm 55
pípe/exhaust manifold
111 589 03 09 00
Fig. 10: Identifving Wrench Socket (111 589 03 09 00)
000 589 71 03 00
Rlng 'IIYto:h sod:el
Fig. 11: ldentifving Ring Wrench Socket (000 589 71 03 00)
001 599 65 21 00
Fig. 12: ldentifying Torque Wrench (001 589 66 21 00)

Mercedes-Benz
lteparr ma t ena
. 1s
BR00.45-Z- l 005-06A Paste A 000 989 76 51
Remove/install the oxygen sensor - AR14.00-P-5303E
ENGINE 119.97
G11l o 2 sc"sor, bcfórc TWO

G'-'Zlt1' o sciiS4r conMciOr
2
Fig. 13: Identifying Oxygen Sensor ltemove!lnstall Components
Fig. item Work

etc. instructions
G3/2 0 2 sensor ITI Installation : Coat thread on oxygen sensor with *Blt00.45-Z-1 005-
heat-resistant lubricant ~
*BA14.00-P-1001-
~
m.A
~ Fig. 5
~02 SENSOlt
Number Designation Engines 104, 111, 119, 120, 137, engine 166
in model168
BA14.00-P-1 001- 0 2 sensor at exhaust pipe/exhaust
OlA
Nm 55
manifold
ltEPAIR MATEIUALS
BR00.45-Z- l 005-06A Paste A 000 989 76 51
Mercedes-Benz
000 589 7 1 03 Ol)
Fig. 14: ldentifving Box Wrench Bit, Delco R4 And A6 (000 589 71 03 00)
RemovelinstaU an oxygen sensor- AR14.00-P-5303EA
ENGINES 119.981/982
Shown on right 0 2 sensor
G;l/4 R l¡¡ht 0 SCRSOf

2
G;l!4Jt1 Rl¡¡ht o scnsot conncercr
2
Fig. 15: Identifving Oxvgen Sensor Remove/Install Components - Sbown On Right 02 Sensor
Fig. item Work instructions

etc.
Left 0 2 sensor
G3/3xl Remove front exhaust shielding plate
connector
G3/3, G3/4 0 2 sensor

ITJ Installation : Coat thread on oxygen sensor with *BR00.45-Z-
heat-resistant lubricant 1005-06A
*BA14.00-P-
~
1001-0IA
[lJ Fig. 5
B02SENSOR
in model168
BA14.00-P-1 001- 0 2 sensor on exhaust pipe/ exhaust
OlA
Nm 55
manifold
REPAIR MATERIALS
Mercedes-Benz

BROO. 45-Z-1 005-06A Paste A 000 989 76 51
Fig. 16: ldentifving Box Wrench Bit, Delco R4 And A6 (000 589 71 03 00)
Remove/install the oxygen sensor- AR14.00-P-5303F
ENGINE 120.98
R1ght dhg~m : E'n gino 120 LH

Loft dlagram: Engl no 120 M E
G111 t. citO z"'""''•bcforc TWC
G:l/41 R lght o sonsor upstre•m TWC
2
G:ll1:c f t. clt 0 JO liSO( COfJriCC IOr
2
G114Jt2 R lght O sensor connector
2
Fig. 17: Identifving Oxvgen Sensor Remove/lnstall Components
Fig. ítem Work

etc. instructions
G3/3, 0 2 sensor !JJ lnstallation : Coat thread on oxygen sensor with *BR00.45-Z-1005-
G3/4 heat-resistant lubricant 06A
*BA14.00-P-1001-
~
~
~ Fi!!. 5
~ 02SENSOR
in model168
BA14.00-P-1 001- 0 2 sensor at exhaust pipe/ exhaust
55
OlA manifold Nm
REPAIR MATERIALS
INumher IDesi~mation lorder numher
Mercedes-Benz
lBROO.45-Z-1 005-06A !Paste lA 000 989 76 51
\. 000 5S9 71 03 00
''--------~
Fig. 18: Identifying Box Wrench Bit, Delco R4 And A6 (000 589 71 03 00)
TESTING AND REPAIR WORK: PASSENGER CARS: EXHAUST MANIFOLD, ENGINE BRAKE,
EMISSION CONTROL SYSTEM- AR14.00-Z-9104AB
ENGINE 104
Remove/install ENGINES 104.94 199, AR14.00-P-

an oxygen sensor 111.920 /921 /94 /96 /970 /973 /974 /975 /977 5303D
(except, 104.990)
installing ex.haust 3915G
manifold
Removing and ENGINE 104.941 / 942 /943 /944 /991 /992 /994 AR14.30-P-
installing air ENGINE 111.92 /94 /96 I H 7251D
pump
Removing and ENGINES 104.9411942/943/944/991/992/994 AR14.30-P-
installing air ENGINES 111.92/94/96 I H 7252D
pump belt pulley
Removing and ENGINE 104.941/942/944/992/994, 119.97, AR14.30-P-
installing 120.98 ENGINE 104.943/991 I 7264D
electromagnetic
coupling
TESTING AND REP AIR WORK: PASSENGER CARS: EXHAUST MANIFOLD, ENGINE BRAKE,
ENGINE 113
Remove/install the ENGINE 112, 113 ... AR14.00-P-5303A

oxygen sensor
Remove/install an oxygen ENGINE 112, 113 ... AR14.00-P-5303AA
sensor
Remove/insta11 an oxygenENGINE 112.923 in AR14.00-P-5303AB
Mercedes-Benz

ENGINE 112.943 in
MODEL 129.064
ENGINE 113.961 in
MODEL 129.068
Remove/ínstall au oxygen ENGINE 112, 113 ... AR14.00-P-5303GH
sensor
Remove/install an oxygen ENGINE 113.964 in AR14.00-P-5303GZ
Remove/install an oxygen ENGINE 112, 113, 271... AR14.00-P-5303PV
sensor
Remove/install the ENGINE 113, 112 in AR14.00-P-5303R
oxygen sensor MODEL230
Remove/install the ENGINE 113.971 in AR14.00-P-5303RT
oxygen sensor MODEL 251.075 / 175
Remove/ínstall au oxygen ENGINE 112, 113 ... AR14.00-P-5303T
sensor
Remove/iustall exhaust ENGINE 112, 113 ... AR14.10-P-3915A
manifold
Remove/install exhaust ENGINE 112, 113 ... AR14.10-P-3915AA
manifold
Remove/ínstall exhaust ENGINE 112, 113 ... AR14.10-P-3915AU
manifold
Remove/install exhaust ENGINE 112, 113 ... AR14.10-P-3915GH
manifold
Remove/install exhaust ENGINE 113.964 in AR14.10-P-3915GZ
manifold MODEL 164.175
ENGINE 156.980 in
MODEL 164.177
Remove/install exhaust ENGINE 112, 113 ... AR14.10-P-3915PV
manifold
Remove/iustall exhaust ENGINE 113 ... AR14.10-P-3915Q
manifold
Remove, install exhaust ENGINE 112, 113 ... AR14.10-P-3915R
manifold
Remove/ínstall exhaust ENGINE 113.971 in AR14.10-P-3915RT
manifold MODEL 251.075/175
ENGINE 156.980 in
MODEL 251.077/177
Remove/install exhaust ENGINE 112, 113 ... AR14.10-P-3915VM
manifold
Remove/installleft ENGINE 113.967 in AR14.10-P-3930TY
exhaust manifold MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Mercedes-Benz
1990-2002 ENGINE Exhaust Manifolds, Emission Control - 129 Chassis
Remove/install exhaust ENGINE 113.967 in AR14.10-P-4005TY

manifold on right MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install exhaust ENGINE 112, 113 ... AR14.20-P-7662A
gas recirculation valve
Remove/install exhaust ENGINE 112, 113 ... AR14.20-P-7662GH
gas recirculation valve
Remove/install exhaust ENGINE 113.964 in AR14.20-P-7662GZ
gas recircu1ation valve MODEL 164.175
Remove/install exhaust ENGINE 113.971 in AR1 4.20-P-7662RT
gas recirculation valve MODEL 251.075/175
Remove, install air pump ENGINE 112, 113 ... AR1 4.30-P-7251A
Remove/install air pump ENGINE 112, 113 ... AR 14.30-P-7251AA
Remove/install air pump ENGINE 113 ... AR14.30-P-7251AC
Remove/install air pump ENGINE 113.964 in AR14.30-P-7251GZ
MODEL 164. 175
Remove/install air pump ENGINE 113.971 in AR14.30-P-7251 RT
MODEL 251.075/175
Remove, install air purnp ENGINE 113 ... AR14.30-P-7251 RVK
Remove, install air pump ENGINE 113.990 in AR14.30-P-7251 TCK
MODELS 211.076 /276
Remove/install air pump ENGINE 113.967 in AR14.30-P-7251 TY
MODEL 219.375
Remove, install air pump ENGINE 113, 156... AR14.30-P-7251TZ
TESTING AND REPAIR WORK: P ASSE NGER CARS: EXHAUST MANIFOLD, ENGINE BRAKE,
EMI SSION CONTROL SYSTEM - AR14.00-Z-9119AB
ENGINE 119
Remove/install the ENGINE 119.97 AR14.00-P-5303E

oxygen sensor
Remove/install an ENGINES 119.981/982 AR14.00-P-5303EA
oxygen sensor
Remove/install the ENGINE 119.985 AR14.00-P-5303EB
oxygen sensor
Remove/installleft ENGINE 119.97/981 /982 AR14.10-P-3930E
exhaust manifold
Removing and ENGINE 119.985 AR14.10-P-3930EA
installing left exhaust
manifold
Removing and ENGINE 119.97 /981 /982 AR14.10-P-4005E
installing right
Mercedes-Benz
exhaust manifold
Removing and ENGINE 119.985 AR14.10-P-4005EA
installing right
exhaust manifold
Removing and ENGINE 119.97 AR14.20-P-7662E
installing exhaust gas
recirculation valve
Removing and ENGTNE 11 9.97 AR14.30-P-7251E
installing air pump
Removing and ENGINE 119.97/98 I AR14.30-P-7251EA
installing secondary
arr pump
Removing and ENGINE 119.97, 120.98 AR14.30-P-7252F
installing air pump
belt pulley
Removing and ENGINE 104.941/942/944/992/994, AR14.30-P-7264D
installíng 119.97, 120.98 ENGINE
electromagnetic 104.943/991 I
coupling
TESTING AND REP AIR WORK: PASSENGER CARS: EXHAUST MANIFOLD, ENGINE BRAKE,
ENGINE 120
AR14.00-P-
Remove/install the oxygen sensor ENGINE 120.98
5303F
Removing and installing front left AR14.10-P-
ENGINE 120.98
exhaust manifold 3960F
Removing and installing rear left AR14.10-P-
ENGINE 120.98
Removing and installing front right AR14.10-P-
ENGINE 120.98
Removing and installing rear right AR14.10-P-
ENGINE 120.98
Removing and installing exhaust AR14.20-P-
ENGINE 120.980/981
gas recirculation valve 7662F
AR14.30-P-
Removing and installing aír pump ENGINE 120.980/981
7251F
Removing and installing air pump AR14.30-P-
ENGINE 119.97, 120.98
belt pulley 7252F
Removing and installing ENGINE 104.941!942/944/992/994, 119.97, 120.98 AR14.30-P-
electromagnetic coupling ENGINE 104.943/991 I 7264D
Mercedes-Benz
REMOVE/INSTALL EXHAUST MANIFOLD- AR14.10-P-3915
Removelinstall exhaust manifold - AR14.10-P-3915AA
ENGINE 112.922 in MODEL 220,063
ENGINE 112.944 in MODELS 220.065 /165
ENGINE 113.941 in MODELS 220.070/170
ENGINE 113.960 in MODELS 215.375, 220.075 /175
ENGINE 112.972 in MODELS 220.067 /167
ENGINE 112.975 in MODELS 220.087 /187
ENGINE 113.948 in MODELS 220.083 /183
ENGINE 113.966 in MODELS 220.084 /184
1$5 Exhwu m•nffol d

15&/f NtJts
155!5 Sea/
PU 10-11lSJ· 11
Fig. 19: Identifving Exhaust Manifold Remove/Install Components - Sbown On Engine 112 In Model 220
Sbown on engine 113 in model 129

Mercedes-Benz
155 Exh•usr m•nffold

156/1 Nuts
15MI Su/
I'U 10 -2001-11
Fig. 20: ldentifving Exhaust Manifold Remove/lnstall Components - Sbown On Engine 113 In Model 129
~'
[g] Remove/install
'
Remove catalytic converter AR49.10-P-
l Models 215,220
or front exhaust system 5531AA
AR49.10-P-
Model 129
5531AB
R emove cover on front side
2
ofengine
3 R emove air filter housing
AR15.12-P-
4 R emove ignition coils
2003A
5 Remove exhaust manifold
@ Installation : Replace nuts ( 156/ 1) and gaskets
(156/5).
~ Nut on exhaust manifold
OJ l fbolts on the flange connection offront exhaust *BA14.10-P-
system/exhaust manifold are stiff, or the thread is 1001-0lB
damaged: ?
AR49.10-P-
Replace the rivet nuts in the exhaust manifold..
5531-01DA
~ Flange connection, exhaust manifold and front *BA14.10-P-
exhaust pipes 1002-01B
~ EXHAUST MANIFOLD
Number Designation Engine 112 Engines 113.940/941/942/943/944/
except 945/946/948/ 960/961/962/ 963/964/965/
112.951/976 966/967/968/ 969/971/980/ 981/982/984/
986/992/993/ 995
R A 14.10-P- Nut on exhaust
Mercedes-Benz
1001-0lB manifold N m 16 16
Flange connectíon,
BA14.10-P-
exhaust manifold and N m 20 20
1002-0lB
front exhaust pipes
Removelinstall exhaust manifold- AR14.10-P-3915GH
Shown on M112
1111 Solls
1$8 EJrhltusr motitolrf
15&11 Nuls
15111~ Su/
p .. 1002... 01
Fig. 21: ldentifying Left Exhaust Manifold Components- Shown On M112
Shown on Ml12
1111 Bolls
158 Exhilusl n~atitolrf
15811 Nurs
PW. . t0...Q2LS..() 1
Fig. 22: ldentifying Right Exhaust Manifold Components - Shown On M112
~¡gj
.. ~
Remove/instaU
1 Take off front wheels ~ *·BA40.10-P-1 001-01A
~AP Remove/install wheels, AP40.1 O-P-4050GH
Mercedes-Benz
rotate if necessary
2 Rem ove plastic fender AR88. 10-P-1300GH
liner
3. 1 Rem ove shield OJ At left-hand exhaust
manifold only.
4 Unscrew bolts (1 1/ 1) at If bolts are sluggish, or
flange connection thread damaged: ?
between front exhaust Replace rivet nuts in AR49.10-P-5531-01DA
system 1exhaust manifold exhaust manifold.
~ *BA14.10-P-1002-01B
5 U nscrew front exhaust OJ Installation: Install
system from exhaust new nuts.
bracket on transmission
6 Remove exhaust manifold OJ Installation: Fit new
nuts ( 156/ 1) Install new
seal (156/5).
~ *BA14.10-P-1001-01B
~ EXHAUST MANIFOLD
112.9511 976 113.940/9411
942/943/944/
945/946/948/
960/9611962/
963/964/965/
966/967/968/
969/9711980/
9811982/984/
986/992/993/ 995
BA 14.10-P-1001 - Nut on exhaust Nm 16 16
OIB manifold
BA 14.10-P- 1002- Flange connection, N m 20 20
OIB exhaust manifold
and front exhaust
pipes
~ WHEELS
Number Designation M odels 163.113/128/
136/154/1571 172/175
BA40.1 0-P-1 001 -01A Wheel bolt Nm 150
Mercedes-Benz
103 589 01 ~ 00
Fig. 23: ldentifving Cocking Bolt (103 589 01 39 00)
REMOVE/INSTALL LEFT EXHAUST MANIFOLD- AR14.10-P-3930E
ENGINE 119.97/981/982
Sbown on ENGTh'E 119.97
Fig. 24: Identifving Left Exbaust Manifold Remove/Install Components- Sbown On Engine 119.97
,
~[gJ.. Remove/install
l Detach/attach lower
engine compartment
paneling
2 Remove transverse pipe ~ *BA14.10-P-1002-
lbetween exhaust !!.U!
manifold and exhaust
Mercedes-Benz
system
~ *BA49.10-P-1003-
OlA
3 Remove fan shroud
4 Unscrew bottom left Refer to repair manual for engine
front and right engine 119.960/970/971 /972/974/975
mounts from below Mechanic II Op-no .. 22-21 10
5 Remove self-locking ~ Replace *BA14.10-P-1003-
bolts (11) OlB
~ BT Exhaust manifold bolts Engine 119 _97 BT14.10-P-0002-01A
altered
@ Risk of explosion Engine 119.97
Observe accident prevention
regulations!
6 Release fue] pressure via Engine 119.97
service valve on fuel OJ See DH Engine, Volume 2,
distributor Index 3.1
[lJ Fig. 25
[lJ F ig. 26
7 U nscrew fu.el feed ( 17/3) Engine 119 _97
and return line (17/2) OJ Collect fuel
8 Raise engine at oil pan
using a telescopic lifter
(inspection pit lift or
fork-lift truck)
9 Lift exhaust manifold f necessary after checking: ? AR49.10-P-5531-
(156) up and out Replace the rivet nuts in the OlDA
exhaust manifold.
~ BT Exhaust manifold Engine 119.97 BT14.10-P-0003-01A
material altered
~ BT Exhaust manifold altered Model 140 RL with engine BT 14.10-P-0001-0 l B
119.97
10 Replace gaskets OJ Clean sealing surfaces. Insert *BR00.45-Z-1010-
new seal with plate side on the OlA
cylinder head in fixing pins. If
the seal is not held in position by
the fixing pins then apply sealant
at various points
order
~EXHAUST MANIFOLD
BA14.1 0-P-1 002-0 lB Flange connection, exhaust manifold and front exhaust pipes N m 20
Mercedes-Benz
IBA14.10-P-1003-01 B IBolt to exhaust manifold Nml3o
~EXHAUST SYSTEM
BA49.10-P-1003-01A Bolt, flange connection to crosspipe 1 exhaust system N m 25
REPAIR MATERIALS
BR00.45-Z-1010-01A Sealant A 001 989 25 20
TIIS!tr
F ig. 25: Identifying Tester {103 589 00 21 00)
119 589 04 69 00
PfB~!Vf& M:9t
Fig. 26: Identifving Pressure Hose (119 589 04 63 00)
103 599 01 3Q 00
Fig. 27: Identifying Cocking Bolt (103 589 01 39 00)
REMOVING AND INSTALLING FRONT LEFT EXHAUST MANIFOLD- AR14.10-P-3960F
ENGINE 120.98
Mercedes-Benz
Showing engine 120.980/981
12 So/f.locltln¡¡ nllt
15ec Fronr ICI'f oxn•usr m•nffold
1!e12 G•sl!cr
Fig. 28: ldentifving Front Left Exhaust Manifold Removellnstall Components - Showing Engine
120.980/981

ítem,
etc
OJ complete exhaust system 7000F
Air injection pipe on cylinder
unscrew and push to outside
head and on engine block
12 Self-locking nuts OJ Replace
*BA14.10-P-
~
1001-01B
156c Exhaust manifold

OJ Remove, replace from above.
If necessary after checking ?
AR49.10-P-
Re place riveted nuts in exhaust manifold
5531-01DA
OJ To assist assembly, apply spots of seahng *BR00.45-Z-
156/2 Gaskets compound. Closed metal surfaces point towards
1010-0lA
cylinder head
~ EXHAUST MANIFOLD
N umber Designation Engine 120
BA14.1 0-P-1 001-01B Exhaust manifold nut Nm 30
REPAIR MATERIALS
Mercedes-Benz
Number Designati oo Order number

BR00.45-Z-101 O-OlA Sea1ant A 001 989 25 20
REMOVING AND INSTALLING REAR LEFT EXHAUST MANIFOLD- AR14.10-P-3990F
ENGINE 120.98
12 Scit-loc~fng nut
15411 Rc~r lcrt o.rh~u.n m~nffolrl
1Mir G~s«or
15511 G•s«er
Arrow E.rha ust port lil r o xh~usr gas
roc lrcui.Jiion
Fig. 29: Identifving Rear Left Exhaust Manifold Removellnstall Components - Sbown On Engine
120.980/981

etc.
Remove front left exhaust AR14.10-P-
IIl manifold, install 3960F
AR30.20-P-
IIl actuator together with throttle valve Engine 120.980/981
1262F
body, install
AR30.20-P-
IIl Engine 120.982/983
1262FA
Remove exhaust gas recirculation AR14.20-P-
IIl valve, install
Engine 120.980/981
7662F
Model140
Unscrew bottom bolts at engine motmt.
IIl Left engine mount
See RA Engine Mechanical Engine 120
Op. no. 22-2110
*BA22.10-P-
~
1001-01B
Mercedes-Benz
12 Self-locking nuts OJ replace

*BA14.10-P-
~
1001-01B
OJ With engine block pulled to the right,
156d Exhaust manifold lift up, insert.
If necessary, after examining ?
Replace rivet nuts in the exhaust AR49.10-P-
manifold 5531-01DA
~BT
BT14.10-P-
Exhaust manifold modified Engine 120.980/981
0001-01A
156/1 '
OJ Apply dots of sealant to facilitate *BR00.45-Z-
Gaskets installation. Closed metal faces point
156/2 1010-01A
toward cylinder head
~EXHAUSTMANIFOLD
Number Designatioo Engine 120
BA14.10-P-1001-01B Nut to exhaust manifold Nm 30
~ ENGINE MOUNTING, ENGINE MOUNTS, ENGINE SUPPORTING BRACKET

Number Designation Engine 120 in model
140 with transmission
717 .4, 722.4/5
BA22.1 0-P-1 001- Bolt of engine M8 N m 25
OlB mount to front axle
carrier ! body
REPAIR MATERIALS
Number Designa tioo Order number
BR00.45-Z- 1010-01A Sealant A 001 989 25 20
REMOVING AND INSTALLING RIGHT EXHAUST MANIFOLD- AR14.10-P-4005E
ENGINE 119.97/981/982
Showing engine 119.97

Mercedes-Benz
111 11
Fig. 30: Tdentifving Right Ex haust Manifold Remove!Install Components- Showing Engine 119.97
,
~¡g¡. removing and
installing
Removing and
installing bottom
1
engine compartment
paneling
Removing and
AR49.10-P-
2 installing complete
7000E
exhaust system
Remove self-locking *BA14.10-P-
3 ~Replace
screws (11) 1003-0lB
~BT
Exhaust manifold BT14.10-P-
Engine 119.97
screws modified 0002-0lA
Remove front right refer to Repair Instructions, engines
4 engine mount from 119.960/970/971/972/974/975 Mechanical II Work no.
below 22-2110
Lift engine at oil sump
5 with telescopic jack
(pit lift or stacker)
Remove exhaust
6 manifold (156) from If necessary after checking: ?
abo ve
AR49.10-P-
Replace riveted nuts in exhaust manifold
5531-0lDA
~BT Exhaust manifold
BT14.10-P-
Engine 119.97
material modified 0003-0lA
~BT Model 140 RHS with engine 119.97
Rx h au ~t mani fo ld RT I4. 10-P-
Mercedes-Benz
modified 0001 -0lB

ITl Clean sealing surfaces. Fit new gasket on locating pins *BROO 45_z_
7 Replace gaskets with ~eta~ side to cylinder head..If gasket is not held by 1010_0 ¡A
locatmg pms, apply spots of sealmg compound
8
order
~ EXHAUST MANIFOLD
BA14.10-P-1003-01B Exhaust manifold screw Nm30
REPAIR MATERIALS
BR00.45-Z-1010-01A Sealant A 001 989 25 20
103 E·B9 Ot 39 00
&.Dp su ew
Fig. 31: ldentifying Stop Screw (103 589 01 39 00)
REMOVING AND INSTALLING FRONT RIGHT EXHAUST MANIFOLD- AR14.10-P-4035F
ENGINE 120.98
Sbowing engine 120.980/981

Mercedes-Benz
12 Solf-loc/(/ng nllt
158. Ftont ri¡¡ht oxh•ust m•nlfo/d
15&1'1 GuAer
15612 G•sllcr
Fig. 32: Identifying Front Right Exhaust Mauifold Removellnstall Components - Showing Engine
120.980/981

item, etc
complete exhaust system 7000F
if assembly is diffícult
OJ generate r
Refer to Repair Instructions, Electrical System
Model 140 work No: 15-5032
Removing and installing air AR14.30-P-
IIl pump
if assembly is difficult
7251F
Guide tube for oil dipstick loasen and turn to one side
Air injection pipe on cylinder
unscrew and push to one side
head and on engine mount
Air fi lter for air pump with
remo ve
hoses
12 Self- locking nuts OJ Replace
*BA14.10-P-
~
1001-01B
156a Exhaust manifold
OJ Remove, replace from above.
AR49.10-P-
5531-01DA
15611,
OJ To assist assembly, apply spots of sealing *BR00.45-Z-
Gaskets compound _Closed metal surfaces point towards
156/2 1010-0lA
cylinder head
Mercedes-Benz
1990-2002 ENGINE Exhaust Manifo lds, Emission Control- 129 Chassis
~ EXHAUST MANIFOLD
BA14.10-P-1001-0 lB Exhaust manifold nut N m 30
REPAIR MATERIALS
Num ber Designation Or der num ber
BR00.45-Z-010-01 A Sealant A 001 989 25 20
REMOVING AND INSTALLING REAR RIGHT EXHAUST MANIFOLD - AR14.10-P-4065F
ENGINE 120.98
Sbowing engine 120.980/981
12 Soif-lo~~fnSI nlff
15tlb Fro nt r~ht oJth;wst m;.nifold
1S6tl Gn'<ct
Anow E.x'h~ust g~H ch•nncJ for c.xh~u.st
g~.s roclrcuNtfon
111b
~12
P141~
Fig. 33: ldentifving Rear Right Exbaust Manifold Remove/Install Components - Sbowing E ngine
120.980/981
Fig. Wor k instructions

item, etc.
[]] Removing and installing front AR14.10-P-
ríght exhaust manifold 4035F
[]] AR1 4.20-P-
exhaust gas recirculation valve
7662F
Engine 120.980/981
AR30.20-P-
DJ electronic accelerator actuator Engine 120.980/981
1262F
with throttle valve
Engine 120.982/983 AR30.20-P-
Mercedes-Benz
1262FA
Cover panel from steering
Model129
idler arm and starter
Model129
Automatic transmission oil
GJ Before removing, drain approx. 0.5 liter of
oil from automatic transmission. After
dipstick
installation, check oillevel and top up as
requ ired
12 Self-locking nuts ITl Replace
*BA14.10-P-
~
1001-01B
156b Exhaust manifold
ITl Remove, replace from above.
AR49.10-P-
5531-01DA
(Gi=BT BT14.10-P-
Exhaust manifold modified Engine l20.980/981
0001-01A
ITl To assist assembly, apply spots of sealing*BR00.45-Z-
156/2 Gaskets compound. Closed metal surfaces point towards
1010-01A
cylinder head
~ EXHAUST MANIFOLD
BA14.10-P-1001-01B Exhaust manifold nut N m 30
REPAIR MATERIALS
BR00.45-Z-1 O1O-OlA Sealant A 001 989 25 20
REMOVE/INSTALL EXHAUST GAS RECIRCULATION VALVE- AR14.20-P-7662
Remove/install exhaust gas recirculation valve- AR14.20-P-7662A
ENGINE 112.910 in MODEL 202.026 /086
ENGINE 112.920 in MODEL 202.029 /089
ENGINE 112.940 in MODEL 208.365 /465
ENGINE 112.921 in MODEL 210.063 /081 /263 /281

Mercedes-Benz
ENGINE 112.941 in MODEL 210.065 /082 /265 /282
ENGINE 112.944 in MODEL 220.065 /165
ENGINE 113.940 in MODEL 210.070 /270
ENGINE 113.941 in MODEL 220.070/170
ENGINE 113.960 in MODEL 215.375, 220.075 /175
ENGINE 113.980 in MODEL 210.074 /274
ENGINE 113.944 in MODEL 202.033 /093
ENGINE 113.943 in MODEL 208.370 /470
ENGINE 113.984 in MODES 208.374
ENGINE 112.912 in MODEL 203.061 /261, 209.361 /461
ENGINE 112.946 in MODEL 203.064 /264
ENGINE 113.968 in MODEL 209.375 /475
ENGINE 112.913 in MODEL 211.061 /261
ENGINE 112.949 in MODEL 211.065 /265
ENGINE 113.967 in MODEL 211.070 /270
ENGINE 113.987 in MODEL 209.376 /476
ENGINE 112.955 in MODEL 209.365 /465
ENGINE 112.916 in MODEL 203.081 /281
ENGINE 112.953 in MODEL 203.084 /284

Mercedes-Benz
ENGINE 112.975 in MODEL 220.087 /187
ENGINE 113.948 in MODEL 220.083 /183
ENGINE 113.966 in MODEL 220.084 /184
ENGINE 112.917 in MODEL 211.080 /280
ENGINE 112.954 in MODEL 211.082 /282
ENGINE 113.969 in MODEL 211.083 /283
ENGINE 113.988 in MODEL 203.076 /276
Shown on engine 112
fQ lnr.ollc m•ntold
'Q UtJ•usrg.. recircut~/on v•JVII
&llf ExhiiUSCfliD lliCfrcUJat/on 1/mJ
11112 v..uum rcsctvolr
'!lr1 Unlon nut
•1> v..uum lino rrom lnr.~ e pipo
Vocuumllno
Y31J! ARF tl~uum r.~nsdtlccr
Fig. 34: ldentifving Exhaust Gas Recirculation Valve Components (1 Of2)
Shown on engine 112

Mercedes-Benz
1 0 11 dlpstic~ gulde tu be
1 Fue/ roN
J Ptu¡¡ «>nncction
t9 Elth•ust g . . rcclrcU/iltlon Vil/Ve
íg{1 Un /en nut
YJ I/ 1 ARF ~uum tr•nsduoc r
P1 i 20-1076-02
Fig. 35: Identifying Exhaust Gas Recirculation Valve Components (2 Of2)
Modification notes
13.5.02 Value changed from 23 to Value in series altered *BA14.20-P-1002-01B
40Nm BA 14.20-P-1002-01B for
engine 112.913/949
~¡g¡
;..., Remove/install
&oanqer! Risk of injury W ear safety gloves, protective clothing and safety ASOO.OO-Z-
to skin and eyes glasses, íf necessary _ 0002-0IA
caused by
handling hot or
glowing
objects.
1 Remove cover 11odel 129, 211, 215, 220, 230
on front side of
engine
2.1 Remove air Model17L473 AR09.10-P-
filter housing Model203.076/ 276 1150AC
Model209.376/ 476 as of24.4.04
2.2 Remove engine except modell7L473
cover with Model203.076 /276,
integrated air Model209.376/ 476 as of24.4.04
filter ITI The air filter is integrated in the engine cover.
Remove engine cover or air filter by pulling it
vertically up and off the cylinder head covers.
ITI Installation : 11oísten slightly with lubricating paste
retainers on the cylinder head covers and the sealing
ring of the hot film mass air flow sensor in the air filter
housing.
Lubricating paste *BR00.45-Z-
1002-06A
Mercedes-Benz
3 Remove hot Engine 112.91 O/920 / 921 /940 /941 AR07.07-P-

film mass air Engine 113.940 1454A
flow sensor
with air intake
p1pe
Engine 112.922 /923 /943 /944 /975 AR07.07-P-
Engine 113.941 /948 / 960 /9611963/966 1454AA
Engine 113.943 /944 / 980 /984 AR07.07-P-
1454AG
Engine AR07.07-P-
112.912 /9 13 /916 /917 /946 /947 /949 /953 /954 /955 1454SV
Engíne 113.967 /968 / 969 /987 /988 /989
4.1 Remove oil Model203 , 209
dipstick guide IJJ l nstallation : Ensure correct seating of sealing ring
tube (1) and of oil dipstick guide tube (1) in oil pan top section.
turn to the side
4.2 Detach oil Model171.473
dipstick guide Model 211
tu be ( l) from
bracket on
exhaust gas
recirculation
valve (89) and
turn to the side
5 Remove Model171.473
- -
retammg Model230.475
bracket from oil Model203.076/ 276
dipstick guide
tube (1)
6 Detach fuel Model 2ll
distributor rail
(2) on right side
and push to the
side
7 Unplug Modei 17L473
connector (3) Model211
from ínjection Model203.076/ 276
val ve
8 Unplug
connector on
EGR pressure
transducer
(Y31/l).
9 Detach vacuum
line (b) to
vacumn unit
Mercedes-Benz
(89/2) and EGR

pressure
transducer
(Y3111)
lO U nscrew union ITl Model21l , 23 0.475 : pull EGR pipe (89/ 1) out of
nut (89/3) on exhaust gas recirculation valve (89).
exhaust gas
recirculation
valve (89
~ *BA14.20-P-
1002-0lB
11 Dismount EGR Except model230.475
line (89/ l) from
intake manifold
(19)
~ *B A14.20-P-
1003-01B
12 Unscrew ~ *BA14.20-P-
exhaust gas 1001-01B
recircu lation
pipe (89) from
cylinder head
13 Remove @ lnstallation : Replace gaskets. Note length and
exhaust gas routing of vacuum line from intake manifold to EGR
recirculation [ARF] vacuum transducer (Y31/ l ). Incorrect routing
valve (89) may cause throttle lever to jam.
14 Instan in the
reverse order
~E
m
xh aust gas rec1rcu 1at10n
.
Number Designation Engine l
112.910/912/916/920/921/922/923/940/941/942/943/944/945/946/947/953/972/975 :
1
BA 14.20- Bolt, N m 20
P- lOOl- exhaust gas
OlB recirculation
valve to
cylinder
head
BA 14.20- Unionnut, N m 40 ,
P-1002- exhaust gas
OIB recirculation
p ipe to
exhaust gas
recirculation
valve
Mercedes-Benz
BA14.20- Bolt, Nm 9
P-1 003- exhaust gas
OlB recirculation
pipe to
intake pipe
~Eh
m
x aus t gas recrrcuJa tion
Number Designatioo Engine 113.989
BA14.20-P-1001-01B Bolt, exhaust gas Nm 20
recirculation valve to
cylinder head
BA 14.20-P-1 002-0IB Union nut, exhaust gas N m 40
recirculation pipe to
exhaust gas recirculation
valve
BA14.20-P-1 003-0IB Bolt, exhaust gas Nm9
recirculation pipe to
intake pipe
. 1s
R epatr matena
BR00.45-Z-l 002-06A Lubricating paste A 000 989 01 60
Removing and installing exhaust gas recirculation valve- AR14.20-P-7662E
ENGINE 119.97
Fig. 36: Identifying Eogine Cover

Mercedes-Benz
Fig. 37: Identifving Exhaust Gas Recirculation Valve
~'
[g]' Removal, installation
1 Remove cover (1)

2 Detach vacuum hose (tr/vi/br)
AR09.20-P-1310-
Connection diagram of intake manifold
OlE
3
Remove exhaust gas recirculation OJ replace gasket and self-locking
valve (89) securing bolts
Removing a nd installing exhaust gas recirculation valve- AR14.20-P-7662F
ENGINE 120.980/981
Left-hand side illustrated
5J Sl!~od />OSO
54 Hose clip
IV E.rh• u.st flid t oci t cut• tlon v• Aio
l i 11 Unlon nut
111!2 Unlon nut
111!3 Socurlr>g bolt
Mte!l l.otr olee tton/c .ecorcr• tor (EA)
••w•tot
Mercedes-Benz
Fig. 38: Identifying Exhaust Gas Recirculation Valve Remove/Install Components- Left-Hand

Remove air cleaner, install AR09.10-P-1050F
89/1 Union nut
000 58971 03 00
Fig. 39: Identifying Box Wrench Socket, Delco R4 And A6 (000 589 71 03 00)
REMOVING AND INSTALLING AIR PUMP- ARI4.30-P-7251
Remove/install aiJ· pump- AR14.30-P-7251AA
ENGINE 112.922 in MODEL 220.063 /163
ENGINE 112.944 in MODEL 220.065 /165
ENGINE 113.941 in MODEL 220.070 /170
ENGINE 113.960 in MODEL 215.375, 220.075 /175 /875
ENGINE 112.972 in MODEL 220.067 /167
ENGINE 112.975 in MODEL 220.087 /187
ENGINE 113.948 in MODEL 220.083 /183
ENGINE 113.966 in MODEL 220.084 /184

Mercedes-Benz
ENGINE 113.986 in MODEL 220.073/173
Shown on engine 112
5 Botr
611 A t h oso
MJJ A Ir p<Jmp
Arro w.- Elo~trlul connocror
Fig. 40: ldentifving Air Pump Remove/lnstall Components - Shown On Engine 112
Fig. itero Work instructions

etc.
[JJ Cover at front endl of engine unclip, take off
Bolt connecting air pump bracket to *BA14.30-P-1003-
~
timing case OlA
5 Bolt OJ Pay attention to ground cable_
5/ 1 Air hose detach
Disconnect electrical connector
M33 Airpwnp
(arrow)-
~AmPUMP
Number Designation Engine 112 Engine 113.940/941/942/943/944/945/946/948/
except 112.960/ 960/961/962/ 963/964/965/ 966/967/968/
961AMG 969/971/980/ 9811982/984/986
Bolt connecting air
BA14.30-P-
pump bracket to N m 12 12
1003-0lA
timing case
Removing ancl installing air pump - AR14.30-P-7251D
ENGINE 104.941 /942 /943 /944 /991 /992 /994
ENGINE 111.92/94/96
Mercedes-Benz
Models 124, 129, 140
Modtll 124.1 :lll. 1<10
Fig. 41: ldentifying Air Pump Components- Models 124, 129, 140
Models 124, 129, 140
125 Alrpump
12511 &Jir
12Sf2 Bolt
12$13 Shopedhosc
Arrow Connomrcoupllng
Fig. 42: Identifving Air Pump Remove/lnstall Components- Models 124, 129, 140
Modols 202.201
Fig. 43: ldentifving Air Pump Remove/lnstall Components - Models 202, 208
Models 202, 208, 210

Mercedes-Benz
10511 Bolt
125 A!t pump
12511 Bolt
125/t Sh;apod hos o
12$112 Bolt
AtroW Conncctor 'oup Nng
Fig. 44: Identifying Air Pump Removellnstall Components- Models 202, 208, 210
126 A ir shut-off val ve
Fig. 45: ldentifving Air Shu t-OffValve
~¡g¡ Removing, installing

'"
AR09.1 0-P-
1.1 Remove air cleaner Models 124, 129, 140
l OSOD
Models 124, 129, 140
See RI Engine Mechanical II
2.1 Remove poly V -belt
Op. no. 13-1200 engine 104
Op. no. 13-1202 engine 111
Take off engine AR61.20-P-
3.1 Models 202, 208
compartment panel llOSA
AR61.20-P-
Model210
llOSAB
Take off cover of
4 coolant thermostat
housing
T o do this, take off connector (arrow) and shaped hose
tfJ25/3), unscrew bolts (105/ 1, 125/ 1, 125/2, 125/1 2)
5 Remove air pump (125) i Installing: o? model202, 208 Examine rubber
mounts, replace tf necessary
[JJ When replacing the air pump on vehicles with engine
104 nn to OR/Q4 ::mrl with P.mtinP. 111 (J) ~ ::~lso
Mercedes-Benz
replace the air shut-off valve (126)

ll::rBT Air pump discontinued
BT14.30-P-
9404-0lD
Install in reverse
6
sequence
Removing a nd installing air pump - AR14.30-P-7251E
ENGINE 119.97
1 Bo/t
Bolt
$/apod/losc
4 Bo/t ot • Ir pump c•mor
11$ A l rpump
YJJ A l rpump cloctro~neftc coupllnSI
connccror
F ig. 46: Identifying Air Pump Remove/Install Compo nents
, ...
~¡g¡ Removal, installation
see Repair Instructions Engine
1 Remove poly V-belt, install Mechanical II Engine 119,
Op. no. 13-3420
Unplug connector of air pump
2
electromagnetic coup ling (Y33)
3 Take off shaped hose (3)
4 Remove bolts (1 , 2)
IIJ Pay attention to different lengths
ofbolts
~BT
Fit washer of air pump attachment BT14.30-P-
modified 0003-0lA
5 Take off air pump carrier

IIJ Clean threaded holes. Use new
micro -encapsulated bolts
*BA14.30-P-
~
1002-0lA
ll::rBT Material of air pump carrier modified
BT14.30-P-
0002-0lA
ll::rBT Material of air pump carrier modified
BT14.30-P-
0002-0IB
To do this, take off cover for
6 Take off distributor cap
distributor
7 Take off air pump ( 125)
Mercedes-Benz
~AIR PUMP
Number Designation E ngine 119
BA14.30-P-1002-0 lA Bolts of air pump carrier N m 25
RemoviDg and installiDg secondary air pump - AR14.30-P-7251EA
ENGINE 119.97/98
Sh• pod hose

4 Sott or • Ir pump support
MU El octrlo • Ir p llmp
/81JX1 El octrlc • l r p u mp cónnoctor
Arrow Solt of m•tfng bo•rlng
Fig. 47: ldentifving Secondarv Air Pump Componen ts
Fig. ítem, etc. Work instructions

OJ Fan shroud Detach
ITJ Unbolt front right See Service Microfiche System Engine
engine mount from 119.960/970/971/972/974/975
below, raise engine Mechanical II Op. No. 22-2110
3 Shaped hose Pull off
4 Bolt of air pump
support
~ *BA14.30-P-1002-
OlA
M33xl Electric air pump
connector
Arrow Bolt of mating
bearing
~A·Ir pump
Number Designatioo Engine 119
BA14.30-P-1001-01A Nut of belt pulley to air Nm 35
pump
Mercedes-Benz
IBA14.30-P-1002-01A IBolts ofair pump support
Removing and installing air pump - AR14.30-P-7251F
ENGINE 120.980/981
1 Bolt
2 Solt
J Shilpodho>e
4 Shilpod hose
125 Alrpump
Fig. 48: Identifying Air Pump Remove/InstaU Components - Shown On Engine 120.980/981
~[g] Removal, instaUation

""
AR09.10-P-
1 Remove air cleaner, install Right-hand side
lOSOF
See RA Engine Mechanical II Engine
2 Remove poly-V -belt, install
120, Op. no. 13-3420
Unplug connector of air pump
3
electromagnetic coupling (Y33)
4 Unscrew bolts (1, 2) OJ Pay attention to different bolt
lengths
5 Take off air pump (125)
~BT Material of air pump bracket modified
BT14.30-P-
Engine 120.980
0002-0IA
REMOVlNG AND INSTALLING AIR PUMP BELT PULLEY- AR14.30-P-7252
Removing and installing air pump belt pulley- AR14.30-P-7252D
ENGINES 104.941/942/943/944/991/992/994
ENGINES 111.92/94/96
Mercedes-Benz
125..S Nut
Fig. 49: l dentifying Air Pump Belt Pulley Remove/Install Components- Engine 104

etc.
See RI Engine Mechanical II
Remove poly V-belt,
ITl install
Op. no. 13- 1200 e ngine 104
Op. no. 13-1 202 engine 111
Counter-hold with Allen wrench (arrow) when
125/5 Nut
slackening
*BA14.30-P-1001-
~
OlA
~AIRPUMP
BA 14.30-P-1001-01A Nut of belt pulley on air pump N m 35
Removing and installing air pump belt puUey - AR14.30-P-7252F
ENGINE 119.97, 120.98
6 Sc/t pUlley
1a ClrcffJ
F ig. 50: Identifying Air Pump Belt Pulley Remove/Install Components - E ngine 119, 120
Mercedes-Benz

etc.
see Repair Instructions Engine Mechanical II
ITJ Remove poly V -belt, install Engine 119 or Engine 120,
Op. no. 13-3420
counter-hold with bexagon socket (arrow)
ITJ Nut
when screwing on
*BA14.30-P-
~
1001-0lA
6 Belt pulley
fG?'BT
BT14.30-P-0001-
Spacer ring of belt pulley Engine 120.980
OlA
n:::r-er Diameter of air pump belt BT14.30-P-0004-
Engine 119.97
pulley modified OlA
~AIRPUMP
Number Desigoation Engine 119 Engine 120
BA14.30-P-1001-01A Nut of belt pulley to air pump N m 35 35
REMOVING AND INSTALLING ELECTROMAGNETIC COUPLING- AR14.30-P-7264D
ENGINE 104.941/942/944/992/994, 119.97, 120.98
ENGINE 104.943/991
11515 Nur
115,0 BclrpuRoy
11511 Clrcllp
115!'1 Clrcllp
11$19 Eltlcfr0-$0/CM/d
Arrow LOCitlf!Sip/n
Fig. 51: ldentifving Electromagnetic Coupling Remove/lnstall Components

etc.
Remove air pump belt pulley, AR14.30-P-
125/6 Engine 104
install 7252D
AR14.30-P-
Engine 119, 120
7252F
enQaQe in lockin Q nin (arrow) when
Mercedes-Benz
lsolenoíd linstalling

REMOVING AND INSTALLING INTAKE MANIFOLD, REPLACING GASKET- RA14001041310X
(14-1310)
Removing and installing intake manifold, replacing gasket- RA14001041310X(14-1310)
14 - 1310
IP14-0001-55 ,.,.-oou•·••
Fig. 52: ldentifving Intake Manüold, Gasket Remove/lnstall Components
Ground cable on
battery
Engine compartment
remove, install.
panelling, bottom
V acuum line for brake
booster
Electrical plug
detach at all components which are connected to tbe intake manifold, plug in.
connections
Line holding rail (5) unscrew, screw on.
Fuel supply and retum
disconnect, connect (pay attention to note).
lines
Mercedes-Benz
Bowden cable at throttle controllever, detach, attach (30- 0025).

Detach, attach control pressure Bowden cable.
Throttle controllinkage at actuator, detach, attach (only for vehicles with ASR or cruise control).
Potentiometer for electronic accelerator, unscrew, screw on (only on vehicles with ASR).
Dipstick tube remove, install.
Bracket (2, 2 off) at intak:e manifold, unscrew _
Idle speed motor unscrew, screw on.
lntake manifo ld bolts unscrew, screw in.
Intake manifold ( 1O) take off, clean and fit on. Check flange faces witb straightedge; machine on
dressing plate ifnecessary.
&
When installing, ensure that no vacuum lines and electric wiring are jammed.
Intake manifold gasket
( 12) rep1ace.
Leak test of all
check with engine running.
connection points
Throttle control check, adjust if necessary (30 - 1O1O)_
Idle speed check, adjust ifnecessary (see Diagnosis Manual Engine, Volume 1).
CIS-E control unit fault . . . .
read out, erase 1fnecessary (see DiagnosiS Manual Engme, Volume 2, Index 0).
memory
NOTE:
NOTE: When installing the fuel line (arrow) from the fuel distributor to the diaphragm
pressure regulator, ensure that the open-end wrench does not press on the air
flow sensor potentiometer and damage it.
Mercedes-Benz
Fig. 53: Locating Fuel Line F rom Fuel Distributor
Removing and Installing Intake Manifold; Replacing Gasket - RA14001191310X(14-1310)
Preceding work:
Removing and installing air cleaner (09-0015)
14-1310
P14 • 2003· 57
Fig. 54: Identifying Intake Manifold Gasket Remove/InstaU Components
NOTE:
The intake manifold can be removed complete.
Coolaut partially drain, top up.
Electrical plug connections
of all compouents at intake disconnect, connect.
manifold
CTniiiP r~il f()r ~n~rk nlno
Mercedes-Benz
cables remove, install.

V acuum lines of all
components located at detach, fit on.
intake manifold
Fuel supply and fuel return d. t t
. 1sconnec , connec .
lme
V acuum line for brake
booster
Rear large connector at unplug, plug in. Withdraw cable 1oom from intake manifold area on right
EZLIAKR control unit side.
remove, install (only on vehicles with cruise control or ASR). Detach, attach
Longitudinal throttle throttle controllinkage for this step and remove locking element at
control shaft longitudinal throttle control shaft, fit on. Remove rear bearing bracket of
longitudinal throttle control shaft, install.
Electronic accelerator
tmscrew complete with throttle control and control pressure Bowden cable,
pedal potentiometer
screw on.
bracket
Coolant hose at front of
detach, attach.
intake manifold
Heating hose at rear of
detach, attach.
intake manifold
Screws of intake manifold unscrew, screw in.
take off, clean and fit on. Examine flanged
lntake manifold
faces with straightedge; dress on dressing plate if necessary. Replace gaskets.
6
Wben installing, ensure that intake manifold engages in the dowel pins.
REPLACING INTAKE MANIFOLD (INTAKE MANIFOLD REMOVED)- RA14001041346X(l4-1346)
Replacing intake manifold (intake manifold removed)- RA14001041346X(14-1346)
Preceding work: Removing and installing intake manifold, replacing gasket (14 1- 31 O)
Removing and installing mixture control unit (07.3-1668)
14- 1346
Mercedes-Benz
F ig. 55: Replacing Intake Manifold
unscrew and fít onto new intake manifold with new gaskets.
All parts bolted to removed intake NOTE:
manifold Since July 1989 the intake manifold is no longer sand-cast but
die-cast.
PRODUCTION BREAKPOINT: JUL Y 1989

Model E ngine Engine End No. manual transmission Engine End No. automatic transmission
124.051 104.980 000166 000299
129.061 104.981 000053 000464
Replacing Intake Manifold (Intake Manifold Removed)- RA14001191346X(14-1346)
Preceding work:
Removing and installing air - cleaner (09 00 15)
Removing and installing intake manifold, replacing gasket {14-1310)
Removing and installing mixture control un it (07.3-1668)
Removing and installing injection valves (07.3-6520)
14- 1346
Mercedes-Benz
60
18
Fig. 56: Replacing lntake Manifold
All parts screwed to removed . . . .

· t k ·e ld unscrew and mstall on new mtake mamfold wtth new gaskets.
m a eman11o
unscrew from intake manifold bottom sectíon (18), screw on; remove
exhaust gas recirculatíon pipe (25), install for thís step.
When assembling intake manifold top and bottom sections, use new rubber
Intake manifold top section intermediate rings (30).
(10)
NOTE:
Since July 1989 the intake manifold has been manufactured as a die
casting and no longer as a sand casting.
PRODUCTION BREAKPOINT: JULY 1989

129.066 119.960 001192
REMOVING AND INSTALLING EXHAUST MANIFOLD- RA14001043915X(14-3915)
Removing and installing exhaust manifold- RA14001043915X(14-3915)
14-3915
Mercedes-Benz
Fig. 57: ldentüving Exhaust Manifold Remove/lnstaU Components
at exhaust manifold, unscrew, screw on. Replace self-locking

Exhaust pipes (10)
nuts.
Exhaust support at transmission, unscrew, screw on.
remove, instaH by unscrewing bolt for attachíng aír injectíon
pipe to cylinder head, screwing on. Unscrew retaining clip
Air injection pipe (129)
:from air injection pipe, screw on. Disconnect hose at air
pump, connect.
Self-locking nuts ( 11) unscrew, screw on, replace.
Exhaust manifold remove, insert.
NOTE:
Clean sealing suñace. Renew gaskets (closed metal
suñace faces cylinder head). Apply sealant A 001 989 25
20 in series of dots to new gasket to facilitate installation.
Leak test of all connectíon points check wíth engíne runníng.
NOTE:
Since July 1989 exhaust manifolds with
modified shape have been installed to
provide greater clearance for the air
pum p.
PRODUCTION BREAKPOINT: JUL Y 1989

Model E ngine Engine end no. Manual transmission E ngine end no. Automatic transmission
124.051 104.980 000166 000240
Mercedes-Benz
1129.061 104.981 000065 000459
Since September 1989 the flange for the ARF valve on RHD and LHD vehicles is identical.
PRODUCTION BREAKPOINT: SEPTEMBER 1989

124.051 104.980 000558 001708
129.061 104.981 000134 000765
Since November 1990 collar nuts have been used for attaching the exbaust manifold to the cylinder head;
previously nuts witb washer.
PRODUCTION BREAKPOINT: NOVEMBER 1990

124.031
124.051 104.980 004373 018803
124.091
129.061 104.981 000844 008198
Since April1991 the shield between exhaust manifold and air pump is of a sandwich design, previously
pressing.
PRODUCTION BREAKPOINT: APRIL 1991

Model Engine Engine end. no. Manual transmission Engine end. no. Automatic transmission
124.031
124.051 104.980 005972 026409
124.091
129.061 104.981 001181 011225
Removing and InstaJling Exhaust Manifold- RA14001193915X(14-3915)
14-3915
Mercedes-Benz
r------- - -------------------------- - ~----------- - -

: C-..JI
1
:
1
1
1
:
1
1
1
1
1
1
1
1
1
: , ... ...,.t:r te
L- ----- -- ---- ----- - ---- -- ----- ----- --- --- -- ----- --- -
Fig. 58: Identifying Exhaust Manifold Remove/Install Components
REMOVING AND INSTALLING RIGHT EXHAUST MANIFOLD

Exhaust pipe joint (1) separate at flange (2), connect.
Exhaust pipe (3) unscrew at exhaust manifold, screw on.
Exhaust bracket at transmission unscrew, screw on.
Oxygen sensor plug connection
detach, attach.
(G3/2xl)
NOTE:
• T urning union nut to the left as far as stop --> to open
• T urning union nut to the right as far as stop --> to lock
Strut below exhaust system remove, install.
Rubber rings on exhaust system detach, attach, remove exhaust system, insert.
Exhaust manifold bolts ( arrows) unscrew, screw in (pay attention to notes, step 3)
remove, insert Replace gasket and rivet nuts on exhaust manifold
Exhaust manifold
flange.
REMOVING AND INSTALLING LEFT EXHAUST MANIFOLD

Exhaust pipe connection remove, instalL Unscrew pipe at exbaust manifold aud at exhaust system,
(1) screw on for this step.
Left engine mount unscrew from below, screw on (2 bolts).
Mercedes-Benz
Ring at fan cover remove, install.

Engine carefully raise slightly to improve access to exhaust manifold bolts (arrows).
Exhaust manifold bolts
unscrew, screw in (pay attention to notes, step 3)
(arrows)
Exhaust manifold remove, insert. Replace gasket and rivet nuts on exhaust manifold flange.
Notes
l. Since January 1990 the mounting eye at the bottom of cylinder 8 is narrower.
PRODUCTION BREAKPOINT: 01190

129.066119.960004738
2. To facilitate installation, the shape ofthe clips for the expansion bodies between the exhaust manifolds
has been modified since June 1990.
A Pre·>'!oos verston
a Prestlrt W15.100
Fig. 59: ldentifying Clips Previous And Present Version

129.066119.960008516
3. The attachment of the exhaust manifold to the cylinder head has been modified since July 1991.
Only 3 long bolts witb sleeve (1) and 8 short bolts witbout sleeve (2) are now used for attaching each
exhaust manifold.
When performing repairs, this type of attachment can also be used on engines manufactured prior to this
date.
Mercedes-Benz
Replace only bo1ts which are damaged.
1 l ong bots WJ~ sloow

2 Stlort~s
Fig. 60: ldentifying Exbaust Manifold Bolts
Shown on right exhaust manifold:
1 LoníJ bdi:s. '"lh ~e9•1ll
~
2 9\oitbdts
tJI [jJ ' •

Fig. 61: ldentifying Long Bolts With Sleeve An d Short Bolts

129.066119.960021570
4. Material of exhaust manifold for cylinders 5 and 8 rnodified since February 1992.

IModel E ngine Engine end no.
Mercedes-Benz
032006 (exhaust manifold cylinder 5)

129 066119 960
· · 032185 ( ex.haust manifold cylinder 8)
REMOVING AND INSTALLING AIR PUMP- RA14001047251X{l4-7251)
Removing and installing air pump- RA14001047251X(14-7251)
Preceding work:
Removing and installing poly V-belt {13-1200).
Removing and installing viscous fan clutch (20 - 3120).
Operation No. of operatíon texts and work units or standard texts and flat rates:
14-7251
Fig. 62: Identifving Air Pump Remove/lnstall Components- 1st Version

Mercedes-Benz
Fig. 63: ldentifying Air Pump Remove/lnstall Components- 2nd Version
l st version 2nd version

Plug connection of electromagnetic clutch of air pump unplug, plug in.
Air intake hose ( 1) and air injection hose (2) at air pump (125), detach, fit on.
Screws (3) remove, insert.
Aír pump (125) remove, insert.
Poly V-belt tension (see 13-343).
NOTE: A spacer ring (arrow) is installed in front of the bearing in the belt pulley;
previously without spacer ring.
~
A ......
.... .-.-
~
~
A Pre-Vtrrus vor-sron l(l(J!I
B Pr&S~mt verStoo
IIXJI
~
R
•?
11
Fig. 64: Locating Spacer Rings

Mercedes-Benz
124.031
124.051 104.980 006698 030075
124.091
129.061 104.981 001465 013140
Removing and Installing Air Pump- RA14001197251X(14-7251)
Preceding work:
Removing and installing poly V -belt (13-340)
14-7251
Fig. 65: Identifying Plug Connectioo Of Air Pump Electromagnetic Coupling
Fig. 66: ldentifving Air Intake Hose And Air Injection Hose
Mercedes-Benz
Plug connection of air pump electromagnetic coupling (Y33) unplug, plug together.
Air intake hose (1) and air injection hose (2) detach at air pump, attach.
Bolts (3) unscrew, screw m.
Air pump take off, fit on.
NOTE:
After installing, tension
poly V-belt (see (13-340)).
NOTE:
Since August 1989 spring hose clips of 27 mm dia. (previously 30 mm
dia.) have been used for attaching the air intake hose and air injection
hose to the air pump.

129.066 119.960 001612
Since October 1989 the shaped hose from the air pump to the air cutoffvalve has been lengthened by 13 mm
and the attachment at the air shutoff valve improved.
PRODUCTION BREA.KPOINT: 10/89

129.066 119.960 002223
Since October 1989 the installation condition of the air pump has been improved by means of an angled face on
the bottom mounting eye.

M o del Engine E ngine end no.
129.066 119.960 002648
Since Febmary 1990 a different material has been used for the support.

129.066 119.960 004951
Securing bolt for air pump support at oil sump now with washer, previously bolt + washer assembly.

M odel Engine E ngine end no.
129.066 119.960 016022
Material for air pump support modified.

Mercedes-Benz

129.066 119.960 037769
REMOVING AND INSTALLING ELECTROMAGNETIC CLUTCH- RA14001047264X(14-7264)
Removing and installing electromagnetic clutch- RA14001047264X(14-7264)
Preceding work:
Removing and installing air pump {14-7251)
14- 7264
Fig. 67: Identifying Electromagnetic Clutch Remove/lnstall Components
tmscrew, screw on by holding tight with hexagon socket (arrow).

Nut (5)
Tightening torque 35 ± 5 Nm.
Retaining ring (7a) remove, install.
Drive gear (6) pull off, fit on.
Retaining ring (7b) remove, instalL
Electromagnet (8) take off, fit on.
Removing and Installing Electromagnetic Coupling- RA14001197264X(14-7264)
Preceding work:
Removing and installing poly V -belt (13-340)
Removing and installing air pump (14-7251)
Operation no. of operation texts and work tmits or standard texts and flat rates:
Mercedes-Benz
14-7264
.,... ~,.
Fig. 68: Identifying Poly Nut
Fig. 69: ldentifying Electromagnetic Coupling Remove/Install Components
Nut (5) unscrew, screw on; hold hexagon socket (arrow) tight for this step.
Retaining ring (7a) remove, install.
Drive gear (6) pull off, fit on.
Retaining ring (7b) remove, ínstaU.
Electromagnet (8) take off, fit on.
REMOVING AND INSTALLING AIR PUMP SWITCHOVER VAL VE- RA14001047305X(14-7305)
Removing and installing air pump switchover valve- RA14001047305X{l4-7305)
Mercedes-Benz
14-7305
Fig. 70: Identifving Air Pump Switchover Valve Remove/Install Components
Accessories compartment
remove, install (only on modell29).
cover
Electrical connection (arrow)
at air pump switchover valve tmplug, plug in.
(Y32)
detach, fit on.
Vacuum hose (tr/vi/bl)
Pay attention to color coding on vacuum hose (see function diagram of
air injection).
Vacuum hose for check valve detach, fit on.
Bolt (6) unscrew, screw m.
Air pump switchover valve
at carrier, detach, attach.
(Y32)
CIS-E controltmit fault read out, erase ifnecessary (see Diagnosis Manual Engine, Volume 2,
memory Index 0).
NOTE:
Stored faults which may originate from test work resulting from
cables being disconnected or from a simulation, must be erased in
the fault memory after completing the work.
Mercedes-Benz
40 D.a¡Wagm p-es-siUie re¡¡ll¡xCIJ' N113 EZUAI<R ccroOI urtl

89 AAF 110Cve Y27 ARF !W'Jdl:lll~( V9L119
90 Reggnera~oo v !:1\•e Y32 ~r .ntea.on svt-:tiloYflt va ve
123 ñvo:::evnl·.·e assemb~¡1 Y33 e e.tuomagrtebe ~tru:h
125 Alr pump Y5911 Re.gener¡x¡on sv.l.!dlo\'91 "' "'e
126 Alr SIUO \'l)l\'9 a to IUII1&r accessooes
127 Cil&tk vá\'e (l~c•oo ar) b to ellllrcoal ea»S!er
128 Otetl.. ,.ft.•e (vac~
156 EXhfll.lli! mallllctd
Fig. 71: Function Diagram Of Air Injection And Exhaust Gas Recirculation (Model124)
Function diagram of air inj ection and exhaust gas recirculation, model124
NOTE: ARF switchover valve (Y27) and ARF valve (89) only 0 and ~ .
Mercedes-Benz
II'IYI/bl
40 Du;ptrngm pressl.fe rEtgiJia:Or Y4 Ec onomy mode SWlll:l'lover valva

90 R&genora:ron Vfl.le Y27 AJ:I.F SNitchowr valva
123 Ttfotle wtve assembtf Y32 tur 1119Cbon S'Mtchov1!r vaM!
125 An punp Y33 BK~omagneic cllll:h
126 Nr stutof vaNit Y5811 RegeflCrabon sw b:l'lover \'!We
127 Chock va.'ve Oll&ctlon a.J) a tohd1or accossonas
126 Cho ek \'!We (vacwm) b to chaitoalc 1111ster
158 Eld181.1 st moofokl
N1i3 EZL/AKR cottrol Ul'
Fig. 72: Function Diagram Of Air Injection (Model129)
Function diagram of air injection, modell29

Mercedes-Benz
40 Olaphragm pressure regulamf N1/3 EZLIAJ<R control Ullt

89 ARFvaM! Y27 AAF swi cho\Ollr vaN-e
Q{) Regen 8í!ilion ve.\to Y32 A.lr i r(atbo:n s.-o~tthover vaMi·
123 TIYo'Jo ~aNo assem~ Y33 Bettomagt~eíc dltth
125 Anpump Y5!!11 R~nerabon s~~trhover vat•e
126 Alr shtñO: wtve 8 toturiler aocas sones
127 Chlltkvallra {in;ecbonlllf) b tochaieoalc!llllster
128 Cfleckwlve ivacwm)
156 Exhausímanf~
Fig. 73: Function Diagram Of Air Injection And Exhaust Gas Recirculation (Model)
Function diagram of air injection and exhaust gas redrcuJation, model 0 and ~
Removing ancl Installing Air Pump Switchover Valve- RA14001197305X(l4-7305)
14-7305
Mercedes-Benz
Fig. 74: Identifying Air Pump Switchover Valve Removellnstall Components
Cover of component
remove, install.
compartment
Bracket (31) take off, fit on.
Electric coupling at air pump
unplug, plug in.
switchover
valve (Y32)
Vacuum lines to intake
detach, fit on.
rnanífold and to air
NOTE:
shutoffvalve Pay attention to color coding on vacuum lines (see function diagram of
air injection and exhaust gas recirculation).
Air pump switchover valve
remove from bracket (31 ), fit on.
(Y32)
LH . [; read out; erase, ifnecessary (see Diagnosis Manual Engine, Volume 2,
centro 1urut au1t memory Register O).
Mercedes-Benz
......___ ____._N3
~--------~--~------------N16
a9 Exhaust gas rearrule'Jon vaiiG 156 Exi'IBIJ st mBI"Ifold

123 Thro!!le vafve BSSaml*¡ N3 KE e ontrcl Ull!
125 An pump N16 En.g¡ne s,.stems coolfolurlll(MAS)
126 Au shllol va.'ve Y27 Elcllaust gas r earrufajoo swtcfloWI vslvo
117 Checkvatve O!ledíon a:r) Y32 Air pump sll4tcflovBf v!We
128 Chec k ...atve (veruum) Y33 1\Jr pump oledrom&QJ'lBtle couplng
Fig. 75: Function Diagram Of Air Injection Aud Exhaust Gas Recirculation
Function diagram of air injection and exhaust gas recirculation
REMOVING AND INSTALLING EXHAUST GAS RECIRCULATION VAL VE- RA14001047662X(14-

7662)
Removing and installing exhaust gas recircuJation valve - RA14001047662X{l4-7662)
Operatíon No. of operatíon texts and work units or standard texts and flat rates:
14-7(ió2
Mercedes-Benz
Fig. 76: Identifying Exhaust Gas Recirculation Valve Remove/Install Components
Vacuum hose at exhaust gas recirculation valve (89) detach, fit on.
Union nut remove, insert.
remove, insert, take off exhaust gas
Securing bolts of exhaust gas recirculation valve
recirculation valve, fit on, replace gasket.
NOTE:
Exhaust gas recirculation valve with modified diaphragms
since September 1991. Reason: improved leaktightness.

Model Motor Engine end no. Manual transmission Engine end no. Automatic transmission
124.031 ~
104.980 006976 031718
124.051
124.091
129.061 ~ 104.981 001591 014274
Removing and lnstalling Exhaust Gas Recirculation Switcbover Valve (muy 0, ~)- RA14001197662X(14-7662)
14-7662
Mercedes-Benz
Fi2. 77: ldentifyin2 Exhaust Gas Recirculation Switchover Valve Remove/lnstall Components
Cover of component compartment remove, ínstalL

Bracket (31) take off, :fit on.
Electric coupling at exhaust gas
unplug, plug in.
recirculation swítchover valve (Y27)
detach, fit on.
Vacuum lines to intake manifold and to NOTE:
exhaust gas recírculatíon valve
Pay attention to color coding on vacuum lines (see function
diagram of air injection and exhaust gas recirculation).
Exhaust gas recirculation switchover
remove from bracket (31 ), :fit on.
valve (Y27)
read out; erase, if necessary (see Diagnosis Manual Engine,
LH control unit fault memory
Volume 2, Register 0).
Mercedes-Benz
....___ ___._ N3
~------~~---------------N16
89 Exhaust gas roorrula5on vam 156 B<llaust manlold

1Z3 molle V!lNe assembtf N3 KE tllltrcl UJt
125 Aupump N 16 Eng¡ne S)'Siilmscon.-olurlll{MAS)
126 An shlicl V!lNe Y27 Exila'Jstgas reara.llalicn swtchowr valva
127 Chetkvat./e ~~oo !W) Y32 Air pump sllildlCVI!f \f!We
128 Check vatve {varu..lt!1) Y33 Alrpump 91edrcmagnelle c~ng
Fig. 78: Function Diagram Of Air Injection And Exhaust Gas Recirculation
Ftmction diagram of air injection and exhaust gas recircu1ation
REMOVING AND INSTALLING EXHAUST GAS RECIRCULATION SWITCHOVER VALVE-

RA14001047692X(14-7692)
14-7692
Mercedes-Benz
Fig. 79: Identifying Exhaust Gas Recirculation Switchover Valve Components
Accessories compartment cover remove and install (modell29 only).

Electrical connector (arrow) at
exhaust gas recirculation unplug, plug in.
switchover valve (Y27)
detach, fit on.
Vacuum hose (tr/vi/br)
Pay attention to color coding on vacuum hose (see Ftmction díagram
air injection and exhaust gas recirculation).
Vacuum hose for check valve detach, fit on.
Bolt (7) unscrew, screw in.
Exhaust gas recirculation
detach at carrier, attach.
switchover valve (Y27)
read out, erase ifnecessary (see D iagnosis Manual Engine, Volume 2,
CIS-E control unit fault memory
Index 0).
NOTE:
Stored faults which may originate from test work resulting from
cables being disconnected or from a simulation, must be erased in
the fault memory after completing the work.
Mercedes-Benz
40 Diaptregm pressu:e reguJalo( N113 EZl!AKR cottrol mi

89 P.PFvaMI Y27 M<F MchC'IIlf valvo
90 Rog91'1am.~valve Y32 Alr IEJ&cbon SMtdlovel vaM!
123 Ttrntie valva assembt¡t Y33 aec.-omagne e connoctcr
125 Alr punp Y5811 R89911Dm!IOn SWIICOOVOf ll!llve
126 Alr stntol v.We a to fu"ller scussooes
127 Chec-k vatoe Oll&ctlon ar) b to chetcoal e!lllsier
128 Check valve {vacwm)
156 Exhallst m6111fcld
Fig. 80: Function Diagram Of Air Injection And Exhaust Gas Recirculation (Model124)
Function diagram of air injection and exhaust gas recirculation, model124

Mercedes-Benz
40 O.aphragm pressiJle re;rula!or N113 EZI../AI<R c.oniJoi iJllt

89 ARFval',¡o Y27 ARF swi thOVIll vake
90 Regen!IIalionvaÑe Y32 Ajr iq11rtion S'illi!chover v~..a
123 Thro~e 1/!We assembly Y33 EleciJomagne~c coontKICf
125 Aupunp Y~1 Regonem!lon S'illll!:hover w.\la
126 Au shúol val\te a to ftriler ac"Ces sones
127 Chockvalve {írGE~ctloo aa-) b tocharcoelc-atllste;
128 ChtKk \'RNe (varuum)
15& Exhaust manfold
Fig. 81: Function Diagram Of Air lnjection And Exhaust Gas Recirculation (Model129)
Function diagram of air injection and exhaust gas recirculation, model129
TECHNICAL MODIFICATIONS ENGINE 104 COMBUSTION CIS-E INJECTION-

RA1400104TAOOX
14 INTAKE MANIFOLD, EXHAUST MANIFOLD

breakpoint No.
14-
Intake manifold Is no longer sand-cast but díe-cast 07/89
1346
14-
Shape modified 07/89
391 5
Exhaust manifold
14-
Flange for ARF valve RHD identical to LHD 09/89
391 5
Mercedes-Benz
Additional mounting point at intake manifold

Mount for actuator cable
support, engine 104.980
12/89 -
14-
Mount of exhaust manifold Collar nut, previously nut with washer 11/90
3915
Shield between exhaust 14-
Shield in sandwich design, previous1y pressing 04/91
manifold and air pump 3915
14-
Air pump belt pulley lnstallation of spacer ring in front of bearing 08/91
7251
Exhaust gas recirculation valve (ARF) with
Exhaust gas recirculation 14-
modified diaphragm Reason: improved 09/91
valve (ARF) 7662
leaktightness
TECHNICAL MODIFICATIONS ENGINE 119 COMBUSTION KE INJECTION- RA1400119TAOOX
14 INTAKE MANIFOLD, EXHAUST MANIFOLD

Op. Designation Nature and reason for modification Production
no. breakpoint
14- Is now a die casting instead of sand
Intake manifold 07/89
1346 casting.
14- Spring hose clips Air intake and air
Diameter reduced. 08/89
7251 injection hose of air pump
14- Installation condition improved by angled
Air pump 10/89
7251 face on bottom mounting eye.
14- Air pump shaped hose to air shutoff Shaped hose lengthened by 13 mm and
10/89
7251 val ve mounting improved.
14- Mounting eye at bottom of cylinder 8
Exhaust manifold 01/90
3915 narrower.
14-
Air pump support Material modified. 02/90
7251
14- Clips for expansion body between
Clips modified in shape. 06/90
3915 exhaust manifolds
14- Bolt for air pump support at oil sump
Air pump support 02/91
7251 modified.
14-
Exhaust manifold Attachment of exbaust manifold modified. 07/91
3915
Exhaust gas recirculation valve ARF with modified diaphragm. Reason:
- 10/91
(ARF) improved sealing.
14-
Exhaust manifold, cylinders 5 and 8 Modified material, cost saving. 02/92
3915
14-
Air pump support Modified material. 07/92
7251
INTAKE MANIFOLD - RA1400FLHOOIOX(14-0010)

Mercedes-Benz
Intake manifold - RA1400FLH0010X{l4-0010)
A. E ngine 104
Matched to LH fuel injection system.
Fig. 82: ldentifying F uel Injection System
B. E ngine 119
Resonance pipes lengthened.
Resonance pipe inner diameter:
Engine 119.970: 40 mm
Engine 119.971: 37 mm.
The fuel vapors from the activated charcoal filter and also the blow-by gases pass through the union (1 ).
Mercedes-Benz
Fig. 83: Identifying Gases Pass Through Union
The fuel vapors and blow-by gases are distributed to all the cylinders ofthe appropriate ban.k through the
distribution ducts (2).
Fig. 84: l dentifying Cylioders Distribution Ducts
The quantity of fue] vapors and blow-by gases allocated to the individual cylinders is metered through
restriction openings (3) in the intake manifold gaskets.
Mercedes-Benz
3 3
cc;s·dn~~
[Po~'}Q?º~
3 3
Fig. 85: ldentifying Intake Manifold Gaskets
C. Engine 120
Because of the intake manifold design, the air inducted on the left-hand side flows into the right-hand
bank of cylinders and vice versa. Consequently, components such as actuators, air mass sensor and
switchover valves are assigned to the opposite bank of cylinders in line with their positioning.
Fig. 86: Identifying Intake Manifold Design - Engine 120
D. National versions 0 and ~
Connectíon for exhaust gas recírculation switchover valve at intake manifold (arrow, see 14-0030).
Shown on engine 104

Mercedes-Benz
Fig. 87: Locating Switchover Valve At lntake Manifold
Intake Manifold - RA1400HFM0010X(14-0010)
A. Resonance intake manifold engine 104 with HFM
The length of the intake manifold has a decisive influence on d1e torque pattem and on the power output
of the interna! combustion engine.
In the induction stroke, the pistons produce a strong vacuum which sets the air contained in the intake
manifold in motion when the inlet valve is opened. As a result, the inflowing air or the air/fuel mixture
develops a considerable kinetic energy. When the inlet valve closes, a dynamic pressure is produced
which irnmediately begins to expand in the opposite direction. The level of this pressure depends on the
flow velocity and on the mass of the gas which is contained in the intake pipe.
If the gas column is accelerated and braked in a rapid altemating sequence, a vibration is produced, the
frequency of which is dependent on the length of the intake manifold. If the engine timing is matched to
the vibrations of the gas column, a certain charge effect is achieved as a result of the resonance vibrations.
As the vibrations of the gas column are also dependent on engine speed, it is possible to achieve
resonance vibrations with a given intake manifold length only witbin a certain engine speed range.
To enable this charge effect to be utilized over a greater engine speed range, these engines are equipped
with a "resonance intake manifold". In the case ofthis intake manifold, a "resonance flap" makes it
possible to utilize two different intake manifold lengths.
Mercedes-Benz
a Resooance flap d osed

b Resonanr e flap open
C WltiOUreSOilallCO lap
Md Engillatorque
n Eng111e spaed
~--------------------~"
P0?-5594-1 3
Fig. 88: Engine Torg ue Graph
Design and function
A pneumatically operated resonance flap (22) is provided at the intake manifold_
617 lil!ake atr tei'TP'9Ia'.l.lre sensor
P0?-5649-13
Fig. 89: Identifying Resonance Flap Provided At Intake Manifold
The resonance intake manifold switchover valve (Y22/6) is connected to the resonance flap (22) and is
actuated by the HFM control unit as follows:
Idling speed at 3900 rpm
Fullload engine 104_942 3450 rpm
engine 104_992 3350 rpm

Mercedes-Benz
P07-5-610-13
Fig. 90: ldentifying Intake Manifold Switchover Valve Connected To Resonance Flap
Resonance flap closed
The inducted air flows in the resonance intake manifold (19a) through the intake pipes which are
branched downstream ofthe throttle valve, into the aír collecting housing ofthe ram manifold (19b). The
air collecting volume is split into two by the resonance flap (22). This results in a significant rise in the
torque in the lower rpm range.
P07-5591-1 3
Fig. 91: ldentifying Intake Manifold And Ram Manifold
Resonance flap open
When the res onance flap is opened, the a ir collecting volume of the ram manifold ( 19b) is no longer split
into two. The inducting cylinder makes use ofboth intake pipes ofthe resonance intake manifold (19a).
Mercedes-Benz
P07-5592'-13
Fig. 92: ldentifying Ram Manifold Intake Pipes Of Resonance lntake Manifold
B. Partial intake manifold preheating engine 111 with HFM
Partial intake manifold preheating PSV (KAT only)
4 PSV elements (R8/3- R8/6) (PTC elements) are provided in the cylinder head in order to preheat the
mixture during the warming-up phase. The relay (K3/ 1) is actuated by the HFM control unit with ground
for heating the 4 PSV elements.
P07-5458-1 3
Fig. 93: ldentifying PSV Elements
Operating principie
If the engine is started at a coolant temperature <60 °C, the PSV elements are energized by the relay
(K3/ 1).
Mercedes-Benz
As the temperature of the PSV e lements rises, the current flow (PTC elements) is constantly reduced untiJ
the HFM control unit interrupts the ground actuation to the re! ay (K3/ 1) at a coolant temperature of about
60 oc. The maximum current consumption of a PSV element is about 6 - 1O A.
P 14-2027-13
Fig. 94: Identifying PSV Elements Relay
Intake manifold- RA1400KE20010X(14-0010)
In the intake manifold a resonance pipe (intake port) is assigned to each cylinder. The resonance pipes merge
into a common larger chamber (bottom part of intake manifold on engines l 02, 116, 117, 119).
As a result of this layout and the sucking pistons, the air column in the resonance pipe resonates. This causes the
intake air upstream of the inlet val ve to be pre-compress.ed (intake manifold charging). Engine output increases.
Resonance pipe length and inner diameter are adapted to the engine. Throttle val ve connections and injection
valves are fitted to the intake manifold. In addition, hose line connections for the vacuum supply (brake servo
unit, vacuum systems etc.) are also provided.
Engine 102
The intake manifold is flanged to the left ofthe engine. The bottom part ofthe intake manifold (18) can be
unscrewed.
The diameter ofthe intake ducts ís 38 - 42 mm.

Mercedes-Benz
Fig. 95: Identifying Intake Manifold Components (Example Engine 102.983/99)
Intake manifold
Example engine 102.96/98
Engine 102.983/99: The intake ducts are forked just upstream ofthe cylinder head. Consequently, each inlet
valve has an intake duct (diameter 26- 28 mm).
lntake manifold
Example engine 102.983/99

Mercedes-Benz
Fig. 96: Locating Intake Ducts
~----V8
••7
1
- • ""'!fJ
=----2
~
!@CUlO
Fig. 97: Identifying Intake Manifold Components (Example Engines 103, 104)
Intake manifold
Exampleengines 103, 104
The intake manifold (1 O) is flanged to the left of the engine_ Idle speed air duct and connection for crankcase
ventilation are integrated on the face side to the cylinder head_ The id] e speed air duct merges into the intake
duct via the air-enveloped injection valves_
Mercedes-Benz
Fig. 98: Identifying Intake Manifold Components (Example Engines 116, 117, 119)
Intake manifold
Example engines 116, 117, 119
The intake manifold is positioned between the cylinder banks. The bottom part of the intake manifold (18) can
be unbolted and is connected by rubber intermediate pieces to the intake ducts.
EXHAUST MANIFOLD- RA1400FLH0020X(l4-0020)
Exhaust manifold- RA1400FLH0020X(14-0020)
A. Engine 104
Exhaust gas recirculation valve only on national versions 0 and ~ .

Mercedes-Benz
Fig. 99: Identifying Exhaust Gas Recirculation Valve Onlv On National Versions
B. Engine 119
Exhaust gas recirculation, see 14-0030, section "C".
left
Fig. 100: ldentifying Exhaust Gas Recirculation - Left
Fig. 101: ldentifying Exhaust Gas Recirculatioo - Right

Mercedes-Benz
C. Engine 120
Three outlet openings each are combined by an exhaust manifold.
The exhaust manifolds are designed as double pipes (sheet steel) with insulation between the outer and
. .
mner ptpe.
left
Fig. 102: ldentifving Exbaust Manifolds Pipe - Left
Fig. 103: ldentifying Exhaust Manifolds Pipe- Right
An exhaust duct (arrow) for drawing off gases for exhaust gas recirculation is provided in each flange at
the exhaust opening for cylinders 4 and 1O.
Mercedes-Benz
Fig. 104: Locating Exhaust Duct
Exhaust Manifold- RA1400HFM0020X(14-0020)
Engine 104 HFM
A double-wall design ofthe exhaust manifold is installed in order to enable the catalytic converter to reach its
operating temperature more rapidly.
Repair notes
Modified exhaust nuts should be used for installation.
P 14-5173-13
Fig. 105: ldentifying Exhaust Manüold
Exbaust manifold- RA1400KE20020X(l4-0020)
The exhaust manifolds merge the exbaust ducts at the cylinder head and connect them to the front exhaust
Mercedes-Benz
pipes.
Depending on the exhaust system, the exhaust manifolds are designed as a single- or double-pipe system. The
connection to the exhaust pipes is by means of outer spherical connections without seal (exception: model201,
1st version with flanged joint) .. Rivet nuts are press-fitted at the exhaust manifold for attaching the exhaust
pipes.
If exhaust gas recirculation is fitted, the ARF val ve is positioned at the exhaust manifold (exception: engine
119)..
Fig. 106: ldentifving Exhaust Manifold Bolt
Engine 102
The exhaust manifold is a single casting (grey iron casting) and double-piped. Stability is enhanced in a number
of cases by reinforcing ribs (anows).
Fig. 107: Locating Ribs
On engine 102.91/96/98 KAT as of09/89 the oxygen sensor (G3/2) is screwed in at the rear area ofthe exhaust
manifold.
Mercedes-Benz
G31l Ol(ygen SOOSOf

145 EmtSgons tost connod on®
Fig. 108: Identifying Oxygen Sensor
Engine 102.983/99
Exhaust manifold designed as steel manifold and merges ínto double-pipe exhaust system. The pipes are
combined by cylinders 1 and 4 and also cylinders 2 and 3. The pipe diameter is approx. 42 mm.
@ version as of 1989 exhaust manifold with emissions test connection (145).
MS
Fig. 109: Identifying Exhaust Manifold With Emissions Test Connection
Engines 103, 104
2 exhaust manifolds are flanged on the ríght of the engine. 3 cylinders each are combined in an exhaust
manifold.
In@) version as of 1989 emissions test connections ( arrows) are orovided.

Mercedes-Benz
Fig. 110: Locating Emissions Test Connections
Engines 116, 117, 119
An exhaust manifold with expansion element is installed for each bank of cylinders. On a number of KAT
versions the exhaust manifolds are connected to a cross pipe at the rear of the engine (M 116, 117) or below the
engine (M 119).
Mercedes-Benz
rt•·Ml.•lt
1 Crosswo 5 Gasket
2 aamp. 6 Lell exhaust manrfcld
3 Slueld 60 Exhaust gas re.orculaioo \'M
4 Rlgtt eltlaust maniold
Fig. 111: ldentifying Exhaust Manifold (Eogines 116, 117, 119)
Engines 116, 117 in modell26
Engines 116, 117 in model 107
2 exhaust manifolds are fitted for each bank of cylinders in modell 07:
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3 Shteld
16, 17 Rlglhxhaustmoofold
S Gasket
18, 19 Le~ elilausl mamtold
60 Elihaust gas reuc\la5oo
\i!llve
Fig. 112: ldentifying Exhaust Manifold (Engines 116, 117 In Model107)
Engine 119
A three-section exhaust manifold is installed for each bank of cylinders.
Englno 119, Ioft sido
Fig. 113: Identifying Exhaust Manifold Bolts- Engine 119, Left Side
Mercedes-Benz
Eng¡lne 119, nght side
Fig. 114: ldentifying Exhaust Manifold Bolts- Engiue 119, Right Side
EMISSIONS CONTROL SYSTEM - RA1400KE2A030X(l4-0030)
Emissions control system- RA1400KE2A030X(14-0030)
A. General
In certain engine operating states part of the exhaust gases is passed back through the exhaust gas re-
circulation valve into the intake manifold in order to reduce the oxides of nitro gen (NOx ) in the exhaust.
The oxygen-poor exhaust gases are mixed in the intake manifold with the fresh, oxygen-rich mixture. The
portien of fresh mixture drops and correspondingly, less oxygen is available for combustion. As a result,
combustion temperature in the combustion chamber drops and thus the formation ofNOx.
The quantity of exhaust gases recirculated depends on the throttle valve position and coolant temperature.
The driving properties ofthe vehicle are not affected by exhaust gas recirculation.
Air injection
Air is fed into the hot zone downstream of the exhaust val ves to achieve post-combustion of the
incompletely combusted exhaust elements of carbon monoxide (CO) and hydrocarbon (HC). This air is
either injected by an air pump or by a self-aspiration system. As a result of post-combustion, the cata.lytic
converter also reaches operational readiness more rapídly (from approx. 250 °C).
The injection air is eitber inducted through a separate filter or taken from the air cleaner housing.
ENGINES WITH EXHAUST GAS RE-CIRCULATION AND/OR AIR INJECTION

Engine Version Exhaust gas re-circulation Air injection
102.961 <§) 84/85 X X (air pump operating constantly)
@) ]984-
I9R6 X (s e l f-::~snirl'ltion svstem. unto 09/S5
Mercedes-Benz
01984 - two non-return valves)

102.96 X
1987
@)
102 102 982 1985/ 1986 X (self-aspiration system with dual non-
X retum valve)
. 01985 -
1987
102.985 ~ 1991 X (70 oc thermovalve) -
®®®0®as
of1991 - X
11odel 124,126,201
103
0~Model124 X X
126, 201 '
11odel129 X X
104
KAT - X
0~ X X
RUF and Standard (220
1161117 X -
kW)
KAT X
@KAT (Modell26 as of09/87:
X
0KAT vacuum control valve
0 omitted)
@<!iS/Y X X
X (air pump operates constantly up to
@ 0 X 2500/min irrespective of coolant
temperature)
119 KAT X X
E missions control system- RA1400KE2B030X(14-0030)
B. Exbaust gas recirculation and air inj ection

a. Engine 102.961 @ 1984/1984
Engine 102.96@) 1984 - 1986, 01984 - 1987
Engine 102.982 @ 1985/86, 0 1985 - 1987
F unction diagram
Engine 102.961 @ 1984/85

Mercedes-Benz
Fig. 115: Function Diagram OfEmissions Control System {Engine 102.961)
EXHAUST GAS RECIRCULATION (ARF)

1 manifold Intake connection flange for ARF
2 body Throttle valve witb vacuum control valve (73)
3 housing Air guide restriction in green connection fitting
9 darnper Vacuum
31 manifold Exhaust with flange for ARF valve
36a opens at approx. 40 °C, color code black, screwed into test
40 °C
thennovalve sensor housing
44 valve Non-return vacuum, housing = cylindrical or stepped
60 valve ARF flanged to exhaust manifold (31)
73 valve Vacuum control bolted to throttle valve body
Exhaust gas
74 line from ARF valve (60) to intake manifold (1)
recirculation
N37 unit ARF control in right of component compartment
S29/2 switch Throttle valve attached to vacuum control valve (73)
Y27 valve Switchover at bulkhead, right of engine compartment
A=Connection intake manifold vacuum
B=Connection control vacuum (reduced)
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AIR INJECTION
25 pump Air vane pump with rotation filter
26 valve Pressure reliefopens from approx. 300 mbar
28 filter Damper noise insulation
29 valve Non-retum prevents exhaust gases flowing back
32 head Cylinder outlet duct
FUEL EVAPORATION SYSTEM

2 body Throttle valve extraction connection for fuel vapors
50 tank Fue1 opens if overpressure/vacuum in fuel tank: tank 30 - 50/1 - 16 mbar
5 1 valve Vent
52 filter Active charcoal stores fuel vapors
53 valve Regeneration opens from 20- 35 mbar vacuurn
f= admissionAir from engine compartment
Engine 102.96@ 1984 - 1986, 0 1984 -1987
Fi~. 116: Function Dia~ram OfEmissions Control System (E n~ine 102.96)
1 manifold Intake connection flange for exhaust gas recirculation

2 body Throttle valve with vacuum control valve (73)
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9 damper Vacuum
31 manifold Exhaust with flange for ARF valve
36a opens at approx. 40 °C, color code black, screwed into test
40 oc
thermovalve sensor housing
vacmun, housing = cylindrical or stepped, as of 1985 .fitted
44 valve Non-return
onto thermovalve (36a)
Exhaust gas
74 line from ARF valve (60) to intake manifold (1)
recirculation
N37 unit ARF control in right of component compartment
S29/2 switch Throttle valve attached to vacuum control valve (73)
Y27 valve Switchover at bulkhead, right of engine compartment
A Connection Intake manifold vacuum
B Connection control vacuum (reduced)
CID
with manual/automatic transmission
Dístributor
SELF-ASPIRATION SYSTEM
Non- prevents exhaust gases flowing back. As of 10/85 dual non-retum valve as
29 valve
retum engine 102.982
31
Exhaust with screw connection for self-induction system
manifold
38 cleaner Air connection fitting for self-induction system
AUXILIARY AIR AFTER START AND IN DECELERATION MODE (WITH MANUAL

TRANSMISSION)
11 valve Deceleration recirculating airvacuum-controlled, restriction in recirculating air inlet
12 distributor Id le air
39 hose Shaped
Engine 102.982 @ 1985/86, 0 1985 - 1987

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29
74
-
Fig. 117: Function Diagram Of Emissions Control Svstem (Engine 102.982)
EXHAUST GAS RECffiCULATION (ARF)

1 manifold Intake connection flange for exhaust gas recirculation
2 body Tbrottle valve only available with vacuum control valve (73)
9 damper Vacuum
31 manifold Exhaust with. flange for exhaust gas recirculation valve
36a 40 oc opens at approx. 40 oc, color code black, screwed ínto test
thermovalve sensor housing
44 valve Non-return vacuum, housing = cylindrica1 or stepped
Exhaust gas
74line from ARF val ve ( 60) to intake manifold (1)
recirculation
N37 unit ARF control in fuse/relay box
S29/2 switch Tbrottle valve attached to vacuum control valve (73)
Y27 valve Switchover at bulkhead, left of engine compartment
A Connection intake manifold vacuum
B Connection control vacuum (reduced)
SELF-INDUCTION SYSTEM
129 valve Dual non-return orevents exhaust gases flowing back
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31 manifold Exhaust with screw connection for self-induction system

38 cleaner Air connection fitting for self-induction system
Auxiliary air after start and in deceleration

(with manual transmission)
mode
vacuum-controlled, restriction in recirculating air
11 valve Deceleration recirculating air
inlet
12 distributor Idle air
39 hose Shaped
e connection Vacuum to intak:e manifold cylinder 3
Function of exhaust gas recirculation (ARF)
Fig. 118: Function Diagram Of Exhaust Gas Recirculation
Exhaust gas recirculation is performed above a coolant temperature of approx. 40 oc and with
throttle val ve at idle speed or full throttle stop.
When tbrottle valve is at idle speed or full throttle stop, the control un.it (N37) switches voltage to
the switchover valve (Y27). The signal for this is supplied to the control unit (N37) by the tbrottle
va1ve switch (S29/2).
The switchover valve (Y27) switches over and admits air to the exhaust gas recirculation (ARF)
valve (60, connection A), as a result ofwhich the valve closes.
If the tbrottle val ve moves into a position between idle speed and full tbrottle, the signa! from the
tbrottle valve switch (S29/2) to the controltmit (N37) is switched off. The control unit interrupts
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the voltage supplíed to the swítchover valve ('127).
As a result, the switchover valve (Y27) switches intake manifold vacuum to the ARF valve (60,
connection A). At the same time, more or less air is admitted to the ARF valve (60, connection B),
depending on throttle val ve position, through the vacuum control val ve (73). The ARF valve (60)
opens partially or fuUy.
F unction of components
Exhaust gas recirculation valve (60)
Atmospheric pressure (arrow) acts constantly through an air admission drilling in the diaphragm
chamber via the cut-off diaphragm ( 1).
A CoonGctloo {roo), to s•Mii:hcve~ wtve

8 Coooodioo {bwwn), loo varuum velv9
1 Cu~o! daphre.gm
2 BO'Mtpediaphlagm
:> Worl<lng áaphragm
Fig. 119: Identifying Exhaust Gas Recirculation Valve
If intake manifold vacuum acts through connection A (red) in the diaphragm chamber below the
cut-off diaphragm (1), the latter is pressed down against the force ofthe spring. The ARF valve
opens if air is admitted simultaneously to the diaphragm chamber vía the working diaphragm (3).
Mercedes-Benz
,.----~- 1
Fig. 120: ldentifying Diapbragm Chamber
Vacuum control valve (73)
When the engine is idling, this valve reduces the intake manifold vacuum toa constant level. Ifthe
throttle valve 1s moved to the closed position, the cam disc (2) moves in the direction of the arrow.
The reduced vacuum at connection (B) is further lowered, as a result of which the exhaust gas
recirculation valve opens.
A lnlal<e manfoldcomec•on
B Campar cooooction, exhal.IS: gas rearaJ!aion vaMI
C A'6 gu!de housmg ronnllWon
F1 Sphencal spmg
F2 P rM911SIOilllQ spnng
F3 ComprosSJon spnng
1 Hcusmg
2 Cam disc
3 levar
4 Spnng plals
5 Slee\19
6 S aa:ilgplata
7 Dieptragm
8 Tuba
Fig. 121: ldentifying Vacuum Control Valve
Throttle valve body with vacuum control valve and throttle valve switch (S29/2)
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Fig. 122: ldentifying T hrottle Valve Bodv With Vacuum Control Valve And Throttle Valve
Switch
Vacuum damper (9) with restriction
This prevents sudden opening or closing of the exhaust gas recirculation valve. A restriction is
installed in the connection (gn).
Throttle valve switch (S29/2)
It operates the control signal for switching off the ex.haust gas recirculation valve when the throttle
valve is in the idle speed and full throttle position.
X56 Pk.lg ccnnecbon , lt\!ottleva.lve S'o'.!il:h
F ig. 123: ldentifying Throttle Valve Switch
40 °C thermovalve (36a, color code black)
It opens from a coolant temperature of approx. 40 oc and then allows the intake manifold vacuum
to flow through.
Mercedes-Benz
A. To non-rotun \'at.le
B To 1rtake manfold
1 Brnatalplale
2 0-nng
Fig. 124: Identifying Thermostat Valve
Switchover valve (Y27)
Installed at the bulkhead in the engine compartrnent. When the throttle valve is in the idle speed
and full throttle position, the switchover val veis energized and switches over to atmospheric air
admission.
Fig. 125: Identifying Switchover Valve
Non-return valve (44)
It prevents the intake manifold vacuum at d1e exhaust gas recirculation valve dropping as the
throttle valve closes further.
Cylindrical or stepped versions possible.

Mercedes-Benz
bl ws sw bl sw
A.= Vaa.rum tritlt
Fig. 126: ldentifying Non-Return Valve
Control unit (N37)
Dependíng on the control signal from the throttle valve switch, it switches the voltage for the
switchover valve on or off.
Modol 124
Fig. 127: ldentifying Control Unit
Functioo of air injection @
25
Fig. 128: Fuoction Of Air Injection
Air is injected into the hot zone downstream of the exhaust valves in order to reduce the
inr.()mniP.tP.Iv C'.()mhm:tP:rl r.()mn()nP.nt.<: in thP: P.xh~11 st P~ S
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The air pump (25), driven by means of a belt by the crankshaft, supplies a continuous flow of air
when the engine is running.
The excess air debvered by the air pump at high engine speeds is blown off to atmosphere above a
line back-pressure of approx. 300 mbar in the downstream pressure relief val ve (26).
The quantity of air inj ected is constant from this line backpressure on.
A damper filter (28) is fitted to the blow-off line for noise insulation.
A non-return valve (29) is installed between pressure reliefvalve (26) and cylinder head (32, C =
exhaust port) to prevent any hot exhaust gases flowing into the air injection line.
Function of self-aspiration system @ @
Fig. 129: Function Of Self-Aspiration Svstem
It performs the same function as air injection.
When the engine is running, fresh air is drawn constantly out of the air cleaner as a result of the
alternating pressures (pressure vibrations) in the exhaust manifold.
When a vacuum exists in the exhaust manifold, the non-return valves open and allow air to flow
into the manifold. It is mixed with the hot e:xhaust gases. The atmospberic oxygen reacts with the
incompletely combusted components in the exhaust gas and reduces them. When overpressure
exists in the exhaust manifold, the non-retum valves elose preventing exhaust gases flowing to the
air cleaner.
Mercedes-Benz
NOTE: On engine 102.98 in model124 and on engine 102.962 in model 201

as of 10/85 the two non-return val ves (29) are combined to form a
dual non-return valve (29).
29 NOOf etl m v¡¡¡.us/

dlJalnO!He~m vaM!
:>1 Elfurust mamfold

:>8 A.-cleaner
Fig. 130: Identifying Non-Return Valves
Function of auxiliary air after star t and in deceleration mode@@ (witb man ual
transmission)
A deceleration recirculating a ir valve ( 11) is installed for engine speed increase after start and for
improving combustion in the deceleration mode.
This valve is controlled by the intake manifold vacuum (e). Part ofthe metered air from the air
guide housing (3) is passed along shaped hoses and the idle a ir distributor ( 12) to the id le air duct in
the intake manifold (1), bypassing the throttle valve.
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Fig. 131: Function Of Auxiliary Air After Start And In Deceleration Mode
Engine speed increase after start
When the engine is switched off, atmospheric pressure exists in the lower and upper diaphragm
chambers. After the engine is started, a high vacuum is briefly produced in the lower diaphragm
chamber (5), which overcomes the force of the compression spring (6). The valve (8) is pressed
down and the passage for the bypass air is opened.
It closes as soon as the vacuum in the two diaphragm chambers is again equalized by means of the
restriction orífice (10).
A lntake man!oldvaanm
comecjoo
B Connl!dlon lor l!lr gude
hOUSing
C Conne::bonto 11lean
listnbúor
1 Top part of housmg
2 Upper li&phragm cl&nbm
3 Ar aOOll SSIOO openngs
4 Dlapl'legm
5
6
Lower d!aphragm chamb!O{
~SSIOO spnng
e
7 Sealng <iapl'lagm
B VeNas
9 Bo~om part of housmg
10 Restndloo omce
11 AIr actn•SSioo openng
11 PresslJrO l mbngvelve
Fig. 132: Function OfEngine Speed Increase After Start
A tllal<e mlllllfoldvawu:n
comedon
B Connottion fclar gu;de
hoosmg
C Connedion lo ide air
dlstnbúor
1 Top part ofhousang
2 Upporóaph~charnbor
3 Alf adiTUSSion openngs
4 Dlaptfagm
5 Lowor dlaphragm chamber
6 Compressaon s;mng
7 semgdiaplngm
B Vat.&s
9 BoiJ:om pcertofhousmg
10 Res.tnctJon cm ce
11 A.. sdnuSSion oponng PC17 · 0Ua-u
12 Pres<;ur& limlrigvalvo
Fig. 133: Function OfEngine Speed Increase After Start
Air supply in deceleration mode
If a balanced pressure condition exists in the upper and lower diaphragm chambers during constant
driving, the compression spring (6) closes the valve (8).
In deceleration mode. the vacuum in the lower diaohragm chamber (5) increases more raoidlv than
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pressure equalization wíth the upper díaphragm chamber can be achíeved through the restriction
orífice (10). As a result ofthe adjusting force ofthe high vacuum, the compressíon spring (6) ís
overcome. The valve (8) opens and the bypass air is able to flow from the air guide housing into the
idle air duct.
The pressure limiting valve (12) with the two air admissíon openíngs (3) opens when a high
vacuum exísts. It admits a ir to the diaphragm chamber (2) through the valve (8). As a result of this,
the val ve (8) remains open longer.
b. Engine 102.985 ~ 1991
821 Exhaust gas reorrulaloo tarrper1Wre s-ensor, 94 Delayv:We {crl¡ mar~.~alltransmJsSion)

Calilornaooly 123 Tnrollle v.a~e boo¡
N112 EZl i!JliOil cooirol Ullll 155 Exhaust man;fold
4 Plt:al<e m an;fold 158 Re gen erabon •no
21 Exhaust gas rearcula)on líno a Regonllfabon •no toat5vecharcoalfíCDr
78 Regonem!lon v!We f<lf IU9I evapora~on S"¡stem llne co!ou e odin g
79 ThemlGvalvefor fuel ew¡>Ofa~on ~em , opens at 70 lx lxO'M'I
·e, closes ans ·e S'.V blac.k
so Theunovalve ror exhaust gas rec.-cUabOfl, opens al70 ws whtB
·c, closes at60 •e
VI VJol.el
81 AIJ!pn]abc trall !illliS'.i!Ofl
89 Exhaust gas reorculalon va.w
Fig. 134: Function Diagram OfExhaust Gas Recirculation
Function diagram of exhaust gas recirculatioo
The level ofvacuum which exists at the exhaust gas recirculation valve (89) díffers according to the
throttle valve position.
When the thermovalve (80) is open, the vacuum controls the exhaust gas recirculation valve (89),
as a result of which the exhaust gas recirculation valve is partially or fully opened and exhaust
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gases thus pass along the exhaust gas recirculation line (21) into the intake manifold (4).
The delay valve (94) on vehicles with manual transmission prevents the exhaust gas recirculation
valve (89) opening too rapidly.
Exhaust gas recirculation is performed
• In part load mode:

a. when coolant temperature rises abo ve +70 oc
b. when coolant temperature drops to +60 oc
No exhaust gas recirculatiou is performed
• When engine idling and at fuU load

• If coolant temperature below +60 oc
Exhaust gas recirculation temperature sensor (B21), California only
lnstalied in exhaust gas recirculation line.
Tightening torque 23-28 N m. The temperature ofthe recirculated exhaust gases is detected by the
temperature sensor. Refer to diagram for resistances.
Fig. 135: ldentifying Exhaust Gas Recirculation Temperature Sensor
If the exhaust temperahrre when driving drops below approx. 120 °C, "no exhaust gas
recirculation" is performed. This is recognized as a fault by the KE controltmit and stored. In
addition, the CHECK ENGINE indicator lamp comes on.
Mercedes-Benz
200
100 ~
\
Dla!)fam
Exhaust IOITPBT!l~l&te~sblilto a! ·eldlaJJ st gas roarrule~on
tempemrure sensor
10
'\~
~\
2
\ ~
~
1
1110 1$0 2100 250 3010
•e
Fi~. 136: Exhaust Temperature Resistance Graph
c. Engine 103.984 model129
N16 Eng;r¡e S'f.>tllms con~<llulllt{MAS) 128 Non-rallEn vat~e (vacwm)

Y:U I'Jr pump vacwm 'Vlilve 156 ExhiW st m anfold
Y33 AJr pump etectromagnetic cUdl 125 Alrpump
79/1 70f:l-5 ·e thBITil~va.<ve 126 I'Jr cu~O: vatve
89 Exhaust gas r eorculaíon va!ve 127 Non-re!um valva fl!loctloo ~Y)
Fig. 137: Function Diagram Of Air lnjection And Exhaust Gas Recirculation
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Function diagram of air injection and exhaust gas recirculation
Air injection (only KAT version)
The air pump is flange-mounted in the combined mounting bracket above the alternator. The air is
drawn in through a maintenance-free dry air filter (arrow) integrated in the air pump housing and
inj ected into the air passage in the outlet duct ofthe cylinder head between cylinders 3 and 4_ Air
injection is performed for up to approx. 2 minutes (at coolant start temperature of20 °C) after
starting the engine. It is operational at:
o Coolant temperature between + 17 oc and +40 oc

o Engine speeds <3500/min
o Full throttle contact open
Fig. 138: Locating Maintenance-Free Drv Air Filter
Exhaust gas recircuJation (only KAT version)
The exhaust gas recirculation valve is positioned on the exhaust manifold for cylinders 1 - 3_
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Fig. 139: Locating Exhaust Gas Recirculation
The exhaust gas recirculation valve is a single-stage design and is supplied with vacuum from a
coolant temperatme of +70 oc through the thermovalve (arrow) anda throttle valve angle of > 11°.
Fig. 140: Locating Thermostat Switch
d. Engine 103@) @ 0 0 ® Models 124, 126, 201 as of 1991
Function diagram air injection

Mercedes-Benz
123 nuotte vaM! bo<tf

125 A•purrp
126 A• ctJ!-offv!IMl
127 N001e\1Jm vaM! (irtadon
Blf)
12'8 NOMellmvalve (vawun)
156 E~eust mantold
K1 7/3 A•ntedof'll1mnsmssoo
stilt ~tm!ard ll!la'1
N3 KE lljedlon sys'.Bm C«Uoo
urd
Y32 M p11rrp swtcl'l owr va/ve
Y33 A• purrp eledro
magnebc <itcl'l
a
a To shltpollt mtard solenold
valva {Y312)
Fig. 141: Function Diagram Air Injection
Air injectíon is activated
• after engine start ata coolant temperature between + 1Ooc and +40 oc (e.g. for 80 seconds at
+20 °C)
• engine speed <3500/min
• full throttle contact open (idle speed, part load)
The KE injection system control unit (N3), contact 14, supplies a control signa} to the air
injection/transmission shiftpoint retard relay (Kl7/3), as a result ofwhich the relay operates.
Thís causes the air pump electromagnetic clutch (Y33) and the air pump switchover val ve (Y32) to
be actuated at the same time. The vacuum-operated air cut-offvalve (126) opens and air is injected.
The air pump switchover valve (Y32) is positioned on model 124 at tbe front right wheelbouse, on
model 20 l at the partition panel on the right of the component compartment
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1-
\---
---r---
;~
e~~~--~
M00BI 201
Fig. 142: ldentifying Relay
Mo<fal 124
Fig. 143: Identifying Air Injection/Transmission Shiftpoint Retard Relav
The air pump (125) is flanged to the mounting bracket above the alternator. The air is drawn in
through a maintenance-free dry air filter integrated in the air purnp housing and fed to the exhaust
gas downstrearn ofthe exhaust va]ves. Air injection is performed at the cylinder head between
cylinders 3 and 4.
Mercedes-Benz
Fig. 144: Identifying Air Pump F langed To Mounting Bracket Above Alternator
e. Engine 103 0 ~ models 124, 126, 201
Function diagram air injection and exhaust gas recirculation
as ~ll'Jsl gas remtúatioll

vi!We
113 Thro~e vaMI bOO¡i
125 A.-pwrp
126 Arr cU!.()ffvaM!
127 NCXHftimvaMI (lrtedon
an)
128 NCXHOllm vatve {vaanrn)
156 Elt!B!Jst man:lold
N3 KE llJOcbon systom C><Xtrol
urlt
N16 E ngme systems e ortrollnt
(MAS)
Y27 ~"ftust gas reruclhlboo
s'AI!chover vi!We
Y32 Ar purrp swtdlover v&Ne
Y33 Ar purrp electro
magnet¡c dtch
P14•0007-U
Fig. 145: Function Diagram Air Injection And Exhaust Gas Recirculation
f. Engine 104
Function diagram air injectiou
Engine 104 KAT

Mercedes-Benz
128
123 Tnrct~ va.Mil>c6f

125 A,.pulfll
126 Air C"tt..o.'f vaM1
127 NOMet.lm va.\<9 (iqed on
¡¡¡r)
118 NOfWinlm vi!Ml (varuum)
153 Eme!JSI manfold
N16 En~oo systems comcl Ullt
(MAS)
Y32 A.. pulfll varuum ve.."vn
Y33 Art pulfll elaclro
megnetic cUdl
Fig. 146: Function Diagram Air ln jection
Air injection is performed for a maxirnum of 2 minutes (at coolant start temperature of 20 °C) after
starting engine. It is activated if:
o coolant temperatu re between + 1O oc and +40 oc

o engine speed <3000/min
o full throttle contact open
Fig. 147: Identifving Air Pump & Air Injection Between Cvlinders 3 & 4
The air pump ( 125) is flanged to the mounting bracket of the alternator. The air is drawn in through
a maíntenance-free dry aír filter (arrow) íntegrated in the alr pump housing and supplied to the
exhaust gas downstream ofthe exhaust valves. The air is injected (1 0) between cylinders 3 and 4 at
the cylinder head.
Mercedes-Benz
NOTE: System test of air injection by KE control unit, see Group 07.3.
Fig. 148: Locating Free Drv Air FiJter
40 OtapfTagm presstn regula~ N113 EZLIAKR IQillbOO comclmt

89 Bchaust gas roarrulaion vaMI Y27 Exhoostgasreorrula oo SINichowrv!We
90 Regen aratJoo Vlllve Y32 AJr II'J&dloo mtchover vat.<a
123 Throt~e va'Vil bOO¡t Y33 Eletl'OITI8!J18liC dul!:h
125 Air ru\.of \IBWe YSB/1 Rageneroboo swlthovefVBÑ&
127 Norl.fetlnl V!!Ne flfledloo 111') a To tarther consuners
128 NOIH&tlnl \'Bive (vacwm) b To adllle dlercoal iler
156 Exllaust manfold
Fig. 149: Function Diagram Air Injection And Exhaust Gas Recirculation (Model 124 Engine
104)
Function diagram air injection and exhaust gas recirculation, model124 engine 104 0 ~
Mercedes-Benz
NOTE: As on engine 119, the air injection switchover valve (Y32) is actuated
by the engine systems control unit and the exhaust gas recirculation
switchover valve (Y27) by the KE control unit.
g. Engines 116, 117
1 Mtxrure coniolunt 90a Cut-off daphra1111

1l ~eke m!lrlfold 90b Non-telurn vat.'e
79 50'C lhetmo·{~{e (nabonalwr5ion @ 123 Thr<l!tle va.'Va oo~t;
~'lllhctli KAT 4D 'C) 155 Exhaust gas ream.rla~-on llne
156 Exhau st mell!fcld
S.9 Exhaust gas rearrulmon vaM!
9'() Cortr<llvatvu
Fig. 150: Function Diagram Exhaust Gas Recirculation With Vacuom Control Valve Up To
08/87
Function diagram exhaust gas recirculation witb vacuum control valve up to 08/87
Exhaust gas recirculation is performed subject to the following operating condítions:
• Coolant temperature >50 oc

• In allload states, except idle speed and fullload.
When the throttle valve is closed, atmospheric air is adrnitted to the exhaust gas recirculation valve
(89) through a connectíon at the throttle valve body ( 123), the thermovalve (79) and the vacuum
control valve (90, connections II and III).
Mercedes-Benz
Fig. 151: Identifying Exhaust Gas Recircu1ation Valve
Ifthe throttle valve is partially opened, vacuum flows along the same path to the exhaust gas
recirculation valve and opens the valve.
Exhaust gas recirculation is still maintained by the control val ve in the high engine load range (not
yet fu U load) althougb the exhaust gas recirculation valve would already close in accordance with
its characteristic curve. The opening is closed by the diaphragm and the vacuum is retained. In the
full load range, tbe vacuum drops sufficiently so that the exhaust gas recirculation valve eloses
agam.
The connection (1) at tbe vacuum control valve ensures rapid air admission to tbe exhaust gas
recirculation valve during the transition frorn the part load range to idling and thus shuts off exhaust
gas recirculation.
Mercedes-Benz
a
b
PC11 · nr~- u
a To em eus.t g.as re CJr( ulaúc111hormova.'ve

b To ruel evaporaban sys\llm lherrn<Y~
e From ro-gWlllrHÜofl vmve
d lo eXheus.t gas morcW!tioo varuum como! \>Bhte
Fig. 152: Identifying Vacuum Valve
... Oltlllr
1 MIXtura con~olurd 123 Ttro!la vatwe bo!t¡

12 hake manilcld 155 Exhaus: gas rearruleton i ne
79 50 ·e toormov a.'ve 15$ Exhau st m alllfold
Fig. 153: Function Diagram Exhaust Gas Recirculation Without Vacuum Control Valve As
Of 09/87 And (Model Year 1988)
Function diagram exhaust gas recirculation without vacuo m control valve as of 09/87 and
model year 1988
The exhaust gas recirculation vaJve is supplied direct with vacuum only dependent on the
tbermovalve .
Mercedes-Benz
Air injection
..,.
78
N112 lgntion s~tem (EZl) cortrol tllll 79 FuelllV!lpotaioo system lhermoV&'vo

Yl1 An pump S'Nichovllf VM 8() E:maust gas r&orcula oolhennove!lle
a From SIC deao!lf 89 E:moo st gas raorcutet.oo vat.e
b To i.Jeltari< 90 CcrtrolvaMI
e Au admJSSilon 123 TIY-o:!IG ViW& bod¡l
1 Mixture ton~oiUIII 125 Au punp
40 OlapiTagm pressu-e rg,guleilr 126 Aír cu~cJ 'Yalve
77 Ac tive chalcoal litsr 127 Non-fallrn V<lNe Ort&tllan liT)
78 Re¡¡onemboo vetvo 118 Non-felu-n \IBNe (Vacuum)
129 T1mng casocover
Fig. 154: Function Diagram Air Injection And Exhaust Gas Recirculation
The signal for switching the a ir pump on and off via the relay (K17) is processed by the KE
control unit .
Mercedes-Benz
(
Fig. 155: ldentifying Cut-OffValve
Air injection is performed provided the following conditions are met:
• Coolant temperature > 17 oc <70 oc

• Engine speed <2500/min
• Fullload contact open
• Lambda control not operating.
If these conditions are met, the electromagnetic clutch of the air pump is activated by the KE
control unit (N3) via the relay (K17, see wiring diagram). At the same time, the switchover valve
(Y32) ís operated vía the same relay, which in tum aHows the vacuum to flow to the air cut-off
valve (126).
The vacuum overcomes the spring force and pulls the diaphragm up, lifting the valve off its seat.
The air drawn in from the air cleaner is injected through the cut-offvalve (126), the non-retum
valve (127) as well as through the ducts ofthe tíming case cover and ofthe crankcase ínto the
exhaust ducts ofthe cylinder heads.
N ational versioo @ CD
On the versíons wíthout catalytíc converter the aír pump runs constantly up to 2500/mín
írrespective of coolant temperature.
Mercedes-Benz
h. Engine 119 KA T
Mercedes-Benz
,___ _____,_ N3
~------~----~-----------N16 P OJ- OICI7 -:S9
89 Exhaust gas raarrula1on vM9 156 Exhau st merifold

123 TRo::!o vatvo body N3 KEcortroiU!l!t
125 Aupunp N16 Engine sy.;tems ron~otuOJI (MAS)
126 Au ru~cC va.'Ve Y17 Extloostgas reolaJia~on swtchover va.'Yo
12i Ncn-return V!We ~flEicbOO ~) Y32 An punp vacwn valve
126 Ncn-rotum V!We {vatwm) Y33 An punp o!edromagnebc cktch
Fig. 157: Function Diagram Air Inj ection And Exhaust Gas Recirculation
Air injection (only KAT version)
Air injection is performed up to a maximum of 2 minutes after starting engine. It is operational at:
o Coolant start temperatures between + 1O oc and +40 oc

o Engine speed <2500/min
o Full throttle contact open
Mercedes-Benz
The air pump is flanged below the alternator. The air is drawn in through a maintenance-free dry air
filter (arrow) integrated in the air pump housing. The air flow is split downstream ofthe air cut-off
val ve and injectedl into air ducts in the crankcase at cylinders 1+5.
Fig. 158: Locating Free Dry Air Filter
The exhaust gas recirculation valve (89) is positioned on the intake manifold. The exhaust
extraction point is in the exhaust duct of cylinder l. The exhaust gas passes through a passage in
the cylinder head to the exhaust gas recirculation valve from where it flows into the intake
manifold.
Exhaust gas recirculation is controlled by the KE control unit via the exbaust gas recirculation
switchover valve (Y27).
Exhaust gas recirculation operates at:

• Potentiometer voltage at air flow sensor >2 V
• Full throttle contact open
• Idle speed contact open
NOTE: System test of air injection and exhaust gas recirculation by KE

control unit, see Group 07.3.
Mercedes-Benz
Fig. 159: ldentifying E xhaust Gas Recirculation Valve
Ernissions control system- RA1400KE2C030X(l4-0030)
C. Oxygen sensor
The oxygen sensor is screwed into the front part of the exhaust system upstream of the catalytic
converter. It uniformly detects the exhaust flow of aU the cylinders in the exhaust pipe.
Model107
Asrcw Oxyen sensor 10 Ulderioor e~ cornrerter
Fig. 160: Locating Oxygen Sensor (Model107)
Modell26
Mercedes-Benz
~gen sonSOf m U!ldetfoorc&:alytlc cooverter
Fig. 161: ldentifying Oxygen Sensor CModel126)
Model126
G312 ~gen sensor

1 '57 Ftrewa3ca~,tc convert!lf
Fig. 162: ldentifying Oxygen Sensor And Firewall Catalytic Converter (Modell26)
Model 129
G312 ~gon senSOf

114 Splashpanel
Fig. 163: ldentifving Oxvgen Sensor (Model129)
Models 124, 201

Mercedes-Benz
locabon <Jf O)rfgen Silllsor m lrort exha!lst pipe
Fi2. 164: Identifying Oxygen Sensor (Model124, 201)
Models 124, 201 as of 09/89 with engine 102
G312 ())(ygen sensor m e>fla~B maníold
Fig. 165: Identifying Oxygen Sensor (Models 124, 201 As Of 09/89 With En~ne 102)
The active part of the oxygen sensor is a ceramic body consisting primarily of zirconium dioxide. It is
coated on the surface with a gas-permeable platinum layer as well as with an additional protective layer
on the exhaust side.
A metal tube with several slots protects the ceramic body from mechanical stresses (shocks).
Heated oxygen sensor

Mercedes-Benz
40 S enSOf housn¡g
41 Cet:amc supportJngtl.bo
42 Conoodlon cablo
43 Metal~ 'Mth slots
44 Acbvo SllllSOI cernmJC
45 Cootact p<llt
46 PrctedrYe s!eove
47 Healng elemert
48 Termnah:onnedlonsfOf h8atrlgelemert
Fig. 166: ldentifving Heated Oxygen Sensor
The outside of the active sensor ceramic is exposed to the exhaust emissions while the inside is connected
to atmosphere.
At operating temperature the ceramíc material is conductive for the oxygen ions. A voltage is produced in
the oxygen sensor as the result of the different oxygen portien between exl1aust gas and atmosphere.
At operating temperature (>300 °C) the oxygen sensor supplies a voltage signa! to the KE control unit
Voltage >450 m V rich mixture.
Voltage <450 mV lean mixture.
A voltage jump is produced duríng the transition from the rích to the lean range. As a result of this steep
voltage rise at lambda (a)=l , the exhaust composítíon can be rapídly detected by the KE control unit and
the fuel/air mixture corrected within a narrow control range (lambda closed-loop control).
Mercedes-Benz
B
t
A Rlch fuellalr nixture

B Lean fueVar mbrture
0,9 1,0 1,1 - l
Fig. 167: Rich & Lean FueVAir Mixture Voltage Graph
In addition to the oxygen portien in the exhaust gas, the temperature of the cerarnic body also plays a
decísíve role.
The response time for a voltage change wheu a cbauge occurs in the composítíou of the mixture is a
matter of secouds wheu the ceramic temperature is below 300 °C, and less than 50 ms at the optimal
operating temperature around 600 °C.
Models 107, 124, 126, 201
The oxygen sensor sigual is passed via plug couuection G2/3x2 and a screened cable to the KE control
unit. Voltage for the oxygen sensor heater is supplied by the fuel pump relay via the 2-pin plug
couuection G3/2xl.
The plug couuections are located in the ríght footwell or at the component compartment panel.
Mercedes-Benz
N3
r·-·-·-·-·-·
1 -()
Gl/2 lie.ated oxygen sensor

G3/2.x1 Plug , co.nnectlo.n oxyge11 sensor heatlng coil
G3/2:x2 Pfug oo.n.ned.lon, oxyg en sensor slgnal
N3 KE contra unJt
W10 Batte ry gTound
z Con.nector sl(ll)ve ($Oidered oonnector m hamMs
temtltlal 31 (ground)
FueJpump felay, terminal 87 « 87H
Fig. 168: Control Unit Circuit Diagram (Models 107, 124, 126, 201)
Location of plug connection
Plug connection, oxygen sensor in right footwell below floor panel
Fig. 169: ldentifying Plug Connection, Oxygen Sensor In Right FootweiJ Below Floor Panel
Engine 102 with oxygen sensor in exhaust manifold:
Plug connections, oxygen sensor, at component compartment panel on right

Mercedes-Benz
Fig. 170: Identifying Plug Connections, Oxygen Sensor, At Component Compartment Panel
Model129
The oxygeu sensor plug connection (G3/2x 1) has 3 pins and is firrnly attached to the transrnission ttmnel
on the right from the outside. When the plug connection is separated, the union nut is turned anti-
clockwise and pulled off. To plug, tum union nut clockwise.
P07-6849-13
G312:x 1 Plug connectlon, h&atoo oxygen sensor (3-<pin)

N3 KE con tra untt
W16 Componen! com~11ent ground
Z Connector s!@e-VQ (soldere<J connector ill hame:ss
terminal 31 (g round)
a E.ngin.e sys tems oontrd unit, tf!ffl'li nai87SH
Fig. 171: Control Unit Circuit Diagram (Model129)

Mercedes-Benz
Fig. 172: ldentifying Plug Connection, Heated Oxygen Sensor
1 Oxygen sefl.$()r s!QIUIJ

2 Oxygen sensor healer
Fig. 173: ldentifving O xvgen Sensor Signa] And Heater
Testing oxygen sensor signal
For testing, separate plug connection and connect cable nmning to KE control unit to ground (lean
simulation). As a reaction to this the KE control unit enriches the fuel/air mixture (lambda < 1). The
oxygen sensor which is at normal operating temperature must now output a voltage greater than 450 m V
(max. approx. 1V) when the engine is nmning.
Emissions controJ system- RA1400KE2D030X(14-0030)
D. Oxygen sensor heater
The oxygen sensor contains a heating element (4 7) which is supplied with voltage under certain
conditions. This ensures that the operating temperature ofthe active sensor ceramíc (44) is maintained at
a constant leve!. In addition, the operating temperature is reached more rapidly.
Testing oxygen sensor beater
For testing, separate plug connection and connect into the arnp-meter cable. For test see Diagnosis
Mercedes-Benz
Manual Engine.
Fig. 174: l dentifving Heater Oxvgen Sensor
a. Oxygen sensor heater up to 08/89
The heating element of the oxygen sensor is supplied with voltage vía terminal 87 of the fuel pump
relay and is heated for as long as the fuel pump is running.
b. Oxygen sensor heater as of 09/89
1st version up to approx. 12/89
The fuel pump relay is fitted with an additional connector for the oxygen sensor heater with the
designation 87H. Consequently, the cable assignment at the relay was also modified. Actuation is
performed as before as the additional connector 87H is linked vía a bridge to the connector with the
designation 87.
Mercedes-Benz
F ig. 175: Oxvgen Sensor Heater Circuit Diagram (1st Version)
2nd version as of 01/90
From this date on the bridge between terminals 87 and 87H is no longer fitted. The electronic
circuitry in the relay was modified as a result. The cut-in temperature for the oxygen sensor heater
is +20 oc and is determined by the coolant temperature sensor.
N16/4
r -·- - · -- ·- ·- -1
1
<> 1
l711 50 31 87K 15 T O U' H30 7 i
4·--t+H· --+·+·H·--+
Fig. 176: Oxvgen Sensor Heater Circuit Diagram (2nd Version)
NOTE: Only the new fuel pump relays are available as replacement parts.
This means on vehicles manufactured prior to 09/89 actuation of fuel
pump and oxygen sensor heater continues to be performed by
connector 87. Connector 87H does not perform any function on these
vehicles.
c. Oxygen sensor heater, engine 103.984 (m odel129)
The oxygen sensor is heated from a coolant temperature of20 °C. The voltage supply is effected by
Mercedes-Benz
engíne systems control unít, terminal 87SH.
d. Oxygen sensor heater, engines 104, 119
The heating capacíty ofthe oxygen sensor is:
Engine 104 up to 08/89 heating capacity 12 W
Engine 104 as of 09/89 heatíng capacíty 18 W
Engine 119 heating capacity 18 W.
The KE control unít supplíes a control sígnal for the oxygen sensor heater to the engine systems
control unit which then controls the oxygen sensor heater. The engine systems control unit supplies
an information signal regarding the oxygen sensor heating current (feedback) to the KE control unit
for diagnostíc purposes.
e. Oxygen sensor heater, engine 103 @ 0 0@@ as of 1991

The heating capacity of the oxygen sensor has been increased to 18 watts.
Actuation of the oxygen sensor heater is performed from a temperature of approx. +20 oc by the KE
injectíon system control unít (N3) vía the oxygen sensor relay (K35).
The oxygen sensor relay (K35) on model 124 is installed in the fuse/relay box in relay position "E", on
model201 in front ofthe electrical center in the relay box in relay position "F".
Mercedes-Benz
, 1
A
1~
'11
1
K
u
[1 ~
m i
B JG
[ll
Mo<lel 124 1 K
locabon of relays IC n
~~
l H
u
ID
loo m
...--..
lE K
DI
l~ J
m-
§[ g} .._.. ll4.$¡~ .. . U ] §
Fig. 177: Identifying Fuse/Relay Box
Mercedes-Benz
S2{1
1 ' ,,
~~~HJ
7~~ onL ~ '\ .,,_.,____
1
W3
_¡
1
l W10
~tttrh,
ás~ .é
...---fJ"'i-7
-
I F1
-
X26
1__;;
R _2_)
F1 Fuse and relay box N1 6/4 Fuel pump and kickdown cut-offrelay
G3l2 Heated <>xygen sansnr S211 lgnilion &~.arter swhch
G312X 1 Plug ronncdlon. oxygen senS<tr heallng col W3 Ground, al front ~fl wheelnouse Qgnillon ool)
Plug oonnedlon. oxygen san sor slgnal W10 Battel)' ground
G312X2 X26 Plug oonnedlon. lnlerior/englne (12"1)in)
K35 Oxygen sensor relay
NS KE injedlon system ronttol uni t
Fig. 178: Wiring Diagr am Oxygen Sensor Heater (Engine 103 Model124)
W iring diagram oxygen sensor he ater
Engine 103 model124@ 0 0@ ®

Mercedes-Benz
' j'x2
t:O.
·-
,,
,, t
1)
,___ _ _ __ ___¡ l
W'IO rt
~~HHlilliliJHWt.
r·=·<D·=~~~:~I
u LI
N3
P01·04tn·.$-1
F1 Eleclrical centre N3 KE lnj edion S)'$1em control Lllil

G3l2 Heated oxygen sen~r N16J4 Fuel p ump and klckdown c:ut-off relay
G312X 1 P1ug connedion, oxygen sensor heallngcol S2J1 lgnklon staJ1er swttoh
G312X 2 P1ug conneálon, oxygen san~r $1gnal W3 Ground, al front lofl wheelhouse Qgnitlon coi!)
W10 Balt&lY ground
1<35 Oxygen sansor relay
Fig. 179: Wiring Diagram Oxygen Sensor Heater (Engine 103 Model 201)
Wiring diagram oxygen sensor heater
Enoine
tl
103 model201 @)G)G)@@)
Emissions control system- RA1400KE2G030X{l4-0030)
G. Lambda closed-loop control
A prerequisite for high efficiency of the emissions control system is a highly accurate mixture
composition.
Differences from the stochiometric fuel/air ratio (a =1) can be detected and corrected by means ofthe
control loop formed with the aid ofthe oxygen sensor (G3/2).
The control principie is based on measuring the residual oxygen content in the exhaust.
Mercedes-Benz
D.J 0.1! lO 1.11 u A
A El<tle11stom•s~ons
8 C-cnlrof rango around A=1 (c.atal', st •NJndow)
Fig. 180: FueVAir Ratio Graph
The test sensor used is the lambda sensor (oxygen sensor) which displays a voltage jump exactly when a
stochiometric mixture exists (lambda= l) and thus supplies a signal which indicates whether the mixture is
rícher or leaner than lambda= l .
The stochíometric aír/fuel ratio is the mass ratio of 14.7 kg aír to 1 kg petrol theoretically necessary for
complete combustion. The air index or the air ratio lambda (lambda) indicates the extent to which the
air/fuel mixture actually present differs from that theoretically necessary:
Air mass supplíed
lambda=
Theoretical air demand
The KE control unit monitors the oxygen sensor, amplifies the signa! and calculates from the input
signals the output signal for the electrohydraulic actuator. The current in the case of lambda closed-loop
control fluctuates from approx. -lOto+ lOmA (in the case of engine 116/ 117 approx. 12.5 to + 12.5 mA) .
The lambda closed-loop control is deactivated in the following operating conditions, i.e. open-loop
control exists:
• Oxygen sensor not operating or faulty

• Deceleration mode with decel fu el cut-off
• Fullload operation
• Acceleration enrichment
• When starting engine below +15 oc coolant temperature up to coolant temperature ofapprox. +40 °
Mercedes-Benz
e to 70 oc (depending on version).
• Engines 116, 117: post-start enricbment >O mA (only after starting).
• Engine 103.984
Engine 104 up to 08/89
The lambda control operates in the open-loop mode for a maximum of2 minutes after starting (at
coolant start temperature of20 °C), depending on coolant temperature. After this, the lambda
closed-loop control is enabled.
• Engine 104 as of 09/89
The lambda closed-loop control is enabled once post-start enricbment is completed (a maximum of
11 O seconds at coolant temperature of +20 °C) and a coolant temperature of 50 oc
is reached.
• Engine 119
Lambda closed-loop control is enabled once post-start enrichment is completed (a maximum of 120
seconds at coolant temperature of + 20 °C) and a coolant temperature of 55 oc
is reached.
Testing, adjusting lambda closed-loop control
The lan1bda test signal is produced from the oxygen sensor signal in the KE control unit. This enables the
fueVair mixture to be assessed and adjusted, ifnecessary (see Diagnosis Manual Engine Volume 1).
The lambda test signal from the KE control unit, contact 23, is a square-wave voltage the on/off ratio of
which is measured as a percentage with the lambda control tester between contact 3 ofthe diagnostic
socket/terminal block TD (XII) and ground.
Mercedes-Benz
JI
~
o
J.
DIT
: Xfl P01a«~-~
L---·--·--·--·--------·--·-----·--·--·--·--·--·--·--·--·---~
:
N3 K = C(}J'IÍfOI unEt {25-oln)

l 1 11DC sensot
X 11 Oiagnos5c s.o.cl<.e'tl:crm nal b'cdc:, 'xmriinal TO
X2óf1 Oll~mo-del201 p ug caruw&...on, heaó':amo ha:rflass (1-
Fig. 181: Emissions Control System Circuit Diagram
Engines with fault memory
Engines 102, 103, 116,117
The KE control unit outputs to contact 23 not only the lambda test signal but in addition the pulse signal
for the fault memory. The lambda test signa! is output on a priority basis ( exception: national version
~) .
In order to initiate the pulse output of the fault me mory, the start button on the pulse counter must be
pressed accordingly.
National version ~
The pulse signa! ofthe fault memory is output on a priority basis. To adjust the lambda closed-loop
control, the KE control unit must first of al! be switched over to onloff ratio output.
The switchover is performed with the pulse counter.
On California version the switchover can also be performed at the push-button switch of the test coupling
for diagnosis (Xl l /4).
Mercedes-Benz
Fig. 182: Locating Push-Button Switch Of The Test Coupling For Diagnosis
Engines 104, 119
The KE control1mit (55-pin) outputs the lambda test signal to contact 30. The pulse output ofthe fault
memory is passed to contact 7.
N3 I<E corúol mt {55-pm)

l1 T0C WllSOl
U2 Vald lor Ca.lifoma
X11 Otegnos!Jc sod<e!ltommalblock, toomnallD
X1 1f4 Test tot.Cllng for ~osas, pulse OOpt.t
(cortaá3)
X11f4s1 SNtálwlhlED, CaSfom¡a
Z7 COilll&dOJ s!-oave, telTT1JlBI87E, fe&dfrom Oll8f\Oiage
ptetecbon ralay
Fig. 183: Emissions Control System Circuit Diagram (Engines 104, 119)
EXHAUST MANIFOLD MODIFIED- BT14.10-P-0001-01A
ENGINE 120.980 ## as of 017400 as of 1.11.92,

Mercedes-Benz
120.981 ##as of 001400 as of 1.10.92

Engine LHS Transmission Engine Engine Production Production Nature and Reference/Remarks
RHS end end period as period up reason for
no. as no.up of to modification
of to
120.980 017400 LI L92
120.981 001400 1.10.92
Since October 1992 the 4- 6 and 10 - 12 cylinder exhaust manifolds have been provided with an air gap
insulation between the outer and inner pipe as a phased-in measure_ The previous insulation is discontinued.
BOLTS OF EXHAUST MANIFOLD MODIFIED- BT14.10-P-0002-01A
ENGINE 119.960 ##as of021570 as of 1.7.91,
119.970 ## as of002486 as of1.7.91,
119.971 ## as of 001049 as of 1.7.91,
119.974 ## as of001173 as of1.7.91,
119.975 ## as of 000018 as of 1.7.91

RHS end no. end no. period as period reason for
119.960 021570 01.07.91
119.970 002486 01.07.91
11 9.97 1 001049 01.07.9 1
119.974 001173 01.07.91
119.975 000018 01.07.91
Right exhaust manifold illustrated

Mercedes-Benz
1 l.ong bob wftt>siDcvo
2 SI!Orr ootrs
Fig. 184: ldentifying Bolts Of Exhaust Manifold Modified
Since about 07/91 only 3 long bolts with sleeve and 8 short bolts without a sleeve have been used for attaching
each exhaust manifold.
OJ
When performing repairs, this type of attachment can also be installed on models manufactured prior to this
date.
MATERIAL OF EXHAUST MANIFOLD MODIFIED- BT14.10-P-0003-01A
ENGINE 119.970 ##as of 028099 as of 1.9.92,
119.971 ##as of 013709 as of 1.9.92,
119.972 ##as of 000996 as of 1.9.92,
119.975 ##as of 007805 as of 1.11.92,
119.974 ##as of 006916 as of 1.11.92
Cylinder 1
ENGINE 119.970 ##as of 028204 as of 1.9.92,
119.971 ##as of 013804 as of 1.9.92,
119.972 ##as of 001072 as of 1.9.92,
119.974 ##as of006917 as of1.11.92,
119.975 ##as of 007843 as of 1.11.92
Cylinder4
ENGINE 119.970 ## as of 013293 as of 1.1.92,

Mercedes-Benz
119.971 ##as of 006319 as of 1.1.92,
119.974 ## as of 003525 as of 1.2.92,
119.975 ##as of 002393 as of 1.2.92
Cylinder 5
ENGINE 119.970 ## as of 013501 as of 1.1.92,
119.971 ## as of 006420 as of 1.1.92,
119.974 ## as of 003622 as of 1.2.92,
119.975 ##as of 032185 as of 1.2.92
Cylinder 8

11 9.970 028099 01.09.92 Cylinder 1
11 9.97 1 013709 01.09.92 Cylinder 1
119.972 000996 01.09.92 Cylinder 1
11 9.974 006916 OL 11.92 Cylinder 1
119.975 007805 01.11.92 Cylinder 1
119.970 028204 01.09.92 Cylinder 4
11 9.97 1 013804 01.09.92 Cylinder 4
119.972 001072 01.09.92 Cylinder 4
11 9.974 006917 01.11. 92 Cylinder 4
11 9.975 007843 01.11. 92 Cylinder 4
11 9.970 013293 01.01.92 Cylinder 5
11 9.971 006319 01.01.92 Cylinder 5
119.974 003525 01.02.92 Cylinder 5
119.975 002393 01.02.92 Cylinder 5
11 9.970 013501 01.01.92 Cylinder 8
11 9.971 006420 01.01.92 Cylinder 8
119.974 003622 01.02.92 Cylinder 8
11 9.975 032185 01.02.92 Cylinder 8
The material ofthe exhaust manifold for cylinders 1, 4, 5 and 8 has been modified for cost reasons (previously
grey cast iron Sí Mo 51 , now grey cast iron 40)_Refer to the standard production breakpoints for the dífferent
production breakpoint dates.
Mercedes-Benz
EXHAUST MANIFOLD IN A DOUBLE-WALL DESIGN- BT14.10-P-9404-01G
. /Mod"fi
P ro d uction b rea k(pomt • 1cationsIN ew fieat ores
Engine LHS Transmission Engine Engine Prod, Prod, Nature and Reference!Remarks
RHS endno. end no. lperiotl lperiotl reasonfor
aso/ up to aso/ up to modification
104 l.l.94
111 ~Model year 1995
Left.tla.nd flg., engln•l11 @¡)

model )'l>ar1995
Rlght-hand flg. engine1CM
Fig. 185: Identifying Left And Right Exhaost Manifold
In arder to reach the operating temperature more quickly, an exhaust manifold in a double-wall design
(insulated by an air gap) is installed.
Modified exhaust nuts are to be used for installation
SPACER RING OF BELT PULLEY- BT14.30-P-0001-01A

Engine LHS Transmission E ngine Engine Prod. Prod. Nature and Refer ence/Remarks
as of up to as of up to modification
119.970 004377 1.8.91
119.971 001819 1.8.91
119.974 001603 1.8.9 1
120.980 003432 1.8.9 1
A spacer ring (arrow) has been installed in front of the bush in the belt pulley as a phased-in measure as of
08/9 1; previously without spacer ring.
Mercedes-Benz
r
El
A Ptctllous vcrslon ~
8 PrcJC nt vcn;on """'
CJ ~
A 11
m m
~
. ...
~ .
lt'1~.0t
Fig. 186: Locating Spacer Ring
MATERIAL OF AIR PUMP CARRIER MODIFIED- BT14.30-P-0002
Material of air pump carrier modified - BT14.30-P-0002-01A
ENGINE 119.970 ##as of002949 as of 1.7.91,
119.971 ##as of 001289 as of 1.7.91,
119.972 ##as of000018 as of1.7.91,
119.974 ##as of 001330 as of 1.7.91,
119.975 ##as of 000038 as of 1.7.91,
120.980 ## as of 000667 as of 1.5.91

119.970 002949 1.7.91
119.971 001289 1.7.91
119.972 000018 1.7.91
119.974 001330 1.7.91
119.975 000038 1.7.91
120.980 000667 1.5.91
Air pump carrier since 05/91 or 07/91, respectively, dye casting; was sand casting.
Material of air pump carrier modified - BT14.30-P-0002-01B
ENGINE 119.970 ##as of 013434 as of 1.1.92,
119.971 ##as of 006370 as of 1.1.92,

Mercedes-Benz
119.974 ## as of 003002 as of 1.1.92,
119.975 ##as of 001625 as of 1.1.92

119.970 013434 01.01.92
119.970 013434 01.01.92
119.970 013434 01.01.92
119.971 006370 01.01.92
119.974 003002 01.01.92
119.975 001625 01.01.92
Since 01/92 a modified material has been used for the air pump carrier (GD AL SI 10 MG, was GD AL SI 9
CU3); in addition, the ribs have been reinforced_
FIT WASHER OF AIR PUMP ATTACHMENT MODIFIED- BT14.30-P-0003-01A
ENGINE 119.970 ##as of 023574 as of 1.6.92,
119.971 ##as of 010680 as of 1.6.92,
119.974 ## as of 005381 as of 1.6.92,
119.975 ##as of 005114 as of 1.6.92
STANDARD PRODUCTION BREAKPOINTS/MODIFICATIONS/1\TEW FEATURES

119.970 023574 01.06.92
119.970 023574 01.06.92
119.970 023574 01.06.92
119.971 010680 01.06.92
119.974 005381 01.06.92
119.975 005114 01.06.92
Since 06/92 a modified fit washer has been used for attaching the air pump to the carrier.
This reduces the instaUatíon clearance and avoids the carríer fracturíng_
Mercedes-Benz
DIAMETER OF AIR PUMP BELT PULLEY MODIFIED- BT14.30-P-0004-01A
ENGINE 119.975 ## as of 000095 as of 1.9.91,
119.974 ##as of 001710 as of 1.9.91,
119.970 ##as of 006248 as of 1.9.91,
119.971 ## as of 002731 as of 1.9.91
STANDARD PRODUCTION BREAKPOINTS/MODIFICATIONS/NE W FEATURES

119.975 000095 01.09.91
11 9.974 001710 01.09.91
11 9.970 006248 01.09.9 1
119.970 006248 01.09.91
119.97 1 002731 01.09.91
Since 09/91 the diameter ofthe air pump belt pulley has been modified (0 104 mm, was 0 88.5 mm).
AIR PUMP DISCONTINUED- BT14.30-P-9404-01D
ENGINE 104.94 /99 as of 1.1.94
except@) 0 ® 0 ~ 0®
PRODUCTION BREAKPOINT/MODIFICATIONS/NEW FEATURES

Engine LHS Transmission Engine Engine Prod. Prod. Nature and Reference!Remarks
except®0®
104.94 1.1.94
0~0®
except®CD®
104.99 1.1.94
0~0@
As a result of the rapid heating up of the catalytic converter the air pump has been discontinued since January
1994 with the exception of the following national versions:
Mercedes-Benz
1990-2002 ENGINE Fuel System- 129 Chassis
1990-2002 ENGINE
Fuel System -129 Chassis
BASIC KNOWLEDGE
FUEL PUMP ASSEMBLY OVERVIEW- GF47.20-P-0025-02A
Engines 104.94/99, 111, 112.910/920/921/922/923/940/941/ 942/943/944/945/972/973/975,

113.940/941/948/960/961/962/963/966/986/991/992, 119, 120, 137, 166, 272, 273, 275, 285
S urvey offiue1pumps
Production
Number of period (phased-
Model Engine: pumps in) Pump designation
124 except station wagon 104.94/99, 2 up to 1/95 Bosch: O 580 254
119.974/75 950
Pierburg: E2T
124 station wagon 104.94/99' 111 2 (pump l only Bosch: O 580 254
Bosch possible 950
because of flxture) Pierburg: E2T
124 except station wagon 104.94/99, 1 as of 11/94 Pierburg: E3L
119.974/975
124 111 1 Bosch: O 580 254
950
Pierburg: E2T
124 119 1 Down2/95 Pierburg: E3L
124.040/060 except ~ 111.940 1 Bosch: O 580 254
124.022/042/062 except 111.960 950
~
124.079/082 except ~ 111.960 2 Bosch: O 580 254
950
124~ 111 2 Bosch: O 580 254
950
129 104.943/991 , 119, 2 up to 08/94 Bosch: O 580 254
120 950
Pierburg: E2T
129 104, 119, 120 1 Down09/94 Pierburg: E3L
129 112, 113 1 Pierburg:
7.21960.04
140.0 104.990, 119.97, 1 up to 08/94 Bosch: O 580 254
120.980 950
Pierburg: E2T
140.0 104, 119, 120 1 Down09/94 Pierburg: E3L
Mercedes-Benz
1990-2002 ENGINE Fuel System - 129 Chassis
163.136 111 .977 1 Down04/98 Pierburg: E3-SS

163 . 154~ 112.942 1 Down 10/97 Pierburg: E3-SS
168.031/033 166 1 Pierburg: E3S-F
170.435 111 1 Bosch: O 580 254
950
170.445/447 111 1 Pierburg: E3L
202 except 202.024/025 1 Pierburg: E3TS
and~
202.024/025 1 Pierburg: E3L
202~ 104, 111 2 Up to model year Bosch: O 580 254
1993 950
Pierburg: E2T
202~ 104, 111 1 As of model year Pierburg: E3TS
1994
202 112.910/920 1 Pierburg: E3TS
208.335 111.945 1 Pierburg: E3TS
208.347 111.975 1 Pierburg: E3L
208.365/465 112.940 1 Pierburg: E3TS
210 111 1 Bosch: O 580 254
950
210 104, 112.921/941, 1 Pierburg: E3L
119
210 113.940 1 Pierburg: E3TL
210 111.947 1 Pierburg: E3L
215,220 112, 113 except 1 Pierburg:
113.986/991 7.28143.00
215,220 137.970 1 Pierburg:
215,220 113.991 1 Pierburg:
7.00240.00
Pierburg: E3L
XXL
215,220 113.986 1 wíth pluggable Pierburg:
connections 7.28143.00
215,220 113.986 1 with screwable Pierburg:
connections 7.21960.04
215,220 275 1 Pierburg:
7.28195.01
230 112,272 1 Pierburg:
7.28143.02
230.474 113.992 1 Pierburg:
7.00228.00
230 113.963,273 1 Pierburg: E3L
Mercedes-Benz
230.476 275 1 Pierburg:

7.28195.01
240 285 1 Pierburg:
7.28143.00
463 112.945 1 Pierburg: D-
722156.00
463 113.962 1 Pierburg: D-
722156.00
PURGE CONTROL VALVE, LOCATION/TASK/DESIGN/FUNCTION- GF47.30-P-4030L
MODEL 124
MODEL 129
MODEL 140, 163
MODEL 170 with ENGINE 111,112 (except, 112.96)
MODEL202
MODEL208
MODEL 209 with ENGINE 112, 113
MODEL 210
MODEL 215 with ENGINE 113,137 (except 113.99)
MODEL 220 with ENGINE 112,113,137 (except, 113.99)
MODEL 230 with ENGINE 113 (except 113.99)

Mercedes-Benz
Y5&'1 PuJVe c.ontrol vlllve

Y58/2 lell purge control v•Jv• (englne 120)
Y5&13 RlghtpuJVe control va!ve (ong{ne120)
Y5811
Y58l2
B toaefivatedeharcoa/CIInlolor
e to engme (ldantiflt:ation • onglne l nspéetlOlJi
YS8I3
Fig. 1: ldentifying P urge Control Valve Design/Function
Purge control valve Model 124 GF47.30-P-4030-01C

position Model140 GF47.30-P-4030-01S
Modell63 GF47.30-P-4030-01GH
Modell68 GF47.30-P-4030-01GC
Modell 70 GF47 .30-P-4030-0 1G
Model202 GF47.30-P-4030-0IE
Model 203, 209 GF47.30-P-4030-0IP
Mode1210 GF47.30-P-4030-01F
Model211 GF47.30-P-4030-0l T
Model215 , 220 GF47.30-P-4030-01L
Model230 GF47.30-P-4030-01R
Purge control valve task Opening and closing the
connecting line between
the activated charcoal
canister and the intake
manifold.
Purge control valve Electric swítchover valve
design with two line terminals
and one 2-pin plug
connection.
Purge control valve GF47.30-P-4030-02KE
function
SAFETY PRECAUTIONS
RISK OF EXPLOSION CAUSED BY FUEL IGNITING. RISK OF POISONING CAUSED BY
Mercedes-Benz
INHALING AND SW ALLOWING FUEL AS WELL AS RISK OF INJURY TO EYES AND SKIN
CAUSED BY CONTACT WITH FUEL.- AS47.00-Z-0001-01A
No tire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked
containers. Wear protective clothing when handling fuel.
Potential risks
Risk of explosion, poisoning and injury
Fuels are highly inflammable and toxic if inhaled. Fuel may cause damage to skin. For example, skin is
degreased when it comes into contact with gasoline fuel. Fuel vapors are explosive, invisible and spread out at
floor leve!. Th.is vapor is poisonous when inhaled and has an anesthetizing effect in high concentrations.
Safety precautions/instructions
• Observe the national safety precautions and regulations.

• No fire, sparks, open flames or smoking.
• Ensure the work place is adequately ventilated.
• Never drain or pour in fuels over assembly pits.
• Store drained fuel in a suitable and sealed vesseL
• Immediately eliminate any fuel which has flowed out
Conducting work on a vebide witb open flames
( e.g. welding etc.)
• Before carrying out this work, remove relevant parts of fu el system and seal open fuel lines with plugs.
First aid measures
• Clean afiected skin areas with water and soap.

• Change affected clothing as qu.ickly as possible.
• Iffuel gets into the eyes, rinse eyes with water immediately and calla doctor ifnecessary.
TESTING & REPAIR

REMOVING AND INSTALLING FUEL COOLER- AR47.00-P-3061F
ENGINE 120
Mercedes-Benz
Fig. 2 : ldentifying F uel Cooler

item, etc.
Release through service valve at
[g] fuel raiL See
Fuel pressure
Diagnosis Manual Engine,
Volume 2, Index 3.2
@ Fig.
~
@ ~
4
[g]' drain (observe recycling
Air conditioner
instructions)
[g]' Check refrigerant level of a ir conditioner/automatic see RI Climate Control Model
climate control, adjust to correct level 140 Op. no. 83-8312
75 Fuel cooler remove, install
Fig. 3: ldentifying Tester (103 589 00 21 00)

Mercedes-Benz
1t9 589 04 63 00
Pr& Silllll h O!II
TESTING AND REPAIR WORK: PASSENGER CARS: FUEL SYSTEM- AR47.00-Z-9104AB
ENGINE 104
Removing and ENGINE 104, 111 , 119, 120... AR47.20-P-

installing fuel 5713B
pumps
Removing and ENGINE 104.941 /942 /943 /944 /991 /992 /994, AR47.20-P-
installing fuel 111.920 /940 /941 /944 /960 /961 /974 /975 5713D
pumps
installing check 5820D
valve for fuel
pump
TESTING AND REPAIR WORK: PASSENGER CARS: FUEL SYSTEM- AR47.00-Z-9113AB
ENGINE 113
Remove!install fuel filter ENGINE 113.989, 271 , AR47.20-P-5510V

272 in MODEL 171
Removing, instaHing fuel ENGINE 112, 113... AR47.20-P-5710AV
pump
Remove/install fuel pump ENGINE 112, 113, 137, AR47.20-P-5710MA
275 ...
Remove/i.nstall fuel pump ENGINE 113, 275. .. AR47.20-P-5710MB
Remove/i.nstall fuel pump ENGINE 113... AR47.20-P-5710QV
Remove/install fuel pump ENGTNE 112, 113... AR47.20-P-5710QVS
Remove/install fuel pump ENGINES 112, 113, 272, AR47.20-P-5710R
273 in MODEL 230
ENGINES 275.951 /954
in MODEL 230
Removing, installing fuel ENGINE 272.967 in AR47.20-P-5710RT
pump MODEL 251.065 /165
Mercedes-Benz
ENGINE 113.97 1 in
MODEL 251.075 /175
Remove/ínstall fuel pump ENGINE 113.989, 27 1, AR47.20-P-57lOV
272 inMODEL 171
Remove/install fuel ENGINE 112, 113 ... AR47.20-P-5713A
pumps
Remove/install fuel ENGINE 111, 112, 113 ... AR47.20-P-5713GH
pumps
Remove/ínstall fuel ENGINE 113.990 in AR47.20-P-5713TK
pumps MODEL 211.076 /276,
219.376 ENGINE
156.983 in MODELS
21 1.077 /277,219.377
Remove/install fuel filter ENGINE 111, 112, 113 ... AR47.20-P-5714GH
with pressure regulator
Removelinstall pressure ENGINE 113.992 in AR47.20-P-5716R
regulator MODEL 230.474
ENGINE 113.995 in
MODEL 230.472
Remove/install fuel pump ENGINE 113.992 in AR47.20-P-5717R
control unit MODEL 230.474
ENGINE 113.995 in
MODEL 230.472
Remove/install fuel pump ENGINE 113.988 in AR47.20-P-7000AC
andl fuel tank sensor MODEL 203.076 /276
ENGINE 156.982 in
MODEL 209.377 /477
Remove/install fuel pump ENGINE 113, 156,272, AR47.20-P-7000GZ
andl fuel tank sensor 273, 629, 642 in MODEL
164
Remove/install fuel pump ENGINE 113,272, 156, AR47.20-P-7000RT
andl fuel tank sensor 642 in MODEL 251
Remove, ínstall fuel ENGINE 112, 113, 271 , AR47.20-P-7000TA
pump and fuel tank 272, 273 (except,
sensor 113.990) inMODEL 211
Remove/install fuel pump ENGINE 113, 156, 272, AR47.20-P-7000TX
andl fue) tank sensor 273 in MODEL 219
Removing and ínstalling ENGINE 112, 113 ... AR47.25-P-0008GH
the fuelline from the fuel
filter to the fuel
distribution strip
Removing and installing ENGINE 112, 113 ... AR47.31 -P-8022A
safety valve
Removing and installing ENGINE 112, 113, 119... AR47.31-P-8022B
safety valve
Mercedes-Benz
Removíng and installing ENGINE 113, 137... AR47.31-P-8022M

safety valve
Removíng, installing ENGINE ll2, 113 ... AR47.31-P-8023A
shutoffvalve
Remove shutoffvalve, ENGINE 112, 113, 119... AR47.31-P-8023B
install
Removíng, installing ENGINE 111, 112, 113 ... AR47.31-P-8023D
s hu toff valve
Remove/install shutoff ENGINE 111 , 112, 113 ... AR47.31-P-8023GH
val ve
Removing, installing ENGINE 113, 137... AR47.31-P-8023M
shutoff valve
Remove/install fuel tank ENGINE 112, 113 ... AR47.50-P-0050GH
pressure sensor
Remove/install fuel tank ENGINE 113, 156, 272, AR47.50-P-0050GZ
pressure sensor 27 3 in M ODEL 164 with
CODE (494) USA
vers10n
Remove/install fuel tank ENGINE 113, 156,272 AR47.50-P-0050RT
p ressure sensor in MODEL 251 witb
CODE (494) USA
verswn
TESTING AND REPAIR W ORK: PASSENGER CARS: FUEL SYSTEM- AR47.00-Z-9119AB
ENGINE 119
Removing and installing ENGINE 104, 111 , 119, AR47.20-P-5713B

fuel pumps 120...
Removing and installing ENGINE 119.97, AR47.20-P-5713F
fuel pumps 120.980/981
Removing and installing ENGINE 119.97, AR47.20-P-5820F
check valve for fuel 120.980/981
pump
Removing and installing ENGINE 112, 113, 119... AR47.31-P-8022B
safety valve
Remove shutoff val ve, ENGINE 112, 113, 119... AR47.31-P-8023B
install
TESTING AND REP AIR WORK: P ASSENGER CARS: FUEL SYSTEM- AR47.00-Z-9120AB
ENGINE 120
Removíng and ínstalling fuel cooler ENGINE 120 H I AR47.OO-P-3061F

Mercedes-Benz
Removing and installing fuel pumps ENGINE 104, 111 , 119, 120... AR47.20-P-5713B
Removing and installing fuel pumps ENGINE 119.97, 120.980/981 AR47.20-P-5713F
Removing and installing check valve for fuel pump ENGINE 119.97, 120.980/981 AR47.20-P-5820F
TESTING AND REPAIR WORK: PASSENGER CARS: FUEL SYSTEM- AR47.00-Z-9129AA
MODEL 129
AR47.10-P-
Empty 1 fill fue) tank MODEL 124, 129, 140, 170,210,215,220, 461, 463 ...
4001B
Draining and filling fuel MODEL 129, 170, 210 with CODE (494a) USA version with AR47.10-P-
tank CODE (808) Model year 1998 4001F
AR47.10-P-
Remove/install fuel tank MODEL 124, 129, 140
4100D
MODEL 129
fuel tank 4100FA
MODEL 129
fuel gauge sensor 7000FA
Removing and installing MODEL 124.0, 129, 140.0, 170, 202.0, AR47.10-P-
guide funnel 210.03 /04 /05 /06 /07 /08 /23 /24 /26 /27 /28 /663,208 7571D
Removing and installing MODEL 129 with CODE (491) U.S. version with CODE (808) AR47.30-P-
activated charcoal filter Model year 1998 8212B
AR47.30-P-
activated charcoal MODEL 124, 129, 140, 170, 202, 208, 210 ...
8212D
canister
AR47.30-P-
activated charcoal MODEL 129 with ENGINE 119, 120
8212FA
canister
DRAINING AND FILLING FUEL TANK- AR47.10-P-4001F
MODEL 129, 170,210 with CODE (494a) USA version with CODE (808) Model year 1998
Shown on model 21 O
Mercedes-Benz
012 OrMnhou
014 Conncctor
Oh! Ctomp
51 Fue/ suotion holO
Fig. 5: ldentifying Drain Hose, Connector, Clamp And Fuel Suction Hose
® Risk of explosion from N o fire, naked flame or AS47.00-Z-0001-01A

ignition. Risk of smoking
poisoning from inhaling Pour fuels only into
and swallowing fueL suüable and appropriately
Risk of injury as a result marked containers
of fu el coming into W ear protective clothing
contact with skin and when handling fuel
eyes
1 Remove cover
2 Pinch off fu el suction ® Fig. 7
hose (53)
3 Detach fuel suction hose
(53)
4 Fit on drain hose (012) ® Fig. 6
together with connector [g] The vehicle must be
(014) connected to the safety
tank by a grotmd cable in
order to avoid static
charging
5 Rernove cap at fuel filler
neck
6 Drain fue] into safety
tank
Mercedes-Benz
210 589 Ot 91 00
Fig. 6: ldentifying Connector (210 589 01 91 00)
Fig. 7: ldentifying Clamp (000 589 40 37 00)
169589 00 9!'J 00
Fig. 8: ldentifying Suction Hose (168 589 00 90 00)
REMOVE/INSTALL FUEL TANK- AR47.10-P-4100
Remove/install fuel tank- AR47.10-P-4100D
MODEL 124, 129, 140
Shown on model124 sedan/coupe4

Mercedes-Benz
21511 0-rlng
.SJ Fuclho:sconthcsvctlonsldcwlth
connocting pipo
74 Fuol rcturn bas-e
751! Sounct ln5Uio!lon strip

7011 Vcnt lino
Fie. 9: ldentifyine Fuel Tank Components (Model 129 Sedan/Coupe4)
n:::r-sr
Removellnstall
0
No fue, sparks, naked flames or
~sk of ex?losion caused by fuel igniting,
smoking. Pour fuels only into suitable
nsk of ~msoning caused by inhaling and AS47.00-Z-
OJ swallowmg.fuel as well as risk of injury to
and appropriately marked containers.
0001-0lA
Wear protective clotlúng when
eyes and skin caused by contact with fuel.
handling fuel.
AR47.l0-P-
1 Empty fue] tank, fill.
4001B
@) *BF47.10-P-
1001-01A
Remove trim panel of fuel tank as well as
2
left and right side trim panel of trunk
Dismotmt fuel hose on the suction side
3 (53), fuel return hose (74) and vent line
[gj Collect remaining fue), seal
(76/1) connections
@ Fig. 10
*BA47.10-
~ P-1004-01B
4 Take out fuel tanks (75) Model ?
AR47.10-P-
Model l24.008/02/032/052
4100-01DA
AR47.10-P-
Model124.088/092
4100-0lDB
AR47.10-P-
Modell24.066
4100-0lDC
Mercedes-Benz
AR47.10-P-
Modell29
4100-01DD
AR47.10-P-
Model 140
4100-01DE
If necessary replace. Stick on sound
5 Check sound insulation strip (75/5)
insulation strip (self-adhesive).
6 Remove fuel strainer (26) Clean and check reusability
[l]
[g] The splash bowl in the fuel tank is *BA47.10-
secured against turning with 2 pins. It P-1001-0IB
is attached together with the fuel
strainer (26)
7 Re place 0-ring (26/1 ) Oil to facilitate installation
0847.10-P-
9 Dispose of fuel tank
0001-01A
[l] FUEL TANK

Number Designation M odel M odel M odel
124.008/019/022/028/029/031/032/040/042/051/052/091 124.079/082/088/092 124.03
BA47.10- Fuel
P-1001- strainer in Nm 40 40 40
OlB fuel tank
Self-
B A47. 10- locking
P-1002- nut to U Nm - 30 -
01B raíl offuel
tank
Fuel hose
with
BA47.10-
connectionN
P-1004- fi. m 30 30 30
lttmg to
01B
fu el
strainer
[l] FUEL TANK

Number Designation Model129 Model140
BA47.10-P-100 1-01B Fuel strainer in fuel tank N m 40 40
BA47.1 0-P-1 004-0 lB Fuel hose with connection fitting to fuel strainer N m 30 30
®FUELTANK
Number Designation Model Model Model Model
124.008/019/022/028/029/032/040/042/052 124.07/08/09 124.034/036124
witb
Mercedes-Benz
large
tan k
capacit
eo de
915
BF4 7.1 0- Fuel Total L. 70 72 90 90

capact.ty 1ters
P-1001 - tank ~--~---+--------------------------~------~------~-----
OlA capacityReserye Liters 99 11 11.5
capactty
®FUELTANK
Number Designation Model Model Model140 without Model140 witb
124.06 129 code 282a or code code 282a or code
308 308
Total
Liters 70 80 100 90
BF47.10-P- Fuel tank capacity
~~~------+------+----~--------------~------------~
1001-01A capacity Reserve
Liters 11 10 12.5 12.5
capacity
~
000 5S9 1t 03 00
\.. ./
Rlng l'.':'llndl SOCt:ll!
Fig. 10: Identifying Ring Wrench Socket (000 589 71 03 00)
Removing fucl tank- AR47.10-P-4100-01DD

Mercedes-Benz
26 Fuol str~lnor
2tlll O ·rln¡¡
11 Covor
14 Rcrum hose
75 Fuct t•.ntt
7e Vcnr v•tvc
Fig. 11: Identifying Fuel Tank Remove/Install Components (Model129)
Fig. 12: Identifying Pusb Back Cover And Remote Control Module
---c::L o o r
Fi¡:. 13: Locating Plastic Wed¡:es

Mercedes-Benz
Fig. 14: Pulling Fuel Tank
l_ Remove, install fuel gauge sender.

2. Remove partition.
3_ Loosen clip to push back cover (71 ).
4. Remove infrared remote control module (N54).
5. Remove vent valve (76) and fuel retum hose (74). Todo this, detacb and bang exhaust system from tbe
rubber rings. Remove left drive sbaft at inner coupling flange.
6. Remove fuel tank (75). If necessary lever out from the opening using plastic wedges (arrow) or similar.
Pull fuel tank: complete!y back to the left and take out at filler neck
7. Install in reverse sequence. Ifthere is insufficient space, remove fuel strainer (26) and install from below.
Replace 0-ring (26/1).
Removing and installing fuel tan!k- AR47.10-P-4100FA
MODEL 129
Sbown on model129.076
Mercedes-Benz
25 Fuctotr~lnct
Wl 0 -rlng
$3 Fue/ hos,c • t suct lon e nd wlth

Qonnccrlon tlrllng
11 COVct
14 Fuet tctutn hose
7S Fuot~nll
151~ Sound-df>•donfrl¡¡ strip

1611 Vont pipo
Fig. 15: ldentifving Fuel Tank Remove/lnstall Components (Shown On Model129.076)
Fig.16: Identifying Push Back Cover And Remote C()ntrol Module
-c::::L C) o (
Fig. 17: Locating Plastic Wedges

Mercedes-Benz
~BT
CD
@ Risk of explosion Observe accident prevention regulations!
Carefully pump out fuel so that no fuel remains in
l Empty fu el tank (7 5)
tank
*BF47.10-P-
Observe capacity
1001-01A
Remove fuel tank trim and
2 also left and ríght side trim
oftmnk
Take off fuel hose at
suction end (53), fuel
3
retum hose (74) and vent
® Collect remaining fue~ seal connections
pipe (76/l)
[lJ *BA47.10-P-
1004-01B
@ Fig. 10
Remove fuel gauge AR47.10-P-
4
sender, install 7000FA
5 Remove partition
6 Push back cover (71) Slacken clip for this step
Remove control module of
7 infrared remote central
locking (N54)
Take offvent valve (76)
8 Detach exhaust system at mbber rings for tb.is step
and fu el return hose (74)
Disconnect left driveshaft AR35.30-P-
9
at inner connecting flange 0620A
[g] Use plastic wedges (an ow) or similar, if
10 Take out fuel tank (75) necessary, to lever out of opening. Pull fuel tank in
car fully to the rear left and take out at the filler neck.
Mercedes-Benz
Examine sound-deadening Re place if necessary. Stick on sound deadening strip

11
strip (75/5) (self-adhesive)
~ Clean and check whether it can be re-used
[g] The splash pot in the fuel tank is secured against
12 Remove fuel strainer (26) turning by 2 bolts. It is attached to the fuel strainer
(26). If insufficient space is available, install fue)
strainer from below after inserting the fuel tank.
*BA47.10-P-
~ 1001-01B
13 Replace 0 -ring (26/ l) Oil to facilitate installation
~FUELTANK
Number Designation Model129
BA47 .10-P-1 00 1-0l B Fuel strainer in fuel tank Nm40
BA47.1 0-P-1 004-0 lB Fuel hose with connection fitting to fuel strainer Nm30
@FUELTANK
Number Designation Modell29
Total capacity liters 80
BF47 .1 0-P-1 00 1-0lA Tank capacity
Reserve capacity liters 10
000 599 7t 03 00
Fig. 19: Identifying Box Wrench Socket, Delco R4 And A6 (000 589 71 03 00)
REMOVING AND INSTALLING FUEL GAUGE SENSOR- AR47.10-P-7000FA
MODEL 129
Mercedes-Benz
A Flaat and I!!V«·!ype sensor

B trmmlan hAle sem«
1!4 Fuel gil'l.lge semllf
4814 GaSket
Fig. 20: Identifying F u el Gauge Sensor Components (1 Of 2)
1 Solt ll>p compiirlmontcovcr
Fig. 21: Identifving Fuel Gauge Sensor Components (2 Of 2)
~BT
CD
No frre, sparks, naked flame and
Risk of explosion from fu el igníting, risk of smoking Pour fuels only into
poisoning from inhaling and swallowing fu el suitable and appropriately marked AS47.00-Z-
ITJ as well as risk of injury to eyes and skin vessels 0001-0lA
from contact with fue l. Wear protective clothing when
handling fu el
If fuel tank is full, pump out about 8 liters of [g] Except version ~ ( code 491) AR47.10-P-
1
fu el as of09/97 4001B
[g] Version ~ (code 491) as of AR47.10-P-
09/97 4001F
Disconnect connector (arrow) frorn fuel gauge Secure electric leads against
2
sensor (B4) slipping down
3 TTnc::rrPw c;:p::~linP t1::~nPP ::~nrl fnPl P::llWP. c::P.nc::or ltJ * RA.t7.10-P-
Mercedes-Benz
(B4) 1003-0lB
Float and lever-type sensor replaces BT47.10-P-
Lh immersion tube sensor 0001-01A
4 Remove hard top
Close soft top so that it is completely foJded
5 out of soft top compartment ( 1) and the soft
top compartment cover (1) is still open
6 Take out fuel gauge sensor (B4)
8 Replace 0-rings ¡g] Oil to facilitate installation
0CJ FUEL T ANK

Number Designation Modell29
BA47.10-P- 1003-0 lB Sealing flange and fuel gauge sensor on fuel tank N m 40
Pl491
Fig. 22: ldentifying Puller (210 589 01 07 00)
REMOVING AND INSTALLING GUIDE FUNNEL- AR47.10-P-7571D
MODEL 124.0, 129, 140.0, 170, 202.0, 210.03 /04/05/06/07/08 /23/24/26/27/28 /663, 208
4~ Guille funncl
AUOW10 Rlvcts
Fig. 23: Identifving Guide Funnel Components

OJ Risk of explosion from !No fue, naked flame or AS47.OO-Z-0001-01A
ignition. Risk of smoking.
Mercedes-Benz
and swaUowing fu el. suitable aud appropriately

Risk of injury as a result marked contaiuers.
of fu el coming into W ear protective clothing
contact with skin and when handling fuel.
eyes.
Arrows Rivets @ pull out of guide Fig. 24
funnel
~ Ensure no rivets drop
iuto the fuel tank.
They prevent proper
operation ofthe splash
po t (reserve quantity
canuot be used).
45 Guide funnel [g] lnstallation: knock in
rivets with a drift
123 589 05 33 00
Fig. 24: Identifying Extractor (123 589 05 33 00)
REMOVE/INSTALL FUEL PUMP- AR47.20-P-5710MA
ENGINE 112.944 in MODEL 220.065 /165
ENGINE 113.941 in MODEL 220.070/170
ENGINE 113.960 in MODEL 215.375, 220.075 /175 /875
ENGINE 137.970 in MODEL 215.378,220.178/878
ENGINE 113.948 in MODEL 220.083 /183

Mercedes-Benz
ENGINE 113.966 in MODEL 220.084 /184
ENGINE 112.975 in MODEL 220.087 /187
ENGINE 113.991 in MODEL 215.374, 220.074 /174
ENGINE 112.972 in MODEL 220.067 /167
ENGINE 275.950 in MODEL 220.176, 215.376
ENGINE 113.986 in MODEL 215.373, 220.073 /173
ENGINE 275.980 in MODEL 220.179, 215.379
MODEL 215, 220
Shown on MODEL 220
52 Fuo/ /loso ro cn/1fno

53 Fua/ Ju~;lion hoJa
55 Fuo l ffltcr
5$11 Oap ss/ng Nna
so Covcr of fiJO/ pump
~ Ale/ pro.s:surc hose
14 Fue/ rerum lino
111 Fua / pump (FP)
PCU0-2003-02
Fig. 25: ldentifving Fuel Pump Remove/lnstall Components (Shown On Model 220)
Modell29
Mercedes-Benz
52 Flloi/Klso 11> en~nc

5J Fue/ sucrlon /Klso
54 Fllo/1/nc to surJ~mry IINtcr (ror
srationary llaatcr. «>de 221)
55 Fue/ ffltcr
5511 Do¡¡using Nnc
50 Covor of fiJa/ pump
64 Filo/ pr85Suro hou
1~ Filo/ roturn lino
IAJ FP asnml>ly
P&l-10·2001·02
Fig. 26: Identifying Fuel Pump Removellnstall Componeuts {Model129)
n:::r" BT
Remove/Install
CD
Risk of explosiou caused by fuel No fire, sparks, open flames or smoking.
igniting, risk of poisoning caused by Pour fuels only into suitable and
[[] AS47.00-Z-
inhaling and swallowing fue) as well appropriately marked containers.
0001-0lA
as risk ofiujury to eyes and skin Wear protective clothing when handling
caused by contact with fue l. fu eL
Turn key in ignition switch to [g] Vehlcles with Keyless Go code 889:
1 press start/stop button repeatedly until the
position "O".
ignition is switched off.
Release pressure in fuel tank
[gJ At the same time open fuel filler flap
2
and remove cap.
Align vehicle between the columns of the
Risk of death cased by vehicle hydraulic hoist and position the four
ASOO.OO-Z-
IJJ slipping or toppling off of the lifting support plates below the hoist support
0010-0lA
platform. points s pecified by the vehicle
manufacturer.
3 Raise vehicle.
4 Remove cover offuel pump (60)
Pinch off fuel suction hose (53) and
5 ® Clamp Fig. 7
fuel pressure hose (64)
pliers
&oan<~e<! Pinch-off *WH58.30-Z-
1013-02A
Disconnect fuel suction hose (53) and
fuel pressure hose (64) at fuel pump [g] Iustallation : Replace hose clamps.
6
*WH58.30-Z-
&oanaerl Clamping pliers
1011-02A
Disconnect electrical lines at fu el
7 pump
Mercedes-Benz
~ lnstallation : Observe correct seating

of plastic foil on the fuel pump. The
plastic foil must project on both si des of
8 Remove fuel pump
the retaining clamp. Direct contact of the
fuel pump and the retaining clamp can
lead to galvanic corrosion.
GF 47.20-P-
n::rAP Fuel pump assembly overview
0025-02A
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving.
[JJ ASOO.OO-Z-
running. Risk of injury caused by W ear dosed and snug-fitting work
0005-01A
contusions and burns when working clothes. Do not grasp hot or rotating parts.
in engine during starting procedure
Start engine and inspect fuel system
10
for leaks
Fig. 27: ldentifving Clamp (000 589 40 37 00)
Number Designation
WH58.30-Z-1011-02A Clamping pliers
WH58.30-Z-l O13-02A Pinch cock
REMOVING AND INSTALLING FUEL PUMPS- AR47.20-P-57l3
Removing and installing fuel pumps- AR47.20-P-5713B
ENGINE 104.945 /995, 111.921 /942 /943 /945 /946 /947 /970 /973 /974, 119.981 /982/985, 120.982 /983
Mercedes-Benz
52 Fuol prcnuro hoSIJ

5J Fu<>lsuct/on hose
5e l"lasli< sloeve
Fig. 28: Identifying Fuel Pumps Components (Engine 104, 111)
Model210 T-model
/IJ Fuolpump
Fi~. 29: ldentifying Fuel Pump (Model210 T-Model)

IJJ Risk of explosion from N o frre, naked flame or AS47 .OO-Z-0001-01A
ignition_ Risk of smoking_
and swallowing fueL suitable and appropriately
Risk of injury as a result marked containers.
of fu el coming into Wear protective clothing
contact with skin and when handling fueL
eyes.
Arrow Model210 T-model Do uot pinch fu el suction
h ose at elbow
~ ~ Plastic sleeve (56) check, replace if
necessary. The plastic
sleeve must project at
both sides of the bracket
as contact corrosion may
oc cur if there is direct
contact between fuel
Mercedes-Benz
pump and the bracket.

~AP Summary of components GF47.20-P-0025-02A
fuel pumps
52, 53 Fuel suction hose, fuel pinch off
delivery hose
@ Fig. 7
54a, 54b, 59 Cap nut or banjo bolt replace copper sealing
rings (62)
[lJ *BA47.20-P-1001-01A
[lJ *BA47.20-P-1002-01A
[lJ *BA47.20-P-1001-01B
[lJ *BA47.20-P-1004-01B
llJ F uel pump

Number Designation Engine 104, 119, 120
BA47.20-P-1001-01A Banjo bolt of fuel pipe to Nm 27
fuel pump or fu el filter
BA47.20-P-1002-01A Cap nut of fuel pipe to Nm 27
fuelpump
ue pump
BA47.20-P-1001-01B Banjo bolt of fuel pipe to N m 27
fuel pump or fuel filter
BA47 .20-P-1 004-0 lB Cap nut of fu el pipe to N m 27
fuel pump
\.. 0!)0 589 40 37 00

Clamp
Fig. 30: ldentifying Clamp (000 589 40 37 00)
Removing and installing fuel pumps- AR47.20-P-5713D
ENGINE 104.941 /942 /943 /944 /991 /992 /994, 111.920 /940 /941 /944 /960 /961 /974 /975
Shown on model 124 sedan/coupe

Mercedes-Benz
Engine 104
(fue! pump positionetl ahetul of rear axle)
52
5J
$4.t
Fuol dcfolo ry h ose
Fuol suetion liOSo
CliP nut !?
$41> CliP nut
56 l'luric s/eovo
62 Coppor su/lng rfng
05 Sp.tccrl•d¡¡ptu
Fig. 31: ldentifying Fuel Pumps Components (Shown On Model124 Sedan/Coupe)
Model 202, 208 except ~
52 FU<:I dcNVory hose

53 Fuetsuclion hose
S6.t l'luric s/eovo
62 Coppcr su//nJI rfng
66 Dcg•ssl ng hoso
Fig. 32: ldentifving Fuel Pumps Components (Model202, 208 Except)
Model 202, 208 ~

Mercedes-Benz
52 Fuol dcNvo ry h oso

.53 Fuo! J-u<fion hose
.541> c.., nut
se Pl;utic slccva
5V B1mj o oolr
62 Coppcr sullng rfng'
62
~
Fig. 33: Identifying Fuel Pumps Components (Model202, 208)
Loft -ttan d lll u strati on

/.todet 124 T mo<lol
181 Fue 1pu mp

Riunt-'ITI;m d illustu tlon
X36/3 Connec mr. lttol pump
h~rnoss
(2 -plfl) (In trunlt}
Fig. 34: Identifying Fuel Pumps Removellnstall Components (Model 124 T -Model)
MODIFICATION NOTES
Introduction of modífied fuel Model 202.028 C 36 AMG, see operatíon "Installing modified
1.4.97
pump fuel pump"

item,
etc.
Risk of explosion from ignition. Risk No fire, naked flame or smoking.
of poisoning from inhaling and Pour fuels only into suitable and
AS47.00-Z-
IIl swallowing fueL Ris,k of injury as a appropriately marked contaíners.
0001-0lA
result of fu el comíng into contact wíth Wear protective clothing when handling
skin and eyes. fueL
~ Do not pinch fuel suction hose at elbow
Arrow Model 124 T model [g] Modell24 T model always has two fuel
pumps
check, replace if necessary. The plastíc
sleeve must project at both sides of the
~' Plastic sleeve (56) bracket as contact corrosion may occur if
there ís direct contact between the fuel
pump and bracket
Mercedes-Benz
¡g¡' Diagonal strut on right remove, model 208.435/445/447

[l] *BA61.10-
P-1003-01C
Helical spindle pump replaces dual BT47.20-P-
& fuel pump assembly 0001-0lA
~AP Summary of components fuel pumps
GF47.20-P-
0025-02A
53, 52, Fuel suction hose, fuel deJivery hose
Pinch off
66 and degassing hose
@ Fig. 7
54a,
Cap nut or banjo bolt Replace copper sealing rings (62)
54b, 59
[l] *BA47.20-
P-1001-0lA
[l] *BA47.20-
P-1002-0lA
[l] *BA47.20-
P-1001-01B
[l] *BA47.20-
P-1004-0lB
Insert f uel pump with guide into slot of
plastic sleeve and insert the latter into
56a Plastic sleeve
bracket guide. Model 202, 208 only except
~
65 Spacer/adapter Pay attention to installed position
separate in trunk, model 202, 208 only
X36/3 Connector of fu el pump hamess
except~
AR47.20-P-
Install modified fuel pump Model 202.028 C 36 AMG
5713-0lA
BT47.20-P-
Lt Fuel pump modified
0002-0lA
[lJ FUEL PUMP

Number Desiguation Eugines 104, 119, 120
BA47 .20-P-1 001-0 lA Banjo bolt of fu el pipe to fu el pump or fu el filter N m 27
BA47.20-P-1 002-0 lA Cap nut of fuel pipe to fuel pump Nm 27
llJ FUEL PUMP

Number Designatiou Eugine 111
BA47.20-P-1001-0IB Banjo bolt of fuel pipe to fu el pump or fu el filter N m 27
BA47 .20-P-1 004-0lB Cap nut of fuel pipe to fuel pump N m 27
llJ FRAME FLOOR

Mercedes-Benz
Number Designation Model

208.435/445/447/465/470
BA6Ll0-P-1003- Self-locking bolt of cross strut at rear to frame
N m 60
01 C floor
ctaii"Cl
Fig. 35: Identifying Clamp (000 589 40 37 00)
Removing and installing fuel pumps- AR47.20-P-5713F
ENGINE 119.97, 120.980/981
(Fuel pump positioning: in front of rear axle)
$2 Fuol dotlvery hose

JI Fuots.uctlon hoSIJ
S<IJ C oljl nut
&lb C;op nut
56 PIJ..ric sloovo
62 Coppcr sc•l
6S SpJcor olomcnr
Fig. 36: Identifving Fuel Pumps Components (Fuel Pump Positioning: In Front Of Rear Axle)

item,
etc.
@ Risk of explosion Pay attention to accident prevention regulations !
Summ ary of
GF47.20-P-
n::rAP components fuel Engine 119, 120
0025-02A
pumps
Fuel suction hose, fuel
52, 53 pinch off
delivery hose
Mercedes-Benz
@ Fig. 7
Screw spindle pump
BT47.20-P-
A replaces double fuel
0001-0lA
pump unit
*BA47.20-P-
54a, 54b Cap nut llJ Replace copper seals (62) 1002-01A
¡gj Examine, replace if necessary _The plastic sleeve
must project on both sirles of the bracket as contact
56 Plastic sleeve
corrosion may occur if direct contact exists between fue!
purnp and bracket
65 Spacer element Pay attention to installation position
~FUELPUMP
BA47 .20-P-l 002-0 lA Cap nut offuel pipe to fue! pump N m 27
REMOVING AND INSTALLING CHECK VALVE FOR FUEL PUMP- AR47.20-P-5820
Removing and installing check valve for fuel pump- AR47.20-P-5820D
ENGINE 104.942 up to 31.7.94,111.940/960 up to 30.9.94 in MODEL 124.### #1
ENGINE 104.992, 111.940/960 up to 31.1.95 in MODEL 124.### #B
ENGINE 104.943 /991 up to 30.9.94 in MODEL 129
ENGINE 104.944/994 up to 31.8.94 in MODEL 140
ENGINE 104.941, 111.92 /941 /944/945/961 /974/975 up to 31.10.94 in MODEL 202
Sbown on model 124 sedan

Mercedes-Benz
51 F ue/ dcl/tlcry hose
'
53 F ue/ su crlon h ose
.s.l• c.,.nut
62 Coppu sc•llng rlng
62• Coppcr sc•ling rlng
6J Cheoll: v•tve
Fig. 38: ldentifving Check Valve For Fuel Pump Components (Shown On Model124 Sedan)

item,
etc.
Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Pour
poisoning from inhaling and swallowing fuels only into suitable and AS47.00-Z-
IJJ fue l. Risk of inj ury as a result of fu el appropriately marked containers. Wear 0001-01A
coming into contact with skin and eyes. protective clothing when handling fuel.
53, 52 Fue] suction hose, fuel delivery hose pinch off
@ Fig. 7
rg¡... Do not pinch off fuel suction hose at
Model 124 T -model
elbow
54a,
Cap nut, check valve Replace copper sealing rings (62, 62a)
63
[l] *BA47.20-P-
1002-01A
[l] *BA47.20-P-
1003-01A
[l] *BA47.20-P-
1004-0lB
[l] *BA47.20-P-
1005-01B
[l] FUEL PUMP

Number Designation Engines 104, 119, 120
BA47.20-P- 1002-0IA Cap nut of fue! pipe to fuel pump Nm 27
BA47.20-P-1003-0IA Check valve to fue! pump Nm 27
Mercedes-Benz
rtJ FUEL PUMP

Number Designation Engines 111
BA47 .20-P-1 004-0lB Cap nut of fuel pipe to fu el pump N m 27
BA47.20-P-1005-0lB Check valve to fuel pump N m 27
Removing and installing check valve for fuel pump- AR47.20-P-5820F
ENGINE 119.97, 120.980/981
52 Fue/ dt:Jivory hose

51 Fu<:/ sucr/on hoSI:
$4Q CiOp nut
112 Coppor n~l
62• Coppor SCII
IIJ ChOcll v•IIIO
Fig. 40: Identifying Check VaJve For Fuel Pump Components (Engine 119.97, 120.980/981)

etc.
@ Pay attention to accident
Risk of explosion
prevention regulations!
53, 52 Fuel suction hose, fuel delivery hose ®pinchoff Fig. 7
Screw spindle pump replaces double BT47.20-P-0001-
Lt fuel oumo unit OlA
Mercedes-Benz
54a, 63 Cap nut, check valve replace copper seals (62, 62a)
[lJ *BA47.20-P-
1002-01A
[l] *BA47.20-P-
1003-01A
llJ FUEL PUMP

BA4 7.20-P-1 002-0 lA Cap nut of fu el pipe to fue 1pump Nm 27
BA47.20-P-1003-0IA Check valve to fuel pump N m 27
Fig. 41: ldentifving Clamp (000 589 40 37 00)
REMOVING AND INSTALLING ACTIVATED CHARCOAL FILTER- AR47.30-P-8212
Removing and installing activated charcoal ftlter- AR47.30-P-8212B
MODEL 129 with CODE (491) U.S. version witb CODE (808) Model year 1998
77 A ctrviJ red e h~rco ~~ c.~Jnl.stcr

A t./no for ul1v~toll ch~rco~l c ~nlstcr
swltcho~ v~Atc • tCfiCncr~t/on
C Vcnt /1nc for ó1CtAf•tad c.horco.JI
coniste r · fue/ tonl< filler tubo
D Une rrom f ue/ t~nlt ro ul1v•rod
charco~/ c~nistct
G Une rtom ~cov~tall ch~rco•l
c~n iste r ro «t"'~tad eh~Jt'Co~
c~n.iSta r shut~ ott· v Jlvo
Fig. 42: Identifying Activated Cbarcoal Filter Components
I ~A
-~ BT 1Removing, installing
Mercedes-Benz
N o fire, nak:ed flames or

smoking.
A voíd formatíon of sparks.
Risk of explosion from fu el vapors igniting. Risk
Pour and store fuels only in
[O of poisoning from inhaling fuel vapors and open
vessels provided for this
working with fuel. Risk of injury from fuel
purpose.
splashing ínto eyes.
W ear protective gloves and,
if necessary, eye protection
when handling fuel.
1 Remove left side wall paneling
2 Remove lines from activated charcoal canister (77) [g] Connection schematic: ?
Model 129 ~ with engine AR47.30-P-
112 as of 09/97 8212-01DH
113 as of09/97 8212-01DJ
119 8212-01EC
3 Remove activated charcoal canister (77) [g] Release upward
Connection diagram of evaporative emission control system - AR47.30-P-8212-01DH
Connection diagram of evaporative emission control system engine 112 version ~ as of 09/97
17 Fuoird 1)
10 lntJAc m• nlolrl
5$11 Fucltllter
75 Fuelrm~
77 Act lttll»d <lllteo~ filrct
8413 Prc ssu~ s ensor
M1 Fuclpump
M151t Eloctron/e oecolor.uor ••lll•ror
Ywt PUriJO control v.tvo
Y5&f4
.,.,...
Acrltt•rcrJ cll•rcoiM ffl!cr sllurorr
Y5115 Prcssurc tclld v•ltto (ORV~

Y61 Fucllnjcctor
A Actlv•l»rl cll•rcoi>l fil!ot ·purgo
control Y~ Ale line
B Purgo corrttol v.tlva ·lm•Jc•
m•ntrotrJMno
e AG1Nt11!1ct 'l!tli,Oiil tflrcr · fila/ t'illtlt
lino
Pl1.JO·l007·il6
D Fue/ r•n~ • .xliv•rerJ ,,.,..., E Alcl f'ilrar • file/ unf( dagJssln!J F Ale/ filler· filo/ r.nf( rcrum flow
tNrer lino Mnc l nc
Fig. 43: Connection Diagram Of Evaporative Emission Control Svstem (Engine 112 Version As Of 09/97)
Connection diagram of evaporative emission control system- AR47.30-P-8212-0IDJ
ronnPrtion ili~or~m of PV~nor~tÍvP PmÍ~~Íon rontroJ ~v~tPm PnoinP 111 VPr~ion (USA)
Mercedes-Benz
17 Fuclr• W
18 lnt•~• m• alfold
5$11 Fucl t~ r wtrl! lnrcgrocod ftlo/
pros:suro rcgu l«r>r
75 Fuclrmk
77 Activ<JrDd ChQfCO~I c..Jnlster
84111 Fuct tQnl( prcssure .sensor
/.U Fucl pump (FP)
YSflt Purgo conrrol v•tvc
YSI/4 Actlv iltodch•rco.JI ca-nistcr s hutotf
VI!VC
Y62 lnjocton (LH-SR. HFII-SFt PEC
[L.H. HFM. PIAS#
17 111
PH l0· 2DOHI6
A Act.V•tod ch•rco•l ••nl.srcr purgo conttol v•llo'O tille O Fue/ ton~ ~>cllv•rcd ch•rco•l••nfstcr Nnc
B Purgo controiV•Ivo • /nr;,ltc m•nffold lino E Fuo/ tlttcr- fuol t•nK deg•u lngllno
C \l'ent lino lrom ;><tfV.Cod ch•t<ool<.lnlstort o fiJo/ tan~ F Fue/ tlltcr - ftlol tank tuo/tcturn Nno
Fig. 44: Connection Diagram Of Evaporative Emission Control System (Engine 113 Version)
Connection diagram of evaporative emission control system- AR47.30-P-8212-01EC
Connection diagram of evaporative emission control system model 129 with engine 119
Model Year 98 version ~
D
18 sucllonplpo
~511 FucttMrar
75 Fuetc•nk
77 Actlll• lod cl!•r•o•l conlsrcr
844 Prcs.suro s ensor
tiiJ Fuolpump
11!1511 Elocttonlc •cco/o.-arcr ••cu•ror
Y5f/1 Purgc 'ontrol v•Jvc
Y3114 Act.V•tod ch•r•o•lc.nl$1ot $hUtoff
Vii/VO
18 a
A Actlll•lod cl!orco•l cmlstor • purgo
control v•lllc pipo
B Purgo c.onttol v~vo · l nQko
m•nlfold pipo
e Actlll•tcd ch•tco• l c•nlstct - ftle/
t•nl<plpo
o Fuer riln~ · a'lfv-ar~ ,,,"~'
••nlstcr pipo
E Fuoltlltor - fucJ t •nlr dogouíng
pt>o
F Fuct filtfJ r · rucJ CQnlr t'uc Jrct urn
u 16/1
tlo w pipo
P• 7. lO..Ol10-0ii
Fig. 45: Connection Diagram Of Evaporative Emission Control Svstem (Model Year 98 Version)
Removing and installing activated charcoal canister- AR47.30-P-8212D
MODEL 124, 129, 140, 170, 202, 208, 210

Mercedes-Benz
MODEL 170 with CODE (491) up to Model Year 97 U.S. version
MODEL 129, 202, 208 with CODE (491) up to Model Year 98 U.S. version
Left-hand illustration Shown on model124 Right-hand illustration Shown on model 202, 208
77 ActAiitft:ll tll~ttoa/ canlsrw

A ActfV•tcctcll•rco•l cmlstrrt / purge
~ontrol ~rvo pipe
D Vont volvo l octi~ted e horco• !
<= •nlstu pipo
E Vont pf¡o
Fig. 46: Identifving Activated Charcoal Canister Components (Shown On Model 202, 208)
Mode1129
77 ActfV•ted cll•rcoa~ cóllllster

A ActAiitted cllorco•l c•nlster / purgo
control v•fV• pipo
D Vont volvo l •cllvotDd charco•!
<=anlstru pipo
E Vcntplpo
Fig. 47: ldentifving Activated Charcoal Canister Components (Model129)
Model140 with 100-liter fuel tank

Mercedes-Benz
Fig. 48: Identifying Activated Charcoal Canister Components (Model140 With 100-Liter Fuel Tank)
Model170 ~ up to MY 97
Model140 with 90-liter fuel tank
P HJ!I11 H7-01
Fig. 49: Identifying Activated Charcoal Canister Components (Model140 With 90-Liter Fuel Tank)
77 A<t.Vat!>O' chatcoal canlsr~>r

A Aot.Vat!>O'chat<o•l ••nlsr~>r tpurgo
c:ontroltrotlo pipo
D Ventlllllle l a<f1v•r~>d<h~tCOII
e: •nl3tor pfpo
POUD-42&9-0S
Fig. 50: Identifying Activated Charcoal Canister Components (Model170 Up To MY 97)
Model208.4
Mercedes-Benz
77 Act/V;,tr:ct charco•/ ••nlstr:r

A ActN•ted ch~rco~_l c~n;srcr / purgo
c:onttol V.1/Vc pipe
D Vcntvolvo l •ctiv•tr:ctch•r•o•l
c:•nJsrcr pipo
P&J l0-2005-115
Fig. 51: Identifying Activated Charcoal Canister Components (Model 208.4)
Model210
77 Actlll•mct ch•rca.l c•nlslrlr

A ActiV•tr:d cll•rco•l c•nlstr:r l pUf/10
c:onrrol v•.Vo pipe
D Vcnt V.11Vo l •ctiv•tr:d oh•rc.oiOI
c:•nbtor pipe
Fig. 52: Identifying Activated Charcoal Canister Components (Model210)
Model 210 ~ up to MY 97
17 Aet/Valcd ch•rco•l C.>nJ~W

YW" Aetlll..md ch•rcoiOI ••nlsh>r shuroft """"'
Fig. 53: Identifving Activated Charcoal Canister Components (Model 210 Up To MY 97)
Mercedes-Benz
Model 210 ~as ofMY 98
17 A ct lti~!Cd ch~~~Colll c~ nlsrcr
1111 Fue/ o vcrflow lnc

12/2 ORVR • cnt llnc
YSI/4 Ac:tltl iltod ch iltcoal c~nistor s h utott llt~lvc
A ActN ~fvd chvcolll •~isfvr 1 p UrfiO controt volvc lino
D Nno
FucltiJn~ f ¡¡ctfv~mdc h~J.rco~t c~n lstcr
Pl 1 JO.QJ~9- 0 J
Fig. 54: ldentifying Activated Charcoal Canister Com ponents (Model 210 As Of MY 98)
[$='BT CEJ Removing, installing

[JJ Risk of explosion due Fire, sparks, naked flame and AS47 .00-Z-000 1-0lA
to ignition, risk of smoking forbidden.
poisoning through Only pour fuels into suitable,
inhaling and appropriately marked containers.
swallowing fuel and Wear protective clothing when
as well as risk of handling fueL
injury dueto fuel
coming into contact
with the skin and eyes.
1.1 Remov e wheel arch Models 124, 129 front left
inner panel Models 140, 202, 208 rear left
Model 21 O rear right
1.2 Detach cover of fuel Model170
pump/ activated
charcoal canister
2 Disconnect lines from Models 124, 129, 140 lines (A, D,
activated charcoal E)
canister (77) Models 170, 202, 208, 21 O lines
(A, D)
[g] lnstaUation: Connecting
diagram?
Model l 24 with engine 104, 111 AR47 .30-P-8212-
OIDA
Mercedes-Benz

without ski bag
Model 140 with engine 104 with AR47.30-P-8212-
ski bag OlDB
Model202 with engine 104, 111 AR47 .30-P-8212-
01DC
Model 170 with engine 111 AR47.30-P-821 2-
OIDE
Models 202, 208, 21 O with engine AR47.30-P-82 12-
112 version ~ up to 09/97 01DF
M odel 21 O with engine 113 version AR47.30-P-8212-
~up to09/97 01DG
Models 129, 202, 208, 210, 220 AR47.30-P-8212-
with engjne 112 version ~ as of OlDH
09/97
Models 129, 202.093, 210, 220 AR47.30-P-8212-
with engjne 113 as of 09/97 01DI
Models 129, 202.033, 210, 220 AR47.30-P-8212-
with engine 113 version ~ as of 01DJ
09/97
Models 129, 202, 208, 210, 220 AR47.30-P-8212-
with engine 112 as of 09/97 OIDK
Models 170, 202, 208, 21 O with AR47.30-P-8212-
engine 111.921/42/45/46/70/74 01DL
without code 923 low emission D3
Models 170, 202, 208, 210 with AR47.30-P-8212-
engine 111.921/42/45/46 with 01DM
Code 923 1ow-emíssion D3
Models 129, 140, 210 with engine AR47.30-P-8212-
119.97 OlEA
Model129 with ~1e 119.98 AR47 .30-P-8212-
except code 491 usA as ofMY 98 OlEB
Models 140, 210 with engine
119.98
Model 129.067 with engine AR47 .30-P-8212-
119.982 with code 491 ~as of OlEC
MY98
Modell 70.447 with engine AR47 .30-P-8212-
111.973 with code 491 ~as of OlED
MY98
3 Remove activated On models 124, 129, 140, 210,
charcoal canister (77) disengage upwards
Model 170, disengage to one side
Models 202, 208, unscrew
Mercedes-Benz
lrnstall in reverse order 1
Connecting diagram of evaporation emission control system - AR47.30-P-8212-0IDA
Connecting diagram of evaporation emission control system HFM-SFI models 124, 129, 140 without :ski
bag with engine 104
Sbown on model 124
l'b R am lnto~o m•nlold

19b Rcsonancc lí!ra~c manltotd
7!5 Fuo l t~nJc
78 Vcnt VtlÑ'D
77 Ac.riviJtcd ch~rcoQ/ eJnl stet
MI6JO Id/e spccl1 control (ISC) ulll•tor
N:J/4 HRII scqucntl•l multlport fUe/
ln}cction'lgnltlon .tystom {I*'M-SFI)
c:o ntrol module
Y!Siil Pur~e 3WÍtc hove r v ilfvc
A ActiV•ICd """"'"' conlstcrlpurpo
swftr:hovct vowc pipo
B Purgo swltr:hovet votvt>Ji dlo speod
control ~SC) octu•tor (IM6J6) pipo
D Vcnt troAroiiiCtAt•tod chorcool
con/storplpc 77
E Vcntplpc
Fig. 55: Connecting Diagram Of Evaporation Emission Control System (Shown On Model 124)
Connecting diagram of evaporation emission control system PEC 1st version model124 witb engine l ll
19 lnto~c mon/fo/11
19 Thcrmo volve (opons ilt 10 •CI
Clases •t J!S'C)
50 Purgo v•tvc
7!5 Fuc/ tonll
16 Vcntv-.J ~o
77 Actfv•tad chiJrcoiJI c~lstcr

141618 tdlc spood control (ISC) ocll/otor
A Actlv•ICd chorco•tconl stcrl purpo
v•IVc pipe
B Purgo volvcfldlcspccd control ~SC)
••lll•tor (1116'5) pipo
e Purgo ViJivc.-rthormo v.11vo piJe
D Vent vo/Vctoct iV•tod chorcool
c•nlstor pip o
E Vcnt plpc
Fio_ ~ll~ í'onnPrtino ni~or~m Of F.v~nor~tion F.mi~~ilm í'ontrol SvdPm (MociPl 12.::1 With F.noinP 111)
Mercedes-Benz
Connecting diagram of evaporation emission control system HFM-SFI model 124 and PEC 2nd version
model 124 with engine 111
Sbown on engine 111 with HFM-SFI
19 lnr. ~o m•nrfD 111

75 Fuc/C.nlt.
70 Vcnt Vil Ale
n A ellv•.W e h•~o~ e •nlstcr
M10>G Id/e speed control (ISQ iiC'fllil tor
H1/4 ~ soc¡ucnrt•l mulriport tucl
ln)eolionttgnlrton systom {HFM-SFI)

control modulo
Y!l/1 Purgo swttr:hovcrv•l""
A A ellv•.W e horcoit.l < •nlsterl purgo
switr:holfCr VIIAIC pipo
8 Purgo switchcvorv•lvC!Idie specd
control OSC) octu•tor(IIHtl/6) pipo
D Vcnt VitAIO'ilctAiiltod charcOill
c<Onistorp¡,o
E Vontplpo
T1
H1.»020.....
Fig. 57: Connecting Diagram OfEvaporation Emission Control Svstem (Showu On Engine 111 Witb
HFM-SFD
Connection diagram of evaporative emission control system - AR47.30-P-8212-0IEA
Engine 119.97
Connection diagram ofLH-SFI evaporative emission control system model 129, 140 without skibag with
engine 119.97
19 ln~M m•nlfD/11
75 Fuelr.nlt
76 Vemvo~~e
77 Aclfv•tod chorcooiiRtor
IA1811 Elcctronlc •occlor~or (EA)Icruisc
control (Cqlldle specd control {ISC)
a'llleror
NJ/1 Afr l>ot w/ro {UI·SF/) control mo di/le
YSI/1 Purgo e onrrot v•Ne
A Aclfv•.W ch•rco•l rMtor ·purgo
co nrrol ""'"" pq,o
8
o
Purgo conlrolv•Nc • octu•tor
(111411) pipe
Vcnt v•Aio- •ctNotod ch•rcool flter
M1e/1
,._
pipe
E Vcntplpo
-o
Mercedes-Benz
Fig. 58: LH-SFI Evaporative Emission Control System Connection Diagram (Modell29, 140 Without
Skibag With Engine 119.97)
Connection diagram ofLH-SFI evaporative emission control system model140 with skibag with engine
119.97
19 ln~Ac mon!to Ir!

75 Fuc/~nll: N3fl
76 1/cn t lililAfc
77 Acrfvo!O<I cltorcool fRtot
~3
111611
NJ/1
Fuol oxponsfon r csCNOir
Eloctronlc ••• ol ot.tor (EA)Icrufso
control (CC}itdlc spccd corrrrol (lSC}
IC tll~tor
Air hot W/ro (Ui·SFO control modulo

-• Vllltl
YW1 Pur~e c onrr-o lv~ lv c

A Acrtvotod cltareool fRtot - purgo
control vo/vc p*'c
.,..., A
a
S Purge e onrr-ol v~ Jvc .. ~tlfltot
(11 1611) p$lo
D Vcnt vaAo'o - actN•tod chiitco.tl ti/ter
pipo
E Vc n t ptpc
Fig. 59: LH-SFI Evaporative Emission Control System Connection Diagram (Model140 With Skibag
With Engine 119.97)
Connection diagram of LH-SFI evaporative emission control system model 124 with engine 119.97
19 In~~· monlto Ir!

15 Fuoltonlt
7e Vcnt v-.t"c
71 Acrtvo!O<I choteo al fltot
IMM El oct ron!c oocclomor (EA)Icrulsc
control (C C}If<llo &pccd control (ISC}
iiCIIIiitot
NJ!t A ir hOt wlro (l.H-sF!) control mor/U/o
'1'5111 /'urge c ontrol VINe
A Acr!votod chorco•l f Wtor ·purgo
control volvo ptJo
S
·-
Purgo c ontroiV•Jvc - octuotor
(Mffll1) p$lc 11161'1
D Vcnt vo/Vo • .o ctJntod e horco.>/ fllor
pipo
-
E Vcntplpc
77
Fig. 60: LH-SFI Evaporative Emission Control System Connection Diagram (Model124 With Engine
119.97)
Mercedes-Benz
Function diagram of evaporative emission control system- AR47.30-P-8212-01EB
Connection diagram of evaporative emission control system, ME-SFI mode1129, 140, 210 with engine
119.98
19
19 Suc tio.n pipe

7$ Fuolr~n~
70 VontVil/vc
77 AcrAiiltod chorcoill ~~n/stcr
M16!f Electronl c aocolcr-.ror (EA)Icrulso
control (CC)IIdlo specd oonll'ol
(1$Q .Jcll/~ror
N3t10 Uororolocrronlcs (IAE.$1'!) control
modulo
YW1 Purgo control v.tva
A ActAiiltod charc.W can/stcr • pur¡c
control ~Ato pipe
8 Purgo control v.a/Vo- il<lllator
D
(141011) pipo
Fuol tan~· ilOtJVJtod charooal
t
e anlstcr pipo A
1713
71
Fig. 61: Connection Diagram Of Evaporative Emission Control System, ME-SFI (Model129 With Engine
119.98)
Removing and installing activated charcoal canister- AR47.30-P-8212FA
MODEL 129 with ENGINE 119, 120
A AotAtarod charco~/ canlriror- putgo

control vawo pipe
D Venr va/Vo • J<:tAI..rod <llaroo.JI fíltor
pf>o
E Ventplpo
77 ActAt•rod chorcoill coanfstat
Fig. 62: Identifying Activated Charcoal Canister Components
iGr'BT
CD
@ Observe accident prevention
Risk of explosion
regulations!
l Remove front left inner fender ra 88001290 l30x
2 D1 c::r.onnPr.t ninP.<:: ::tt ::tr.t1v ::!tPrl r.h::trr.o::t 1
Pipes (A, D, E)
Mercedes-Benz
canister (77)
Connection diagram of evaporative AR47.30-P-8212-
Engine 119.97
emission control system OlEA
AR47.30-P-8212-
Engine 119.98
OlEB
AR47.30-P-8212-
Engine 120.980/981
OlFA
AR47.30-P-8212-
Engine 120.982/983
01FB
3 Remove activated charcoal canister (77) Release upward
Connection diagram of evaporative emission control system - AR47.30-P-8212-01FA
Engine 120.980/981
Connection diagram ofLH-SFI evaporative emissioo control system model129, 140 without skibag with
engine 120
7! Fucltank
76 Vcnt v~Ai o
77 Acrivotod e horco o/ fNtor
V$ Fo ulcx~ns/on r<Dorvolr t
lof16/: R/¡¡ht oloC'fronlc ~c c/crilfor (F.A)I
crulsc ccnrrot (CC}IIdl c spccf1
co nrrol ~SC) oct uotcr. pos/tlonod on
14/t ot cngino
lof1614 Lolt ol oc rronlc ocooloratcr (EA}/
crul so cont rr>l (CC)ildl o spood
conrrot ~SC) octuotcr. pos/tloncd on
rlght ot cnglnc
NJ/1 l.alt hot w lro (UI·SFI) control
module
NJ/1 R/¡¡ht hot Wlro (LH·SR) conrrol
mod ule
Y$112 La tt pursJc c:o nrrolti~Jvc, p OJ irfon cd
ln r lght o f cnginc comportmcnr
YWJ Ri¡¡ ht purgo e ontrol voAic. posltioncd
In lcft <>f cnglho compo rtmcnt
A Acrivotod chorco•lfNtor· purgo 81 Purgo c4nrrol volvc • •ctuotor (1111613) E Vorrtplpc

conlrol valvo pipe pipe
Bf Purgo e onrrol v•Aic - octuotct O Vcnt votvc - octlvotod chorcoJif/tfJ:r
(M f5f4) pipe pipe
Fig. 63: LH-SFI Evaporative Emission Control System Connection Diagrarn (Model 129, 140 Without
Skibag With Engine 120)
Counection diagram ofLH-SFI evaporative emission control system model140 with skibag with engine
120
Mercedes-Benz
7S
77
Fuot~niC
Aeltvlll:d ChilfCOII fNtor

N3f2
-
es FouiOJtp~nslon rcsorvoiT
1At8!3 Rl¡¡ht otocrronl r: .accolorillor (EA}!
Mte./4
crulso control (CC}IId/o sp ood
conrrot ~$C) ..:tu•ror, posllionod on
lelt o f cngino
l.olf olocrronJc aceotor•tor (EA)/
crulsc control (CC)IIdlo spcod
'
control ~SC) i~eluotor. posltlonod on
rlght ot e nglno
lht1 Lotl hot wh (LH·SF/) control
lnOdUio
NJ!1 Rl¡¡ht hot wirc (I.H.SFI) conrrol A-.
~
modulo Vliatz
'1'51'2 Lotl pur¡¡o contro/voivo, pos/rionod
In rlgbt ot ongino comportmont
Y51t~ Rl¡¡ ht purgo e antro/ VINO. pas/IJonod
lnloftofcnglno comp;¡rtmont
A Aeltv1tod r:hlf<OII fNtor· purgo 82 Pur¡¡o control Vllvo . ICtultor (1811111) E V ent plpe
conrrot voJvc pipo pipe
Pur¡¡o r:ontrol "'"'" • iletuator D Vont V~lvo · •<IIV~tod e horco o! tmr
(l.fW<f}pf>c pipo
Fig. 64: LH-SFI Evaporative Emission Control System Connection Diagram (Model140 With Skibag
With Engine 120)
Connection diagram of evaporative emission control system- AR47.30-P-8212-01FB
Engine 120.982/983
Connection diagram of ME-SFI evaporative emission control system model 129, 140 without ski bag with
engine 120
Mercedes-Benz
7$ Fuclt~n ~
-
77 Acrf!loted chorco•l f Ntet
M1813 Rlgllt clocttonlc ..cclotiltor (EA)/
crulsc oonttol (OC}IIdto spcod
control ~SC) ..ru~tot. posltioncd on
+
lctt of 011/llno
1816J4 U lt ctoctronfc occotctlttot (EA)f
crulsc control (OC}Ifr!lc sp ccr!
control psc; ¡oct u•tor. posltioncd on
ri¡¡ht of onglno
NJttt Lolt IAE-SR control module
N"J/12 Rlg nt h'E-SFI c ontrot mor! ule
Y5112 Loft purgo con trolllillvc, postttonod
In rlght o f onglnc eo mpartmont
YW~ R/gflt purgo c onrrot v•IVo, poslllonor!
In lcfl of on¡¡lnc comp~rtmont
7a
-D
N7 3f).OV'4Cit
A Acr!votod thorc<>•l fNtor- purgo 82 l'u rgo control volvo. •ctuotor (M I 611) E Vorztp/po
control v./ve pipo pipo
81 l'urgo ccntrolvoiVo- "'t uotot D Fuol ton~· oc:tlv•tod ch•rcool fNter
{IIW4} plpc pipo
Fig. 65: ME-SFI Evaporative Emission Control System Connection Diagram (Model129, 140 Witbout
Ski Bag With Engine 120)
Connection diagram of ME-SFI evaporative emission control system model140 witb ski bag, engine 120
75 Fucl lilnl!:
77 Acr!votod chorco•l f Ntor
93 Fue/ OJI~nslon =~
1816!3 R/ght oloctronlc occolor.ttor (EA)/
cru/se co/lllol (CC)!Idle speod
control ~SC) . .ruotor.pos/tionodc
lof't o f cngino
•
'"'"'- Lolt e/ce rronlc •• color• tor {EA)f
crulsc control (OC)fldlo spccr!
control VSC) ocruotor. posilionodc
rl¡¡ht of ongJno
NJ/11 Lolt ME· SR control modulo
NJ/12 Rlgllt IIE-SFI control modulo
Y$111 Lclt pu rgo control volvc, posltfon o'
In rlght cf onglnc co mpoltmont
YW1 R/gllt pu rgo corztrotvoiVo, posltlon
In Ioft of onglr!o comportmont
A Acr!votod ch•rcool fRtor· purgo 82 Purgo control vo/vc. ocruotor (Mt613) E Vcntp/po
control v./ve pipe pipo
81 /'u rge c ontrol v• .Vc - oct u•tor D Fuot 011p•m10n r.n~ - •ctlvotod
{Mf6<'4)plpc ch•rcool filler pipo
Fig. 66: ME-SFI Evaporative E mission Control System Connection Diagram (Model140 With Ski Bag,
Engine 120)
Connection diagram of ME-SFI evaporative emission control system model 129 ~ witb engine 120
Mercedes-Benz
1$ Fuol~nle -~
17 A cf'iv•I.W e"""""' rltot 71 Hl/11
84,14 Putgo mon!rotlng prcssuto sensot
Mf&"' Rl¡¡ht olocttonlc •ccolotMor (EA)/
cruiu conttoi (CC}IIdlo spcod
contrgl ~SC) óJCtu•IDt,posltionodon
l
lctrot englno
1At&.'4 l.c tr oloctronlc accolor•ror (EA}!
crulso eontrgJ (CC}IIdlo spcod
control ~SC) octu~tor, posltionod on
right ot onglno
10111
NJ/12
l.ortME-SFI control modulo
R /¡¡ ht/IE·SFI e onrro/ module
...
Y$&12 l.o rt purgo centro/ v ~ve. posltionod
In rlghr ot englno comp.rtmont
YWJ R/¡¡hl purgo controlv•IVo. posltloncd
In lctr ot ong lno comp rtmont
v.¡a
A Acf'iv•tod ch•rco•l fMtor ·purgo D FucJ 101111 • •ctiv•tod c,.r,c o•l tltor E Ventp/po
control voJivo pf>o pipo
8 Purgo control v•IVc • octu•ror
{lllte/'J. /Af&,lfJ pipe
Fig. 67: Connection Diagram OfME-SFI Evaporative Emission Control System (Model129 With Engine
120)
Connection diagram ofME-SFI evaporative emission control system model140 ~ with engine
1$ Fuolto>n~
77 Acf'iv•todcll•rcool fltor
iJ Fuo/ oxp.mlon tillllf
84!1 Fue/ prossutc sonsot
Mf&/1 Rl¡¡ht otocrronlc iltco/omor (EA)/
crulso control (CC)IIdlo spcod
D
control ~SC) octu~ror. positionod on
lctt ot cnglnc
1At6'4 l.otr cloctronic •ccclcnror (EA)/
crulso control (CC)IId/o spood
control ~SC) ocruoror, posllioncdon
rlgllt ot onglno
N'J/11 l.otr ME-SR conttol modulo
NV12 Rl¡¡ht IIE·SFI control module
YW2 l.otr purgo control v•Jvc, pos/lioncd
lnrlght ofonglho comp•rtmont
YWJ Rl¡¡ lit purgo e ontrol v•ltlo. poslllor>od
In Ioft ot englno comp•rrmonr
YSii <l Acf'ivltod cll•rco•l fNtor shfJt'-oft
v~Jvo
Yfill/1
A Acf'iv•I.W ch•rco•l fMtor · purgo D Fue/ oxp•nslon r~nl! • •criv•t•d

contrg/ VIIVO pipo cl!arcool filtcr pipo
8 Purgo control v•IVo • ocru•tor
/Mfll/2 UfS .. I niM
Fig. 68: Connection Diagram Of ME-SFI Evaporative Emission Control Svstem (Model140 With Engine
120)
REMOVING AND INSTALLING SAFETY VALVE- AR47.31-P-8022B

Mercedes-Benz
ENGINE 112.923 in MODEL 129.059 with CODE (494a) USA version with CODE (808) Model year 1998
ENGINE 113.961 in MODEL 129.068 witb CODE (494a) USA version witb CODE (808) Model year 1998
12 Pre.ssurc rolicf V ;Ji vc

1111 Fue/ overflow pipo
1112 M !IR vonrptJo
1113 Vcn t lioso
Arrow Nuts
Fig. 69: ldentifying Safety Valve Components

item
etc.
Risk of explosion from ignition. Risk of N o tire, naked flame or smoking Pour
poisoning from inhaling and swallowing fuels only into suitable and AS47.00-Z-
OJ fuel. Risk of inj ury as a result of fuel appropriately marked containers W ear 0001-0lA
coming into contact with skin and eyes. protective clothing when handling fu el
..
[g] Hose clips re place
¡g¡ Trim panel of fu el tank remove
82 Pressure relíef valve remove
82/ 1 Fuel overflow pipe disconnect
82/2 ORVR vent pipe
82/3 Vent hose disconnect
Arrow Nut unscrew
REMOVE SHUTOFF VALVE, INSTALL- AR47.31-P-8023B
ENGINE 112.923 in MODEL 129.059 witb CODE (494a) USA version with CODE (808) Model year 1998
ENGINE 112.943 in MODEL 129.064 witb CODE (494a) USA version with CODE (808) Model year 1998
FNr.TNF. 1 B.961 in MOfiRT . 129.06R with r.onR (494~) TTSA vPr~ion with r.onF. lROR) MoiiP.I vP.~r 199R
Mercedes-Benz
8Z/S A.r adrru110n ana r~ase ln~ o l.h!lrom llettlrkto at!Mttedcnarcoal o l.h! lrom attwal!<l charcoal carisler
Y58t4 Sl'lllof vaNe can!ster 10 a!W•!<I charcoal canlster Shlt<:tl
valile
NIOII S«IC!I
Fig. 70: Identifying Shutoff Valve Components
~BT
CD
No flre, sparks, naked flame and
Risk of explosion if ignition takes place,
smoking Pour fuels only into suitable
[]] risk of poisoning caused by inhaling fue] AS47.00-Z-
and appropriately marked vessels
vapors or swallowíng fuel as well as risk 0001-01A
Wear protective clothing when
of injury to skin and eyes exposed to fuel.
handling fuel
Remo ve trim panel of fuel tan.k as well as
1
right and left side trim panel of tmn.k
2 Remove vent line of fu el tank
lg] Installation : Connection
diagram?
Model l29 ~ with engine 112 as of AR47.30-P-
09/97 8212-01DH
Model 129 ~ with engine 113 as of AR47.30-P-
09/97 8212-01DJ
AR47.30-P-
Model129 ~ with engine 119
8212-01EC
AR47.31-P-
3 Remo ve pressure relief valve
8022B
4 Remo ve rear wall of fuel tan.k
Remove bottom left mount of luggage
5
compartment lid shock absorber
Mercedes-Benz
6 Remove left rear wh.eel

[l] *BA40.10-P-
1001-01A
7 Remove fender liner.
8 Raise soft top
9 Remove cover in soft top compartment
Press air admission and release line (82/5)
10 out of rubber grommet from wheelhousing
to inside
Detach coupling (arrow) of shutoff valve
11
(Y58/4)
¡gj R emovaJ : Use e.g. screwdriver to
12 Remove shutoffvalve (Y58/4) press it out of rubber grommet toward
luggage compartment
¡gj lnstallation : Installation position
is set by locating lug on shutoff valve
(Y58/4) Spray rubber grommet with
silicone spray to facilitate installation
llJWHEELS
Number Designation Model124,129,168,170,202,208,210
BA40.1 0-P-1 001-01A Wheel bolt Nm 110

REMOVING AND INSTALLING FUEL TANK- RA47001044100X(47-4100)
Removing and installing fuel tank- RA47001044100X(47-4100)
47-4100
A. Model 124 Sedan

Mercedes-Benz
Fig. 71 : Identifying Fuel Tank Components (Modell24 Sedan)
® Pay attention to safety instructions.

Pressure in fuel tan.k release by opening fuel cap (62), fitting on.
Seal (62a) check, replace if necessary.
Fuel gauge sending unit (B4) remove, install (47-7000).
drain. Carefully pump out fuel so that no fuel remains in the
Fuel tank (50)
tank. Capacity approx. 70 liters.
Cup seal (60a) remove, install.
Fuel tan.k lining as well as left and
remove, 1nstall.
right trunk sideline
FnPl ~nnnlv hn~P ( ()C}) niPl rPtllm hn~P detach, attach.
Mercedes-Benz
(70),
breather line (64), breather valve (51) Collect remaining fuel.
Plug connections.
Check suitability for re-use.
Ensure cup seals are correctly instaHed.
Nuts (50b, 4 off) screw down, screw up, use washers (50a).
Fuel tank (50) remove, insert.
Glue soundproofmg strips (74) wíth MB universal glue 000 989
92 71.
Fuel strainer ( 68) remove, install, clean and check for re-use.
Replace seal (68a).
Leak test of all connection points check with engine running.
NOTE: To avoid hoses being kinked, t he fuel supply hose (69) from the fuel tank
to the fuel pump has been modified toa moulded hose (except Station
Wagon).
PRODUCTION BREAKPOINT: OCTOBER 1989

Modei Vehicle Ident End No.
124 B 097367
Special tool
001 589 72 21 00
00
B. Model 124 T-model

Mercedes-Benz
~02
Fig. 73: Identifying Fuel Tank Components (Modell24 T-Model)
@ Pay attention to safety instructions.

Pressure in fue) tank release by opening fuel cap (62) and closing.
Seal (62a) check, replace if necessary.
Fue] gauge sending unit . t ll ( _ )
(B4) remove, ms a _47 7000_.
empty. Pump out fuel carefully so that no fu el remains in the tank. Capacity
Fuel tank (50)
approx. 72 liters.
Cup seals (60a) remove, install.
Breather line (64a) remove, install.
NOTE:
Pre-install breather line at fuel tank. Lay line with constant slope and free of
kinks. Ensure cup seal (60b) is correctly located.
Fuel supply line (69),
detach, attach.
fuel retum line (70),
leak line (72) Collect remaining fuel.
Seal connections.
Check suitability forre-use.
Breather val ve (51) detach, attach.
Mercedes-Benz
Exhaust system detach at rear suspension points, attach. Detach with V -belt.
Splash guard (58), filler detach, attach.
neck
Level line bracket
detach, attach.
(lefthand side)
U rail (56), fixture (50a, . t ll
50b, 50c) remove, ms a .
Tightening torque 30 Nm as reference vaiue.
Replace self-locking nut (50c).
® Support fuel tank when performing this step.
Fuel tank (50) remove, insert.
@)
When removing fuel tank, ensure that the connection for the breather line ( 64a,
at filler neck) does not catch on a line. Push exhaust pipe and levelline to the
left.
Glue soundproofing strips between rear tloor and fuel tank with MB universal
glue 000 989 92 71, ifnecessary.
Fu el strainer ( 68) remove, install, clean and check forre-use.
Replace seal (68a).
Leak test of all check with engine running.
connection points
Special tool
001 5.89 72. 2.1 00

00
C. Model 124 Convertible

Mercedes-Benz
75
2611-o
26-1
73~
:-~
Fig. 75: ldentifving Fuel Tank Components (Modell24 Convertible)
® Pay attentíon to safety

precautions!
open, close. To do thís, open soft top sufficiently until the compartment
Soft top compartment cover
cover can be opened.
Cap (51) take off, fit on.
Seal (51/1) examine) replace ifnecessary.
Fuel tank (75) drain, carefully pump out fuel so that no fuel remains in the tank.
NOTE:
Capacity about 70 liters.
Trim in soft top compartment remove, install.
Coupling (arrow) for fuel gauge ·
sensor (B4) unp1ug, P1ug m.
Vehicles with hydraulic soft
top
Holder for hydraulic pipes unbolt, bolt on.
Mercedes-Benz
AU models
Cover in soft top compartment unbolt, bolt on.
Trin1 panels in trunk remove, install (68-480).
Spare wheel remove, insert.
Partition ( 67) together with
remove, install.
angle bracket (67/ 1)
Cup seal (75/4) remove, insert.
Fuel suction hose (53), fuel
return hose (74), vent pipe take off, fit on.
(76/ 1)
Collect remaining fuel, seal connections, check suitability for re-use.
Ensure cup seals (72, 73) are correctly located. Tightening torque 30
N m as a reference value.
Nuts (75/ 1, 2 of) and bolts
remove, fit on. Use washers (75/2). Tightening torque 20 Nro.
(75/3, 2 of)
remove, insert; remo ve right taillamp unit if necessary, install ( 82-
Fuel tank (75)
4905, see Ill. note).
Examine soundproofmg strips (75/5), replace ifnecessary. Todo this,
stick on soundproofing strips with MB universal adhesive 000 989 92
7l.
Fuel strainer (26) When installing, raise fuel tank at front left.
remove, clean, check suitability for re-u se~ install. Tightening torque 40
Nm .
0-ring (27/ 1) replace.
Leaktightness of all connection check with engine running.
points
SpeciaJ tools
001 589 72. 21 00

00
Fig. 76: ldentifying Special Tool {001 589 72 21 00 00)

Mercedes-Benz
000 589 11 03 00
83
Dlustration note
Fig. 78: ldentifying Fuel Tank
D . Model129
Mercedes-Benz
71J2
o
~
71
C>7112
c07111
Fig. 79: Identifying Fuel Tank Components (Model 129)
® Pay attention
to safety
regu lations.
Ground cable at
battery
Pressure in fu el
release by opening fu el cap (40), closing.
tank:
Seal (41) check, replace ifnecessary.
remove, install (47-7000).
Mercedes-Benz
sending unít (B4)

Partition wall remove, instan.
Clip nuts for
attaching partítíon pull off, fit on.
wall at top
Cover (61) slacken, push back, push forward, tighten.
Infrared remote - -
control (N54 ) unit remo ve, mstall (tf fitted).
empty. Carefully pump out fuel so that no fuel remaíns in the tank. Capacíty approx.
Fuel tank (50)
80 liters.
Cup seal (60/ 1) remove, instan.
Fuel supply line slacken at fuel strainer (68) with ring wrench socket 000 589 71 03 00, tighten and
(69) check forre-use.
Cup seals (80,
remove, instan.
81), springs (82)
Breather valve
remove, fit on by detaching exl1aust system at the rubber rings (detach with V-belt),
(51), return hose
attaching, and removing left drive shaft at inner connecting flange 35-620.
(70)
Collect remaining fueL
Seal connections.
Check suitability forre-use.
Bolts (50/ 1) unscrew, screw m.
Use washers.
Fuel tank (50) remove, insert
Ifnecessary, lever fue) tank out ofthe opening with plastic wedges or similar. Pull
fue) tank fully to the rear left in the car and remove at filler neck If space is restricted,
remove fuel straíner for installíng fuel tank and re-install from below afterwards. If
necessary, glue soundproofmg strips (74) wíth MB universal glue 000 989 92 71.
Fuel strainer (68) remove, instan, clean and check for re-use.
Seal (68/ 1) replace_
Leak test of alJ check with engíne runníng_
connection points
Special tools
Mercedes-Benz
000 589 1i 03 00
83
Removing and lnstalling Fuel Tan k- RA47001194100X( 47-4100)
Preceding work:
Removing and installing fuel- gauge sending unit (47 7000)
47-4100
Mercedes-Benz
s:J7112
-07111
P47·JOt~ - -
Fig. 82: Identifying Fuel Tank Components
® Pay attention to
safety precautions!
Fuel filler cap (40) take off, fit on. Check sea] (41)~ replace ifnecessary.
Partition waU remove, install.
Cover (61) slacken, push baclc, push forward, tighten (see Notes).
Infrared control unit
remove, install (see Notes).
(N54)
Fuel tank (50) drain. Carefully pump off fuel so that no fuel remains in the tank.
Capacity approx. 80 liters.
Mercedes-Benz
Cup sea! ( 60/1) remo ve, insert

Fuel supply line (69) slacken at fuel pump set inlet, tighten. Collect remaining fuel.
slacken at fuel strainer (68) with box wrench socket 000 589 71 03 00, tighten
Fuel supply líne (69) and check suitability forre-use.
Cup seal (71) at fuel strainer, remove, insert.
remove, install.
Detach exhaust system at rubber rings, attach for this step (detach with V-belt)
Vent valve (51), return and remo ve left drive shaft at inner connecting flange (35-620). Collect
hose (70) remaining fuel from retum hose.
Plug connections.
Check suitability of parts forre-use.
unscrew, screw in. Use washers.
Bolts (50/ 1)
remove, instaU; lever out of opening with plastic wedges or similar, if necessary.
Fue! tank (50) Pull fue! tank in vehicle fully to the rear left and take out at filler neck (see
Notes).
Stick sound-deadening strip (74) with MB universal adhesive 000 989 92 71, if
necessary. Remove fu el strainer for instaUing fue! tank if space confmed and re-
instan subsequently from below.
® The surge bowl in the fuel tank is secured with 2 pins to prevent it turning. It
is attached with the fue! strainer (68).
Leaktightness of all
connection points
Special tools
000 589 71 00 00
83
F ig. 83: Identifying Special Tool (000 589 71 03 00 00)

Mercedes-Benz
00\ 589 72 21 00
00
Notes
61 Gover
N54 Gon!roluJllt
Fig. 85: Identifying Pusb Back Cover And Remote C()ntrol Module
-o o O (
Fig. 86: Locating Plastic Wedges

Mercedes-Benz
Removing and installing fuel tank- RA47LH1044100X(47-4100)
A. Without skibag
Mercedes-Benz
Fig. 88: Identifying Fuel Tank Components (Without Skibag)
® Pay attention to safety

precautions! release by removing fuel filler cap (40), fitting on.
Grouncl cable at battery
Pressure in fuel tank examine; replace, if necessary.
Seal (41) empty. Carefully pump out fuel to ensure that no fuel remains in the
Fuel tank (50) tank. Capacity about 100 liters.
Cup seal (55) release, insert.
Fuel tank lining as well as left
remove, install.
and right side trunk lining
Cover for fuel pump set remove, insta U.
Coupling (arrow) for fuel gauge ·
sender unp1ug, p1ug m.
take off, fit on. Collect remaining fuel, seal connections. Check
Fuel suction hose (53), fuel
suitability forre-use. Ensure cup seals (72, 73) are correctly located.
retum hose (74), vent hose
Special tool 000 589 71 03 00 Tightening torque 21 Nm
Mercedes-Benz
Nuts (38, 4 ea.) unscrew, screw on. Use washers (35). Tightening torque 21 Nm.
NOTE:
lf optional "Bose Sound System" is fitted, remove amplifier unit,
install (82-7720).
remove, insert. Examine sound insulation strips (29, 30), replace if
Fuel tank (50) necessary. Todo this, stick on strips with MB universal adhesive 000
989 92 7 1.
remove, clean, check suítabilíty for re-use, install. Tighteníng torque 40
Fuel strainer (23)
N m.
0-ring (26) replace.
Leaktightness of all connections check with eugine running.
Special tools
~
~
000 589 71 03 00
83
/
001 581} 72 21 00
00
F ig. 90: Identifying Special T ool (001 589 72 21 00 00)
B. W ith skibag
Mercedes-Benz
30
~
Fig. 91: Identifying Fuel Tank Components (With Skibag)
@ Pay attention to
safety precautions!
Expansion tank remove, install (47-8021).
Seal (41) examine, replace if necessary.
Coupling (arrow) for
unplug, plug in.
fuel gauge sender (B4)
empty. Carefully pmnp out fuel so that no fuel remains in the tan.k. Capacity
Fuel tank (50)
about 90 liters.
Cup seal (55)
Fuel suction hose (53), remove, insert.
fuel retum hose (74)
take off, fit on. Collect remaining fuel, seal connections, check suitability forre-
use. Ensure cup seals (72, 73) are correctly located. Special tool 000 589 71 03
OO. T ightening torque 30 Nm as reference value.
Nuts (38, 4ea.)
unscrew, screw on. Use washers (35). Tightening torque 21 Nm.
NOTE:
Fuel tank (50)
lf "Bose Sound System" is fitted, remove amplifier unit, install (82-7720).
remove, insert. Examine sound insulating strips (29, 30), replace if necessary. To
do th1s, stick on strips with MB universal adhesive 000 989 92 71.
Bracket (24) of skibag
motmt
Fuel strainer (23) remove, install.
remove, clean, check suitability for re-use, install. Tightening torque 40 Nm.
0-ring (26) replace.
Mercedes-Benz
connection points
Special tools
000 589 71 03 00
83
001 589 72 21 00
00
REMOVING AND INSTALLING FUEL GAUGE SENDING UNIT- RA47001047000X(47-7000)
Removing and installing fuel gauge sending unit- RA47001047000X(47-7000)
47 -7000
A. Model 124 Sedan

Mercedes-Benz
Fig. 94: Identifying Fuel Gauge Seoding Unit Components (Model124 Sedan)
® Pay attention to safety regulations.

Pressure in fuel tank release by removing fuel filler cap, fitting on.
Fuel tank lining remove, install.
Connector at fuel gauge sending unit (B4)unplug, plug in. Secure against slipping.
Sealing flange (65) unscrew, screw on.
NOTE:
lf fueltank full, pump out approx. 8 liters beforehand.
Fuel gauge sending unit (B4) remove, install, run dry if necessary.
Remove locking pin below adhesive strip (new part only).
Replace seal.
Tightening torque 39 Nm as a reference value.
Special tool
001 589 72 21 00 1
00
B. Model 124 T -model

Mercedes-Benz
Fig. 96: Identifying Fuel Gauge Sending Unit Components (Model124 T-Model)
® Pay attention to safety regulations.

Pressure in fuel tank release by removing fuel filler cap, fitting on.
Front load area flap or 3rd bench seat remove, install.
backrest
Load area lining partially remove, install.
Cap unclip, clip in.
Connector at fuel gauge sending unit (B4) unplug, plug in.
Fuel gauge sending unit (B4) remove, install, run dry if necessary.
NOTE :
lf fuel tank is full, pump out about 8 liters first of all .
Replace seal.
Remove locking pin between adhesive strip (new part only).
Tightening torque 39 N m as a reference val u e.
Special tool
001 539 72 21 00
00
Mercedes-Benz
C. Model 124 Convertible
B4
~
~4812
Fig. 98: ldentifying Fuel Gauge Sending Unit Components (Model124 Convertible)
® Pay attentíon to safety

precautions!
open, close. To do this, open soft top sufficiently until the compartment
Soft top compartment cover
cover can be opened manually or hydraulically.
disconnect, connect. Todo this, remove right side trim panel in trunk,
instan.
Trim in soft top compartment remove, install.
Pressure in fuel tank releas e by taking off fuel filler cap, fitting on.
Coupling (arrow) for fu el
unplug, plug in.
gauge sensor (B4)
remove, install. Run sensor until empty, ifnecessary. Replace 0-ring
Fuel gauge sensor (B4)
(48/2).
®
If fuel tank is full, pump out about 8 liters.
NOTE:
lf new part, remove locking pin below adhesive strip.
Mercedes-Benz
Special tool
001 589 72 21 00
00
Fi~. 99: Identi fyi n~ Special Tool (001 589 72 21 00 00)
D. Model 129
Fi~. 100: Id entifvin ~ Fue) Gau ~e Sendine Unit Components (Model 129)
® Pay attentíon to safety regulatíons.

disconnect, connect by removing right side lining in trunk,
installíng.
Pressure in fue] tank release by taking off fuel filler cap, fitting on.
Hard top remove, fit on.
Soft top fold open, retract.
Cap unclip, clip in.
Connector at fuel gauge sending unit
unplug, secure against slipping off, plug in.
(B4)
Fu el gauge sending unit (B4) remove, install, run dry if necessary.
NOTE:
lf fuel tank full, pump out about 8 liters first of all.
Replace seal.
Remove locking pin below adhesive strip (only ífnew part).
Tightening torque 39 Nm as a reference value.
Mercedes-Benz
Special tool
001 589 7 2 21 00
00
Removing and Installing Fuel Gauge Sending Unit- RA7001197000X(47-7000)
47-7000
Fig. 102: ldentifying Fuel Gauge Sending Unit
® Pay attention to safety

precautions!
Hardtop detach, fit on.
close sufficiently for the soft top to move fully out ofthe stowage
Soft top
compartment and for the stowage compartment cover to still be open.
Ground cable at battery detach, attach by removing ríght side trirn in tnmk, installing.
Cover of fu el gauge
in stowage cornpartment, unclip, clip in place.
sending unit
Coupling at fue] gauge
unplug, secure against slipping, plug in.
sending lmit (B4)
Fuel gauge sending unit
remove, install; run to empty if necessary.
(B4)
Mercedes-Benz
Replace seal. Remove security pin below adhesive strip (new part only).
SpeciaJ tool
001 581) 72 21 00
00
Fi~. 103: Identifyin~ Special Tool (001 589 72 21 00 00)
Removing and installing fuel gauge sending unit- RA47LH1047000X(47-7000)
Operation No. of operatíon texts and operation values or standard texts aud flat rates
47-7000
~14
~17 20
P47-0082-57
Mercedes-Benz
Fig. 104: ldentifying Fuel Gauge Sending Unit Components
® Pay attention to safety instmctions!

Overpressure in fuel tank reduce by taking off pressure cap, fitting on.
Ground cable disconnect at battery, connect.
Cover for fuel tan.k remove, install.
Fuel gauge sending unit connector
unplug, plug in.
(arrow) (B4)
Sealing flange (14) unscrew, screw on.
® lf fuel tank full, pump out approx. 8 liters. Tightening
torque 39 Nm.
0-rings (17, 20) renew.
Fuel gauge sending unit (B4) remove, install. lf necessary, run send.ing unit until dry.
NOTE:
lf new part, remove locking pin below adhesive strip.
REMOVING AND INSTALLING GUIDE FUNNEL - RA47001047571X(47-7571)
Removing and installing guide funnel- RA47001047571X(47-7571)
47-7571
Fig. 105: ldentifying Guide Funnel Components
Guide remove, install by withdrawing the two rivets (arrows) as far as the stop with puller 123 589
funnel (1) 05 33 00, knock in with drift.
® The rivets rnust not drop into the fuel tank as they neutralize the function of the surge
bowl (reserve quantity cannot be used).
NOTE:
A guide funnel (1) is installed beca use of the smaller pistol neck for unleaded fu el. lf the
Mercedes-Benz
fuel tank is replaced, a guide funnel must be installed.
Special tool
12'3 589 os 33 00 1
07
F ig. 106: ldentifying Special Tool (123 589 OS 33 00 00)
NOTE: Vehicles with KAT except 0 Since June 1989 the guide funnel has additional
notches (arrows) to facilitate installation.
F ig. 107: Locating Guide Funnel Notches
PRODUCTION BREAKPOINT: JUNE 1989

Vehicle ident end no.
Model Engine A/B F
124.031 104.980 020969 -
124.051 104.980 021039 -
124.091 104.980 - 114201
Removing and Installing Guide FunneJ- RA47001197571X(47-7571)

Mercedes-Benz
47-7571
Fig. 108: ldentifying Guide Funnel Components
Guide remove, install by pulling out the two rivets (arrows) as far as the stop with puller 123 589 05
funnel (1) 33 00, knocking in witb drift.
NOTE:
A guide funnel (1) is installed because of the smaller fuel dispensing pump pistol for
unleaded fuel. lf the fuel tank is replaced, a guide funnel must be installed.
Special tool
123 589 ~ 33 00
07
Removing and installing guide funnel- RA47LH1047571X(47-7571)
Operatíon No. of operation texts and operatíon values or standard texts and flat rates
47-7571
Mercedes-Benz
Fig. 110: ldentifving Guide Funnel Components
® Pay attention to
take off, fit on.
safety instructions.
NOTE:
Cap for fuel tank
Guide funnel (45) must be fitted to vehicles with catalytic converter.
remove, install. Remove the rivets (arrows) with special tool 123 589 05 33 OO.
Guide funnel (45)
When installing, knock in rivet with mandrel.
® Ensure that no rivets drop into the fuel tank. They result in the splash pot
being rendered inoperative (reserve fu el quantity cannot be used).
Special tool
12'J 5a9 05 33 00
07
REMOVING AND INSTALLING CHARCOAL CANISTER- RA47001048212X(47-8212)
Removing and installing cbarcoal canister- RA47001048212X(47-8212)
Mercedes-Benz
47- 8212
52 Charcool canstm A Ragenerabon • na

64 Bóe11~er lna lB To iJ el trui<
Fig. 112: ldentifying Charcoal Canister Components
Left front wheel unscrew, screw on.

Tightening torque of wbeel bolts 11 O Nm.
Interior lining in wheelhouse remove, install.
Lines at charcoal canister (52) detach, attach.
Charcoal canister (52) withdraw upward, insert from above.
Removing and InstaJling Activated Charcoal Canister- RA47001198212X(47-8212)
47-8212
Mercedes-Benz
52 Aclva'.Dd eh BfCOal C1llliS!ar A Regenerallon t oo

64 Ventln& 13 To kleHank
Fig. 113: Identifying Activated Charcoal Canister Components
Front left inner fender remove, install.

Lines (64, A and B) at activated charcoal canister (52) detach, fit on.
Activated charcoal canister (52) withdraw upward, insert from above downward.
Removing and installing activated charcoaJ f1lter- RA47LH1048212X(47-8212)
Operation No. of operation texts and operation values or standard texts and flat rates
47-82 12
Mercedes-Benz
t N311
55
P47-5007-55
Fig. 114: Function Of Activated Charcoal Filter
Modal 140, 100 '"~etuel tark'lltltlott slobag Mcdel 140, 90 ltre fue! lallk'llttl s!Qbag
Fig. 115: Identifying Activated Charcoal Filter Components
Left rear wheel on model 140 remove, fit on.

Pay attention to tightening torque of wheel bolts (see 40-1450).
Wheelhouse liner remove, install.
Pipes at activated charcoal filter (52) detach, attach.
Activated charcoal filter (52) release upward, insert downward.
REMOVING AND INSTALLING REGENERATION SWITCHOVER VALVE (FUEL

EV APORATION)- RA47001048252X(47-8252)
Removing and installing regeneration switchover vaJve (fuel evaporation)- RA47001048252X(47-8252)

Mercedes-Benz
47 -8252
Mcdet 12'9
Fig. 116: ldentifying Regeneration Switchover Valve Components (Model129)
MOOel 124
Fig. 117: ldentifying Regeneration Switchover Valve Components (Modell24)
Electrical connector at unplug, plug in.

rPPP.nP.rMion ~witr.hovP.r
Mercedes-Benz
val ve
Both regeneration lines at regeneration switchover valve (Y58/ l), detach, fit on.
Screw tmscrew, screw m.
Regeneration switchover
remove, insert.
valve (Y58/ l)
CIS-E control unit fault read out, erase ]f necessary (see Diagnosis Manual Engine, Volume 2, lndex
memory 0).
NOTE:
Stored faults which may originate from test work resulting from cables
being disconnected or from a simulation, must be erased in the fault
memory after completing the work.
Removiog and Iostalliog Regeoeratioo Switchover Valve (Fuel Evaporation Control System)- RA47001198252X(47-
8252)
Preceding work:
Removing and ínstalling air cleaner (09-0015)
47-8252
1
Fig. 118: ldentifying Regeneration Switchover Valve Components
Mercedes-Benz
Electric coupling
at regeneration switchover valve (Y58/ l), unplug, plug in.
(arrow) (Y58/ l)
Nuts (2 of) at regeneration switchover valve bracket, unscrew, screw on.
Reoeneration switchover withdra~ upward, insert. . .
{ (YSS/ l) Detach lmes to regenerat10n valve and to throttle valve assembly, fit on for thts
va ve step (see KE function diag¡·am 07.3-0003).
KE control unit fault read out; erase, ifnecessary (see Diagnosis Manual Engine, Volume 2, register
memocy ~-
NOTE:
wiring or simulation, must be erased in the fault memory after completion of
work.
Removing and installing regener.ation switchover valve (fuel evaporation)- RA47L H1048252X(47-8252)
47-8252
F ig. 119: Identifying R egeneration Switchover Valve Components
Electricai connector (arrow) disconnect, plug in.

Both regeneration lines at regeneration switchover valve (Y58/ l), disconnect, plug in.
Regeneration switchover valve
detach with rubber holder, attach.
(Y58/ I)
read, erase ifnecessary (see Diagnosis Manual Engine, Volume 2,
Index 0).
TEC HNICAL MODIFICATIONS ENGINE 104 COMBUSTION CIS-E INJECTION-

RA4700104TAOOX
Mercedes-Benz
Fuel system
Designation Nature and reason for Production O p.

modification breakpoint No.
Guide funnel with
Guide ftumel in ft1el tank filler neck Vehicles H additional notches 47-
06/89
with KAT except 0 Reason: facilitates 7571
installation
Conversion to moulded 47-
Fuel hose from fuel tank to fuel pump 10/89
hose 4100
FUEL COOLER- RA4700FLH0005X(47-0005)
FueJ cooJer- RA4700FLH0005X(47-0005)
To reduce the fonnation ofvapor bubbles in the fuel system at high outside temperatures, a fuel cooler (75) is
installed. It is located in the refrigerant return line between evaporator and A/C compressor. The ft1el cooler is
attached to the left wheelhouse in the engine compartment.
When the engine is running, the fue) fed back by the diaphragm pressure regulator flows back pressureless
through the fuel cooler into the fuel tank.
As soon as the A/C compressor is switched off, gases re frigerant, which flows through the inner pipe of the fu el
cooler, removes the beat from the fuel.
Fig. 120: Identifying Fuel Cooler
Fuel cooler - RA4700KE30005X(47-0005)
NationaJ versions 0 0 ~
' '
Mercedes-Benz
3 8 7 A 4
~~I~P----I---~--1------~I------~
1, 2 Fuel retum i ne 8 k1stJ!aoog hc>se

3, 4 Refngemnt retum file 9 AC compmssoí
6 Otlter pep.e 75 Fue! coofer
7 lnner pipe
Fig. 121: Example OfFuel Cooler Fitted To Engine
Example of fuel cooler fitted to engine
A fuel cooler is installed to reduce the formation ofvapor bubbles in the fuel system at high outside
temperatures. The fuel cooler is located in the refrigerant return line between evaporator and AC compressor.
When the engine is running, the excess fuel in the fuel distributor flows back pressureless through the fuel
cooler into the fuel tank
So long as the AC compressor is operating, heat is withdrawn from the fu.el by tbe gaseous refrigerant whicb
flows througb the inner pipe of tbe fuel cooler.
Mercedes-Benz
Example model201 up to 08/85
Fue! cooler at left wheelhouse
Foelrellm l ne i"om fl.lel cisrtKJIDr

2 Foel re1Jm l no ID fual !Bnk
75 Foelcooler
Fie. 122: Example OfFuel Cooler At Left Wbeelhouse (Model201 Up To 08/85)
Examplemodels 107, 126onengines 116, 117
Fuel cooler at left wheelhouse
3 2 1 6 7 8 4
1 Foelrelum l oo lrom fiJel <istllutDr
2 Foel rellm l no ID fl.lol tank
3, 4 Refngemrt retum l oe
6 Ot.cer~e
? lmerptpe
8 ~sulatng hose
75 Foel tooler
P47-0054-17 ,.,.0014 _17
Fig.123: Example OfFuel Cooler At Left Wbeelbouse (Models 107, 126 On Engines 116, 117)
Mercedes-Benz
FUEL TANK WITH SPLASH BOWL- RA4700FLH0010X(47-0010)
Fuel tank with splash bowl- RA4700FLH0010X(47-0010)
57 70
87/1 71
Fi2. 124: Function OfFuel Tank Components With Splash Bowl
A splash bowl (67) is installed in the fuel tank Its task is to reliably supply the engine with fuel when the fuel
level in the tank is low and during long comering.
The fuel returnjet flows at high speed out ofthe return nozzle into the splash bowl when the fuel pump is
operating. It thus entrains the fuel around the return nozzle with it into the splash bowl. The retum nozzle is
located at the bottom of the splash bowl.
The fuellevel (h) is retained in the splash bowl even ifthe level in the fuel tank drops below the height (h). The
vapor bubbles contained in the fuel flowing back are separated from the fuel in the separating chamber (67/ 1)
and rise up vía the riser pipe (71 ). This avoids splashing noises.
Fuel Gauge Sender- RA4700HFM0010X(47-0010)
A. Model124
Mercedes-Benz
1 VVii!'W coliact 4 Guido and COO!ad rod

2 Float 5 RI}SOIVewantng cootacl
3 Cmactplsto
Fig. 125: Function OfFuel Gauge Sender Components (Model124)
As the fuellevel drops, the variable resistance is increased by the float (2) moving down, as a result of which
the voltage drops and the needle in the instrument cluster m oves back.
If the fuellevel drops to the reserve quantíty, the reserve warning contact ( 5) eloses and switch es ground to the
reserve warning lamp, as a result of which the lamp comes on when the engine is running.
The reserve warning lamp comes on when the ignition is switched on (check function). It goes out as soon as
the engine is running provided the fuel tank contains more than the reserve quantíty.
B. Models 129, 140
NOTE: The reserve warning lamp comes on with a weak light for the check function,
and with a brighter light to indicate reserve quantity.
Mercedes-Benz
P4i-0018-S5A
1 VVi~ cortaa
2 Floe~
3 Gude end conteá rod
Fi2. 126: Function Of Fuel Gau2e Sender Components (Model129, 140)
Sbown on engine 129
As the fuellevel drops, the variable resistance is increased by the float (2) moving down, as a result of which
the voltage drops and the needle in the instrument cluster moves back.
Ifthe fuel level drops to the reserve quantity, the reserve warning lamp is switched on by the electronics in the
gauge. As the reserve quantity decreases, the needle moves in the reserve display panel toward the end stop
(dynamic display).
The reserve warning lamp comes on when the ignition is switched on (check fimction). The lamp goes out as
soon as the eugine is running provided the fuel tank contains more than the reserve quantity.
C. Model 202
NOTE: The reserve warning lamp comes on with a weak light for check function, and
with a brighter light to indicate reserve quantity.
The sender (B4/ l) is a lever sender with wíper contact. A sender is installed in eaeh chamber of the fuel tank.
Mercedes-Benz
88 OUtet Yalve
89 Lefi closang pla!B
8411 Laltluel gauge sende!
P 47..511 1-13
Fig. 127: ldentifying Outlet Valve, Left Closing Plate And Fuel Gauge Sender
Fue] tank with splash bowl- RA4700KE30010X(47-0010)
P47-5017-55
66 Fuolller 7011 Rel\Sn oo2J!e

67 Splash 00t.1 79 Rel\Snlne
Fig. 128: Identifying Sheet Steel Fuel Tank Components With Splash Bowl
Sheet steel fuel tank
A splash bowl (67) with fuel filter (66) is installed in the fuel tank. Its task is to reliably supply the engine with
fuel when the fuel level in the tank is low and during long comering.
The fuel returnjet flows along the return line (79) when the fuel pump is nmning ata high speed out ofthe
retum nozzle (7011) into the splash bowl. In so doing, it carries with it into the splash bowl the fuellocated
around the return jet.
Splash bowl with lid

Mercedes-Benz
As of 1989 as a phased implementation measure on all models and on model 201.034 ( 190E 2.3-16) as of
vehicle ident end no. 117 955 a lid with an approx. 20 mm dia. hole is fitted additionally to the splash bowt
(67). This ensures that fuel is reliably supplied to the injection system even ifthere is only a small quantity of
fuel in the tank (reserve quantity) and during high lateral acceleration.
The fuellevel (h) is also retained in the splash bowl even ifthe fuel level in the tank drops below the height (h).
NOTE: On vehicles with plastic fuel tank the splash bowl is integrated directly in the
tan k.
The function corresponds to the splash bowl in the sheet steel fuel tank.
P47-00 22-531>41- 0()22 - s,1
67 ~~hbo•t.! 70 Retun ille

67f1 Separmng dlflll'tl9f 71 Rlserlne
Fig. 129: ldentifying Vapor Bubble Filteriog F uel Tank Components W itb Sp lasb Bowl (Models 107, 126,
129)
Vapor bubble filtering models 107, 126, 129
An additional separating chamber (67/ 1) is created in the splash bowl (67).
The gas vapors contained in the fu el flowing back are separated from the fu el in the separating chamber (6711)
and led upward along the riser line (71). This avoids fuel splashing noises.
PRODUCTION BREAKPOINT (FUEL VAPOR FILTERING)

Mod el Vehicle ident end no.
107 as of A 069 655 (approx. 05/87)
126 as of A 327 880 (approx. 03/87)
FUEL GAUGE SENSOR- RA4700FLH0020X(47-0020)
Fuel gauge sensor- RA4700FLH0020X(47-0020)
A. Modell24
Mercedes-Benz
1 Wlpur cortact 4 Gude and cortad rod

2 Flcat 5 Re selVa wlllring coolacl
S Cortad pla:e
Fig. 130: Function Of Fuel Gauge Sensor Components (Modell24)
As the fuellevel drops, the variable resistance is increased by the float (2) moving down, as a result of
which the voltage drops and the needle of the gauge in the instrument cluster moves back.
Ifthe fuellevel drops to the reserve quantity, the r eserve warning contact closes (5) and switches ground
to the reserve warning lamp, as a result of which tlús lamp lights up when the engine is running.
B. Models 129, 140
NOTE: The reserve warning lamp lights up with a weak light as a check function,
with a strong light to indicate reserve quantity.
Testing fue) gauge (54-257) .

Mercedes-Benz
1 IMpar contad
2 Flo1it
4 GudD and rornact roo
Fi2. 131: Function Of Fuel Gau2e Sensor Components (Models 129, 140)
Shown on model1 29
As the fuel level drops, the variable resistance is increased by the float (2) as it moves down, as a result of
which the voltage drops and the needle of the gauge in the instrument cluster m oves back.
If the fuellevel drops to reserve quantity, the reserve warning lamp is switched on by electronics in the
gauge. As the reserve quantity decreases, the needle m oves in the reserve field of the gauge to the end
stop (dynamic indication). The reserve warning lamp lights up when the ignition is switched on (check
function). As soon as the engine is running, it goes out provided the fuel tank contains more than the
reserve quantity.
NOTE: The reserve warning lamp lights up with a weak light as a check function ,
and with a stronger light to indicate reserve quantity.
Testing fuel gauge (54-257) .
F uel Tan k - RA4700HFM0020X(47-0020)
A. M odel 124
Mercedes-Benz
.52/1
fa 52tt
a Topu-gmg v~
P 47-5075.57
Fig. 132: Function Of Fuel Tank (Model124)
The fuel tank vent system consist of a central pipe (54) with interruption vessels (54/1) at the ends.
The interruption vessels (54/ l) prevent fuel escaping along the vent pipe (64). The vent pipe (64) runs from the
central pipe through the vent val ve (51) to the activated chru·coal filter (52).
Air is supplied to the activated charcoal filter (52) ru1d to the fuel tank (50) from the engine compartment
tbrough the cup seal (52/ 1).
B. Models 129, 140

Mercedes-Benz
-
p 4 7-0084-57
Fie. 133: Function OfFuel Tank (Models 129, 140)
The fuel tank vent system consist ofa central pipe (54) with interruption vessels (54/ 1) at the ends.
The interruption vessels (54/ 1) prevent fuel escaping along the vent pipe (64). The vent pipe (64) runs from the
central pipe through the vent val ve (51) to the actívated charcoal filter (52).
Model129
Air is supplied to the actívated charcoal filter (52) and to the fuel tank (50) from the front left síde member.
Modell40
Air is supplied to the activated charcoal filter (52) and to the fuel tank (50) from the rear left wheelhouse.
C. Model140 with through-loading facility

Mercedes-Benz
55
P4T-5076-S5
50 Fuellank 55 Expans10n taric
51 Ventv~ 64 Ventppe
52 Ac&va!ed charooel fit& B To pu-gJng ..,Blve
Fig. 134: Function OfFuel Tank (Model140 With Through-Loading Facility)
On models with the through-loading facility, the fuel tank (50) is lowered in the middle and the expansion tank
(55) is located on the outside.
D. Model202
Mercedes-Benz
9511 8014 9112
80 90/& to/4
P47-5106-57
8014 S~po! 9511 l elt sucti en spray punp
9014 F eed p¡pe 9512 Rtght su ctlon Spmf pufTll
9018 Oegastng connedonftuel punpro~m
Fig. 135: Function OfFuel Tank (Model202)
On models fitted with through-loading facility, the fuel tank (80) is positioned on the frame floor ahead of the
rear axle.
The fuel tank (50) is split into two chambers because of the U-shaped recess. The chambers are connected to
each other in the top halfwrule the lever senders for the fuel gauge, the suction spray pumps as well as the
piping from the left to the right fuel tank chambers are installed in the bottom half
The splashpot (80/4) is welded into the right hand chamber ofthe fuel tank and is required as a fuel reserve
vessel when comering and when the fuellevel is low. Two fuel feeds, one from each chamber ofthe tank, and
from the fuel filler neck merge in the splash pot (80/4). A strainer (80/6) is installed in the housing ofthe splash
pot and the right suction spray pump at the housing.
The suction spray pump pumps the fuel out ofthe left-hand and right-hand chambers ofthe fuel tank into the
splash pot. The latter has a nozzle through which the fuel retum is accelerated. The retum spray from this
nozzle flows at high velocity into the pipe running to the splash pot. As a result, it entrains the fuel around the
nozzle with it as it flows into the feed pipe and fills the splash pot.
Part of the retum quantity flows through the suction spray pump into the left-hand chamber of the tank while
the remaining quantity flows through the second suction spray pump. Both pumps fill the splash pot.
Mercedes-Benz
P 47-510<1-13
9511 l eft sucboo spa¡ypufll>
A Nonio
B To splasfl p-ot
R Fuelrotun
z lndudedluoJ
Fig. 136: ldentifyiog Suction Spray Pump Operation
The fu el gauge sender (B4/ l ), the outlet valve (88) and the suction spray pump (9 5/ 1) are attached to the closing
plate (89). Each chamber ofthe fuel tank is provided with a screw plug.
TI1e fuel tank can only be drained through the two outlet valves (88).
P47-5102-1 3
Fig. 137: Identifying Fuel Gauge Sender, Outlet Valve, Suction Spray Pump And Closing Plate
The expansion tank (39) is installed in the rear right wheel arch. It is used as a collecting vessel for the fuel
when corneríng and when it heats up.
Mercedes-Benz
P 47-5 105-13
82 Vootptp&to i et nGJ: I<

'91/2 Ventplpefcnafuai ng
9>1/3 Aum1ot andv-erd ws to·,..om V8Na·
il1 AJrutota"ldvomptpa fromtualt,M<
Fig. 138: ldentifying Expansion Tank, Vent Pipe To F iler Neck And Vent Pipe For Refueling
Fuel gauge sensor- RA4700KE30020X(47-0020)
A. Models 107, 124, 126, 201
4 Guda snd c'Oiltact ro<!

2 Ftom 5 Resetve WBIIllng con!Bct
3 Cortact plaJ!
Fiº- 139: Fnnc.tion OfFnel Gauge Sender Comnonents

Mercedes-Benz
As the fuellevel drops, a higher resistance is detected by the wiper contact ( 1) at the float (2), the current drops
and the needle in the instrurnent m oves back.
If the fuellevel drops to the reserve quantity, the reserve warning contact (5) is closed and ground is tbus
connected to the reserve warning lamp.
An electronic circuitry delays switching off and on ofthe reserve warning lamp by approx. 2 minutes (phased
implementation as of 09/87) in order to prevent tbe reserve warning lamp flickering in the transition range
before the reserve quantity is indicated.
NOTE: The reserve warning lamp lights up weakly for the check function and brightly
to indicate reserve quantity.
Testing fuel gauge sensor (54 -256).
Testing fue] gauge (54 -257).
The reserve warning lamp comes on when the ignition is switched on (check function). As soon as the engine is
mnning, it goes out provided the fuel tank contains more than the reserve quantity.
Model 201 as of 09/87
The installation position has been modified from approx. 15° (difference from vertical) to approx. 5°.
The instrument is matched to the new sensor position.
The modified sensor (5°) may also be installed in place of tbe previous sensor (15°), but not vice versa.
B.Model129
The fuel gauge sensor is telescopic in desif:¡rn and is moved to maximum position by means of spring pressure.
The sensor is guided by a conical sleeve in the lower area of the fuel tank and stands up at the bottom when
installed.
For ftmction refer to section A; in variation ofthis, the reserve fuel indicator is operated as follows:
When the reserve fuel quantity is reached, the reserve warning lamp lights up. At the same time, the reserve
quantity in the reserve area of the fu el gauge is indicated.
The r eserve fuel quantity is detected like the normal fu el gauge by means of the resistance wire in the fu el
gauge sensor. This eliminates the need for tbe reserve contact in the sensor and the connection is now only 2-
pm.
For testing fu el gauge see Diagnosis Manual Body Volu me l.

Mercedes-Benz
Fig. 140: ldentifying Fuel Gauge Sensor Maximum Position
FUEL TANK POSITIVE AND NEGATIVE VENTILATION SYSTEM- RA4700FLH0030X(47-0030)
Fuel tank positive and negative ventilation system- RA4700FLH0030X(47-0030)
A. All models
Mercedes-Benz
40 Cap 43 Compressicn spnng

41 Soal 44 Filarn&d<
42 lcd~11gba¡
Fig. 141: Function Of Fuel Tank Positive And Negative Ventilation System Components (All Models)
Cap
The fuel evaporation gases are able to escape through the cap ata pressure of 100-300 mbar. This only occurs,
bowever, if, for example, the vent pipe from the fuel tank is blocked as a result of crimping or improper routing.
Ifthe system is operating properly, a pressure ofup to 50 robar may occur in the fuel tank.
B.Model124
Mercedes-Benz
.52/1
54 64
a 1 0re~on ~nv~•e
--g
F ig. 142: Function OfFuel T ank Positive And Negative Ventilation Svstem Components (Model124}
The vent system consists ofa central pipe (54) with interruption vessels (54/ 1) at the ends. The interruption
vessels (5411) prevent the fuel escaping along the vent line (64). The vent line (64) runs from the central pipe
through the vent valve (51) to the activated charcoal filter (52). Air is admitted to the activated charcoal filter
(52) and fuel tank (50) from the engine compartment through the cup seal (52/ 1).
C. Models 129,140
Mercedes-Benz
.. .
Fig. 143: Function OfFuel Tank Positive And Negative Ventilation System Components (Model129, 140)
The vent system consists ofa central pipe (54) with interruption vessels (54/ 1) at the ends. The interruption
vessels (54/ 1) prevent the fue! escaping along the vent pipe (64). The vent pipe runs frorn the central pipe (64)
tbrough the vent valve (51) to the activated charcoal filter (52).
Mode1129
Air is admitted to the activated charcoal ftlter (52) and fue! tank (50) from the left front ofthe side member.
Mode1140
Air is admitted to the activated charcoal filter (52) and f11el tank (50) from the rear left wheelhouse.
D. Modell40 with through-loading facility

Mercedes-Benz
50 Fuellank 55
51 V&n!vat.u 64 VM!pipe
52 Adva!Dd charcoai iUOJ a Te> regenarmon vat.u
Fig. 144: Function OfFuel Tank Positive And Negative Ventilation System Components (Model140 With
Through-Loading Facilitv)
On vehicles with through-loading facility, the fuel tank (50) is lower in the middle and the expansion tank (55)
is located to the outside.
F unction Diagram ofFuel Evaporation Control System- RA4700HFM0030X(47-0030)
A Engine 104 HFM, models 124, 129, 140 witbout ski bag
Mercedes-Benz
N314
t
-
1911
YSB/1
A-
19a Remmanlckl 6 f"urQilg swlchover vatve. Kfe speed cootoi(LLR)

19b Resonanc IHrtake manfold adltator (M1IW) ptpe
75 Fuel tlnl< o Vert \'!lt.le • actwatedcharccalfíte; p¡pe
76 Vontvst.& E Alr 111ake p¡pe
77 Aciva:&d charroalliler M15.'6 ldia speed cortrcl (llR) ocll a1or
A Aeiva:&d eh arce al C.er - pu-Qilg sNii: llover vatie N314 HQ,tfim eng¡ne managemert(~Ml comcltnt
p¡pe Y58tl Purg;ngswlthover vatve
Fig.145: Function Diagram OfFuel Evaporation Control Svstem (Engine 104 HFM, Model140 Without
Ski Bag)
Shown on engine 124
Mode1140 with ski bag

Mercedes-Benz
N314
P47-5150-57
19a Rammamfold 8 Purgong S'Méchcvor vatve - Kilo speed cooiol (llR)

190 Rosonanc e mtal<& ml'llllold actuator {tvt1 615) ptpe
75 Fullllallk o Varo vatve- actM!iedchaícoalfímr ptpe
76 VentvaMI E Alr lnlllke ptpe
77 Aeiva)W dlarcoal fitor M1616 Ida s¡H~edccnlrcl (UR) m:k.ia!or
93 Fuel e¡q>an 5100 lallk N314 Hcl film &llgine manegom91t(HFM) cortrol unit
A Ac,va:&d charcoal tilor - purg;ngs'MII:hover valva Y58l1
pipe
Fig.146: Functioo Diagram Of Fuel Evaporatioo Control System (Eogine 104 HFM, Model140 With Ski
Bag)
Model202
Mercedes-Benz
75
P47-5149-57
19a Rammantold 93 Fuel Blt)atlSIOfliBnk

19b Resonanc e utaka ml!lllfold A Aclva~ charroal filar. pu-~g SYitlrhcVar~e
4E/3 Ventptpeto i lerneck ptpa
75 Fue l!lnk B PUrgng S'<l' lllchoverlllW& - l cle spoedcomrol (LLR)
76 VentvaM! adi.JalOf (M1616) we
77 Adva'.nd charroal M:or o Ven ! vaNa • adl\'!lted dlarcoal U:or wo
7713 Au~rtetcap
M15f6 klo spood cortrol (llR) adl.lator
N3."1 Hot 11m en~e m81l!!gomll!t (HFM) c-ortrolm'
91/2 Vent PIPG for roruetng
YS811 Purpng &Mtcllover vat.e
91/3 AJr 1rtel andvert llC'6 tovort V.We
92 AJr 1rtet andvert ~e fromfuellaril
Fig. 147: Function Diagram OfFuel Evaporation Control System (Engine 104 HFM, Model 202)
B Engine 111 HFM, model124

Mercedes-Benz
Y5811
A-
t- o
71
P47-SOS2-S7
19 lrtaka marífold o Vantvalve - actJwted chatcoalil:erwe

75 Fuellank E Alr 1 m!!ke~
76 Vontvatve M1616 liJe speed coruol «-LR) actuetor
77 Adva~d dlarcoal rt~ N314 Hot U n ooQIIlom611agomem {1-FM)comolun
A Atlva!ed dlarcoal fitBf- purg11g S'Nllrhc>ver 'I!Wo Y5611 PUrgng !M!lchc>ver va!lte
pipe
B P\lrgmg s•t~~lchcver vé!Ml - 1d:e spaad comol «-LR)
actualor (M1616) ~
Fig. 148: Function Diagram Of Fuel Evaporation Control System (Engine 111 HFM, Model 124)
Model202
Mercedes-Benz
9113
M1016
sw
V5811
t t
A O
7713
75
P47-514~57
19 lrtake manfold 9:3 Fuel e~am1on1Bnk

46/l Venlpipelo llar oock A Act va'.ad chBfCoal filar- purg,11g sv..t:hover ~e
75 Fuel !iml, pipa
76 B Purpng Mtdlover vaMI - lde speedv~e ack.lailr -
n Aclvaled eh are cal filler ad!Yc!ted charroal Uer PIPO
n/3 Auírtetcap o Vent vaMI- adlvaled chi!{c"Oalliler pipe
M16/6 kle s¡MJod ocrtrot (llR) actuator
91/2 Veot pipe for reluolng
9113 Au utet andvert p;po to vert vaNe N314 Hol Un angane managemert (HFM) cortrolml
92 ~~ ut9l andvert PIPO trornfueltark
Y58f1 Purgng Mtchover vat.e
Fig. 149: Function Diagram OfFuel Evaporation Control System (Engine 111 HFM, Model202)
C Engine 111 PMS, model 124

Mercedes-Benz
P4 7-50B4-57
19 lrreke moofcld B Purg~ng \'Bive - d e speed cooiol(llR) actua!cr

39 TheflTl().va!ve {opens at 70'Cldose-'S el3.5 ' C) (M1 6/6)p~pe
50 Pu~ngV!We e Purg~ng ~e - tlOllTl~vat;e P!P8

75 Fueltank o Ven t val\<8 • amvated cha.rroal Uer ptpe
76 Ventva.'lie E Au arietl)!pe
77 Adve'.ad dllilcolll ~er M1616 Ida speBOCCitrol(llR)aáU!IIOf
Fig. 150: Function Diagram O fFuel Evaporation Control Svstem (Engine 111 PMS, Model124) - 1st
Version
1st version
NOTE: The thermo-valve (39) and the purging valve (50) are replaced by the purging
switchover valve (58/1) as a phas·e d-in measure (see 2nd version).
Mercedes-Benz
Y5811
A-
t- D
P 47-5082-57
19 Waka m11111fokl o Vent v&'Ve - edi-.aled charcoal ilor p¡po

75 Fuoltank E A1r u tel IJIIHl
76 VentvaMI M1616 LlR actuator
77 Actvéd eh are®! flter N3.14 HFM corool U'lt
A Acivéd ch·arroal hiEK- pu-gng s.,..l!:hovor \'<We Y58J1 f\Jrgng s:Attchoverv!lNe
IJIJ)e
8 Pur!llng s:~o~tchover v¡¡M¡ - LLR actuator (M1616) ptpe
Fig. 151: Function Diagram OfFuel Evaporation Control Svstem (Engine 111 PMS, Model l24)- 2nd
Version
2nd version
Model202
Mercedes-Benz
91fJ
e
t
A D
75
P47-5144-57
19 Walm marwlcld 91/3 Au l net and vom we to vert I'BNe

39 Thefmo-wtfo {opens al 70 'C/doses al 35 'C) 92 AJr 1riel and vort we from fuolt611k
46tl Ventp(peto i lcr nec k 93 Fuer e>t;umgon tank
50 f'Ur¡;~ng ~fe A Achlt.OO charcoal RIOf - purg¡¡g va.\re PIP9
75 Fuel took 8 P\Jrgng \'!We -ld!e sptloó coorolac~e1cr (M1'6/6)
76 Vontva.'\ie PIPE!
n Aciva'.ed charcoal fitOf e P\Jrging \'!We - tlerm~e.l..a p¡pe
n f3 AJr srtat e ep o Ven ! val·..a - erttvalod chatroalller we
91/2 Vent pepe for reluei ng M1616 Ido speod ccrtrol (llR) sduator
F ig. 152: Function Diagram Of F uel Evaporation Control System (Engine 111 PMS, Model202)- 1st
Version
1st version
NOTE: The thermo-valve (39) and the purging valve (50) are replaced by the purging
switchover valve (58/1) as a phas·e d-in measure (see 2nd version).
Mercedes-Benz
9113
-76
t
A
75
P 47 -5143-57
19 ~ake man~fold 93 Fool BJ()OOSIOOiank

4 6/3 Ventpípeto tler neck A Acha»d charcoal fl.ar- pu-g;r¡g S'llllrhovar ~E
75 Fuol !allk p¡pe
76 Vootvlt.-e B Puf9ng S'MichGvar valw - tde spaedvalva !d.J8
atbvated charcoallilor PlllS
n AcivOOMI charcoal hlar
o Ven! vaMI • &etMited dlafooal Uor p¡p&
n/3 Alr in!etcap
M1616 klo speed cortrol (l.LR) actuatOI"
91/2 V8fltp¡pGt01" relueing
91/3 N3.14 Hot thl engru~managemart (1-FM) CO!úolllll
Al miel andvert ptlle to veri \'Biva
Alr tria! andvelt ptlle from fuel tark
Y5611 Purgtng SM!chovar val\9
92
Fig. 153: Function Diagram OfFuel Evaporation Control Svstem (Engine 111 PMS, Model202)- 2nd
Version
2nd version
Fuel tank air admission and ventilation- RA4700KE30030K(47-0030)
A. AU models
Mercedes-Benz
.1
40 43 C~mplS'SSIOfl spnng
41 44 F Mned<
42 Closang d amp
Fig. 154: F unction Diagr am Of F uel Tank Air Admission And Ventilation (AII Models)
Filler cap
The fuel evaporation gases can escape through the filler cap atan overpressure of 100-300 mbar (emergency
ventilation, e. g. ifvent line crimped or vent valve faulty).
Ifthe system is operating properly, a pressure of30- 50 mbar is produced in the fuel tank.
NOTE: As a phased implementation measure, the filler cap is provided with a plastic
slide ring to facilitate operation. The filler cap (40) slides on this ring with
minimal friction and locks in both end positions.
F unction of vent valve (51)
If a pressure of 30-50 mbar is exceeded in the fuel tank, the vent val ve (4) opens and the fuel vapors flow to the
active charcoal filter.
NOTE: The pressure in the fuel tank improves fuel supply and counteracts the
formation of vapor bubbles.
Vent valve (51) open to active charcoal filter

Mercedes-Benz
Fig. 155: Function OfVent Valve
Vent valve open if overpressure exists. Ventilation to atmosphere (without fuel evaporation system).
1 Cornpr~'.i 51011 spring

2 Va'w hooSing
3 Spnng retllll1 or
4 Vortva.v&
5 V atvB pla!e 7-----~
6 A .. admJsSion vatve
7 Conne<:boo it11ng 6-----..~
A AfiNe dla;coal iltlll conn eálon
8 Fuel tark connedlon 5 --~u·1fi!iíf"
4--~- ...L:"....w;.
3 ---~'!111
~=~~~~
Fig. 156: Function Of Vent Valve (Without Fuel Evaporation Svstem)
If a vacuum of 1-16 m bar is produced in the fu el tank, the air admission valve (6) opens. On vehicles fitted with
fu el evaporation system, air is admitted to the fu el tank through a cup seal on the left wheelhouse panel and
through the active charcoal filter (see 47-0200).
Mercedes-Benz
Vern v.a.\re ~5-1 ) cpan tcfool tark
Fi~.1 57: Function Of Vent Vahre
B.Modell07
--~~ ~~----66
'\·--~-60
62 51
53
50 Fuoltank 53 R9Ql9llore0011 '<&'va

51 Venlvalve 55 Fuel e)t!)anSion lank
52 Aelive chan:calfil:nr 64 PIJ}BS
5211 Alf atiiTIJSSIOO cap 6411 Vent l ne
Fig. 158: Function Diagram Of Fuel Tank Air Admission And Ventilation (Model107)
Function diagram fuel tank air admission and ventilation
A seoarate fuel exoansion tank (55) is oositioned above the fuel tank. The fuel exoansion tank (55) is connected
Mercedes-Benz
to the fu el tank (50) by 5 pipes ( 64). Depending on fu el leve! and fuel temperature in the tank, these pipes may
actas overflow, discharge or vent lines.
The vent line (64/ 1) runs from the fuel expansion tank (55) through the tail floor panel to the vent valve (5 1).
C. Models 124, 126 and 201
Air is admitted to and released from the fuel tank through the air admission cap (52/ 1) of the active charcoal
filter (52).
On vehicles without fuel evaporation system, air is admitted to the fuel tank and released from the tank by the
vent valve (51) directly to atmospbere.
For function offuel evaporation system see 47-0200.
52f2
J t
52
so Fooltank 54 C enralpipe
51 VootvaMI 54/1 lrt8frq)ÓOO vessels
52 Ac•va cha«oalñtsr 64(1 Ventline
5212 C141 seal
Fig. 159: Function Diagram OfFuel Tank Air Admission And Ventilation (lVlodels 124, 126 And 201)
Function diagram fuel tank air admission and ventilation

Mercedes-Benz
In the case of the sheet steel fuel tank, the ventílation system consists ofa central pipe (54) with interruption
vessels (54/1).
The interruption vessels prevent the fuel escaping along the vent line (64/ 1). The vent line (64/1) runs from the
central pipe to the vent valve (51).
Air is admitted to and released from the fuel tank (50) via the cup seal (52/2) and the active charcoal filter (52).
On vehicles without fuel evaporatíon system, air is admitted to the fuel tank and relea sed from the fuel tank by
the vent valve (51) directly to atmosphere.
Note regarding plastic fuel tank
The integrated air admission chamber above the plastic fuel tank replaces the central pipe and performs the air
admission and release function.
D. Model 126 with ASR first version and special protection vehicles
J47-00M-&7
50 Fuollook 54 Caruelptpa
51 Vootvatva 54/1 lrte¡n¡pllorl V&SSols
52 Adve chaccoalfil'.ef 64 VooUne
52/2 Ctp soal
Fig.160: Function Diagram OfFuel Tank Air Admission And Release (Model126 With ASR)
Mercedes-Benz
Function diagram fuel tank air admissíon and release
On vehicles with ASR the active charcoal filter (52) is positioned below the rear floor. Aír is admitted to the
fu el tank (50) through the airpermeable floor (arrows) of the active charcoal filter (52). The cup seal in tbe left
front wheelhouse is discontinued. The line (A) runs to the regeneration valve.
E. Model 129
-
..
36 70 ·e lttormo v!IM! (black w fl whiiD suJroUnd) 52 .A.dve charc oalfiblf

45 ltro~e VtJt.te body 5213 Frort, left slde m lliTi>er
50 Fuol mnk 53 Regen embon vatve
51 V9l11vaM:l
Fig. 161: Function Diagram OfFuel Tank Air Admission And Release (Model129)
Function diagram fuel tank air admission and release, model 129
The vent line ( 64/ 1) runs from the fu el tank (50) through the vent valve (51) to the active charcoal fílter (52).
Air is admitted from the front, left side member (52/3), air is released through the fuel evaporation system.
Location of components
Vent valve (51)

Mercedes-Benz
The vent valve (5 1) and the fuel return líne (70) are only accessible ifthe exhaust has flrst ofall been detached
at the rubber rings (49 - lOO) and the left input shaft has been disconnected at the inner connection flange (35-
620) ..
Fig. 162: ldentifying Vent Valve Components Location
Active charcoal filter (52)
Positioned in front, left wheelhouse behind front wheel.
To perform repair work, remove inner fender, install (88-130) .
52 Actr•e charcoal U er
6411 Vertlne
A Regenemboo lille
B To filel lanl<
'
L- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Fig. 163: ldentifying Active Charcoal Filter Components Location
FUEL EVAPORATION CONTROL SYSTEM- RA4700FLH0200X(47-0200)
Fuel evaporation control system- RA4700FLH0200X(47-0200)
A. Function diagram
a) Eogioe 104
Mercedes-Benz
so
51
S2
1 lrteke manfold M16/1

--IOOt--
BEKi'OOC accelefalorpedal {EFP) aduatOf
50 FUElllanl< N3/1 LH coorolul'lt
51 Vmlvat.o Y5811
52 Aciva:ed charroal ftler
Fig. 164: Fuel Evaporation Control Svstem Function Diagram (Engine 104)
b) Engine 119
1 lnte!<e m anfold N3f1 LH contolul'lt

2 loft<ylinderhead Y5811 Ragenern!Jon S'l'olll:hcver velve
50 Fuellank
51 VentvaMI
52 Acliva!Dd dlarcoal fl:er
Fig. 165: Fuel Evaporation Control System Function Diagram (Engine 119)
e) Engine 120
Mercedes-Benz
1
50
1=
!='uel mnl< NJ/'1 LoffLHcootrolunll
51 Vent vatva NJ/3 Righ!LH romrol Wli
52 Ac&va!M d:le¡QP.allitor Y58J2 loftr8'generabon S'Mtthover vatvo
M1613 Righl otedronic a:cceferalorp~a:ca.a~r Y5813 Rl\t4 regao€!fa oo swíl.chowrv&ve
M1614 l ett eltsctromc ac celerator p adel acwalor
Fie. 166: Fuel Evaporation Control System Function Diaeram CEneine 120)
d) Vebicles with througb-loading facility

Mercedes-Benz
5() Fuellallk B To ragoner!Ñon vaMI (sa~ sBCbon B, e)

51 Ventvafw&
52 Acava:od dl111t-oal filar
55 Expanston tart<
64 Ventlne
Fig. 167: Fuel Evaporation Control System Function Diagram (Vehicles With Through-Loading Facility)
B. Function
Regeneration takes place provided the following conditions exist:
• coolant temperature <70°C

• <2 minutes after starting engine
• engine not in deceleration mode.
A fuel evaporation control system is installed so that fuel vapors pass to atmosphere. The fuel vapors stored in
the activated charcoal filter are drawn off at coolant temperatures >70°C through the regeneration switchover
valve (Y58/ l , engine 120 Y58/2 and Y58/3) and combusted in the engine (not in deceleration mode).
Y58/3 Right regeneratjon switchover val ve
Arrow Regeneration switchover valve coupling

Mercedes-Benz
Fig. 168: ldentifying Right Regeneration Switchover Valve And Regeneratio111 Switchover Valve Coupling
To control the quantity regenerated, the regeneration switchover valve is actuated (pulsed) with a frequency of7
1/2 Hz by the LH control unit (N3/l, engine 120 N3/2 and N3/3). The regeneration quantity is determined by
the constant opening and closíng of the switchover valve in on and off times of various length.
The cross section in the switchover valve is altered as a functíon of the íntake manifold vacuum by the
diaphragm-guided valve needle.
Testing fuel evaporation control system, see Diagnosis Manual Engíne, Volume 2 LH Gasoline Injection
System.
Regeneration switchover valve (Y58/ l , engine 120 Y58/2 and Y58/3), de-energized closed.
Valve plate opened.

Mercedes-Benz
6 Valve plale
7 VBÑenoode
8 Oiaphragm
Y58/1 Ragooormon V58 / 1
mtcl'lover va.'llo V58.12
(eng~ne 104) Y58/3
Y58/2 l o: regenoc!Óon
s'Mtdlover vaMI
YSS/3 Riglt ragene;abon
mtd'lover vaMI
Fig. 169: Function OfRegeneration Switchover Valve
Fue) evaporation system- RA4700KE30200X(47-0200)
A. Models 107, 124, 126 and model129 with engine 103
51
Fig. 170: ldentifying Fuel Evaporation System Components (Model 107)
Modell07
Mercedes-Benz
Thelmo va.\!a 51 VoolvaMI

re<l 50"C 5-2 Ac~vacharco,;lflil!r
black wtil 1-.tllte SUTCun d as ot 09187 1o•c 52/2 Cupse.al
50 Fuel tank 53 Re-gan&ralíon valva
Fig. 171: ldentifying Fuel Evaporation System Components (Models 124, 126, 201)
Models 124, 126, 20 l
General
A fuel evaporation system is installed to reduce the quantity of fuel vapors escaping to atmosphere. The fuel
vapors are passed from the fuel tank (50) to the active charcoal filter (52) where they are stored.
Depending on the operating conditions of the engine, the fuel vapors are drawn off by means of the intake
manifold vacuum through the regeneration valve (53) and the throttle valve body and combusted in the engine.
The fuel vapors are not drawn off if:
• the coolant temperature drops below approx. 50°C or 70°C, respectively (thermo valve closed),
• the throttle valveis resting against id le speed stop.
Function diagram
Model 107
Mercedes-Benz
...¡_
36 Th811l10VaÑ8
so ·c red
es o1 O!MI7 70 •e blad<l
wlita
45 Throtle vaMI bcdy J

50 Fuel t!ll'k
51 Vortva!vo
52 Acl!ve dlarroel Uer
5211 A• adrms'Sion UlP
53 Regeoeraóon \'lllve
••
l
Fig. 172: Function Diagram Of Fuel Evaporation Svstem (Model107)
Function diagram
Model124
Modell26
Model201
Mercedes-Benz
...
_,
45
lS Thallllovalvo
50 ·e rod
as ot 0~.~7 70 ·e bl&l<l
wtltll
45 Throlt-e ve.\19 bW¡r 1

'!
50
51
Fuel tank
Vertvat.<e
•
52 AdJva dlarcoall or
....
52/1
5l
Cupseal
R egooorallcn vatve
- 50
t ~~ ~ ~~ !! ~
' 52 t t51
1
Fig.173: Function Diagram OfFuel Evapor ation System (Models 124, 126, 201)
Model 124 as of 09/87
The regeneration line mns from the active charcoal filter through the component and engine compartment to the
throttle valve body. The regeneration valve is located on the le:ft in front of the partition panel.
Function diagram
Model 126 with ASR first version and special protection vehicles
Mercedes-Benz
3ó 70 •e lhermovatve
45 Thro~vaMI~ ~
•
.t
50 Fueltali<
51 Vertvat.<e
52 Acbve dlarccal ller
53 Regi!OOfallon v.We
....
-
t
-
Fig.174: Function Diagram OfFuel Evaporation System (Model126 With ASR)
On vehícles with ASR ftrst version and specíal protection vehícles the active charcoal ftlter (52) is repositioned
below the rear :floor. The air is aclmitted to the fuel tank through the airpermeable :floor of the active charco al
filter.
Fig. 175: ldentifying Active Cbarcoal Filter

Mercedes-Benz
..
1
52
36 70 'C lherroo vft.-e (b!Bt k 'AIQ'l whta SUJTOUOd) 51 Advo eharc oá fifilr
45 l'Rotle valva bo<t{ 5213 Frort, lefi stde m enner
50 Fuella/11< 53 Regoneraboo vaNo
51 Vcntv~
Fig. 176: Function Diagram Of Fue) Evaporation Svstem (Model129 With Engine 103)
Function diagram modell29 with engine 103
Function
Ifan overpressure of30 -50 mbar is reached in the fuel tank, the vent valve (51 /4) opens and the fuel vapors
flow to the active charcoal filter.
Vent valve (51) open to active charcoal filter

Mercedes-Benz
6112 5113 51/6 5111
5111 C001Jf9S-sion spmg 51{6 A.. admis-sion vatvl:l

5112 Vat.rehousmg 51n Conrmcbon iting
51f3 Spóng retamar A Active dlarcoalliler
5114 Vemw.'Ve comacion
5115 Vawc~~ B Fuel tarlo< c~nnecbon
Fig.177: Function OfVent Valve (Open To Active Charcoal Filter)
Ifa vacuum of 1- 16 mbar is produced in the fuel tank, the air admission valve (5116) opens_Air or fu el vapors
are thus drawn in by the active charcoal filter.
5111 51/4 5116

Vart va.'va {51) opoo to fuel tllli<
..
51/2 51/3 51/5 51{7 Jct-'41-..lt
Fig. 178: Function OfVent Valve (Open To Fuel Tank)
Vent valve (51) open to fuel tank When the engine is running and the coolant temperature is more than 40°C,
50°C or 70°C, respectively, the intake manifold vacuum passes through the thermo val ve to the regeneration
valve (connection C), when the throttle valve is slightly open_
Thermo valve identification :
40°C black CD@ 0 engine 102 without KAT)
50°C red
70°C black with white ring

Mercedes-Benz
36 Thomlo vatwo
36/1 8unet1ll pla'.e
36fl 0-Mg
A To reganembon wtve
B Tot!Tolle vatve ood'{
Fig. 179: ldentifying Thermo Valve
When the vacuum is more than 20-35 mbar, the diaphragm (53/3) is pulled up against the spring force.
The passage from connection A to B is opened.
Regenera5on vaN& {53) open

5312 COI1llf8S51on spmg
5313 Oia¡¡hragm
A To a:cive chartoalftl!or
6 TottT~o vaJ.re body
C Varullll coonedon
53
Fig. 180: Function Of Regeneration Val ve
If the throttle valve is closed further, the extraction drilling (e) in the throttle valve body becomes effective. The
fuel vapors stored in the active charcoal filter are thus drawn off. The active charcoal is regenerated.
Example
Engines 116, 117

Mercedes-Benz
Fig.181: ldentifying Tbrottle Valve Bodv Passage fEngines 116, 117)
Example engine 102
e Two extraction drillings (b), effective one after the other, merge into a passage (b).
Fig. 182: Identifying Tbrottle VaJve Body Passage (Engine 102)
The throttle valve body has at least one vacuum and one extraction connection. Depending on tbe version,
further hose line connections may also exist.
Example engines 116, 117

Mercedes-Benz
a El«laust gasrsarulabcm cartrollin&

b R egonerellon valva cort&ol i ne
e RegtJnerebon ine
P 07 • ZI TS · Q
Fi2. 183: ldentifyin2 Throttle Valve Body Passa2e (En2ines 116, 117)
NOTE: In order to prevent mixture enrichment from the active charcoal filter, the
regeneration line to the throttle valve body should be detached at the
regeneration valve (53) and sealed when performing work such as "Adjusting
idle speed" or "Testing, adjusting engine".
Fig. 184: ldentifying Regeneration Valve
B. Models 124, 129 with engines 104, 119

Mercedes-Benz
4!
1 Wakc mBllllold 52/3 Suro member

45 lhlollo YW& boáf 53 RagenernbOn V8Ne
50 Fuellank ¡¡ To- I<E contolurnl
51 Voolvat.o Y58!1 Ragen embon s.... er havar vat.ta
!.lJ ~~~.~ollUibl
Fig. 185: Function Diagram OfFuel Evaporation System (Model129 With Engines 104, 119)
Function diagram fuel evaporation system modell29 wjth engines 104, 119
The regeneration switchover valve (Y58/ l) is operated by the KE control unit in order to draw the fuel vapors
out of the active cbarcoal filter (regeneration).
For function ofvent valve (51) and regeneration valve (53) see section A.
Regeneration is performed:
At coolant temperatures >70°C (engine 104 as of09/89 > 80°C) and idle speed contact open, the regeneration
switchover valve (Y58/l) is operated by a ground signal from the KE control unit, contact 2. Fuel vapors can be
drawn off from the active charcoal filter (active charcoal is regenerated).
At coolant temperatures >95°C (engine 104 as of 09/89 > l 00°C) or intake air temperatures >55°C and vehicle
speed <5 km/h the active charcoal is also regenerated if the idle speed contact is elosed.
Mercedes-Benz
Modell29
The active charcoal filter (52) is positioned in the front left wheelhouse behind the front wheeL Air is admitted
to the active charcoal filter or to the fuel tank from the front left side member.
:~----------------:}·-~~-~~~~-----------------~
52 Adlve che.re:ost li er 64 Vent lin&

64 VenHine A
A Rogenl!r.a!Jon tn e
8 To fuol lank
Fig. 186: ldentifying Active Charcoal Filter, Vent Line And Regeneration Line
The regeneration valve (53) is located at the left wheelhouse between spring dome and EZLIAKR ignition
control unit.
53 Re99fll!l1lllon V.We
A Re-geoora11on lin a
B To ect!w cttarroel !llar
C Vacwml ne
Fig. 187: Identifying Regeneration Valve, Vacuum Liine And Regeneration Line
The regeneration switchover valve (Y58/ l) on engine l04 is located at the left front wheelhouse and on engine
119 at the mixture control unit (below air cleaner).
Mercedes-Benz
loca!Jon on ellgllle 119
Fig. 188: Identifying Regeneration Switchover Valve (Engine 119)
The regeneration switchover valve (Y58/ l) and the regeneration valve (53) are located at the left partition panel
in the engine compartment
Fig. 189: Identifying Regeneration Switchover Valve And Regeneration Valve (Model124 With Engine
104)
FUNCTION OF FUEL EVAPORATION CONTROL SYSTEM- RA4700HFM0040X(47-0040)
Function
A fuel evaporation control system is installed to limit the fuel vapors which pass to atmosphere. The fuel vapors
stored in the activated charcoal filter are drawn off through the purging switchover valve (Y 58/ 1) at coolant
temperatures >80°C and combu sted in the engine (not in deceleration mode).
The HFM control unit processes the following information for this purpose:
Mercedes-Benz
• Engíne speed
• Airmass
• Coolant temperature
• Intake air temperature
P0?-5445-13
Y5!Y1 Purgíng s·Mtdlover v.BMI
A To actWate.dcharcoalfif.r.lt
8 Toengme
Fig. 190: ldentifving Purging Switchover Valve
The purging switchover valve (Y58/ l) is actuated (pulsed) by the HFM control unit with a frequency of 5, 10 or
20 Hz from an rpm dependent map in order to control the purging quantity. As a result, a uniform supply of fu el
vapors ís assured to all the cylinders. The purgíng quantity is determined by constantly opening and closíng the
switchover valve for on and offperiods ofvarious lengths.
Purging switchover valve (Y58/1)
It is located below the control unít (N3/6) and is actuated by the control unit ífthe followíng condítions exíst:
Operating :
• Coolant temperature >70°C

• Lambda control active (KAT), at the earliest 40 s after start
• At the earliest 40 s after start (without KAT)
• Engíne speed once > 1000 rpm ( end start recognized)
Not operating :
• Coolant temperature <30°C

• T.::~mhcht c.ontrol not ::~c.tive (K A T)
Mercedes-Benz
• Deceleration >4000 rpm

• Engine not running
P07-5445-13
Fig. 191: ldentifving Purging Switchover Valve
REMOVING AND INSTALLING, REPLACING FUEL COOLER- RA47LH1043061X(47-3061)
Operation No. of operation texts and operation va]ues or standard texts and flat rates
47-3061
Fig. 192: Checking Leaktightness Of Connection Points
release through service valve (see Diagnosis Manual Engine, Volume 2, Index
Fuel pressure
3, Testing fuel pressures and intemalleaktightness).
Air conditioner system drain (recycling).
Mercedes-Benz
Fuel and refrígerant lines unibolt, bolt on.

Fuel cooler (75) remove, ínstall.
Air conditioning system evacuate and re-fill.
Leaktíghtness of aH
connection poínts
REMOVING AND INSTALLING FUEL EXPANSION TANK (MODELS WITH SKIBAG)-

RA47LH1 048021 X(47-8021)
Operation No. of operation texts and operation values or standard texts and flat rates:
47 -8021
P07-5804-13
Fig. 193: ldentifying Fuel Expansion Taok Components
® Pay attention to safety precautíons!

Ground cable at battery dísconnect, connect.
Pressure in fuel tank release by taking off fu el filler cap, fitting on.
pull out of skibag mount, insert. To do this, release locks
Skibag (34)
(arrows), engage.
Bolts (25) unscrew, screw in.
Skíbag mount (28) n~lA:::tSA :::tnrl mtll ()l'lt ()f thA fmnt mmmt (?7) fit t()P'AthPr :::tnrl
Mercedes-Benz
insert in mount.
Fuel tank trim as well as riobt side trirn .
of trunk ~ release and pull out, :fit together and msert.
detach at fuel expansion tank (76), fit on. Todo this, slacken
Fuel hoses (75)
hose straps, attach.
® If fuel tanlc is full, purnp out about 8 liters.
Nut (anow) unscrew, screw in.
pull out, insert. Release vent lines (77, 78), ifnecessary, clip into
Fuel expansion tank (76)
place.
®Do not kink vent line.
LEVER SENDER REPLACES IMMERSED PIPE SENDER- BT47.10-P-0001-01A
MODEL 140 as of 1.4.95,
129 as of 1.10.96

World Model LBS Prod. Veh. Veh. Prod. Prod. Nature and Reference/Remarks
manuf. RHS plant ident ident per iod period reason for
eo de end no. end no. as of up to modification
as of np to
140 1.4.95
129 1.10.95
A lever sender is installed in place ofthe immersed pipe sender.
Modifications :
• fastened with a bayonet catch

• pressure sensor (arrow) for purging the activated charcoal canister (USA only)
Mercedes-Benz
Fig. 194: Locating Pressure Sensor
SCREW SPINDLE PUMP REPLACES DOUBLE FUEL PUMP UNIT- BT47.20-P-0001-01A
M O DEL 124.008 /028 /029 /088 #1 as of 1.8.94, 124.008 /028 /029 /088 #B as of 1.2.95,
124.032 /052 /066 /092 #1 as of 1.8.94, 124.032/052 /066 /092 #B as of 1.2.95, 124.019/040 /060 /079 #1 as of
1.8.94, 124.019 /040 /060 /079 #B as of 1.2.95, 124.022 /042 /062 /082 #1 as of 1.8.94, 124.022 /042 /062 /082
#B as of 1.2.95, 124.034 #1 as of 1.8.94, 124.034 #B as of 1.2.95, 124.036 #1 as of 1.8.94, 124.036 #B as of
1.2.95, 129 (except 129.060 /061 /066) as of 1.10.94, 140 (except 140.1) as of 1.9.94, 202 (except 202.1) as of
1.11.94

World Model LHS Prod. Veh. Veh. Pro d. Prod. Nature and Reference/Remarks
manuf. RHS plant ident ident period period reason for
eo de end no. end no. as of up to modification
as of up to
124.008 I 1.8.94
124.028 I 1.8.94
124.029 I 1.8.94
124.088 I 1.8.94
124.008 B 1.2.95
124.028 B 1.2.95
124.029 B 1.2.95
124.088 B 1.2.95
124.032 I 1.8.94
124.052 I 1.8.94
124.066 I 1.8.94
124.092 I 1.8.94
124.032 B 1.2.95
124.052 B 1.2.95
124.066 B 1.2.95
124.092 B 1.2.95
124.019 I 1.8.94
124.040 I 1.8.94
124.060 I 1.8.94
124.079 I 1.8.94
124.019 B 1.2.95
124.040 B 1.2.95
124.060 B 1.2.95
124.079 B 1.2.95
124.022 I 1.8.94
124.042 I 1.8.94
124.062 I 1.8.94
Mercedes-Benz
124.082 I 1.8.94
124.022 B 1.2.95
124.042 B 1.2.95
124.062 B 1.2.95
124.082 B 1.2.95
124.034 I 1.8.94
124.034 B 1.2.95
124.036 I 1.8.94
124.036 B 1.2.95
129.058 1.10.94
129.063 1.10.94
129.067 1.10.94
129.076 1.10.94
140.028 1.9.94
140.032 1.9.94
140.033 1.9.94
140.042 1.9.94
140.043 1.9.94
140.050 1.9.94
140.051 1.9.94
140.063 1.9.94
140.070 1.9.94
140.056 1.9.94
140.057 1.9.94
140.076 1.9.94
202.028 1.11.94
202.018 1.11.94
202.020 1.11.94
202.022 1.11.94
202.023 1.11.94
202.024 1.11.94
202.025 1.11.94
202.078 1.11.94
202.080 1.11.94
202. 083 1.11.94
The previous double fuel pump set has been replaced as a phased-in measure by a Pierburg fuel pump (screw
spindle pump).
Modifications :
Mercedes-Benz
• Fuel pump (screw spindle pump)

• Steel fuel pipe from fuel pump to fuel filter replaced by fuel hose. Installed with hose clips
• Fuel feed pipe no longer bolted on, but inserted and installed with hose clip
¡gj Use the hose clips listed in the parts microfiche for attaching the fuel hoses.
MISCELLANEOUS NOTES
DISPOSING OF FUEL TANKS- OS47.10-P-0001-01A
Before opening the fuel tank, empty completely, clean thoroughly and rinse out with a non-combustible fluid,
e.g. witb water, steam oran inert gas, e.g. nitrogen, carbon dioxide.
Sheet metal fuel tanks
Open sheet metal fuel tanks with a chisel or metal saw by approx. 30x30 cm. Dispose of sheet metal ventilated
fuel tanks as metal scrap.
Plastic fuel tanks
Open the plastic fuel tank using a suitable saw by approx. 30x30 cm.
In Germany the opened plastic fuel tank can be returned through the Mercedes Recycling System (MeRSy) as
"other plastic parts" for recycling.
Operations not connected to MeRSy can dispose of similarly pretreated plastic fuel tanks along with the fraction
of industrial refuse similar to household waste.
Transport
Cut-open and ventilated end oflife fuel tanks are not subject to the requirements ofthe Hazardous Goods Road
Transport Regulations.
P!7:11HIJJH I1
Fig. 195: Disposing Of Fu el Tanks

Mercedes-Benz
2001 -02 STARTING & CHARGING SYSTEMS Generators & Regulators - 129 Chassis
2001 -02 STARTING & CHARGING SYSTEMS
Generators & Regulators - 129 Chassis
IDENTIFICATION
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS (or AIR BAG SAFETY
PRECAUTIONS) and DISABLING & ACTIVATING AIR BAG SYSTEM in
appropriate AIR BAG RESTRAINT SYSTEMS article.
NOTE: When t he battery is disconnected, vehicle computer and memory system may
lose data. Driveability problems may exist until computer systems have
completed a relearn cycle.
CHASSIS & ENG INE IDENTIFICATION

Mod el (Year) C hassis Engine
SL500 (2001 -02) 129.068 113.961
SL600 (2001 -02) 129.076 120.983
DESCRIPTION
Bosch generators are available in various amp ratings depending on engine application. Voltage regulators are
trausistorized aud internal to generator. See GENERA T O R APPLICAT ION table.
GENERATOR APPLICATION
Amp Ratingl
150
ADJUSTMENTS
NOTE: Vehicles have automatic belt tensioners. No adjustment is necessary.
DRIVE BELT ROUTING
For drive belt routing, see F ig. 1 .

Mercedes-Benz
2001 -02 STARTI NG & CHARGING SYSTEMS Generators & Regulators - 129 Chassis
1 . ldler Pulley
2. Automatic Belt Tensioner
3. Power Steering Pump
4. Air Conditioner Compressor
5. Crankshaft
6. Coolant Pump, Fan
7. Generator {Aiternator)
G00284721
Fig. 1: Drive Belt Routing

TROUBLE SHOOTING
PRELIMINARY INSPECTION
Verify customer complaint by operating system. Visually inspect for obvious signs ofmechanical and electrical
rh m :::. O'P r h Pr.lc O'PnPr::.tflr h P.It t PnC:Ífln ::~nri (',()tlOÍt Ífln Pn~nrP th M h ::.tt P.rv vfllt::!O'P. íc: withín ~nPr í fir.MiflnC: Tnc:n Pr.t
Mercedes-Benz
2001-02 STARTING & CHARGING SYSTEMS Generators & Regulators- 129 Chassis
for blown fuses and damaged relays .
Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring
harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause
system malfunction but prove good in a continuity/voltage check witb system disconnected. Ensure any
aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. [f no fault is found,
check for conditions that might cause an interrnittent situation.
SERVICE PRECAUTIONS
BATTERY DISCONNECT/CONNECT
Disconnect Procedures
NOTE: Numbers and letters in text refer to numbers and letters in figures.
l. On vehicles not equipped with TELE AID, go to step 5. Vehicles equipped with TELE AID, switch
TELE AID into service mode by turning ignition ON.
2. Turn ON telephone and enter code "*#4610#" on handset.
3. Confrrm that "No Telematics Service" appears on handset witb okay.
4. Turn OFF handset.
5. Turn OFF ignition.
6. Open hood and open snap fasteners (1) on dust filter housing. See Fig. 2 .
7. Remove dust filter housing (2) exposing batte1y.
8. If not using quiescent current retention unit, go to step 14 . [f using quiescent current retention unit, go to
next step.
9. Connect quiescent current retention unit by switching on quiescent current retention unit (7) and then first
connecting positive terminal (8) and negative terminal (9) of retention unit to positive cable and battery
ground (WlO). See Fig. 3 .
10. On vehicles equipped with TELE AID, remove luggage compartment cargo anchoring lugs and remove
floor paneling.
11. Remove screws (1). See Fig. 4.
12. Dismantle cover from TELE AID control module (A35/8).
13. Disconnect cmmection coupling for back up battery and remove back up battery.
14. Disconnect negative battery cable ( 1) and insulate terminal. See Fig. 5 .
Mercedes-Benz
G00315155
Fig. 2: Removing Dust F ilter Housing

Mercedes-Benz
G00284772
Fi~. 3: Connectin~ Quiescent Current Retention Unit

Mercedes-Benz
Fi~. 4: Removin~ Emer~ency Call System Battery

Mercedes-Benz
G00315157
Fig. 5: Disconnecting Ground Lead From Batterv

Connect Procedures
l. To install, reverse removal procedure. Install new back up battery for TELE AID. Switch OFF service
mode in emergency call system by tuming ignition on. Confinn "Leave Service Mode" with okay on
handset and then confrrm "No Telematic Service" with okay. If removed, tighten luggage compartment
cargo auchoring lugs to 15ft. lbs. (20 N.m).
2. lf a quiescent current retention uuit was not used, perform basic programming. See BASIC
PROGRAMMING . After repairs using appropriate sean tool retrieve and erase any DTCs from
memory. See RETRIEVING & ERASING DIAGNOSTIC TROUBLE CODES.
BASIC PROGRAMMING
l. Set time ou instrument cluster. See SETTING TIME .

2. If equipped, set time on auxiliary or stationary beater.
3. Normalize side power windows. See NORMALIZING POWER WINDOWS .
4. Start engine and nm at idle. Tum steering wheel from one lock position to the other to actívate steering
angle sensor. Center steering wheel. Message "EL STAB. PROGRAM GO TO GARAGE" should erase
from multifunction display panel.
5. If equipped, normalize tilting/sliding roof. See NORMALIZING TILTING/SLIDING ROOF .
Mercedes-Benz
2001-02 STARTI NG & CHARGING SYSTEMS Generators & Regulators- 129 Chassis
6. If equipped, normalize memory power seats, steering colurnn and outside mirror if components are
installed. See NORMALIZING MEMORY POWER SEATS, STEERING COLUMN & OUTSIDE
MIRROR.
Normalizing Power Windows
l . Completely close each window with manual switch. Hold switch in closed position for .3 second.
2. Repeat procedure for each power window.
Normalizing Memory Power Seats, Steering Column & Outside Mirror
l . Using manual switch, move seat to each end position and hold for .3 second. Repeat procedure for each
switch except rear stop ofbackrest.
2. Repeat procedure for end positions of steering wheel and outside mirrors.
Normalizing Tilting/Sliding Roof
Open roofwith SR switch until mechanical stop is reached. Continue to press switch for .5 seconds.
Setting Time
l . Use bottom left button on steering wheel to scroll through menus on instrument cluster to "Settings"
menu.
2. Move selection marker with + or- button to "Time" submenu.
3. Press up or down arrows to "Clock, hours" setting. Confirm selection marker is on the hour setting.
4. Press + or - to set hour. Press reset knob in instrument cluster to confirm.
5. Move selection marker with + or - button to "Time" submenu.
6. Press up or down arrows to "Clock, minutes" setting. Confirm selection marker is on the minutes setting.
7. Press + or - to set minute. Press reset knob in instrument cluster to confirm ..
TESTING
If generator malñmctions, check for Diagnostic Trouble Cedes (DTCs) in Motor Electronics Sequential Fuel
Injection (ME-SFI) system. See appropríate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. If
cause of generator malfunction is not engine performance related, replace generator.
RETRIEVING & ERASING DIAGNOSTIC TROUBLE COD,ES
NOTE: Before replacing any component that sean tool suggests are faulty, ensure that
all wiring connections and harness connectors are okay. Ensure that power and
ground circuits are functioning properly. For circuit identification, see
appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM
WIRING DIAGRAMS for vehicle being tested.
Mercedes-Benz
RETRIEVING DIAGNOSTIC TROUBLE CODES
NOTE: For diagnostic equipment connections, see FAULT CODE DIAGNOSIS

EQUIPMENT CONNECTION .
Te retrieve cedes using hand held tester, see Fig. 6.
Diagnostic trouble codes (DTC's) which have been stored dueto testing or
the disconnectlon of lines must be erased from the diagnostic trouble code
memory at the end of testing.
• Connect Hand-Held Tester (HHT) accordlng to connecnon dlagram.

The following functions can be performed according to the instructions on
the display:
a) Reading/erasing DTC memory e) Performlng activations
b) Reading actual values d) Programming control modules
Speclal Tools
965 589 00 01 00 965 589 00 50 00

G00275246
Fig. 6: Retrieving Codes Using Hand Held Tester

CLEARING DIAGNOSTIC TROUBLE CODES
Disconnecting vebicle battery will net erase cedes. Fellow sean teel equipment manufacturers instructiens te
erase fault cedes.
FAULT CODE DIAGNOSIS EQUIPMENT CONNECTION
Te connect hand held tester sean teel te Mercedes-Benz data link cennecter, see Fig. 7. Te cennect hand held
tester sean teel te OBD-Il data link cennecter, see Fig. 8 .
Mercedes-Benz
087
o
094
38-pole Data link Connector (X11/4)

087 Hand- Held Tester (HHT)
094 Multiplexar, 965 589 oo 40
X 11 /4 Data link connector
G00284764
Fig. 7: Connecting Hand Held Tester Sean Tool To Mercedes-Benz Data Link Connector
Mercedes-Benz
087
Battery +
r------1----rd_j
16-pole Data Link Connector (X11/4)

Connect HHT as follows:
Black wire (circuit 31, ground): socket 1
White wire (circuit 15, voltage): socket 16
Red wire (circuit 30): Battery +
Yellow wire to diagnostic output socket of the

system being testad.
087 Hand-Held Tester (HHT)
X4/1 O Terminal block, circuit 30
X11/4 Data link connector
Adapter cable, 965 589 00 50 00 (not shown)
G00284765
Fig. 8: Connecting Hand Held Tester Sean Tool To OBD-ll Data Link Connector
ON-VEHICLE TESTING
Mercedes-Benz
WIRING CONTINUITY
l_ Connect voltmeter between generator B+ terminal and ground_ Voltmeter should indicate battery voltage_
Ifbattery voltage is not indicated, check battery and check wiring between generator and battery for
corrosion, loose tenninals, etc.
2. Tum ignition on and ensure instrument cluster charge indicator light (battery symbol) comes on. lf light
does not come on, check wiring between generator and warning light, including indicator bulb.
GENERATOR OUTPUT
l . Ensure connections at battery and generator are clean and tight Ensure generator, engine and body are
properly grounded. Ensure generator drive belt is properly adjusted and in good condition.
2. Connect load tester/ammeter as per tester manufacturer's instructions. Connect voltmeter leads to battery
terminals. See Fig. 9 _Start engine and run at 2500 RPM. Adjust load tester to obtain maximum generator
output DO NOT allow voltage to drop to less than 12.7 volts.
3 _ Maximum generator output should be within a few amps of generator rated output stamped on generator.
If output is not within a few amps of generator rated output, check generator diodes. See DIODE TEST _
Replace generator as necessary.
Mercedes-Benz
••~ W10
r:... o&9a-·-·,
t---.:.......~ ll ·- il
1'00198=·-· i ,_____
~·..,r....fl
003
! rV-·r i ~ COOJI ti
• - CCIJ
~-~~:=) j o o o e
003 Multimeter W1() Ground (battery)

065 OC clip-on probe W16/2 Ground (component compartment)
079 Volt 1 ampere tester with load X4/1 Connector terminal 30/
resistor interior
C2 Altematorlbattery line electrolytic X4/10 Connector terminal 30, 6-pin
capacitor interference suppression br brown
G1 Battery bl black
G2 Altemator rd red
M1 Starter
G00316820
Fig. 9: Cbecking Geuerator Output

VOLTAGEREGULATORCONTROL
l. Connect multimeter. See Fig. 10. Ensure charge indicator light goes out when engine is idling and with
increasing engine speed up to 3000 RPM. Apply load to battery by turning on headlights and noting
reading after 2 minutes.
2. Voltage reading should be 13-14.5 volts. Ifvoltage is not to specificatíon, replace voltage regulator. See
VOLTAGEREGULATOR under REMOVAL & INSTALLATION. Ifregulator is okay, replace
Mercedes-Benz
generator. See GENERATOR under REMOV AL & INST ALLATION.
.,.. 003
L c::::J cocfr 11
••-tW10 + - CCXJ
"
;~
l.t.C2
.1
'
1
W16/2
003 Multimeter W16/2 Ground (component compartment)

C2 Altematorlbattery fine electrolytlc X4/1 Tenninal block circult 30/
eapacitor lnterference suppression interior compartment
G1 Battery X4/10 Connector terminal 30 .. 6-pin
G2 Generator BR brown
M1 Starter sw black
W10 Ground (battery) rt red
G00316822
Fig. 10: Checking Voltage Regulator

DIODE TEST
Connect DC clip-on pro be from engine tester with oscilloscope to positive battery terminaL See Fig. 11 . Start
engine. Switch on low beam. Access diode test at 3000 RPM. See Fig. 12 -Fig. 14 . Replace generator as
necessary.
Mercedes-Benz
·- =::1110-lt--i+·-
·--·~
L·-·-·
G1
-1 w1o
030
•
l.
•
t¡..
....'l.t.C2
•
W16/2
1'
030 Engine tester with oscilloscope X4/1 Terminal block (circuit 30

065 D.c. clamp . interior)
C2 Electrolytic capacltor (altemator/ X4/10 Terminal block (circuit 30/30Ü/61e/
battery hamess noise suppressor) 87l) (6-pln)
G1 Battery br Brown
G2 Generator rt Red
M1 Starter sw Black
W10 Ground (battery)
W16/2 Major assemblles compartment
ground (electrolytlc capacitor, noise
suppression generatorlbattery fine
G0031e816
Fig. 11: Identifving Oscilloscope Connection

Mercedes-Benz
G00316725
Fig. 12: ldentifving Oscilloscope Patterns (No Fault Indicated)

Mercedes-Benz
G00316727
Fig. 13: Identifying Oscilloscope Patterns {Positive Diode Defective)

Mercedes-Benz
G00316728
Fig. 14: Identifying Oscilloscope Patterns (Negative Diode Defective)


GENERATOR
NOTE: Numbers in text refer to numbers in figures.
Removal & InstaUation
l . Disconnect and shield negative battery cable. See BATTERY DISCONNECT/CONNECT under
SERVICE PRECAUTIONS.
2. Remove air intake pipe. Remove fan sbroud. Remove fan from fan clutch. Remove "V" belt.
3. Disconnect generator B+ electrical connector (1) and electricalline circuit 61 (D+) (2). Remove 2
generator bolts (3). Remove generator. See Fig. 15 .
4 Tn in c:t:.ll l rP.vPrc:P rPmnv:.l l nrnrPrinrP TTc:in a ~TA R c:r.:.ln tnnl n Prfnrm P.IPrtrÍr:.ll nnPr:.ltÍnn :.ll r h P.r.k
Mercedes-Benz
1 Terminal30 cable (B+) 4 Cover sleeve

2 Termlnal61 cable (0+) 5 Generator
GOOI31S818
Fi¡:. 15: Removin¡: Generator

VOLTAGEREGULATOR
NOTE: Numbers in text refer to numbers in figures.
RemovaJ & lostaUatioo (Compact Generator)
Disconnect and shield negative battery cable. Remove generator from vehicle. See GENERATOR. Remove 3
screws (1). Unclip cover (2) by pushing apart retaining lugs (3) and remove. Remove 2 screws (4). Remove
regulator (5) toward side. See Fig. 16. To install, reverse removal procedure. When inserting regulator (5),
ensure ground lug (6) makes contact with regulator.
Mercedes-Benz
7
3
-s!
4
'\.
~·
-·-· 1
1 Bolts (cover) 5 Regulator

2 Cover 6 Ground lug
3 Retaining lugs 7 Generator
4 Bolts (regulator)
800316814
F ig. 16: Removing Voltage R egulator (Compact Generator)

Removal & lnstallation (Bowi-Type Generator)
Disconnect and shield negative battery cable. Remove generator from vehicle. See GENERATOR Remove 2
regulator screws from back of generator. Remove regulator. See Fig. 17 .
Mercedes-Benz
•
.... .
~-····
7 Bofts
7- 8 8 Regulator
G00316823
Fig. 17: Removing Voltage Regulator (Bowl-Tvpe Generator)

Application Ft. Lbs. (N.m)
Generator Motmting Bolts 30 (42)
Generator Pulley Nut 52 (70)
Mercedes-Benz
WIRING DIAGRAMS
See CHARGING SYSTEM in appropríate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
Mercedes-Benz
1990-2002 ENGINE PERFORMANCE Mixture Formation- TESTING & REPAIR- 129 Chassis
1990-2002 ENGINE PERFORMANCE
Mixture Formation- TESTING & REPAIR -129 Chassis
TESTING & REPAIR

ENGINE TEST AND SETTING OPERATIONS - ARO? .00-P-3000
Engine test ancl setting operations - AR07.00-P-3000W A
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL 129
ME-SFI fuel injection and ignition system with hand-held tester
ENGINE 104.944/994 as of 1.6.96,
119.980 /981, 120.982
inMODEL 140
ENGINE 112.942, 113.942 in MODEL 163
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
inMODEL170
ME-SFI fuel injection and ignition system with hand-beld tester
ENGINE 104.941,111.944 as of1.8.96,
112.910 /920, 113.944
in MODEL202
Mercedes-Benz
1990-2002 ENGINE PERFORMANCE Mixture Formation - TESTI NG & REPAIR- 129 Chassis
ENGINE 111.974 in MODEL 202 with CODE (491) USA version
ENGINE 111.975 as of 1.8.96 in MODEL 202.024
ME-SFI fuel injection and ignition system witb hand-held tester
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208
ENGINE 111.947, 112.911 /921 /941, 113.940 /980, 119.985 in MODEL 210
ENGINE 104.995 as of1.6.96 in MODEL 210
with CODE (491) USA version
with CODE (498) Japanese version
Testing
Testing, adjusting engine with hand-held tester AR07.00-P-3001WA
Testing, adjusting idle with hand-held tester AR07.OO-P-3002WA
speed
Testing engine output and with hand-held tester AR07.00-P-3003WA
exhaust emissions
Enlargement to testing, with hand-held tester AR07.OO-P-3004WA
adjusting engine
Mercedes-Benz
¡g¡' Additional information AH07.OO-P-3000-02WA

on actual value screens
¡g¡ Notes on actuations in AH07.00-P-3000-03WA
HHT
Engine test and setting operations- AR07.00-P-3000WB
ENGINE 104.943/991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ME-SFI fuel injection and ignition system with STAR DIAGNOSIS
ENGINE 104.944 /994 as of 1.6.96,
119.980 /981, 120.982
in MODEL 140
ENGINE 112.942, 113.942 in MODEL 163
ME-SFI fuel injection and ignition system witb STAR DIAGNOSIS
ENGINE 111.943,
111.946 as of 1.6.98,
111.973 in MODEL 170
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
inMODEL202

Mercedes-Benz
1990-2002 ENG INE PERFORMANCE Mixture Formation- TESTI NG & REPAIR- 129 Chassis
ME-SFI fnel injection and ignition system with STAR DIAGNOSIS
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208
E NGINE 111.945 as of 1.6.98 in MODEL 208.335
ME-SFI fuel inj ection and ignition system with STAR DIAGNOSIS
E NGINE 111.947, 112.911 /921 /941, 113.940 /980, 119.985 in MODEL 210
ENGINE 104.995 as of 1.6.96 in MODEL 210
ENGINE 112.922 /944, 113.941 /960 in MODEL 220
Testing
Testing, adjusting engine with STAR DIAGNOSIS AR07.00-P-3001WB
(HHT-WIN)
Testing, adjusting idle with STAR DIAGNOSIS AR07.00-P-3002WB
speed (HHT-WIN)
Testing engine output and with STAR DIAGNOSIS AR07.00-P-3003WB
exhaust emíssions (HHT-WIN)
Enlargement to testing, with STAR DIAGNOSIS AR07.00-P-3004WB
adj usting engine (HHT-WIN)
Additional information AH07.00-P-3000-02WA
Mercedes-Benz
¡g¡' on actual value screens

¡g¡ Notes on actuations AH07.00-P-3000-03WA
E ngine test ami setting operations- AR07.00-P-3000WC
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ME-SFI fuel injection and ignition system with engine diagnosis tester Datascope D 980
ENGINE 104.944/994 as of 1.6.96,
119.980 /981, 120.982
inMODEL140
ENGINE 112.942, 113.942 in MODEL 163
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
in MODEL 170
ME-SFI fuel injection and ignition system with eogine diagnosis tester Datascope D 980
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
in MODEL202
Mercedes-Benz
ME-SFI fnel injection and ignition system with engine diagnosis tester Datascope D 980
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208
ENGINE 111.947, 112.911 /921 /941, 113.940/980, 119.985 in MODEL 210
ME-SFI fu el injection and ignition system with engine diagnosis tester Datascope D 980
ENGINE 112.922 /944, 113.941 /960 in MODEL 220
Testing
Enlargement to testing, with engine diagnosis AR07.00-P-3004WC
adjusting engine tester Datascope D 980
CHECK AND ADJUST ENGINE- AR07.00-P-3001
Check and adjost engine- AR07.00-P-3001WA
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
Mercedes-Benz
ME-SFI fuel injection and ignition system witb bandbeld tester
ENGINE 104.944 /994 as of 1.6.96,
119.980 /981, 120.982 in MODEL 140
ME-SFI fuel injection and ignition system witb handbeld tester
ENGINE 112.942, 113.942 in MODEL 163
ME-SFI fuel injection and ignition system with handheld tester
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
inMODEL170
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
inMODEL202
ME-SFI fuel injection and ignition system with handbeld tester
ENGINE 111.974 in MODEL 202 with CODE (494a} USA version
ME-SFI fuel injection and ignition system witb handheld tester
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208

Mercedes-Benz
ME-SFI fnel injection and ignition system with handheld tester
ENGINE 111.947, 112.911 /921 /941, 113.940/980, 119.985 in MODEL 210
with CODE (494a) USA version
Connection diagram of checking and adjusting engine ME-SFI fuel injection and ignition system with
HHT
(shown on Modell40 with Engine 120)
A ThrottJe control
)/1114 C»tiJin~ eonnector
oos En»J'sslon sM sor
~ E.lthallst ot,./yzer
014 Exhaus t sucdon tunneJ
018 01 ranJO(o dt-otmomotl!l'
042 Pressure measu.d11g devk e
087 Handhekl tester
oru Multf>ll!x cable
P07..1lo-1032 06
Fig. 1: ldentifying Connection Diagram OfEngine ME-SFI Fuel Injection And Ignition System
m Risk of accident. Secure vehicle to ASOO.OO-Z-0005-01A

Accidents may result if prevent it from moving.
the vehicle starts off Wear closed and snug-
Mercedes-Benz
1990-2002 ENGINE PERFORMANCE Mixture Formation- TESTI NG & REPAIR - 129 Chassis
unintentionally with the fitting work clothes.

injury as working rotating parts.
around the engine
during start-up or while
running may result in
ITl Risk of death. Death Do not touch parts ASl S.lO-Z-0001-0lA
not carry out work on
[g] References to test Air conditioning or AH07.00-P-3000-01A
conditions for engine automatic air
testing and adj usting conditioning switched
work off, coolant at correct
levd, oil in engine at
correct level, A TF at
correct level and no
leaks in automatic
transmission (visual
inspection), ancillary
consumers switched off.
[g]
' If problems exist in the
start or waming-up
phase, do not condition
engine to operating
temperature but proceed
on a complaints-related
basis
[g] relevant IlliT contents:
Check engine
Engine cold start
Engine warming-up
phase
[g]
' Test and adjustment inHHT
values ¡gj Engine 119 dh0a00pm00062x
¡gj Engine 120 dh0a00pm0006lx
1 Connect test equipment
according to connection
diagram
Lh Connection of Connect the HHT ADOO.OO-P-2003A
diagnostic test Handheld tester *WH 58.30-Z-1 036-13A
equipment Test cable *WH58.30-Z-1037-13A
Mercedes-Benz
4-point analyzer *WE58.40-Z-100 1-06A

&.oanqcrl
with lambda calculation

@ Exhaust probe Fig. 2
2 Inspect throttle control
for ease of operation and
condition. Lubricate all
bearing points and baH
sockets.
3 Read fault memory of ¡g¡ If fault code is
ME-SFI control module displayed?
& Gasoline injection and Engine 104 AD07.61-P-4000C
ignition system (ME- Fault codes from POOOO
SFI) diagnosis - to P0449
diagnostic trouble code Engine 104 AD07 .61-P-4000CA
memory Fault codes from P0450
to Pl747
Engine 111 AD07.61 -P-4000D
Fault codes from POOOO
to P0699
Engine 111 AD07 .61-P-4000DA
Fault codes from P0700
to P1747
Engi.ne 112 AD07.61-P-4000A
to P0299
Engi.ne 112 AD07.61 -P-4000AA
to P0699
Engine 112 AD07 .61-P-4000AB
to P1747
Engine 113 AD07 .61-P-4000B
to P0304
Engi.ne 113 AD07 .61-P-4000BA
to P0743
Engi.ne 113 AD07.61-P-4000BB
to P1747
Engine 119 dh0905pm00011x
Engi.ne 120 AD07.61-P-4000F
up to P0209
Engi.ne 120 AD07.61-P-4000FA
Mercedes-Benz

up to P0439
Engine 120 AD07.61-P-4000FB
up to P0799
Engine 120 AD07.61-P-4000FC
uptoP1747
4 Test engine oil ¡g] Engine 112, 113 with
temperature HHT
5 Test coolant temperatme with HHT
6 Test intake air with HHT
temperature
7 Selector lever position with HHT
P/N
8 Test AC compressor with HHT
9 Test battery voltage with HHT
10 Test idle speed and full with HHT
throttle recognition
11 Test WOT/CTP stop at
pedal value sensor
12 Test idle speed with HHT
¡g¡ Selector lever
position PIN
AC and additional
13 Test air mass with HHT
¡gJ Engine: Idle
14 Test HFM voltage with HHT
15 Test ignition angle with HHT
16 Test inj ection time with HHT
¡g¡ Engine: Idle
17 Test throttle valve angle with HHT
18 Test throttle valve stop with HHT
19 Test actuator with HHT
20 Test pedal value sensor with HHT
21 Test camshaft solenoid ¡g] only engine 104, 111
22 Test camshaft Hall with HHT
sensor
23 Test 0 2 sensor voltage with HHT
sensor upstream of
TWC
24 Test heater of sensor with HHT
Mercedes-Benz
upstrearn ofTWC
25 Test lambda control with HHT
upstrearn ofTWC
26 Test 0 2 sensor voltage ¡g] only ilOO /EURO 3
sensor downstream of with HHT
TWC
27 Test heater of sensor ¡g] only il 00 /EURO 3
downstream ofTWC with HHT
28 Test lambda control ¡g] only i 100 /EURO 3
downstream ofTWC with HHT
29 Test self-adaptation with HHT
¡g] Engine: idle/partial
load
30 Test onloff ratio of withHHT
purge control valve
31 Test purge system withHHT
32 Test safety fuel shutoff with HHT
33 Test idle speed emission only on models not
value without TWC fitted with TWC
¡g] set with HHT
34 Check engine running in selector lever position
D and with consumers
switched on. Parking
brake and service brakes
applied
Special tools
12.'6 589 11 a3 00
F ig. 2: ldentifying Emission sensor(126 589 11 63 00)
·u1y avat•ta ble too s

e ommercta
Number Designation
WH58.30-Z-1036-13A Handheld tes ter (HHT) 651 100 01 99
WH58.30-Z-l037 -13A Test cable (multiplexer) 651 100 40 99
Mercedes-Benz
4-gas tester
Check and adjust engine- AR07.00-P-3001WB
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ENGINE 104.944/994 as of 1.6.96,
119.980 /981, 120.982
inMODEL 140
ENGINE 112.942, 113.942 in MODEL 163
ME-SFI fu el injection and ignition system with STAR DIAGNOSIS
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
in lVIODEL 170
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
in MODEL202
ENGINE 111.974 in MODEL 202 with CODE (494a) USA version

Mercedes-Benz
ME-SFI fnel injection and ignition system with STAR DIAGNOSIS
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208
ENGINE 111.947, 112.911 /921 /941, 113.940/980, 119.985 in MODEL 210
with CODE (494a) USA version
ENGINE 112.922 /944, 113.941 /960 in MODEL 220
STAR DIAGNOSIS
(shown on Model210)
Mercedes-Benz
X1114 OIBgnosrie dota 6nk connector

{1&- or 38-ph)
DOS E111/ul on sen sor
Elthaust anatyur
014 Elthaustsuclion funnel
0100 STARO/AGNOSIS
.1 Jrt1JI lt1114
~
014
Fig. 3: ldentifyi.ng Connection Diagram OfEngine ME-SFI Fuel lnjection And lgnition System With Star
Diagnosis
IIJ Risk of accident. Secure vehicle to ASOO.OO-Z-0005-0lA

the vehicle starts off WeaT closed and snug-
engine mnning. Risk of Do not grasp hot or
around the engine
during start-up or while
running may result in
IIJ Risk of death. Death Do not touch parts ASlS.lO-Z-0001-0lA
¡g¡ References to test Air conditioning or AH07.00-P-3000-01A
testing and adjusting conditíoning switched
level, oil in engine at
correct level, ATF at
leaks in automatic
inspection), ancíllary
Mercedes-Benz

[g)... If problems exist in the
start or warning-up
phase, do not condition
engíne to operating
temperature but proceed
on a complaints-related
basis
[g)... relevant HHT-WIN
contents:
Check engine
Engine cold start
Engine warming-up
phase
[g)... Test and adjustment inHHT-WIN
values [gl Engine 119 dh0a00pm00062x
[gl Engine 120 dh0a00pm00061 x
diagram
& Connection of Connect STAR ADOO.OO-P-2003A
diagnostic test DIAGNOSIS
equipment Diagnosis system STAR *WH58.30-Z-1048-13A
DIAGNOSIS
&oanaerl 4-point analyzer *WE58.40-Z-1001-06A
with lambda calculation
2 Inspect throttle control [gl except model 220
bearing points and ball
sockets.
3 Read fault memory of [g) If fault code is
ME-SFI control module displayed?
& Gasoline injection and Engine 104 AD07.61-P-4000C
ignition system (ME- Fault codes from POOOO
SFI) diagnosis - to P0449
diagnostic trouble code Engine 104 AD07.61-P-4000CA
memory Fault codes from P0450
to Pl747
Engine 111 AD07 .61-P-4000D
to P0699
Engine 111 AD07 .61-P-4000DA
Mercedes-Benz
to Pl747
Engine 112 AD07.61 -P-4000A
to P0299
Engine 112 AD07. 61-P-4000AA
to P0699
Engine 112 AD07. 61-P-4000AB
to Pl747
Engine 113 AD07 .61-P -4000B
to P0304
Engine 113 AD07.61-P-4000BA
to P0743
Engine 113 AD07 .61-P-4000BB
to Pl747
Engine 119 dh0905pm00011x
Engine 120 AD07.61-P-4000F
up to P0209
Engine 120 AD07.61-P-4000FA
up to P0439
Engine 120 AD07.61-P-4000FB
up to P0799
Engine 120 AD07.61-P-4000FC
up toP1747
4 Test engine oil ¡gj Engine 112, 113 with
temperature HHT-WIN
5 Test coolant temperature with HHT-WIN
6 Test intake air with HHT-WlN
temperature
7 Selector lever position with HHT-WIN
P/N
8 Test AC compressor with HHT-WIN
9 Test battery voltage with HHT-WIN
10 Test idle speed and full with HHT-WIN
throttle recognition
11 Test WOT/CTP stop at
pedal value sensor
Mercedes-Benz
12 Test idle speed with HHT-WIN

¡g¡ Selector lever
position P/N
AC and additional
13 Test air mass with HHT-WIN
¡g¡ Engine: Idle
14 Test HFM voltage with HHT-WIN
15 Test ignition angle with HHT-WIN
16 Test inj ection time with HHT-WIN
~ Engine: Idle
17 Test throttle valve angle with HHT-WIN
18 Test throttle valve stop with HHT-WIN
19 Test actuator with HHT-WIN
20 Test pedal value sensor with HHT-WIN
21 Test camshaft solenoid ¡g¡ only engine 104, 111
22 Test camshaft Hall with HHT-WIN
sensor
23 Test 0 2 sensor voltage with HHT-WIN
sensor upstream of
TWC
24 Test heater of sensor with HHT-WIN
upstream of TWC
25 Test lambda control with HHT-WIN
upstream ofTWC
26 Test 0 2 sensor voltage ¡gj only ~ /EURO 3
sensor downstream of with HHT-WIN
TWC
27 Test heater of sensor ¡gj only ~ /EURO 3
downstream ofTWC witb HHT-WIN
28 Test lambda control lg] only ~ /EURO 3
downstream ofTWC witb HHT-WIN
29 Test self-adaptation with HHT-WIN
¡g¡ Engine: idle/partial
load
30 Test on/off ratio of with HHT-WIN
purge control valve
31 Test purge system witb HHT-WIN
32 Test safety fuel shutoff witb HHT-WIN
33 Test idle speed emission only on models not
value without TWC fitted with TWC
¡gj set with HHT-WIN
Mercedes-Benz
34 Check engine running in selector lever position

D and with consumers
switched on. Parking
brake and service brakes
applied
Special tools
126 ssg 11 63 00
Fig. 4: ldentifying Emission sensor (126 589 11 63 00)
e ommerc1'allty ava1"l a ble tool s

Number Designation
WH58.30-Z-l048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
Workshop equipment
IWE58.40-Z-1001 -06A 14-gas tester
TEST, REGULA TE IDLE SPEED- AR07.00-P-3002
Test, regulate idle speed- AR07.00-P-3002WA
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ENGlNE 104.944 /994 as of 1.6.96,
119.980 /981, 120.982
in MODEL 140

Mercedes-Benz
1990-2002 ENGINE PERFORMANCE Mixture Formation- TESTI NG & REPAIR- 129 Chassis
ENGINE 112.942, 113.942 in MODEL 163
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
inMODEL170
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
inMODEL202
ENGINE 111.974 in MODEL 202 with CODE (491a) USA version
ME-SFI fu el injection and ignition system with band held tester
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208

Mercedes-Benz
ENGINE 111.947, 112.911/921 /941, 113.940/980, 119.985 in MODEL 210
Check connection diagram of idle, regulate ME-SFI fuel injection and ignition system with handheld
tes ter
(shown on Modell40 with Engine 120)
A ThrOftJe control
X1114 Otlalnkconneelor
005 Em/ssl"" • en sor
006 Exhaust eno/yur
014 Exhaustouction funner
Oflt 01 remcc.lhermomecer
042 Preswre musllling di! vice
Olt7 Handheld taslor
ot4 MuJrt>.-.xeeb/e
Fig. 5: Identifying Connection Diagram OfRegulate ME-SFI Fuel Injection And lgnition System
[JJ Risk of accident. Secure vehicle to ASOO.OO-Z-0005-0lA

around the engine during
start-up or while running
may result in contusions
and bums
[JJ Risk of death. Death Do not touch parts AS15.10-Z-OOOI-01A
Mercedes-Benz

[g]
' References to test Air conditioning or AH07.00-P-3000-0lA
testíng and adjusting conditioning switched
leaks in automatic
consumers switched off
[g] Test and adjustment inHHT
values [g] Engine 119 dh0a00pm00062x
[g] Engine 120 dh0a00pm0006l x
[g] relevant HHT contents:
'
Test idle speed,
emission test (AU)
diagram
LÍi Connection of Connect the HHT ADOO.OO-P-2003A
diagnostic test Handheld tester *WH58.30-Z-l 036-13A
equipment Test cable *WH58.30-Z-1037-13A
only for models not &oan<>er! 4-point analyzer *WE58.40-Z-1001-06A
fitted with TWC or for with lambda calculation
emission test (AU)
only for models not @ Exhaust probe Fig. 2
fitted with TWC or for
emission test (AU)
2 Inspect throttle control [gJ except model 220
bearing points and ball
sockets.
3 Test closed throttle/wide
open throttle stop at
pedal value sensor
4.1 Selector lever position
of automatic
Mercedes-Benz
transrnission readout
PIN
4.2 Depress clutch pedal of
manual transmission
readout ON/OFF
5 Start engine [g] Warm up engine to
(coo lant temperature >
80°C)
6 Test engine oil [g] Engine 112, 113 with
temperature HHT
7 Test coolant temperature with HHT
8 Test idle speed with HHT
9 Check idle speed with HHT
recognition (accelerator
pedal not actuated):
Display ON
10.1 Test lambda control with HHT
upstream ofTWC
right/left (if fitted)
10.2 Test idJe speed exhaust with HHT
value without TWC and [g] Models not fitted
set with TWC
11 Test smootb engine Test in selector lever
mnnmg position D (parking and
service brake applied)
and with consumers
switched on.
12G~ 115300
Fig. 6 : ldentifying Emission sensor (126 589 11 63 00)
e ommerc1a·nty availa ble t001S

Number Designation
WH58.30-Z-1036-13A Handheld tester (HHT) 651 100 01 99
WH58.30-Z-1037-13A Test cable (multiplexer) 651 100 40 99
Mercedes-Benz
Workshop equipment
IWE58.40-Z-l 00 l-06A 14-gas tester
Test, regulate idle speed- AR07.00-P-3002WB
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ENGINE 104.944 /994 as of 1.6.96,
119.980 /981, 120.982
inMODEL140
ENGINE 112.942, 113.942 in MODEL 163
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
in MODEL 170
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
in MODEL202
ENGINE 111.974 in MODEL 202 with CODE (491) U.S. version

Mercedes-Benz
ENGINE 111.944/975, 112.940, 113.943 in MODEL 208
ENGINE 111.947, 112.911 /921 /941, 113.940/980, 119.985 in MODEL 210
with CODE (491) U.S. version
ENGINE 112.922 /944, 113.941 /960 in MODEL 220
Connection diagram for testing id le speed.
Shown on Model 21 O
Mercedes-Benz
XU/.4 01Bgnos6o aota 6nlc connector

(1f>. or3~ín)
00$ Emlss!Ofl un.sor
006 Exhau51 anolyur
014 ExhaVSI $UCiion funnel
0100 STAR 0/AGNOSI$
Fig. 7: ldentifying Connection Diagram For Testing ldle Speed- Shown On Model210
ITl Risk of accident. Secure vehicle to ASOO.OO-Z-0005-0 l A

Acc.iidents may result if prev ent it from moving.
around the engine during
start-up or while running
may result in contusions
and bums
ITl Risk of deatb. Death Do not touch parts ASlS.lO-Z-0001-0lA
[g] References to test Air conditioning or AH07.00-P-3000-01A
testing and adjusting conditioning switched
leaks in automatic
Mercedes-Benz
¡g¡' Test and adjustment in HHT-WIN

values [g] Engine 119 dh0a00pm00062x
[gJ Engine 120 dh0a00pm00061 x
¡g¡... relevant HHT-WIN
contents:
Test idle speed,
emission test (AU)
diagram
& Connection of Connect STAR ADOO.OO-P-2003A
diagnostic test DIAGNOSIS
equipment Diagnosis system STAR *WH58.30-Z-1 048-13A
DIAGNOSIS
only for models not &oanacrl 4-point analyzer *WE58.40-Z-1 001-06A
fitted with TWC or for with lambda calculation
emission test (AU)
only for models not @ Exhaust probe Fig. 2
fitted with TWC or for
emission test (AU)
2 Inspect throttle control [gJ except Model 220
bearing points and hall
sockets.
3 Test closed throttle/wide
open tbrottle stop at
pedal value sensor
4.1 Selector lever position
of automatic
transmission readout
PIN
4.2 Depress clutch pedal of
manual transmission
readout ON/OFF
5 Start engine [gj w arm up engme
. to
(coo lant temperature >
80°C)
6 Test engine oil [gJ Engine 112, 113 with
temperature HHT-WIN
9 Check idle speed with HHT-WIN
recoQTiition (accelerator
Mercedes-Benz
pedal not actuated):

Display ON
10.1 Test idle speed exhaust with HHT-WIN
value without TWC and
set
10.2 Test lambda control with HHT-WIN
upstream ofTWC [g] Models not fitted
right/left (if fitted) with TWC
11 Test smooth engine Test in selector lever
running position D (parking and
service brake applied)
and with consumers
switched on.
126 58911 53 00
Fig. 8: ldentifying Emission Sensor (126 589 11 63 00)
e ommerc1a·u1y availa ble t 00lS

Number Designation
WH58.30-Z- l048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
4-gas tester
TEST ENGINE PERFORMANCE AND EXHAUST EMISSIONS- AR07.00-P-3003
Test engine performance and exhaust emissions- AR07.00-P-3003WA
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ME-SFI fu el injection and ignition system with hand held tester
RNGTNR 104.944 /994 as of 1.6.96.

Mercedes-Benz
119.980 /981, 120.982
inMODEL140
ME-SFI fu el injection and ignitioo system with hand held tester
ENGINE 112.942, 113.942 in MODEL 163
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
in MODEL170
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
in MODEL202
ME-SFI fuel injection aod ignition system witb bandheld tester
ENGINE 111.974 in MODEL 202 witb CODE (491a) USA version
ME-SFI fuel injection and ignition system witb bandheld tester
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208
ME-SFI fuel injection aod ignition system with handheld tester

Mercedes-Benz
ME-SFI fu el injection and ignition system with hand held tester
ENGINE 111.947, 112.911/921 /941, 113.940/980, 119.985 in MODEL 210
HHT
(shown on rnodell40 with engine 120)
A Throttle control
X11f4 Oolalnl< conneclof
00$ Ena~'sston$ensor
OOIS Exhaust onalyzer

014 &h•ustsuction funMt
018 OW remOiethOtmometllf
042 PreU<Jre measlfrlll{l devl'ce
081 lliltldheld tester
094 AM!.,Iexeab/e
Fig. 9: ldentifying Connection Diagram ME-SFI Fuel Injection And Ignition System - Shown On Model
140 With Engine 120
Risk of accident. Accidents Secure vehicle to prevent it from ASOO.OO-Z-0005-

rnay result ifthe vehicle starts moving. OlA
offunintentionally with the Wear closed and snug-fitting work
engine running. Risk of injury clothes.
Mercedes-Benz
as working around the engine Do not grasp hot or rotating parts.

during start-up or while nmning
may result in contusions and
burns
[JJ Risk of death. Death may Do not touch parts carrying hígh AS15.1 0-Z-0001-
result if contact is made with voltages. OlA
parts carrying high voltages. Persons who wear electronic
implants (e.g. heart pacemakers)
must not carry out work on the
ignition system.
¡g¡' References to test conditions AH07.00-P-3000-
for engine testing and adjusting OlA
work
~' Notes regarding test conditions The driven period is to be limited AH07.00-P-3003-
when testing engine output and solely to the time required toread OlA
exhaust gas offthe instruments (approx. 5
seconds for the output
dynamometer; approx. 20 seconds
for the exhaust emission test).
¡g¡ Test and adjustment values inHHT
[g] Engine 119 dh0a00pm00062x
¡g¡ Engine 12O dh0a00pm00061 x
¡g¡ relevant HHT contents:
Serví ce (check engine
performance)
1 Check and adjust engine AR07.00-P-
3001WA
diagram
& Connection of diagnostic test Connect the HHT ADOO.OO-P-2003A
equipment Handheld tester *WH58.30-Z-
1036-13A
Test cable *WH58.30-Z-
1037-13A
& Donaer! 4-point analyzer with *WE58.40-Z-
lambda calculation 1001-06A
@Test connection Fig. 11
@ Tool for removing Fig. 12
@ Adapter Fig. 13
3 Secure front wheels ~ Place wheel chocks 100 mm in
front of front wheels.
4 Ignition: OFF, detach clutch of ¡g) Models fitted with
Mercedes-Benz
ABS/ ASR hydraulic unit in ABS/ ASR/ESP1ASR/ETS/ABS

wheelhouse.
ESP/ASR/ETS/ABS
malfunction indicator lamp
illuminates during driving.
"Slip, ASR, control regulation"
is shown in t he multifunction
display.
¡gj After test, fit together plug
connection and erase fault
memory!
5 Direct a ir flow at radiator and ~ Danger of engine overheating
underside of vehicle (oil pan,
exhaust, 3-way catalytic
converter, tires). Maintain a
distance of approx. 1 m
between blower and vehicle.
6 Warm up engine at part load, ¡gj Engine oil temperature > 80°C.
selector lever position "D" or ~ Do not exceed 120°C
3rd gear at a load of about 25
kW
7 Test engine oil temperature [gJ Engine 112, 113 with HHT
8 Test coolant temperature withHHT
9 Test idle speed withHHT
[gJ Selector lever position P/N
AC and additional consumers
switched off.
10 Test air mass withHHT
¡gj Engine: Idle
11 Test HFM voltage withHHT
12 Test ignition angle withHHT
13 Test injection time withHHT
[gJ Engine: Idle
14 Test camshaft solenoid [gJ only Engine 104, 111
15 Test camshaft Hall sensor withHHT
16 Test intake air temperature withHHT
17 Test onloffratio ofpurge valve withHHT
18 Test battery voltage withHHT
19 Test actuator withHHT
20 Test pedal value sensor withHHT
21 Test throttle valve angle withHHT
22 Test idle speed and full throttle withHHT
recognition
23 Test WOT/CTP stoo at oedal
Mercedes-Benz
value sensor
24 Test knock sensor system withHHT
enable
25 Test knocking ignition angle with HHT
26 Test knock sensor withHHT
27 Test AC compres sor wíthHHT
28 Test transrnission protection withHHT
29 Test inertia fuel shutoff withHHT
30 Test fullload output [g] Drive at fullload output only
long enough to read off the
instruments. Compare
performance figures indicated with
test and setting specifications. In
this case, note barometer level,
coolant temperature and intake air
temperature.
Use correction table for AHOO.l 0-P-201 0-
detennining performance except 02A
engine 111.943, 111.944, 111.947,
111.973, 111.975
Reference to capacity correction AHOO.lO-P-2010-
OlA
31 Test exhaust emission Test under load. Air cleaner
values/lambda control installed. Engine approx. 80°C,
cool down ifnecessary.
Fullload CO
Upper part load CO (detach purge
system), readout varíes.
Lower part load CO ( detach purge
~stem) , readout varíes.
If catalytíc converter is hot
(engine oil > 100°C) a high
conversion rate (or self-control)
is reached, this produces a full
loadCO
reading of> 1 %by vol.
It is important to ensure that the
fullload is detected.
JJ::rAP Purge control valve, GF47.30-P-4030L
locationltask/design/function
32.1 Test exhaust backpressure [g] Only conduct if necessary, if
engine performance does not
correspond to specification.
Test under load.
Remo ve lambda pro be and install
Mercedes-Benz
test connection 103 589 00 9 l 00,

fi.t on pressure connection of
tes ter.
[g]
Coat test connection with hot
lubricating paste, part no. 000 989
76 5 l.
33.1 Test charge pressure of engines [g] Only conduct if necessary, if
fitted with supercharger. engine performance does not
Detach purge line at idle speedl
control actuator and connect
E!_essure tester.
~ only engine 111.943, 111.944,
111.947, 111.973, 111.975
Special tools
126 589 11 53 00
Fi2. 10: Identifying Emission sensor {126 589 11 63 00)
11
11
103 589 00 91 00
Tes::oom!!GSon
Fig. 11: ldentifving Test connection (103 589 00 91 00)

Mercedes-Benz
Fig. 12: ldentifving Wrench socket (111 589 03 09 00)
Fig. 13: Identifying Adapter {140 589 14 63 00}
e ommerc1a·u1y ava1'la bl e t 00l S

Number Designation
WH58.30-Z-l 036-13A Handheld tester (HHT) 651 100 01 99
WH58.30-Z-l037-l3A Test cable (multiplexer) 651 100 40 99
4-gas tester
Test engine performance ami exnaust emissions- AR07.00-P-3003WB
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL 129
ENGINE 104.944 /994 as of 1.6.96,
119.980 /981, 120.982
inMODEL140
Mercedes-Benz
ENGINE 112.942, 113.942 in MODEL 163
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
in MODEL 170
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
in MODEL202
ENGINE 111.974 in MODEL 202 witb CODE (491) U.S. version
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208

Mercedes-Benz
ENGINE 111.947, 112.911 /921 /941, 113.940/980, 119.985 in MODEL 210
ME-SFI fuel injection and ignitioo system with STAR DIAGNOSIS
with CODE (491) U.S. version
witb CODE (498) Japanese version
ENGINE 112.922 /944, 113.941 /960 in MODEL 220
Connection diagram for testing engine.
Shown on Model 210
)(1114 Dlagnoslic dota lfnlc connector

(16- or34-pln)
005 Emlsslon s sn..,.
004 Exhaust•nalyzer
014 Exh.u$1sueelon funnel
0100 STAROIAGNOSIS
Fig. 14: Identifying Connectiion Diagram For Testing Engine- Shown On Model 210
[IJ Risk of accident. Accidents Secure vehicle to prevent it from ASOO.OO-Z-0005-

may result if the vehicle starts movmg. 01A
Mercedes-Benz
offunintentionally with the Wear closed and snug-fitting work

engine running. Risk of injury clothes.
as working around the engine Do not grasp hot or rotating parts.
during start-up or while running
may result in contusions and
bums
[JJ Risk of death. Death may Do not touch parts carrying high ASlS.lO-Z-0001 -
result if contact is made witb voltages. OlA
parts carrying high voltages. Persons who wear electroníc
implants (e.g. heart pacemakers)
must not carry out work on the
ignition system.
¡g¡.. References to test conditions AH07.00-P-3000-
for engine testing and adjusting OlA
work
~ ~ Notes regarding test conditions The dríven period is to be límited AH07.00-P-3003-
when testing engíne output and solely to the time requíred to read Ol A
exhaust gas offthe instruments (approx. 5
seconds for the output
dynamometer; approx. 20 seconds
for the exhaust emission test).
¡g¡ Test and adjustment values inHHT-WIN
[g] Engine 119 dh0a00pm00062x
[g] Engine 120 dh0a00pm00061 x
[g].. relevant HHT-WIN contents:
Service (check engine
performance)
1 Check and adjust engine AR07.00-P-
3001WB
accordíng to connectíon
diagram
~ Connection of diagnostic test Cotmect STAR DIAGNOSIS ADOO.OO-P-2003A
equipment Diagnosis system STAR *WH58.30-Z-
DIAGNOSIS 1048-13A
&.oanCler! 4-point analyzer with *WE58.40-Z-
lambda calculation 1001-06A
@ Test connection Fig. 11
@ Tool for removing Fig. 12
@ Adapter Fig. 13
3 Secure front wheels ~Place wheel chocks 100 mm in
front of front wbeels.
4 Ignition: OFF, detach clutch of [g] Models fitted with
Mercedes-Benz
ABS/ASR hydraulic tmit in ABS/ASR/ESP/ASR/ETS/ ABS

wheelhouse.
ESP/ASR/ETS/ABS
malfunction indicator lamp
illuminates during driving.
"Slip, ASR, control regulation"
is shown in the muJtifunction
display.
[g] After test, fit together plug
connection and erase fault
memory!
5 Direct a ir flow at radiator and [g] Danger of engine overheating
underside ofvehicle (oil pan,
exhaust, 3-way catalytic
converter, tires). Maintain a
distance of approx. 1 m
between blower and vehicle.
6 Warm up engine at part load, [g] Engine oil temperature > 80°C.
selector lever position "D" or [g] Do not exceed 120°C
3rd gear ata load of about 25
kW
7 Test engine oil temperature [g] Engine 112, 113 with HHT-
WIN
[g] Selector lever position P/N
AC and additional consumers
switched off.
10 Test air mass with HHT-WIN
[g] Engine: Idle
11 Test HFM voltage with HHT-WIN
12 Test ignition angle with HHT-WIN
13 Test injection time with HHT-WIN
[g] Engine: Idle
14 Test camshaft solenoid [g] only engine 104, 111
15 Test camshaft Hall sensor with HHT-WIN
16 Test intake air temperature with HHT-WIN
17 Test on/off ratio of purge valve with HHT-WIN
18 Test battery voltage with HHT-WIN
19 Test actuator with HHT-WIN
20 Test pedal value sensor with HHT-WIN
21 Test throttle valve angle with HHT-WIN
22 Test idle speed and full throttle with HHT-WIN
recognition
Mercedes-Benz
23 Test WOT/CTP stop at pedal

value sensor
24 Test knock sensor system wíth HHT-WIN
enable
25 Test knocking ignition angle with HHT-WIN
26 Test knock sensor with HHT-WIN
27 Test AC compres sor with HHT-WIN
28 Test transmissíon protection with HHT-WIN
29 Test inertia fuel shutoff with HHT-WIN
30 Test fullload output [g] Drive at fullload output only
long enough to read off the
instruments. Compare
performance figures indicated with
test and setting specífications. In
thís case, note barometer leve!,
coolant temperature and intake air
temperature.
[g] Use correctíon table for AHOO.lO-P-2010-
determining performance 02A
Except Engine 111.943, 111.944,
111.947, 111.973, 111.975
[g] Reference to capacíty correction AHOO.IO-P-2010-
OlA
31 Test exhaust emíssíon Test l!mder load. Air cleaner
values/lambda control installed. Engine approx. 80°C,
cool down ifnecessary.
Fullload CO
Upper part load CO (detach purge
system), readout varíes.
Lower part load CO (detach purge
~stem) , readout varíes.
If catalytic converter is hot ( engine

oil > 100°C) a high conversion
rate (or self-control)
is reached, this produces a full
load CO
reading of > 1 % by vol.
It is important to ensure that the
fullload is detected.
[ ! rAP Purge control valve, GF47.30-P-4030L
locatíonltask!desígn/function
32.1 Test exhaust backpressure [g] Only conduct ifnecessary, if
engine performance does not
Mercedes-Benz
Test under load.

Remo ve lambda pro be and install
test connection 103 589 00 91 00,
fit on pressure
connection of tester.
[gJ..
Coat test connection with hot
lubricating paste, part no. 000 989
76 51.
33.1 Test charge pressure of engines [gJ Only conduct if necessmy, if
fitted with supercharger. engine performance does not
Detach purge line at idle speedl
control actuator and connect
fg¡essure tester.
Only Engine 111.943, 111.944,
111..947, 111.973, 111.975
SpeciaJ tools
126 589 11 63 00
Fig. 15: Identifying Emission sensor (126 589 11 63 00)
103 589 00 91 00
Fig. 16: Identifving Test Connection (103 589 00 91 00)

Mercedes-Benz
Fig. 17: Identifving Wrench socket (111 589 03 09 00)
Fig. 18: Identifving Adapter (140 589 14 63 00)
e ommerc1a·u1y availa ble t 00lS

Number Designatioo
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis 6511 180100
4-gas tester
EXTENSION TO TESTING, ADJUSTING ENGINE- AR07.00-P-3004
Extension to testing, a<ljusting eogine- AR07.00-P-3004WA
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ENGINE 104.944 /994 as of 1.6.96,
119.980 /981, 120.982

Mercedes-Benz
ME-SFI fuel injection and ignition system witb band-beld tester
ENGINE 112.942, 113.942 in MODEL 163
ME-SFI fuel injection and ignitioo system with hand-held tester
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
inMODEL170
ME-SFI fuel injection and ignition system witb band-beld tester
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
in MODEL202
ME-SFI fuel injection and ignition system witb band-held tester
ME-SFI fuel injection and ignition system with hand-beld tester
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208

Mercedes-Benz
ENGINE 111.947, 112.911 /921/941,113.940 /980,119.985 in MODEL 210
ME-SFI fuel injection and ignition system witb hand-beld tester
IJJ Risk of accident as a Secure vehicle to prevent ASOO.OO-Z-0005-0lA

result of vehicle starting it starting off.
off when engine running. W ear closed and close-
Risk of injury as a result fitting work clothes.
of bmises and burns if Do not grasp hot or
you insert your hands into rotating parts.
engine when it is being
started or when it is
runrung.
IJJ Hazard from contact Do not touch parts AS15.1 0-Z-0001-0lA
with parts conducting conducting high voltages.
not carry out any work on
[g]... Notes on test conditions AH07.00-P-3000-0lA
for engine test and
adjustment operations
1 Connect testers according
to connection diagram
~ Connect test equipment ConnectHHT ADOO.OO-P-2003A
diagnosis
Hand-held tester * WH58.30-Z-1 036-13A
Test cable *WH58.30-Z-1037-13A
2.1 Compression test withHHT
[g] only if appropriate
complaint exists
[g]... Notes on compression AH07.00-P-3004-01WA
test
2.2 Test smooth engine withHHT
runnin!l rru , nn v 1·f ~nnrnnnlltP:
·
Mercedes-Benz
complaint exists
Notes on testing smooth AH07.00-P-3004-02W A
. .
engme runnmg
2.3 Test ignition circuit with HHT
shutoff only engine 113
[g) only if appropriate
complaint exists
Notes on testing ignition AH07.OO-P-3004-03WA
circuit shutoff
e ommerc1'allty avat'} a ble t 001S

Number Designation
WH58.30-Z-l 036-13A Handheld tester (HHT) 651 100 01 99
WH58.30-Z-l 037 -13A Test cable (multiplexer) 651 100 40 99
Enlargement to testing, adjusting engine- AR07.00-P-3004WB
ENGINE 104.943 /991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ENGINE 104.944 /994 as of 1.6.96,
119.980 /981, 120.982
inMODEL140
ENGINE 112.942, 113.942 in MODEL 163
ME-SFI f uel injection and ignition system with STAR DIAGNOSIS
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
in MODEL 170
Mercedes-Benz
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
in MODEL202
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208
ENGINE 111.947, 112.911/921/941, 113.940 /980, 119.985 in MODEL 210
ME-SFI fuel injection aod ignitioo system with STAR DIAGNOSIS
with CODE ( 498) Japanese version
ME-SFI fuel iojectioo aod igoitioo system with STAR DIAGNOSIS

Mercedes-Benz
ENGINE 112.922 /944, 113.941 /960 in MODEL 220
OJ Risk of accidentas a Secure vehicle to prevent ASOO.OO-Z-0005-0IA

result of vehicle starting it starting off.
off when engine running. W ear closed and elose-
of bmises and bums if Do not grasp hot or
runmng.
ITl Hazard from contact Do not toucb parts ASlS.lO-Z-0001-0lA
witb parts conducting conducting high voltages.
[!!] Notes on test condítions AH07.00-P-3000-0 lA
for engine test and
adJustment operations
1 Connect measuring
instruments after
connection scheme
~ Connect test equipment Connect STAR ADOO.OO-P-2003A
diagnosis DIAGNOSIS
Diagnosis system STAR * WH58.30-Z-1 048-13A
DIAGNOSIS
2.1 Compression test with HHT-WIN
complaint exists
rg¡ 'Notes on compressíon AH07.00-P-3004-01WA
test
2.2 Test smooth engine witb HHT-WIN
runmng
[gl only if appropriate
complaint exists
[gJ' Notes on testing smooth AH07.00-P-3004-02W A
engine running
2.3 Test ignitíon circuit with HHT-WIN
sbutoff onJy engine 113
complaint exists
Mercedes-Benz
Notes on testing ignition AH07.00-P-3004-03WA

circuit shutoff
e ommerc1a·u1y avat.•a ble t001S

Number Designation
WH58.30-Z-l 048-13A STAR DIAGNOSIS diagnosis 6511 1801 00
Enlargement to testing, adjusting engine- AR07.00-P-3004WC
ENGINE 104.943/991 as of 1.6.96,
112.923 /943, 113.961, 119.982, 120.983
inMODEL129
ENGINE 104.944 /994 as of 1.6.96,
119.980 /981, 120.982
inMODEL140
ENGINE 112.942, 113.942 in MODEL 163
ME-SFI fuel injection and ignition system with engine diagnosis tester Datasco pe D 980
ENGINE 111.943,
111.946 as of 1.6.98,
111.973
in MODEL 170
ENGINE 104.941, 111.944 as of 1.8.96,
112.910 /920, 113.944
inMODEL202
Mercedes-Benz
ME-SFI fuel injection and ignition system witb engine diagnosis tester Datascope D 980
ME-SFI fu el injection and ignitioo system with engine diagnosis tester Da tasco pe D 980
ME-SFI fuel injection and ignition system with engiue diagnosis tester Datascope D 980
ME-SFI fuel injection and ignition system witb engine diagnosis tester Datascope D 980
ENGINE 111.944 /975, 112.940, 113.943 in MODEL 208
ME-SFI fuel injection and ignition system with engine diagnosis tester Dataseope D 980
ENGINE 111.947, 112.911 /921 /941, 113.940 /980 in MODEL 210
ME-SFI fuel injection and ignition system with engine diagnosis tester Dataseope D 980
Risk of accidentas a Se cure vehicle to prevent ASOO.OO-Z-0005-0lA

result ofvehicle starting it starting off.
off when engine running. W ear closed and close-
of bmises and bums if Do not grasp hot or
Mercedes-Benz
running.
[JJ Hazard from contact Do not touch parts AS15.10-Z-000 1-0 lA
with parts conducting conducting high vo1tages.
1 Test contactless high Engine 104, 111 ARlS.l 0-P-3000WD
voltage distribution Engine 112, 113 AR15.10-P-3000WA
Engine 119, 120 AR15.1 0-P-3000WE
TESTING AND REPAIR WORK: PASSENGER CARS: MIXTURE FORMATION- AR07.00-Z-

9104AB
ENGINE 104
Engine test ENGINE 104, 111 , 112, 11 3, 119, 120... AR07.00-P-

and setting 3000WA
operations
Engine test ENGINE 104, 111, 112, 113, 119, 120... AR07.00-P-
and setting 3000WB
operations
Engine test ENGINE 104,111, 112, 113, 119, 120... AR07.00-P-
and setting 3000WC
operations
Check and ENGINE 104, 111 , 112, 11 3, 119, 120... AR07.00-P-
adjust engine 3001WA
Check and ENGINE 104, 111, 112, 11 3, 119, 120... AR07.00-P-
adjust engine 3001WB
Test, regulate ENGINE 104, 111, 112, 113, 119, 120... AR07.00-P-
idle speed 3002WA
Test, regu1ate ENGINE 104, 111 , 112, 113, 119, 120... AR07.00-P-
idle speed 3002WB
Test engine ENGINE 104, 111, 112, 113, 119, 120... AR07.00-P-
perfonnance 3003WA
and exhaust
emissions
Test engine ENGINE 104, 111, 112, 113, 119, 120... AR07.00-P-
performance 3003WB
and exhaust
enusswns
Extension to ENGINE 104, 111 , 112, 113, 119, 120... AR07.00-P-
testing, 3004WA
adjusting
Mercedes-Benz
engine
Enlargement ENGINE 104, 111 , 112, 113, 119, 120... AR07.00-P-
to testing, 3004WB
adjusting
engine
Enlargement ENGINE 104, 111,112, 113, 119, 120... AR07.00-P-
to testing, 3004WC
adj usting
engme
Removing and ENGINE 104.94 /99, AR07.03-P-
installing fuel 111.920 /921 /94 /96 /970 !973 /974 /975 /977 (except, 1450D
raíl with 104.990)
injection
valves
installíng 111.920 /921 /94 /96 /970 !973 /974 /975 /977 (except, 6522D
injection 104.990)
valves
ínstalling hot 111 .921 /943 /944 /945 /946 /947 /96 /970 /973 /974 /975 /977 1453D
film mass air (except, 104.990)
sensor
installing 111.920 /921 /94 /96 /970 !973 /974 /975 (except 104.990) 1450D
diaphragm
pressure
regulator
Removing, ENGINE 104.941 /942 /943 /944 /99 1 /992 /994, AR07.51-P-
installing 111.920 /940 /941 /944 /96 o/961 1459D
HFM-SFI
variable
reference
resistor
TESTING AND REPAIR WORK: PASSENGER CARS: MIXTURE FORMATION - AR07.00-Z-

9113AB
ENGINE 113
Engine test and setting ENGINE 104, 111 , AR07.00-P-3000WA

operations 112, 113, 119, 120...
Eugine test and setting ENGINE 104, 111 , AR07.00-P-3000WB
operations 112, 113, 119, 120...
Engine test and setting ENGINE 104, 111, AR07.00-P-3000WC
operations 112, 113, 119, 120...
Mercedes-Benz
Check and adjust engine ENGINE 104, 111 , AR07.00-P-3001WA

112, 113, 119, 120.. .
Check and adjust engine ENGINE 104, 111 , AR07.00-P-3001WB
112, 113, 119, 120...
Test, regulate id le speed ENGINE 104, 111 , AR07.00-P-3002WA
112, 113, 119, 120...
Test, regu1ate idle speed ENGINE 104, 111 , AR07.00-P-3002WB
112,113,119, 120...
Test engine performance and ENGINE 104, 111 , AR07.00-P-3003WA
exhaust emissions 112, 113, 119, 120...
Test engine performance and ENGINE 104, 111 , AR07.00-P-3003WB
exhaust emissions 112, 113, 119, 120...
Extensíon to testing, adjusting ENGINE 104, 111 , AR07.00-P-3004WA
engme 112, 113, 119, 120...
Enlargement to testing, ENGINE 104, 111 , AR07.00-P-3004WB
adjusting engine 112, 113, 119, 120...
Enlargement to testing, ENGINE 104, 111 , AR07.00-P-3004WC
adjusting engine 112, 113, 119, 120.. .
Remove/install fue! rail with ENGINE 112, 113 ... AR07.03-P-1451A
injectors (ME-SFI)
Remove/install fue! distributor ENGINE 112, 113 ... AR07.03-P-1451AA
with injection valves (ME-SFI)
Remove/install fuel raíl with ENGINE 113.964 in AR07.03-P-1451GZ
injectors (ME-SFI) MODEL 164.175
Remove/install fuel raíl with ENGINE 113.971 in AR07.03-P-1451RT
injectors (ME-SFI) MODEL 251.075 /175
Remove/ínstall fuel raíl with ENGINE 113.967 in AR07.03-P-1451TY
injectors (ME-SFI) MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install injection valves ENGINE 112, 113 ... AR07.03-P-6520A
(ME-SFI)
Removing/installing injectors ENGINE 113.964 in AR07 .03-P-6520GZ
(ME-SFI) MODEL 164.175
Remove/install injectors (ME- ENGINE 113.971 in AR07.03-P-6520RT
SFI) MODEL 251.075 / 175
Removing/ínstalling injectors ENGINE 113.967 in AR07.03-P-6520TY
(ME-SFT) MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install hot film mass ENGINE 112, 113 ... AR07.07-P-1454A
air flow sensor together with
air intake pipe
Remove/install hot fi lm mass ENGINE 112, 113 ... AR07.07-P-1454AA
Mercedes-Benz

air intake pipe
Remove/install hot film mass ENGINE 112, 113 ... AR07.07-P-1454AG
air intake pipe
Removing/installing hot film ENGINE 113.964 in AR07.07-P-1454GZ
mass air flow sensor together MODEL 164.175
with the air intake pipe
Remove hot film mass air flow ENGINE 113.942 in AR07.07-P-1454MV
sensor together with air intake MODEL 163.172
pipe, install ENGINE 113.981 in
MODEL 163.174
ENGINE 113.965 in
MODEL 163.175
Remove/install hot film mass ENGINE 113.971 in AR07.07-P-1454RT
a ir flow sensor together with MODEL 251.075 / 175
air intake pipe
Remove/install hot film mass ENGINE 112, 113 ... AR07.07-P-1454SV
air intake pipe
Removing/instaUing the bot ENGINE 113.967 in AR07.07-P-1454TY
film mass air flow sensor MODEL 219.375
together with air intake pipe ENGINE 113.990 in
MODEL 219.376
Remove/install injection ENGINE 113.964 in AR07.08-P-7008GZ
system control unit MODEL 164.175
Removing and installing ENGINE 112, 113, AR07.08-P-7008I
injection system control 137...
module
Remove/install injection ENGINE 111, 112, AR07.08-P-7008P
system control unit 113, 156, 611 , 612,
646 .. .
Remove/install injection ENGINE 112, 113, 275 AR07.08-P-7008R
system control unit inMODEL230
Remove/install injection ENGINE 113.971 in AR07.08-P-7008RT
system control unit MODEL 251.075 / 175
Remove/install injection ENGINE 112, 113, AR07.08-P-7008T
system control unit 646, 647, 648 ...
Remove/install fuel injection ENGINE 113.967 in AR07.08-P-7008TY
system control unit MODEL219.3
Remove/install throttle valve ENGINE 113.967 in AR07.51-P-1401 TY
actuator MODEL 219.375
ENGINE 113.990 in
MODEL 219.376
Remove/install heated 02 ENGINE 113.967 in AR07.52-P-5303TY
Mercedes-Benz

ENGINE 113.990 in
MODEL 219.376
Remove/install fuel pump relay ENGINE 113.989,271, AR07.52-P-5793V
272 in MODEL 171
Remove/install throttle valve ENGINE 113.964 in AR07.61 -P-1401GZ
actuator MODEL 164.175
Remove/install throttle valve ENGTNE 113.971 in AR07.61-P-1401RT
actuator MODELS 251.075 / 175
Remove/install throttle valve ENGINE 112, 113 ... AR07.61-P-1401SVK
actuator

9119AB
ENGINE 119
Engine test and setting ENGINE 104, 111 , 112, 113, AR07.00-P-3000WA
operations 119, 120...
Engine test and setting ENGINE 104, 111 , 112, 113, AR07.00-P-3000WB
Engine test and setting ENGINE 104, 111 , 112, 113, AR07.00-P-3000WC
Check and adjust engine ENGINE 104, 111 , 112, 113, AR07.00-P-3001WA
119, 120...
Check and adjust engíne ENGINE 104, 111 , 112, 113, AR07.00-P-3001WB
119, 120...
Test, regulate ídle speed ENGINE 104, 111 , 112, 113, AR07.00-P-3002WA
119, 120...
Test, regu1ate id1e speed ENGINE 104, 111, 112, 113, AR07.00-P-3002WB
119, 120...
Test engine performance ENGINE 104, 111 , 112, 113, AR07.00-P-3003WA
and exhaust ernissions 119, 120...
Test engine performance ENGINE 104, 111 , 112, 113, AR07.00-P-3003WB
and exhaust emissions 119, 120...
Extension to testing, ENGINE 104, 111, 112, 113, AR07.00-P-3004W A
adjusting engine 119, 120...
Enlargement to test1ng, ENGTNE 104, 111, 112, 113, AR07.00-P-3004WB
Enlargement to testing, ENGINE 104, 111, 112, 113, AR07.00-P-3004WC
Removing and installing ENGINE 119.981 /982 /985 AR07.03-P-1451E
fuel raíl with injectors
(ME-SFI)
Mercedes-Benz
Removing and instaHing ENGINE 119.97 AR07.03-P-1452E

fuel rail with injection
valves (LH-SFI)
Removing and installing ENGINE 119.981 /982/985 AR07.03-P-6520E
injectors (ME-SFI)
injection valves (LH-
SFI)
insulation sleeves or
rubber rings (for
injection valves) (LH-
SFI)
Removing and installing ENGINE 119.981 /982/985 .AR07.07-P-1453E
sensor
diaphragm pressure
regulator (LH-SFI)
Removing and installing ENGINE 119.981 /982/985 AR07.17-P-1452E
diapbragm pressure
regulator (ME)
hot wire mass air flow
sensor
Removing and installing ENGINE 119.97 in MODEL AR07.41-P-1459E
LH-SFI variable 124.03, 129, 140
reference resistor

9120AB
ENGINE 120
ENGINE 104, 111, 112, 113, AR07.00-P-

Engine test and setting operations
119, 120... 3000WA
ENGINE 104, 111, 112, 113, AR07.00-P-
119, 120... 3000WB
ENGINE 104, 111, 112, 113, AR07.00-P-
119,120... 3000WC
ENGINE 104, 111, 112, 113, AR07.00-P-
Check and adjust engine
119, 120... 3001WA
ENGINE 104, 111, 112, 113, AR07.00-P-
Check and adjust engíne
119, 120... 3001WB
FN<TTNF: 104. 1 11 112. 113 AR07.00-P-
Mercedes-Benz
Test, regulate idle speed 11 9, 120 ___ 3002WA

ENGINE 104, 111 , 112, 113, AR07.00-P-
Test, regulate idle speed 11 9, 120 ___ 3002WB
ENGINE 104, 111 , 112, 113, AR07.00-P-
Test engíne performance and exhaust emíssíons 119, 120 __ _ 3003WA
ENGINE 104, 111, 112, 113, AR07.00-P-
Test engine performance and exhaust emissions 11 9, 120 ___ 3003WB
ENGINE 104, 111 , 112, 113, AR07.00-P-
Extension to testing, adjusting engine 11 9, 120 ___ 3004WA
ENGINE 104, 111, 112, 113, AR07.00-P-
Enlargement to testing, adjusting engine 119, 120 ___ 3004WB
ENGINE 104, 111 , 112, 113, AR07.00-P-
Enlargement to testing, adjusting engine 119, 120 ___ 3004WC
Removing and installing fuel rail with injectors AR07.03-P-
ENGINE 120.982 /983
(ME-SFI) 1451F
Removing and installing fuel raíl with injection AR07.03-P-
ENGINE 120.980 /981
valves (LH-SFI) 1452F
AR07.03-P-
Removing and installing injectors (ME-SFI) ENGINE 120.982 /983
6520F
AR07.03-P-
Removing and installing injection valves (LHSFI) ENGINE 120.980 /981
6521F
Removing and installing hot film mass air flow AR07.07-P-
ENGINE 120.982 /983
sensor 1453F
Removing and installing diaphragm pressure AR07.17-P-
ENGINE 120.980 /981
regulator (LH-SFI) 1451F
Removing and installing diaphragm pressure AR07.17-P-
ENGINE 120.982 /983
regulator (ME-SFI) 1452F
Removing and installing hot wire mass air flow AR07.41-P-
ENGINE 120.980 /981
sensor 1453F
Removing and installing LH-SFI variable reference AR07.41-P-
ENGINE 120.980 /981
resistor 1459F
REMOVING AND INSTALLING FUEL RAIL WITH INJECTION VALVES- AR07.03-P-1450D
ENGINE 104.94 /99, 111.920 /921 /94/96/970 /973/974 /975/977 (except, 104.990)
Engine Series 104

Mercedes-Benz
1811 0-rlngs
f7 Fuclfilll
17/ 2 Fuol retum floMI Nno
17/3 Fuol fr>crl lino
Y61 lnjecrors
Fig. 19: ldentifving 0-Rings, Fuel Rail, Fuel Return Flow Line And lnjectors
Using Engine 111.940 for illustration purposes
111 Sorllir:c~lvo
151 0-rlngs
f7 Fuolrd
17/ 2 Fum roturn ff.oW líno
1713 Fucl focd lino
Y62 ff!/Cell>rs
Fig. 20: ldentifying Service Valve, 0-Rings, Fuel Rail, Fuel Return Flow Line And Injectors
tr.::r' BT (D Removing, instal1ing

OJ Risk of explosion from No fue, sparks, naked flames or AS47 .00-Z-0001-0lA
ignition, risk of smoking. Pour fuels only into
poisoning from suitable and appropriately
inhaling and marked containers.
swallowing fuel as weU Wear protective clothing when
as risk of injury from handling fueL
Mercedes-Benz
skin and eye contact

with fuel.
1.1 Remove air filter cross ¡gj Except engine AR09.10-P-8031G
ptpe 111.943/947/973/975
2 Use service valve (111)
to bleed pressure from
the fu el rail ( 17).
@ Fi~. 21
@ Fig. 23
3.1 Remove the oil filter. ¡gj Only engine 104 with
integrated oil-water cooler
@ Fi~. 22
4 Remove the fuel rail ¡gj Installation: Replace 0 -
(17). rings ( 16/8), oil to facilitate
installation
00 Engine 104 *BA09.20-P-1001-01B
00 Engine 111 *BA07.52-P-1001-01B
5 Unscrew the fuel ¡gj Catch emerging fuel in a
supply line (17/3). suitable container.
6.1 Unbolt fuel return flow ¡gj Except engine 111.977
line (17/2) Catch emerging fuel in a
suitable container.
7 Reverse the removal
sequence to install.
~ Intake manifold
BA09.20-P-100 1-0lB BoEts and nuts of intake N m 25
manifold to cylinder head
00 F uel rail
111.92/94/951/952/955/956/957/96/97/981/982 111.958/983
BA07.52-P- Bolt offuel N m 25 25
1001-01B rail to
cylinder
head
BA07.52-P- Fuel feed N m 24 24
1002-01B line to fuel
rail
Mercedes-Benz
1035S9 00 21 00
Teu ar
103 589 02 09 00
soct:al rtlrlctum lll
Fig. 22: ldentifying Socket Attachment (103 589 02 09 00)
119 5B9 04 03 00
Fig. 23: ldentifying Pressure House (119 589 04 63 00)
REMOVE/INSTALL FUEL RAIL WITH INJECTORS (ME-SFI)- AR07.03-P-1451
Remove/install fuel rail with injectors (ME-SFn- AR07.03-P-1451A
ENGINE 112.910 in MODEL 202.026/086
ENGINE 112.920 in MODEL 202.089 /029
ENGINE 112.921 in MODELS 210.081/281/063/263
ENGINE 112.940 in MODEL 208.365 /465

Mercedes-Benz
ENGINE 112.941 in MODELS 210.282 /065 /082 /265
ENGINE 113.940 in MODEL 210.070 /270
ENGINE 113.980 in MODEL 210.074 /274
ENGINE 113.944 in MODEL 202.033 /093
ENGINE 113.943 in MODEL 208.370 /470
Dlustrated on M112
t/'1 S.rvlco vaNo

114 Bol!
VI Rosoflitnee housll'lg
17 Fue/ ds!rlbu1or
1711 8o/IS
1712 Food lino
Y62 Fuellnjeclion va.ves
1'07..<0 021Hl6
Fig. 24: ldentifying Service Valve, Bolt And Resonance Housing

Mercedes-Benz
~BT Remove/lnstall
OJ Risk of explosioo caused No fue, sparks, open AS47 .00-Z-0001-0lA
by fuel igniting, risk of flames or smoking.
poisoning caused by Pour fuels only into
inhaling and swallowing suitable and
fuel as well as risk of appropriately
iojury to eyes and skin marked containers.
caused by contact with Wear protective clothing
fue l. w hen handling fu eL
1.1 Remove cover on front ¡g¡ Model 129.
side of engine
2 Remove cylinder head [g] Remove cylinder head
cover trim panel or air cover trim or air filter by
filter lifting upwards from the
3.1 Take off resonance [gJ Only on models with
housing (2/ 1) air filter attached to
vehicle.
4 Remove plastic cover [gJ Remove screw (1 /4).
5 Release fue) pressure [gJ Collect fuel!
through service valve
(1/ 1) @ Pressure hose Fig. 23
6 Detach feed line (17 /2) [g] Collect fuel! x
[gJ Ml12:? *BA07.52-P-1001-01A
~
[gJ Mll3:?
~ *BA07.52-P-1001-01A
7 Separate electrical
connector at fuel injection
valves (Y62)
8 Take out screws (1711 ), [g] Inspect 0-rings for
lift fuel rail ( 17) together damage.
with all injectors off the [g] Oil 0-rings before
intake manifold installing the fuel rail. ?
Remove/install injectors
(ME-SFI) AR07.03-P-6520A
~ Check
9 Test fuel injectors (Y62) ¡g¡ Refer to DMAN
Engine, Volume 4, Index
3111
llJ Fuel rail

Mercedes-Benz

112 except
112.945/951 /
960/96 1
BA07.52-P- 100 1-0 l A Disconnect fuel feed line N m 38
at fu el rail
~ F uel rail
E ngine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
Number Designation 986/988
BA07 .52-P- 1001 -0 lA Fuel feed line to fuel N m 38
distributor
119 589 04 63 00
F ig. 25: Identifving Pressure Hose (119 589 04 63 00)
Removing and installing fuel rai~ with injectors (ME-SFI) - AR07.03-P-1451E
ENGINE 119.981 /982 /985

Mercedes-Benz
16 Scrows
16tf o-rlr>gs
17 Fuol distrlbutor
1711 Fuol retum lino
1713 Fuolsupply //no
Y62 Fue/ lnjcctlon volvo
NJ/10 Englnc control moó:Jio ,_,E- SF~

Arrow Conncctor
Arrow Conncc tor
Fig. 26: ldentifving Screws, 0-Rings, Fuel Distributor, Fue) Return Line, Fuel Supply Line And Fuel
Injection Valve
~BT(D Removal, installation

OJ Fuel presents an Fire, openlights and AS47 .00-Z-0001-0lA
explosion hazard , fuel smoking probibited.
vapors are toxic when Fill and store fuel only in
inhaled or absorbed. containers intended for
Contact witb fuel can this purpose and marked
cau se skin and eye accordingly _
IDJUry . Wear protective clothing
when handling fueL
1 Release fuel pressure in See Diagnosis Manual,
fuel distributor with Engine, Volume 2, Index
service valve 3.1
@ Fig. 21
@ Fig. 23
2 Remove vacuum Iine for
brake unit
3 PuU off hoses for [g] On model210.072 E GF07.61-P-0001-05A
crank:case ventilation 50 AMG: Routing of
purge Iine modified
4 Dísconnect vacmun hose
from diaphragm pressure
regulator
5 Unscrew fue] supply [g) Catcb fueL Do not
( 17/3) and retum line ~mscrew fuel supply and
(17/2) return lines to check
Mercedes-Benz
injectíon valves On
model210.072 E AMG:
Routing and mounting of
fuellines modified ?
Routing and mmmting of GF07.6l-P-OOO l -09A
fuel lines for model
210.072 E AMG
6 Disconnect connectors
for injection valves (Y62)
7 Disconnect connector
frorn engine control
module (ME-SFI),
(N3/10) and connector
(arrows)
8 Remove left ignition coil
cover
9 Expose wiring hamess F or this purpose,
disconnect all electrical
connectors on línes
leading to intake
manifold over fuel
distributor
10 U nscrew screws (16)
11 Pull fuel distributor ( 17) Cover holes for injection
out of intake manifold valves
together with ínjection
valves and thread wiring
harness through
12 Replace 0-rings (16/8) [g] Oil for installation
~ Testing
13 Check fuel injection Se e Diagnosis Manual,
valves (Y62) Engine, Volume 2, Index
3.1
If necessary, after
checking:?
Replace injection valves AR07.03-P-6520E
14 Reinstall in opposite
order
Mercedes-Benz
T<eslar
119 589 04 63 00
Prassul8 hose
Removing and installing fuel rail with injectors (ME-SFI)- AR07.03-P-1451F
ENGINE 120.982 /983
16 scrows
1511 O.rln~s
17 Fuo/ dfstrlbutDr
1712 Fuol rcrum lino
1 7~ Fuol supp/yl/no
Y82 Fue/ lnjccllon v • .v...
Artow ConnoctDr
Fig. 29: Identifying Fuel Rail With Injectors (ME-SFD Removellnstall Components
[$=" BT
CD
<§ Explosion hazard Observe accident prevention regulations!
1 See Diagnosis Manual, Engine, Volume 2, Fig. 21

R P.IP~ C::P f11PI nrPC::C::llrP 1n fi1Pl TnclPx i ?
Mercedes-Benz
distributor with service val ve @

@ Fig. 23
Model140
For this pwpose:?
Partially remove cable duct on
2 Remove air collection housing, reinstalL See
bulkhead
Repair instructions for automatic heater, model
140, Operation no. 83-140
Disconnect vacuum. line from
3 automatic transmission at intake Model140
manífold
Remove mounting straps for all
4 electrical leads leading over fuel
distributor
Disconnect vacuum. hose from
5
diaphragm pressure regulator
Unscrew fuel supply (17 /3) and ¡gj Catch fuel. Do not unscrew fuel supply and
6
return lines ( 17/2 return lines to check injection valves
7 Disconnect connectors (arrow)
8 Unscrew screws (16)
Disconnect vacuum. line from
¡gj Cover holes for inJ·ection valves. Replace 0-
9 automatic transmission at intake
manifold rings, oil for installation
10 Reinstall in opposite order
Testing
See Diagnosis Manual, Engine, Volume 2,
11 Test injection valves (Y62)
Index 3.2
Remove and install injection AR07.03-P-
12
val ves 6520F
103 5B!I 00 21 00
Fi~. 30: Identifyin~ Tester (103 589 00 21 00)

Mercedes-Benz
119 589 04.63 00
REMOVING AND INSTALLING FUEL RAIL WITH INJECTION V AL VES (LH-SFI) - AR07 .03-P-
1452
Removing and installing fuel raíl with injection valves (LH-SFI)- AR07.03-P-1452E
ENGINE 119.97
16 Sc:rcws
1611 o-rlngs
11 Fuolr•ll
1712 Fucl rctum pfle
1713 Fuolfcodplpo
Y61 Fuol /n}llcrfon v•lve
Arrow Coupllng
Fig. 32: ldentifving Fuel Raíl With Injection Valves Remove/lnstall Components- Engine 119.97
~BT
CD
<§ Pay attention to accident prevention
Risk of explosion
regulations!
see Diagnosis Manual Engine, Volume
Release fuel pressure through service
1 2, lndex 3.1 Fig. 21
valve at fue) rail @
@ Fig. 23
Di~connect ::~11 the electri c::~ l connector~
Mercedes-Benz
of the cables which run vía the fu el rail to

2
the iutake manifold
Disconnect vacuum pipe for brake servo
3
unit
4 Detach hoses for crankcase ventilation
Detach vacuum hose of diaphragm
5
pressure regulator
Disconnect fuel feed pipe (17/3) and

¡gj Connect fueL Do not discormect
6 fuel feed and retum pipes for testing
return pipe ( 17/2)
the injection valves
7 Unplug couplings (arrow)
8 Remove screws (16)
Pull fuel rail (17) together with iujection
9 Cover over holes for iujection valves
valves out of intake manifold
10 Replace 0-rings (16/8) ¡gj Oil for installing
11 Examine insulating sleeves If necessary, after examiniug: ?
Remove insulatiug sleeves or rubber AR07.03-P-
rings (fbr injection valves), install 6570E
B Testing
12 Test fuel injection valves (Y62) 2, Index 3.1
Ifnecessary, after testing:?
Remove injection valves, replace, AR07.03-P-
instan 6521E
103 599 00 21 0!)

Mercedes-Benz
119 589 04 63 00
Pr&SilllllhO!II
F ig. 34: Identifying Pressure Hose (119 589 04 63 00)
Removing and installing fu el rail with in,jection valves (LH-SFI)- AR07.03-P-1452F
ENGINE 120.980 /981
16 Scrows
1611 CH/n¡¡s
17 FuclrMI
1712 Fual rctum pt>a
1713 Fuolfcodp/po
Y62 Fuol/rrjcction VoNcs
Arrow C-onnce-tor
1'07C>4l2Q1.CO
F ig. 35: Identifying F uel Rail With Injection Valves Remove/Install Components- Engine 120.980 /981
~BT
CD
@ Pay attention to accident prevention
Risk of explosion
regulations!
see Diagnosis Manual Engine, Volume 2,
Release fuel pressure through
1 lndex 3.2 Fig. 21
service valve at fuel rail @
@ Fig. 23
Model140
For this step: ?
Remove cable duct partially at the
2 Remove, install air inlet plenum. See RA
fue wall
Automatic Heater Control Model 140, Op.
no. 83-140
3 Disconnect vacuum pipe from Model140

automatic transmi ssion at the intake
1
Mercedes-Benz
1
manifold
Remove top parts of cover of high
4
voltage distributor
Disconnect all the e lectric
5 connectors of the wíring which run
via the fue] rail
Disconnect the vacuum hose of
6
diaphragm pressure regulator
[g] Collect fuel. Do not disconnect fuel
Disconnect fuel feed pipe ( 17/3) and
7 feed and return pipes for testing the
return pipe ( 17/2)
injection valves
8 Unplug connectors (arrow)
9 Remove screws (16)
Pull fuel raíl (17) together with
[g] Cover over holes for injection valves.
10 injection val ves out of intake
Replace 0 -rings. Oil for installing.
manifold
Installation is performed in reverse
11
order
~ Testing
see Diagnosis Manual Engine, Volume 2,
12 Test injection valves (Y62)
Index 3 .2
AR07.03-P-
13 Remove, install injection valves
6521F
~M
b
~~
103 589 00 21 1}!)
\.
/' '\
~aJ
119 589 (M 63 00
' ./
REMOVEIINST ALL INJECTION V AL VES (ME-SFI)- AR07.03-P-6520

Mercedes-Benz
Remove/install injection valves (ME-SFI)- AR07.03-P-6520A
ENGINE 112.910 in MODEL 202.026/086
ENGINE 112.920 in MODEL 202.089 /029
ENGINE 112.921 in MODEL 210.081 /281 /063 /263
ENGINE 112.922 in MODEL 220.063 /163
ENGINE 112.940 in MODEL 208.365 /465
ENGINE 112.941 in MODEL 210.282 /065 /082 /265
ENGINE 112.944 in MODEL 220.165 /065
ENGINE 113.940 in MODEL 210.070 /270
ENGINE 113.941 in MODEL 220.070 /170
ENGINE 113.960 in MODEL 215.375, 220.075 /175
ENGINE 112.945, 113.962 /982 in MODEL 463
ENGINE 113.980 in MODEL 210.074 /274
ENGINE 113.944 in MODEL 202.033 /093
ENGINE 113.943 in MODEL 208.370 /470
ENGINE 112.912 in MODEL 203.061 /261, 209.361 /461
FNr.TNF. 112.946 in MOflF.T. 203.064/264

Mercedes-Benz
ENGINE 112.961 in MODEL 203.065 /265
ENGINE 113.968 in MODEL 209.375 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065 /265
ENGINE 113.967 in MODEL 211.070 /270
ENGINE 113.987 in MODEL 209.376 /476
ENGINE 112.955 in MODEL 209.365 /465
ENGINE 112.916 in MODEL 203.081 /281
ENGINE 112.953 in MODEL 203.084/284
ENGINE 113.990 in MODEL 211.076 /276
ENGINE 113.991 in MODEL 215.374, 220.074 /174
ENGINE 112.972 in MODEL 220.067 /167
ENGINE 112.975 in MODEL 220.087 /187
ENGINE 113.948 in MODEL 220.083 /183
ENGINE 113.966 in MODEL 220.084 /184
ENGINE 112.917 in MODEL 211.080 /280

Mercedes-Benz
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
ENGINE 113.988 in MODEL 203.076 /276
Shown on engine 112
fiS/7 AntJ.twfsl /oek

17 FIN dslrlbU!OI'
l'S2 Fu@/ fnjeeiJon VaNOS
/lffow: Square e eleh
Fig. 38: ldentifying Anti-Twist Lock, Fuel Distribut()r And Fuel Injection Valves
~BT
CD Remove/install
1 Remove fuel Model 129.059/ 064/ 068
distributor (17) Model163.154/ 157 1 172/ 174/ 175
together with Model202.026/ 029/ 033/ 086/ 089/ 093
the fuel Model208.365 /370 /374 /465 /470
inj ectors (Y62) Model210.063 /065 /070 /074 /081 /082 /263 /265 /270 /274 /281 /282
Model 170.465 /466
Model 171.473
Model203.061 /261 /064 /065 /076 /081 /084 /264 /265 /276 /281 /284
Model209
Model 211.061 1065 1070 1076 1 080 1 082 1 083 1261 / 265 1270 1276 1280 1 282 1 2:
Model215.374/ 375
Model
220.063 /065 /067 /070 /074 /075 /083 /084 /087 /163 /165 /167 /170 /174 /175 /183 / U
Model230
Mercedes-Benz
Engine 112.945, 113.962 in model463

Engine 113.982 in model463.241 /243 /246
~Check 0 -rings for damage otherwíse this can lead to leakage. Before installíng fuel
i!tjection valves (Y62) lubricate 0-rings.
l?1l Anti-twist locks (1617) must latch into the square catch (arrow) ofthe fuel injection
(Y62)
2 Install in the
reverse order
Removing and installing injectors (ME-SFI)- AR07.03-P-6520E
ENGINE 119.981 /982 /985
12 Ro~rton loe~
1611 O.rlng
Y62 Fuol lnjccrton VI~C
Arrow Squ~ro lug
F ig. 39: Tdentifying Rotation Lock, 0-Ring, Fuel Injection Valve And Sg uare Lug
Item illustration, etc. Working notes

[g]
' Remove fuel distributor AR07.03-P-1451E
wíth ínjectíon valves
12 Rotation lock on injection ¡g] Ensure that rotation
valve lock catches in square lug
(arrow) on fuel injection
valve (Y62)
16/8 0 -rings [g) Replace, oil for
installatíon
Y62 Fuel injection valves
Removing and installing injectors (ME-SFI)- AR07.03-P-6520F

Mercedes-Benz
ENGINE 120.982/983
12 lllorólllon I«A
14 0-rlng
16ft 0-rfng
Y62 Fuollll}ocr/onv•lvo
Arrow Squ•ro ~11
@).,,.
f07 eo.MQ.-1,
Fig. 40: ldentifving Injectors (ME-SFI) R emove/lnstall Components
Item Working notes

illustration,
etc.
[g].. Removing and instalJing fuel AR07.03-P-
rail with injectors (ME-SFI) 1451F
Rotation lock on fuel
[g] Ensure that rotation lock catches in
12 square lug (anow) on fuel injection valves
injection valve
(Y62)
14, 16/8 0-rings [g] RepMace. Oil for installation
REMOVING AND INSTALLING INJECTION VAL VES (LH-SFI)- AR07.03-P-6521
Removing and installing injection valves (LH-SFI) - AR07.03-P-6521E
ENGINE 119.97
Mercedes-Benz
12 Anli·IW/st locl<
1611 O.ring
Y62 Fuollnjoction v•Jvo
Arrow Four·point IU¡¡
Fig. 41: ldentifving lojection Valves Remove/lnstall Components- Engine 119.97

item, etc.
[g]' Remove fuel rail together wíth AR07.03-P-
injection valves, install 1452E
Anti-twist lock at injection [gJ Anti-twist lock must engage in four-point
12
val ve lug (arrow) at fuel injection valve (Y62)
16/8 0-rings [gJ replace, oil for installing
@) 0-ring at fuel injection valve BT07.03-P-
modified 0002-02A
Y62 LH-SFI fuel injection valves
@) LH-SFI fuel injectíon valves BT07.03-P-
modífied 0001-0lA
Removing and installing injection valves (LH-SFI)- AR07.03-P-6521F
ENGINE 120.980 /981

Mercedes-Benz
11 Anú-rwtst loe~
14 Oorlng
1611 o-rtng
Y6l Fue/ lnjocrfon vafvc
Arrow Four-polnt /ug
Fig. 42: Identifying lnjection. Valves Removellnstall Componen.ts- Engine 120.980/981

item,
etc.
[g]' Remove fuel rail together wíth AR07.03-P-
injection valves, install (LH-SFI) 1452F
Anti-twist lock at fu el ínjection
[gJ Anti-twist lock must engage in four-
12 point lug (arrow) at fuel injectíon valve
val ve
(Y62)
14, 16/8 0-rings [g] Replace. Oil for ínstallíng.
Y62 LH-SFI fuel injection valves
@ LH-SFI fuel ínjection valves BT07.03-P-
modified 0001-01A
REMOVING AND INSTALLING INJECTION VAL VES- AR07.03-P-6522D
ENGINE 104.94/99, 111.920 /921 /94/96/970/973/974 /975/977 (except, 104.990)
Shown on engine 104

Mercedes-Benz
161'1 Anrf·twlst locll

1611 O·rlng
1619 0~/ng
Y62 Fuo/lnjoct lon vo!vc
Atrow F our·p oinr tug 1
~~m
i
11176!!!!3
YIZ'
1&110
Fig. 43: Identifying Anti-Twist Lock, 0-Ring, Fuel lnjection Valve And Four-Point Lug
Fig. itero, etc. Work instructions

[g] Remove fuel raíl together AR07 .03-P-1450D
' with injection valves,
install
1617 Anti-twist lock on ~11 off
injection valve lnstalling: the anti-
twist lock must engage in
the four-point lug (arrow)
on the injection valve
(Y62)
[g] 16/8, 16/9 0 -rings replace, Oil for installing.
REMOVING AND INSTALLING INSULATION SLEEVES OR RUBBER RINGS (FOR INJECTION

VAL VES) (LH-SFI)- AR07.03-P-6570E
E NGINE 119.97
Mercedes-Benz
Fig. 44: ldentifving lnsulation Sleeves Or Rubber Rings

etc.
[g] Remove fuel rail together with injection AR07.03-P-
valves, install 1452E
[gJ 0-ring replace, oil for installing
pull out of intak:e manifold,
35 Insulating sleeves
press Ln
REMOVING AND INSTALLING HOT FILM MASS AIR FLOW SENSOR- AR07.07-P-1453
Removing and installing hot film mass air sensor- AR07.07-P-1453D
ENGINE 104.94 /99, 111.921 /943 /944/945 /946/947 /96/970/973 /974 /975 /977 (except, 104.990)
Right-t1and •lustrulon
Shown on •ngln• 104
._,, O·rlng
82/S Hotfilrl'l motU ~it un.sor
Arrow Unlon nut
Ltft..,and tlustrlllon
Shown on •ngln• 111.$7$
Arrow Unlon nut
Fig. 45: Identifving 0-Ring, Hot Film Mass Air Sensor And Union Nut
Mercedes-Benz
Right·h•nd Mlustr•tlon
Snown on englne 111 S45/"t77
411 0 - rlí!g
82.15 Hot film mu.s • Ir sansor
~e lt -nand llustrallon
Snown on engine 111.947
8215 Hot fim m,¡u illr >ll nso r
p¡¡¡ 51-0511~1 f07.11i1.c6'2'loct1
Fig. 46: ldentifving 0-Ring And Hot Film Mass Air Sensor

Arrow U nion nut, plug ~ lnstalling: tighten
connection union nut until it engages
4/1 0 -ring inspect, replace if
necessary, oil to facilitate
installation
B2/5 Hot film mass air sensor
Removing and installing hot film mass air flow sensor - AR07.07-P-1453E
ENGINE 119.981 /982 /985
J1 e onnoc tlng nos e

J2 Hose clip
8:215 Hot tMm IIAF 10nsor
81 7 IAT$CIISOr
Arrow lnst.l/latlon /ug
P01A1-Mil0.11
Fig. 47: ldentifving Connectiing Hose, Hot Film MAF Sensor, Hose Clip, IAT Sensor And Installation
L ug
Figure/ltem, etc Work instructions

[gJ InstaUation Coupling for hot film Tighten union nut until it
MAF sensor (B2/5) engages
Bl7 Intake air temperature Check 0 -ring and replace
sensor if necessary
31 Connecting hose ~ Reo lace if necessarv
Mercedes-Benz
[g] Observe installed

position (arrow) of
connecting hose/hot film
MAF sensor (B2/5)
32 Hose clip Loosen, tighten * WH58.30-Z-1002-06A
e ommerc1a· uty availa ble too s

Number Designation
Removing and installing hot film mass air flow sensor- AR07.07-P-1453F
ENGINE 120.982/983
JJ lllolded lioso
$t Hose clip
B2AI Lotr llot f ilm tAAF sonstJt (loc~rad on
riSI:ht sido or on11ln•J
B2n RISII!t l!ot fflmMAF sensor (loc•tcct
on tatr sl clo of onllfnlj
f07 111.ot"1a.oe
Fig. 48: Identifying Hot Film Mass Air Flow Sensor R emove!Install Components
Figure/ltem, etc Work instructions

[g] lnstallation Coupling, hot film MAF sensor Tigbten union nut until it engages
53 Molded hose ~ Replace if necessary
REMOVE/INSTALL HOT FILM MASS AIR FLOW SENSOR TOGETHER WITH AIR INTAKE
PIPE- AR07.07-P-1454
RemovelinstaU bot ftlm mass air flow sensor togetber witb air intake pipe- AR07.07-P-l454AA
ENGINE 112.922 in MODEL 220.063 /163

Mercedes-Benz
ENGINE 112.944 in MODEL 220.065/165
ENGINE 113.941 in MODEL 220.070 /170
ENGINE 113.960 in MODEL 215.375, 220.075 /175
ENGINE 112.972 in MODEL 220.067 /167
ENGINE 112.975 in MODEL 220.087 /187
ENGINE 113.948 in MODEL 220.083 /183
ENGINE 113.966 in MODEL 220.084 /184
112 CrJnl<c.so vcnt Hotion llno

2!2 Alr lnt•lt• <onnoct!on
8215 Hot f Nm mas olr ft ow $ CNOf
Fig. 49: Identifying Hot Film Mass Air Flow Sensor With Air Intake Pipe Components
~BT
Q) Remove/install
1 Withdraw ignition key
Mercedes-Benz
2 Remo ve cover on front side of engine

Take off a ir filter together with intake
3
ptpes
Separate electrical connector at hot film
4
mass air flow sensor (B2/5)
Detach crankcase ventilation line (1/2) at
5
air inlet connection (2/2)
Press down catch (arrow) of air inlet ~ Avoid excessive pressme otherwise catch may
6
connection (2/2) with a screwdriver break off.
[g) Before removing the air inlet connection (2/2),
Take out hot film mass air flow sensor
7 detacb cable (arrow) of electronic accelerator
(B2/5) with air inlet connection (2/2)
actuator.
8 Install in tbe reverse order
Remove/install hot film mass air flow sensor together with air intake pipe- AR07.07-P-l 454AG
ENGINE 112.945, 113.962 /982 in MODEL 463
ENGINE 113.980 in MODEL 210.074 /274
ENGINE 113.944 in Model202.033/093
ENGINES 112.923 /943, 113.961 in MODEL 129
ENGINE 113.943 in MODEL 208.370 /470
E NGINE 113.984 in l\10DEL 208.374
Sbown on Engine 112

Mercedes-Benz
ErtSiirtC CCVCf Wf!h lntc¡¡fJI Jlr

cJe~ncr
PI u¡¡ of hoc fMm m.ns off ttow

.S-0/lS-Of
Cr~nl!.c u e vcnt tino
4 A t lnt.2kc rubo
8:2.1$ Hot flfm miils.s-• Ir flow s.cn.sor
P07.61-D61H I!I
F ig. 50: Identifying Engine Cover Witb Integral Air C leaner, Crank Case Vent Line And Air Intake
Tu be
n=:rsr (D Remove, InstaU

1 Remove engine cover [g] Remove by pulling
wíth integral air cleaner straight up from valve
(1). cover.
2 Unplug connector (2) of
sensor (B2/5)
3 Detach crankcase
ventilation line (3)
4 Release crankcase
ventilation line on ríght at
sensor (B2/5)
5 Open catch of hot film
mass air flow sensor
(B2/5) with a screwdriver
6 Push down catch of air Do not damage catch.
intake pipe (4) at
electronic accelerator
actuator and remove air
intake pipe (4) together
wíth hot film mass air
flow sensor (B2/5)
7 Detach hot film mass air [g] Push back retaining
flow sensor (B2/5) from clip with a screwdriver.
air intake pipe (4)
Mercedes-Benz
~
8 Inspect seals of air intake
pipe (4) and ofhot film
mass air flow sensor
(B2/5), replace if
necessary
9 lnstall in the reverse
order
REMOVING AND INSTALLING DIAPHRAGM PRESSURE REGULATOR- AR07.17-P-1450D
ENG INE 104.94/99, 111.920 /921 /94 /96 /970 /973 /974 /975 (except 104.990)
Shown on engine 104
40 Dl~hr•gm prouuro rogul•tor

4011 0-rlng
4Q>'9 0-rfng
40110 Clrclip
4Q!tl V•cuum /loso
...
0@JWJ
.
.
.
1
fOJ17..2:Q311)(H!
Fig. 51: ldentifving Diaphragm Pressure Regulator, 0-Ring, Circlip And Vacuum Hose
Sbown on engine 111.975

Mercedes-Benz
111 Scrvfco v.1~o
-~)
11 Fuctrd
40 DlophnJgm prcnurc rcguliltor
4(111 0-rlng
4(119 0 -rlng
4QI10 Clt<ltl
4/1111 V«uumhosc 4Q
F ig. 52: Identifying Service Valve, Fuel Rail 0-Ring, Circlip And Vacuum Hose
~ BT @ Removing, installing
ITJ Risk of explosion as a N o fire, naked flame or AS47.00-Z-0001-0IA
result of ignition. smoking.
Ris k of poisoning as a Pour fuels only into
result of inhaling and suitable and appropriately
swallowing fuel marked vessels
Risk of injury to skin W ear protective clothing
andl eyes as a result of when handling fuel
contact with fuel
1.1 Release fuel pressure [gl See DM Engine,
through service valve Volume 2 Index 1 and 4,
(1/ 1) or Volume 4 Index 9
@ Fig. 21
@ Fig. 23
1.2 Remove cover of [gl Engine 111.945 in
diaphragm pressure model208
regulator (40)
2 Detach vacuum hose
(40/ 11)
3 Remove circlip (40/ 1O) lg] Installing: inspect for
re-use
4 T ake out diaphragm
pressure regulator (40) at
fu el rail ( 17)
5 Install in the reverse [g) Installing: replace 0 -
order rings (40/8) and (40/9),
Mercedes-Benz
loil to faci litate

installation
Tes!ar
Fig. 53: Identifving Tester (103 589 00 21 00)
REMOVING AND INSTALLING DIAPHRAGM PRESSURE REGULATOR (LH-SFI)- AR07.17-P-

1451
Removing and installing diaphragm pressure reguJator {LH-SFI)- AR07.17-P-1451E
ENGINE 119.97
Mercedes-Benz
40 D l ophr~SPD prossuro rc¡¡vlotor

44 Clrcl~
46 0-rlng
47 O·rlns
Fig. 55: ldentifving Diaphragm Pressure Regulator (LH-SFI) Remove!Install Components- Engine
119.97

etc.
<§ Pay attention to accident prevention
Risk of explosion
regulations!
see Diagnosis Manual Engine, Volume 2
[g]
'
Release fu el pressure through service valve
Index 3.1 ~
at fuel raíl @ ll
@ Fig.
23
46, 47 0-rings [g] replace, oil for installing

Mercedes-Benz
119 589 04.63 00
Removing and installing diaphra:gm pressure regulator (LH-SFI)- AR07.17-P-1451F
ENGINE 120.980 /981
40 0/.,l!r•Sifll pressuro fCIJtll•tor

44 C lre/f¡
40 O.rlng
41 0-rlng
Fig. 58: ldentifving Diaphragm Pressure Regulator (LH-SFI) Remove/lnstall Components - Engine
120.980 /981

etc.
@ Pay attention to accident prevention
Risk of explosion
regulations!
[g] Release fuel pressure tbrough servíce val ve at
~Index 3.2 ~
21
fuel distributor
• Fig.
@
23
46,47 0-rings [g] Replace, oil for installing
Mercedes-Benz
103 SS9 00 21 00
Tes1er
119 5'89 04 63 00
REMOVING AND INSTALLING DIAPHRAGM PRESSURE REGULATOR (ME-SFI)- AR07.17-P-

1452
Removing and installing dia¡>hragm pressure regulator (ME) - AR07.17-P-1452E
ENGINE 119.981 /982 /985
40 D IJPI!ra¡¡m prossure rogu/oror

44 C lrt:llp
40 0 -r/ng
47 0 ~/ng
Fig. 61: ldentifying Diaphragm Pressure Regulator, 0-Ring And Circlip

Mercedes-Benz

Risk of explosion Pay attention to accident
prevention regulations!
Release fuel pressure see Diagnosis Manual
through service valve at Engine, Volume 2, Index
fuel rail 3.1
@ Fig. 21
@ Fig. 23
46, 47 0-rings [g) replace, oil for
installing
,________________
\. 103 589 00 21 ()()
119 589 04 63 00
Removing and installing diaphragm pressure regulator (ME-SFI)- AR07.17-P-1452F
ENGINE 120.982 /983

Mercedes-Benz
40 Dl;¡phr•gm prouuro ra¡¡uloror

44 C lrcl/p
46 O-rln¡¡
41 0-rln¡¡
Fig. 64: ldentifving Diaphragm Pressure Sensor Position- Engine 120

etc.
<§) Pay attention to accident prevention
Risk of explosion
regulations !
¡g¡' Release fuel pressure through service valve at 2, Index 3.1 ~
fuel dístributor @ ~
@ Fig.
23
46, 47 0 -ríngs [g] replace, oil for installing
103 SS9 00 21 OD
Fig. 65: Ideotifyiog Tester (103 589 00 21 00)

Mercedes-Benz
119 5.89 04 63 00
Fig. 66: ldentifving P ressure Hose (119 589 04 63 00)
REMOVING AND INSTALLING HOT WIRE MASS AIR FLOW SENSOR- AR07.41-P-1453
Removing and installing hot wire mass air flow sensor- AR07.41-P-1453E
ENGINE 119.97
" Connoelion hoso

J2 Hose cl~mp
8:212 Hotwlro m~s& • l rfloW>411Jil r
Arrow JnsWI•Ifon /ug
Fig. 67: Identifying Hot Wire Mass Air F low Sensor Remove/Install Components- Engine 119.97
Itero \Vorking notes

illustration,
etc.
Connector for hot wire
[g] Installation mass air flow sensor Tighten uníon nut until it catches
(B2/2)
~ Replace if necessary
31 Connection hose [g] Observe installation position (arrow) of
connection hose/hot wíre mass air flow
sensor (B2/2)
Loosen, tighten, for this purpose remove *WH58.30-Z-
32 Hose clamp
vacuum line for brake unit 1002-06A
C.OMMF:RC.TALT~Y AVATLABLR TOOLS

Mercedes-Benz
Number Designation
WH58.30-Z-1 002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
Removing and installing hot wire mass air flow sensor- AR07.41-P-1453F
ENGINE 120.980 /981
53 Sh•pod hostJ
!S4 HostJ cNp
8113 Lcltmus • l rtloWSIJfUQfWffhhot
Wlirc, lor;•IM on right ot onglno
82., R lght mus a ft ttow sensor wllh hot
w ito, /outod on Ioft ot ongln.c
Fi2. 68: ldentifyine Hot Wire Mass Air Flow Sensor Remove/Install Components - En2ine 120.980 /981

[g] lnstallation Hot wire mass air flow sensor connector Tighten union nut until it engages
53 Shaped hose ~ Replace if necessary
REMOVING AND INSTALLING HFMlLH-SFI VARIABLE REFERENCE RESISTOR- AR07.41-P-

1459
Removing and installing LH-SFI variable reference resistor - AR07.41-P-1459E
ENGINE 119.97 in MODEL 124.03, 129, 140

Mercedes-Benz
PD7 41-02!15-D1
lllodcl124. 03
Fig. 69: ldentifving LH-SFI Variable Reference Resistor- Engine 124.03
Modcl r.29
Fig. 70: Identifving LH-SFI Variable Reference Resistor- Engine 129
1Aodcl140
F ig. 71: Identifying LH-SFI Variable Reference Resistor- Engine 140

item,
etc.
SP.P Di::wnt)C<i<: M::mu::tl Fn~ÍnP. VolnmP 1 TnrlP.x A

Mercedes-Benz
Pay attention to correction posítíon; ínstallnew antí-

LH-SFI variable tamper seal
Rl 7/2 Fig. 72
reference resistor @
@ Fig. 73
LH-SFI variable
@ BT07.41-P-
reference resístor
0001-0lA
modified
Fig. 72: ldentifying Anti-Tamper Seal Pliers (124 589 0137 00)
124 589 2A 63 00
Fig. 73: Identifying Embossing Set (124 589 24 63 00)
Removing and installing LH-SFI variable reference resistor- AR07.41-P-1459F
E NGINE 120.980 /981
R1713 Lcfr •Ir hot wfro (!JI· SR) vorloblo

rcforonce tcslstot
R1 7i 4 Rlght alr hOt wlrc (LH·SFI) ••rloblc
refcrcmc rcslstor
Loft-tumd flg. Modoll Zl
Rlgnt-han d fl g. Modtll >40
Fig. 74: Identifying LH-SFI Variable Reference Resistor

Cover over module box Model129
Mercedes-Benz
¡g¡' Remove, install

¡g¡ Right cover of engine Model140
compartment Remove, install
Rl7/3, Rl7/4 LH-SFI variable reference S ee Diagnosis Manual
resistor Engine Volume 1, Index
A.
Pay attention to correction
position; instaH new anti-
tamper seal.
@ Fig. 72
1
@ Fig. 73
Fig. 75: Identifving Anti-Tamper Seal Pliers (124 589 01 37 00)
124 589 24 63 00
Fig. 76: ldentifving Embossing Set (124 589 24 63 00)
RemBving, installing HFM-SFI variable reference resistor- AR07.51-P-1459D
ENGINE 104.941 /942/943 /944 /991 /992 /994, 111.920/940 /941 /944/960 /961
Mercedes-Benz
Len-nana 11ustrauon
ShoWh on englnt 111, moatl l 24
Rt6J1 V•rl•l>lo rclwcnco rcsiJtor coupNng
(PEC}
Rlght·hand ilustratlon
Shown on englne 104 , modctl202
R1 &15 Hot film oiiSIIM m•n•g~mont
(JiFI,..SFI) v•rl• blc rotctonco rcsl.ror
Fig. 77: Identifying HFM-SFI Variable Reference Resistor

item, etc.
[g] Raise windshield washer reservoir and
Variable reference resistor (HFM- place to the side for removing and
R16/5
SFI) installing.
Fit on new anti-tamper seal
® Fig. 73
® Fig. 72
Variable reference resistor (HFM-
R16/5, Pay attention to adjustment position. See
SFI)/ reference resistor coupling
R16/7 DM Engine, Volume 2, Index 1 and 4
(PEC)
Reference resistor coupling (PEC)
R16/7 BT07.52-P-
@) Reference resistor coupling (PEC)
0001 -0lA
modified
1:?4 SS9 24 S3 00
Fig. 78: ldentifying Embossing Set {124 589 24 63 00)
Fiº. 79: Tdentifvinº Anti-Tamn er SP.al PliP.rs (124 589 01 37 00)

Mercedes-Benz
1990-2002 ENGI NE PERFORMANCE Mixture Formation - REPAIR & ADJUSTMENTS - 129 Chassis
1990-2002 ENGINE PERFORMANCE
Mixture Formation - REPAIR &. ADJUSTMENTS- 129 Chassis

MODEL DESIGNATION, INSTALLATION SURVEY- RA07031040001X(07.3-0001)
Model designation, installation survey- RA07031040001X(07.3-0001)
Model designa tion
The models and components with their 3- to 6-digit designation (e. g. 129 or 129.061) may have different
versions, data and operations.
KAT = Engine with "muJtlfunctional

mixture formation and ignition
system" with catalytlc converter.
ldentiftcation: KAT on engine data
plate and plug of EZl and CIS-E
injection.
Basíc versíons
without
Model or
component
KAT = Engine without catalytic converter
(no reconve.rsion option)
designation
ldentiftcation: none
0
@
National versions @)
CD
CD
@>
F ig. 1: Models And Components Designation Sheet
Mercedes-Benz
1990-2002 ENGINE PERFORMANCE Mixture Formation - REPAIR & ADJUSTMENTS- 129 Chassis
Ifthere are no suffixes following the designation of models or components, the respective data apply to all the
models or components listed in each case.
INSTALLATION SURVEY
Engine Model Manufactured from to
104.980 124.031 09/ 1989 09/ 1992
104.980 124.051 09/ 1989 09/ 1992
104.980 124.061 06/ 1992 06/ 1993
104.980 124.091 09/ 1989 09/ 1992
104.981 129.061 05/ 1989 01/ 1993
Model Designation, InstaUation S urvey - RA07031190001X(07.3-0001)
Model designation
Models and components with their 3- to 6-digit designation (e.g. 129 or 129.066) may have different versions,
data and operations. These differences are indicated by the following suffixes:
KAT= Englne wíth "multifunctíonal

mixture preparation and ignitíon
system" with catal~ic converter.
ldentJfication: KAT on engine data
pJate and plug of EZL and KE
njection system
¡----Baslc versions
withou1
KAT= Englne without catalytic converter
(not reconversion versíon).
Model or ldentification: none
component
desi gnation
G)
@
.___ _ _ Nationalversions
@
CD
<D
@>
F i2. 2: Models And Comoonents Desi2nation Sheet
Mercedes-Benz
1990-2002 ENGINE PERFORMANCE Mixture Formation- REPAIR & ADJUSTMENTS- 129 Chassis
If the designation of models or components does not contain any suffixes, the relevant data apply to all the
models or components listed.
INSTALLATION SURVEY
Sales designation Model Engine Installed
500 SL 129.066 119.960 from 05/89 to 10/92
Model and components sur·vey- RA0703KE10001X(07.3-0001)
A Modelsurvey
Mercedes-Benz
107.041 300 Sl
107 107 .04 ~ 107.M6 500 Sl

107.047 420 S l
107.048 560 Sl @Q)@
124 .003 230 E Speaa'OOd¡t
_ 124 .00 230 E Speaa;bod1d.-.b

- - E 124.004
- -124 .007 260 E SpQti~ t.-.ro
~-- 124.020 200
_ 124 .02 - - 124.021 200 E

- - 124.023 230 E
- - 124.026 260 E
_ 124.0 -
- 124 .03 - c 124.030 300 E
124.031 300 E-24
_ 124.04 124.043 230CE
- - E 124.050 300CE
_ 124 .05 124 .051 300 CE-24
124.061 300 CE-24 convertible
124 - 200T
- - E 124.080
- 124.08
124.081 200TE
124.083 230TE
124 .09 ----c= 124.090 300TE
124.091 300TE-24
124.22 - - - - 124.226
260 E 4MATIC
124 .23
124.2
- 124.29 - - - - 124.230 300 E 4MATIC
--E - - - - 124.290 300 TE 4MATIC
Fie. 3: Model And Components Survey (1 Of 2)

Mercedes-Benz
1 126.020 260 SE
126.02 126.024 300 SE
- - 126.025 300 SEL
- - 126.034 400 SE
- - 126.035 420 SEL
126 126.0 126.03 - - 126.036 500 SE
- - 126.037 500 SEL
126.038 560 SE
126.039 560 SEL
- - E 126.044 500 SEC

126.04 126.045 560 SEC
126.04·6 420 SEC
129.060 300 Sl
129 _ _ _ _ _ _ _ _ _ _ 129.06 129.061
300 Sl-24
- - E129.066 500 Sl
201.018 190E1.8
201 .02
01 .024 190 E, 190 E 2.3 @
190 E 2.0
201 _ _ _ 201 .0 -- 201 .028 190 E 2.3
-201 .034 190 E 2.3-16

201 .03 201.035 190 E 2.~16
- -201 .036 190 E 2. ~16 Evolution 1
201 .036 190 E 2. ~16 Evolutlon 11
Fig. 4: Model And Components Survey (2 Of 2)
B. Components survey
4-CYLINDER ENGINES
Sales designation Model Engine manufactured from - to
200E 124.021102.963 (1985-)
?.00 TF. 1?.4 OR 1 10?. <)fi1 ( 19RR-1
Mercedes-Benz
230E 124.023102.982 (1985-)

230CE 124.043 102.982 (1987-)
230TE 124.083102.982 (1985-)
230 E (special body) 124.003 102.982 (1985-)
230 E (special body lwb) 124.004102.982 (1985 - )
190 E L8 20L018102.910 (1990-)
190E 20L024102.961 (1982 - 1984)
190E 20L028102.961 (23)~ 1983/1984
190 E 201_034102.985 ~ 1985/1986
190 E 2.0 (as of01/91) 201_035102.962 (1985 - 1990)
190 E 2_3 201_036102.962 (1991-)
190 E 2.3-16 201_036102.983 (1984-1988)
190 E 2.5-16 102.990 (1989-)
190 E 2.5-16 Sport (Evolution I) 102.991 (1989)
190 E 2.5-16 Sport (Evolution II) 102.992 (1990)
6-CYLINDER ENGINES
Sales designation Model Engine manufactured from - to
300 SL 107.041103.982(1986- 1989)
260E 124.026103.940 (1985-)
260 E (Iwb) 124.027103.940(1990-)
260E4MATIC 124.226103.943 (1987 - 1990)
260 E (special body lwb) 124.007103.940(1987- )
300E 124.030103.980 (1985- )
300 E-24 124.031103.983 (1986-)
300E4MATIC 124.230 104.980(1989-)
300CE 124.050103.985 (1987-)
300 CE-24 124.051103.983 (1987- )
300 CE-24 convertible 124.061104.980 (1989- )
300TE 124.090 104.980(1992-)
300 TE-24 124.091103.983( 1985-)
300 TE 4MATIC 124.290 104.980(1989-)
103.985 (1987- )
260 SE 126.020103.941 (1985 - 1991)
300 SE 126.024103.981 (1985 - 1991)
300 SEL 126.025103.98 1 (1985 - 1991)
300 SL 129.060 103.984(1989-)
300 SL-24 129.061104.981 (1989 - )
190 E 2.6 201_029103.942(1986-)
Mercedes-Benz
420 SL 107.047116.964(1985- 1989)

500 SL 107.046117.964(1985 - 1989)
560 SL @ [g] ~ 107.048117.967 (1985- 1989)
420 SE 126.034116.965 (1985 - 1991)
420 SEL 126.035 116.965 (1985 - 1991)
420 SEC 126.046116.965 (1985- 1991)
500 SE 126.036117.965 (1985 - 1991)
500 SEL 126.037 117.965 (1985- 1991)
500 SEC 126.044117.965 (1985- 1991)
560 SE 126.038117.968 (1985 - 1991)
560 SEL 126.039 117.968 (1985- 1991)
560 SEC 126.045117.968(1985 - 1991)
500 SL 129.066119.960(1989-)
LOCATION OF COMPONENTS - RA07031040005X(07.3-0005)
Location of components- RA07031040005X(07.3-0005)
Engine 104.980, model 124 LHD

Mercedes-Benz
~ X11
82 Au flow S!lflSOf pcSlioo mdm;tor 51912 Tl'wo1!e wlve w.~tdl, rulloadJ

81112 Coolarn oomperalures011sor IEZl/CISé ) tde speedrecognbon
G312 ~eled o)l'fgen sensor
S2912x1 Plugccmec• oo, lhrot:e v~o~& swidl,
G312lc1 Rlg comeden, Oli:f9Bn sen sOf heatmg c011 M load.! die spead recogrdon
G3J2x2 Plugccme!l oo, oxygen sensor Stgnal
X11 Dtagno2lc SO'd !et (9-Pfl)
K1/1 OveNc!lage protedloo rala'{ 87E (7-p~n) X1114 Test cct;~lng IOf díagnoSis,
N3 C«úol tlllt, CIS-é 11\edtOO system púsereaooUI {16-ptn)
N16 EngiJlo sys!Dms cootolunt {MAS)
S2712 De col tuel shutnlf mtcros·M~h X26 Plugcomec• oo, lltenor/eng¡no
Y1 Bed·on¡dm!llc edul!tcr
Y6 lále speod ao)JsteJ
Fig. 5: ldentifying Components Location - Engine 104.980, Modell24 LHD
Engine 104.981, model 129 LHD

Mercedes-Benz
82 Alr lkl'111 sensor poSI•on u11ic&tor 529/'lx Pkigconnodon, tuolle v8lole swid'l ,
8 11fl Coolart cemperatue soosor (Eli.JCISE) ñlloed.l"o spaod rucogn~on
G3/2 Haaled Ollfg&OO sen sor W16 Groond, co;rponort CCITJ)Bfl'nant
G3/2x Pllg comedon, ox{gen sensor X4/10 Temunal blotk, 1Bfmna130/30U'61 e;67l
K1/1 OV&JVo!!age proteálon rellr¡ 87E {7-pn) X11 Qagno5tlc soclíet (9-Pil)
N3 Como! mil, CIS-E 1r¡edlon ~om X111<1 Te~ <~119 fOI" liBQilOSIS,
N16 Eng¡ne syséllms conkclunt (MAS) pU:s e reedol.i.(16-pcn)
R17 Restslance mmllgpl.ig, CIS-E 11¡edlon syslem
X25 Pllgc0fii18Cion, IIIOOorionQI'le
S2712x Do cal luel shltotf mtcros'lltl!:h
X30/1 Pllgcomecton, ITlll.fu'lcoon block
$2912
Y1 B!lc~olucfmtlíc ertuatOl
Y6 lite ·speod ~ster
Fig. 6: ldentifying Components Location - Engine 104.981, Model129 LHD

Mercedes-Benz
Location of Components- RA07031190005X(07.3-0005)
X1'1
~
~
82 AJf llcw sensor p®Jniome!er X4f10 Temmnal biOO<, !Brmnai30130Úf61a/87L(&ptn)
8 11fl Coo!arn tnmperatu-e sensOf (EZlll<E) {4-)lin) X11 Dlagnoslíc sockol(9-p.l)
G3/2 OxygOI'I SBilSOI' upstream el KAT X1114 Test ~ng fort5agnosas (p\1se reaóool)
G3/2x ())cygen s enSOf p~g eonoodon X 26 Pl.Jgconnecton, lltanorlenq,<la(12-ptn)
K111 OVOIVoliagfl prOIOl:bOil relll'{ 87E (7-iJIO) X261l Pl.lg connecion, eng~~ne s.eparmon po¡nt (30-ptn)
N~ KEcomoiU!llt X3011 PlugconntKloo, rrui'ifuntioo block
N16 Engna S'{.>tems ronrolunt (MAS) Y1 8acroll¡<ta1Jic ectu!!l«
R17 KE reSJstance tnrmunQ pk.Jg Y6 kle spead a~ster
S29!2x Pl.Jg e <lfl!ljKion, llrolfe va..\re S'AI#ch, hllload.ldle va Starting vat.te
sp~Wd rec ognlion
Fig. 7: ldentifying KE Components Location - LHD Model
Location of components LHD models

Mercedes-Benz
82 Alr llow sensor polln,oma:er S2912x1 Pklgcormcton, t\rotla vaM swich , Mloaá.l<le
8 11/2 Coolatt mmpemttso sensor {EZlJKE) (4-pm) sp.aad rac09Rion
G312 Ox'ygoo sensor upstream of KAT X11 Oulgnosbc sod<et(9.p11)
GJ/2x1 Pklgcormc!íon, OXf!IOO sonSOJ 14>5~nam otKAT X1114 Test ~ng for ciagn<rsas (púsoreadoú)
K1!1 OveiVolago protodlcn rolay 87E 17--p~n) X26 Pklg CORlldon, lltllnorfonQIIlO ( 12.p~n)
N3 KE e ortrol urnt Y1 Bacrohydleúlc actuator
N4!1 Boc~ooc accolomlorpodal {EfPYcruJSo cortrol YS ltle &¡l(!Bd ~or
{WM) cortrolmt YS Stamog vet.'o
N16 Engru~s~tsrns con\'olunt{MP..S)
N3011 ASR ccrtrol umt
Fig. 8: Identifying KE Components Location - RHD Model
Location of components, RHD models
REMOVING AND INSTALLING STARTING VAL VE- RA07031041606X(07.3-1606)
Removing and installing starting valve- RA07031041606X(07.3-1606)
Operatíon No. of operation texts and work units or standard texts and flat rates: 07 -1606
Mercedes-Benz
Fig. 9: ldentifying Starting Valve And Fuel Line
Electrical plug connection detach from starting valve, plug in.

unscrew, screw on.
Starting valve fuelline (arrow)
Collect fuel flowing out.
Screws (7) unscrew, screw m.
Starting valve (Y8) remove, install with new gasket.
Removing and Installing Starting VaJve- RA07031191606X(07.3-1606)
Operation no. of operation texts and work units or standard texts and flat rates: 07-1606
Mercedes-Benz
../1
7~ k·
..
Fig. 10: Identifying Starting Valve Components
Electrical plug connection (arrow) unplug from starting valve, plug in.
unscrew, screw on.
Starting valve fuelline (50)
Collect fuel which flows out.
Starting valve (Y8) remove, ínstall with new gasket.
Leaktightness of all connection points check with engine nmning.
PERFORMING FUEL QUANTITY COMPARISON MEASUREMENT- RA07031041609X(07.3-1609)
Performing fuel quantity comparison measurement- RA07031041609X(07.3-1609)
Operation No. of operation texts and work units or standard texts and flat rates: 07-1609
Mercedes-Benz
Fig. 11: Measuring Fuel Ouantitv Comparison
unscrew at fuel distributor and at injectíon valves, screw on. Clean

Inj ection lines
connection points beforehand.
Fuel quantity comparison position horizontally next to vehicle and connect to fuel distributor (see notes
measuring instrument (054) at illustrations for sequence).
Fuel return line of
insert into filler neck of fuel tank.
measuring instrument
Adjusting device for fixing
clamp to stop bar of air flow sensor plate (see notes at illustrations).
air flow sensor plate
Engine systems control unit disconnect, connect contacts terminal 30 and terminal 87 (see notes at
(Nl6) illustrations, arrows). This causes fuel pump to run.
Air flow sensor plate deflect and press buttons 1 to 6 in turn to bleed instrument.
press and hold. Deflect air flow sensor plate with adjusting device far enough
Button l to achieve up to 4 cm3 /min (idle speed quantity). Fix air tlow sensor plate in
place.
press in turn, measure flow quantities and enter on sheet B20 800.99.472.00.
Maximum permissible variation of cylinders to each other 0.4 cm3 /min
(idling).
Then, the same as described previously, test part andl fullload flow. Deflect
air flow sensor plate for this purpose.
Buttons 2 to 6
a. Part load 30 cm3 /min
b. Fullload 100 cm3 /min
Maximum permissible variation of cylinders to each other

P~rt lmlrl 4 r .m 3 /min
Mercedes-Benz
Full load 1Ocm 3 /min

If variation out of tolerance, replace fue] distributor.
Leak test of all fu el check with engine nmning. (set idle speed after performing comparison
connections measurement of fuel quanüties, see Diagnosis Manual Engine, Volume 1).
read out, erase if necessary (see Diagnosis Manual Engine, Volume 2, Index
0).
CIS-E control unit fault
NOTE:
memory
Stored faults which may originate from test work as a result of
disconnecting cables or from a simulation, must be erased in the fault
Special tool
201 SS~ 00 99 00
15 54
Fig. 12: ldentifving Special Tool (201 589 00 99 00 15 54)
COMMERCIAL TOOLS AND TESTERS

Designation e.g. Make, Order No.
Fuel quantity comparison measuring instrument Bosch KDJE-P 300
Tester trolley (l) Bosch M 200/2 or KDJE-W 100
(1) If the tes ter trolley is used for the fu el quantity comparison measming instrument, an additional angle
plate is required. lt may be shop-made or obtained from a Bosch agency.
NOTE: The measurement is performed with the engine not running. The operating
condition (id le speed, part or full load) is simulated and set at the air flow
sensor plate with an adjusting device.
Notes regarding illustrations

Mercedes-Benz
AmmgiHTHH1t cl fu¡¡Jt no s to ruol

G,\Jarlbty COrTCJBlÍSOil m&flSUilO!J
mslrumem
Fi~. 13: Identifyin~ Arran~ement OfFuel Lines To Fuel Ouantity
Setaír low S90S0r plate wll .~smg device
Fig. 14: ldentifving Set Air Flow Sensor Plate
Engmo w~loms ~omol U!llt c'Clmoctor
Fi~. 15: Locatin~ En~ine System Control Unit Connector

Mercedes-Benz
Operatíon no. of operation texts and work uníts or standard texts and flat rates: 07 - 1609
Fig. 16: Identifving Fuel Quantitv Comparison Tester
at fuel distributor and at ínj ectíon valves, unscrew, screw on. Clean connectíon
Injection lines
points beforehand.
Fuel quantity
place horizontally next to vehicle and connect to fuel distributor (see illustration
comparíson tester
notes for sequence).
(054)
Fuel retum line of
insert into filler neck of fuel tank
tes ter
Adjusting device for
fixing air flow sensor clamp to stop bar of air flow sensor plate (see illustratíon notes).
plate
Engíne systems unplug, connect contacts terminal30 and terminal87 (see illustration notes,
control unít (N 16) arrows ). This causes the fu el pump to nm.
Air flow sensor plate push down and press buttons 1 to 8 in turn for bleeding instrument.
press and hold. Push down air flow sensor plate with adjusting device far enough
Button l
to achieve 4 cm3 /min (idle quantíty). Fix air flow sensor plate.
press in tum, measure flow quantíties and enter on test sheet B20 800.99.472.00.
Maxímum permissible spread of cylinders to each other 0.4 cm3 /mín (idling).
Then, as described previously, test part and fullload flow quantity by pushing
down air flow sensor plate.
Buttons 2 to 8
a) Part load 30 cm3 /min
b) Full load 100 cm3 /min
Maximum perrnissíble spread of cylinders to each other
P:nt ln~rt 4 r.m3 /min
Mercedes-Benz
Fullload 1O cm3 /min

If spread is not to tolerance, replace fuel distributor.
(After fuel quantity comparison measurement, set idle speed, see Diagnosis
fuel connections
Manual Engine, Volume 1).
read out; erase, ifnecessary (see Diagnosis Manual Engine, Volume 2, Register
0).
NOTE:
memory
work.
Special tool
201 589 00 99 00
15 54
Fie. 17: Identifyine Special Tool (201 589 00 99 00 15 54)
COMMERCIALLY A V AILABLE TOOLS AND T ESTERS

Fuel quantity comparison tester Bosch KDJE - P 300
Tester trolley(l) Bosch M 200/2 or KDJE-W 100
(1) Ifthe tester trolley is used for the fuel quantity measuring tester, an additional angle plate is required.
It may be shop made or obtained :from a Bosch agency.
NOTE: The measurement is conducted with the engine not running. The operating
condition (idle speed, part or full load) is simulated and set at the air flow
sensor plate with an adjusting device.
Notes regarding illustrations

Mercedes-Benz
AlrBllgemertof ~el lioos to i.leiquarüy

c-omp an !>Ofl tester
Fig. 18: ldentifving Arrangement Of Fuel Lines To Fuel Ouantity
Ftmg an flow s11nsor pla:& ~Mitl a$Jstmg
Fig. 19: Identifying Air Flow Sensor Plate
Fig. 20: Locating Eogine System Control Unit Coupling

Mercedes-Benz
CHECKING, ADJUSTING ZERO POSITION OF AIR FLOW SENSOR PLATE- RA07031041612X

(07.3-1612)
Checking, adj usting zero position of air flow sensor plate - RA07031041612X(07.3-1612)
OperationNo. ofoperatíon texts and work units or standard texts and flatrates: 07- 1612
F ig. 21: ldentifving Zero Position Of Air Flow Sensor Plate
determine by inspecting visually when engine not running. The inspection point is
Zero position of
below the stop bar (arrow). The top edge ofthe air flow sensor plate must be flush wíth
aír fllow sensor
the top edge ofthe cylindrical part ofthe air funnel~ set zero position according to
plate
condition.
todo this:
a. ifposition too high, carefully tap in guide pin (arrow) with a drift toan
Setting zero appropriately lower posítion (mixture control unit installed).
position of air b. if position too low, remove mixture control unit and carefully tap out guide pin
flow sensor plate slightly (arrow) from below.
NOTE:
Mercedes-Benz
Re-position guide pin very carefully so that it is not moved too far.
Avoid at all cause moving severa! times in both directions otherwise interference-fit
seat of pin will be inadequate.
ldling speed set (see Diagnosis Manual Engine, Volume 1).
Testing, Adjusting Zero Position of Air FJow Sensor PJate- RA07031191612X(07.3-1612)
Operation no. of operation texts and work units or standard texts and flat rates: 07- 1612
Fig. 22: Identifving Air Flow Sensor Plate
Fig. 23: Locating Guide Pin

Mercedes-Benz
¿
Fi¡:. 24: Locatin¡: Guide Pin
Z .t" f . determine by visual inspection with engine not running. The air flow sensor plate
ero posi Ionlot arr must be flush with the top edge of the cylindrical part (enlarged detail) of the air
fiow sensor p a e ftmne1. Set zero position
· · accord mg
· to cond1t10n.
··
procedure:
Setting zero a. If position too high, carefully knock in guide pin (arrow) appropriately deeper
position of air flow with a drift (mixture control unit installed)
sensor plate
b. Ifposition too low, remove mixture control unit (see 07.3-1668) and carefully
knock out guide pin (arrow) slightly from below.
set (see Diagnosis Manual Engine, Volume 1).
NOTE:
Idle speed
Alter position of guide pin very carefully so that it is not moved too far. Avoid at
all costs moving severa! times in both directions otherwise the interference fit of
the pin will be inadequate.
REMOVING AND INSTALLING CIS-E RESISTANCE TRIMMING P LUG- RA07031041652X(07.3-

1652)
Removing and installing CIS-E resistance trimming plug- RA07031041652X(07.3-1652)
Operation No. of operation texts and work units or standard texts and flat rates: 07 - 1652
Mercedes-Benz
Model 124
Fig. 25: ldentifving CIS-E Resistance Trimming Plug
Model 124
Mercedes-Benz
Fi~. 26: Identifyin~ CIS-E Resistance Trimmin~ Plu~- Model124

Accessories
remove, install.
compartment cover
unplug, plug in.
CIS-E resistance &.oanaer!
trímmiug plug (R 17) The CIS-E resístance trimming plug must be resealed after ínstallíng with the
sealing pliers 124 589 01 37 00 and the stamping set 124 589 24 63 OO.
read out, erase ifnecessary (see Diagnosis Manual Engine, Volume 2, Iudex 0).
CIS-E control uuit NOTE:

Special tools
1 Mercedes-Benz
1
""""'~
~
/J
124 589 01 37 00
01
"""1
''
124 589 24 63 00
01
Fig. 28: Identifving Special Tools (124 589 24 63 00 07)
MATCHING RESISTANCE TRIMMING PLUG POSITION <--> FAULT

Position Resistance Fault
number ohms
KAT
1 953 none (original state)
2 1270 Slight transition fault when starting >20 oc
3 1620 Transition fault when starting >20 oc
4 2260 Slight transition faults in warming-up phase
5 3320 Poor throttle response when cold
6 5360 Poor throttle response and transition in warming-up phase
Very poor throttle response when cold, operational fault in warming-
7 11500
up phase
MATCHING RESISTANCE TRIMMING PLUG POSITION <--> FAULT

Position Resistance Fault
number ohms
without KA T
1 51 none (original state)
2 105 Excessive part load consumption when engine at operating temperature
3 169 Transition faults when engine at operating temperature
Mercedes-Benz
4 249 Slight transition faults in wanning-up phase

Very poor throttle response when cold, operational faults in wanning-
7 590
up phase
Removing and Installing KE Resistance Trimming Plug- RA07031191652X(07.3-1652)
Fig. 29: Identifving KE Resistance Trimming Plug
Ignition switch off

Componeut
remove, install.
cornpanrnneutcover
Bolt (30) slacken, tighten and press bracket (31) to the side.
Security seal remove, fit new seal.
unplug, plug in.
KE resistance &oanac•l
trimming plug (Rl7) The KE resistance trinuning plug must be resealed with the seal pliers 124 589 01
37 00 and the embossing set 124 589 24 63 00, after installing.
read out; erase, if necessary (see Diagnosis Manual Engine, Volume 2, Register
0).
1 Mercedes-Benz
1
NOTE:
KE control unit fault Stored faults which may originate from test work as a result of detached
memory wiring or simulation, must be erased in the fault memory after completion of
work.
SpeciaJ tools
~
/J
t24 689 01 37 00
07
Fie. 30: Identifvin¡: Special Tool (124 589 01 37 00 07)
~ '1
124 589 2~ 63 00
01
·"'
MATCHING RESISTANCE TRIMMING PLUG SETTING -> FAULT

Position Resistan ce Complaint
number ohms
KAT
1 953 None (original state)
2 1270 -
3 1620 -
4 2260 Slight transition faults in wanning-up phase
Very poor throttle response when cold, driving faults in warrning-up
7 11500
phase
MATC:HTNG RESTSTANC:E TRTMMTNG PLUG SETTTNG --> FAULT

Mercedes-Benz
Position Resistance Complaint

number ohms
withoutKAT
2 105 Excessive part load consumption with engine at operating temperature
3 169 Transition faults with engine at operating temperature
4 249 Slight transition faults in warming-up phase
V ery poor throttle response when cold, driving faults in warming-up
7 590
phase
REPLACING SEAL FOR CONTROL PLUNGER- RA07031041660X(07.3-1660)
Replacing seal for control plunger - RA07031041660X(07.3-1660)
Preceding work:
Removing and installing fuel distributor (07.3-1674)
Operation No. of operation texts and work units or standard texts and flat rates: 07 -1 660
._.... ...
IP07-5039-53
Fig. 32: Locating Screw Plug
Position (arrow) of screw measure with depth gauge and note. Mark position with marking tool as a
plug safeguard.
Screw plug ( 1) remo ve with pronged wrench ( 102 589 00 07 00).
Seal of screw plug replace, ensure seal is correctly seated.
screw in to the value or marking measured prior to removal.
Screw plug ( 1) &nanQer!
F ailure to do this means control plunger adopts incorrect basic setting.

Idling speed set (see Diagnosis Manual Engine, Volume 1).
Mercedes-Benz
Special tool
102 589 00 07 00
07 .)
Fig. 33: ldentifving SpeciaJ Tool (102 589 00 07 00 07)
Replacing Seal for Control Plunger- RA07031191660X(07.3-1660}
Preceding work:
Removing and installing fue!- distributor (07.3 1674)
Fig. 34: Locating Position Of Screw Plug

Mercedes-Benz
Fig. 35: ldentifving Screw Plug
Position (arrow) of screw measure with depth gauge and note. As a security, mark position with
plug marking tool.
Screw p lug (1) unscrew with pronged wrench 102 589 00 07 OO.
Seal of screw plug replace; ensure seal is correctly seated.
screw in to the value or marking measured before rem oving.
&.oanQer!
Screw plug (1)
Failure todo this will result in control plunger adopting an incorrect
position.
Special tool
10-2 589 00 07 00
07 _,)
REMOVING AND INSTALLING AIR FLOW SENSOR PLATE- RA07031041665X(07.3-1665)
Removing and installing air flow sensor plate- RA07031041665X(07.3-1665)
Mercedes-Benz
1 P07-51'41-lS.
Fig. 37: ldentifving Air Flow Sensor Plate
Stop bar ( 1) for aír flow sensor

unscrew, screw on.
plate
heat with hot air fan and carefully unscrew (risk of shearing!), screw
Fastening bolt (2) m.
Tightening torque 5.0- 5.5 Nm.
remove, instal1, center and check zero position (see notes for
Aír flow sensor plate (5)
iUustrations).
Hole for securing air flow sensor
clean with M6 tap.
plate
Idling speed set (see Diagnosis Manual Engine, Volurne 1).
Special tool
Mercedes-Benz
~
~
~
000 589 67 ~1 00
00 .)
COMMERCIAL TOOLS
IDesignation
M6tap
NOTE: Fit air flow sensor plate (5), shaped washer (4) and washer (3) onto lever (6).
Tighten new microencapsulated bolt (2, self-locking) first of all so that it just
makes contact and the air flow sensor plate (5) can still be moved.
1P07-0018-13 PG'P-oota- 1 ~ 1
Fig. 39: Identifving Air Flow Sensor Plate And Shaped Washer
Centering air flow sensor plate
Remove, install engine systems control unit (MAS) (15 -2193). Connect contacts temúnal30 and terminal 87
(arrows). The fuel pump starts, fuel pressure is built up and the sensor plate moves into 11zero position 11 •
Mercedes-Benz
Eng:n·e sysloms coo~ol umtcoonectot
Fig. 40: Locating Engine Systems Control Unit Connector
Use an approx. 0.05 mm feeler gauge to ensure that the air flow sensor p1ate is exactJy centered.
NOTE: The air flow sensor plate must not jam even if a slight lateral pressure is applied
(bearing clearance eliminated).
Tighten bolt to 5.0 -5.5 Nm.
Fig. 41: ldentifving Bearing Clearance
Check that the air flow sensor plate moves easily by pressing it down by hand. The sensor plate must not jam.
When the air flow sensor plate is released, it must Jikewise move back without jamming. It must audibly strike
against the resilient stop. If necessary, re-center sensor plate.
Checking zero position of air flow sensor plate
(Visual inspection with engine not running). The inspection point (arrow) is directly below the stop bar.
Mercedes-Benz
Fig. 42: Locating Air Flow Sensor Plate
The top edge ofthe air flow sensor plate must be :flush with the top edge ofthe cylindrical part ofthe air funnel.
In this position, a play of 1 - 2 mm must exist when the air flow sensor plate is pushed up to the control plunger.
(Depending on fmdings, check and adjust zero position of air flow sensor plate 07.3 - 1612).
Fig. 43: Identifying Top Edge Of Air Flow Sensor Plate
Removing and Installing Air Flow Sensor Plate- RA0703119 1665X(07.3-1665)
Mercedes-Benz
Fig. 44: Identifying Air Flow Sensor Plate And Stop Bar
Stop bar (1) for air flow

unscrew, screw on.
sensor p1at e
. fl . t ( ) remo ve by heating fastening screw (2) with hot-air fan and carefully unscrew
A rr ow sensor p 1a e 5 (ns · o ffl)
. k of s h. earmg · torque 5 .o-5 .5 N m.
· . T.1ghtenmg
. , screw m
Air flow sensor plate (5) install, center and check zero position (see steps 1-3).
~~: :~~s~~a;~t~g air clean with M6 tap.

Idle speed set (see Diagnosis Manual E ngine, Volume 1).
Special tool
~1
~
~
000589 67 21 00
DO

Mercedes-Benz
COMMffiR~LYAV~ABLETOOLS
IDesignation
Hot-rur fan
M6tap
l _ lnstalling air flow sensor plate (S)
Fit air flow sensor plate (5), shaped washer (4) and washer (3) onto lever (6). Tighten new
microencapsulated bolt (2) only slightly at first so that the air flow sensor plate (5) can still be moved.
Fig. 46: ldentifyiog Air Flow Sensor Plate And Shaped Washer
2. Centeriog air flow sensor plate
Remove, install engine systems control unit (MAS) (see 15-2193 )- Briefly connect contacts terminal 30
and terminal 87 (arrows). The fuel pump runs, fi1el pressure is built up, the air flow sensor plate moves
into "zero position."
Engme S'fstems con'lfol urit cOlg)lin~
Fig. 47: Locating Engioe System Control Unit Coupling

Mercedes-Benz
Use a feeler gauge (approx. 0.05 mm) to ensure that the air flow sensor plate is seated exactly centrally.
NOTE: The a ir flow sensor plate must also not jam even when slight pressure is
applied to the side (bearing play eliminated).
Tigbten bolt to 5.0-5.5 Nm.
Fig. 48: Identifying Bearing Play Clearance
Check tbat air fl ow sensor plate moves easily by pressing sensor plate down by hand. The sensor plate
must not jarn. Release sensor plate; it must also not jamas it moves back. It must be heard to strike
against the resilient stop. If necessary, recenter air flow sensor plate.
3. Checking zero position of air Oow sensor plate
(visual inspection with engine not running).
The air flow sensor plate must be flush with the top edge of the cylindrical part (enlarged detail) ofthe air
funnel. In this position, a play of 1-2 mm must exist when the air flow sensor pJate is pressed as far as the
control plunger. (Check, set zero position of air flow sensor plate according to findings 07.3-1612).
" ' · f620-tt
Fig. 49: ldentifying Air Flow Sensor Plate

Mercedes-Benz
REMOVING AND INSTALLING MIXTURE CONTROL UNIT- RA07031041668X(07.3-1668)
Removing and installing mixture contt·ol unit- RA07031041668X(07.3-1668)
Operation No. of operation texts and work units or standard texts and flat rates: 07 -1668
f5~
Fig. 50: Identifying Mixture Control Unit Components
Fuel supply and return lines disconnect, connect (pay attention to note).
disconnect at injection valves, connect.
Injection lines
Tightening torque 10- 15 N m as reference value.
Electric wíring disconnect, connect
unscrew, screw on.
Tightening torque 9 -1 ON m as reference value.
Nuts at rubber stops (3 off)
Check rubber buffer, re place if necessary.
Hose clip ( 15) at throttle
slacken, tighten.
valve body
Mixture control unit (25)
complete with air guide lift off, fit on, detach idle air hose ( 10), fit on.
housing (14)
unscrew from air flow sensor, screw on.
Replace according to condition.
Air guide housing (14) Do not use sealíng compound for installing.
Housing is sealed by sealing lip. The air guide housing is made ofrubber
and it is fixed in positíon by being inserted at the líght-alloy frame.
Leak test of all fuel
connections
Mercedes-Benz
Idling speed set (see Diagnosis Manual Engine, Volume 1).

read out, erase ifnecessary (see Diagnosis Manual Engine, Volume 2,
Index 0).
NOTE:
memory
NOTE: When installing the fuelline (arrow) from the fuel distributor to the diaphragm
pressure regulator, ensure that the open-end wrench does not press on the air
flow sensor potentiometer and damage it.
Fig. 51: Locating Fuel Line
Removing and Installing Mi·dure Control UnH- RA07031191668X(07.3-1668)
Mercedes-Benz
1990-2002 ENGINE PERFORMANCE Mixture Formation - REPAIR & ADJUST MENTS- 129 Chassis
Fig. 52: Identifying Mixture Control Unit
Fuel supply and return lines
Tightening torque l 0- 15 Nm as reference value_
at fuel distributor and at injection valves, disconnect, connect.
Injection lines
Tightening torque 10-15 Nm as reference value.
Idle speed adjuster shaped hose pull off, fit on; to do tbis, slacken hose clip, attach.
Electric wiring disconnect, connect.
Diaphragm pressure regulator unscrew, screw on (see 07.3-1669).
unscrew, screw on_
Nuts at rubber pads (4 off) for Tightening torque 9- 1O Nm as reference value.
suspending mixture control unit Installation note
Check rubber pads, replace if necessary.
Hose clip ( 15) at throttle valve
slacken, tighten.
assembly
Mixture control unit (25)
lift off, fit on_
complete with air guide housing
Leaktightness of all fuel
connections
Idle speed set (see Diagnosis Manual Engine, Volume 1)_
read out; erase, if necessary ( see Diagnosis Manual Engine, Volume 2,
Register 0).

Stored faults which may originate from test w ork as a result of
detached wiring or simulation, must be erased in the fault memory
after completion of w ork.
REMOVING AND INSTALLING DIAPHRAGM PRESSURE REGULATOR- RA07031041669X(07.3-

Mercedes-Benz
1669)
Removing and installing diaphnl!gm pressure regulator- RA07031041669X(07.3-1669)
Operation No. of operation texts and work múts or standard texts and flat rates: 07 - 1669
IPOl-5151-55
Fig. 53: Locating Diaphragm Pressure Regulator
V ent line at crankcase ventilation

pull off, fit on.
moulded hose
Fuel line (arrow) disconnect, connect, collect fuel flowing out.
disconnect, connect. Seal return line with rubber plug. CoUect
Fuel supply and return lines
fuel flowing out.
Díaphragm pressure regulator (40) remove, install by ooscrewing bolt (41), screwing in.
Removing and Installing Diaphragm Pressure Regulator- RA07031191669X(07.3-1669)
Operation no. of operation texts and work tmits or standard texts and flat rates: 07-1669
Mercedes-Benz
Fig. 54: Identifying Diaphragm Pressure Regulator Components
Fuelline to starting valve and injection lines of at fuel distributor and at injection valves, detach,
cylinders 7 and 8 attach.
Fuellines (43, 44) and fuel return line connection (45) at diaphragm pressure regulator, detach, attach.
Injection líne of cylinder 6 at inj ection valve detach, attach.
Bolt(41) unscrew, screw lll.
Diaphragm pressure regulator (40) with holders (46, remove, install by detaching and fitting on vent
47) line (42).
REMOVING AND INSTALLING FUEL DISTRffiUTOR- RA07031041674X(07.3-1674)
Removing and installing fuel distributor - RA07031041674X(07.3-1674)
Operatíon No. of operatíon texts and work uníts or standard texts and flat rates: 07-1674
Mercedes-Benz
Fig. 55: ldentifving Fuel Distributor Components
disconnect, connect (pay attention to note)_

Fuel supply and return NOTE:
lines
Since January 1990 a different material has been used for the fuel feed screw
connection.
disconnect at injection valves, connect
Injection lines
Tightening torque 10- 15 Nm as reference value.
Screws (33) remove, screw m.
Fuel distríbutor (2) detach by turning to left and right, take off, fit on.
Rubber seal (24) replace, ensure seal is correctly seated.
remove engine systems control unit (MAS) for this operation, install {15-2193) _
Check basic position of Connect contacts terminal30 and terminal 87 (see note re illustration, arrows).
control plunger relative The fuel pump starts. The fuel must now just start or stop flowing at the screw
to sensor plate; adjust, connection for the injection lines at the fuel distributor (collect fuel flowing out).
if necessary If necessary, set with the idle mixture adjusting screw (61) (see note re
illustration).
Leak test of all fu el
connections
Idle speed set (see Diagnosis Manual Engine, Volume 1).
read out, erase ífnecessary (see Diagnosis Manual Engine, Volume 2, Index 0).
CIS-E control unit fault NOTE:

memory Stored faults which may originate from test work resulting from cables being
Mercedes-Benz
Engine systems control unít (MAS) Connector
Fig. 58: Locating Engine Systems Control Unit (MAS) Connector
PRODUCTION BREAKPOINT OF SCREW CONNECTION FOR FUEL INLET: JANUARY 1990

Model Engine Engine End No. manual transmission Engine End No. automatic transmission
124.031 104.980 001325 005951
124.051
124.091
129.061 104.981 000221 001766
Removing and InstaJling Fuel Distributor- RA07031191674X(07.3-1674)
Fig. 59: Identifving Fuel Distributor Components
lrnj ection 1ines

Mercedes-Benz
Tightening torque 10-15 N m as reference value.

Electric wiring disconnect, connect.
detach, attach.
Fuel supply and return NOTE:
lines
Since January 1990 a different material has been used for the fuel supply
screw fitting.
Fuel distributor (2) detach by turning to left and right, take off, fit on.
replace, install dry.
Rubber seal (24)
Carefully fit on fuel distributor to avoid the rubber seal slipping.
check, set ifnecessary, by removing and installing engine systems control unit
Basic position of (MAS) (15-2193) . Connect contacts terminal 30 and terminal 87 (see note,
control plunger relative arrows ). The fuel pump runs; the fue) must now just start or stop flowing at the
to air flow sensor plate screw fitting for the injection lines at the fuel distributor (collect fuel flowing
out). Set with idle mixture adjusting screw (61), ifnecessary.
fuel connections
KE control unit fault memory
Perform basic setting of control plunger (2) by altering position of idle mixture adjusting screw (61 ).
read out; erase, if necessary (see Diagnosis Manual Engine, Volume 2, Register 0).
NOTE: Stored faults which may originate from test work as a result of detached wiring
or simulation, must be erased in the fault memory after completion of work.
Mercedes-Benz
1 Sas•,vdnvsr
2 C(lfficl pQ1 gsr

3 A~smgdeVtu ror tambda
comolftdle spoed emtsgons l&vel
4 S&1:Ufltypklg
61 A~S.W.g S U!l'N
Fig. 60: ldentifving Basic Setting Of Control Plunger
EnguTIG systlllTIS eomollnt {MAS) cooplllg
Fig. 61: Locating Engine Systems Control Unit (MAS) Coupling
PRODUCTION BREAKPOINT FOR FUEL SUPPLY SCREW FITTING: JANUARY 1990

129.066 119.960 004328
REMOVING AND INSTALLING FUEL ACCUMULATOR- RA07031041683X(07.3-1683)
Removing and installing fuel accumulator- RA07031041683X(07.3-1683)
Mercedes-Benz
Fi~. 62: Identifyin~ Fuel Accumulator Components
Pay attention to safety instructions!

Overpressure in fuel tank release by opening pressure cap, closing.
Protective box remove, install.
Fuel suction hose (23) and fuel pressure pinch with clamp 000 589 40 37 00,
hose (19) disconnect, connect, release clamp.
Fuellines (5, 12) unscrew :from fu el accumulator (57), screw on.
Collect remainíng fuel.
Screw (20) remove, screw m.
Fuel accumulator (57) remove, install. Bend open tensioning strap (2) for
this operation.
Special tool
Mercedes-Benz
000 589 40 37 00
00
Removing and Installing Fuel Accumulator - RA07031191683X(07.3-1683)
•*7-GOM•., l
Fig. 64: Identifying Fnel Accumulator Components
&oenoer!
Pay attention to safety precautions!

Pressure in fuel tank release by opening fuel filler cap, closing.
Mercedes-Benz
Protective cover remove, instalL

Fuel suction hose (23) and fuel pressure pinch with clamp 000 589 40 37 00, disconnect, connect,
hose (19) release clamp.
unscrew from fuel accumulator (57) , screw on.
Fuellines (5, 12)
Collect remaining fuel.
Screw (20) unscrew, screw m.
Fuel accumulator (57) remove, install by bending up tensioning strap (2).
Leaktigbtness of all connection points check with engine running.
Special tool
00 0 589 40 37 00
00
REMOVING AND INSTALLING AIR FLOW SENSOR- RA07031041686X(07.3-1686)
Removing and instaUing air flow sensor- RA07031041686X(07.3-1686)
Preceding work:
Mercedes-Benz
Fig. 66: Identifying Air Flow Sensor Components
Fuel distributor (2) unscrew from air flow sensor (17), screw on (see 07.3-1674). Replace seal.
Removing and Installing Air Flow Sensor- RA07031191686X(07.3-1686)
Preceding work:
Removing and installing mixture- control unit (07.3 1668).
Mercedes-Benz
Fig. 67: ldentifving Air Flow Sensor Components
A· ·d h · ( ) unscrew from air flow sensor ( 17), screw on.

rr gru e ousrng 14 Replace if necessary. Coat sealing surfaces with sealing compound for installing.
Fuel distributor (2) unscrew from air flow sensor (17), screw on (see 07.3-1674). Replace seal (24).
REMOVING AND INSTALLING COOLANT TEMPERATURE SENSOR- RA07031041687X(07.3-

1687)
Removing ancl installing coolant temperature sensor - RA07031041687X(07.3-1687)
Mercedes-Benz
~
1
1
...
Fig. 68: ldentifving Coolant Temperature Sensor
Pressure in coolant circuit release by opening cap of coolant expansion tank, close.
Plug connection of coolant ull off lu in.
temperature sensor (X59/2) P 'P g
Coolant temperature sensor . .
(B 1112) unscrew, screw m.
Seal (arrow) replace.
Coolant leve! check, top up if necessary.
read out, erase if necessary (see Diagnosis Manual Engine, Volume 2, Index
0).
NOTE:
memory
Removing and Installing Coolant Temperature Sensor- RA07031191687X(07.3-1687)
Mercedes-Benz
F ig. 69: Identifying Coolant Temperature Sensor Components
Pressure in coolant circuit release by opening cap of coolant expansion tank, closing.
Coolant temperature sensor
unplug, plug in.
plug connectíon (X59/2)
Coolant temperature sensor
unscrew, screw m.
(B 1112)
Seal (80) replace.
Coolant level check, top up if necessary.
read out; erase, ifnecessary (see Diagnosis Manual Engine, Volume 2,
Register 0).
NOTE:
memory
wiring or simulation must be erased in the fault memory after
completion of work.
REMOVING AND INSTALLING OVERVOLTAGE PROTECTION- RA07031041688X(07.3-1688)
Removing and iustalling overvoltage protection - RA07031041688X(07.3-1688)
Operatíon No. of operatíon texts and work units or standard texts and flat rates: 07 -1688
Mercedes-Benz
A. Modell24
Fig. 70: Identifying Overvoltage Protection Relay - Model124

Component
remove, install.
coinparanentcover
Bolt (8) unscrew, screw in.
Overvoltage
protection relay pull off, fit on.
(Kl/1)
read out, erase ifnecessary (see Diagnosis Manual Engine, Volume 2, Index 0).

B. Modell29
Mercedes-Benz
Fig. 71: ldentifying Overvoltage Protection Relay - Model 129

Component
remove, instalL
cornpartrnentcover
Overvoltage
protection relay pull off, fit on.
(Kl/1)

Removing and Installing Overvoltage Protection- RA07031191688X(07.3-1688)
Mercedes-Benz
Fig. 72: ldentifving Overvoltage Protection Relay

Component
remove, install.
compartment cover
Overvoltage protection .
relay (Klll) d1sconnect, connect.
read out; erase, if necessary (see Diagnosis Manual Engine, VoJume 2, Register
0).
NOTE:
memory
wiring or simulation must be erased in the fault memory after completion of
work.
REMOVING AND INSTALLING THROTTLE V ALVE SWITCH- RA07031041689X(07.3-1689)
Removing and installing throttle valve switch - RA07031041689X(07.3-1689)
Preceding work:
Removing and installing tbrottle valve body (07.3-621 0)

Mercedes-Benz
Fig. 73: ldentifving Throttle Valve Switch
Screws (25) unscrew, screw in.

take off, fit on.
Throttle valve
switch (S29/2) NOTE:
Since August 1989 an improved throttle valve switch has been installed.
Throttle valve
check, adjust if necessary.
switch setting

S19l2 Fulloadlid:e sp-eeddetection S2912x1

tnrai,.e v.atl'll swi ch r------.....
S19,12x1 Ftlg oonnedlcn
Por- CCDa-tlll
Fi2. 74: Full Load ldle Sueed Detection Throttle Valve Switch Circuit Dia2ram
Mercedes-Benz
a. Testing idJe speed contact
Press throttle val ve lever to idle speed stop. Test resístance between contact l and contact 2 of plug
connection (S29/2xl); adjust if necessary. Specification: <1 ohms.
Move tbrottle valve lever approx. 0.2 mm.
Specífication: infiníty ohms.
b. Testing full throttle contact
Press throttle valve lever to full tbrottle stop. Test resistance between contact 2 and contact 3 of plug
connection (S29/2xl).
Specification: < 1 ohms
Ease throttle valve lever back slightly.
Specífication: infinity ohms.
NOTE: At part load, the readout must be at infinity ohms.
Setting throttle valve switch
Slacken screws (25), tum throttle valve switch and re-tíghten screws (25).
PRODUCTION BREAKPOINT OF IMPROVED THROTTLE VAL VE SWITCH: AUGUST 1989

M o del Engine Engine End No. manual transmission Engine End No. automatic transmission
124.031 104.980 000180 000501
124.051
124.091
129.061 104.981 000078 000484
Removing ami Installiug Tbrottle VaJve Switch- RA07031191689X(07.3-1689)
Preceding work:
Removing and installing mixture- control unit (07.3 1668).
Removing and installing tlrrottle- valve assembly (07.3 6210).
Operatíon no. of operation texts and work uníts or standard texts and flat rates: 07-1689
Mercedes-Benz
POT-2015- U A
Fig. 75: l dentifying Throttle Valve Switch And Plug Connection
Throttle valve switch plug

unplug, plug in (see illustrattion note).
connection (S29/2xl)
Throttle valve switch
take off, fit on.
(S29/2)
Throttle valve switch
check, adjust if necessary.
setting
read out; erase, ífnecessary (see Diagnosis Manual Engíne, Volume 2,
register 0).
NOTE:
memory
wiring or simulation must be erased in the fault memory after completion
ofwork.
a. Testing idle speed contact
Press throttle valve lever to idle speed stop. Test resistance between contact 1 and contact 2 ofplug
connection (S29/2x 1); adjust if necessary.
Specífication: < 1 ohms ..
Operate throttle valve lever approx. 0.2 mm.

Mercedes-Benz
Specification: infinity ohms.
r------.....
S2912x1
S29/2
~·-·n
_
..._....... ___., ..._ _, ~-ª_j
Fig. 76: Throttle Valve Switch Plug Connection Circuit Diagram
b. Testing full throttle contact
Press throttle valve lever to full throttle stop. Test resistance between contact 2 and contact 3 of plug
connection (S29/2x 1).
Specification: < 1 ohrns.
Release throttle valve lever slightly.
Specification: infinity ohms.
NOTE: At part load the reading must be infinity ohms.
Setting tbrottle valve switch
Slacken screws (25), turn throttle valve switch and re-tighten screws (25).
A.rraogemm cf pklg voon9Ctlcn (S29/2x1)
Fig. 77: Identifying Arrangement OfPiug Connection
Note
REMOVING AND INSTALLING MICROSWITCH- RA07031041690X(07.3-1690)

Mercedes-Benz
Vehicles without ASR
Fie. 78: Locatine Microswitch
Electrical connector at microswitch (arrow) unplug, plug in.

Microswitch (S27 /2) take out, insert.
REMOVING AND INSTALLING INTAKE AIR TEMPERA TURE SENSOR- RA07031041691X(07.3-

1691)
Removing and installing intake air temperature sensor - RA07031041691X(07.3-1691)
Operation No. of operation texts and work units or standard texts and flat rates: 07- 1691
Mercedes-Benz
Fig. 79: ldentifving Intake Air Temperature Sensor
Electrical connector at intake

air temperature sensor tmplug, plug in.
(B 17/2)
0-ring check, renew if necessary.
lntake air temperature sensor . . . .
(B ) turn to left, w1thdraw, msert, turn to nght.
1712
read out, erase if necessary (see Diagnosis Manual Engine, Volume 2,
Index 0).
NOTE:
memory
Removing and InstaUing Intake Air Temperature Sensor - RA07031191691X(07.3-1691)
Mercedes-Benz
Fig. 80: Identifying Intake Air Temperature Sensor
Electric coupling at intake air unplug, plug in.

temperature sensor (B 17/2)
0-ring check, replace ifnecessary.
Intake air temperature sensor tum to the left, remove, insert, tum to the right.
(B17/2)
read out; erase, if necessary ( see Diagnosis Manual Engine, Volume 2,
Register 0).

detached wiring or simulation must be erased in the fault memory
after completion of work.
REPLACING ELECTROHYDRAULIC ACTUATOR - RA07031041692X(07.3-1692)
Replacing electrohydra ulic actuator- RA07031041692X(07.3-1692)
Mercedes-Benz
IP0?-0016-55 •.,........
Fig. 81: ldentifying Electrohydraulic Actuator
Plug connection of
electrohydraulic actuator disconnect, connect.
(Yl)
release by detaching fuelline between fuel distributor and starting valve.
Fuel pressure
unscrew, screw m.
Screws (3)
replace. Clean sealing smfaces, ifnecessary, with cleaning petroleum and
0-rings (4)
fluff-:free cloth.
Electrohydraulic actuator
remove, install.
(Yl)
Leak: test of all connections check with engine mnning.
read out, erase ifnecessary (see Diagnosis Manual Engine, Volume 2, Index
0).
NOTE:
memory
CO~RCMLLYAVAaABLETOOL
Screwdriver 2115-T 27 Hazet, D -5630 Remscheid
Mercedes-Benz
Replacing Electrohydraulic Actuator- RA07031191692X(07 .3-1692)
Fig. 82: Identifying Electrohydraulic Actuator Components
plug connection (Y 1)
release by detaching fuel line between fuel distributor and starting valve.
Fuel pressure
unscrew, screw m.
Screws (3)
replace. Clean sealing surfaces, if necessary, with cleaning petroleum and
0-rings (4)
fluff-free cloth.
E1ectrohydraulic actuator
remove, install.
(Yl)
check with engine runníng.
connection points
read out; erase, if necessary (see Diagnosis Manual Engine, Volume 2,
Register 0).

detached wiring or simulation must be erased in the fault memory after
completion of work.
COMMffiRCULLYAV~ABLE TOOL
IDesignation e.g. make, order no.
Mercedes-Benz
lscrewdriver 2115-T 27 Hazet, D-5630 Remscheid
Replacing Electrohydraulic Actuator- RA07031191698X(07 .3-1692)
Y1 0
plug connection (Y 1)
release by detaching fuel line between fuel distributor and starting valve.
Fuel pressure
unscrew, screw m.
Screws (3)
replace. Clean sealing surfaces, if necessary, with cleaning petroleum and
0-rings (4)
fluff-free cloth.
remove, install.
(Yl)
connection points
read out; erase, if necessary (see Diagnosis Manual Engine, Volume 2,
Register 0).

detached wiring or simulation must be erased in the fault memory after
completion of work.
Mercedes-Benz
COMMffiR~LYAV~ABLETOOL
Screwdriver 2115-T 27 Hazet, D-5630 Remscheid
REPLACING VEHICLE SPEED HALL-EFFECT SENSOR- RA07031041693X(07.3-1693)
Preceding work:
Removing and installing instrument cluster (54- 250)
Model124
Fig. 84: Identifying Hall-Effect Sensor
Hall-effect
remo ve, install by unscrewing screw and screwing in.
sensor (B6)
NOTE:
completing ·t he work.
CIS-E control
unit fault
memory
Function
A vehicle speed signa! is fed into the control unit by the Hall-effect sensor (B6) for
controlling the idle speed.
The idle speed control is switched off from a speed of approx. 1.4 km/h as a result of
this signal, which improves performance in the deceleration mode. The idle speed
control is again activated below a speed of 1.4 km/h.
Mercedes-Benz
REMOVING AND INSTALLING CIS-E CONTROL UNIT- RA07031041698X(07.3-1698)
Operation No. of operation texts and work tmits or standard texts and flat rates: 07 -1698
Mo-del 124
Fig. 85: Locating Locking Bar And CIS-E Control U nit- Modell24
Mercedes-Benz
Moo.el 129
F ig. 86: Locating Locking Bar And CIS-E Control Unit - Model 129

Accessories compartment cover remove, install.
Lockíng bar (arrow) open, close.
ClS-E control unit connector unplug, plug in.
Screws unscrew, screw m.
CIS-E control unit (N3) remove, insert.
NOTE: As a result of a software modification, no fault is displayed anymore when

driving at high altitudes.
M odel Vehicle ldent E nd No. Production breakpoint
124 B 140137 November 1989
F 139401 February 1990
129.061 F 001144 July 1989
Since August 1990 the tuning of the secondary air pump and exhaust gas recirculation has been modified
Mercedes-Benz
(introduction of end-of-production-Iine diagnosis).

M o del Engine Vehicle ldent End No. Basic version National version @ ' ~
lg]
124.031 104.980 B 322830 X - X -
B 328633 - X - X
124.051 104.980 B 327269 X - X -
B 323655 - X - X
124.091 104.980 F 156273 X - - -
Since September 1990 CIS-E control units with a modified program have been installed. As a result, the
specified value of the current at the electrohydraulic actuator is available as soon as tbe ignition is switched on
wítbout any time delay.
Tbe modified control units can also be installed on vebicles with a lower vehicle ident end no.
Measuring current at the electrohydraulic actuator (CIS-E control units up to 09/90):
Wben measuring the current at tbe electrohydraulic actuator (after switching on the ignition), a difference of +/-
13 mA from the respective specification is permissible. The specification must be achieved after 15 minutes. If
the amperages are within the specified tolerance, the control unit is operating properly and therefore does not
need to be replaced.

Model Engine Vebicle ident end no.
124.031/051/061/091 104.980 B 343721
F 158705
129.061 104.981 F 019363
Since April 1991 an EZL ignition control unit with modified map anda modified CIS-E control unit have been
instailed for the adjustment range of the inlet camsbaft in order to reduce combustion noises.
The total adjustment range ofthe inlet camshaft is reduced to 29 °CA (previously 34 °CA).
The inlet camshaft advance at part load at engine speed above 5000 rpm has likewise been reduced from 17 o
CAto 14.5 °CA.
The CIS-E control unit must only be installed together with the relevant EZL ignition control unit.
PRODUCTION BREAKPOINT: APRIL 1991 (EXCEPT 1)

124.031 104.980 005792 025654
1 1
Mercedes-Benz
124.051
124.091
129.061 104.981 001134 010894
REMOVING AND INSTALLING IDLE SPEED MOTOR- RA07031042118X(07.3-2118)
Removing and installing idle speed motor- RA07031042118X(07.3-2118)
IP07-5157-57 I'W<OI$H7 1
Fig. 87: Identifying ldle Speed Motor And Electrical Plug Connection
Electrical plug connection (arrow) unplug, plug in.

Idle speed motor Y6 remove, install by detaching shaped hoses (28), fitting on.
Removing and Installing Idle Sp eed Adjuster- RA07031192118X(07.3-2118)
Operationno. of operation texts and work units or standard texts and flat rates: 07-2118
Mercedes-Benz
Fig. 88: ldentifving ldle Speed Adjuster Components
Electric plug connection

unplug, plug in.
(arrow)
Holder (29) detach, fit on.
remove, install.
PuLl off shaped hoses (28), fit on.
Idle speed air valve (Y6) &oenoerl
Attach 30 mm dia. hose strap to air flow sensor side and 27 mm dia. hose strap
to idle air distributor side.
Since October 1990 the shaped hose between idle speed adjuster and air flow sensor is attached with two hose
straps which prevent the shaped hose from slipping.
Model as of vehicle ident end no.
129.066 F 020375
REPLACING OXYGEN SENSOR- RA07031045303X(07.3-5303)
Replacing oxygen sensor- RA07031045303X(07.3-5303)

Mercedes-Benz
Fig. 89: ldentifying Oxygen Sensor Plug Connection
Fig. 90: Identifving Oxvgen Sensor Aod Splash Water Plate
remove, install.
Oxygen sensor plug NOTE:

connection (G3/2xl)
• Turn union nut to the Jeft as far as stop--> to open
• Turn union nut to the right as far as stop--> to secure
Splash water plate
pull off, fit on; open side should face to the rear.
( 114)
unscrew witb ring wrencb socket 000 589 71 03 00, screw in.
lnstallatioo instructioo
Oxygen sensor (G3/2) Coat thread of oxygen sensor (G3/2) with hot lubricating paste, Part No. 000 989
76 51.
Tightening torque 50 - 60 Nm as reference value.
Mercedes-Benz
check, set
Lambda control
(see Diagnosis Manual Engine, Volume 1).
read out, erase if necessary (see Diagnosis Manual Engine, Volume 2, Index 0).

Special tool
000 589 7i 03 00
83 .)
Replacing Oxygen Sensor- RA07031195303X(07.3-5303)
Fig. 92: ldentifving Oxvgen Sensor Plug Connection

Mercedes-Benz
Fig. 93: ldentifying Oxvgen Sensor And Splash Water Plate
remove, instaH.
Oxygen sensor plug NOTE:

connection (G3/2xl)
•· Turning un ion nut to the left as far as the stop--> to open
• Turning un ion nut to the right as far as the stop --> to lock
Splash water plate (114) pull off, fit on; open side must face to the rear.
unscrew, screw m.
Installation note
Oxygen sensor (G3/2) Coat thread on oxygen sensor (G3/2) with hot lubricating paste, part no. 000 989
76 51.
Tightening torque 50-60 Nm as reference value.
test, adjust
Lambda control
(see Diagnosis Manual Engine>Volume 1).
read out; erase, ifnecessary (see Diagnosis Manual Engine, Volume 2, Register
0).
NOTE:
memory
work.
REMOVING AND INSTALLING FUEL FILTER- RA07031045563X(07.3-5563)
Removing an<l installing fuel filter - RA07031045563X(07.3-5563)
Mercedes-Benz
Fig. 94: Identifying Fuel Filter Components
&.oanaor!
Pay attention to safety

instmctions!
Overpressure jn fuel
release by opening pressure cap, closing.
tank
Fuel suction hose (23)
and fuel pressure hose pincb with clamp 000 589 40 37 00, release clamp.
(19)
disconnect at fuel filter (55), fu el accumulator (57) and fuel pump (M3/2),
Fuelline ( 5)
connect.
Union nut (40) tmscrew, screw on.
Seals replace.
Screws for tensíoning
slacken, tighten.
strap (2)
remo ve, insert with plastic foil (25). Check plastic foil (25), replace if necessary.
Fuel filter (55) &.oan®rl
A lw:::tv.<: in<:t::tll nl::t"tir foil(?<:;) hPtwP.P.n n tf>l filtP.r (""' ::tnrl tf>n<:Íonino- <:tnm (?)
Mercedes-Benz
The plastíc foil ofthe fuel filter (55) must project on both sídes ofthe bracket.
Direct contact of the fuel filter with the bracket results in contact corrosion.
Leak test of all check with engine running.
connection points
Special tool
001) 589 .w 37 00
00
The fuel pump set is arranged on the right in front ofthe rear axle on the frame floor, viewed in the direction of
travel.
Fig. 96: Identifying Fue) Pump Set
Removing and Instafiing Fuel Filter- RA07031195563X(07.3-5563)
Mercedes-Benz
~J
Fig. 97: ldentifving Fuel Filter Components
&oanQerl

precautions!
Pressure in fuel tank release by opening filler cap, closing.
Protective cover remove, install.
Fuel suctiou hose (23)
and fuel pressure hose pinch with clamp 000 589 40 37 00, release clamp.
(19)
at fuel filter (55), fue] accumulator (57) and fuel pump (M3/2), disconnect,
Fuel line (5)
connect.
Fuel pressure hose ( 19) at
unscrew, screw on.
fu e1 fíl
1 ter
Seals replace.
Screws for tensioning strap (2), slacken, tighten.
remove, insert with plastic film (25).
Check plastic film (25); replace if necessary.
Fuel filter (55) &oanQerf
Always install plastic film between fuel filter and tensioning strap. The plastic
film nf thP. fi1PJ filtP.r mm:t nrntP.r.t nn hnth ~trlP~ nf thP hr::~r.kPt DirPr.t r.nnt::~rt
Mercedes-Benz
between fuel filter and bracket results in contact corrosion.

connection points
Special tool
000 589 40 37 00
00
The fuel pump set is arranged on the right in front ofthe rear axle on the frame floor, viewed in direction of
travel.
Fig. 99: ldentifving Fuel Pump Set
REMOVING AND INSTALLING FUEL PUMPS- RA07031045713X(07.3-5713)
Removing and installing fuel pumps- RA07031045713X(07.3-5713)
Operation No. of operation texts and work units or standard texts and flat rates: 07- 5713, 07 -5714.
Mercedes-Benz
5 ----.:......---;.
60 -+--+r~
IP07-5031-57
- - - -.. 1
Fig.lOO: Identifying Fuel Pumps Components
A. Removing and installing fuel pump (M3/1)
&oanaerl

instructions!
Overpressure in fuel
release by opening pressure cap, closing.
tank
and fuel pressure hose pinch with clamp 000 589 40 37 00, release clamp (pay attention to note for
(l ) model 124 T-model).
9
Fuel suction hose (23) disconnect, connect.
Uníon nut (60) unscrew, screw on.
Seals replace.
Electric wiring of fuel
pump (M3/ 1) disconnect, connect by pulling off and fitting on protective caps.
Model 124 T-rnodel
RnhhP.r n::~rlc:: from detach, attach.

Mercedes-Benz
straps
Rubber pad at fuel
pull off, examine, replace if necessary, push on.
pump
Model 124 except T-
model, model 129
Tensioning strap (2) open, close.
remove, insert with plastic foil (25). Pay attention to intennediate spacer (65).
Check plastic foil (25), replace if necessary.
&oanoorl
Fuel pump (M3/ l) Always install plastic foil (25) between fu el pump (M3/l) and tensioning strap
(2). The plastic foil ofthe fuel pumps (M3/ l , M3/2) must project on both sides
ofthe tensioning strap. Direct contact of a fuel pump with the tensioning strap
results in contact corrosion.
AU models
Leaktíghtness of aH
check with engine nmning.
connection points
NOTE: Model 124 T -model
Do not pinch fuel suction hose at bend (arrow).
Fuel pump 1 (M3ml) is located between fuel tank and rear axle.
Fi~. 101: ldentifyin~ Fuel Pump
B. Removing and installiog fuel pump (M3/2)
Fuel pump (M3/l) must be

removed beforehand in order to
remove fuel pump (M3/l) (not for
modell24 T-model).
Fuel pump set lower on fuel pump side by detacbing the two rubber rings (35).
Mercedes-Benz
Uníon nut (70) tmscrew, screw on_

Seals replace.
Electric wiring of fu el purnp
disconnect, connect by pulling off and fitting on protective caps.
(M3/2)
Intermediate piece (65) remove, instalL
remove, insert with plastic foil (25). Pay attention to intermediare
spacer ( 65). Check plastic foil (25), replace if necessary _
&oanqert
Always install plastic foil (25) between fuel pump (M3/2) and
Fuel pump (M3/2)
tensioning strap (2). The plastic foils ofthe fuel pumps (M3/l , M3/2)
must project on both sides ofthe tensioning strap_ Direct contact
between a fu el pump and the tensioning strap results in contact
corros ion_
Leak test of all connection points check with engine running_
Special tool
000 58lJ 40 37 00
DO
The fu el pump set ís arranged on the right in front of the rear axle on the fl·ame floor, víewed in direction
oftraveL
Mercedes-Benz
Fig. 103: Identifying F uel Pump Set
Removing and Installing Fuel Pumps - RA07031195713X(07 .3-5713)
Both fuel pumps 07-5750
Fue! pump 1 07-5713
Fuel pump 2 07-5714
Fig. 104: ldentifying Fuel Pumps Components
A. Removing and installing fuel pump (M3/1)
&oancter!

precautions!
Mercedes-Benz

and fuel pressure hose pinch with clamp 000 589 40 37 00, slacken clamp.
(19)
Fuel suction hose (23) disconnect, com1ect.
Union nut (60) unscrew, screw on.
Seals replace.
Electric wiring of fuel
pump (M3/ l)
Tensíoning strap (2) open, close.
remo ve, insert with plastic film (25). Pay attention to intermediate spacer ( 65).
Check plastic film (25), replace ifnecessary.
&oanaerl
Fuel pump (M3/ l)
Always install plastic film between fue] filter and tensioning strap. The plastic
film of the fu el filter must project on both sides of the bracket. Direct contact
between fu el filter and bracket results in contact corrosíon.
Leak-tightness of all
check with engine mnning.
connection points
B. Removing and installing fuel pump (M3/2)
(Fuel pump (M3/l) must be

removed beforehand for removing . . .
tbe fuel pump (M3/2 )). lower on the fuel pump s1de by detaching the two rubber nngs (35).
Fuel pump set
Union nut (70) unscrew, screw on.
Seals replace.
Electric wiring of fu el pump
(M3/2)
Intermediate spacer ( 65) remove, install.
remove, insert with plastic film (25). Pay attention to intermediate
spacer (65). Check plastic film (25), replace ifnecessary.
&oanaerl
Fuel pump (M3/2) Always install plastic ftlm between fuel filter and tensioning strap.
The plastic film ofthe fuel filter must project on both sides oftbe
bracket. Direct contact between fuel filter and bracket results in
contact corrosion.
Leaktíghtness of aH connection
check with engine running_
points
Special tool
Mercedes-Benz
000 589 40 37 00
00
The fuel pump is arranged on the right in front of the rear axle on the frame floor, viewed in direction of
travel.
Fig. 106: ldentifving Fuel Pump
REMOVING AND INSTALLING FUEL PUMP SET- RA07031045770X(07.3-5770)
Removing and installing fuel pump set - RA07031045770X(07.3-5770)
Mercedes-Benz
JPOl-5030-57
Fig. 107: ldentifying Fuel Pump Set Components
Lt.oanQerl

Overpressure in fuel tank release by opening pressure cap and closing.
Electric wiring at fuel pumps disconnect, connect.
Fuel suction hose (23) and fuel pressure hose pinch with clamp 000 589 40 37 00, detach, attach, slacken
(19) clamp.
Rubber pads (35) detach, attach.
SpeciaJ tool
Mercedes-Benz
000 589 40 37 00
00
NOTE: Arrangement of cable connection (arrow) for electric wiring of fuel pumps below
rear bench seat on right.
Model 129
Fig. 109: Locating Cable Connection
The fuel pump is arranged on the right in front ofthe rear axle on the frame floor, viewed in direction oftravel.
Mercedes-Benz
Fig. 110: ldentifying Fuel Pump
Removing and Installing Fuel Pump Set- RA07031195770X(07.3-5770)
Operatíon no. of operation texts and work units or standard texts and flat rates: 07-5770
Fig. 111: ldentifying Fue) Pump Set Components

Mercedes-Benz
&oanacrl
Pay attentíon to safety precautíons!

Pressure in fuel tank release by opening filler cap, closíng.
Electric coupling of fuel pump set disconnect, connect (see illustration note).
Fuel suction hose (23) and fuel pressure pínch with clamp 000 589 40 37 00, release clamp,
hose (19) disconnect, connect.
Rubber pads (35) detach, attach.
Leaktightness of all connection points check with engine mnning.
Special tool
000 589 40 37 00
00
Fig. 112: l dentifying Special Tool (000 589 40 37 00 00)
NOTE: Note
{f~1'~-~ ;¿::>Y ,· · :; ,::;;~~~;.~

.. - , ...
--..-.. ~ :~
. o- . ~ . •~
··4:··. ~
', . ..'
~
Fig. 113: Locating Electric W iring OfFuel Pump Set
The fuel pump set is located on the right in front ofthe rear axle on the frame floor, viewed in direction of
travel.
Mercedes-Benz
Fig. 114: ldentifying Fuel Pump Set
REPLACING CHECK VAL VE FOR FUEL PUMP- RA07031045820X(07.3-5820)
Replaciug check valve for fuel pump- RA07031045820X(07.3-5820)
Fig. 115: ldentifying Check Valve And Fuel Pump Components
1&-.,
P:=~v ::~ttP.ntlnn tn <::::~fptv
Mercedes-Benz
instructions!
Overpressure in fuel tank release by opening pressure cap and closing.
Protective box ( 1O) detach, attach.
Fuel suction hose (23) and fuel pinch with clamp (11) 000 589 40 37 00,
release clamp (pay attention to note for model 124 T-model see 07.3-
pressure hose (19)
571~).
A. Replacing check vaJve on fuel pump (M3/1)
Screw (arrow) at bracket (2) for fuel pump, slacken.

Fuelline (6) unscrew, screw on.
Cap nut unscrew, screw on.
Fuel pump (M3/ 1) push to the left.
remove, install.
Check valve (32) Tightening torque 22 N m as a reference value.
Seals (9) replace.
Leak test of all connectiion pointscheck with engine running.
B. Replacing check valve on fuel pump (M3/2)

remove, install.
Check valve (32)
Seals (9) replace.
Leak test of all connectiion pointscheck with engine running.
Special tool
000 58911037 00
00
The fu el pump set is arranged on the right in front of the rear axle on the frame floor, viewed in direction
oftravel.
Mercedes-Benz
Fig. 117: ldentifving Fuel Pump Set
Replacing Check Valve for Fuel Pump- RA07031195820X(07.3-5820)
'«tv
~or · IMI?t·n
Fig. 118: Identifying Check Valve And Fuel Pump Components
&.oenoer!
Pay attentíon to safety precautions!
Mercedes-Benz
Protective cover (lO) detach, fit on.

Fuel suction hose (23) and fuel pressure hose pinch with clamp (11) 000 589 40 37 00, release
(19) clamp.
A. Replacing check valve at fuel pump (M3/1)
Screw ( arrow) at tensioning strap (2), slacken.

Fuel pump (M3/ 1) push to the left.
remove, install.
Check valve (32) Tightening torque 22 Nm as reference value.
Seals (9) replace.
Leaktightness of all cormection points check with engine running.
B. Replacing check valve at fuel pump (M3/2)
Fuel Iine (5) unscrew, screw on.

remove, install.
Check valve (32)
Seals (9) replace.
Leaktightness of all cormection points check with engine nmning.
Special tool
000 589 40 37 00
00
Fig. 119: Identifving Special Tool (000 589 40 37 00 00)
The fu el pump set is arranged on the right in front of the rear axle on the frame floor, viewed in direction
oftravel.
Mercedes-Benz
REMOVING AND INSTALLING RUBBER PADS FOR FUEL PUMP SET- RA07031045860X(07.3-
5860)
Removing and installing rubber ¡>ads for fueJ ¡mmp set- RA07031045860X(07.3-5860)
Operatíon No. of operatíon texts and work units or standard texts and flat rates: 07 -5860
Mercedes-Benz
IP07-5637-5fA'"''"-m
Fig. 121: ldentüying Rubber Pads For Fue) Pump Set
Illustrated on model124 Sedan
Model 124 T -model
Model124 Sedan/Coupe/Convertible,
model129
unbolt, bolt on (installation position offuel pump, see
Protective box (69)
07.3-5713).
Rubber pads (58) from tabs detach, examine, replace if necessary, attach.
Model124 T-model
&oanQer!
Pay attention to safety precautions!
Pressure in fuel tank release by opening fuel filler cap, closing.
detach, attach (installation position of fu el pump, see
Cover (69a)
Note).
pinch off with clamp (O 11 ), take off (pay attention to
Fuel hose at delivery end (52) and fuel hose
Note).
at suction end (53)
Fuel hose at suction end (53) detach, ftt on. Todo this, slacken hose clip (53/3), tighten.
Mercedes-Benz
detach, attach. Detach rubber pad (58a) from fuel pump 1

Rubber pads (58a) from tabs
(M3ml), examine, replace ifnecessary, fit on.
Leaktightness of all connection points check with engine running.
Special tooJ
000 589 40 37 00
\. 00
NOTE: Mo del 124 T -model
Fuel pump 1 (M3ml) is located between rear axle and fuel tank.
Do not pinch offfuel hose at suction end at the bend (arrow).
Fig. 123: Locating Fuel Pump
Removing and Installing Rubbe•· Pads for Fuel Pump Set- RA07031195860X(07.3-5860)
Operatíon no. of operation texts and work units or standard texts and flat rates: 07-5860
Mercedes-Benz
Fig. 124: ldentüying Rubber Pads For Fue) Pum p Set

Rubber pads (35) detach from straps, attach; replace if necessary.
The fuel pump set is arranged on the right in front of the rear axle on the frame floor, viewed in direction of
travel.
Mercedes-Benz
REMOVING AND INSTALLING THROTTLE VAL VE HOUSING- RA07031046210X(07.3-6210)
Removing and installing throttle valve housing- RA07031046210X(07.3-6210)
Preceding work:
Operatíon No. of operation texts and work units or standard texts and flat rates: 07-6210
15~
..,._...,.I • N"
Fig. 126: ldentifying Tbrottle Valve Housing Componeuts
Control rods and retum spring

detach, attach.
on throttle valve housing (16)
Extraction line for fuel
evaporation control unit
Plug connection (S29/2x1) of
at intake manifold, disconnect, connect.
throttle valve switch
remove, install. Replace gasket. Tightening torque 25-30 Nm as
reference value.
NOTE:
Throttle valve housing( 16)
Throttle valve bodies which have to be replaced after a clear
diagnosis, should be replaced in future only in conjunction with the
throttle valve switch.
Mercedes-Benz
Since August 1989 an improved throttle valve switch has been instaHed
(see 07.3-1689).
Throttle control check, adjust ifnecessary (30-1010) .
Idle speed check, adjust ifnecessary (seeDiagnosis Manual Engine, Volume 1).
Removing and InstaJling Tbrottle Valve Assembly- RA07031196210X(07.3-6210)
Preceding work:
Removing and installing mixture- control unit (07.3 1668)
Fig. 127: ldentifying Throttle Valve Assembly
Throttle val ve switch plug at intake manifold, unplug, plug together. Unscrew coupling from intake
connection manifold, screw on.
Throttle controllinkage (1) at throttle valve assembly, detach, attach.
Extraction line for fuel
evaporation control system
remove, install. Replace gasket.
Throttle valve assembly (16)
NOTE:
Mercedes-Benz
1990-2002 ENGI NE PERFORMANCE Mixture Formation- REPAIR & ADJUSTMENTS- 129 Chassis
lf it is necessary to replace the throttle valve assembly after a clear

diagnosis, the throttle valve switch should be replaced at the same
time.
Throttle control check, set ifnecessary (30-1010).
Idle speed check, set ifnecessary (see Diagnosis Manual Engine, Volume 1).
TESTING INJECTION VAL VES- RA07031046500X(07.3-6500)
Testiug injection valves- RA07031046500X(07.3-6500)
Preceding work:
Removing and installing injection valves (07.3 6-520)
Operatíon No. of operation texts and work units or standard texts and flat rates: 07- 6500
Fig. 128: Testiog Iojectioo V.alves
NOTE: The chatter test and the assessment of the spray jet do not require to be
performed on injection valves with Viton seal seat.
TESTING FOR LEAKS AND OPENING PRESSURE

Injection
connect to tester.
valve
Pressure
bleed wíth shutoff cock open and müon nut
line
Union nut open.
tighten.
perfonn.
Rough leak With shutoff cock open, slowly operate hand lever (approx. 2 s/stroke) and build up pressure
test to max. 1.5 bar. If a leak is detected at the injection valve, the injection valve must be
n~n 1:1 ~P.ti
Mercedes-Benz
check.
Flush through injection valve by operating hand lever rapidly severa! times with the shutoff
Opening
cock closed.
pressure
Open shutoff cock and check openíng pressure with slow movement of hand lever (approx.
2 s/stroke).
perform.
Flush through injectíon valve by operatíng hand lever rapídly severa! times wíth shutoff
cock closed.
Leak test
Open shutoff cock and slowly increase pressure up to 0.5 bar below the opening pressure
determíned prevíously, and maintaín this pressure. No drop should form at the ínjection
valve wíthin 15 seconds.
TEST DATA
new injection valves 4.3 - 4.6 bar gauge pressure
Opening pressure of injectíon val ves
used ínjection valves at least 3. 7 bar gauge pressure
Injection línes to fuel distributor (approx. value) 10 -1 2
lnjection lines to injection valves (approx. value) 10 -15

V alve tester Bosch, KDJEP - 400
Nozzle tester EFEP 60 H(l) Bosch, O 684 200 700
Pressure gauge O- 10 bar, pressure housing 0 lOO mm, quality class 1.0 Bosch, 1 687 231 000
Pipeline Bosch, 1 680 750 001
(l) Similar to previous nozzle tester. The pressure gauge listed or the pressure gauge of the pressure
measuríng device l OO 589 13 21 00 ís required for testíng the injection valves.
NOTE: The tester reservoir must be filled and the unit bled before it is possible to
commence the test of the injection valves. Use only kerosene for testing.
Replace ínjection valves which are beyond the tolerance limits. The injection valves can be replaced
individually within a set.
Testing Injection Valves- RA07031196500X(07.3-6500)
Preceding work:
Removing and installing injection - valves (07.3 6520)
Mercedes-Benz
Fig. 129: Testing lnjection Valves
NOTE: The chatter test and assessment of jet are not applicable to injection valves
with Viton sealing seat.
TESTING LEAKTIGHTNESS AND OPENING PRESSURE

Injection valve connect to tester.
Pressure line bleed with shutoff cock open and union nut open.
Union nut tighten.
perform.
Rough With shutoff cock open, slowly operate hand lever (approx. 2 s/stroke) and build up
leaktightness test pressure to max. 1.5 bar gauge. If a leak is detected at the injection valve, the injection
valve must be replaced.
test.
With shutoff cock closed, flush through ínj ection valve by operatíng hand lever rapídly
Opening pressure several times.
Open shutoff cock and check opening pressure when moving hand lever slowly
(approx. 2 sec. per stroke).
perform.
With shutoff cock closed, flush through injection val ve by operating hand lever rapidly
L ak . h several times.
e ttg tness test Open shutoff cock and increase pressure to 0.5 bar below previously detennined
opening pressure, and hold. No drop may form at tbe injection valve within 15
seconds.
TEST DATA
Openíng pressure of injectíon new ínjectíon valves 4.3-4.6 bar gauge
valve used injection valves at least 3. 7 bar gauge
TIGHTENING TORQUES IN N m
Inj ectíon línes at fue! dístríbutor (reference value) 10-12
Mercedes-Benz
lrnjection línes at injection valves (reference value)
COMMER CIALLY AV AILABLE TESTER S AND TOOLS

V al ve tester Bosch, KDJEP-400
Nozzle tes ter EFEP 60 H( 1) Bosch, O 684 200 700
O - 1O bar pressure gauge, overpressure housing dia. 100 mm, Quality Class 1.0 Bosch, 1 687 231 000
Pipíng Bosch, 1 680 750 001
(I) Corresponds to prevíous nozzle tester. The pressure gauge stated or the pressure gauge ofthe
pressure measuring device 100 589 13 21 00 is required for testing the injection valves.
NOTE: Before commencing the test of injection valves, the vessel of the tester must be
filled and the tester bled. Only petroleum should be used for testing.
lnjection valves which are not to tolerance must be replaced. The injection
valves may be replaced individually wit hin a set.
REMOVING AND INSTALLING INJECTION VAL VES - RA07031046520X(07.3-6520)
Removing and installing injection valves - RA07031046520X(07.3-6520)
IP07•0012-55 •w=--••
F ig. 130: l dentifying In jection Valves Components
Injection lines remove, install, holding injection valves tight.

(']p::m r.nnnP.r.t1nn nnint:<:
Mercedes-Benz
Tightening torque 1O - 15 N m as approx. value.

Bracket (12) unscrew, screw on.
lnjection valves (92) remove, insert.
Rubber seal ( 11) replace.
Removing and Installing Injection Valves- RA07031196520X(07.3-6520)
1&
013
Fig. 131: Identifying lnjection VaJves Components
unscrew, screw on; hold injection valves tight for this step. Clean
Injection lines connection points.
Tightening torque 10-1 5 Nm as reference value.
Screws (16) unscrew, screw 111.
Bracket (10) and bracket bridge
take off, :fit on.
(15)
lnj ection valves (92) remove, insert.
Seal (ll) replace.
Leaktightness of all connection
points
PROGRAMMED REPAIRS ENGINE 104 COMBUSTION CIS-E INJECTION- RA0703104PROOX
NOTE: Engine speed characteristics
The specific engine speed characteristics are described below in order to facilitate fault diagnosis.
Mercedes-Benz
l. Engine speed "After starting"
Since September 1989 KAT vehicles run ata fast idling speed ( 1000 - 1200 rpm) for up to max. 1 minute
after starting or up to a coolant temperature of 30 °C. This "heating speed" enables the catalytic converter
to reach its operating temperature faster.
2. Engine speed "Vehicle moving"
Engines with CIS-E control units to whích the road speed signal ís supplied have an idling speed which ís
50 - 200 rpm higher when the vehicle is moving.
3. Engine speed "In deceleratíon mode"
Deceleration fuel cutoff is actívated as soon as the driver's foot is released from the accelerator.
NOTE: Only on vehicles with automatic transmission, engine speed increases

briefly by 100-300 rpm when combustion is restored in the deceleration
mode. The vehicle speed does not in crease as a result of this, however.
Complaint:
Engine misfires above 4000 rpm in position "D", vibrates (only vehicles with automatic transmission .
Cause
Transmissíon overload protection not operatíng.
Remedy
Test transmission overload protection (see Diagnosis Manual Engine, Volume 2, Index 5.1, Test step 8.0 - 9.2,
and also Volume 4, Wiring Díagrams).
Complaint:
Idling occasionally >1100 rpm (engine at operating temperature)
Cause
l. Return spring wrongly attached at fulcrum lever.

2. Throttle valve id le speed contact (S29/2) is not operated.
Remedy
L Attach retum spríng correctly at fulcrum lever (see Fíg.)

2. Test idle speed contact at throttle valve switch (see Diagnosis Manual Engine, Volume 2, Index 2).
Mercedes-Benz
Fig. 132: Locating Retoro Spring
Complaint:
Engine cuts out when air conditioner operating in deceleratioo mode when clutch is depressed, but can be
started again immediately
Cause
Insufficient idle speed air in deceleration mode.
Remedy
Replace CIS-E control unit.
The control units have been modified as from production date 172 (December 91 ).
Complaint:
Poor throttle response, occasional misfiring, poor idling, engine backfires into intake manifold
Cause
Distributor fmger sparks over or has cracks.
Remedy
Replace distributor finger.
Complaint:
Engine dlfficult to start (long starting time)

Mercedes-Benz
Cause/Remedy
A starting time ofup to 4 seconds with the CIS-E fuel injection system is system-related and should be regarded
as normal. When starting engine, ensure that the throttle is oot depressed .
Complaint:
Eogine does not frre on all cylinders (rough)
Cause
l . Injection valves leaking.

2. Zero position of air flow sensor plate not in order, fuel distributor.
Remedy
l . Check injection val ves, replace if necessary.

2. Check zero position of air flow sensor plate (see 07.3-1612).
Unbolt all the fuel injection lines at the injection valves and at the fuel distributor. Remove fuel pump
re lay and bridge two terminals 30 and 87. When the air flow sensor plate is in the zero position, no fue!
must flow out at the pressure outlets; test fuel distributor and replace, if necessary.
When the air flow sensor plate is deflected, fuel must flow out simultaneously at all the pressure outlets
of the fue 1 distributor; replace fuel distributor if necessary.
Complaint:
Engine cuts out suddenly and starts again after a short time
Cause/Remedy
As it is very difficult to determine the cause ofthis complaint, perform the following checks:
• Check the connections at the ignition coil.

• Test cable terminal TD for occasional short to ground, e. g. at diagnostic socket, at tachometer, at
connection of fu el pump/AC compressor cutoff re lay.
• Check the contacts of the connectors of the fu el pump re lay, overvoltage protection with a gauge (e. g.
individual pin of plug); press together widened contacts. Check the connectors of the fu el pump/AC
compressor cutoff relay for signs of moisture and corrosion. Clean connector if necessary and replace
relay.
• Check position sensor for open circuit by moving the cable at the sensor or at the plug connection; replace
if necessary.
Complaint:
Mercedes-Benz
Engine cuts out when driving, can no longer be started
Cause
Cable of oxygen sensor occasionally touching propeller shaft resulting in short to ground.
Conductor path in fuel pump relay burnt through.
Remedy
Replace oxygen sensor.
Ensure that the cable is correctly rooted.
Replace fuel pump relay.
Complaint:
Engine cuts out when decelerating
Cause
l. Electrohydraulic actuator.
2. No road speed signa! from speedometer to CIS-E controlmlit
Remedy
l. Test electrohydrauhc actuator, replace if necessary.

2. Connect multimeter to connector of CIS-E control unit, contact 29 and ground.
Switch on ignition. Move car forward and back Specification O -12 V without electrical components, O-9
V with electrical components such as cruise control, temperature display. Check whether Hall sender on
rear of speedometer is installed. Check cable routing from Hall sender to connector (X26), contact 11.
Test plug connection (X53/5) (loose contact), install Hall sender ifnecessary, Prut No. 007 542 29 17 as
of production date 06/88.
Check cable routing from Hall sender to fuse 5, e. g. cable shoe not connected at fuse 5.
Manual transmission model124
Remedy (only vehicles up to end 04/90)
Detach cable from pin 28 CIS-E control unit connector to plug connection (X26) pin 10, at plug connection
(X26) and connect to ground.
On vehicles as of05/90 the cable from the CIS-E control unit to plug connection (X26) is no longer fitted.
Mercedes-Benz
&.oan<>erl
Use ohmmeter to check that the cable to the CIS-E control unit pin 28 is connected to ground and not the cable
to the ignition starter switch (S2/ 1) otherwise this will result in a short circuit.
Complaint:
Engine sometimes does not start, or cuts out
Cause
Position sensor for activating the ignition system has occasionally open circuit or short circuit to ground.
Remedy
Test position sensor, replace if necessary (see 15-2133 or Diagnosis Manual Engine, Volume 2).
Complaint:
Poor hot starting
Cause
Fuel accumulator with insufficient holding pressure installed.
Remedy
Check part no. of fuel accumulator, correct part no. is 000 476 09 21 or 10 21. Ifpart no. is not correct, replace
fuel accumulator and fuel pipe 129 470 05 64.
Cornplaint:
Vehicle occasionally vibrates between 140 km/h and 160 km/h (only brief misfiring for about 0.3 s)
Cause
CIS-E control unit. Only on vehicles with the vehicle ident end no. as listed below:
124.0311B 473 729
124.051 lB 469 543
124.091 lF 180 767
129.061 lF 032 455

Mercedes-Benz
Remedy
Installlatest version of CIS-E control unit, recognizable from part nos. which begin with O11 ....
Complaint:
Poor output (engine at operating temperature)
Cause
EZL/ AKR resistance trimming coupling, possibly wrong resistor installed.
Remedy
Check resistances of EZL/AKR resistance trimming coupling from table; if difference exists, replace resistance
trimming coupling.
Resistance trimming coupling Part No. Resistance ohms

015 545 67 28 (with KAT) 2400
015 545 68 28 e® version) 1300
015 545 70 28 (without KAT) 470
Complaint:
OccasionaUy poor output wben starting off and at outside temperatures >+30 °C
Cause
Ignition control unit, sharp retardation of ignition at outside temperatures >+ 30 oc_
Only vehicles affected up to vehicle ident end no. listed below:
124.031 lB 473 729
124.051 lB 469 543
124.091 lF 180 767
129.061 lF 032 455
Remedy
Install ignition control unitPartNo. 010 545 95 32 as ofproduction date 068.
Complaint:
Mercedes-Benz
Poor output when starting off at altitudes above 2000meters
Cause
EZL/ AKR ígnition control unít.
Remedy
Replace Boscb EZLIAKR ignition control unit with Part No. 010 545 39 32 up to production date 946.
Read fault memory in CIS-E control unit and erase, ifnecessary.
EZL/AKR IGNITION CONTROL UNIT

IEngine Part No.
Engine running complaints
In particular sporadic cutting out of engine may be caused by different factors. The following test catalog
enables faults in the different operatíng states to be specifically detected and rectified. The operating state in
which the engine cuts out is particularly important for determining the remedia! measure to be taken.
The test steps should be conducted in the order stated.
Perform the tests as specified in the Diagnosis Manual before working with the test catalog.
Complaint Remedy
l. Contacts at connector of air flow sensor position indicator widened. Press
contacts together, replace socket Part No. 003 545 26 26.
2. If knocking lightly on overvoltage protection causes engine to cut out or
misfire, replace overvoltage protection.
A. Engine cuts out
when idling: 3. Check whether 4 mm contact of cable to crankshaft position sensor is
widened, press together ifnecessary.
4. Idle speed adjuster modified as ofproduction date 951; up to 950 test
intemal resistance. R = 7.5 -10 ohms and measure current at idling I = 600 ±
SOmA.
l. Ground cable at intake manifold andfor suspension dome loose or corroded.
Unbolt cable, clean and bolt on.
2. No road speed signal at CIS-E control unit, pin 29. For remedy see Diagnosis
Manual Engine, Volume 2.
3. If battery voltage exists at pin 28 of CIS-E control unit when starting (only
model124 with manual transmission), separate plug connection (X26) víolet
cable and connect to ground.
R Rnllíne cuts out 4. Tdle sneed conta.ct or deceleratíon fue! cutoff mi croswítch occasional lv not
Mercedes-Benz
after decelerating: closed in idle speed position. Adjust throttle control.

5. Contacts ofterminals 15, 30, 31 or 87 at overvoltage protection widened.
Press together contacts.
6. Check whether 4 mm contact of cable to crankshaft position sensor is
widened, press together if necessary.
7. M ove cable of crankshaft position sensor to EZL ignition control unit. If
engine cuts out when this is done, replace position sensor.
8. Test electrohydraulic actuator, replace ifnecessary.
Complaint Remedy
l. Ground cable at fuel pump loose. Attach ground cable properly.
2. Cables of terminals 1 and 15 at ignition coilloose. Tigbten cables.
C. Engine cuts out when 3. Move cable from crankshaft position sensor to EZL ignition control
driving ata constant speed: unit. If engine cuts out when this is done, replace position sensor.
4. Check whether 4 mm contact of cable to crankshaft position sensor
is widened, press together if necessary.
5. Test EZL ignition control unit, replace ifnecessary.
l. Ground cable at fuel pump loose. Attach ground cable properly.
2. Contacts ofterminals 15, 30, 31 or 87 at overvoltage protection
relay widened. Press together contacts.
3. Cables of terminals 1 and 15 at ignition coilloose. Tighten cables.
D. engine cuts out when
accelerating: 4. M ove cable from crankshaft position sensor to EZL ignition control
unit. lf engine cuts out when this is done, replace position sensor.
5. Check whether 4 mm contact of cable to crankshaft position sensor
is widened. Press together if necessary.
6. Test EZL ignition control unit, replace ifnecessary.
Complaint:
Combustion noises (except ~)
Cause/Remedy
Since April 1991 an EZL ignition control unit with a modified ignition map anda modified CIS-E control unit
for the adjustment range of the inlet camshaft have been installed as part of further engineering developments
with the aim of reducing combustion noises (see Notes 15-2093 and 07.3-1698).
Replace EZI ignition control unit and CIS-E control unit. The CIS-E control unit must be installed only with the
relevant EZL ignition control unit.
Complaint:
Mercedes-Benz
Fuel pump loud
NOTE: In dealing with the complaint "Fuel pump loud" it is important to distinguish
between whether a buzzing sound ora clinking noise is heard.
Remedy
a. Buzzing sound insíde car (transmission of structure-borne sound)

l. Check whether the fuel pipe is in proper condition and is laid free of kinks.
2. Check whether the straíner in the feed connection of the fu el distributor is fouled (hígh
backpressure increases noise level).
3. Install Knecht fuel filter (if not already fitted).
4. Re place fuel pump. As of productíon date 642 wíth shaped track.
b. Clinking noise
l. Replace fuel pump (worn).
2. If this does not bring about a remedy, check drainplug and ftlter in fue] tank for signs of fouling.
Complaínt:
Determining faulty input signals in CIS-E control unit
Cause
Faulty input signals at CIS-E control unit.
Remedy
Use Lambda tester to determine faulty input signals by measuring On/Off ratio.
Then, perform test prograrn (see Diagnosis Manual Engine, Volume 2).
Complaint:
On/Off ratio cannot be set
Sudden increase in fuel consumption (about 2- 3liters)
NOTE: There must not be any leaks in t he exhaust system.
Cause
l . Occasional or constant faílure of oxygen sensor when driving.

2. Screened cable from oxygen sensor connector (G3/2x2) to control unit pin 8 has short to ground.
1 T.oosP. ~on t::~~t or o~~::~sion::~l onP.n ~ir~11 Í t M r.onnP.r.t or s iP.P.VP. 7. (solclP.rP.cl ~onnP.~tor in wirinP h::~mP.ss fmm
Mercedes-Benz
coupling of CIS-E control unít).
Remedy
l. Test Lambda control when engine idling (see Repaír Instructions Engine Combustion, or Diagnosis
Manual Engine) and on the dynamometer in upper load range or when driving (readout must fluctuate). If
the readout on the Lambda control tester moves slowly against the stop on the ríght in the closed-loop
mode, the oxygen sensor must be replaced.
2. Separate plug connection (G3/2x2) for oxygen sensor signa] and also unplug coupling at CIS-E control
tmit and measure resistance of contact 7 to contact 8.
Specification: infinity ohms (< 10 k obms)
If continuíty exists (< 1 ohms), replace engíne wiring hamess.
3. Open coupling of CIS-E control unit (N3) and re-solder connector sleeve Z (soldered connector in
hamess) at contact 7 (co ld solder point).
Comp laínt:
Diagnosis with fault storage (pulse readout at CIS-E control unit, engine systems control unit EZL/AKR
ignition control unit)
Cause/Remedy
NOTE: The pulse readouts stated in the table are stored faults although no faults are
present in the systems. They should therefore be ignored.
&oancaerJ
The engine must be conditioned frrst of all in order to read the fault memory of the EZL/AKR controltmit. See
Diagnosis Manual Engine, Volume 2, Engines 104, 119 CIS-E in the colunlll "Pulse readout".
EngineCIS-E control unit (pulse Engine systems control EZL/AKR. ignition control unit
readout) (pulse readout) unit (MAS)(l) (pulse readout)
104 8 22(2) 2 and 3
(l ) MAS can be diagnosed as of standard installation calendar week 27/89, in order as of part no.
Engine Part no. w/o AC compressor Prut no. wíth AC compressor

104 011 545 82 32 011 545 83 32
119 0 11 545 84 32 011 545 85 32
(2) Only witb engine systems control unit 007 545 59 32 and 007 545 60 32 and only witb version
"witbout KAT".
Boscb ignition control unit 007 545 70 32 in order as of production 946, Siemens ignition control unit
Mercedes-Benz
(3) 007 545 71 32 as ofproduction date 27/89.
Complaint:
ASR indicator lamp lights up when driving and electronic accelerator pedal moves into emergency
running mode (difficult to depress after short idle travel)
Cause/Remedy
l . Check production date of control unit (see Fig.)
Control units with production dates from 16/88 up to 43/88 must be replaced wíth a controltmít as of
production date 44/88 (identification: yellow dot) if this fault occurs.
2. Check throttle controllínkage, adjust (see 30-1010 , Section "B").

3. Replace potentíometer (R25).
Fig. 133: Locating Control Units With Production Dates
Complaint:
Engine misfires around reserve fuel quantity and when cornering
Cause/Remedy
Model124 Sedan, Coupe.
Install new fuel tank.
Complaint:
Clicking noises. Fuelleaking {smell offuel), compressed. Only with fuel evaporation system
Cause/Remedy
Mercedes-Benz
Insufficient ventilation of fu el tank through fu el evaporation system.
1st Cause
Poor routing of hoses in left front wheelhouse (kinked, crimped).
Remedy
Remove bulkhead at left front wheelhouse. Check visibly and also whether hoses blocked (not with compressed
air). Rectify fault.
2nd Cause
Activated charcoal filter is blocked or has insufficient clear passage.
Remedy
Blow tbrough 10 mm 0 connection to 8 mm 0 connection at activated charcoal filter (not with compressed air).
At the same time hold 6 mm 0 connection closed. Compare with new activated charcoal filter, ifnecessary. If
insufficient clear passage, replace activated charcoal filter.
NOTE: Check fuel evaporation system (see Diagnosis Manual Engine, Volume 2).
Complaint:
Irregular, loud clicking or rustling after switching off engine after driving fast
Cause
Because of the twin-shell design of the front muffler and the high temperatures, stresses are produced when the
muffler cools down which results in this noise. A further cause is the high level ofheat radiated from the front
muffler to the shield.
Remedy
A remedy is not possible on the basis of current state of engineering. The fault has no effect on the life of the
exhaust system.
Complaint:
Catalytic con verter makes noises, monolith in KAT loose
Remedy
Install catalytic converter system 124 490 95 19 (LHD) or 124 490 14 20 (RHD), respectívely.
Mercedes-Benz
Complaínt:
Front passenger footwell heats up because of catalytic converter
Remedy
l . Check clearance of heatshield (above catalytic converter) to underfloor of car. Specification: 8 - 1Omm;
adjust clearance if neces.sary.
2. Lay glass fiber mattíng, Part No. 000 989 18 1O below foot mat (only available in square meter sízes).
NOTE: Model124 RUF/KAT: Glass fiber matting in front passenger footwell fitted as
standard since 07/88. Production breakpoint as of vehicle ident end no. A
798379 B 082239
Complaint:
Trunk floor heats up in the area of the left wheelwell
Remedy
• Check clearance from tail muffler to heatshield (specification about 25 mm) and from heatshield to
underfloor of car (specificatíou approx. 10 mm); adjust ifnecessary.
• Modified insulation matting in left side oftrunk (Part No. 129 680 09 25).
Production breakpoint 02.03.90.
• Floor covering oftrunk (part no. as previously) with insulation liner on underside.
Production breakpoínt 01.02.90.
TECBNICAL MODIFICATIONS ENGINE 104 COMBUSTION CIS-E INJECTION-

RA07031 04T AOOX
07.3 Mechanically/electronically controlled gasoline i njection system (CIS-E injection)
Designation Nature and reason of modification Production Op.No.

breakpoint
Fuel inlet screw Material modified 01/90 07.3 -1674
connection
Throttle valve switch Improvement 08/89 07.3- 1689
CIS-E control unit Software modification (no further fault 07/89 phased-in 07.3 - 1698
signa! when driving at high altitudes)
Injection valves Opening pressure increased to 4.3 - 4.6 - 07.3 - 6500
bar
Val ve seats made of Viton - 07.3 - 6500
Mercedes-Benz
Return spring on Number of coils modified. 10/89 -

throttle val ve Length ofwire 50 mm 12/89
housing 59 mm
CIS-E control unit Matching for secondary air pump and 08/90 07.3 -1698
exhaust gas recirculation modified
CIS-E controltmit Program modification at control unit: 09/90 07.3- 1698
current specification at
electrohydraulic actuator is now
available without time delay
CIS-E control Combustion noises 04/91 except ~ 07.3 - 1698
unit/EZL ignition Programmed Repairs
control unit
KE F UNCTION DIAGRAM- RA07031190003X(07.3-0003)
KE Function Diagram
Mercedes-Benz
N3
«>
1 MIXturo ronlrclu11t K29 Tran smJSSion sh~rli retard rel!i'f

40 Dlaptrngm p~assure rag~Jialll L5 Cranksh~ pcsiion sens«
50 Fueltank L511 Cemshaftpcsm~n sens«
51 VootvaM! M3m1 Fuelpump1
52 Ac,valld charcoal c-anJStllr M3m2 Fuelpump2
5l Regenereoon vatva N113 EZL!AKR G«úol U1rt
55 Fuelllfll N3 I<Ecomolural
57 Fuel aOOJrrull!:Dl N16 Eng~ne s')Smms conrolulliHMAS )
89 Exha!Jst gas raarrula5cn vaM3 R18a EZl/AKR re51starrcatnmmng cooptng
123 Thrcll& VBNe assembty R17 KE reSista;Ke tnmrrung pkJg
125 Alrpump S 1tl/1 staltor lcd<O'..Ii andrewtsmg lighl st~itch
126 An shutcl 'Ya've 52912 Thrctie valva st.~tch
127 Chotk vaNo {l flOtÜO!l ai.r) T1f1 lgnilioo eoi 1
128 Chock vat;<e (vawJm) T1f2 lgn\bon Goi 2
156 Bdlaustmarifold Y1 Elec~oll¡drmlic ad!Jator
158 Catat¡bc corr.rerter Y6 ldle speod aqustar
A1p8 Elocrcric ~atar YB Startmg val•e
1\9 f!.Jr cooáilionng C>OOJ!lfessct Y27 Exlloost gas rearru!a3on swtchc\1!1 v!We
A16g1 Knod< sonsor 1 Y32 AJr pump S'r.llchoV!ll VaMJ
A15g2 Knod< sonsor 2 Y33 AJr pump e!ertromag1abc cUál
82 Alr ftow sensor pcfelliome:S. Y49f1 LeltGemstl~ ccrircl actuator 1
81 112 Coclanl mmperatua sensor Y49f2 Rigft ca."TT sha.ft c<lárol actua!or 2
Mercedes-Benz
Fig. 134: KE Function Diagram
TECHNICAL MODIFICATIONS ENGINE 119 INJECTION COMBUSTION KE- RA0703119TAOOX
07.3 Mechanical/Electronic Gasoline Injection System (KE Injection)
O p. Designation Nature and reason for modification Production

no. breakpoint
07.3-
Fue! feed screw fitting Material modifted 01/90
1674
Hose straps for shaped hose
07.3-
between idle speed adjuster and To prevent shaped hose slipping 10/90
2118
air flow sensor
Modification to control unit program: specified
07.3-
KE control tmit amperage at electrohydraulic actuator is now 09/90
1698
available without time delay
07.3-
KE control unit Idle speed increase for increasing charge capacity03/91
1698
VEIDCLE FEATURES- RA0703KE10004X(07.3-0004)
KE KEl KE2 KE3 KES

designation
Engine 102.961/962 102 102, 103, 116, 117 104, 119
EZL Engine 116, 117
lgnition TSZEngine
TSZ performance-boosted: EZL-AKR
system 102.983: EZL
EZL-AKR
lgnition
system only engine
No Yes Y es
resistance 102.983
trimming plug
o with 55-pin
connection
o digital version
with mixture maps
activated by
resistance
trimming plug
o with 25-pin o start recognition
connection vía terminal TD
o Digital version o plausibility circuit
o with 25-pin o witb 25-pin with mixture
connection connection maps activated o lambda control
o analog o analog by resistance o active charcoal
KE control versíon versíon tri mm in!! nln!! fí lter re!!eneratíon
Mercedes-Benz
unit o start o start o start recognition o data interchange

recognition recognition via terminal TD with EZLIAKR
vía terminal via terminal o plausibility ignition control
50 50 circuit unit
o lambda control o camshaft
withKAT adjustment
verswn o maximum speed
control
o air injection
o exhaust gas
recirculation
(engine 119)
KE KEl KE2 KE3 KES

designation
o as of approx.
1986 indefiníte
productíon
Fault breakpoint fault
recognition by diagnosis vía o comprehensive
No No diagnosis and fault
KE control on/off ratio
unit memory
o Engine 102.96/98
as of09/89
additionally fault
memory
Injection
system
No No Y es Y es
resistance
trimming plug
o fullload
contact
o Engine
Throttle valve 102.983: fullload and idle speed fullload and ídle speed
fullload contact
switch fullload contact contact
and idle
speed
contact
o via fuel pump
re lay
via thermo time
Start valve vía fuel pump o Engine 103.984: vía KE control unit
switch or fuel pump
actuation re lay v1a engme
re lay
systems control
unit
Mercedes-Benz
ldle speed
stabilization with
AC compressor or o Engines l 02, 103:
automatíc idle speed control
transmission integrated in KE E . . _ 'dl
Idle speed control .t ngmes 104, 119 . 1 e
Idle speed centro l um . .
integrated in KE . speed control mtegrated
de vice o auxi liary air o Engmes 116, 117: in KE control unit
control unit
valve own control unit
o idle speed for idle speed
adjusting control
screw
KE KE KE2 KE3 KES

designation 1
o Engines 102, 103: o Engine 104: single-
Two-winding rotary single-winding rotary winding rotary
Idle speed positioner with 3-pin positioner with 2-pin positioner with 2-pin
No
adjuster connection and bypass connection connection
adjusting screw o Engines 116, 117, 119: o Engine 119: baffle
baffle plate positioner plate positioner
Further Engine 103.984: engine
features
- -
systems control unit
Engine systems control unit
FUNCTION DIAGRAM KE INJECTION SYSTEM - RA0703KE10010X(07.3-0010)
A. Engine 102.961 Standard

Mercedes-Benz
R21
IP07-0672·S9 >ot ·cr~rl •• 1

82 Alr nowsensor poSitoo 1nclce!or 1 Mroure contolunt
8 11/3 CGolant temporature sallSor 2 J.Jr llow sensor
M3 Fuel pump 15 F ual dtsríbutor
N1f1 TranSI~onzed 1gnioo oonrol urll (f5Z) 40 Olaptragm presst.Je r~lallr
N3 KE irf8tion sys!am cortroloot 55 FuaUier
R21 AUld a¡y BIT valw haallng COII 57 Fuel acourrularor
526 Tnermo tl'ne S'Midl 75 Fuellan!<
527/2 Dncol fual ruott fTII( rosw~dl 92 ..ec• oo va:.o
52911 Thr<> e \'ltlla S'•lltch, i.llload r~K ogrlton a Vant
Y1 Elocroh¡lctal6c tKtuelor b l eal< •ne conne CI!Ofl
va start 1/alve
Fig. 135: KE Injection System Function Diagram - Engine 102.961 Standard
B. Engine 102.983 Standard

Mercedes-Benz
82 Au llcw sensor OOSitcn 1n<1cator 1 Mom.e toolroiUilil

B11f2 C~ lllmperelu"a S811sor z An llcw SQJISOf
M3 FualjliiTlp 15 Fuel dsrtlt!ilf
N1f2 EJed·ooc IQI'lilon (EZl) corirol~.nl 4{) Olaptrngm Pf8SSIS8 leg\ll8illr
N3 I<E u¡acíon system coriroltnl 55 Fuelilw
N161'1 Fualpumprslay S7 Fuel scrurrulaior
S27fl O;¡celtuol ruoff mkrosNich 75 Fueltank
S29f2 liYolle \'!ltve SMtdl, i.IJIG&dfldle speedrecognbon 92 "t:ec•on lltlt;g
Y1 Beo~: ..oh)ldteUic sctuator a Vent
Y6 kle spe ad ad¡us.ter b le!lk too coonacbon
Y8 Sart\'atv'e
Fig. 136: KE Injection Svstem Function Diagram- Engine 102.983 Standard
C. Engines 102.96/98 KAT/RUF 09/88-09/89 l:lJ KAT, ~BT KAT 1989

Mercedes-Benz
R17 0
86C
Y51tCJ-- -- I
(
;¡~·n
LSD
Nl/l _1
(O
- H3
a: ~
l58
p
P07~06l5-57 POr- OG1ll-!7
62 1\irllaw ;,onsor poS1ficn tndica~or YS/1 AC rompmswr lllaclrorna"QnebcdJ:dl

86 HaJ. olact sp&ed seJ'Isor Y6 klo spe&d ~er
81 1!2 Coolart tempembn sensor (EZUI<E) YS Start \'atv-o
817!2 lrtake al! tsmoeratur e sensor (KE) 1 MlXl!Se conrol urnt
G312 Hea!ed Olcygen sensor 40 IJiaph-aíJITI pressu-a r091Jia~
l5 Cmnkstlel poSi•on tndica!or 55 Fuelliler
M3 Fuel pump(moóels 124 081/083twofuelpumps) 57 Fuel accu!TlJia~r
N 1f2 Bed•ooc ~gnilíoo {EZL) control mi 75 Fueltmk
N3 KE tortrol Ult 76 V9111Va!YB
N100 Fuel pu-np r elay 77 Actve elwcoalfti:sf
R1 7 KE roSISianto tnmmng pi!J!) 78 Rogon em!ion valve
S27f2 ()e(;elfuel cl.lolf miC rosNild't 79 70 ·e thermo vaMI
52912 Ttllotle vaNo SW1Ich, tJI Ioadl'l dospeedrecoglllbon 92 tfedonvaMI
T1 lgrrbon e cil 157 Pr~cabYyic coowrla1
Y1 Becroll¡draúlc actuelor 158 Utdelfloor calat¡bc COI'fllflrter
a Cable rot.bng on T modal
c AiradmESscn
Fig. 137: KE l n jection Svstem Function Diagram - Engines 102.96/98
D _ Engines 102.91/96/98 KAT as of 09/89 ® tlJ KAT ¡g] ~ BT KAT as of 1990

Mercedes-Benz
N3
~
B2 P.lr flow sensocpostion 1nticalo{ W3 Ground, rrontreltv.tlaelllousa(tgt~ilon ood)

B6 Hakffect speed sensor W6 Ground, klltwhefll1ouse11 truli< (&lailamp)
81112 CcolanttOITperaálro soos«{EZl.IKEJ2 E-E) Y1 Eleclrohiclndc actuatoc
(4ilfll) Y5f1 AC oompro-sscr olectrornagnebc ó.ld1
81711 lntake lllrletrll«IWre sensor (EZL) Y6 lite speed adjuster
G312 H!Ul~d OX't'!)Oil S811S0r (~11 K AT) Y8 Start \'lllva
1 MlJ<turo ton'ioiUrJI
Engme 102.91~ m exhaust Jl!Pil
2()
Engll1&102.91 0'pre<ataty!K corwerter for @ ·
K311 lntake Blr prehna:er (PSV) ro!ay •
K29 Tr1lllSITltSSioo shftpout retard relay • re.sonsiorfor @
LS Crari<Sha.'l posrbon sensor
M3 Fuelpunp 40 Dlaptragm pressu-a regullmr
N1/2 EZl 1gnbon cMroltnl 55 Fuoliler
N3 KE llJOCtiOn sysl!!m cortrol uni 57 Fuol acculliJIBlDr
74
N16/3 Fuel punp rela'J Fuel ccoler@ Q)@
R812 lntake Blr prohe<!'.ar(PSVT
R16 EZlresu;tance tnnmmg plJg 75 Fuol tank
R16/1 76 Venlvall'll
EZl r&l9l811C:Oroslstcr @>
77 Aclve chercoalfi!Br
R17 KE 11¡edion syslsm reSistanc e lllmmng plJg
78 Re gen eratlon valve
R1711
KE ll)Bdlon system retflli81lcereSI!it()( <§> 79 70 ·e lhermo vaMI
S25113 so 'CI55 •e ISflllera'llro Si\ltm(panallltake 92 ~ecionw.n
maofold prehe1!!er)' 158 Uldedlocr catM,óc corwerter
52712 O&celfuel culDifmlcrcsWlll:h e Alf admiSSIOO
S2912 Throtlo v&Ml swtm, fui load! de spoad roc>01J1ibon
orty KATl.l-0
T1 9\.. 00COII
Fig. 138: KE Injection Svstem Function Diagram- Engines 102.91/96/98 KAT
E_ Engines 102.99 KAT as of 09/88 ~KAT , n:::r'BT KA T , ¡gj as of 1989

Mercedes-Benz
82 /IJr llow sensOf pos6oo tndicalor Y1 BenOO;tcka\ic aci!Ja!Of

86 ~o'ed sp&ed sensor YS/1 AC compressor olectromagnebc wdl
81 112 Coolali !llrnl}erame soosorCEZlll<El Y6 lelo spu<l acf!US!er
81 7(1 Wal<o au t!lmpomlure sonsOf ( EZl) Y8 Start \'atvo
81712 Weke au álmpoflllll o sensor {KE) M~eoonrolurnt
G311 Hae\ od Olt)'gen soosOf 40 Ole¡¡Ml!!ffi prassure rog<Jia:oi
LS Cranl\shC: l}()Slí on sensor 55 FuoUler
M311 Fuol pump1 57 Fuol aocwrula1D!
M3/2 Fuel pump2 75 Fuell&nk
N112 Elot!r()(lt lgilillon cil~Wol unlt (EZl) 76 Venlvalw
N3 KE COrtrollJ\11! 77 Ac~vachBKoafitllr
N1614 Fuel pumo relay and l«ckdc•,-.n 78 Rogoo era!JOI'l vaNa
R1 7 KE rsStslante lrimming ptJg 79 70 ·e lherlll() vaMI
S2712 DKelluBI atotf m K roswl cil 92 ttadonv1lMI
SZ9!2 Ttro:Ha v"!Wo soN!tth, i:JIIoadlíclespeed r ocogníbon 157 Pro-ca.t~c oonwrt8l
T1 lgriboncol 158 l tldelfloor cal&\ót CO!MIItor
e Aír admiSSIOO
Fig. 139: KE lnjection Svstem Function Diagram - Engines 102.99 KAT
F. Engine 102.962 NV KAT/RUF 09/83-09/85 ¡g] 1985/86 ~ 1984 Engine 102.961 (2.3) , ~ 1985/86
Engine 102.985
Mercedes-Benz
- -
,. . ...
..... 4 ...
~ - - - - -- --,
j~ , - - - -t·W·
lw10
~~
P07-0406-5i7A
ptJ J ; I Ut: • ~!ITa
611/3 C-oolad lemperabse sensor 12 ttake ml!l'lfold

G312 HGB!ed oxygoo sensor 15 Fuel <SStlluU!r
G3f2x1 Pllgcomedon, ()Xfgen sensor heabng cotl 33b Uldellloor catal¡bc COIY!lltef
G3f2x2 Pllgcomedon, oJr¡gon sonsor 51!Jllll 50 Fuellank
N3 KE e!ecioriic corVo! ool cat4ling 51 Ventva.'w
S512 Breakerless álsrilutor 52 Acive charcoalfitor
S27f2 Oecel fuel atoff mKrosw~d1 53 Regen orabon valva
529!1 Ttrotia vatva swtd1, i.ll load recog1ion 79 50 ·e thermo vaMI (r od)
W5 Groond, eng¡ne 156 Elchaust marifold
W10 Ground, balte¡y 158 Uldillfloor catat¡«Jc COIY!llter
Y1 Boctoh(draúic aclua!01 a Aír adrmsSion kle(engn-.o compartment)
MIXt!Eo contolunt b Fuel punpretay, c.ortact 2
2 so •e lhermo valva (wli!B) m klo speed adjusler, cortoct 2
3 Non-rotun valole 'Mih tctegaled resmellon Fuel punprelay, cortact 7, tell'!lJ'lal B7
- . - - ... .. - - - .
Fig. 140: KE lniection System Function Diagram- Engine 102.962
G. @ 1984- 86 Engine 102.961

Mercedes-Benz
IP14-0064-57 PIMHUl 1
Exhaust gas rec lrculatlon (ARF} compo nents

Alr lnje ctl on compo nents
A ComeCI!Oil
25 Alrpunp
B Gomodlcn
26 Pres sur e roief v;We
N.37 ARF conrolunt 28 oarrc>er li :sr
S29fl Thrctlo me s.-.t~tth 29 Non-rel!m valva
Y27 .ARf swtthcver vBÑe
32 C~nd&head
1 lrtiako m¡;n¡fold
2 TtroS!e v;We bo<f1
3 Au gude hous11g Fuel eva.poratl on aystem components
g V&lJI.Jlll darrpor 2 ThroUia valva bo<f1
31 Exhaustmanfold 50 RJel tarl<
36a 40 •e lhonno \lllM 51 Vert \'llÑe
44 Non.{a!Uin v.Wo 52 AdllllHha;roal filter
60 ARFvaM! 53 Regonor¡¡ on valYo
73 Var lJI.Jlll cortrol vaMI Alr alinlss!Oll
74 ExhaucS~ ges ro.oJUJia~on i ne
Fig. 141: KE Injection System Function Diagram- 1984 - 86 E ngine 102.961
H . [l] n=:r er 1984/85/86 Engines 102.96

Mercedes-Benz
P14-0053-57
Exhaust ;as reclrculatlon (ARF} compo nents
A Comedlon 3 Alr ~do hoomg
B Comedlon 9 VaciU\'1 dliJTl}Gr
CID Dlstnbúor 31 ~& mMfold
N37 ARF con~olun¡t 36a 40 ·e lhermo vaMI
S2912 Tlrotle vatve sv.itál 44 Non-flltl.rn \'lWe
Y27 ARF swtálOVBl \lllt>le 00 ARFvaM!
1 lrtake m!ll'lltlld 73 Vscwn corboiV!lM
2 Tlro!le vaNo boá¡ 74 Exhau&gssrearrul~onane
Selfinduction system componente

29 Non-n!l\.m vat{G
31 Eld1l;u stm anrold
38 Alr do.aner
Fig. 142: KE Injection Svstem Function Diagram - 1984/85/86 Engines 102.96
L [l] [!rBT 1985/86 Engine 102.982

Mercedes-Benz
29
..J••
P1~0065-57
Exhaust ;as reclrculallo n (ARF} compo n ents

A Conn&diOO 9 Vacuum damper
B Comodioo 31 Emaust ma!llfolcl
N37 ARF C'Ofllrolurrt 36a 40 •e IMITTlo vr;.'vo
S29.12 Thro~ ~e S'Mtcll 44 Noo-rellm valva
Y27 SNtdlOVBf Vft./e 60 AAFvatve
1 hakD m81'llold 73 Vawu;n comol v.a"ve
2 Th:o!lo vatve bo<t¡ 74 EmeiiSI gas recnúaboolne
3 Air gude hoos11g
Selr lnductlon system components

29 Oowe noo-rell.rn va.We
31 Emaustmatlilold
38 Au dean 9f
Fig. 143: KE Injection System Function Diagram- 1985/86 Engine 102.982
J. ~ 1991 E ngine 102.985

Mercedes-Benz
M3
A1e2S CHECK EI'JGi',JE ind.ca:Or lamp S29/2 TI'Jol!lo ~<Wo sNJWl, illbadlid!B spasrl rncognillon
82 /lJJ llcw sensor poSI•oo uúcator T1 IQntJoncci
se HaS-efod speoo sensor Y1 BecrOO{álúc acllJator
81112 Coolart tomperalu'e sensor (EZl.ME/2 E-E) Y511 AC comprassor eloctrornagneic ~::eh
(4-J)fl) Yó lelo spee:d adjusler
B17t1 klak8 /Jr IBmpemtl.fe sensor {EZll Y8 start wt.re
821 Eld1irust gas reorrul&~on fARF) tomperaruros8flsor 1 Modue coorolurit
(Calfoma crty) 40 Olaptragrn pressu-e regulét!llr
G312 He atad Olrf900 sensor 55 Fue!Uer
K3.11 Wake marilold preheOO!f {PSV) reley 57 Fue! acrumula!Df
K29 TIB!lsmiSSIOO sMt pout re!Bfd relay 75 Fuellailk
LS Cmn~at poSitoo sensor 76 VenlvaMI
M3 Fuelpunp 77 AcliveJ:harcoalhrBr
N1f2 EZL•gn•on conrolunt 78 Regenembon VIWe
N3 KE iqedon system eortroJ lrit 79 70 •e lharroo valw
NB AC cornpressorru!olf cortrolmt 89 Eld'tB!lsi gas r eorrulaton vaMI
N1613 Fuel punpreley 92 ~&ion va\11
R8/2 lríBko maafold prelleat!ir (PSV) 94 Oelay va'Ve (crty wtil m8111.131 ttllllsm ss10n )
R16!1 E2l. referencs reSistor 158 Uldolfloor ca!al\bc corwedm
S25f13 60 •ctempoo¡t¡n swtch (PSV) e Aír admJSSIOO
52712 Oecelluel ruoff mJC rosi'ILch
Fig. 144: KE Injection System Function Diagram - 1991 Engine 102.985
K. Engine 103 KA T [l] ~AP ~ BT @ 0 with air injection as of 1991

Mercedes-Benz
,. .. ~ ..,
A1p8 Electooc clctkAachomeler Y1 Elettol:tyltllúlc actuator
82 Nr flcw sooscr poSl•on tndlcelor Y312 Shlfl potrt relilld solenotd va!ve
81112 Coolalt lllmpemture sensor (EZlll<E) {4-ptn) Y6 lela speed a~er
81712 KE irte.clon ~cm utake Sir álmpem!ure SBflSC{ YS S!art \'!ilvo
1
G3f2 Haalod ox¡goo senSOf Y32 Air pump S'Mtchover vaMI )
1
An t~on~ansrnJS51011 sllfl potnl re\erd relay )
1
K1713 '(3,3 Alr pump e:omornegnel!c cltcll )
K35 Oxygan sonsor re!ay 1¡ 1 M:Ddure coo!iolulllt
a wa!t:s)
(haa~ng capecty ioc rea:serl to 1 40 Dlap!Tagn pressu-e re~la!Dr
l5 Crankstla2 poSiion sensor 55 Fuolliler
M3m1 Fual pump1 57 Fuol accurru!a~
M3m2 Fuel pump2 75 Fuollank
N1f2 EZL tgn¡ion coo=-ol unt 76 Ven!vaM!
N3 KE i!lEteicn sys.lem cortrol unit 77 Acivecha:coalf~
N6 AC ccrnpros sor ru!Oft e onrcl Ult 78 Regon eratton va.Vo
N16.C4 Fuel pumpandkiekÓO'M'Icttol role( 79 70160 •e lhem1o 1/!We
R16 EZJ.. !eSIS!BnCB lrtmmlng ~g 92 t];edonva!'.m
R17 KE lftedon syslem reSISliiiY.·Otnmmmg pl.lg 123 Thr~e 1/!We body
S1&11 125 1
Slarter lockO\J!andr!Mirslng lat!ll swich Air pump ¡
52712 Oecel fuel atoff mJCros•..vt ch 126 Air cu1oll vlt{e 1 )
S2912 Ttroale 1/!We st.~tch, iJIIoadficle sp-e&d recognbon 127 Non-terum v.wa (ifledoo a~r) 1 )
T1 lgnboncoi 12'8 Ncn-tnturn wlvo (vatUJm) 1 )
158 Cat~c c>Ofll/erter
Air admiSsicn
Fig. 145: KE lnjectioo Svstem Fuoctioo Diagram- Engine 103 KAT With Air Injection
1) only IIl o::!?'AP n:!i"' BT ® 0 as of 1991
L. Eogioe 104 KAT

Mercedes-Benz
r----· - - · --
A1p8
A16g1
EleárollK speedomelll!
l<ncck SOIISOf 1
Y32
Y33
Alr ptmp V!;(WTI '<!I'We
7-5942-57
Alr punp O:adromagllflbc eU eh

-
A16g2 Kno<k sensor 2 Y49 AdJ¡slablocamshaltllnJng oloctroma¡J~Qiic acllmx
82 AJr lcw sensor posiboo 111dicalor Y5a/1 Ragenemllons>t.~l!:hovervalve
8 11/2 Coolart temperabnl S8l'IS<X (EZU<E/2 E -E) Y59/4 was modlie d to K29, i"anSlmssion slil j)OI'ltratatd
8 17/2 KE ti'J&dlon systam trtak.a ar tamparatu-e sensor relay
G312 Ho!lledoxygen sensor 1 MlX11Ee coorollmt
LS Crark5haftpcsibon sens« 40 Oiapnagm pressu-s regulalor
L511 Camshaftposbon sanso( 55 Fuelilor
M3m1 Fuelpuflll 1 57 Fool accurrula!or
M 3m2 Fu el pufll) 2 75 Fool tMk
N1/3 EZliAKR tgnbon torúollllt 76 Venlvalve
Nl KE coorolun;t 77 Advs chert oal fii:Br
N1a Elgoo systems corúol unit (MAS) 78 Regen erabon va!ve
R16/2 EZliAKR reSistance tnrrrmng COI.!?IJng 92 t\,edoo va.'Ve
R17 KE rasiStanro nnmlngplJg 123 TlYoMe vat.le bOO¡
516/1 Slarter lockoutand revoss11glarnp SV\IIdl 125 Alrpunp
527/2 Dileel i.Jel ctiof mucs.\lldl, n. a. >t.~tl ASR 126 Alr aJIDtf me
529/2 llroWevat>le swlch, tulloi'IC!lde speed raco;pdoo 127 Nono~ebsn \'aoVe (ir¡Bctioo lli')
T1 lgniOOCOJI 118 Nono~&I!Sn valva (VaruJm)
Y1 EledrohydraUit sduatOl' 156 Exhaust marifold

YS kle speed ad¡uster 156 Catat,tlc oonverter
YS Startvalve e Alr adm sSton
Fig. 146: KE lnjection System Function Diagram- Engine 103 KAT
M. Engine 116.964/965 KAT with exhaust gas recirculation and air injection
Mercedes-Benz
P07-5880-59 POH IIIN I
A 1p8 8ectooc speedomo:Dl Y32 Alr puJlll swtch<Mll va:ve

82 Alf llow sensor poSI6oo indicator Y33 Ar PtJill' oleruomagnellc ct.ech
81112 Co"O!arn oompomture seOSOf {EZLJI<E) 1 Mnru e ecrool urít
G312 Heaíed o,.-¡gen sensor 40 Oillj)l'ragm pressureregUiator
LS Crenksll~ po51tOO SOOSOf 55 Fuolliler
M3 Fuolpunp 57 Fuol aoc urmiator
N1/2 EZL IQI'IiOO cootoiUillt 75 Fuol tari<
N3 I<Eir~edcns¡slemcomoiUlt 76 Verr!vatve
N8 ElR e orcrohnt 77 Acbve dlarooal U er
N1fi,l4 Fual pompood klckdo'Ml CU!ol re!ey 78 Regenerelloo wl~o
R16 EZl resiS!Bnce nnmllgpllg 79 so ·e ~ellTlov~te
aa; ~~~o. -.t!liwwAiQilfo'js!iwllliJI'sm~W....,ÍilmiWllltá9 89 Emausl gas roorcUabO!l v~e
S16f1 Sartor lockol.llandrewrsmg lal!1l sw-tdl 90 Cootolv!We
52912 Ttroll& V!We s.\litch, illloadli<fe speed reco~bon 92 ln¡ecbcn ve:ve
T1 lgRbon coi 125 All PtJill>
Y1 Be~lrohfdredíc actuator 126 Ar cutO: va:Ve
Y511 AC compres sor aíectromagoabc d:lch 127 Noo-relumvam ft11eci oo au)
YS Ido ·speed a~er 128 Noo-r~mvaM! {veruum)
Y8 Start va.'Ve 157 FlfB'Ne cai~c oonll9f1ef

158 Undedioor C~,1C COO'V9f1Br
Fig. 147: KE Injection Svstem Function Diagram- Engine 116.964/965 KAT Witb Exbaust Gas
Recirculation And Air I nj ection
Mercedes-Benz
N. Engine 117.964/965/968 KAT with exhaust gas recirculation and air injectioo
Mercedes-Benz
A1p8 Eledrol'lc s;¡eodomoter YS/1 AC compmssoc S!edromagoooc ctich

A1511 K ooct< SOOSOi 1 YS/1 AC compressor electrorn agMtM: cktch
1\1612 Knock Sensol 2 Y8 ld:e speed aQju&or
82 A.. flcWSOI'ISOi poSlbon lndcetOC va stelt~•e
81112 Coolanltorrpora'llre sensor (EZLIKE) Y32 Alr pump S 'Mil: hove• va've
81712 KE 11¡ocbon S')5tem 111akoe au tSfl1)eraiJre sensor Y33 Alr pump e!ectomagneic dllr.h
G31l Hoa:OO oxy,¡an sensor 1 M>WfD COOrol 1.1\'l~
l2 lnductlw road speed sen SOt 40 Dlaphragn prossure r~ator
l5 Cf~shart PQSIOOn sonsm 5~ R.lelfilof
M3/1 Footpunp 1 57 Fuelacrumu'atCf
MJ/2 Foot punp 2 75 Rieltark
N1/3 E ZlJAI<R ig~don con~ol u111t 76 Vert 1/llÑe
N3 KE 11¡edjoo systorn c-orool 1.1\'ll 71 Adlw cnarcoal fíitw
Na ELR coroot un1 78 Regenera~on v&M!
N16/4 Fool punp allá l<ld\dcwn cüoff relay 79 50/70 •e e"IOITTIOVBN8
R16/2 EZlJAKR reststanca hmmllgco\Jl)ling 89 Ellhaust gas recsatabon va~;e
R17 K E 11¡edlon S')5!Dm resastancetnmiTing plJg 92 t¡ealon w,'vs
5 1611 Slalier lockoU aml rove¡s¡ng lamp swCch 123 Thfollle vatoe OOCf
529/2 Thrctte vllMI sl'lteh, tul klad.lde !i,POsd recognDcn 125 Alr PtiTlP
S65 TrooS!msSion ovelload pcotealon s•M!J:h 126 Alr cúolf valva
T1 lgnbon COII 127 tJoo..retum vwe (i:l¡ac!ion alr)
Y1 Eloctroh)'draulc actua!or 12'8 Non-rerum \lat-le {vacuum)
158 Uldertoor e elaty11c e 00\IOOW
Mercedes-Benz
Fig.l48: KE Injection System Function Diagram- Engine 117.964/965/968 KAT Witb Exbaust Gas
Recirculation And Air lnjection
O. Engine 116/117 Standard and RUF version

Mercedes-Benz
A1p8 Be<lrooc speedomelBl X60/2 PlJgcomedon, OJII!!Illl sensor Signa!

82 AJr flow sensor pcSI•on mácator Y1 Bectoh{<húi c actual«
81112 Coolalt lllmpemlu!o sensor jr~¡edion s.,.stemrognibon Y511 A.C compres sor elodtcrnagr~eíc dJI.!:h
s¡stem) Y6 kJo speed a~er
81712 lrnake aar!Bmpera!lnsensor Y8 Slert va•fe
LS Cmilksha1 pcSII on S811SCT 1 MIX!UrB C>Onlrcluf'llt
M3 Fuel pump 40 Dl aphrogm pmssure rngula!Df
N112 EZL Jgn¡loo contol unt SS Fuelliler
N3 KE eoruol tnt 57 Fuel eccurrulalDf
N8 ElR cortrol tnt 75 Fuel tal'lk
N1&14 Fual pumprelay~'o!lh stan v!Wo acllaioo, klckdown 76 VontvaM!
rutolf and eng¡ne speed límibng 77 Aclve cha«O'alfJl!{
R16 EZL resiStallce nnm11gpklg 78 Regonomllon valve
R17 KE in,ecion systemreslstante tnrmung plJg 79 50 •e lherrro ~1/B
S1fhl1 staner lc"Ckou! andrevarsng larrp sNich
89 El<haust gas rearru'aion valw
S2912 Ttr~e v!We SMich for ldlo spoed and M load
90 Cortrol vaN&
re.:ogn&on
92 ll¡edonv¡¡M}
sss Tr!lflsmlssaon owrload PfO:&cton swi ch
159
T1 lrnflnn r ni
Frort mu=ter
Fig. 149: KE lnjection System Function Diagram- Engine 116/117 Standard And RF Version
NOTE: Engines 116.964 and 117.964 with double-pipe exhaust system.

Mercedes-Benz
Engine 116.965 with single-pipe exhaust system.
l.lJ ~BT Engines 116.964/965 with air injection and without fuel evaporation system. 40 oc thermo
valve for exhaust gas recirculation.
P. Engine 119 KAT

Mercedes-Benz
A1p8 Eledromr speadomel!ló Y27 Exhallst gas rcnrruta~on swllchow; vatv-e

A9 AC ccmpressor Y32 Air pump I'MUlJllli!W-a
A16g1 Knocksensor1 YSJ Au pump e!edrornagnOllc cUdl
A16g2 Knock sensor 2 Y49/1 BtKroma~eic aduelor 1, 1&ft a~stabkt camshaft
B1 AJr low sensor posibon l:ldlca~r llnlng
8 1112 Coola!í tomperalml sonsot (EZLf<E/2 E-E) Y49/2 Baclromagna~c adua:or 2, regl'll adj.JsiEblo camsha!
8 1712 IJntng
KE 11\&d!OO systom artak.e aJ temperatura sensor
Y58/1 R&gan amlioo S 'll!llthoV!If va/'(8
G312 Hea!edoxyga11 SOflSor
LS Cmrl<shaft posbcn seos« Y5914 was m<Xiliod to K29, i1lllSITUs-saon shit!)Ctrt ratero
rolay
l511 Camsh!>Jt 1>0 Slbon s enser 1 Mixture ron'olunit
M3m1 Fu el pufll) 1
40 0u1pmgm pressuro r1191Jia!of
M 3m2 Fu el ptlfll) 2 55 Fueliler
N1/3 EZllAKR ignbon cortrol tnl
57 Fuol acruiTlJII!IDí
N3 KE coo!Jol unrt
75 Fuol tank
N16 Eng¡oo systems oortrol uníl (MAS)
76 V8I1l va.'ve
R1512 EZLJA!<R r&Sistance tnrmung couplng 77 AcivechBl"coalfitor
R17 KE res!Siance nnm11gplJg
16 Regen ora!Jon va,\lo
S1511 Startw lod<out and revers11g lamp S'Mtch 89 Exhmlst gas rearrula'on veM!
S29/2 Ttrc!!loV!Wos'Atll:h, M loadfiCie spa~~d re~ogtllicn
123 Ttrc~e vatve l>OO'f
T1/1 l~donc1ltl 1
125 Air pump
T112 ~-oncoíl 2
126 Alr ruloíl v!We
Y1 BactrohyG"aúlc aclualor
127 Non-ralurn v.llve (an,¡Bction arr)
Y6 klespaedatftustar 128 Non-rolum \'!We (vaaJUm)
YB Sartv!Wa
155 Exhau& marifold
JS,B Cal~c converter
e Alr aOOl!s Slon
Fig. 150: KE Injection System Function Diagram- Engine 119 KAT
LOCATION OF COMPONENTS- RA0703KE10015X(07.3-0015)

Mercedes-Benz
A. Model201
Engine 102.961 (KE 1)
Engine 102.962 Standard without AC compressor (KE 1)

Mercedes-Benz
Q .
11
P07-5882-61
82 Au low sensOf oosilon lfldica!or N1811
82 Alr lcw senSOf pos ilion 11<k a!ol N1611 Engin e 102.962: Fuel punpr e tayY~o~tll slaltvatve
8 11/2 Engíne 102.962: Coc!anltEIIJllBfEruro soos« (two aduallcn (ngh! ot ccmpononl compartrnali)
one-p~n connadiom.lor KE ccnrcl Uflt and fi.Kll punp 52712 Oecol fuel atotfmJCroswidl
ralay) 52911 TITolle va.va soMtchiMioadroc~t.Jon
B11/3 Engine 102.961: CoclmliiEIIJllora-:uro SOOS« (oro.
p111 ccmoctontori<E coorcluflll)
(S29f2@ 8 (!)¡
K1 O'Y9Nolago protocbon relay X11 O agoosbc sorl<elJioonllal block !efmnal ID
En gine 102.961: aectncal contBr X S6 PllgcomBCion, lhro,~..e vat.o swidl
Engine 102.962: Rlgt¡ el cornponom compallmenl
Y1 a scvoll¡waúic actuator
N3 KE contol ufllt 11 llfe spoed M SCIOW
N5/1 Engine 102.961: Fuolpurrp rolay (atau:~«h¡¡y rolay 80 Au»i ar¡ mr vaMI
holder an tort el elodncal cerner)
Fig. 151: ldentifving KE lnjection System Components Location - Model 201

Mercedes-Benz
B. Models 124, 201
Engine 102.96/98 up to 08/89 (KE 2, KE 3)
Engine 102.99 (KE 3)
Engine 103 (KE 3)

Mercedes-Benz
N3 o . a o.
~ X11
P07-0661•61 ~OI·ll~ol• el
82 An ow sensor posiboo11dica!or N3 KE coruol t.nt

8 1113 Coolmi temperaue sen'SOf (also 8 11/2) N6 1\C oompresscr cutolf c:ortrol ur1t
G3f2 1-\!~ KAT N16f1 Fuolpump rolay
Healed oxygen sensOf S2712 Oecel fu8l curo!! mJCroswtdl
G3f2x'l v.~I'I KAT S29f1 Trrc~e V1We SW!Idl, illlcad racognioo falso S 29/2
R.Jg oonnedloo, nxygan sensor haallng col wtil illload ami 1dla spaed recng!llbon)
G3f2X2 v.~~ KAT X 11 Olsgnosbc socke!'termilalblock tsrmnallD
Pllg oonncdlon, oxygon sensor stgnal Y1 Bedollfdrat6c atruator
K1 CMlrv-Aage pccleclion rlllay Y6 kfe spi!e:d adjl&or
Fig. 152: ldentifving KE Injection System Components Location - Modell24, 201
Location on engine 103

Mercedes-Benz
82 Aulow s onsor poslllon

ln<ic&~
8 1112 Cooi&IÍ tempon¡Ue
sonsor
527/2 Dccelklalntol
maoSMtdl
529/2 TlTollle VllÑ& S'M!I:h, h.t
load ood ldle speed
r9C0911áon
S29/2x Pllg ronnodlon, UYOIJ.o
vatota sMidl
Y1 Eledrohyth!llc sctuatOf
Y6 ldl& spüd equster
Fig. 153: ldentifying KE Injection System Components Location - Engine 103
Engíne 102.983/99
Location of coolant temperature sensor (B 11/2) at front of cylinder head
Locallon of coolalt lsm~e SOOSOf (811/2) at

tortct t'yinderhead
Fig. 154: ldentifying Coolant Temperature Sensor
C. Models 124, 201
Engine 102.910/96/98 as of09/89 (KE 3)

Mercedes-Benz
P07-0662·5•o7-06&2- S9
82 AJr l cw sensor pcslbon ~ndka!of S27f2 Oecelfuelwolfmteroswlidl

B6 ~e!fect speed sensor S2'9f2 Throllle V!We s,"tdl, ill ktadlide speedrBGognlbon
6 11/2 Coolantemporatu'e SOO'SOJ (EZl..KE/2E-E) S29f2l< 1 PlJgcomecion, e-.rooa vatife s.,.a:h, lúlloadfKie
(4;ltn) speed rfl1:ogrdon
G3/2 Haated oxygon sensor X11 DiaQIICsbc SQd(e~llliTTlllafblockCiirmnallD
X1114 Test coopl ngfOfá&gnoSis
G3/2x1 Pkl_g connedion, oxygen sens01 ooamg ceA
G3/2x2 Y1 Be~!rolrydrmic acluatOf
PlJg connodlon, oxygen sens<lf Slgnal
0\<llfwl:ago prclecllOn ralay87E (7-~)
Y6 ltle spaerl a~er
K111
N3 t<E tfiedloo system con'Tol urit
N!! AC comprassor ruolf coorolullt
N1614 Fu el pufTll and 14cl<do'Ml ruttlff rel¡;y
Fig. 155: Identifying KE Injection System Components Location- Models 124, 201
D_ Modell24
Engine 104_980 (KE 5)

Mercedes-Benz
81 Alr Cow s onsor postlooWldic &!or S17f2 Oec.elfuol CUoltmJCroswidl

8 11/1 Coola:t tomperebse sensor (EllA< E/2 E-El S29/2 Trrolle v.We SMtdl, ill load.llle spead recognilon
G3/2 Heated oxygon sensor S29f2x1 Pl.lg comedon, llrotle vaM! S'Nlch, fl.llload.!de
G3f2lc1 PiJg connedlon, oxygon sensor heamg cot ~ed recognlon
G312X2 Pl.lg connecnon, oxygan sensor Slgnal X 11 Oagnostic socket(9-Jll'l)

K1f1 0\'!lrwlaga protedlon ralay87E (7-pi'l) X 1114 Test COI.I'ing for óagnCYs, pulse readolt
N3 KE rr¡edion sysiom cont"ol unt (16-J)I'l)
N16 Engrne systems corúolllli {M.O.SJ Y1 Bed·ollf<hljc actuatl)(

Y6 ldlo speed atJ5!er
Fig. 156: Identifying KE lnjection System Components Location- Modell24
E. Model129
Engine 104.981 (KE 5)

Mercedes-Benz
82 Au low sens1lf posilonlfldica!Dr S29f2x Pllg come!ion, lhrolle val\<8 swích, M i<l'ad.\11&
8 11/2 Coolalt temp•mllure sen'SOO' (EZl.KE/2 E-E) spaed racognion
G3f2 Healedoxygen sensor W16 Ground, C0111>0110rt <:~arin ert
G3f2x RJg connemon, oxygan sens« X4/10 Temunal block, tarninal30 300 61al87l
K1/1 Ü'l'erYOiaga prolaellcnrola-f87E (7-!*'1 ) X1 1 Dlagoosflc sed< o! f!l-PI'l)
N3 KE lf\Oalon syS<om con;-ol u11t X 1114 Te~ couplifl!l for di&1lflCSIS, ptJiso readott
( 10-pl'l)
N 16 Engme systems oomol uni (MAS)
R17 KE lr¡edlon s{S<om resr.;;lallce lrrnm11g pllg X26 PlJgcomodon, 11ta00f/eng11o
52712 ~eliJelcliO: muosll!ltch X30/1 Pllgcomet~on. multluntion block
S29f2 TIYcllle vatva s....tth, M loadrd& speed recogrllion Y1 Bec~ohydmlllc at!!Ja'.Dr

Y6 kfe speed ad!ustor
Fig. 157: Identifying KE Injection System Components Location- Model129 Engine 104.981 (KE
5)
Mercedes-Benz
F. Model 129
Engine 119.960 (KE 5)
X11
81 Au §ow s OllSC)( postlon 11dic e!!lr N30!1 ABSIASR cortrol tnl

8 11/1 Coolalt temporatua soosor S2912x 1 Pklgcornodon, tuotfe valve S!Artch, U load.t<le
(EZlii<E l {4-ptn) speeó recognton
X 11 ~agnosbc sed\ el (9-pll)
G3/2 Hllated oxygon sensor
X 1114 Tost eot.plng for áagnoS&s, pulse readod
G3f2x1 PlJg connedlon, oxygen sonsor heall'lg coi
(1&-pll)
K111 <mr\'Olage prot&Cbon relay87E (7-pll)
N3 I<E u¡ewon syslem coni"ol unt X26 Pklgcormclon, lllaoortongflo(12.pin)
N411 Bl!dronic accelon;tor pe{fal cortrol unl Y1 Bet:rcllfd'úc actuator
N16 Elgne systems oomol uni (MAS) Y6 kJo speed aquster
Y8 start valva
Fig. 158: ldentifying KE Injection System Components Location- Engine 119.960 (KE 5) Model
129
G. Model 129,R110
Engine 119.960 (KE 5)

Mercedes-Benz
Xt1
82 A.irlow sensor posiboo11díca'!D1 W 16 Gfound, COfTI)Oilelicorrpaltnllff!
8 11/2 Coolmi temporaon SOflsor X 4/10 Termmal block termllal30
{EZlJKE m.edoo sy<;J.emfl E-E) X 11 Olagno SJ sl!erm11al ~k termnal TN
G3f2 Heated oxygSil sensor X 1114 Test coupi ng for dlagno~s. pulse readWi
(1 ~~)
G3!2x PkJg ronnedlon, oxygan sSilsor
K1/1 0\'llrvolage pmlllcboo relll'f 87E/87l {7.pín) X26 Pklgcoooodon, fntrlriof/engíne
N3 I<E C'OiliJoiUilll X2612 Phlg comadon, Bll!JOO se¡>maboo po.~t
N16 Eng¡oo systems ooruollllit (MAS) 130.~)
R17 t<E res1s1Bnce nnm11g pllg X 30ft Pklg comedoo, rrol51unti oo ~
S2912x PlJg connadlon, throále wt.re sMtdl, iJJioadlicfG Y1 Bectchfctauic actuator
speed rerogniloo Y6 lcle speed a~er
Y8 Slalt w lve
Fig. 159: ldentifying KE Injection System Components Location - Model129, RHD
H. Modell07
Engine 116/ 117 (KE 3)

Mercedes-Benz
A1e26 CHECKENGNE índica!oriEIII'll <@ NS ElR cortroltnt

82 Air flc'N sensor poglon tmicmor N1614 FuolptrnpandkiCkdo•Nl cúiol reley
S29!2X 1 Pklgcomedon, tuotle vaM! swích, tulktad.t<la
81112 Coo!alt !Bmperattse sensor (EZllKE) {2-pm)
speed recognion
818 AfllJdesonsor@ Q)<@ X 11 Olagnosbc socke!ltennllalblock, tarrrunal TD
821
Eld'tau~ gas raarn.Cabcn (ARF)lompomtt.Ja sensor@ X92
Te5t cotplng for dlagno;,s,püsa reaclout(B-PIIl <@
Caiforria Y1 Bec.l'ohf!taúíc ad!Jator
G312 Haated oJt>toon son sor Y6 kie speed adjuster
G312X 1 Pllgcomeclon, oJt¡gon sensor healtng cal
G312X 2 Pklg eonneci on, ex;gen sen sor Signa!
K1 OvtliVollaga protedlon ral!rf (5-pcn)
N3 KE ll'"fOdon sor.;tem cortrol~nt (25-pcn ~ng)
Mercedes-Benz
Fig. 160: Identifying KE Injection System Components Location- Model107
L Modell26
Engine 116/117 (KE 3)

Mercedes-Benz
0..
A1e26 CHECKENGIIE índicatorlamJ ~ NS ElR cortroltnt

N 161<l Fuol pumpandklckdom tliO: rolay
82 Alrllow sensor poSilon •ncicator
S2'912X 1 Pilg comecton, tuotte vatve swtdl, h.lloadA<Ie
81112 Coolart IBmpemt¡xe sensor !EZUAJ<R) 14-iltn)
speecl recog-r'on
618
Allildesonsor@ 0 @ X11 OlaQOOsbc sccke~lemrnelblock, tem1mal TD
821 E.xllaust gas reo«: tlaboo (ARF) tsmperabl: e s enser@> X92 Test 00\4)ing for <iagnOSis, pulse reedot.t (8-pcn)
Caifoma @
G312 Heatad Olr{gen sen ser
Y1 Boctoll{lttlillc actuator
G312X 1 Pilgconoocton, o~gen sensorhaabngcod
Y6 ld!o spaod aQ¡uster
G312X 2 F\Jgcomecion, o~gen sonsorsignal
K1/1 OveiVolage !llotedlon rolay 87E {7-pcn)
N3 KE 1'18cicn systom ecmcltnt(25ilm ~ng)
Mercedes-Benz
Fig. 161: Identifying KE In jection System Components Location - Model126
INFLUENCING PARAMETERS AT KE CONTROL UNIT - RA0703KE10020X(07.3-0020)
The examples show the influencing parameters existing at the KE control unit.
A. Basic version Engine 102.961 Standard and Engine 102.962 Standard without AC compressor
(KEl)
IBat!Dry (G1) Groond(W10)(W1 1) l - KE cortrol

1
L - ._ _ _ _ _ _ _,I-D U!11 {N3)
CMlrvotaga protac.bOO (K1)
system presstJre Lowor chll!11oor

pres~ro
Coolad.lem~orehlre sensorfl311fl)
Tomperalllre Signa!
lrsz HEn~espaed ~
'!Jilillon como! rnit IN111) Comols ma>ture ad!lptallco ot
TOS'!Jilal
1\Jr CO'N S8nsof posilon lld!C!Dlr(82) Nr ncw sens(l( plan pi>stbon

Q
Start ennchment
Pos~ slart enndlmsrt
Dil~el ruelcU!o: mcrOS'Aitch (52712) WelmJng.upphas&>
Oecel fuel cúolf
Accelerabon emchment
Fúl load ennctmellt
Detel fuel cúoff
fuot6ovatve S'•"~h (S2'9) fúlload
recognrbon kle spead poSiion
IStart SIQilaltemunaiSO H Stal SI~ \l ~

Fig. 162: KE Control Unit Communication Diagram - Basic Version Engine 102.961 Standard
B. Basic version E ngine 102.962 NV KAT and Engine 102.962 Standard with AC compressor (KE 2)
Mercedes-Benz
Battary (G1) Ground(W10)(W11) 1 . KE rodrol Bec\"oh¡dratlíc acilJatOI' (Y1)

..J¡-t> l.nt(N3)
1
L - ._ _ _ _ _ _ _
l>
~
Volag«~ ~ply lllrmnai87E
()yervcltage prot~tJon (K1)
H LJ loworchambor
pressure
I
Coolalitemperettre sensor
LIB_1_11_2_or_B_1_
113_l_ _ _ _ _ __, TempooEI"e Slgnal-
1 _
¡--;;:>
L~
-sz_s_
::_·oo_c_Oi1rOI
__IIl _ít_(N1
_ 11_)__ =rE
__, Eng:espaed ~
1Coltrols motu;o adaptaban ot
1
fi.Jr low sensor p<}Silloo llcic m {82) H fi.Jr now sensOI' pla'.D p<}Sitlon ~
Start emchmonl
Pos'-start onnctmen
Wamnn~~as&
Acceleraboo omchment
FUI load ennctm8flt
Decel fue! cttotf
Ttrottlev!We S\\llll:.h (529) tul load
rocognb oo 1-(> lambdacomol (\\ll.th KAT)
l>
AC compressOI' a.totf coorohmt(NS)
,Y\111 KAT haa!IH:I oxygon sensor (G3/2) H Oxygen sensor SJ911al 1>
Fig.163: KE Control Unit Communication Diagram- Basic Version Engine 102.962 NV KAT
C. Basic version engine 102/103 KAT/RUF (KE 3)

Mercedes-Benz
1Ba:lury (G1) 1Ground(W10)(W11) l-e- K E corool

t.nt { N3)
Betrohfdraúic aduat01 (Y1l
l_____________JH V"'''...,........,. r
~..osvctagopro!~ctJon(l<1) - . 1 -
~
LJ lcworchambar
pl&ssuro
L~~-~-1-~_i_t&m_p_em-rum--so_n_~----~~~Tom~~eg~~
EZL ignition romol U'li {N1/2), Eng¡ne spe:od slart
lOSigll~ roco gnlion
Au Zow sens04" posibon 11dicalllr {82) f>.Jr flcw sens04" pla~ poSIIIon
(&n!liflB 1Q3 11&191109S ide Stan 811llchmont
spceed)
Pos~start onndmert
Wann1n~pphase
Accelerabon omchmont
FUI load ennchmellt
Dec~ tuol ctiot'f
KE rasiSlBnte w~m111gpklg (R17) Porlofm81lce map amt
cperelmg modo Lambóacortrol {'1-Lth KAT)
Pa~tloadmxi.IHI aóaplatlon{'Mih
RÚF)
Ttr~ttlo valva s•,\llth (S:?-912) hllload.!<h

~ed rec~gmlion
Fu1 tuotfe posnicn Ida ~ed
&ÓJUStllr {Y6)
Terrpcmatcruse cont<llufiii(N4 ) Slgnal lar crur.;ecorool
up 10 09!86 end 19B.1l
modo
Road spead ggnal
l[)e(;ol ilelcutcl mcrosMtch (S27fl)
Haated oxygen sensor {G312)
S!artor lockoul and revors11g l&mp so.\ltch

(S16/1)
AC comp¡'esscr ai.ot'f AC compre:ssOI" rui n signel

cMrol tm~ {NS)
Fig. 164: KE Control Unit Communication Diagram- Basic Version E ngine 102/103
D. Basic version engine 102 KAT as of09/89 (KE 3)

Mercedes-Benz
1Ball.efy {G 1) Grotlld(W10) \W11) KE conwolu11t Elec~otrydra!Ac actuator {Y1)

1 -t> (N3) --{>
~ ~
¡-t·¡
Volsge slqlt¡l
~ago protertloo {K1/1) tnrmnai87E and
lllrmnal30s LO'Mlf chamMr
f-------D -t> pro-ssaa
Ccxllarn temperettn sansor

(81112)
T11111>eca'IJre s;gnal ~ ~
C'Ofirols m~e adaptatOfl ol
EZliQilllon comolool Engtne speod start

{N112) TO Slgnal f-i> reco9f1ilon --!>
~
Start onnctmenl
Post-st"lrt er11ctmem
Alr low sensor posilon Alr lcw sensor plata
11dicll1Dr (82)
f---D poSiion ----D W81TT111Q-UP phas e
Accelemllon ennclmert
r
Fulload emctrnert
KE rosrstance nnmr1g ~9 Pelfonnant a 08{:81 iJ 91 eltol
(R17) map l811"tlda contol
ldle spoed pos~ en

-i>
Th;ollla vrlve s•,'.llth (S29J2) r-1>
i.ll load/1<1& spoed
riiCOg;¡iJon
Ful ll'lolle pos.Jon
L.¡:;, --!:>
Hi~Hffed spoed sensor ( 66) Roed SJH!ed Signa!
f-i::: -t>
Oacali.lalc~o· mcroso.\<tch Oac<:~l tlel Transmrsgoo sh:ft potrt relerd reltry' O< 29) )
{S2712)
f---e al.off --!:> ----t>
Healedoxygen sensor (G312) ())r¡gon sensor Signa! kle s¡Hied ldZo spoed he~Ülg
aquslei (Y6) speed
f---e -i> .-{;> -i>
Startar lod<out and revers11g Selector levar Dla!J)Csllt socket {X 11)

IBI!ll s.vtch (S1 &'1) poSI~on
f-e --!:> ----t>
AC compressor al.o.'f coni'<ll AC cornpressor CUJn Test~ngfordagnoss(X11/4))

FBU'I
li111(N5) SI ¡,mi 1
memOIY 1
1) only'KATLHD
Mercedes-Benz
Fig.165: KE Control Unit Communication Dia gram- Basic Version Engine 102 KAT
E. Basic version engine 103.984, model129 (KE 3)

Mercedes-Benz
Battery (G1) Ground (W11) KE control ElectrohydrauRc actuator (Y1)

(W16) ~
---1>
~
OVervoltage protecUon
(K1/1)
Voltage supply
terminal 87E
f-e>
~II (Nl) 1
system pressure
~
Lower chamber
pressure
Coolant temperatur e
sensor (8 11/2) Coolant
temperatura
slgnal
---{> ~
Controls mixture adaptatlon of
KE reslstance trlmmklg
plug (R17) Performance
map 1----t>
-
_l _
Start enrlc:hment
Alr now sensor posltlon Alr flow sensor Post-start enrlchmenl
lndltator (82) plata posl lon ---{> Warmlng-up phase
and movement Acceleratlon enrlchment
Fui load enr1chment
Decel ruet cutorr
Lambda control
Throttle valve s'Mtch. ldle speed
----e> posltlon -1>
fui loadlldle speed
recog nltlon (529/2)
-
Fullthrottle
----e> posltlon
1----t>
Eledronlc speedometer
(A1p8)
- C> Road speed
slgnal
¡-c.
Decel fu el cutorr
mlcroswltch (527/2)
(n. a. wllh ASR)
.... Decel fuel
retettro nlt -ut: c-61 eram-- cutotr
pedal control unlt
(N4/1) . 1----t>
optlonal equlpment
oxyg en s.ensor (G312) Oxygen sensor

slgnal
---{>
KE lntake alr lntake alr ldle speed poslloner

temperatura sensor temperatura (Y6)
(8 17/2) slgnal ~ '""'-D
Starter lockout and Selector tever

reverslng lamp swl ch posltlon -{>
Englne systems control
(5 1611) unN (N16)
,..._.{)
AC compressor
cutln slgnal.
TOAslgnal
Englne syslems corhol Onlorr ratio al
unlt (N16) dlagnostlc socket (X11)
~
-e
Mercedes-Benz
Fig.166: KE Control Unit Communication Diagram- Basic Version Engine 103.984, Modell29
(KE 3)
F. Basic version engine 116/117 KAT/RUF (KE 3)
Ba!lofy(G1) VcttBge
87E
~ tormnlll Elocioh;'drnúic
I-r> aá!Jator (Y1)
<t-J Systarn pressure
1
¡-t> f-i>
l_,¡cwer
PfGSSUf8
chamb-er
&
CMlrYCilage prore01011
KE comoltmit
(N3)
rclay (K111) -
Controls mDw e adaptallon ot
f:r--
Coo!artlemporatura Tompomlure s1gnal
S.1l11Sor {81 1/2)
--[> re
Slart omchment
t
Pos'-startannchnert
EZL lgllltlotl comof ooi lDsgnal WermJ~pphase
(N1f2Y(N1/3) ------(> {TN Stgnal)
re Acceloration enñchmenl
Flilloadoonchnert
Decolluol CU!olf
An ~N son!\Of p:csiíoo Au llow sensor pl¡m Lambdacoorol

11diC~ (82) -----1> l)(lSibon f-e: Pan load mXIJre ade.¡¡laboo
ldle speed p:ogionf
rl>
d0(81 fuel rulolf
~ Alr tllocboo
Ttrotlle v!INe swll:h rala-¡ (1<17)
(52912)
-
1-c-1 FUI tlrotl!e poSiboo
~
BectroniC speedome!er Road speod SI !J!al
(A1p8) ------(> r<:: Fual JlU11P retay(N 1614)
KE re-stslance nnmng P.arfomlance r:nep

el1d
pkJg (R17) ~
operabng moda )
re
H
HeEltedoxygoo soosor Oxygen sensor DlagncstJc socket (X 11)
(0312) Slg11al
~
-
ttake vtemporwe Tompere1ure Slgnal
sensor {817f2) --[> r-e
Slarter lodo.OUI and SSIDc!OI Iaver pos.!Kln
reversmg lamp swlr: h
(51811,
------(>
f-e
AC ccmpressor aJiolf AC compres ser Slgnal

{CfiroiiJ11 (N6)
------(>
~
Fiº. 167: KR C.ontrollTnit C.ommnnication Diagram- Rasic Version Ji:ngine 116/117

Mercedes-Benz
G. Basic version engine 104 KAT (KE 5)

1
Mercedes-Benz
1
B~tery (Gt ) Ground (W11) KE control unl Electrohydraullc actuator (Y1)

(W16) ~ (N3)
-t:>
& Voltage supply

OVervoltage protecUon
termlnals 30a
and 87e 1 b
retay (1<1/1)
- f----1:> system pressure Lower chamber
pressure
~
Coolantt emperature Coolanl
sensor (8 11/2) temperatura
slgnal f--t> Controls mlxlure adaptaUon or
EZLIAKR lgniUon Data

control unlt (Nt /3) ~
,... lnterchange
f:H> ¿
S1art enrlchment
Post-start enrlchmenl
KE reslstance trlmmlng Warmlng-up phase
plug Alr flow sensor Acceleratlon enrlchmenl
plata posftlon Full load enrlchmenl
Alrflow sensor posltlon
lndlcator (82)
- and m011emenl f--t> Decel ruel cutolf
Lambda eontro l
MaxJmum speed coi1rol
ldle speed
Throttte valve r-t> posltion

s~tch (S2912)
r- Regeneratlon swMch
Fu ll lhrotue 011er vatve (Y58/1)
posltlon
L....t> ~
Variable camshaft
Electronlc speedometer llmlng acl uator (Y49)
(A1p8)
Road speed
slgnal
~ ldJe speed adjuster
(Y G)
MlcroswMch (52712)
(n. a. Wllh ASR)
Start valve (YB)
~c~nre~c~em~l --
- - - - -{> Decel fu el
pedal control unlt culolf
~
(N4/1)
~ Consumpllon lndlc~ or
1
Oxygen sensor Oxygen sensor
slgnal Transmlsslon shlft polnt
(G312)
"'
f--t> retard relay (K29)
lntake alr
temperatura
f--t>
tnlake alr temperatura
sensor (81712) - slgnal
Selector levar
positlon
- Englne systems control
unll (N16)
starter tockout and

f--t>
reverslng lemp swlch
(5 16/1) Dfagnosllc socket (X11)
(S16n) DlagnosH e socket (X11)

AC compressor ,.,_
euUn slgnal.
TNAslgnal.
f-i>
~~nglne systems control
unll fN16"1
dlagnosllc
socket. oxygen
sensor healer
-------------·
~-'Aa ll
J Test coi.4)ilng ror
diagnosis (X11/4) 1
Mercedes-Benz
Fig.l68: KE Control Unit Communication Diagram- Basic Version Engine 104 KAT (KE 5)
H. Basic version engine 119 KA T (KE 5)

1
Mercedes-Benz
1
Starter, KE conl rol uni Electrohydraullc acluator (Y1)

terminal 50 (N3)
---t> f-t>
~ ~
Ground (W11)
Bajtery (G1)
(W16)
~ system pressure Lower chamber
pressure
~
Voltage supply.
terminal 30a
OVervoltage protectlon
relay (K1/1)
and 87e ~
- --!> Controts mlx1ure adaptatlon or
Coolant temperatura
sensor (8 11/2)
Coolant ~
temperature start enrlchment
signal ---t>
Post-start enrlchment
Warmlng-up phase
Deja Acceleratlon enrlchment
EZLIAKR lgritlon
control unlt (N113) lnterchange Fun load enrlchment
<H> Decel fuel cutolf
Lambda contro l
Maxlmum speed control
Alr llow sensor positlon Alr now sensor
lndlcator (92) plate poslion
and movement ---t>
KE reslst ance trlmmlng ~

Regeneratlon swllchover
plug ..... vaiVe (Y5811)
ldle speed
posltlon. decel Variable camshall Umlng
fuel ciJ oO' actuat ors (Y49/1, Y4912)
Throllle valve swi tch r-C'
(S29/2)
¡--
Full throttle ldte speed adjuster (Y6)

~ .....
posIlion -1>
.... start valve (YB)

Electronlc speedometer Road speed
(A1p8) slgnal -1>
Consumptlon In di calor
starter lockout and Selector lever

reverslng lamp swlch posltlon --l> Transmlsslon shlll polnt
{516/1) retard relay (K29)
oxygen sensor 1
signal ~ Englne systems control unlt
Oxygen sensor (N16)
(G312)
lntake alr
tempera! ure -1>
lntake ar temperatura slgnal On/olf rallo output dlagnosllc
sensor (9 17/2) socket (X11)
AC comp res sor

cutln signa!,
TNAslgnal, Exhaust gas reclrculatlon
Engine systems control -1>
t.nlt (N16) dlagnosllc
oxygen sensor __________.. ,
C> swilchover vaiVe (Y27)
heater
Faill Pulse outpiJ
mMlOry
1
)
-
.... Test coupllng ror diagnosis
(X11/4)
Mercedes-Benz
Fig.l69: KE Control Unit Communication Diagram- Basic Version Engine 119 KAT (KE 5)
DESIGN AND OPERATION- RA0703KE1A030X(07.3-0030)
Design and operation- RA0703KE1A030X(07.3-0030)
A. General
The KE injection is a system with mechanlcally/ hydraulically controlled basic functions and
electronically controlled additional functions.
The designation KE means:
K = Continuous fuel injection
E = Electronically controlled mixture adaptation The KE injection system is a further development of the
mechanícal/hydraulic KA injectíon system and has gradually replaced the latter on the 4-, 6- and 8-
cylinder engines. The quantity of air inducted by the engine is controlled by the throttle valve and
measured by the air flow sensor. The latter is positioned at the intake air flow upstream of the throttle
valve. The fu el distríbutor meters the quantity of fu el to the individual cylinders of the engine in line with
the quantity of air measured.
The fuel is passed to the injection valves which inject the fuel continuously in a fmely atomized spray
into the intake port downstream of the injection valves.
The operating states, su eh as starting, wanning-up, acceleration, fullload, KAT operation with lambda
control, deceleration mode etc. are detected by sensors and sígnalled to the KE control unit. The KE
control unit processes this information and influences the composition of the mixture by means of the
electrohydraulíc actuatoc fitted to the fuel distributor.
The KE ínjection system has good emergency running propertíes in the event of a faílure ofthe electroníc
mixture adaptation.
Components of the KE injection system

Mercedes-Benz
123
N3
V6
52912
t1
o
82 N16/1
~K1 (t
R17
55 57 40
~~~~ 92 .e.'
Y8 811/2
1M3
I'W- . .1- &7

82 AJr licw sensor pe>&loo indicator Y6 k!& spcead adjus!&r
81 1f2 Codarn lem¡HJratUHI sensor YS Stlllt\'!!Wo
S29!2 TITo~ Wlllill S'M ich 2 Fuel d'isl.rib!Jl!l
R17 KE irtoctioo systemro~s~aoce llirrming pkJg 25 Air llcw sensor
N1611 Fuel ptlllp r elay 40 Oiaphmgrn pressue r~lallx
N3 KE cortrol tnt 55 Fuei Uer
K1 OVervoCage prcteason refey 57 Fuel ecrurrulalor
Y1 Ele:cto11¡1drelic adllalcr 92 l\adon vllll'll~
M3 Fuolpunp 123 fuo!le wlve bOOy
Fi~. 170: Iden tifyin~ KE Injection System Components
l nteraction of the components

Mercedes-Benz
Engr¡e ln¡adlon
EJ
<}- va:ves
J
El
presrue
Oiaph:agm
SIBrt
or L_________O
regulatcr lñ1f
i
i'
FU91
L___ -ifitor L---------------j
:
1
'
A~dean
í ~
EJ~
=
=
Air
Fu el
Fuelrelum
Fig. 171: Components Communication Diagram
The KE injection system is divided into the following function groups:
• Fuel supply
• Mixture formation
• Functions in the KE control unit
• Further electrícal components and functions
• Start device
• Idle speed device
• Emissíous control (see Group 14 aud 49)
Desigo and operatioo (continuation)- RA0703KE2E030X(07.3-0030)
E. Further electrical components and functions

a. Coolant temperature sensor (warming-up)
The coolant temperature is detected by the temperature sensor.
Location
Engine 102
Coolant temperature sensor (Bll/3), 1-pin version, at front left on cylinder head.
Mercedes-Benz
Fig. 172: ldentifying Coolant Temperature Sensor, 1-Pin Version (Engine 102)
Engine 102
Coolant temperature sensor (B ll/2), 2- or 4-pin version, at front left on cylinder head.
Fig. 173: ldentifying Coolant Temperature Sensor, 2- Or 4-Pin Version (Engine 102)
Engine 102.983
Coolant temperature sensor (Bll/2), 2-pin version, at front on cylinder head in thermostat housing.
Mercedes-Benz
Fig.174: ldentifying Coolant Temperature Sensor, 2-Pin Version (Engine 102.983)
Engine 102.99
Coolant temperature sensor (B 11/2), 4-pin version, at front on cylinder head in thermostat housing.
Fig. 175: Identifying Coolant Temperature Sensor, 4-Pin Version (Engine 102.99)
Engine 103
Coolant temperature sensor (B 11/2), 2- or 4-pin version, at rear left on cylinder head.
Mercedes-Benz
Fig. 176: ldentifying Coolant Temperature Sensor, 2- Or 4-Pin Version (Engine 103)
Engine 104
Coolant temperature sensor (Bll/2).
Fig. 177: ldentifying Coolant Temperature Sensor (Engine 104)
Engines 116, 117 up to 12/85
Coolant temperature sensor (Bll/2), 2-pin v ersion, at rear left on cylinder head.
Mercedes-Benz
Fig. 178: Identifying Coolant Temperature Sensor, 2-Pin Version (Engines 116, 117 Up To
12/85)
Engines 116, 117 as of 01/86
Coolant temperature sensor (B 11/2), 2- or 4-pin version, at cylinder head in front of mixture control
unít.
Fig. 179: Identifying Coolant Temperature Sensor, 2- Or 4-Pin Version (Engines 116, 117 As
OfOl/86)
Engine 119
Coolant temperature sensor (B 11/2)

Mercedes-Benz
Fig. 180: l dentifying Coolant Temperature Sensor (Engine 119)
Function
The coolant temperature sensor is designed asan NTC resistor (NTC = Negative Temperature
Coefficient), i.e. the resistance reduces as tbe temperature increases. The resistance ofthe coolant
temperature sensor alters as a function of engíne temperature (see also characterístíc curve) . Tbe
characteristic curves of all the versions are identical.
The coolant temperature sensor is actuated by the KE control unit with a constant voltage signal.
Depending on the resistance, a corresponding voltage drop is produced.
The KE control unit detects the coolant temperature and determines the current to the
electrohydraulic actuator. The lower the coolant temperature, the higher is the current at the
electrohydraulic actuator and thus the fuel enrichment in the warming-up phase.
Mercedes-Benz
IICaD
~
~000
2CMlOO h.
~
10000 ~
tciOO
MCIO ~
40CIO
~
li(JGO
fQ4JG
""' b.
'lj
1000
~~
liCIO
~
toO
.....
g
11: -
~
2IIC
1IXl
~
' ~..........
.......
~ ......
10
MI
.fCI
~
IICI
10
- 30 -10 o 10 40 eo ea 100 1::10 <OC
"'a-o 1 :n-n
Fig. 181: Temperature Graph
NOTE: Testing of the warming-up phase base value is performed at a

coolant temperature of +20 oc. The temperature is simulated with a
resistance decade of 2.3 -2.8 kohms.
In addüion to wanning-up, the temperature signal in the KE control unit is required for a variety of
further fi.mctions, e.g. acceleration enrichment, decel fuel cut-off, idle speed control, lambda
closed-loop control, start device, air inj ection.
The temperature signal is detected by the KE control unit between contact 21 and ground.
Coolant temperature sensors existas:
• 1-pin version
with 1-pin connection for KE control unit
• 2-pin version
two 1-pin connections for KE control tmit and EZL ignition system
or
two 1-pin connections for KE control unit and fuel pump relay
Mercedes-Benz
• 4-pin version
four 1-pin connections, two for KE control unit and two for EZL ignition system.
The coolant temperature is detected by a dual temperature sensor with two 1-pin connections each.
The temperature signa! is supplied to the KE control unit (contact 21 and engine ground) and to the
EZL ignition control unit On engine 102.96/98 Standard (KE 1 and 2) the temperature signal for
start valve actuation is supplied to the fuel pump relay (terminal TF).
Example engine 102.962 Std.
i i i
- blJ
,.,. .... _
8 11/3 Coolalt tamporellEe senSCf W10
N3
W10
KE con~olu111t
Bai!cly ground """a o.ra ll'lilar
í
Y1 ~ J{
L_
Eledroh';Gill.ic actuator N3 T •
a <NarYOiage prolodlon ralay, lllrmnal87
Note· Ground po¡n~ not mdíciRoo, coorponenl conMdod tG bo~ or
1 2 3 • ' • , • Q ~ " ~~ 1
engmo.
1,. ti te o te 11120 21 112113~ 111 ~
Fig. 182: Coolant Temperature Sensor Wiring Diagram
Fig. 183: ldentifying Coolant Temperature Sensor, 2-Pin
Example engine 102.96/98 KAT/RUF

Mercedes-Benz
8 11/2 Coollll1 temperatu"e sensor (EZU<E)

N1/2 EZl. tgnlllon oorúolmj
N3 KE <'llllrolunt
W3 GrOUld, atrrontlelt'Aileelhouse(I!Jillllon coil)
W10 Belblfyground
W11 Engme ground
Y1
Z
a
8ectrohydral.Jic actualor
Cometlorsle1!YII (soldl!fed comedor in hemoss)
O.er\Olage protec.bon relay, oominal 87
Note Ground potnls not tndicated, component connected ID bodj or
llll!Jinll.
wtO
I
a Y1 811/2
Fig. 184: Coolant Temperature Sensor Wiring Diagram- Engine 102.96/98 KAT/RUF
8 11/2 Coolarttempemture sensor (EZU<E)

N3 KE conrolurll
N16l1 Fu8lptJfl1Halay
.1$ lir
W10 Battsrygound
W11
Y1
Y8
Eng~ne ground
Elec.!rohydrúc actualor
Startvall'e
11
wto t w111.11
a Ü\lllfwílage protecoon relay, 1Drmnal87
11!
Noto Ground ~IS nottndicelod, cornpooent coonect&d ID bodjor
engine.
l
a 0.'10 IJ>"W
Fig. 185: Coolant Temperature Sensor Wiring Diagram- Engine 102.962 Std.
Coolant temperature sensor {Bll/2), 4-pin
The coolant temperature sensor is a 4-pin design. It integrates two independent temperature sensors
(NTC) which do not have any electrical connection to the housing ofthe coolant temperature
sensor. One temperature sensor (NTC) is for the EZL ignition system and the other for the KE
injection system. The benefit of this circuitry is greater measuring accuracy because there is no risk
of a voltage drop between engine ground and control units. TI1e connector ofthe coolant
temperature sensor is designed in such a way that it can be plugged in any position.
Mercedes-Benz
Fig. 186: Identifying Coolant Temperature Sensor, 4-Pin
Example engine 102.962 KAT
8 1112 Coolanltemporature sonsor(EZU<E)

N1f2 EZI.. ~g~~lbon wrtroflxal
N3 I<E conl;olurit
W3 Grould, at lrontlaftW!eello.use (IQil~Ofl«lll)
W 11 Engtne g¡cund
Y1 Eledroh~8'./jc actua!Of
Z Gomeclor stu..a (soldared comedor 111 hatOOss)
.11
a Overvolago prctecbon relay, termnal87

Note Groond al connertor 7 al J<E corirol t.ll1! 1s coonocted 11ternat¡t 1
W11
lo eogme ground, eCllrliK lor 2
r
a
Fig. 187: Coolant Temperature Sensor Wiring Diagram- Engine 102.962 KAT
Example engine 119 KA T

1 Mercedes-Benz
1 1990-2002 ENGINE PERFORMANCE Mixture Formation- REPAIR & ADJUSTMENTS- 129 Chassis
8 11/2 C<lcte.rt tsmpefBiue sensor (E.ZIJKE)

N3 I<E como! mt (55-pln)
X2612 F\Jgcomedoo, enQIOO separaban poilt(30-píl)
'1'1 BeckOO(Ii'lllli e aduator
Z831S Com actor slsevo (soldored conn&etor m hamess)
groond o( camshal posiion soosor sh!eltlng
Z00/1 ' To Ell/AJ<R 1gnbon cOiiroltnt, connector B
(temunallW)
POY~~-1!5
Fig. 188: Coolant Temperature Sensor Wiring Diagram- Engine 119 KAT
Pin assignment:
1=EZL temperature sensor
2=KE temperature sensor
3=Engine ground at intake manifold for EZL
4=KE control unit ground
NOTE: National version ~ 1988 without pin assignment designations
EZL KE
-B-11-/2.-¡uiaiEZl
KE
Fig. 189: Identifying Coolant Temperature Sensor Pins
Notes regarding test

Mercedes-Benz
Coolant temperature sensor {Bll/2)
When testing the coolant temperature sensor, measure and compare the resistances 2 X díagonally.
Fig. 190: Identifying Coolant Temperature Sensor
b. Air flow sensor position indicator (acceleration enrichment)
The air flow sensor position indicator (B2) is bolted to the side of the air flow sensor. Contact is
made by means of a 3-pin plug connection.
Fig. 191: ldentifying Air Flow Sensor Position lndicator
The air flow sensor position indicator contains two resistance tracks. Brush wiper contacts slide
over these tracks and are connected by a lever to the adjusting lever shaft. A variable resistance is
obtained as a result ofthe deflection ofthe air flow sensor plate.
Air flow sensor position indicator

Mercedes-Benz
12 3
1, 2 Brush w~ oartacts o
3 Wipmlever
4
5
Pnrted c.-rut OO!lfd witl resiStance hd<s
A.-llow sen sor ~-------r-~~--------~
6 Aqusbng lowr shaft
6 5 4
Fig. 192: ldentifying Air Flow Sensor Position lndicator Consisting Components
The air flow sensor position indicator (B2) is actuated by the KE control unit between connectors 1
and 3 with a constant voltage signa!. The KE control unit recognizes from the voltage signal of
connector 2:
• Position of the a ir flow sensor plate

• Direction of movement of air flow sensor plate ( opening or closing)
• Speed of movement of air flow sensor plate (throttle speed)
Depending on the position and movement of the air flow sensor plate and taking into account
further influencing factors (coolant temperature, load state of engine etc.), acceleration emichment
is iuitiated by the electrohydraulic actuator.
The air flow sensor plate position and movement signal is processed not only for acceleration
enricbment but also for idle speed control (engine 102 KA T/RUF and engine 103) and, in the case
ofthe basic version RUF, for part load mixture adaptation.
National versions witb altitud e sensor (B 18)
The voltage supply ofthe altitude sensor likewise comes from KE control unit contact 18.
Example engine 119 KAT

Mercedes-Benz
82 Air flow sensor JX>Siioo indicator

8 11/2 Co-otarn tllmporalure soosor (EZliKE)
NJ. KE conlrollll'llt(SS-ptn)
X1612 Pklgcoonedoo, engma sapw:aboo pmnt(30-PVl)
Y1 Bet:~ollydfaúic S(tuator
Z83/5 Ccnnector ~8'\"il{sdc:fered col'lnector m hamess), ground
cl camshait posation seftsor shleldllg
ZSB/1' To E.ZllAKR lgrtJboo e cnlrol umt ccmM.trlf 8 (fBmlnel
lW)
Fig. 193: Coolant Temperature Sensor Wiring Diagram- Engine 119 KAT
Example engine 1 02
Mercedes-Benz
N3
82 AJr low sei!SOf poslbon
ruiclélr ·---·-·-·-·--·-·-·-·-·-·-·-·-
-·--·---·
. ·-.. ~ ·-·-·-· fQ.
8 11/2 Coollllt temperature
N3
U1
sensor {E2UKE)
KE oonlrol unt (25-p¡n)
KE 1 and KE 2 coc1rol
·-
tnt vers1011
U2 KE 3 «rlro!Ull \¡9{'gon
1 1
Y1
zar::
Bectroh)dral.fic acruatoc
CotNC!or Slee\18 1
• Ul
i• 1 8 i
"U2 •
{solderedcomacloon
hame'.iS). !JOUnd ~·-·-·J
. ~--·-·J
,
Z9611 " ToEZIJA.KR i gllflion
c«troi uni ccmertoc B
{!emmallW)
IJ GfOUld loe ruthar
sonsocs
b N!!ÍIOilaiVersJOnS '11111
a:5tude sensor
Aliude soo sor vollage
Sl.4llltY
Fig. 194: Coolant Temperature Sensor Wiring Diagram- Engine 102
c. Throttle valve switch
Fig. 195: Identifying Throttle Valve Switch
The throttle valve switch (S29/2) is bolted to the síde of the throttle valve body and is operated by
the throttle valve shaft. Versíons only with fullload recognitíon (with TSZ ignition system) and
versions with idle speed and fullload recognition are fitted.
The throttle valve switch signals the throttle valve positions idle speed and fullload to the KE
control unít and to the EZL ignition control unit, respectívely. This ís done by a contact closing in
each of the end positions of idle speed and fullload.
Full load contact
• Wben the fullload contact is closed, the K.E control unit initiates fullload enrichment.
• Engines 116, 117 and engines with EZL/AKR: fullload recognition additionaJly for the EZL
Mercedes-Benz
ignition control unit or EZL/AKR ignition control unít.
Idle speed contact
• Engines 116, 117, 119: ídle speed recognition for deceleration fuel cut-off.
• Engine 102 KAT/RUF and engines 103, 104: When the throttle valve is closed, acceleration
enrichment ís inhibited.
• Tdle speed control.
• Engines 102, 103 and engines with EZL/ AKR: ídle speed recognition additionally for the
EZL ignition control unit or EZLIAKR ignition control unit.
Throttle vaive switch
Swid111gga!e
2 FuJ loadconl:act
3 Thrc~ we shafi
4 Bedncalconnsc'oo
5 ldle sp.ll ¡¡d corlt act
Fig. 196: ldentifying Throttle Valve Switch Components

Mercedes-Benz
N3 I<E coorolunt(Z.>ptn)
52911 Ttm.'tte 'lfWe swllth
S2"911x1 Pk¡g conoodlon,DTc-11e Vlltle 51Mldl, illload r~O!JIIton
W11 Eo!Jine groond (e~octnc cable boledoo)
Fig. 197: Throttle Valve Switch Wiring Diagram- Engine 102.962 Std.
N1f2 EZL ¡gniloo corooh.n•

N3 I<E coofrolunt{2'5-ptn)
NS kle speedcomoltnt
52912 Ttrott!c vat.te sw':th wn
S2912ll1 PkJ¡¡ connemoo, llhr~a V!Wa sv.~tch, llfelfu'l load
re,'()gniloo
O;l!i~ 1: t
W11
X48
Eo~J~ne !JQtlnd (elednc cable boledoo)
C{)meclof sle!MI (scldered comedorW~ hamess)
OJS br,_ml~
~
, f :¡
x1 a i.
~tt 'b
~ ~ ~ ~
n
"t
o o o ~
o 0 X48
o •
1
•
L·-·-·:!1
$2912
Fig. 198: Throttle Valve Switch Wiring Diagram- Engine 117.968
Vehicles with automatic 5-speed transmission
The accelerator pedal potentiometer is integrated additionally in the throttle valve switch. It detects
the accelerator pedal position and thus determines the downshift point.
Mercedes-Benz
529/4 ThroWe va.'Ve sw.11t:h

S29/4x1 PkiQ connectJon, icleí.,.lloadrocog,rJton swadl
S29!4x2 Pklg connectJon, acceleralor padal pc:Oniomelsr
S29t4
Example engínes 104, ll9
r·-·-·~·-·-·-·J
L ·- · -· - ·
AG4 VerSion •td l automabc 4- speoó lransmt&sion anó S 29,14 Ttr O::le II!I.'VB S'Mtch
mllll'lJ!ll trallSIT1SSIOO S29l4r1 Acco ereloc ~al po:Snbome!Dr
AG5 YerSIOfl'Mih m.ttomallc 5-speerl ~ansmtSSion S29J4s 1 klfl speed/i.llload reco!Jillon swtc.h
N1.G EZUAKR 1g11ilon ooltrol unt S29J4x1 PkJgcomedon, de 5J>e&dlf\aloadrec"Ogllboo sw.~tth
N3 KE CMtol U!lll { 5,5-ptn) S29J4x2 PlJgcctl'lOCton, aoceleralnr pedal piltertiomMol
N151'1 Au!Dmabt 5-spe~d lransmt!>SIOO c•onioluntt W1 1 Eng~~eg¡otnl (aleche cable boleó on)
S2912 Ttrc!le vak>/o &'Mich
S2912x1 PkJgccmedoo, tlrclfe vatvu s.vich , tdle sp¡tedAúl
lo1ld n~c"Ognib on
Mercedes-Benz
Fig. 200: Throttle Valve Switch Wiring Diagram- Engine 104, 119
Engine 102 national versions
® 1985, [l] up to 1986, ~BT up to 1987
On these versions with exhaust gas recirculation (without catalytic converter), a throttle valve body
with vacuum control valve is fitted. The throttle valve switch (S29/2) at the vacuum control val ve
with idle speedlfullload recognition influences the KE control unit, EZL ignition control unit and
the exhaust gas recirculation control uní t.
Example engine 102.982 [l] ~BT

Mercedes-Benz
Y4 Y27 S2912
e d
WJ
P14·ttu -n
N37 Elihaust gas remrulmon ocntolunt Y27 Elihaust gas roarrulaloo swidlowrvalve
529.12 Tiro'llll vat;e S'<'.tlch a Te E2l tgmbon comrol urA, cortad 2
W3 Ground, attcrtleftwheol'louse (ig¡lcn oetl) b To KE contolurtJ~ cortad 5
W11 EnQille g¡OUild (ele~r" cable bcled 011) Co~ng, i.Jel punv rele¡
X56 PII.Jgcomedon, ;¡rotte vat.v swich, idle spoEtc!NI d Pl.lgcomedon, eng~ne (1Bfllllllal15)
load rEtrogn~cn a To 100 •e IEtllllEtra~re sNJtch
Y4 2nd u-ansmss1011 modo S't.!lclloVerv!IM! (Ewoomy), To lo: wasller nonm heator
Off.¡ wtt oolomabc trensmrsSicn
F ig. 202: Throttle Valve Switch Wiring Diagram- Engine 102.982
d. Deceleration fuel cut-off microswitcb (S27/2)
The deceleration cut-off microswitch (S27/2) is installed on engines 102, 103 and 104 at the
accelerator contro1. When the accelerator pedal m oves back into idle speed position, the
microswítch passes a sígnal to the KE control uní t. Thís actívates deceleratíon fuel cut-off as a
function of further influencing parameters ( e.g. engine speed, coolant temperature, throttle valve
switch).
When the accelerator pedal ís depressed, the microswitch opens before the throttle valve moves. It
interrupts deceleration fuel cut-offbefore the throttle valve opens thus ensuring smooth resumption
of combustion.
Mercedes-Benz
Fig. 203: ldentifying Deceleration Cut-OffMicroswitch
On engine 102.961/962 Standard and 102.962 NV KAT/RUF, acceleration enrichment is inhibited

via the deceleration fu el cut-off microswitch when the throttle vaJve is closed.
The deceleration fu el cut-off microswitch (S27 /2) switches engine ground (W 11) to the KE control
unit, contact 24 (engine 104, contact 10).
N3 KE conlrolunt
Elgne 103. 25-~
Engine 104 55-¡w¡
527/2 Oetulmalion i.Jol cú-df mocroswtch

W11 Et9no ground (elemc c:able boled on)
Y1 Eledroh;da!Jic eduator
P07-ó828-16
Fig. 204: Deceleration Cut-OffMicroswitch Wiring Diagram
Engine 102.96/982 Standard
The microswitch is actuated by the KE control urut, contact 6, with a constant voltage signaL The
KE control unit recognizes contacting at contact 13.

Mercedes-Benz
N3
r ·-·--·---~·-·-·-
!r.-
N3 KE coortolurll
K12 Oe~elerabon ilel cU!.oWTempomal cruose comol relay
S'17/2 ~elereboo tU-'Off mtcros'MIC h

SW1 Th:OU!e VIJÑ8 Sl\l'!ch x1
SW1x1 Plug connecboo,ltfToele 'Y!!Ne s.'.ltch, á.llloed recogwioo
X3J PlJg CCflnedlcn, Tempomat cruse coruo1 LYI 1 a1
Y1 Bectrollyt!raúlc actuator ~ ~ ~ ~ ~
AA ~ ~·r ·.~
i ·-·
L.-.J i.!;·-·-·-·=.i L---~ L!::.:i.i
$2712 K12 $2911 V1
P00'-58:29-15
Fi~. 205: Deceleration Cut-Off Microswitch Wiri n~ Dia~ram - En~i n e 102.961 Std.
Model201 with Tempomat cruise control
On engine 102 (KE 1 and 2) up to 09/86 the signal from the microswitch is looped via the
deceleration cut-off/ Tempomat cmise control relay (K12). As a result, deceleration cut-offis
inhibited during Tempomat cruise control operation.
Vehicles with ASR
The microswitch is omitted. The cable is tied back in the harness. The signal for deceleration cut-
off is then formed by the position sensor (R25) and supplied to the KE control unit via the
electronic accelerator pedal control unit. The separation point between the control units is the plug
connection (X89/4).
Location on model 129
X8914 PlJg COiln&dJoo, oelel;ionc ac~e•era:or pedal (EFPVKE

roRro! unl (1iJtn)
Fig. 206: Iden tifying Plug Connection

Mercedes-Benz
Note re engines 116, 117, 119
The throttle valve switch (idle speed contact) performs the tasks ofthe deceleration cut-off
microswitch.
e. Tempomat cruise control
The KE control unit inhibits deceleration cut-off during operation of the Tempornat cruise control.
Cruise control operation is recognized, depending on version, as follows:
KE control unit without road speed signa) :
• On engine l 02 (KE 1 and 2) in model 201 up to 09/86 the cable from the deceleration cut-off
microswitch (827/2) is looped via the deceleration cut-off/Tempornat cruise control relay
(K12) and the plug connection ofKE injection system/Ternpomat cmise control (X33) (see
section "Deceleration cut-off microswitch").
• The "Ternpomat ON" signal is passed from the Ternpomat cruise control unit (N4), contact 5,
via the Tempomat cruise control plug connection (X33) to the KE control unit, contact 6.
KE control unit with road speed signal :
(indefmite production breakpoint as of 09/88, engines 116, 117 as of start ofproduction) Ternpomat
ON is recognized indirectly via the road speed signa! (cmise control mode only possible frorn
speed of approx. 40 km/h).
f lntake air temperature sensor (B17/2)
Location
Engine 102.91/96/98: intake air temperature sensor (arrow) installed at front ofair cleaner housing.
Fig. 207: Locating lntake Air Temperatttre Sensor- Engine 102.91/96/98

Mercedes-Benz
Engine 102.983/99: intake air temperature sensor positioned at rear of air cleaner housing.
817/1 lllake a;rtempwatue sensorfcrEZL

817/2 ktake MtompomiUs sonsorfcrKE
Fi~. 208: Locatin~ Iutake Air Temperature Sensor - E n ~ine 102.983/99
Engines 103, 104: intake air temperature sensor (arrow) installed in intake pipe of air cleaner.
Fig. 209: Locating Intake Air Temperature Sensor- Engines 103, 104
Engines 116, 117: intake air temperature sensor (B17/2) installed in intake air scoop (9).
Mercedes-Benz
Fig. 210: Locating Intake Air Temperature Sensor- Engines 116, 117
Note re engine 102.96/98 KAT as of 09/89
The intake air temperature sensor (B 17/2) as well as the 80% onloff ratio output in the KE control
unit are not provided.
The intake air temperature sensor (B 17/1) for the EZL ignition system has a differing characteristic
curve.
Function
The intake air temperature sensor on KAT/RUF engines (as ofKE 3) and on national versions
without altitude correction sensor, is located in the intake scoop, in the intake pipe of the air cleaner
or at the air cleaner housing.
It supplies its temperature sígnal to the KE control unít. When the intake air ís cold, the mixture is
enriched (see section "Intake air míxture adaptation").
The characteristic curves of coolant temperature sensor and intake air temperature sensor (B 17/2),
as welJ as actuation with a constant voltage by the KE control unit are ídenticaL
Mercedes-Benz
-
~000
:tOeOO ~
".¡:
10000 ~
~
toOO
~
""Q
40GO
MIGO
~
,
......
~
HGG
h.
11X0
~~
ICID
~
wo
....g
ct -
-4«1
!lliC
11)0
~
' ~..........
.......
~ ......
10
4!11
.f4)
~
OC!
10
- 30 - !10 o » "o eo ea 100 tao9C
•t&oO U1 -1 $
Fig. 211: Temperature Graph
g. Fuel pump relay
Fitted to engines 102, 103, 116, 117 (engines 104, 119 see Engine systems control unit, section h).
Location
Model107
Fuel pump relay (Nl6/4) behind glove box.
Remove glove box for testíng.
A flap can be removed in sorne cases on the bottom of the glove box.
Mercedes-Benz
Fig. 212: Identifying Fuel Pump Relay- Engines 102, 103, 116, 117
Models 124,201
Fu el pump re lay (N 16/ 1) on right of component compartment.
Fig. 213: Identifying Fuel Pump Relay- Models 124, 201
Model201 with engine 102.961
Fu el pump relay in front of electrical center.

Mercedes-Benz
Fig. 214: ldentifying F uel Pump Relay- M odel 201 With Engine 102.961
M odel 126
Fuel pump relay (N16/4) on left of component compartment.
Fig. 215: Identifying Fuel Pump Relay- Model 126
NOTE: The fuel pump relay is designated differently depending on year of

manufact ure or appropriate optional equipment. Possible
designations are NS/1 , NS/2, N16/1 , N16/2, N16/3, N16/4.
The fuel pump relay performs the following functions, depending on the engine version:
o Actuation offuel pump

o Governing engine speed
o Kickdown cut-off with automatic transmission
Mercedes-Benz
o Actuation of start valve, see section F "Strut devices"

o Oxygen sensor heater, see Group 14 section "Oxygen sensor heater"
o Actuation of auxiliary air valve (only engine 102) with idle speed stabilization, see section G
"Idle speed devices"
Actuation of fuel pump
The fuel pump operates as soon as the fuel pump relay has picked up and terminals 30 and 87 are
thus connected. The voltage supply is not fused. In the event of a short circuit, a conductor in the
fuel pump relay fuses.
The fue! pump is actuated as fo llows:
• Briefvoltage supply (approx. 1 second) to fuel pump when ignition is switched on vía
terminall5 (full running protection when engine stopped and ignition switched on).
• Fue] pump actuated when engine starting vía terminal 50. Necessary because the pulse
sequence from terminal TD/TN is only adequate from engine speeds above 80/min in order
to keep the contact terminal 30 -87 in the fuel pump re lay constantly closed.
• Fuel pump actuated when engine nmning via terminal TD/TN and terminal 15.
• Fue! pump switched off as soon as no pulses supplied via terminal TD/TN of ignition control
unit.
V ehicles with ASR
The voltage supply for the fuel pump relay (N16/4, terminall5) on vehicles with ASR is supplied
via the protective circuit ofthe electronic accelerator pedal (see 30-350).
Governing engine speed
Once a certain number ofpulses supplied by terminal TD/TN is reached (depending on maximum
engine speed), the fuel pump is switched off.
Wiring diagram offuel pump relay, example modell24

Mercedes-Benz
¡,
~
r
W11
' - - -- -0.1S ~
h- o.re~
.,.
W3
·"' rllN - 0)1 """" - '1 .ll
8 1112 Coolanl ternpererure soosor 12-p¡n) X26 Pllgcornec~oo. oogme hemes-s (12-Jllll)
G312 He atad oxvaen sensor AsSigmulrt 1 ID lgRiiOil starter switch,
G3/2 Hea!edoxygon sensor
temmal 15
G3/2x1 l"lg connectJon, oxygen sensOl healilg c (lj
{2..pcn) Assigrnnlllll 7 lo startor, tomlnal 50
G312X2 Pllg cooneáion, oxygen sens()( sa!Jil!ll {1..pcn) X36 PllgcOMedon, llelpurrp
M3 FuelpWT¡l YB SlaJt v;We
N3 KE CCil~ciUJlll e T8f1Tllnal block, eng,ne, ~enninal 30
N16f1 Fu el PIJil1l relay g CNeiVcl:age prc~e ál cn, tenmnal 15, coo~tl6
W3 Ground, a!frontlea'l'tleerhouso {l!}ll .ti0/1 c>Od) h EZl 1grd on coo~olun~ termnal TO {4-pm connector,
W10 Balrory ground suppty)
W 11 En¡jne ground {elodnc cable bollad oo) V CNeiVotage protetfion, tennmal 87, ccnlact 2
W12 Cemre consolegromd y EZl. 19J11icn con~olurd{4-~ comector, sensor)
X 11 Dlagrlas!Jc socl<etftormnal block, terrn1181TO
Fi~. 216: Wiring Diagram OfFuel Pump Relay, Example Modell24
Kickdown cut-off with automatic transmission
The purpose ofkickdown cut-off is to ensure that the transmission performs an upshift before
maximum engine speed is reached (activation of engine speed governor).
In kickdown position, the solenoid valve (Y3) at the automatic transmission is activated by terminal
15 via the fuel pump relay and the closed kickdown switch.
Approx. 200/min before maximum engine speed is reached, this actuation is interrupted in the fuel
Mercedes-Benz
pump relay (terminal 87K) anda transmissíon upshift thus ínitiated.
W12
T
O,I'I..Jwe v!~.b
d
.
i i
i.::.:U
Y4 P07-68:3'Joa6
N112 EZl rQillli011 con'"ol urJt X26 F'tlgcomed011, eogrne hamess{12-~)
N1614 Fuel pullprelay>Mih ldckdown at-o.'f V3 A.u!!lmabt transm"ssion kickoo,..rn ~e
S1615 2nd trnnsm ssiOn mcxle SMtch Y4 2nd transmss100 moda swtchover va!\19
516/7 Klckdooo swtch wih 2nd lrll.rlSmssron m o-de a To 1g11iJ011 starteT s.-.tcll, !emlnal 15
W11 Eng111e grOUld {e1ecnc e eble boled 011) b To KE coorol ulit
W12 Cerne console gromd To o~age protedlonrelay, tarmnal 15, cortact6
X11 Dlagnosbc scd<e~'tenn11albl<x:k, temnnal TD
Fig. 217: Wiring Diagram OfKickdown Cut-Off, Example Model124
Wiríng diagram of kíckdown cut-off, example model 124
h. Engine systems control unit (MAS)
Positioned in the front right ofthe component compartment and equipped with removal/ínstaUation
aid. The previously known components of "Fuel pump relay and compressor cut-off control unit"
are integrated in this control unit as a unit, with additíonal functions. For design and operation as
well as removal and ínstallation, see Group 15.
Model129
Mercedes-Benz
N16 Engoo sys!oms rorirol uni
Fie. 218: ldentifyine Eneine Systems Control Unit (MAS) - Model129
Model 124
N16 Engma systems cootrol una
Fie. 219: ldentifyine Eneine Systems Control Unit (MAS>- Model124
1. Throttle valve body

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Fig. 220: Throttle Valve Bodv Communication Diagram
The throttle valve body (123) is positioned between mixh1re control unit (1) and intake manifold
(12). The throttle valve body is flanged to the intake manifold. The connection to the mixture
control unit is by means of a mbber cup seal.
The throttle valve in the housing is bolted to the throttle val ve shaft. The shaft is mounted on plain
or ball bearings. One shaft end operates the throttle valve switch. The throttle valve lever at the
other end is connected by a ball head to the accelerator control.
b Exlmcúoo mlfrtg for fuel ewpora 011 system (morge irto 8

dlamef ami operate ooe a•erlhe ofher)
Fig. 221: ldentifying Throttle Valve Bodv
The quantity of air inducted by the engine and thus the fuel metering by the KE injection system is
dependent on the opening angle of the throttle val ve. The position of the throttle valve thus
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determines engine output.
Example engine 103 KA T
1 Regenemoon 1/Bl(B cortrOI t ne

2 Regeneraban k! e
2 El41 !ll.lst ges rearctJialloo corúolllna
Fig. 222: l dentifying T hrottle Valve Body Parts
When the engine is running, the vacuum conditions at the throttle valve alter depending on the
opening angle. Drillings (a, b) in the housing are opened by the throttle valve depending on their
position and the hose connections supplied with vacuum. Depending on the engine, they are
required for different functions:
• Control of exhaust gas recirculation.

• Extraction 1ine from regeneration valve of fuel evaporation system.
• Controlline of regeneration valve
• Ignition advance (TSZ).
Fig. 223: Locating Regener ation Valve

Mercedes-Benz
@ 1985
lll up to 1986
[!r'BT up to 1987
Throttle valve body with vacuum control valve
Fig. 224: ldentifying Throttle Valve Body With Vacuum Control Valve
J. Fuel consumption signal (trip computer)
The fuel consumption signa! is required in the tríp computer control unit or, in the case of model
129, for the consumption display in the instrument cluster.
The momentary fuel consumption is dependent primarily on the position of the air flow sensor. The
position is detected by the air tlow sensor position indicator.
The KE control unit is supplied with a signal from the air flow sensor position indicator and forms
from ita fuel consumption signal matching fuel consumption.
Signal output:
KE control unit (25-pin): connector 4
KE control unit (55-pin): connector 8
FUEL SUPPLY- RA0703KEIB030X(B.)

Mercedes-Benz
lt f f f l 9¡tslempressureAJppeHhamberpressum
LC'A'IIf d1anbor pressure
r.•.•... o¡ lrtetilonprossure
lf f l pressurelllss
1, 1 1
Fig. 225: Fuel Supply Function Diagram
The fuel supply consists of:
• Fuel tank (75) with fuel evaporation system (see Group 47)
• Fuel pump (M3)
• Fuel filter (55)
• Fuel accumulator (57)
• Fuel distributor ( 15)
• Diaphragm pressure regulator (40)
• Injection valve (92)
The fuel is drawn out ofthe fuel tank (75) by the electric fuel pump (M3) and pumped through the fuel filter
(55) to the fuel dístributor (15) and start valve (Y8)_ At the same time, the fuel accumulator (57) which is
connected in parallel to the fuel filter ís also filled_ The diaphragm pressure regulator (40) maintaíns a constant
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Holding pros SLI e

lt j f<tl
pre sSLI e!ess
Fig. 226: Fuel Supply Function Diagram
When the engine is switched off, the pressure conditions change. The diaphragm pressure regulator (40)
determines the leve! of the holdíng pressure. The holding pressure is always below the opening pressure of the
injection valves.
The sealing plate (anow 1) in the diaphragm pressure regulator closes the fue] retum line to the fuel tank.
The non-retum valve (anow 2) on the pressure side ofthe fuel pump prevents the fuel :flowing back into the fuel
tank from this side.
The pretensioned compression. spring behind the diaphragm ( arrow 3) in the fu el accumulator ensures that the
holding pressure is maintained over a lengthy period.
The holding pressure largely prevents the formation of vapor bubbles in the fuel system and thus ensures good
starting properties of the warm engine.
a. Fuel pump set

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Fu el purrp set 'M tl 1 hiel pump

----
Shown en modal 201
Fig. 227: ldentifying Fuel Pump Set Components - With 1 Fuel Pump Model201
The fuel pump set is composed offuel pump (M3), fuel filter (55) and fuel accumulator (57). On models
with double pump version, two fu.el pumps are connected in series at the fuel pump set.
The fu el pump set is attached to the frame floor in the area of the rear axle. At first, the pump set was
suspended on rubber-metal vibration dampers (35). A conversion was made subsequently to rubber rings.
A plastic cover (1 O) protects the fuel pump set.
The brackets (2, 2a) at the fuel pump set vary in design depending on pump diameter, number of pumps,
filter diameter, type of suspension system and line routing.
Filter and pump are installed at the bracket with plastic sleeves (25, 26) to avoid contact corrosion.
On various models two fuel pumps M3/1 and M3/2 are installed (connected in series).
Mercedes-Benz
Fuel punp set 't.lth 1 ftJel pump

Sho'<lll en mooel 124 Sedoo.Coupti
Fig. 228: ldentifying Fu el Pump Set Components - With 1 Fu el Pump Model124 Sedan/Coupe
Fuel punpsetl'lllh Ztuel pumps

ShO'IIfl en mo<lel124 T model
Fig. 229: ldentifving Fuel Pump Set Components - With 2 Fuel Pump Model 124 T Model
The fue! pump is suspended on rubber rings between rear axle and fu el tank in order to achieve short
suction distances. In the case ofthe double pump version, the second fu e! pump is housed in the fuel
pump set. In the case of versions with one fuel pump, the space in the fuel pump set is vacant.
Mercedes-Benz
Fuol pumpsct'Mth 11uol pwnp

Shc·.-.n oo modols 107, 126
Fig. 230: Identifying F uel Pump Set Components- With 1 Fuel Pump Model107, 126
\
\
F uol punp set 'Mth 1 fuol punp
StlO'M J an modol 129
- -- ---
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Fig. 231 : ldentifying Fuel Pump Set Components- With 1 Fuel Pump Model129
b. Fuel pump
S6 Oaflller
-·--·
67 Pressu-ereiol w!ve
72 NOIHBium valva
Fig. 232: Cross-Sectional View OfFuel Pump
The fuel pump ís desígned as a roller cell pump. It is driven by a permanently excíted electríc motor.
The pump is completely filled by the flow offuel ("wet pump") which eliminates any risk of explosion
because no ignitable mixture is able to form in the small recesses in the absence of oxygen.
The fuel is drawn in from the fuel tank and pumped to the fuel dístributor and diaphragm pressure
regulator. The pump delivers more fu el than the maximum needs of the engíne. This ensures that
sufficient, cool fuel is always available to the engine. The excess fuel pumped to d1e engine flows back to
the fuel tank.
A damper ( 66) is ínstalled at the suctíon side in the fuel pump to avoid noises.
In addition, the fuel pumps featme a coated track as of approx. 02/86.
When the engine is switched off, the non-retum valve (72) prevents the holding pressure being reduced
through the fuel pump.
As a result ofthis, the formation ofvapor bubbles in the injection system is largely prevented and thus
ensures that the warm engíne has good starting properties.
The non-return valve (72) in the screw fitting can be replaced separately.
In the event of a pressure rise to approx. 8 bar, e. g. because of constrictions in the fuellínes, the pressure
reliefvalve (67) opens and connects the suction side to tbe pressure side within the fuel pump and thus
prevents any further rise in pressure.
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Various models are fitted with two fuel pumps (connected in series) in order to boost delivery capacity.
The fuel pumps have a diarneter of 52 mm (small pumps) or 60 mm (large pumps). Ifthe brackets are
designed for the larger pump (standardization), the smaller fuel pump is installed with a spacer sleeve.
F unction of the roller cell pump
...._...
1 Rctordisc b Ooivory~de
2 Re er Fuel Pf8!'.~Ufele!'. s
3 Fuot purnphoosmg {Wih rct« nng) d Pwrpmgruet
a Sucllon sida 8 Fuol Ulldol pro~Jrn
Fig. 233: Identifying Function Of Roller Cell Pump
The rotor disc (1) has 5 pocket-shaped recesses (cells) in each ofwhich is located a roller (2). As a result
of the centrifuga! force produced by the rotor disc which is driven by an electric motor, the rollers are
pushed out against the rotor ring in the fuel pump housing (3) and act as a seal. As a result of the
eccentric arrangement ofthe rotor ring relative to the rotor disc, the volume between the rollers (2) alters,
producing the suction and pumping effect.
c. Actuation of the fuel pump

Mercedes-Benz
bl bU
be bccv.n
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go " y¡¡low
gn glll!lil
IS = p«lk
lt red
SN blaO<
ws = m te
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ltJ-a•••-41
8 11/2 üc<Jiarn !arn¡l<ltatur~ SetiSOI' {2.p.n) X36 Pllgc<lmedon, úelpu~

M3 Fuelpump Y8 startvalve
N3 KE coru<JI~nt ( 2~P'" cct.ping) t T ennlllal blod<, engane rormnel 30
N 16/1 FuBI pumprel!lywth startvatve acluajon g OvoiVo&lga pcolectlon 00m1nal 15, cortad 6
ws Ground, ang.n a h Bacrooc tgnt~oo systam (E2l) COfirol unt, terrmnal
1/119 Grcund, et torUefiheacDsrrc> lllt TD (4illn cooneáor, sq¡pt¡)
W 12 Ground, cetterccnsola V Ov&IVoCiJGe prol~tbon armnal87, eorl:ad 2
X11 Ola¡¡oosbc sod<e!ltennnalblock, tennmal TD y Becrooc: IQilJion s¡stem (Ell.) COftrol unt
(4- pin connec ter, sen sor)
X26 Pllgcomedcn, enganewnng hamess{12-ll«l)
Fig. 234: Fuel Pump Circuit Diagram
The voltage for the fuel pump is supplied through the fuel pump relay or through the engine systems
control unit (engine 103.984, 104 and 119).
The fuel pump runs as soon as the terminals 30 and 87 are connected (relay picks up ). The voltage supply
of the fuel pump is not fu sed.
For safety reasons, the actuation oftbe fuel pump is designed so that the pump can only run subject to the
following conditions:
• When the ignition is switched on for about l second via terminal 15 (full mnning protection when
engine stopped and ignitíon swítched on).
• When engine is started via terminal 50
• When engine is running via terminal TD/TN (speed signal of ignition systern).
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Switching off t he fu el pump
As a protective circuit the fu el pump is switched off 1 second after the last pulse from terminal TD/TN _
When a certain number of pulses is achieved at terminal TD/TN (engine speed signa!), the voltage supply
of the fuel pump is interrupted and max:imum engine speed is thus govemed.
Exception: Engines 102, 103 in Standard versíon (KE 1 or KE 2) do not have engine speed governing by
means ofthe fuel pump relay (engine speed governed by ignition system)_
NOTE: In addition to actuation of the fuel pump, further functions are contained in
the fuel pump relay and in the engine systems control unit (see sections
"Fuel pump relay" and "Eng ine systems control unit" ).
d. F uel filter
Fig. 235: Fuel Filter Function Diagram

--·
The fuel filter (55) is positioned at the fuel pump set
The fuel filter traps impurities in the fuel before they reach the fuel distributor. For this purpose, the fue]
filter is installed in the fuelline downstream ofthe fuel pump.
The filter is a fine filter with paper element A darnper ( 1) is installed on the fu el inlet si de to avoid fu el
no1ses.
The direction of the fuel flow is indicated by an arrow on the filter housing. It is essential that the filter is
correctly installed during routine replacement
Fuel pump set, example model 201

Mercedes-Benz
M3 FueJpump
55 Fue1me1
57 Fuel eccumu1ator
Fig. 236: ldentifving Fue) Filter And Fuel Accumulator
e. Fuel accumulator
The housing of the fuel accumulator is made of stainless steel. The interior is divided by a diaphragm into
a spring chamber and an accumulator chamber.
As soon as the fuel pump is mnning, the fuel (at system pressure) flows through a restriction slowly into
the accumulator chamber (approx. 20 cm3). The diaphragm is deflected against the pressure ofthe spring
as far as the stop and the compression spring (58) is fully pretensioned.
As a result ofthe slow filling ofthe fuel accumulator, the fuel pressure at the injection valves ís rapidly
built up which improves starting characteristics and smootb running of the engine after start.
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81
58 C~presstoo ·spnng
59 Dlaphragm pla~
60 Bafflepl&e
61 Coonedtoo fiimg lor leak l ne {vel'lt)
Fig. 237: ldentifying F uel Accumulator Components
After the engine ís switched off, the holding pressure is maintained in the fuel system untíl the
accumulator volume is exhausted. The period of time for this depends on the intemal leaktightness of the
system.
The fuel accumulator, as a result of its construction, has a damping effect on fuel pump noíse.
Fuel pump set, example model 20 1

Mercedes-Benz
MS Fuel pump
55 Fuel lilor
57 Fuel aocumu&or
Fig. 238: ldentifving Fuel Filter And Fuel Accumulator
55
M3 Fuolpump
55 Fuel filer
57 Fue! accumiÍ!l!Cll'
75 Fuel tarA<
b lsak lne (vert)
Fig. 239: Fuel Accumulator Function Diagram

---
The leak line (b) vents the spring chamber during movements ofthe diaphragm. For safety reasons, the
leak line is connected to the pressureless suction s.ide of the fuel pump which prevents fuel flowing to the
outside if the diaphragm is defective.
f. Diaphragm pressure regulator
The diaphragm pressure regulator is positioned next to the mixture control unit.
The fuel pumped by the fuel pump passes along the feed line and through the fuel distributor to the
diaphragm pressure regulator. It controls the system pressure when the engine is running and maintains
this pressure at a constant leveL
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The system pressure ís ütctory-set and cannot be altered. It varies from 5.3 to 6.4 bar dependíng on the
engine.
Fluctuations in the system pressure have a direct influence on the air/fuel ratio because the system
pressure acts in the fuel distributor as a backpressure on the control pisten (see section "Mixture
formatíon"). The delivery quantity ofthe fuel pump and major variatíons in the quantity offuel injected,
e. g. during rapid load changes, have no influence on system pressure over wíde tolerances.
~ 53
50 S1stom presSI.Jre :e.ed

51 Fuol rntum
53 Fuol ms'"ibumr re~ m
Fig. 240: ldentifving Svstem Pressure Feed, Fu el Return And F uel Distributor Return Line
Diap,hragm pressure with engine running

Mercedes-Benz
52
41 Systam press1.1e tootol spong
42 Dlap!Tagm
43 Presslf& dlBITber 41
44 Systsm pross1.1e cootolvalve
45 V&MJ boct¡
46 Seali'igpla!e
47 CloSilQCOfllXBS5100 sprllg
48 Ceniatdr• ng
49 Stop a
52 Vort
8 Systnm pr&SSlf9 f~
b Fuelretlnl
Rellm from fuel ti sin Wor
P!O'·- ·e
e=! Syslllln pressu-e

pras:sureless
e=!
Fig. 241: Cross-SectionaJ View OfDiaphragm Pressure With Engine Running
The fuel delivered by the fuel pump flows into the pressure chamber (43) and moves the diaphragm (42) up
against the system pressure control spring (41 ). At first, the moving valve body (45) follows. It is pushed up by
the dosing compression spring (47) until it rests against the stop (49). The system pressure control valve (44)
operates.
The sealing plate (46) connected to the valve body is now lifted offits seat The control and leak quantity from
the fuel distributor (e) flows to the return (b).
The excess pumped fuellikewíse flows to the return (b) tlu·ough the system pressure control valve (44) and the
central drilling (48).
Fuel system with engine running

Mercedes-Benz
u:tJ!j 9y'2om preSS\Ire/~r charrtl!lfpressure

Lcwflf chamboer pcessuro
tL:t::&::lj t'(.adon pcessuro
l f f l pcessure!ess
~
Y1 Ele!trotr¡dn!Uíc actuatcr SS FueiUer
Ya Start va.'ve 57 Fuel eccu rrula!Df
1 Mixture coofroluflll 75 Fuel ta;nk
2 Alf llow sensor 92 lqedonvaM3
15 Fuol dlsiil\J!Or a V&lll
40 Dla:phragm presst~e regula!:ll b le al< l ne
F ig. 242: Fuel System Function Diagram - With Engine Running
Diap·hragm pressure regulator with engine switcbed off

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41 Systom ptessu-e contolspnng

42 Oiaprr&gm
44 Sys!Dm ptesstJa coorol vatve
45 VaMibody
46 Sealllgplate
47 ctosflg COfTllrBSSIOO spmg
a Syslllm pressue feed
b Fuelrehrn
e Retlm from flllll áslnbúDr
e==! Htokingptossuro
c:==J pressureloss
Fig. 243: Cross-Sectional View OfDiaphragm Pressure Regulator With Engine Switched Off
When the engine is switched off (fuel pump de-energized) the pressure conditions alter. The system pressure
decreases by a certain amount through the system pressure control valve (44) which is still open for a short
time. The system pressure control spring (41) pushes diaphragm (42), valve body (45) and sealing plate (46)
against the closing compression spring (47). The sealing plate is pressed onto its seat and seals off the fuel
system to the return (b).
The fuel pressure drops rapidly below the opening pressure of the injection valves so that the valves elose
tightly. Following this, the holding pressure adopts a constant level, which is determined by the fuel
accumulator.
Fuel system with engine switched off

Mercedes-Benz
rm Hclóng prassur&
PfGSSU"OieS S
c:=:::J
Y1 Boci'OO¡t<kmilc artuetct 55 FUil! Uet
YS Slall valva 57 Fue! aoc!Jrrula!Of
MIXb.re ccnl"olunt 75 Fuel lllllk
2 AJt llcw :.enser 92 ~&cnvaM!
15 Fuolds~tor a V81lt
40 DI aptragm pressu-e re gulaiDr b l eak l no
Fig. 244: Fuel System Function Diagram - With Engine Switched Off
MIXTURE FORMATION - RA0703KEIC030X(C.)
a. Mixture control unit
The mixture control unit consists of
• air flow sensor with controllever and air flow sensor position indicator.
• fuel distributor and electrohydraulíc actuator.
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82 A-.llow S!lflSOf pogfioo tn<:i~or

Y1 El&clroil11h!Jíc 11t~atlr
2 A-.flcwsoosor
9 Stopbar
15 Fuol distnbl.tor
Fig. 245: ldentifying Mixture Control Unit Components
b. Air flow sensor
The air flow sensor is installed in the induction flow upstream ofthe throttle valve and measures the total
quantity of a ir inducted b y the engine. This quantity of air is the principal control parameter of the
mechanical mixture basic adaptation.
The a ir flow sensor consísts of an a ir funnel ( l ), the control lever (2) with counterweíght ( 5) or return
spring (only on engine 102) and air flow sensor plate (4 ). Tbe controllever (2) pivots around the pivot
point (3) .
The deadweight of air flow sensor plate (4) and controllever (2) is compensated by the counterweight (5)
or by a return spring (only on engine 102).
rw-HM- w
Airñ.mel
2 Cortrof levar
3 Ptvotpomt
4 Air ficw sansor pla!B
5 Coonmrweight
6 Conlrcl p l stCfl
7 Ml:le11xe regulaing !;CfB'..V
Mercedes-Benz
Fig. 246: Identifying Air Flow Sensor Components
3 1
1 A• hJI'Inel
2 Con~oii&VQ(
3 P ivol piltrt
4 Aflllcw sensor plata
8 Re'llms,pmg
8 2
Fig. 247: ldentifving Air Funnel And Control Level
Measurement of the quantity of air is based on the suspended body principie which states that a
suspended body m oves :iin a uniform cone in proportion to the air throughput.
The suspended body shown in the illustration pennits an air throughput equivalent to the annular surface
(al) in the case oflift (a) and equivalent to the annular surface (bl) in the case oflift (b). Hence: the
greater the air throughput, the greater is the lift of the suspended body.
In the air flow sensor of the mixture control unít, the air flow sensor plate is the suspended body, the air
funnel is the cone.
In accordance with the quantity of air inducted by the engine, the air flow sensor plate adopts its position
in the a ir funnel of the a ir flow sensor. The movement of the air flow sensor plate is transmitted to the
control pisten by the controllever. The control pisten alters the cross-section ofthe opening at the control
slots. Consequently, a large quantity offuel is metered toa large quantity ofair and vice versa.
Fig. 248: Suspended Body Dimension Of Air Flow Sensor
The following forces are active at the air flow sensor: The intake air acts on the aír flow sensor plate as an
~ir fnrr.P (F 1) ()nnm:P.rl t n it i~ thP hvrlr~nlir fnrr.P (F?) nf thP. ~v~tP.m nrP.~~nrP. whir.h ~r.t« fmm ~hovP. on
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the control piston.
The deadweight of air flow sensor plate and controllever, the force (F3), is compensated by the
counterweight (F4) or by a retum spring (onJy on engine 102).
The position of the sensor plate alters until the air force (F 1) and the hydraulic force (F2) are in
equilibrium.
Thus, the deflection ofthe air flow sensor plate and thus tbe position ofthe control piston in the case of
tbe basic function are detennined only by the air throughput.
/
F1 lrta.k& atr fof~e
F2 S'¡rstem pre sst~re force
F3 Force, de:adM!Ightof comol tavorlaS-Howsensor plate
F4 Fore o, COOlOOI"welgii or r !Wm spmg
Fig. 249: ldentifying Air Flow Sensor Forces
Wben the engine is switched off, the air flow sensor plate is in the zero position, resting against a resilient
stop. The zero position of the sensor plate is adjustable.
In the case of misfiring (Hback:firing") the resilient stop is overcome, the air flow sensor plate moves up
and opens a relief cross-section at the a ir funneL The pressure in intake manifold is reduced and damage
to the air flow sensor plate is prevented. The upward travel of the sensor plate is limited by the stop bar.
Matching of air flow sensor plate and control piston or mixture adjustment is performed with the mixture
regulating screw.
Mercedes-Benz
4--t;Jgg;a
1 ScrewdnV9f 2----f====i
2 Ad;Jsbng de\lce
3 Hexagon
4 A~tamper plug
81 Mnduror!tg'lamgscrew
Fig. 250: Matching Of Air Flow Sensor Plate And Control Piston Or Mixture Adjustment
Air tlow sensor with shaped air flow sensor plate
The shaped air flow sensor plate permits a higher air throughput compared to the flat sensor plate at the
same detlection.
ró1 - om -1~
Fig. 251: ldentifying Air Flow Sensor Plate Clearance
c. Fue) distributor
The fuel distributor meters the quantity of fuel to the individual cylinders depending on the position of the
sensor plate in the air flow sensor.
Mixture control unit

Mercedes-Benz
Y1 Eledroh¡drauk atll&llr
2 Art flcw sensor wth llll
fumol, Ellr llow wnsor plalB
and comol lo\'llf
3 IJifferomal PIQSstr9VlWO
4 lnrection lino lo a.n m;-edon
vatYe
9 Slopbar
15 F uel diS!nbúor
16 Cooiol ptston
17 Metonng slolboáf
Fig. 252: ldentifving Mixture Control Unit Components
Fuel distributor
14 16 17 18
14 S~Bi1181 w.tl pOffilarlert
m8!J19t
16 Coo~olp¡Sioo
17 Me!oong, ;.lot bod¡
18 Con!rolomca
2() Uppe~ chamber
21 Oiapkagm
22 L<lwar chamber
2:> COOlPfOS 5100 spnng 20
26 Saowpklg
(rorbol p¡ston)
2t
27 Shap&dnng
28 RBS!ncbon 22
29 Connocbon 28
Connecbng In o lo diaphragm
pra~sure regUia.!<lr (tortrol
2Q
and leal< quaniy)
a to eleelrohidrauk & ~ alcl
b lo 11¡ecllon vat>to
21 26 23 flOr........
Fig. 253: ldentifying Fuel Distributor Components
Fuel distributor
Mercedes-Benz
S(S1em pressuref\;lpor dlarroer pressure

Lowor ehamb:er pro SS!JO
lilecien pres SU' e
presweklss
1 Me:oong slot b:OO¡I 5 Lower chember

2 Comol prs!on 6 Otaph"agn
3 Otforen~al pr&Ssu-e velw a Comrollleel< quillljtyto dlaplngm pressure r~ator
4 Uppor ehemb:or
Fig. 254: Fuel Distributor Function Diagram
The metering slot body with the metering slots ( 1) and the control piston (2) is positioned in the center of
the fuel distributor. A differential pressure valve (3) is allocated to eacb metering slot. The number of
differential pressure valves corresponds to the nurnber of cylinders in tbe engine. Eacb differential
pressure valve is divided into an upper chamber (4) anda lower chamber (5).
The two chambers are separated by a diaphragm ( 6). The upper chambers are sealed off to each other. An
injection line runs from eacb upper chamber to the respective injection valve. All the lower cbambers, in
contrast, are connected to each other.
d. Mechanical mixture adaptation
Mixture control unit

Mercedes-Benz
Cortrollever
2 Cortrol P! ston
Fig. 255: Mechanical Mixture Function Diagram (1 Of 4)
The mixture basic adaptation is perfonned mechanically. In accordance with the quantity of air inducted
by the engine the air flow sensor plate adopts íts posítíon ín the air funnel of the aír flow sensor. The
movement of the air flow sensor plate is transmitted to the control piston (2) by the controllever (1 ). The
control píston alters the cross-section ofthe opening at the metering slots. 'Ihus, a large quantity offuel is
metered to a large quantity of air and vice versa.
Mercedes-Benz
#--- ~ --..
-- .
9fstem prassure/upper dlBITÍler ¡lfessure
lower e ham~er llf9SSure
qetiOOilf&ssur e
Fuel metering in the case of mixture basic adaptation is performed by altering the cross sections of the
openíngs at the metering slots. The fu el flows through the metering slots into the upper chambers and
then to the injection valves. The illustration (a) shows a slight opening cross section ofthe metering slot.
The engine is nmning at low load with a smaU quantity of fuel. In the illustration (b) the opening cross-
section of the slots is large. The engine is running at a higher load with a greater quantity of fue l.
A pressure difference is necessary to enable the fuel to flow through the metering slots. This means, no
fu el would flow if the pressure upstream and downstream of the metering slots were the same,
irrespective of the position of the control piston.
Mercedes-Benz
5 f F IH System pms~ure/~.poer cham'oi!r Pf&S51.lf9

lcwer dlarnbatpre~sue
t? t • • • • "1 lnjectioo pre sw re
lf f l presStJrele~"S
The pressure difference for the mechanical basic ftmction of the fu el distributor is fixed by the design. lt
is approx. 0.4 bar. Fuel rnetering is performed mechanically with a constant pressure difference. In this
case, the control piston alters the opening cross-section at the metering slots in accordance with the
quantity of a ir inducted b y the engine.
Mercedes-Benz
5_,0 5,4
IJF ti lí>IH S•¡IS!Bm pcessunt,lup-per chamhBr pressure

lOWOl dlambor pntSSU9
ft\ •t >• •J lnJOtoon pressuro
lf ti l pres!rurBiess
e. Electronic mixture adaptation
In addition to the mecbanical basic adaptation, the re is a further possibility of adapting the fuel/air
mixture to the different operating states of the engine. It is possible to alter the pressure difference at the
metering slots - and thus the quantity of fu el - by altering the pressure in the lower chambers with the
electrohydraulic actuator. A basic rule in this procedure is that the upper chamber pressure alters in the
same ratio to the lower chamber pressure.
Ifthe lower chamber pressure is low, this produces a large pressure difference at the metering slots and
thus an enrichment of th.e mixture.
Example for mixture enriclnnent by means of electronic mixture adaptation (position of control piston (2)
constant):
• Lower chamber pressure low (4.4 bar).

• Differential pressure large (l. O bar).
Mercedes-Benz
• Diaphragm (3) in the differential pressure valve curves down and opens a larger outlet cross-section
to the injection line (1).
• Mixture enrichment.
Fi~. 259: Electronic Mixture Function Dia~ram (1 Of 8)
If the lower chamber pressure is bigh, tbis produces a lower pressure difference at the metering slots and
thus a leaner mixture.
Example for leaner mixture by means of electronic mixture adaptation (position of control pis ton (2)
constant):
• Lower chamber pressure bigh (5.1 bar).

• Differential pressure small (0.3 bar) (only 0.1 bar less than the design-related valueof0.4 bar).
• Diaphragm (3) in the differential pressure valve curves upward and narrows the outlet cross-section
to the injection line (1).
• Leaner mixture.
Mercedes-Benz
- I A 6- 'Ii
Fig. 260: Electronic Mixture Function Diagram (2 Of 8)

Mercedes-Benz
lf fiB lf fl
---
IFFf"E 9f.;tem Pf&!>~r~ d'IBITtlec pr&s~re 1
Lcwer chamber pr&!;!;ure 2 V5Nepl&'.a
~ ~C'Ofl Pf9'>Sl.r8 3 FIXed restncboo
LEJ!J
An electrohydraulic actuator (1) wbich controls the fuel feed (arrow) to the lower cbambers and thus the
lower chamber pressure is necessary in order to alter the lower chamber pressure. The fuel feed can be
opened more or less by moving the valve plate (2). A fixed restriction (3) which together with the lower
chamber pressure determines the quantity of return fuel is located at the outlet of the inter-connected
lower chambers.
The val ve plate in the electrohydraulic actuator can be moved into directions from its base position with
the help of a solenoid (arrow).
If current flows through tbe solenoid, the val ve plate m oves in the direction of fuel feed. The lower
chamber pressure is reduced and tbe pressure difference at metering slots is thus greater.
Mercedes-Benz
"'•MOe•D
By altering the direction of the current at the solenoid, the valve plate is moved away from the fuel feed.
The lower chamber pressure rises and the pressure difference at the metering slots is thus less.
The pressure difference at the meteríng slots is always altered when the lower chamber pressure is altered.
Alteríng the pressure difference enables the composition of the mixture to be rapidly controlled for al!
operating states of the engine. This applies both in the sense of enriching the mixture as well as in the
sense of achieving a leaner mixture up to deceleration fuel cutoff.
Mercedes-Benz
1'01 __ _,

Mercedes-Benz
0---~
,.... . . . IT
~em ¡xessurefl4lper ctJarrt Hn ¡xes~re

Lower chamhe; ¡xessure
~odon ¡xessuro
The electrohydraulic actuator is energized by the KE control unit. The KE control unit determines the
control current from various influencíng parameters.
Influencing parameters may be for example:
o start sígnal
o engine temperature
o engíne speed sígnal (TD sígnal)
o load state of engine
o air flow sensor position indicator signal (position and movement of air flow sensor plate, opening
rate)
o Lambda sígnal in the case of KA T
Mercedes-Benz
0 --
S(stllll1 pnssuref\clper dlootulf pres~ne
fin]
lower chamber presstro
~ qacaon pras5Ue
CI::lJ
Mixture enrichment
lfit is necessary to enrich the mixture for operatíon ofthe engíne, for example in the warmíng-up phase,
the engine temperature is signalled to the KE control unit by the coolant temperature sensor. The
corresponding control current is now supplied by tbe KE control unit to the electrohydraulic actuator. The
val ve plate in the electrohydraulic actuator is moved in the direction of fuel feed. As a result of this, the
feed quantity is reduced and the lower chamber pressure drops (e. g. 4.4 bar). The pressure difference at
the metering slots is increased and thus also the quantity of fuel injected.
Mercedes-Benz
START
::F{)¡.-_ ......
TD
H
~e~----___.
0---
Sys!em proSSl.lr9114)per ch!lllber prossuro
l ower chamber pres-sure
lf1;edon pressure
prassura•es-s
Deceleration mode
If no fuel is required in engine deceleration mode, the KE control unit is supplied with the information
"throttle valve closed" by the decel fuel cutoff microswitch or the idle speed contact in the throttle valve
switch and from terminal TD with the infonnation that the momentary engine speed is above idling
speed.
The KE control unit alters the polaríty ofthe control current to the electrohydraulíc actuator for this
operatíng state.
The valve plate ís now moved away from the fuel feed. As a result, the lower chamber pressure rises (e. g.
5.4 bar) up to the level ofthe system pressure (e. g. 5.4 bar). The diaphragm is deflected further up with
the aid ofthe spring force and stops the fuel feed to the ínjectíon valves. No pressure dífference exísts at
the metering slots. Deceleration fuel cutoff is cancelled again by the KE control unit before idling speed
is reached.
Engine at normal operating temperature

Mercedes-Benz
Ifno additional mixture adaptation is required once the engine is at normal operating temperature, the
valve plate (1) adopts a certain middle position, depending on the engine version. This middle position of
the valve plate produces the design-specified pressure difference of approx. 0.4 bar at the metering slots.
Fig. 267: ldentifying VaJve Plate
If the valve plate ( 1) is moved out of the middle position in the direction of fue! feed by a control current,
the mixture is enriched.
Fig. 268: Identifying Valve Plate
If the direction of the control current is altered, i. e. a change in polarity is performed at the solenoid, the
val ve plate ( 1) is moved out of the middle position toward the fu el feed. This produces a leaner mixture.
Mercedes-Benz
Fig. 269: Identifying Valve Plate
On vehicles fitted with catalytic converter and lambda control, the val ve plate ( 1) constantly moves
around its middle position in order to produce the necessary richer or leaner mixture. The KE control unit
constantly alters the direction of the current for this purpose.
Fig. 270: ldentifving Valve Plate
Mercedes-Benz
31 Feed (nozzle)
32 V aM1 plata
33 Pennanert magnat
34 Sol9001d
35 Rod<l!f
36 Screw ~g
37 A djusbng ser ew
(operamg pou1)
Emergency running properties
The KE injection system possesses good emergency running properties. In the event that the
electrohydraulic actuator is de-energized, e. g. as a result of an open circuit in the wiring, the pressure
difference is set to the design-specified leve! of approx. 0.4 bar. Tbe mechanical mixture basic adaptation
remains operational. The engine can continued to be operated in the normal operating temperature state.
Warming-up is restricted, however. It is no longer possible to adapt the mixture to lean or rich.
---·
Fig. 272: KE Injection Svstem - Emergency Ru.nning Properties
f. lnjection valves
Mercedes-Benz
Fig. 273: l dentifying Injection Valves
An injection valve (92) is positioned in the intake manifold for each cylinder of the engine. The injection
valves spray the fuel metered by the fuel distributor continuously ínto the íntake ports downstream of the
ínjectíon valves. The ínjectíon valves do not perform any metering functíon.
The injection valves open when a certain pressure exists in the fuel system and atomize the fuel as a result
of the vibration movements of the val ve needle ( chatter val ve).
After the engine ís switched off, the ínjection valves close leaktíght as soon as the pressure in fuel system
has dropped below theír opening pressure. The holding pressure ís retaíned in the ínjectíon lines to ensure
good hot starting characteristics.
Mercedes-Benz
4b
1 k"(ectioo v~
2 Se.al
3 F 11t
4a Valv& neetlo ll'l rast poslbon
4b V!We neede ll'l OJH!fa ng posd10n
Fig. 274: ldentifving Injection Valves Components
Air-shrouded or air-enveloped injection valves
To improve mixture formation at idling speed, the required quantity of idle speed air is supplied directly to the
fuel outlet ofthe injection valves through insulating sleeves in which the injection valves are attached, or
througb ducts in the intake manifold (Ml03, Ml04). This ensures better atomization ofthe fuel.
Air-shrouded injection valve
Engines l 02.983/ 102.99/116/ 1171119

Mercedes-Benz
2 lns!Jatrng sle&ve
3 P lffihc S~pOO
a FUIII
b Aw
e FuaVa~rrTn~ro
t41· f·~· ..••
Fig. 275: Identifying Air-Shrouded Injection Valve Components
Notes regarding version
All 6- and 8-cylínder engines have air-shrouded or air-enveloped ínjectíon valves . In the case of the 4-cylínder
engine, they are ínstalled in engínes with 4 valves per cy linder.
Air-enveloped injection valve
Engines 103/ 104
a Fue!
b Al" trom td!a au <lJtt 11 irtBke mlllllfold
Fig. 276: Identifying Air-Enveloped lnjection Valve Components
EJECTION AND OPENING PRESSURE OF INJECTION VAL VES IN BAR (EXAMPLES)

Engine System pressure Opening pressure Opening pressure
of new injection at least
valves
102, 103 up to 08/88 5.3- 5.4 3.5- 4.1 3.0
Mercedes-Benz
as of09/88 5.3- 5.4 3.7-4.3 3.2

104' 116' 11 7' 119 6.2- 6.4 4.3 - 4.6 3.7 (l)
(l) Injection va1ve with Viton needle seat as of 09/90
FUNCTIONS IN THE KE CONTROL UNIT - RA0703KE1D030X(D.)
a. General
The KE control1mit (N3) analyzes the data regarding the operating state of the engine supplied by the
sensors.
It forms from these data a control current for the electrohydrau1ic actuator (Yl ).
N3
Loretion on modol 107
Fig. 277: ldentifving KE Control Unit- Model 107
Location ofKE control unit (see also 07.3-0015)
• Models 124, 129, 201: on right of component compartment

• Modell07: in right footwell below floor panel
• Modell26: in right footwell behind side trim panel
Locabon on modol 126

Mercedes-Benz
Fig. 278: ldentifying KE Control Unit- Model126
&oanqerl
Ifthe ignition is switched on or the engine is nmning, do not unplug coupling at KE control unit as the
KE control unit may be damaged as a result ofvoltage or current peaks.
The influeucing parameters at the KE control uuit and the functions in the KE control uuit differ
accordiug to the respective version (see also 07.3-0004 and 07.3-0020).
locaborl on models 124, 201
N3
_,.-... ,.----.I'OJ·I~TI · la
Fig. 279: Identifying KE Control Unit- Model124, 201
KE control unit (N3), model 129
Located in front right of component compartment. It has 55 connections and a metal housing to improve
heat dissipation. The coupling is locked to the control unit by means of a spring clamp.
Loalt!Ofl on m odel 129

Mercedes-Benz
Fig. 280: ldentifying KE Control Unit- Modell29
KE control unit standard version
A fuel injection program without lambda control is stored in the KE control unit
KE control unit KAT/RUF version
The KE controlunit has two fuel injection programs (with/without lambda control). The respective
program is activated by the resístance trimming plug. For@ [g] ~ reference resistors are installed_ For
~ as of model year 1988 the reference resistor is integrated in tbe KE control unit.
When the ignition ís switched on, a certain current is supplied to the electrohydraulic actuator and a
certaín on/off ratio is output at the lambda test output.
KE control unit KAT/without KAT version engine 102 as of 09/89
The fuel ínjection program for the RUF mode is omitted in the KE control unit.
KE control unit KAT/without KAT version
The KE control unit contains two fuel ínjection programs "KAT" and "without KAT" whích can be
activated with the KE resistance trimming plugs (R17) "KAT" and "ECE".
b. Voltage supply, KE control unit relay (overvoltage protection)
N3
K1 Owrvcl ege protedlon
relw{
N3 KE contol unt
(Z!>prn couplng)
W5 Gf001d, l30íJne
W10 Gfound, batiBfy
1 OfHif COOSI.Jll!){S e. g.
Id!& 5peed a~lor
( TBm1Wlal30
n Telllllnal 15, I!JliiOO
stad:Of S'Mtdl
-
....
4
l
YI10
_ ___,.,_e
' - - - - 0,'75rs/rt - f t P'OJ-1641 · »
Fig. 281: KE Control Unit Relay Voltage Supply Diagram
The voltage supply of the KE control unít as well as of further electronic control units in the vehícle is
Mercedes-Benz
performed by the overvoltage protection relay.
Battery voltage exists constantly at terminal30. A 10-ampere flat fuse prevents an overload oftenninal
30.
When the ignition is switched on, the relay is actuated by the ignition starter switch via terminal 15 and
the NO contact connects terminal30 to terminal 87. Voltage is thus supplied to the KE control unit via
tenninal 87 (or 87E). Ground is connected via connector 2 in the case ofthe KE control unit with 25-pin
coupling.
Fig. 282: l dentifving O ver voltage Protection Relay
The overvoltage protection is performed by a Zener diode with a Zener voltage of22 volts. Ifthis voltage
is reached, the Zener diode is conductive in the blocking direction and voltage peaks in excess of 22 volts
are switched directly to ground. The relay thus opens its NO contact. Terminal87 (or 87E) has no
voltage.
liCS
li" ~
11
lit 01
1 ~ ¡¡
· ~ ;;~
1 ¡.
1¡. ~
t
1 ¡. •
• .. 1
1• 1
- r- · ~. t•¡.:
- ¡-.. . 1
.r
Fl
Fig. 283: KE Control Unit Relay Voltage Supply Diagram (1 Of 3)
Notes regarding version

Mercedes-Benz
The overvoltage protection relay exists in various versions. It is designated accordingly in the wiring
diagrams with Kl , Kl/1 or Kl/2.
A 4-pin version was installed in model 201 at start of series production. This overvoltage protectjon re lay
is inserted directly into the electrical center (Fl) witb its own plug connection for terminal 87 (P).
__ . K1/,_ _
Fig. 284: KE Control Unit Relay Voltage Supply Diagram (2 Of3)
In the case ofthe 7-pín version, the electroruc control uruts are supplied with voltage from terminals 87E.
Terminal 87L supplies further consumers, e. g. the idle speed adjuster. The fault memories in the control
units are supplied constantly witb voltage via terminal 30a.
In the case of the 9-pin version, a separate relay and fuse are installed for terminal 87L.
1
l:w 17~ ..
~fltttr~
Fig. 285: KE Control U nit Relay Voltage Supply Diagram (3 Of 3)
In the case ofKE control unit with 55 connections (engine 104, 119) the voltage supply is performed as
follows:
1 Voltage supply terminal 30a (fault memory)

Mercedes-Benz
6 Ground W 16 (ground for output stages)
9 Voltage supply terminal 87E (n_ a_as ofvehicle ident end no_ lF 002 245)
19 Ground Wll ( electronícs ground)
41 V oltage supply terminal 87E
D &:ICIJCICICICIO
202122:2.3 24 2526 27 282 ~30 31 3233 34 36 3637
~DDDQaDDDDDOODCDDD
oa•••••••••••••••~o
1 2 3 4 5 6 7 8 9 10 11 t2 13 f 4 15 H~ 17 18 19
P07-ooes- s3
Fig. 286: l dentifving KE Control Unit With Terminals Connections
Voltage supply KE control unit (55 connections, KE 5)

Mercedes-Benz
NS
.~-- --·-(l
-·---~~--·
-·-
f1 fuse alld relay box, llse 9, l.llprctecteds!de W16 Ground, c0fl1l00ertc~íllinert

K 1/2 Ov81Vor.age prctectioo rolay 87EI87l/3Ga {G-pin) X4 Tennmal block toomnallO, hJse a.nd relB';' bo>dírtenor
N3 I<E conrol tnt {2-pfl)
S 2ft lgnboo sill«or S'Mlrh X 4/10 Tenn1nal biGck tenn~ai30130U'61 e/87l ( 5-ptn)
U6 n a. asdvohde ldeli ooono. 1f 002 245(connodlon X 1114 Tos! <0\Png for ~!lgnos¡s (1 ~n)
n· n
ID deietoó) X 26 Pllg comedan, ~lllnorleng¡ne e1 2.ptn)
W11 Ground, 9flgll18 eolean e '/.!fes boledon) Z7 Comedor sloeve tennmai 87E
Z7' F eod tr001 owrwtage prctecbon rolay
a lgnbon e~ tenn~al 1 5
Fig. 287: KE 5 Control Unit Voltage Supply Diagram
c. Warming-up phase
Starting ofthe engine and the post-start phase (see section F "Start devices") is followed by the wanning-
up phase of the engine. The fuel/air mixture has to be enriched in the warming-up phase because part of
the fuel precipítates at the still cold íntake manifold, at the injection val ves and cylinder walls.
Warming-up enrichment is thus dependent on the coolant temperature. The lower the coolant temperature,
the higher the current at the electrohydraulic actuator and thus the fue! enrichment.
The coolant temperature is detected by the coolant temperature sensor (B 11/2 or B 1113) and supplied to
the K.E control unit (see section E "Coolant temperature sensor").
On KAT versions the lambda control is enabled in the warming-up phase (e. g. from 40 oc coolant
temperature). The warming-up and lambda control functions then overlap.
1 Mercedes-Benz
í
!!..1:-1 - - - - - t t ----~---- 13-----1
J
• 11 e:
t{,l) ..
t1 Slalterrichm!lff¡{dtJrabon e. g. 2 ·s-EI!oods)
t2 Post-s.tarlt enlidlment(d>Jralion ·&. g. 20 s!troflds)
t3 Wamíng-up (dura on <fepllnding on codWlt
tempare11Jie)
a S!art
b End ol start
Comment-emem oll mmgpo-st.start ennchmern
e E no cf po·st-slait eonchmelll
Gommencemllrn olwarmn!}up pha.s-e
1ST (mA) CtJIHmtate et~oh¡tdratltc aduator
Fig. 288: Warming-Up Enrichment Graph
Testing warming-up base value
For the test, simulate 20 oc coolant temperature and measure the current at the electrohydraulic actuator
inmA.
Depending on the engine version, pay attention to the following points:
• Test with separate plug connection for oxygen sensor signal (G3/2x2).
• Measure current level within a certain time after starting engine.
• Do not measure current level until coolant temperature at 80 °C, then compare with the value at 20
oc coolant temperature.
Warming-up control
Engine 103.984, 104, 119
Engine 103 [l] n:!rAP ~Gi""BT @ 0 as of 1991
In the fuel injection system (KE 5) the warrning-up phase is dependent not only in the coolant
temperature but also on other influencing parameters (e. g. time, throttle valve position, selector lever
Mercedes-Benz
position).
Engine 103.984
Ifthe throttle valve is closed and the coolant temperature is 20 °C, post-start enrichment for KAT engines
up to 8 seconds [8 seconds] after start 4- 8 mA [21 - 27 mA]. After this, it is limited to the warming-up
base val ue which 1 - 2 minutes [ 1 - 2 minutes] after start is between O and -4 mA [ 15 - 22 mA].
[Figures without KA T].
The lambda control operates in the open-loop mode up to maximum 2 minutes (at coolant start
temperature of20 °C) after start. The lambda closed-loop control is enabled thereafter.
1
1
- - - - 1!>!<3- - - A- elo sed-loop - - - -!>

cortrol
Start 20 60 120 Time ~ l

Fig. 289: KAT Engines And +20 °C Coolant Start Temperature Diagram- Engine 103.984
Diagram for KAT engines and + 20 oc coolant start temperature (simulated)
Engine 104 up to 08/89
With the throttle valve closed and the coolant start temperature at 20 °C, post-start enrichment for KAT
engines up to 8 seconds [8 seconds ] after start is 1 - 3 mA [4- 7 mA] with selector lever in position P/N
and 5-8 mA [5 -8 mA] with a Drive mode engaged. After this, the current at the electrohydraulic
actuator is limited within 4 seconds [10 seconds] to the warming-up base value in the case ofKAT
Mercedes-Benz
engines ofO- 1 mA [O- 1 mA]. The warmíng-up base value remaíns constant up toa maxímum of 120
seconds [120 seconds] after start (at coolant temperature of20 °C).
[Figures without KA T]
The lambda control operates in the open-loop mode for up to maximum 2 minutes after start (at coolant
start temperature of 20 °C), depending on the coolant temperature. F ollowing thís, the lambda closed-loop
control is enabled.
1
1<1-- - - - - - - <J?afl-kx)p morle --------{> b--"-comot
dos&<! loop ---{>
Start 8 12 120 Time [ s J

D Selector lever position P/N
D Orive mode
Fie. 290: KAT Eneines And 20 °C Coolant Start Temperature Diaeram - Eneine 104 Up To 08/89
Diagram for KAT engines and 20 °C coolant start temperamre (simulated).
Engine 104 as of 09/89
With the throttle val ve closed and the coolant start temperature at 20 °C, the post-start enrichment up to 8
seconds [8 seconds] after start ís 3- 5 mA [4- 7 mA] wíth the selector lever in position P/N or wíth
manual transmission in Neutral and 5 - 8 mA (5 - 8 mA] with selector lever in Drive mode. Following
this, the current at the electrohydraulic actuator is limited within 6 seconds [8 seconds] to the warming-up
base value ofO- l mA [O- l mA]. The warming-up base value remains constant up toa maxímum of 110
seconds [120 seconds] after start (at coolant temperature of20 °C).
Mercedes-Benz
[Figures without KA T]
The lambda control is enabled once post-start enrichment is terminated (a maxirnum of 110 seconds at
+20 °C coolant temperature) and a coolant temperature of 50 oc
is reached.
Start 8 14 11 o lime [ s J
D Selector lever position P/N D Orive mode
Fig. 291: KAT Engines And 20 oc Coolant Start Temperature Diagram- Engine 104 As Of 09/89
Diagram for KAT engines and 20 oc coolant start temperature (simulated).

Engine 119
With the throttle valve closed anda coolant start te mperature of20 °C, post-start enrichment for KAT
engines up to 15 seconds [15 seconds] after start is 5-8 mA, [8- 13 mA] with selector lever in positi on
PIN and 18-25 mA [24- 31 mA] with Drive mode engaged in the case ofKATengines. Following this,
the current at the electrohydraulic actuator is limited within 2 minutes [2 minutes] after start to the
warming-up base value in the case ofKAT engines ofO ± 1 mA [O to+4 mA).
The limiting time is dependent on the start temperature ( 105 seconds in the case of coolant temperature of
20 °C).
fFüwres without KA Tl
Mercedes-Benz
The lambda control is enabled once the post-start enrichment is completed (a maximum of 120 seconds in
the case of coolant temperature of +20 °C) and a coolant temperature of 55 oc is reached.
25
18
o
Start 15 120 Time [ s ]
D Se.lector lever position P/N D Orivemode
Fig. 292: KAT Engines And 20 °C Coolant Start Temperature Diagram- Engine 109
Diagram for KAT engines and 20 oc coolant start temperature (simulated).

Engine 103 ~ n:!rAP tr::rsT @ 0 as of 1991
With the throttle valve closed anda coolant temperature of +20 °C, post-start enrichment up to 20
seconds after start is 4 - 8 mA. Following this, the current is limited to the warming-up base value which
is between O and -4 mA 60 - 80 seconds after start.
The lambda control operates in the open-loop mode up to a maximum of 2 minutes (in the case of coolant
start temperature of +20 °C) after start. Following this, the lambda closed-loop control is enabled.
Mercedes-Benz
1 ~] l < l - - - - - - - -A
----t>!<J------
8 -----t>
-4
e
20 60 80 Tune [s J
A Open.lo<lp moda
B l lll!txfa dos Qd.foop romol
e Stwt
Fig. 293: KAT Engines And 20 °C Coolant Start Temperature Diagram- Engine 103 As Of 1991
d. Acceleration enrichment
lf the throttle val ve is opened rapidly for accelerating, this briefly produces a leaner fu el/ air mixture. The
mixture must be briefly enriched accordingly in order to achieve smootb pickup without jerking during
acceleration.
The acceleration enrichment is dependent on the signal from the air flow sensor position indicator (B2)
(see section E "Air flow sensor position indicator"). It detects the position and movement ofthe air flow
sensor plate (opening rate).
The extent and duration of the enrichment is dependent on engine load and speed. A higb enrichment is
performed at high engine load and low change in rpm. Slight enrichment is performed in the reverse case.
Acceleration enrichment is dependent on the coolant temperature. When the engine is cold, higher
enrichment is necessary because of fu el condensation on the cold parts of the engine. Depending on
engine version, acceleration enrichment is inhibited from a coolant temperature of 80 °C.
Wb.en the engine is idling, acceleration enrichment is inhibited by the idle speed contact in the throttle
valve switch or by the microswitch.
Mercedes-Benz
Wiring díagram of acceleratíon enrichment Example engine 102.982 KAT/RUF
tl i i
~
_j
1
1 1
1 ffj_J
8 2. 811/2
X11
82 Au ~w senscc posíboo 11<ic a~r

8 11 12 Ccolan'tlemp!!ralure sens.or
N1/2 B&ctrooic tW~boo (EZl.) con!Jolunt
N3 KE II]~Y~:-bcfl systern conr.clulllt
N16/1 Fuefpt~ITl) relay ~~~ slartvaJ\0{1 actuabon
S1912 fucltla v!We sw.trh, fulloadtde spaa.d re(Oglllioo
Wl Grcund, trcrlt 10: •M1eei:house {a\ l{ffiD
Oll co!l)
W11 Grotmd, batmoy (eloc!nc ~able ~oo oo)
X11 OtagiloSis wd<o1tennínalbfock, terminal ID
X48 Comeclor sleGve (sokfar come ctoc 11 Wl"tng hamess)
XS6 Pklg connodi ofl, lhrc e vat.re S'Mtch
Y1 Bedrohydra11lc actuator
a lltake ra temp-eratufie soosor, cortad 2
v OWtwiage proteCÓOf"', coomct 2, termmal87
Fig. 294: Acceleration Enrichment Wiring Diagram

Mercedes-Benz
e. Part load mixture adaptatioo
This function is only active on engines in Standard or RUF version. At part load the prime consideration
is to achieve low fuel consumption and good emissionlevels.
Part load mixture adaptation is only active when the engine is at nom1al operating temperature (from
approx. 60 oc coolant temperature). The KE controltmit detects the momentary load state ofthe engine
from the air flow sensor position indicator. In conjtmction witb coolant temperature and engine speed, the
KE control unit determines the current at the actuator and thus the composition ofthe mixture in the part
load range. Depending on engine version, a sligbtly leaner mixture is then produced in most cases.
f. Fullload enrichment
Maximum engíne torque is demanded when the throttle valve is fully open (full load contact in throttle
valve switch closed). The fuel/air mixture must be enriched for this purpose.
In order to enrich the mixture, the KE control unit supplies a current to tbe electrohydraulic actuator
within a specifíed engine speed range. This engine speed range differs according to engine version. The
level of the cunent is dependent on engine speed.
On KAT vehicles the lambda closed-loop control is not operational at fullload (open-loop mode).
g. Lambda close-loop control
The control loop formed wíth the lambda probe enables impermissible variations in the air/fuel mixture to
be detected and corrected.
In the event of a variation, the KE control unit corrects the quantity of fuel injected by means of the
electrohydraulic actuator. This enables the quantity of fuel to be so exactly metered as to achieve an
air/fuel mixture which differs from lambda=l onlywithin very narrow lirnits in all operating states (see
Group 14, section "Lambda control").
Wiríng diagram of lambda control Example engine 102.962 KAT/RUF

1 Mercedes-Benz
1 1990-2002 ENGINE PERFORMANCE Mixture Formation - REPAIR & ADJUST MENTS- 129 Chassis
N162
G312 Heaied oxygllll sensor

G312x1 A:lg ('()llnecbon, oxygen sensor heallng e oj
G312x2 A:lg conoeclion, oxygen sensor ggnaJ
N3 I<E conlrolulll
N1612 Fuelpurrp relay 'Mih start v~ ac!uauon,
lockdown ruofl ami 611!JOO s:;;ced l mll1g
W10 GrOUld, battBry
W11 Ground, engJne {e!e<ix cabl:e boled on)
X35 Temmalblo-ck engtne, temunal30.! omunal61 (ba,e¡y)
X48 COMOttocsmeve (soldered ~Mector 11 harness)
a Fuel purrp
o Tormr1al block, tennmal30, fuse and rolay box
v OWIVOlogo pro!eroon, rontat12, temunal87
Fig. 295: Lambda Control Wiring Diagram
h_ Deceleration fuel cutoff
As a result of deceleration fuel cutoff, fu el injection is interrupted in the deceleration mode (e. g_ when
travelling downhill, when braking and when coasting).
This results in reduced fuel consumption - also when driving in cities.
As no fuel is combusted when deceleration fuel cutoff is active, no exhaust gases are produced.
The KE control unit is supplied with the following information in order to control deceleration fu el
cutoff.
• "Throttle valve closed" signal :from the decel fuel cutoff microswitch (S27 /2) or idle speed contact
in the throttle valve switch (S29/2).
• Engine speed
o Decel fuel cutoff operating if e. g. 3000/min has been exceeded once.
o Activation speed for decel fuel cutoff, e. g. engine speed above 1500/min_
o Reactivation speed of combustion following decel fuel cutoff, e. g. without AC compres sor at
1000/min and with AC compressor at 1200/min; depending on the version, the reactivation
speed may also depend on the engine speed pattern during decel fuel cutoff
No decel fuel cutoff is performed when the engine is cold, depending on the version the coolant
temperature must be above e. g. +40 oc_
Mercedes-Benz
• Tempomat cruise control
The KE control unit inhibits decel fuel cutoff during cmise control operation as follows:
KE control unit without road speed signal :
• On a number of engines 102 (KE 1 and 2) the cable from the decel fuel cutoff microswitch
(S27/2) is looped via the decel fuel cutoff/Tempomat cmise control relay (K12) and the plug
connection ofthe KE injection system/Ternpomat cruise control (X33) (see Repair
Instructions "Cruise control system").
• The "Tempomat ON" signal is passed from the Tempomat cmise control unit (N4), contact 5
via the Tempomat plug connection (X33) to the KE control unit, contact 6.
KE control unit with road speed signa! (indefinite production breakpoint as of approx. 09/88,
engines 116,117 as ofstart ofproduction).
o Tempomat OFF is detected indirectly vía the road speed signal for cmise control mode is not
possible unless speed is approx. 40 km/h or higher.
If the conditions for decel fuel cutoff exist, the KE control unit alters the direction of the current to
the electrohydraulic actuator (approx. -60 mA). As a result, the fuel supply to tbe injection valves is
interrupted (see section C "Electronic mixtme adaptation").
Decel fu el cutoff is cancelled again once:
o the throttle valve is opened again
or
o engine speed drops below a certain value (reactivation speed), e. g. 1000/min.
When the accelerator pedal is depressed, the decel fuel cutoffmicroswitch (S27/2) opens before the
throttle val ve operates and decel fu el cutoff is interrupted before the throttle val ve opens. This prevents
any cut-in surge when combustion reconunences.
A nurnber of.KE control units output a certain on/offratio in the case of decel fuel cutoff:
KE control unitOn/off ratio readout with decel fuel cutoff

Bosch 50%
VDO 95%
Engines 103, 104 with ASR
The decel fu el cutoff rnicroswitch (S27/2) is not fitted to vehicles with A SR. The cable is tied back in the
wiring harness. The signa! for decel fuel cutoff is then formed by the position sensor (R25) and supplied
via the electronic accelerator nedal control unit to the KE control unit.
Mercedes-Benz
Modell29: The separation point between the control units is the plug connection (X89/4).
The operation ofthe decel fuel cutoff on al! engines is basically the same although differences are
possible in respect of specific engine versions. A number of examples are given below:
Fig. 296: Identifving Plug Connection (X89/4)
Dece] fuel cutoff operating once engine speed above 1500/min and decel fuel cutoff
Engine 102.910
microswitch (S27/2) closed.
Engine
102.96/98
Decef fuel cutoff also wíth cruise control mode.
KAT/RUF as of
09/88
Engine Decet fuel cutoff is operational once coolant temperature is above 40 oc and engine
102.96/98 KAT speed exceeds 3000/min. The onloffratio readout with decel fuel cutoffis 95% or 50
as of09/89 %, respectively.
Dece] fuel cutoff operational above coolant temperature of 45 °C. Engine speed of
2100/rnin in the case of manual transmission, 1500/min for automatíc transrnission
must lbe exceeded to actívate decel fuel cutoff
Engine 102.990
Combustion recommences at 1600/min with manual transmission, at 1200/min with
Dece] fuel cutoff also in cnlise control mode.
Combustion recommences at different engine speeds. If rapid drop in rpm, combustion
recommences at higher engine speed than with slow drop in rpm. Following slow drop
Engine 116, 117
in rpm, combustion recommences at approx. 1300/mín. No decel fuel cutoffbelow 20
kmlh, below 1300/min aud when selector lever in position P and N.
Engine speed exceed 1600/rnin. Combustíon recommences at 1100/min. Lambda
Engine 116, 117 control operates in open-loop mode up to 800/min. Open-loop mode is dependent on
KAT increased engine speed and time. Lambda closed-loop control restored after 1O s or when
output 800/min reached.
No decel fuel cutoffbelow 20 km/h.
1 Mercedes-Benz
1. Intake air mixture adaptation
The intake air temperature is detected by the intak:e air temperature sensor (B 17/2). It is positioned at the
air cleaner or at its intake pipe (see section E "Intake air temperature sensor (B 17/2)") -
Mixture adaptation is perfom1ed as a function of the intake air temperature in the case of:
Engines 102, 103, 116, 117
On al1 KAT and RUF versions (KE 3) the temperature signal is fed to the 25-pin KE controltmit, contact
11.
Engine 102.910/96/98 as of 09/89
The temperature signa] of the intake air temperature sensor (B 17/2) for the KE control unit is omitted.
Engines 102, 103, 117, 117 @ [g] ~
No mixture adaptation as a ftmction of intake a ir temperature is performed on these national versions _

Contact 11 at the 25-pin KE control unit is assigned to the altitude sensor signaL
Example engine 102.982 RUF/KAT
81712
~J
"W11
~
T
!
-::li
jj ....."'
JI
J.
wn a
"'UliCI"
B 17/2 ln!Bke au l9f11Mil Eñlm sllllSor

N3 KE e-omol un~
529/2 Throt! e vaM! swtd'l, fUI loecU<fe speed ret'Oglliboo
S29bc1 Pklg romactJon,lhrotttevalve S'Mil:h
W11 Ground, b~ety {e ectnc cable bcll'adon)
a EZl lgnbon c<li1rclwt
v OVoNo age prote<i oo, cOO!ad 2, tennlnal87
Mercedes-Benz
Fig. 297: Intake Air Temperature Sensor Circuit Diagram- Engines 102, 103, 117, 117
Engines 104, 119
On al! basic and nationa1 versíons (KE 5) the temperature signal from the intake air temperature sensor
(B 17/2) is detected in the 55pin KE control unit between contacts 5 and 14.
8 1712 hako aJ" temperalure sensor

N3 KE coolrol Ullt
Y1 8ectrchydr.al.tc actuatOJ
Fig. 298: lntake Air Temperature Sensor Circuit Diagram- Engines 104, 119
An additional mixture emichment is performed if the intake air is cold. The colder the intake air, the
greater the mixture enrichment. The following temperature ranges apply:
Engine Enrichment at
102.96 (up to 08/88) -30 oc up to O oc
102.98
103
104
102.96 (09/88- 09/89) -30 oc up to +5 oc
102.99
116 -30 oc up to + 15 oc
117
119
J. Engine speed governing
Maximum engine speed can be governed by means of the :
• fuel pump relay or engine systems control unit by switching off the electric fuel pump (see section
E "Fuel pump relay" or "Engine systems control unit").
• the KE control unit by interrupting the fuel supply to the injection valves.
The KE control unit detects maximum engine speed from the number ofTD, TN speed pulses or from the
1 Mercedes-Benz
short-círcuit-proofTDA, TNA speed pulses. Thís produces a change in the direction ofthe current to the
electrohydraulic actuator. Remaining operation conesponds to deceleratíon fuel cutoff.
Example engine 102.982 KAT/RUF
Y1
Ga
lrr-(.1
1•;1 ·:...
e
1
1
...
r.-·
!f :
1' ·1
~QI!U · tll
N3 KE ccmol U!lt
X11 Dllagnosbc sod<a!Jlsnn~r~alblock tormnallD
X48 C{)flllettOi sleeve ( s'Oidored coonectcr m hemess)
Y1 8et:toh{OOJWC actuator
a Fuol punprelay, corllac.t 10, tenmnaiTD
o A.C c001prosS« rela.'¡, ccriact 2, tarmnallD
e EZl tgn¡ion conrolun~ oormnal TD
Fig. 299: KE Control Unit Circuit Diagram- Engine 102
Example engine 103 in model129

Mercedes-Benz
N112
A1
N3
lnsln.rnen! distar
N1f2 EZ1. 1g111Joo comol oot
KE Wlirol uni
N16 Eog~no systomscorirolur~I(MAS)
X26 Pllg comecboo,Jrtenoú911g1no•(12-pm)
t tt:
2~d
t
Y1 E ledrohfcllauk ati!JE:Of
:e.
e e
lt
o
P07-ti746-16
Example engine 104 in model 129
NS
.-·--·-·-·-·
i -tQ
N1/3
r·-·-·-·-·-· N16
r-·-·-··-·-·-·
i ! -(> i ! -(> ~
A1 .,slrument ciJ s!cr
·~·-·- ·-·-·--·
N1f3 EZl/AJ<R 1gnbol'l cortrol
urit
NJ KE ronrolunt{55-pi'l) ~--- o.r:. t7fr- _ __,
N15/1 S.spead aúoma'ic
~ansmi ssioo cootol Uflí
N16 Engine system s cortro1
111t(tv1AS)
X26 Pklg ronoocflcn, 1rt01101/
ongsno (12..p~n)
Y1 Boctrotr,Waliic actuaior
M3 Manual t!lllsmlsSioo
AG 4 4-spMd atomaj c
r ansm1SSIOO
AG5 5-spead et..tomatc
~Bilsmi SSIOO
r::·-·-·~ ~·-·-·-,
•AG 5 T ,- • MG
1
1' i
~ ,AG -4 ~
t t 1 ~
•
1
~4 ¡
~
1
•
•
1
5 1
•
1
1[i
L 1Í j
N1511·.
"-·-·-~ L..._._ ...... A1
'P01-6147~7

Mercedes-Benz
k. Road speed signal
The road speed signal is supplied to the KE control unit, contact 6.
The road speed signal inhibits the idle speed control above a speed of approx. 1.4 km/h which improves
the handling when the vehicle is coasting.
Provision ofthe road speed signal enables the Tempomat cruise control signa! to be omitted (no cmise
control mode possible below approx. 40 kmlh).
Engines 116, 117
The road speed signal is supplied to the KE control unit, contact 24. Deceleration fuel cutoff is inhibited
below 20 km/h.
Engines 104, 119
The road speed signal is supplied to contact 29 of the 55-pin K.E control unit. For wiring diagram ofroad
speed signal see Wiring Diagrams, Model129, Group OO.
The road speed signal inhibits deceleration fuel cutoffbelow 20 km/h, influences regeneration of the
active charcoal filter and of the maximum speed control.
Example model 124

Mercedes-Benz
b- o~ wrJrt ..,.
X6a/6 POT-5748-13
B6 Ha!-ef:ottroad ·speed sensor

Nl KE OOl1trol urut
W1 Mem groond (ngtdfo1l~l)
X'16 Pklg connectloo, inl:eri«fongme {12-pin)
X 53.6 Mw po111tpkJg ccnnodlon, HBJ.effoct sonsor oro¡ •Mih
cpbonal eq,up.·mml{e. g. outsuie b:lmpornrure display)
b Stop larnp S'Mith, tennmal 15
Fig. 302: Road Speed Sensor Circuit Diagram- Model124
Example model 107 with engines 116, 117
A1p8 Bodronic spoedometor

N3 KE oonrolunt
Na ldlns¡¡eodcomohnt
K3 B adrcmc SJH~Odometer !onmnalblock
X26 Pklg cooooellcn,lrnanorll!l1glne {12-Pill
Fig. 303: Road Speed Sensor Circuit Diagram- Model107
Models 124, 201
The Hall-effect sensor (B6) at the speedometer produces the road speed signaL
Mercedes-Benz
Fig. 304: Identifying Hall-Effect Sensor
Models 107, 126, 129
The road speed signal is supplied by the electronic speedometer (Alp8). The inductive road speed sensor
(L2) at the transmission actuates the electronic speedometer (Al p8).
Depending on equipment version, the road speed signal is required for further functions:
Electronic accelerator pedal; Tempomat cnúse control; 5-speed automatic transmission; automatic heater,
temperature or climate control; soft top operation (model 129); idle speed control (engines 116, 117);
outside temperature display .
.
1
L..·-·-·
A1 pe
A1p8 Ele-ctrooc s¡¡eBdometer

L2 k'lwctJve roed spe9d sensor, lr8flsrmsi3loo
X2&1 Z Pklg coonecboo , uteriorl\'ansmJ·ssaoo (6-~)
a Roa.dspeedsignal
Mercedes-Benz
Fig. 305: Road Speed Sensor Circuit Diagram
Example model 129
Ifthe following complaint is received "Jerking when vehicle coasting", test the road speed signaL Onfoff
ratio of 60 % output by the KE control unit or fault stored.
~ 1988: The KE control units do not recognize a faulty road speed signal.
l. KE resistance trimming plug
The KE resistance trimming plug (Rl7) is located at the KE control unit (N3).
• Models 124, 129, 201: right of component compartment

• Modell07: right footwell below floor panel
• Modell26: right footwell behind side trim panel
localicn on model 107
Fig. 306: Identifying KE Resistance Trimming Plug And KE Control Unit- Model107
locaiY'..o oo mod91 1 Z6
Fig. 307: Identifying KE Resistance Trimming Plug And KE Control Unit- Modell26
Mercedes-Benz
Localion 011 modols 124, 201
Fig. 308: Identifying KE Resistance Trimming Plug And KE Control Unit- Model124, 201
Fig. 309: ldentifving KE Resistance Trimming Plug Location
The KE resistance trimming plug (Rl7) influences the KE control unit:
• Operatíng mode
With/without lambda closed-loop control is determined by exchanging the KE resistance trimming

plug on KE control units in KAT/ RUF version. A certain current exists at the electrohydraulic
actuator when the ignition is switched on, depending on the operating mode.
• Mixture map
If complaints are received, the system can be tuned in 7 stages. The KE resistance trimming plug ís
plugged in the other way round for this purpose.
NOTE: Altering position only permissible if "Testing, adjusting engine" has been
performed and driving faults continue to occur.
The KE resistance trimming plug must be sealed tamper-proof.
The 25-pin KE control unít (engines 102, 103, 116, 117) recognizes the resistance between contact 22 and
Mercedes-Benz
contact 7 (ground); the 55-pín KE control unit (engines 104, 119) between contact 33 and contact 49.
N3
~---·----·-·-·-·---·-·
¡22 -()7 ~
N3 2S.¡m K E ccrnrolwut
R17 K E rggst.anco tnmmng pkJg
W11 GrQU!d, eng¡n¡¡ {olodric 'M re~ ooted on) .11 .b
q ~
Z ConOBctor sl!Hlva {solde; ed Cúflfloc lor 10 harnl)~s)
...
~
~HHHfl
NO{a Gf0111dol comedOf p!ll7 a! KE cortrol unil15
CcmGCted I!ÍIImaly lo 8f19108 gJOUnd, Comet!Of pm 2. Wt1
1.!:._.__ -·-·-·-·;!J
R17
Fig. 310: 25-Pin KE Control Unit Circuit Diagram
Resistance trimming plug with green inscription "KAT"
• Engines in basic version KAT.
The KE control unit KAT/RUF version has two fuel inj ectíon programs (with/without lambda control).
The program with lambda control is activated by the "KAT" resistance trimming plug.
The KE control unit K.AT/without KAT version has one fuel injection program with lambda control. The
"KAT" resistance trirnming plug cannot be exchanged.
The resistance trimrning plug is installed and sealed tamper-proof in position 1 in the original state.
If complaints are receíved, a tuning of the mixture map can be performed in 7 stages.
Fig. 311: ldentifying Resistance Trimming Plug With Green lnscription "KAT"
Position No. Resistance ohms± 10% Complaint

Mercedes-Benz
1 953 N one (original state)

o Slight pickup faults after start >20 oc
2 1270
o Engines 116, 117 as of 09/87 and engine 119: not assigned
o Pickup faults after start >20 °C
3 1620
o Engines 116, 117 as of09/87 and engine 119: not assigned
4 2260 Slight pickup faults in warming-up phase
6 5360 Poor throttle response and pickup in warming-up phase
Very poor throttle response when cold
7 11500
Driving faults in warming-up phase
Resistan ce trimming plug with white inscriptio n "ECE"
• Engines in basic version RUF

• Engine 117.968 Standard 220 kW
The KE control unit KA T/RUF version has two fuel injectíon programs (with/without lambda control).
The program without lambda control is activated by the "ECE" resistance trimming plug.
The resistance trimming plug is installed in position 1 in original state.
If complaints are received, ttming of the mixture map can be performed in 7 stages.
Fig. 312: ldentifying Resistance Trimming Plug With White Inscription "ECE"
Position Resistance ohms± Complaint

No. 10%
Excessive part load consumption when engine at operating
2 105
temperature
3 169 Pickup faults when engine at operating temperattue
Mercedes-Benz

6 442 Poor throttle response and pickup faults in wanning-up phase
7 590
Driving faults in warming-up phase
Resistance trimming plug with white inscription "KE E6"
• Engine 103.980 Standard
The resistance trimming plug is installed in position 1 in the original state.
If complaints are received, tuning of the mixture map can be perfonned in 7 stages.
Fig. 313: ldentifying Resistance Trimming Plug With White Inscription "KE E6"
Position Resistance ohms± Complaint

No. 10%
1 o None (original state)
Excessive part load consumption when engine at operating
2 487
temperature
3 953 Pickup faults when engine at operating temperature
6 4420 Poor throttle response and pickup faults in wanning-up phase
7 8660
Driving faults in wanning-up phase
National versions@ [g] ~
A 2-pin connector with reference resistor (O ohms) is integrated in the wiring hamess.
~as of 1988
Mercedes-Benz
The reference resístor is integrated in the KE control unit.
@ [g] ~ model 129
The reference resistor is integrated in the KE control unit.
m. Transmission shift point retard of automatic transmission
To enable the catalytic converter to reach its operating temperature more rapidly, the 2 --> 3 upshift in the
automatic transmission is retarded. This means the gearshift is performed at a slightly higher vehicle
speed. The retarded upshift is activated for not more than 80 seconds after each engine start.
Further preconditíons are:
• Coolant temperature approx. O oc -max. 50 oc

• Road speed > 1O km/h and <48 km/h
The figures stated for activation are average values which may differ upward or downward depending on
. .
engme verswn.
-Shift point retard by means of solenoid valve up to 05/91
Engine 102.96/98
Engine 104 KAT
Engine l031lJn::rAP ~ BT @0
Enoo-ine 1191ll n::rAP o::r BT @ CD

Mercedes-Benz
K 29 Transmlssioo stllftjl{llrt r e!ardrel&{ X 21f7 Pklg comed en, shltjl{llrt relardva.'v e {1-i)ln)
Modal 114 Riglt of c.ompooert compartrnont Y3/2 Sl'iitjl{llrt rotard sofenoid V!Wo
Modlll 129 Fuse and relay box, codo llllter E
Modai2Q1 Rigltwlleollouse
Fig. 314: l dentifving Transmission Shift Point Retard Of Automatic Transmission Component.s
NOTE: on engine 103 llJ o:!rAP ~ BT @
0 K29 is replaced by Kl7/3 (air injection/transmíssion shift point retard relay)
Function
The transmission shift point retard relay (K29) is actuated by the KE control unit by means of a ground
signa!. The shift point retard solenoid valve (Y3/2) is energized as a result of which the 2 --> 3 upshift is
performed ata hígher road speed. For this purpose, the governor pressure is lowered by means of a
pressure oilline at the governor pressure test connection (MR). Ifthe condítions are met, the solenoid
valve is de-energized and the governor pressure is fully restored.
Mercedes-Benz
O Oil sump dram

MR Govemor JlfflSSIS& tes.tc.ome.cfion
Y3/2 Shl po11t retard swtcllcvnr v!We
Fig. 315: ldentifying Transmission Shift Point Retard Relay And Shift Point Retard Solenoid Valve
Example model 201
N3 KE cortroh nt
K29 Tram;:russon sliltpo!rt rs:ard rolay
X22fl PtJgccmaclon, tansmJwon shlftp<~~rt retard II!Wa
(1·Pill
Y312 Transm,ssaon shltpotrtr~dsolenocdVflt.lof
swtchover vatve
ll Ovfl!Vollt¡¡e proledlon ro!ay, temmal67l
K29 Y3/2 P07-671S2·13
Fig. 316: KE Control Unit Circuit Diagram
Engine 119 KAT
On vebicles with engine 119 basic version KAT, the transmission shift point retard is controlled
hydraulically by a memory spring in the control valve housing.
Engine 103 only [l] !Gf»AP [$="BT@ CD
Air injection and transmission shift point retardare operated in paraUel by means of the air
injectionltransmission shift point retard relay (Kl7 /3). The air injection/transmission shift point retard
relay (Kl7/3) is actuated by the KE inj ection syste m control unit (N3), contact 14.
Mercedes-Benz
Transmission shift point retard operates only under the following conditíons:
• Coolant temperature between +lO -40 oc for not more than 80 seconds after each start.
• Engine speed <35QO/mín.
Function diagram of air injectionltransmission shift point retard
K17l3 AJr 11¡e<non.t"ansmtsSIOO

shft PQ!nl ro:ard rola'¡
N3 KE 11\&Cbon s{Stem
comrol unil
Y32 AJr pump Sl\t!I:hcver
va.Ve
Y33 Au pump eledrot113W1 e1c
dAeh
a To shi~ pOifllrota.rd
solanatd \'!We (Y3f2)
123 Th:ottle valva bOO¡I
125 AJrpump
126 Au a.t-off vawe a
127 Ncn-renm vawe
{ifl;edlon ilil")
128 NOJ>rotu'n vrjve
("{8CUUm)
15S Exhaust ma~~fold
Fi~. 317: Air lnjection/Transmission Shift Point Retard- Function Dia&ram

Mercedes-Benz
K1 / 1 Y6 K17/ 3 Y32 V33 V3 / 2
,. . .!X26
N3
F1 Bedhc al e ertei X22fl Pklgcomerion, shltpo¡rtrelardvatv'ol1·ptn)

K1t1 0(81Vol!age prctectton rolf'I¡8.7E f7.p~n) X26 Pklgcome(•on, lllooorlenQJlo
K17/3 Alri~I!Cbootansmisstoo shlftposrt ratard relay Y312 Shlft part retard sole1101 d vaNe
N3 I<E trtOCion system corDel lllll Y6 kfo speod ad¡uster
S2t1 lgraboo slariDr stMir: h Y32 Alr piJTlp StMtdlover vltvB
W10 Ground, bat!Oty Y33 Ale pomp olactromagoolle cUoh
X4110 Tei!Tllnal block, lermnal3fif.ermnal61 (blillllry? a To ba'laty {G1)
b To tlel ou.~ rolay, teunmal15
Fig. 318: Wiring Diagram Transmission Shift Point Retard - Model201
Wiring diagram transmission shift point retard
Engíne 103 in model 20 1 llJ !Gf"AP ~BT ® 0

Mercedes-Benz
Y6 K17/3 Y32 Y3/2

1e; l
~
t-t,.
o,.- ([7'\
., 1 ~~
~
..
1
W10
~hDJ --
11'1;10/Q~
X22/7
~ ~~
r,•
,n
~1~ ~~
G,";¡o!.g-
~
·~
~~
,1
,,
l ~· · 10014 57
F1 F uso illld relay box xnrr Pklg eomat ioo, sllft p011'1l relardva.' fe ( 1-pm)
K 111 0/ervo\'i!J;¡e proted!on rBiflf 87E (7 -pm) Y3f2 Slllft p,oirt. retllld so!eootd vaM!
K 17/3 Air lflOCllonf!rensrm sSioo shit pout retard rcle-f Y6 ld:e spee~ ad;'l.ls!er
N3 KE 1qecion system COfÚlll Ullt Y32 AJJ pump S'.-.itdlover vat.te
S211 l¡¡¡lbon slarCBr sw~h Y33 AJr pum¡> 01sctromagootK cUcll
S2611 Thermo swtdl - h eaing/washer system a Tobalery {G1)
W1 0 Ground, battery b To tJ al p.u!Tl) rola'/, tenninal15
X 4f10 Termmal blo'Ck, lllrnlnal30flsrmnal61 {ba1ler)l)
F ig. 319: Wiring Diagram Tr ansmission Shift Point Retard - Mode1124
Wiring diagram transmission shift point retard
Engine 103 in model 124 llJ n:!rAP IGr BT @ 0

-Pneumatic shift point retard, as of 06/91
The previous shift point retard by means of the so lenoid valve in the govemo! ~ssure.Estem is
discontinued, with the exception of vehicles with engine 103 llJ@ n:!rAP ~ BT e¿:)
All other vehicles with catalytic converter are fitted with a pneumatically operated shift point retard
which acts on the control pressure valve in the val ve body housing_
INST ALLATION SURVEY

_·o_n_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--r-,---,-~-----t
IModel IEngine IV_e_r_s•
t-
Mercedes-Benz
1990-2002 ENGINE PERFORMANCE Mixture Formation- REPAIR & ADJUSTMENTS- 129 Cha55i5
Basic version KAT [l]@ ~AP ~BT Q) @ ~

' ~¡g¡
124 104 X X X X X
129 104 X X X - X
129 119 x CI) X X X X
201 102 X - - - X
( l) Except basic version KA T, shift point retard p erformed by a memory spring in val ve body housing.
N311
S11(1
NJ/1 LH ot KE comolmi(N3) 1 C~ol pressur&Bcmdon cable

5 16/S On-mgmode sMtch {2ndmode) 2 Non1otu-n valva
5 1617 Kic:kdo•lll!l swlch 3 lrtake manfcld
Y3 Kic:kdo'Ml so!anotd vllMt 7 S and E mode VBCUIITI elemeli
Y313 Shlft pout retacd sMtrilGver valle 8 Shlft pout retard vacUIITI element
Y4 Onmgmode SMtchovervalw {2ndmode) 9 Vat UIITI reSBMllr
Fig. 320: LH Control Unit Or KE Control Unit- Function Diagram
Function
The LH control1mit (N3/ 1) or KE control unit (N3) actuates the shift point retard switchover valve (Y3/3)
with ground deoendent on coolant temoerature. road soeed and time. The vacuum element (8) in tbe
Mercedes-Benz
control pressure cable is then supplied with vacuum via the switchover valve.
The vacuum element for shift point retard (8) is located in the control pressure cable above the vacuum
element (7) for the 2nd driving mode. The conditions for shift point retard remain unaltered.
P27-0201-6t
1 Corúolpressu-o cable 5 Spmg

2 Slde va.lvo 6 Olaphragm
3 Bolaari< 7 s aro E modo. varuum e!!lmorn
Fig. 321: Section View OfVac uum E lement
Operation of vacuum element (8)
The vacuum pulls the diaphragrn (6) to the left against the force ofthe spring (5). The slide valve (2) is
thus moved up with the rocker arm (4) irrespective ofthe position ofthe control pressure cable (1).
The slide valve (2) then operates the control pressure valve via a connecting rod and the beU crank (3).
Mercedes-Benz
n. Camshaft adjustment (inlet camshaft), engines 104, 119
When the engine is nmning, the camshaft adjuster advances the inlet camshaft hydraulically/mechanically
by 34° crank angle and tben retards it. Tbe camsbaft adjuster is operated by the KE control unit vía the
camshaft actuators (Y49). Two camshaft adjusters and camshaft actuators (Y49/ l and Y 49/2) are fitted to
engine 119.
The adjustment is dependent on engine load and speed. The camshaft adjustment is not operational at a
coolant temperature below + 15 oc on engine 104 and +20 oc on engine 119.
ADJUSTMENT RANGE WITH INCREASE IN ENGINE SPEED

Adjustment Selector lever in Drive mode and low Selector lever in P/N and manual
range engine load transmission only engine 104
Engine 104 Engine 119
Idle speed up to Idle speed up to
Retarded Idle speed up to 2000/min
1700/min 2000/min
1700/min-
Advanced 2000 - 4 700/min 2000/min - 5000/min
5000/min
Retarded n > 5000/min n >4700/min n >5000/min
ADJUSTMENT RANGE WITH REDUCTION IN ENGINE SPEED

Retarded Stall speed up to 4900/min Stall speed up to 4400/min Stall speed up to 4900/min
Advanced 4900/min- 1200/min 4400/min - 1700/min 4900/min - 1700/min
Retarded n <1200/min n < 1700/min n < 1700/min
CAMSHAFT ADJUSTMENT HAS THE FOLLOWING EFFECTS ON COMBUSTION

Retarded in lower engine speed range Idling improved
Reduced residual gas quantity
Smaller valve overlap
Increased torque
Advanced in mid engine speed range
Reduced fresh gas losses
Inlet valves open and close later
Retarded in upper engine speed range
Cylinder charge improved (turbo effect)
Wiring diagram engine 104

Mercedes-Benz
N3
·-·-·-·-·-·-·-.
(( '.T.'"·--~-~·-·-·
<10' 20
rol
~~·
N3 KE coollclunt
YS StMVS:{8
Y49 Adjuslable camsha! •m11gacila:or
Y!\811 RegOil!lfaicn swlcñover vei>te
Z7 Fe.ed from ov91Volage pro!ec*oo rellr¡ , termmai87E Z7
-
1
~·~
~
.l!~¡e
~ ! JI
SS.r 5 ~ ~
Fig. 322: KE Control Unit Wiring Diagram- Engine 104

Mercedes-Benz
N3
N3 KE coorolunt t \f
X2612
Y8
Y27
PlJg connedlon, 911911& separabon pout (30-pln)
Start va.'va
Exh13UStgos recrcúabon s>MtchcvervE!Ml
~
o
"Z1
.
o
JI
g.
Y4911 lal adjustahla c:amshattiJmng aduator

Y4912
YSSJ1
Rl~ aó¡ustalllec Bmshalttrrung Bd!Jator
Rogooe;a'Jon swichowovat.le
t
S
t..
Z7 FB1ld from overvolag<¡ pro'.Bc lon retay, temunai87E
211 2!1 Q ~
X2812
t l
Q Q
!~.~
va
P07-6754-17
o. Maximum speed control, engines 104, 119
Engine 104
When a speed of 250 km/h is exceeded, the current and the electrohydraulic actuator is continuously
limited to -10 mA. As a result, the fuel supply to the injection valves is reduced. At the same time, the
signal is passed along the data line to the ignition controlmút, wbich results in ignition timing being
retarded to 15° crank angle before TDC. If vehicle speed ís still >250 km/h, the inlet camshaft is
advanced, which results in a further reduction in engine speed and vebicle speed.
Engine 119
lf a speed of 250 krn/h ís exceeded at full throttle, fust of all the two inlet camshafts are advanced, which
results in a reduction in torque. The actual goveming is perfonned vía the current at the electrohydraulic
actuator (Yl) ofthe KE ínjection system, as a result ofwhich a sufficiently lean fuel/air mixture is
produced, depending on aerodynamic drag (incline, backwind or headwind) to acbieve a steady-state
maximurn speed of v=250 km/h.
lfthe control function fails because of a fault in tlle KE electroníc circuitry, the power supply to the fuel
pumps is switched off by the engine systems control unit (N16). The engine systems control unit (N16) is
supplied wíth a road speed sígnal from the ABS control unit for tbis purpose.
Mercedes-Benz
Note re engine 117.968
On engine 117.968 maximum speed is governed via the ignition system, see Group 15 _
p. Data interchange of KE control unit and EZL/AKR ignition control unit engines 104, 119
Data interchange is a constant sequence of inforn1ation blocks and is interrupted only in the event of
faults and output of the stored faults.
The following information is exchanged along the data line:
• The intake air temperature is analyzed in the KE control unit and passed to the EZL/AKR ignition
control unit
• The pressure conditions in the intake manifold are passed by the pressure sensor in the EZLIAKR
ignitíon control unit to the KE control unit Differences in absolute pressure, e. g_ for altitude
correction, are also taken into account
• The values of both NTC elements (KE or EZLIAKR) in the coolant temperanlfe sensor are
compared. If ímplausible variations occur, a substítute temperature is selected. In the case of minor
variations between the one coolant temperature sensor and the other, e. g. KE 90 oc and EZL 70 o
C, the EZL/AKR ignition control unit always continues operating wíth the hígher temperature
leveL
• The "maximum speed control operating" signal is passed by the KE control unit to the EZLI AKR
ignition control unit
• Faults detected in the KE control unit and in the EZLIAKR ignition control unit are exchanged.
• If the id le speed contact is elo sed and the idle speed adjuster faulty (high engine speed), the ídle
speed emergency running curve is selected in the EZLIAKR ignition control unit This achieves the
latest possible ignition timing point and counteracts a rise in engine speed.
• Allocation of EZL/AKR ignition control unít to KE control unit and vice versa. Incorrect allocation
is stored as a fault
q_ ldle speed control
For detailed description ofthe various systems see section "Idle speed devices" .
Engines 102, 103, 104, 119
The idle speed control function is integrated in the KE control unit The idle speed adjuster is actuated by
the KE control unit
E ngines 104, 119
If an open circuit in the wíring, a short-circuit or a mechanical fault of the id!e speed adjuster or an open
circuit in the KE<-->AEZL/AKR data line is detected, the actuation to the idle speed adjuster is switched
off Following this, ignition timing is retarded in such a manner asto produce only an insignificant
increase in idle speed_
Mercedes-Benz
Engines 116, 117
The idle speed adjuster is actuated by the separate control unit of the idle speed controL
Note re engine 102
For engine 102.961 Standard and 102.962 Standard without air conditioner see section G "Idle speed
stabilization".
r. Start valve actuation, engines 104, 119
Actuation of the start valve is performed by the KE control unit on engine 104 up to a coolant
temperature of 70 oc and on engine 119 up to a coolant temperature of + 15 oc. The current to the start
valve is limited to 1.2 A. The actuation to the start valve is performed in accordance wíth a characteristic
curve which produces a pulsed injection of the start valve.
N3
·-·-·--·-·-·-·-.
,[- ·r-·-·~· r-·-·-·
,410~ 20 pi
2~·
N3 KE oonrolunt
YS Startvaf.fe
Y49 Adjuslabl& camsll~ i mJJgsclle>'llr Z7
Y5B/1 R&g&nerMon swtchowr v!Wo
Z7 l=eed from ovONolege pro:St ion reley,
tsrmnai87E -
1
itf ~ t 1
SS~ 11!
o ~ ~
Fie. 324: KE Control Unit Wirine Diaeram- E ueine 104
s. Actuation and diagnosis of oxygen sensor heater, engines 104, 119
The KE control unit supplies a conn·ol signal for the oxygen sensor heater to the engine systems control
unit (Nl6) whích then controls the oxvílen sensor heater The encrí ne svstems controlunít rN16) sunnlies
Mercedes-Benz
au information signal regarding the oxygen sensor heater current (feedback) to the KE control unit for
diagnosis purposes.
t. Air injection
NOTE: For air injection system see also Group 14.
Engine 103 ~@ n:!rAP tr:!r BT 0
The KE control unit (N3) supplies a control signal to the air injectionltransrnission shift point retard relay
(Kl7/3).
Engines 103.984, 104, 119
The magnetic clutch of the air pump is actuated by a signa! supplied by the KE control uuit (N3),
dependent on coolant start temperature, via the engine systems control unit (N16). Air injection is
performed at a coolant start temperature between + 1O oc and +40 °C. Air injection is switched off at full
throttle or atan engine speed above 3000/min in the case of engine 104 or above 2500/min in the case of
engine 119. Following an engine start at approx. + 20 oc the air pump runs for about 2 minutes (for as
long as the lambda control is in the open-loop mode).
E ngines 104, 119
Air injection system check
The diagnostics of the KE control unít checks the operation of the entire system.
If the engine is at normal operating temperature, lambda control operating, engine idling and vehicle
stationary, the air pump is actuated once after each engine start for 5 seconds. It is possible to determine
from the oxygen sensor signa! whether aír injection is operating. lf a fau lt is detected, it is stored in the
fault memory of the KE control unit. lf any of the preconditions (e. g. engine idling) alters before 5
seconds have elapsed, the check is aborted.
Mercedes-Benz
! t
'---------~a r.. t
X1114
W16
1.01:11"----..... ~
1 ~
ll '
~ §
~
L.:;.;..a
Y32
P07~155-f7
N3 KE con_.olurit
N16 Engine systems arirol mi (MAS)
W16 Gmuld, componentoompadmeft
X1114 Test coq¡lng 1or <I8!;J10Sis, pdse readolt ( 1t4Jin)
Y32 Air punp swEhover \IBive
Y33 AirpunpeleclromagJieic ciiEh
Y33x1 ~ connedioo, air punp eledromajJ18tic cUdl
Fig. 325: KE Control Unit Wiring Diagram- E ngine 104, 119
Example engine 104
Engines 116, 117
The KE controltmit (N3) supplies a control signal to the air inj ection relay (Kl7). As a result ofthis, the
air pump electromagnetic clutch (Y33) and tbe air pump switcbover valve (Y32) are actuated
simultaneously.

Mercedes-Benz
(~IIJ N3
'--------'0,75 b r / b l - - - - .
N3 KE cooiJoiUI'II
K 17 Alr 11¡ecboo rolay a b
W10 Gro!J1d, b"ettary
Y32 Alr pump S>'lllthovor valva
Yl3 Alr pump e.et.-omagnetc clutth
a Fusa ood relaybox,lusa 5, !Drmnal 15 W10
'----- 0,75 rt/ge - - - - -
b
m
Olorvolage prot¡¡rocn relay, r.ermnal87
Auxlwyfan relay
T
0.75
' - - lcwlrl - - -- - - - - , T
br 0,75sw/g n - - ~~
'¡'
U
75br ~W10
0,?5sw/gn l .1
rl-~-H---.
twi 1~1
LiJ
Y32
L._._J
K17
Fi~. 326: KE Control Unit Wirin~ Dia~ram- En~ine 117.968
u. Exhaust gas recirculation
Engine 119
The exhaust gas recirculation electríc switchover valve (Y27) is actuated by the KE control unít in the
following operating states:

• Potentiometer voltage at air flow sensor >2 V
• Fullload contact open
• Idle speed contact open
Exhaust gas recirculation system check
The diagnostics of the KE control unit checks operation of the entire system. During deceleration fuel
cutoff, the exhaust gas recirculation switchover valve is actuated for 3 seconds. It is possible to determine
from the íntake manifold pressure sígnal whích ís measured by the EZL/ AKR ignítion control unit
whether exhaust gas recirculation is operating. If a fault is detected, it is stored in the fault memory of the
KE control unit. If the deceleration phase ís <3 seconds, the test is aborted.
Wiring diagram engíne 119

Mercedes-Benz
N3
1 J
t t
~
o S.
i
...
Q '~
~
L1
~
S.
f i
- ...
Q. Q
~
L.;. • .;;;.J
Y8
P07..lii'Pi4-f1
N3 KE oonllolunt
X261'l Ptl.g connedioo, engileseparabon p01nt (30i)in)
Y8 Start VBNe
Y'l7 Exhaust gas recl'ru>abon soMtctlove1 v&.re
Y49l1 Le• aci)Jstable camSilaftbmog act1.Jat01:
Y4911 Ri~ a$Jstabte camshaftllruog actuator
Y5811 Regenera onsw~dlowrvat.re
ll Fe ed from ove¡yobge prc~flo11 rBiay,

larmnai87E
Fig. 327: KE Control Unit Wiring Diagram- E ngine 119
~California
On Board Diagnosis System
A temperature sensor (B21) is installed in the exhaust gas recirculation line on vehicles with on board
Mercedes-Benz
diagnosis system. The temperature of the recirculated exhaust gases is detected by the temperature sensor.
Ifthe exhaust gas temperature drops below approx. 120 oc when drivíng, no exhaust gas recírculatíon is
performed. This is detected as a fault by the KE control unit, stored at the CHECK ENGINE indicator
lamp actuated.
Engine 102
821 Exhaust gas marcuabon tempMature sens'{)r
Fig. 328: ldentifving Exhaust Gas Recirculation Temperature Sensor
~ California 1988
Mercedes-Benz
A1&26 CHECK ENGN:

rltiiCalcrlamp
821 Bmaustgas
roo re liabon
!Dmpam.tura sensor
N3 I<E conrolurit
X11 Oiagnosbc sockel/
lllmlnal blol:k, llllmllal
ID
X1114 Testc<qlingfor
~oSis, puiSe readctli
(6-pm)
X1114s1 Pusltltttoo s'Mtch 'Mth
LEO
X8012 Pltg conn&CIIon,
o>tt8U5t gas
roorculabon
lllmpcerature s ensor
(re!erenco grOUJd)
X8013 Pltg c~J18Cbon,
e>tt8U5t gas
rocuctlabon
lllmpe:aturo sensor (KE
Slgnal)
Z Comeclor sleew
(solder ed e omacefor 1n
hamess)
1Bmlnal31
a Overvolage protecbon
relay, tQllllllai87E
Fig. 329: KE Control Unit Wiring Diagram- Engine 117.968
v. Active charcoal fllter regeneration, engines 104, 119
The regeneration switchover valve (Y58/ l) is actuated by a ground signal suppJied by the KE control
unit, contact 2. Fuel vapors are extracted from the active charcoal filter (regenerated) (see Group 47-
0200).
Example engine 119
Y58/1 RegeoEK atoo swtchowr vBÑe
Fig. 330: ldentifying Regeneration Switchover Valve
Conditions for actuation ofregeneration switchover valve (Y58/I):

Mercedes-Benz
Idle speed contact Coolant temperature above +70 oc

open (above +80 oc for engine 104 as of09/89)
Coolant temperature above +95 oc
Idle speed contact
(abo ve +100 oc for engine 104 as of 09/89) or intake air temperature abo ve 55 oc
closed
and! vehicle speed below 5 km/h
·--·-·---·-·-·_.
N3
....
N3 I<E con7ol unt
(e•ro·-·~· "'"·-·-·
40' 210 rl
2 ~.
YS Sanva!ve
Y49 Ad,'us!OO!e camshlrt imll'lg&clll a:or
Y5811 Regeneraíoo swídH>veJ v~e
Z7 Fo.ed 1r001 ovEHVol:age pro!adoo rol&f,
lermnai87E
Z7
Fig. 331 : KE Control Unit Wiring Diagram - Engine 104
W iring diagram engine 119

Mercedes-Benz
·-·-·._·-----·-·-·-·-·-·-·-·
N3 KE tortTollllil
X26f2 Pklg eomec!Jon, en!Jjne sopara~on pout(30-pm)
YS StartvaM!
X27 Eltia'l!St ga:s rearcúabon S'loltl:hover vntve t
Y4911 leftad¡ustablecamshafftrmng aduatOJ lt
o
Y4912 R9118$1Siab!o camsh~ im~ngactaa'N
Y5811 Reglltlllrabon sNtchover vaM3
"D
Z7 F eeó tom <wervollage proteroon relay,
tormmai87E
t
S ..
2lll Zl
)(2$/2
w. Altitude correction
The low air density in higher locations necessitates a leaner fuel/air mixture. The volume flow measured
with the air flow sensor corresponds toa lower air mass as a consequence oftbe low air density. This
difference is corrected in order to avoid a too rich mixture with excessive fuel consumption and increased
pollutant emissions.
Engines 102,103,116,117@ [g] ~
Location of altitude sensor (B 18)
Modell24, 201: Right of component compartment.
Modell07, 126: Right footwell.
Example model 124, 201

Mercedes-Benz
818 Ali'JdiH 8llSOf
••
Fig. 333: Identifying Altitude Sensor Location
The altitud e sensor (B 18) is actuated with a constant voltage parallel to the air flow sensor position
indicator (B2) and supplies a voltage sígnal to the KE control unit, contact ll .
NOTE: The KE intake air temperature sensor (817/2) is not fitted on vehicles with
altitude sensor.
NS
,..~~~~-·-·-·-·-·-·
i -()
'-·
N3 KE coorolull!í
82 Au low sensOl pcsillon ildlca!OJ
8 18 Altude soo sor
8.2 818
Fig. 334: KE Control U nit Wiring Diagram
VOLTAGE LEVELS OF SENSOR FOR ALTITUDE CORRECTION (B18)

Heigbt above MSL in Air pressure p Voltage at contact 11 (to ground) in
meters absolute/mbar volts
o 1013 4±1
1000 899 3±1
2000 795 2±1
1 Mercedes-Benz
Engines 104,119
The pressure conditions in the intake manifold are detected by the pressure sensor in the EZLIAKR
ignition control unit and passed along the data line to the KE control unit. The absolute pressure is taken
into account for the altitude correction.
x. Fault recognition by KE control unit
Fault diagnosis by means of on/off ratio
Engine 102 as of approx. 04/86
Engine 103 as of approx. 03/86
Engine 104, 119 as of start of production
Engine 116, 117 as of approx. 12/85
The KE control unit (N3) enables various components of the KE injection system to be tested. The on/off
ratio can be read at the test output in the diagnostic socket (Xll) with the lambda control tester (012). The
on/off ratio provides information regarding possible causes of faults. Only faults whlch exist at that
moment and are detected are displayed. A certain on/off ratio is allocated to each fault. Output of fault
messages has priority o ver the output of the lambda control signa!. If the lambda closed-loop control is
not operational (e. g. oxygen sensor temperature too low), the reading is 50 % ( open loop mode/constant
readout). lfthe lambda closed-loop control is operating, the readout fluctuates armmd an average value. lf
severa! faults occur simultaneously, the fault which corresponds to the lowest onloff ratio is always
displayed. This process is continued tmtil all the faults ha ve been rectified. An allocation of on/off ratio
and possible cause offault is provided in the respective test program (07.3-121).
____ -- .....
..,... ~
.:..
..._..,. ......
ooo• ~
Fig. 335: Connecting KE Control Unit With Lambda Control Tester
Fault memory
Mercedes-Benz
Engine 102.96/98 as of09/89
Engine 103, only ¡gj ~ as of 1990
Engine 104, 119
When the engine is running, faults which occur and are recognized (e. g. open circuit, short-circuit and
implausible values) are stored in the KE control unit. Loose contacts are also recognized as faults and
stored. The stored faults can be read at the test coupling for diagnosis (Xll/4) with the pulse counter. A
condition is that the battery has not been disconnected in the meantime otherwise the stored faults hav e
been erased.
G1 &~ry
X11f4 Tesícouplingfof
dagnOSIS
Engin&s 102, 103, 11 6,
117 a.pcn votsion
Engmos 104, 119"
1~n\'9fSion
0 13 Pu'.secotrier
Fig. 336: ldentifying Battery And Pulse Counter
&oanaerl
When dealing with engine running complaints, always read the fault memory and note any faults before
performing repairs.
This ensures that a distinction can be made between faults which have in fact occurred and "simulated
faults" as faults are stored when performing test operations with the engine running which may result
from a simulation or from a disconnected cable. After completing test operations, the fault memory must
be erased. for pulse output and fault table see Repair lnstructions for engines 102, 103, 116, 117 or
Diagnosis Manual Engine for engines l04, 119.
The KE control unit supplies to contact 23 not only the on/off ratio (lambda test signa!) but in addition the
pulse signa! for the fault memory. The on/off ratio is output on a priority basis (except ~ ). The start
button on the pulse counter must be pressed in order to initiate pulse output ofthe fault memory.
Mercedes-Benz
National version ~
The pulse signa} ofthe fault memory is output on a priority basis. Iffaults are stored, the "CHECK
ENGINE" indicator lamp lights up. In order to recognize faults by means ofthe on/offratio or for
adjusting the lambda control, the KE control unit must fust of all be switched o ver to on/off ratio output.
This is done with the pulse counter. On the California version switchover can also be performed at the
switch ofthe test coupling for diagnosis (Xll/4).
National version ~ Calüornia
See in addition the section "On Board Diagnosis System''.
Engines 102, 103, 116, 117
.b
~
J.
N3 I<E ron!ro4urat(25-ptn)
L1 TDC SBllSOf
X 11 Dlagnosbc sod<etilarmnal block tenmnallD
X2&1 Grnymooel201 Pklgc01100cioo, ho!K!!amphemoss
(1-pin)
X 11~ Testcouping for di a~c-s1s, plfsereadoti
(8-ptn, oootact 3)
Fig. 337: KE Control Unit Wiring Diagram- Engines 102, 103, 116, 117
Engines 104, 119
The KE control unit (55-pin) supplies the on/offratio (lambda test signal) to contact 30. The pulse output
of the fault memory is performed at contact 7. It is not necessary to switch o ver between on/off ratio
output or pulse output.
Engines 104, 119

Mercedes-Benz
N3
N3 KE cc1'trcl tnt (~n)

l1 TDC 59115()(
U2 Va d lor Clñfoma
X 11 Dlagnosbc socke.\l!ermt'lalbkx:k illrmnal TD
X11f4 Ttls! Cil~ng fOJ diagMs.s, ptJise re.adO\Jl (1&pln,
cootact 3)
X 1114s1 Svtch wlih LEO, C~om1e
Z7 CoonettOJ sl&eve, terml'lai87E
F eed trom o\l9IVOI&ge. protedion rG!F!f
X11
Fig. 338: KE Control U nit Wiring Diagram- E ngines 104, 119
Measuring on/off ratio with ignition on
Engines 104, 119
The KE control unit features this 3rd possibility of detecting and outputting faults which have occurred in
the system_ With the ignition switched on, the input signals to the KE control unit are tested in the static
state ofthe components. The faults are not stored and can only be displayed immediately (i. e. only ifthe
fault exists at that moment) by measuring the onf off ratio at the diagnostic socket (Xll). This output
mode can also be used for a rapid check of the signals monitored in this case. Por measuring on/off ratio
and fault table see Diagnosis Manual Engine_
On Board Diagnosis System
~ California as of 1988
All the components ofthe KE inj ection system and ofthe exhaust gas recirculation system which effect
exhaust ernissions are monitored by the KE control unit Malfunctions resulting from an open circuit in
the wiring or failure of one of these components are signalled by the "CHECK ENGINE" indicator lamp
in the instrument cluster and simultaneously stored in the KE control unit
The test coupling for diagnosis (X92 or X l l/4) is fitted with a push-button switch (2, arrow) andan LED
(4) for "on board diagnosis".
Mercedes-Benz
Fig. 339: ldentifving Test Coupling For Diagnosis
The test coupling for diagnosis is located on the right of the component compartment panel (model l 07
on left wheelhouse panel). The 8-pin version is replaced by a 16-pin version on engines 104, 119.
Ifthe push-button switch (ignition: ON) is operated for between 2 and 4 seconds, the flash pulse output
is initiated and the fault path indicated by the number of flashes.
After completion of the flash pulse output, the LED shows a steady light. If the push-button switch is
again pressed for between 2 and 4 seconds, any fl.llther fault path can be displayed. 1f no further fault is
recognized, the KE control unit switches over to on/off ratio output.
Erasing flash pulses
Once a fault has been rectified without the KE control unit having been disconnected, the flash pulse
output displayed must be erased as follows:
• With the flash pulse output displayed, operate push-button switch for 6 -8 seconds after a waiting
period of 2 seconds.
• LED flashes once, stored fault is erased.
Each displayed flash pulse output rnust be erased individually.
NOTE: Pushbutton switch and LEO have been developed to enable customers
and non-MB dealers to locate the fault path as specified by legislation with
"on board means". A pulse counter has been developed for DB workshop
personnel which indicates the stored fault(s) by means of a digital display
(see pulse output at test coupling for diagnosis).
On/off ratio output
The output for the on/off ratio is not perfonned until after the KE control unit has been programmed to
on/off ratio outout. Otherwise. with the engine running, tbe readout is at O % or 85 % if the "CHECK
Mercedes-Benz
ENGINE" indicator lamp comes on.
To test the lambda control, the control unit is switched over to onloff ratio output by pressing the push-
button switch (see Op. No. 07.3-105 or 07.3-110).
¿OanQer!
When dealing with engine running complaints, the fault memory should be read and the faults noted as
part ofüp. No. 07-1100 before performing repairs. This ensures that a distinction can be made between
faults which have in fac t occurred and "simulated faults" as faults are stored when performing test
operations with the engine runníng which may result from a simulation or a disconnected cable.
After completing test operations tbe fault memory must be erased.
y. Emergency running (plausibility)
The signals supplied by the peripheral components to the KE control unit are continuously analyzed. If
the composition of the signals is no longer logical, a substitute value (emergency running property) is
formed automatically for the non-plausible signal by the electronic controL
If, for example, a rapid change in temperature is simulated - engine at normal operating temperature and
coupling of coolant temperature sensor then unplugged, the microprocessor in the control unit compares
the momentary temperature with the stored temperature. The control unit detects open circuit (short-
circuit) and programs emergency running mode. The control unit does not detect a slow change in the
characteristic curve (characteristic curve drift).
START DEVICES- RA0703KE2F030X(F.)
When the engine is started from cold, the inducted fuel-air mixture becomes considerably leaner.
Causes for this are:
o Poor swirl of fuel particles at low engine speeds

o Low evaporation of fuel at low temperature
o Considerable fuel precipitation on cold engine parts.
In order to compensate for these unfavorable influences during a cold start and to facilitate starting of the
engine, fuel is injected additionally as follows:
• Start enrichment by the KE control unit

• Start enrichment by the start valve
• Post-start enrichment by the KE control unit
The KE control unit recognizes engine starting, dependíng on version, vía terminal 50 (KE 1 and 2) or from the
engíne speed pulses supplied by terminal TD/TN (as ofKE 3).
1 Mercedes-Benz
As a result of start recognition, the KE control unit initiates start and post-start errrichrnent.
1 ( 1) •
t1 Startemchment(dtration e.g . 2secoods)

t2 Pos.t-start emdlmont
{dlJra!Jon e.g. 20 seronds)
t3 Warmn!}I..IP (d'urmon dep.ending oo coolant
tamperalure)
a S!art
b E rtd of start, <orrmenHimBill of lim~ng post.-start
ennchmern
L Eod of post-slart,e rnchmert, commencemam of
Wamll'lg.ql
1sr (mA) Cturent ate ecr otr¡~OO!tD< actuatOf
Fig. 340: E ngine Speed Pulses Graph
a) Start recognition by KE control unit via terminal 50
When the engine is started, battery voltage exists at the KE control unit (contact 24) and at the stru1er via the
ignition starter switch (terminal 50).
On vehicles with automatic transmission, the voltage is passed from terminal 50 via the starter lock-out switch.
When the selector lever is in position P and N, the circuit is closed and it is possible to stm1 the engine. When a
Drive mode is engaged, the circuit is intem1pted and no starting is possible.
Wiring diagram of start recognition vía terminal 50
Example model 124.023 with manual transmission

Mercedes-Benz
X-4911 N3
pa¡ -5832-36
G1 Battory X4 Tamunal bkxk, 1.9fmnal 3-Q

M1 S.lllter X4110 Temunal blod<, tennnal30J';IlfiTinal61, batter¡(3-pln)
N3 KEcomcllnl X26 PlJ,g cometacn, fllilnoflerlg¡ne
N1611 Fuel pu;np relay X27 Pllgcomedcn, starter hamess
S2/1 lgn11on slllllllr s~l!:h X49J1 Pllgconnedon, reversmg lamps'MI!:h
W1 0 Batt01y g;ound V1 B ac iohfctaUic ad!Jator
Fig. 341: Wiring Diagram Of Start Recognition Via Terminal SO- Model 124.023 With Manual
Transmission
Wirrng diagram of start recognition vía terminal 50
Example model 124.023 with automatic transmíssíon

Mercedes-Benz
G1 BBI!e¡y X4 TlllTTlJnBI blod<, IBrmnai3G

M1 Salle!" X4f10 TlllTTltnBI blod<, !Brmnal 30ilermnal S1, batte¡y (3-ptn)
N3 KE e Cltr<ll tnl X 26 Pbgcomaclcn, l'l!ooorton~e
N1&2 Fuel pump rolay X27 f'tl g comed en, stllltor ham ess
5211 lgnuon s!adN sv..trll X49!1 F't19 comedon, revom~ng lamp swl!: h
S1611 S:arter lock-oú and rovorsmg lamp SWlk:ll Y1 Elo csoh¡ldraltlc actuator
W10 Battow grOUld
Fig. 342: Wiring Diagram Of Start Recognition Vía Terminal SO- Modell24.023 With Automatic
Transmission
b) Start recognition by KE control unit via terminal TD/TN
As soon as the starter rotates, engíne speed pulses are produced by the ignition control unit of the ignition
system (TD/TN signal).
Once a certain number of pulses is reached ( approx. > or =30/min), this indicates commencement of starting for
the KE control unit -start and post-start enrichment are initiated.
The engine speed pulses are detected at contact 25 ofthe 25-pin version ofthe KE control unit.
On engines 104, 119 with 55-pín version ofthe KE controltmit, the short circuit-proof engíne speed pulses
(TDA/TNA signal) are detected at contact 27.
Wiring diagram start recognition via terminal TD
Example modell24.023
Mercedes-Benz
A1p7 Eler~OI'IIc dod<Aathomotor W3 Grountt, a~ tOl'I!Jeftwl'leallousa ~llfii600 cod)

N1f2 EZI.. tg¡noo ccnrol u111t X11 Olagrosac socko~leiiTl:JJalblcxk, temunallO
N3 J<E ccmrol tnl X 26 PkJgc()llOOciOO, ~terror/eng¡ne
N6 AC compres ser cu~.QJ como! une Y1 8ocvoh¡la-auic actual«
N16/.l Fual punp rol!!'¡
Fig. 343: Wir ing Diagram St art Recognition Via Ter minal TD (1 Of 2)
N3
r·-·-·-·-·-·
i -()
X28,
~
~
1~
A1
P07-6S36-ati_
A1 lnslrumen! c~er X2612 P\lgcomedoo, engme separaboo pol'll{30.pl'l)

N1/3 EZlJAJ<R igniioo ccn!rol uni W3 Grouod, at lrortloft wheellouse ~grri~oo coíl)
N3 KE ccrtrol Ullll Y1 Elecrohydrlll.i e aduatOf
N1511 A.ummt~lK 5- speeo r ansmtsSioo coorol umt AG4 A.utomallc 4-spood transmtsstoo
N16 Eng¡ne sysillms coorolunt AGS A.utnmalx 5-spearl f811SffliS'SIOO
X26 P\lgcomedoo, IJlteoofleng¡ne
Fig. 344: Wir ing Diagram Start Recognition Via Ter minal TD (2 Of 2)
Wiríng diagram of start recognition vía terminal TD

1 Mercedes-Benz
Example modell29.066
e) Start enrichment
Start enrichment is initiated when the engine starts. The level ofthe enrichment (high enrichment) is dependent
on the coolant temperature. The KE control unit limits emi chment (current at electrohydraulic actuator) after
approx. 1 - 2 seconds to the temperature-dependent warming-up base value plus post-start enrichment.
• p '
~-t - - - - - t : t - - -+---t;J--ool
• t (IJ •
11 S!srtomchmenHáUrabon e.g, 2seconds)

t2 Po~-startennduneot
{dwation e.g. 20 seroods)
13 Warmng.UJ> (dunnoo according ro c-cclMtterrpora~re)

a Slart
b Eod ct start, c.orrmonrernent oflimimg post-start
ennchme:t
e Eod of posl:-slart emchmert, comm!l:lcemert ot
WBm111'l~
•sr {m A.) Current at e'aclrotr¡r!huic actuator
Fig. 345: Engine Speed Pulses Graph
d) Post-start enrichment
This stabilizes the smooth run.ning characteristics of the engine after starting. The end of starting is the
commencement of limiting of p ost-start enrichment.
The level and duration ofthe enrichment are dependent on the coolant temperature.
The post-start enrichment period is followed by the start of the warming-up phase of the engine (see sections D
"Wanning-up" and E "Coolant temperature sensor").
e) Start valve
Example engine 104

Mercedes-Benz
va sart va!Ye
Airow FueHeed (sys.tem
prassure)
Fig. 346: Locating Start VaJve
The start valve (Y8) ís flauged to the ídle a ir duct. System pressure exists at the fu el feed of the start valve.
When the eugine is started ata coolant temperature below + 15 oc or +60 °C, fuel ís ínjected additionally
through the start valve as a starting aid.
Depeuding ou the version, the start valve is actuated via the:
• Thermo time switch

• Fuel pump relay
• Engine systems control unit (engine 103.984)
• KE control unit (engines 104, 119).
The solenoid core (3) and the solenoid (2) are located in the start valve housing. In the offposition, the moving
solenoid core is pushed against a seal by the spring (4)- the valve is closed.
Ifvoltage is applied to the solenoid, the solenoid core is lifted offthe valve seat and opens the fhel flow. The
fue] is injected by the nozzle (5) as a finely atomized spray into the idle air duct.
Mercedes-Benz
..,_.,,
Fuel feed
2 Solenmd
3 Solenotd eme
4 Spnng
5 Nozzle
Fig. 347: Section View Of Start Valve
f) Start valve actuation- vía thermo time switch, engine 102.961 Std .
The thermo time switch (S26) is located at front of cylinder head and screwed into the coolant circuit.
Mercedes-Benz
Fig. 348: Locating Thermo Time Switch
When the engine is started ata coolant temperature below +5 °C, the start valve (Y8) is actuated vía terminal 50
and the closed contact (terminal W) in the thermo time switch (S26) to ground. At tbe same time, voltage is
supplied to the electrically heated bimetal spring (terminal G). This is necessary to limit the maximum operating
time of the start val ve when starting the engine.
Fig. 349: Thermo Time Switch - Wiring Diagram
The thermo time switch is closed at coolant temperatures below +5 oc. The closing time ofthe thermo time
switch and thus the opening time of the start valve increases as the temperature decreases and reaches about 12
seconds at -20 oc.
1 Mercedes-Benz
Fig. 350: Section View Of Thermo Time Switch
- via fuel pump relay
Actuation (terminal 87V) of the start val ve (Y8) is dependent on the coolant temperature and the start signal.
The coolant temperature is input to the fuel pump relay via the coolant temperature sensor (terminal TF) and the
start signal vía terminal 50.
Wiring diagram of start valve actuation by fu el pump relay
Example engine 102.982 KAT/RUF

Mercedes-Benz
H1611
JI
)!>
1
WtZ
l,l'!i9!fl • --~
h- - 015tn/Jo
~!."lftw ~ ~~ y
waf-u ..
xn
1
.. ,~· · ···
a 11n Coolatt lllmpereture sensor (2.pin) X 36 Pltgconnat•on, llelpurrp

M3 Fuelpump va Sart v,t(e
N3 I<E cQdrol U!lll ( 25-pin couping) e TFmnlnal b!cc~ engme,lomunal30
N 18f1 Fuel pump ro!aywlh startvalv&ac.Me§on g CNON~ge pcotedlon rel!r¡, tetmmal15,
W3 Ground, al '"oo!leftwtlee§louso Ogrdon cod) coolact6
W11 Eng;no·grOU!ld {e'~.-.c cable botted on) h EZl 1g¡~ion oontrolurn~ wrmnal TO (4?n OOflnedor,
W 12 Cemre consola grot11d su~ply)
X 11 Dlagnosllc socko~ermJ'lalblock, teomunal TO V Ov91Vol:ago proledJon, tetmmal87, cortact 2
X26 ~g comec~on, &llQine hamess (11-Pil) y EZl iQJlllon rontrolurntj 4-Pfll comec!of, smr sor)
F ig. 351: Wiring Diagram Of Star t Valve Actuation By Fuel Pump Relay
The coolant temperature is detected by the coolant temperature sensor (Bll/2) and supplied to the KE control
unit, contact 21. A processed temperature signal is passed by the KE control unit, contact 9, to the fuel pump
relay (terminal TF).
On engine 102.961/962 Standard (KE 1 and 2) the temperature signa! from the coolant temperature sensor
(Bll/2) is supplied directly to the fue! pump relay (terminal TF).
Wiring diagram of start valve actuation by fuel pump relay
Example engine 102.962 Standard

Mercedes-Benz
--. ,.,_ ................. -- ..........-- .. -- .. ~-.- .. -- ..-- ... --......... --........... -- ..--.................. -- .......... -- .......... -- ...........-- ..--.......... -- .. --... -- ... -- ...-- ............--... - ................... -- ............,
, ,
:'
!
i
i'
:
''
''
''
!
!
:
:
i'
:
!
i
1
:'
i
'
¡'
1
• . . .41&1tl ¡
--------------------------------------------------------------------------- ·-----------------------------~
Wiring dlagram of start valve actuation lby fuel pump relay
&ample engine 102.962 Standard
82 1\u f.ow sensor poSll: 01 •no ca:o~ W10 36l!:O'Ygro.Jfld {ngnt'l'l!l!lll -noU>e)
61112 Cooart álmoeraiuro sc'lSot {ll,DO::O~ systnmtcold W1 1 Erlgíne grodfld (o .cc~ie cal! o bo."lld 0!1)
stalt Vfilo/o BCIUat;OO) X9 "'t.Jg comotoon {1-p n), rorm nal 30
;:¡ Sour,calceroro X11 Oagoos~c socko1tcmú'lalbC~<I<,tcMúl&iTD
K1 OvoNo:ngo oro:croon rcay X1B :>J Q COJ'II'ICCF.~1, tal ~ harooS1i
>vl3 Fuo!p.J!Tlp X27 P'Jgco"'f''Ctbo~. ~rrc•namoss
N3 'l,CCCO'l system tO'I!I'ol Ulll X35 -orm na b'oc'>t, "IIllTlllla 301tormna 61 foa:DIV)
N16/l Fual p.!IITipr olaywlh attl.lalu:m ol cok! silart vava and X 56 Pi.Jg C1l!ll1CCÍ0:1, ;¡ro=o va\Q sw~cn
IQC>(down w:-0:
Y1 3octrollfdrau.;c acrua:ot
RS A.Jxia'Y BJ r vaw he a!ll'l!l c.o 1 Y8 Stanvavc
S28 Ooce~cra'on ruo;.D" maoswt cl'l Eng:i:'la spccd sa;¡lfi za:oo switd'iovcr va'll:l
a
52911 Tnro;¡;;e vavo S't4.1Cl'l, ~ :oad rec cg!li: en
h Tra:JS~S!onzcd IQ!lr!cn {TSZ) cornro un:
W3 Grtuncl, at i'D11t!oñwhoo:nc~ sc (i~~O!l cOl!)
W6 GroJna, lo..'twnco:llo.Jso 11 crunl<
Fig. 352: Wiring Diagram Of Start Valve Actuation Bv Fuel Pump Relav- Engine 102.962 Standard
Depending on the version, the start val ve is actuated at a coolant temperature of up to + 15 oc or up to +60 oc.
The duration of the actuation likewise differs and is, for example, for engine 103 Std.: approx. 10 seconds at -20
oc O seconds at +60°C.
Diagrarn of start val ve actuation up to +60°C Example engine 103 Std.
Mercedes-Benz
.....
"a. \ ' 1
..
6
7
' 1
1\ 1
"3
,2: '' f' ......
1
-... ~
-20-10 D 10
Fig. 353: Temperature Grapb

~
---·
30 .&0 !10 801 "M 80 §0100 OC
-via engine systems control unit, engine 103.984
The Start val ve (Y8) is actuated via terminal 87V depending on coolant temperature, up to +60 °C.
The coolant temperature is detected by the coolant temperature sensor (B 11/2) and supplied to the KE control
unit, contact 21. A processed temperature signal is passed by the KE control unit, contact 9, to the engine
systems control unit (terminal TF)_
The Engine systems control unit recognizes faults (TF signal, terminal 50, output stage terminal 87V etc.), see
15-0030 .
Wiring diagram of start valve actuation
Example engine 103.984 with manual transmission

Mercedes-Benz
~~X4
.~~ -a
!
''
i 'JI'
oq, Q
"' 1:
Q.
¡ 01
11 10
..
3
~
'
: !
1 :
' '
! !
! !
'' ''
! ..._...................
!
! B11f2 M1 PDT~ !
-------------------------------------------------------------------------
Wíríng diagram of start valve actuation
Exan,:>le engine 103.984 wth manualtransmssion
6 1112 Coo!a'lt ~mpelllliJI'e se'lSor X4110 Term na bloc!<., iDmllnaJ 3ll/3.0UIS1elfl7 _ (5-oln)
~11 X221<1 ~g cGmccóo~. man!lal )'a'ISJTl sgo'"liong no
N 16 En¡¡_ne sys:oms co~Jo un: {4- IHl)
N3 t<Ecomol..l!tt X26112 :::>wg CO'l!lOC"JO~, ll:IH OffJallS.ffi.SSlG~ (&p.n)
S211 gn 001 s:ar11r sw:a::n X27 P J QCO'l!looon, s.tar.c: 'lamess (5..¡n )
X4 Term na! b oc.<, l:C rmnal 30, tJse a"lc re f!ff ooxirtenGI 48 s:a:tva've
(2-P""l) a To EZL 'Q11 ¡¡on como un:
Fig. 354: Wiring Diagram Of Start Valve Actuatioo- Eogine 103.984
- via KE control unit, engines 104, 119
Wben the engine is started (terminal 50), the strut valve is actuated by the KE control unit up to +70 oc in the
case of engine 104 or up to + 15 oc on engine 119. The current at the start val ve is limited to 1.2 A. Actuation to
the start val ve is performed in accordance with a characteristic curve which produces a pulsed injection of the
start valve.
Voltage is supplied to the start valve (Y8) by the overvoltage protection relay (terminal87E). Ground is
connected for actuating the start valve vía an output stage with current limiter in the KE conn·ol unit.
Wiring diagram of start valve actuation
Example engine 104

Mercedes-Benz
r---------·-------·-·--·--·----·--·--·-·--·--·----·--·--·--·-------·--·--·----·--·--·-·--·--··---------------------
r---·--·-·--·-~-·--·-•-•-•-•-•-• ·-·-·-:f·-·-:-·
·-·-·- ·-·-· -·
i311/2 Coo'am ¡e'l1JH)Illl»o scnscr (EZLil<fJLH) {4-pm) X 2214 Pllg co'1!1ctcon

K 112 OveNo':agc pro!oroO'l rc.ay ManJal transmiss~nleng;~o (4-llln)
M1 ~allCf X26/12 Pe.~g eO'lTlQtoon, lll::Cnorl:rens.'TI>.s; on (6-pm)
N3 KE comol lJI'I,! X 27 ~g co'I!!Cdon, s:ta!w hames~ (5-pin)
N16 Engr1e sysooms COil:<ol un,¡ Y1 Etcc'l'oll¡idraJ e acrua1or

S2f1 lgnit on s~J sw.l!:h va s:anva'Vc
5161'1 stancr lod<-o..l and revcrs.ng tamp SWll!:h Y49 Ad,.Jstah'c eamshaít ll11lng aaua:or
W 16 GroJnd, cGS"rOoncrtcomparonCJt, g¡ound poirtw~n~~ Y!iBI1 Rcg cncra!io'l swt.l:!lovcr va've
dcsgna~on. componc'IÍ comecwd d'rect;y to cnymc, Z7 Coanoctor s'ccvc, tcmrnai 87E
runn;n~ geer ot oooy (se rricred cooncc:on n namoss)
X4 Tc¡minal olod(, oormna: 30, fusc ano re ayooxAntenor
(2-M) a í=rorn l!l"l'liM s:artor sW!'J:h,wrn na 15
X4f10 b Te EZJ../AJ<R igrrwn CO.'Iilol unt
{2-pín)
X4f1 0 - OJ1Tilnal b'D'c:.<, oo<mna 3C/30UI61aJ87L (5-o¡n) b To EZ!J~ I qn:-oncortrol urtit
X1 1 ~ Test coup ng fo· ltag'l o51s, puse re.acou:z AG A!J'Dma~c tr<>l!srn s >-en
(16-¡m) MG Marua1transmss,on
X 22'2' PllJ g C 0/lOOC 00
A!s'llma:c uansm sSJo'lfcngonc {8-¡¡•n)
Fig. 355: Wiring Diagram Of Start Valve Actuation- Engine 104
IDLE SPEED DEVICES - RA0703KE2G030X(G.)
The following idJe speed devices are installed :
lldle speed IEngine IFeatures

dev1ce
Mercedes-Benz
102.961 Stct
@[lj~BT
Idle speed Auxiliary air valve and additional bypass valves with air
102.962 Std.
stabilization conditioner and with automatic transmission
~ ~BT without
AC compressor
Electronic idle speed control integrated in KE controltmit
102 except
Idle speed adjuster depending on version designed as double-
102.961/962 Std. (see
winding rotary positioner (3-pin connection) or as single-
above)
winding rotary positioner (2-pin connection)
Electronic idle Electronic idle speed control integrated in KE control unit
103, 104
speed control Single-winding rotary positioner (2-pin connection)
Electronic idle speed control in separate control unit
116, 117
Idle speed adjuster designed as impact plate positioner
Electronic idle speed control integrated in KE control unit
119
Idle speed adjuster designed as impact plate positioner
The idle air quantity is tapped via the idle air duct downstream of the air flow sensor plate. As a result of this
layout, the idle a ir quantity is measured by the air flow sensor and the appropriate quantity of fuel metered by
the fuel distributor.
Depending on the idle speed device, the idle speed adjuster or the auxiliary air vaLve with bypass val ves are
positioned in the idle air duct The idle air quantity and thus the idling speeds are influenced by the cross-
section of their opening.
The idle speed devices perform the following tasks:
• Enriching the mixture in order to achieve stable idling when engine cold. This overcomes the increased
friction.
• Preventing uncontrolled changes in engine speed resulting from additional engine loads such as power
steering at fulllock, AC compressor switched on or Drive mode engaged with automatic transmission.
• Achieving minimal fuel consumption when engine idling.
• Warming up engine more rapidly by means of fast idling_
• The id1e speed control prevents excessive engine speed, e.g. when engine warm.
• Idle speed control elimínates the need for adjusting idle speed. Compensates for changes to the engine
which influence idle speed.
• On vehicles with catalytic converter, idle speed is increased after each engine start for about 30 seconds
(heating speed for heating up catalytic converter).
a) ldle speed stabilization (engine 102.961 Std _@ ~ ~BT and 102.962 Std _[lJ ~BT without AC
compressor)
Function diagram ofidle speed stabilization on engines with AC compressor and automatic transmission
Mercedes-Benz
POJ. OUI · S ~
M!Xtu!e coorol unrt 113 Selector lever poSibon (81.4omallc lansrnJsSion)

11 kto spMG aa screw 114 AJr roná:.ionet 18fTl)era':uro sido como!
12 IJteke marllold 117 NorHolum\l!lllte
80 AIJld al)l air VSYB 118 Re'Solnclloo
as Syposs va!vo(yelow), wromalíc transmiss¡on 119 Thanno vaM! (colc~K cod& Wll o)
86 Bypass vat(e(mta), ACcorrpresSOf u Va:cutJITl supjltf ror fu~er oonsumors
92 qect on valve Co!ours ol c-ables
93 Slart llai'Ye gn graen
!)9 Thermo t.ne S'Mith gr gey
111 Becnc S'l.llthe>vorvat.'e (BI1Qino sp.e od mcrease, rt red
alJtomaic transmssiOfl) \11 IIIO!at
112 Elecnc S'Mithoverva.Va {BI1Qino speed mcrease, AC \V S •M1to
compres SOl)
Fig. 356: Function Diagram O fldle Speed Stabilization On Engines Witb AC Compressor And
Automatic T ransmission
Auxiliary air valve
The auxiliary air valve (80) is positioned on the left ofthe engine, below the intake manifold to cylinder 4.
Mercedes-Benz
Fig. 357: Locating Auxiliarv Air Valve
The auxiliary air valve is controlled by a bimetal spring and supplies a metered quantity of idle air to the engine
in the warming-up phase by bypassing the throttle valve. The bimetal spring is heated electrically by the engine
heat. The heating coil is connected electrically in parallel to the fuel pump .
Auxiliary air valve (schematic)
1 A.- d<Jd
2 Brnetal spnng
3 Hea'.lngcoll
4 omcepla:D
-·llla.tJ
Fig. 358: Section View Of Auxiliary Air Valve
Actuation of fu el pump and auxiliary a ir val ve

Mercedes-Benz
l
~ ..
075oWil
G." •ol\1
•
b
7ljllilt - -1
"'-+-+---+--___J e~,n,....,.
l,~..
•"
•f
o:>i ••
we
N t .........
F1 Beencale erúe X 11 Oíegnostic sod<e~lerrn.-.alblock, terrnmal ID

M3 Fuol pump !l EJed·.calcems, c~ng u, coda« 5
N1/1 TSZ lgn¡loo oonrrolurtl (teaninal 15)
N511 Fuol pumprelay b Cable connoctOf, OOQiil& hiliTl<lss, tomnnal50
R21 Au~lia¡y ar v!lMllme!Jng cod I<E e orool urd, ccnta:tt 24
W3 Gfoond, a! lrcrn Ioft wheellou!óe (ignjoo ccd) d I<E comrol urtl, oontad 25
W6 Gfcund, leftwheellcuse 1111rurk e Becncalcome, terrnmal30
'vVS Gfound, allroll!lefth~ Ulli Glound, nozzle heater WJndslueld washer s¡stem
Fi2. 359: Auxiliary Air Valve - Wirin2 Dia~ram
An orifice plate (4) controls the opening cross section in the auxiliary air valve. The orifice plate (4) is operated
by a bi-metal spring (2). The opening cross-section ofthe orífice plate adopts a position dependent on the
temperature of the bimetal spring so that an appropriately large cross-section is open during cold start, which is
constantly reduced as engine temperature rises. A slight quantity of leak air is permissible when the engine is at
normal operating temperature.
1 A .. duct
2 Brnetal !ópnng
3 PIVot shalt
4 Orli ce pla:ll
Fig. 360: ldentifying ldle Speed Stabilization

--·
Mercedes-Benz
ldle speed stabilization witb automatic transmission and AC compressor
Engines with automatic transmission
Idle speed stabilization is performed by means ofthe electric switchover valve (Yl2) and the bypass valve (85).
When the selector lever is in positions Por N, voltage is supplied to the electric switchover valve. When a Drive
mode is engaged, the voltage at the electric switchover val ve drops . The bypass valve (85) is supplied with
vacuum from the intake manifold and opens.
A greater quantity of metered air is inducted by the engine, bypass in the throttle valve, and idling speed is
stabilized at approx. 50/min below idling speed.
Y12 Allomatic lrans;ms-s~on switchowr vaJve

Y14. A.Ccom:>re·s-sot S'Mirho
lden5fica5on on •Mnng hamess
a A.- cootliionor, red
b Atl!omaác tfar¡smission, yeilow
Fig. 361: ldentifying Electric Switchover Valves
Locatíon of electríc swítchover val ves
Location ofbypass val ves below intake manifold to cylinder 4

Mercedes-Benz
85 6'.9ass va.'{e {yelow), aúomabc 'ansmtsSioo

86 B)'Pass V!We l'l'tlt e), AC compn~ssor
F ig. 362: ldentifying Bvvass Valves
,.------: 5.1 - -
r\'12·- ·-,
~
F1
'-T--------=-=~3,..... e x11 b- -·!l

~.tlvd O'~b¡hi -K~'I."'91YM 0,1'5lw - -J
------~ ~~~· p
.-----0.?~/1¡• - r
~;t;~... ·· -
s
1
["'"
~
~- ~
1 ,.. ~
•L . __J
Sll0/1
F1 Bec ~cal ceme Y12 Engjna ·sJWedincraese swi chO'

MS En~·e ground b T·emunal block, eng;me, lenmnal
S 16/1 ~arter lod<-00! end revarStng lemp s•1111th Tenmnal blod< XS/1 , tamunal 1!
S3011 Ki ckdo•Nn swt cil p Revers111glamp, ccn!ad: 4
X 71 Pkig com<u:i on, eng1oo speltd st~za~ on swt cho·•or r S!op larrp swich
VaMl S Tomnnal50 {~gnitlon lod<;)
Y3 Auromaoc lmlls.mtss.Jcn ~ckdown Vl!Ne
Fig. 363: Actuation Of Automatic Transmission- Wiring Diagram

Mercedes-Benz
Actuation of automatic transmission
Engines with AC compressor
Idle speed stabilization is performed via the electric switchover valve (Y 14) and the bypass valve (86). When
the AC compressor is operating, voltage is also supplied to the electric switchover valve in parallel to the
electromagnetic clutch of the AC compressor. The bypass val ve (85) is supplied with vacuum from the intake
manifold and opens.
A greater quantity of metered air is inducted by the engine, bypass in the throttle valve, and idling speed
increases to approx. 30/min above idling speed.
Actuation of AC compressor
F1
m
t
l+o W1
i I
----=-f- 1
)'5
~
!
-
J
:;¡
N19
l!__ j
810/6
1 ~
1
L._.J
VS/1
.
!;JJ
S31
8 10/6 IN9 Groond, et frortklfiha&d!a!T1> 1111

F1 Boc fnc al CtliÚ8 YS/1 AC comprossor a!edromagnal!c ckJ!ch
531 AC comprossor swtch Y14 Eng~~e speod s!abtt2l!'.lon SWJtchover vaM!
N1S Temp«atml sllde ccrirol m Slo'..ver S'Mich, corlBCI 3
W1 Mm aOUid oont 111sttunert ck.ismrl
Fig. 364: Actuation Of AC Compressor- Wiring Diagram
b) E•ectronic idle speed control
- Engine 102.96/98 (KE 2) witb double-winding rotary positioner
Function diagram of electronic idle speed control with double-winding rotary positioner

Mercedes-Benz
-
N3 KE cOff¡¡oltn t 88 Aó]u sbng saew
Y6 kle spe&d a~er (<lcubla~.-.onding rota~Y poSilonet) 92 tledoo ve.'ve
Y8 Saii 'Yll!Ve 93 tls-uabng slee\11!
W1 0 Baltety grouml \f Qv¡¡¡v~go pro!Gdlon relay, <ooeatl2,
W11 EnQIOa gcound (ele<l·JC cable boloo on) lllmliHi87
1 MD<.turo toolrol ur~t z liJa speed adJ,Js4ei t est e00il9don
12 lrtake manilold
F ig. 365: Electronic l dle Speed Control - Function Diagram
The idle speed control is integrated in the KE control unit but the operation is decoupled from the KE injection
system.
The id le speed adjuster (46) is designed as a double-winding rotary positioner and is recognizable by the 3-pin
connection.
Wiring diagram of electronic idle speed control
Example engine 102.962 Std. with AC compressor and automatic transmission

Mercedes-Benz
JI
l
WIO
8 1113 Coolalt camperal!ED sansor X18 Pllgcomecaon, IBillanlJ hamess

K1 OvlliV~go prot~on rolay X35 Terminal block, ~nai30J'.ermnal 61 (batte¡y)
N3 KE e ortroltnt X48 Comector s!eevefsoldereo c:onnoctorm hamess)
N& AC compressoc w~ol como! uni Y& lela spa8d aO,uster
N16J2 ¡::uel ounp rolay 8 BE~. che si e eme {!ennnal 1 S:)
S27f2 Dec:e!er!Don CU'-ol mcros.~~tch b lgn.bon cotúoltnt (tarmnal ID)
W10 Bettecyground e Ele.l::ncalceme {tem111al S:O)
W1 1 Engil& grOIJld (eleox cable lxlled on) d Starter Jo.ck-otJt and reverslng Jamp st~~~lch
X11 Olagnosilc so"Cko!lteanllalblock, temunal ID
Fig. 366: Electronic Idle Speed Control - Wiring Diagram
The idle speed control processes the following information:
• Engine speed from terminal TD, necessary for set/actual speed comparison.
• Coolant temperature in order to control idle speed as a function of temperature.
Example engine 102.982 Std.:
approx. 1200/min at -30 oc

approx. 750/min at +70 oc
• Idle speed signal from the deceleration cutoff microswitch (827/2) for id le speed recognition.
• Selector lever position in the case of automatic transmission. When engine nmning, engagement of Drive
mode is recognized via terminal 50 and idle speed is lowered by approx. 100/min.
• AC compressor cut-in signal. The opening cross-section of the idle speed adjuster is enlarged shortly
before the AC compressor is operated. Consequently, idle speed remains approximately constant.
Mercedes-Benz
Double-winding rotary positioner
The idle speed adjuster is located behind the mixture control unit on engines 102.96/982.
Fig. 367: ldentifying Idle Speed Adjuster Behind Mixture Control Unit
On engine 102.983 the idle speed adjuster is located below the intake manifold. As the idle speed adjuster is not
easily accessible, a test connection (Xll/9) is provided in the right of the component compartment for
perfonning tests.
Fig. 368: ldentifying ldle Speed Adjuster On Intake Manifold
Engine 102.983
Mercedes-Benz
Fig. 369: ldentifying ldle Speed Adjuster
Double-winding rotary positioner
85 Shaft
85 Sole1101d
85 Adlus•ng screw
89 RotatyV!W&
00 Pa11Tll!116llt m agnet
a Alr 111et
b Air OIJ!et
Fig. 370: Section View OfDouble-Winding Rotary Positioner
TI1e idle speed adjuster has a rotary solenoid drive, consisting of two coils, the rotary armature, a torsion spring
and a rotary valve. The position of the rotary valve attached to the armature shaft is determined by the two coils
and the torsion spring.
The coils in the idle speed adjuster are actuated with a pulsed voltage signal. This produces at the armature a
torque which counters the force of the torsion spring and opens a certain cross-section. The opening cross-
section is altered by changing the dwell angle of the pul sed voltage.
The idle speed control compares the momentary actual e ngine speed with the stored set engine speed. lf
differences exist, the opening cross section in the idle speed adjuster is altered until set and actual speed agree.
If the voltage supply of the idle speed adjuster is interrupted, the rotary valve is moved by the force of the
torsion spring into a defmed position and opens an emergency cross-section (fast idling). A slight correction can
Mercedes-Benz
be performed with the adjusting screw (88) in the case of differences in idle speed (bypass air).
- Engines 102 (KE 3), 103, 104 with single-winding rotary positioner
Function diagram of electronic idle speed control with s:ingle-winding rotary positioner
Example engine 103
·-----------+------ ~~~
~
x.;¡ 1 wut--o·"'"'
!i S27t2
'~
y
va
--
82 An llow sensCf pooSJion m:lica!Cf Y6 lcle speod ad1,1star (slflg!a.<Mnding rcta;y posibOfler)
8 1112 Cooialt lllmpermure sensor YB Stalt v.lti&
N3 KEcomolmt MIXI!Ee conlroluFlll
S27fl Oace!et e'ion cu~of maoSOMtch 12 nllke mlll'llold
529.'2 TlYo:!lo ViJNo S'Mich, de speedífl.ftloedrecognbOfl 92 ln¡ecQon valva
S29!2X1 Pllgcormc8on, Olrotfe vllMl swi&r V Overvcl'.Bge prcledíon rolay, contad 2,
W10 Battaty ground termJnal87
W11 EngJ~aground (amen table~&d on)
y EZl. tg11ion tOfliolufllt
X48 ComodCf smeve f soldared connedor m hamess)
Fig. 371: Function Diagram OfElectronic Idle Speed Control With Single-Winding Rotarv Positioner
The idle speed control is integrated in the KE control unit, althougb operation is decoupled from the KE
injection system.
The idle speed adjuster is designed as a single-winding rotary positioner recognizable from the 2-pin
connection.
Mercedes-Benz
• Engine speed from terminal TD, necessary for set/actual engine speed comparison.
• Coolant temperature in order to control idle speed as a function of temperature.
Example engine 103 KAT/RUF:
approx. 900/min at -30 oc
approx. 650/min from +70 oc
• ldle speed recognition.
Idle speed signal from the deceleration cutoff rnicroswitch (S27/2) or, with ASR, from the electronic
accelerator pedal control unit.
• Road speed sibrnal.
Indefinite production breakpoint as of approx. 09/ 88 in the case of engine 102, as of approx. 09/87 for
engine 103 oras of start of production for engine 104, a road speed signal is supplied to the KE control
unit (see section "Ftmctions in KE control unit"). As a result ofthis signal, the idle speed control is
deactivated from a speed of approx. 1.4 km/h. This improves handling in the deceleration mode. The idle
speed control is re-activated below 1.4 km/h.
• Signal from air flow sensor position indicator in the case of engines 102, 103.
Necessary for recognizing the momentary air throughput. Idle speed is deterrnined as a function of engine
speed, idle speed recognition and coolant temperature.
• Selector lever position in the case of automatic transmission.
When the engine is running, engagement of a Drive mode is recognized via terminal 50 and idle speed
reduced by approx. 100/min.
• AC compressor cut-in signal.
The opening cross-section of the idle speed adjuster is enlarged shortly before the AC compressor cuts in.
Consequently, idle speed remains approximately constant.
Vehicles with ASR
The signal for deceleration cut-off/idle speed recognition is formed by the position sensor (R25) and input to the
KE control unit vía the electronic accelerator pedal control unit. The separation point between the control units
ís the plug connection (X89/4).
On vehicles with ASR, the deceleration cut-off microswitch (S27/2) is not fitted. The cable is tied back in the
Mercedes-Benz
Fig. 372: ldentifying Plug Connection
Example engine 102.962 KAT/RUF with AC compressor and automatic transmission

Mercedes-Benz
S29/2
r·-·.,
irn i
~f{J
li , JI
"'1 o.q. ~
o o
Wf1 J--G¡511r
. - - - - -GIS l>tfil> - - - - '
a b
X18 t •
>t-o.Ylí..,.. tl
...2:!-o-Ylí .. - e o~ 11!
o
wt()l
d-O.liS tublt
.__---OJ'!I 'lll/QI ~~.l'S rd'#lt
W'HT X46
JJ
N112
8 1112 Coolart fllmPilfll(u'o SBnSO( X 11 Dlegnosbc sock8vlemmalblock,teamnai1D

K1 Olervo!mge protectJon relay X 18 ~gcomaclon, IBIII8fTllhBmoSS
N1f2 EZl lgnlon coni"olunt X4S Comed« slaeve (soldereó connector 10 ham ess)
N3 KE col1rohlilll va ltls speod &djustor
S27f2 Doce!oraion cu~ill mcrosv.etch a Fuel pumprelay, cortad 10, t!IITTI11allD
S29f2 Throlle vatve SAttch,ICie speacUJdlloeórooognbon b AC compressouelll'f, cortad 2,toanr.BIID
S2912x1 Plugcomeclon, tu~e val\'9 swtch Fuel pu11prola'¡, cortad 6, leanr.al87 k
W10 Batte¡y QJOUflÓ d AC compres sor cu~ill c"O"rool ooi, cortad 4, 'lllminal
W11 EIIQ!Ile grOUld (etec~IC cable boled on) 8 7Z
Fig. 373: Wiring Diagram OfEiectronic Idle Speed Control- Engine 102.962 KATIRUF
Example engine 103.984 K.AT with AC compressor

Mercedes-Benz
N3
r-·-
. - ·-·-·-·-··- ·---·----·-·-·-·---
-(> ----·
z:r
W1t
T
11
$
a Z6
S2/t
82 Alr Hcw sensot p<>Siioo i ncicalot X22J4 F'tlgccmecioo, manuallransmt sgon'angme

8 11/2 Coolart lemperalUro sensor ( as 0:09169, 4pm) {4-p!ll)
K1f2 Ov&IV~·Qo protedloo relay X26112 F'tl g ecmedon, JlOOnorAmn srn.sston (6-pln)
M1 Startel X 27 F'tlg ecmecioo, startlll hamess (5-~)
N1f2 EZL 1grdon oonlrol unit W3 Gfound, a! tonl llh't whoellouse (ig!llioo cetl)
N3 KE eCfl!rch nt W11 Ellg~~eground {elocnc cebloboted on)
N15 EllQJlO s)'Sterns control url! W16 Compooanl romprutmont ground
S2/1 lgnboo slarter s'AIIth Y6 ld!ea s;¡eed ~or
S 1611 Startllllock~ and rovorstng lamp s'lltlth Z6 Comedor Sloovo, ground W11
S27/2 Oet-elma co wt-ol mcros·Mtdl Z6f3 Comectotsteove, KE sensorgrOUld
X4 Temunalblcd<, !llrmnal30, 1use andr e!ayboxAN!onCf Z7 Comector Slenve, termJlai87E
(2-~)
AG Autcm8!1C tremmrssion
X4110 Termtnalblod<, lllm'lnal3013our61el87l {5-ptl'l) MG Mall'J!II trensmsston
X11.t4 Te>t couping fot <iag¡¡o;~s, pulse reaoou
GES Road ~1ld sagnal trom múlltuncboo blod<
(1S.pll)
a To EZl. ~áclu:oruol uni
X22f2 PkJgccmeclioo, aulomabc ~ansmtsSioolellQino (S-~) b To ¡gmboo staltllf s'llltch, termna~ 15
e To JlsUI.mon! dls!Brllachooleler)
Fig. 374: Wiring Diagram OfElectronic ldle Speed Control- Engine 103.984 KAT With AC Compressor

Mercedes-Benz
Example engine 104.981 with AC compressor
r-·-·-·-·-·-·-~-·-~·-·-·-·-·--·-·-·-·
Z1
82 Anllow sensOf po51ton lntiCfi!Of X2tll12 F'tlg comedon, lllllnorAmll;mJSSion (S-p11)

8 11/2 Coaant :&mperature sensor X27 F'tlgcOflleclon, start~ hamess (S.p11)
K1/2 OveiVol!l!ge prclecbon relay W3 Groontl, at &-ort loltwheotoose 6911bon cot)
M1 starter W1 1 Eng11eg:OUld (elecnc e able bol&d on)
N11J EZL •gn•on cooraunt W16 C~mponort rom~artrnent grOIJnd
N3 I<E eorúol Ullt Y6 kle spe&d ~ster
N16 Eng111e systnms conrolunt V ComectOf sleeve, temmal B7E
S2/1 lgrlbon slarlBr s~lth AG 4 Autllm1lllc 4-s¡xted a-ansm1s51on
S1611 Started otk-ott and rev~ng lamp S\\IU:h MG M8fll.lal lransrriSSIOll
S27/2 Oecelera'ion ru~O: maos~o~tdl GES Roed speed Slgnal trom mUtlilnctlon blcd<
X4 Termmal blctk, fnrmnal30, fusa andrelaybolCAn!enOf a To ~ibon &~o~tch, 19fmnal15
!2-Pill h To EZliQI\ilon cctúo1111i
X4f10 Torm1nal blctk, lllrmnai30130U'61e/87l (S.pln) e Gloontl, Ylacomector sloow, camshafistleking
X 1114 Test cCJ~ tor <iagnoSis, pulse roaoou d To ~nslrumert cl.lsmr (IBChomeiBr)
(16-prl)
X2212 F'tlgcomecion, aulomatlc ransm¡ s;gor/~ne (8-Pil)
X2214 Pklg e onnecioo, ma.nualtansmiSSJon'eoQine
{4-Pil)
Fiº. 375: Wirinº Diagram OfF:Iectronic TcUe Sneed C.ontrol- F,ngine 104.981 W ith AC: C:omnressor
Mercedes-Benz
Examples of idle speed control, engine 103.984 and 104.981
1100
1000
900 ~
,-------------------,,
',,
''
800
~ '-----,,, · - ·-··········---~.. Sefactorlever posa5oo
'•. PfN
700 --< ', ' - - - - - - ! > . ..-
' ' ', ..................... ..
__
'
600 '' -----------t>
- 30 o 30 B0 C-colard lmnpernue
Fig. 376: ldle Speed Control Graph
WARMING-UP PHASE, ENGINE 104.981

Coolaut temperature 1/min
-30 oc up to +30 oc (+20 °C) 1100 ± 30
>+30 oc up to +80 oc
Droppi ng continuously to 700 ± 50
(>+20°C up to +80°C)
F igures in parentheses for engine 103.984
ENGINE AT NORMAL OPERATING TEMPERATURE

Selector lever position 1/min
Drive mode 600 ± 50
P/N 700 ± 50
Single-winding rotary positioner
Location of idle speed adjuster, example engine 104

Mercedes-Benz
Y6 28 Shap&dhose
27 Arrow PkJgcomoct oo
Fig. 377: Identifying Idle Speed Adjuster- Engine 104
On engines 103, 104 the idle speed adjuster (Y6) is positioned in front ofthe mixture control unit, on engines
102.91/96/98 behind the mixture control unit at the intake manifold.
On engínes 102.983/99 the idle speed adjuster ís located below the íntake manifold.
In view of the difficult access for testing the id le speed adjuster, the idle speed adjuster plug connection
extension (X80) is positioned at the rear intake manifold.
Mercedes-Benz
~--Y1
~:kl~~~~~-82
e
827/2
Fig. 378: Identifying IdJe Speed Adjuster
Idle speed adjuster (single-winding rotary positioner)
1 EI!Kmcal comedlon
2 Housing
3 To;Sion spnng
4 Col!
5 Rolafy annabse
6 Air duct as 0')1lB:Ss to llrotlo vaM:I
7 Stop
8 Rolary 111l~.rn
8 7
Fig. 379: Section View Ofldle Speed Adjuster (Single-Winding Rotary Positioner)
The idle speed adjuster has a rotary solenoid drive, cons isting of a coil anda rotary armature. The position of
the rotary valve attached to the armature shaft is determined by the coil and the torsion spring.
Mercedes-Benz
The coil in the id le speed adjuster is actuated with a pulsed voltage signal. This produces at the armature a
torque which acts against the force ofthe spring and opens a certain cross section. The opening cross-section is
altered by changing the dwell angle of the pulsed voltage.
NOTE: The pulsed voltage signal to the idle speed adjuster is measured in mA (instead
of% or 0 Angle) on engines 102.91, 102.96/98 as of 09/89 and on engine 104.
The idle speed control compares the momentary actual engine speed with the stored set engine speed. If
differences exist, the opening cross section in the idle speed adjuster is altered until set and actual speed agree.
Ifthe voltage supply ofthe idle speed adjuster is intermpted, the rotary valve is pushed by the force ofthe
torsion spring against a stop and opens an emergency nrnning cross-section (fast idling).
- Engines 116, 117, 119 with impact plate positioner
ldle air routing
Engines 116, 117, 119
Y6 kle speed &d¡usiBr

12 k!e ar dsrdluoor
92 tljedlon v<We
Fig. 380: Identifying Idle Air Routing
The idle speed adjuster is designed asan impact plate positioner.
On engines 116, 117 the idle speed control is housed in a separate control unit (N8). On engine 119 it is
integrated in the KE control unit, although operation is decoupled from the KE injection system.
• Idle speed recognition
via the closerl idle sneed contact in the throttle val ve switch
Mercedes-Benz
• Road speed signal
idle speed control performed when vehicle stationary (road speed signal=O).
• Engine speed from terminal TD/TN
necessary for set/actual speed comparison.
• Selector lever position
when engine running, engagement of Drive mode is recognized vía terminal 50 and idling speed of
engine at operating temperature is lowered by approx. 100 - 150/ min. In addition, idle speed in the
warrning up phase ís dependent on the selector lever position.
On engines 116, 117 with increased output, start recognition is performed via terminal 50 in order to
actívate brief fast ídling after engine starts.
• Coolant temperature; idle speed is controlled in stages until normal operating temperature is reached_
COOLANT TEMPERATURE SPECIFICATION

Coolant temperature Idle speed P or N Drive mode
below O oc 800/min 780/min
O oc to 30 oc 700/min 1700/min
30 oc to 40 oc 650/min 600/min
above 40 oc 650/min 500/min
• AC compressor cut-in signa!
When the AC compressor cuts in, the idle speed control is supplied with a voltage signa! from the AC
compressor cut-off control unit (N6) or engine systems control unit (N16) (terminal 87Z). The AC
compressor cuts in with a time delay (350 ms), bowever. Tbe idle speed control processes the voltage
signal and actuates the idle speed adjuster (current reduction approx. 60 mA). Consequently, tbe opening
cross-section at the idle speed adjuster becomes greater before the AC compressor cuts in so that idling
speed remains approximately constant
Engines 116, 117
The idle speed control is housed in a separate control un.it (N8). On the output-increased engines 116.965,
117.965/968 as of09/87, fast idling ofapprox. 1000/min is specified for a maximum of 40 seconds when the
engine is started at a coolant temperature between O oc and 50 oc_ This is followed by idle speed controL
Location of idle speed control unit (N8)
Model 107: behind glove box.

Mercedes-Benz
Fig. 381: ldentifying Idle Speed Control Unit- Model107
Modell26: in right footwell below floor paneL
Fig. 382: Identifying Idle Speed Control Unit- Model126
Function diagram of idle speed control, engines 116, 117

Mercedes-Benz
r-·--·- -·- -·
N3 Q-
c.
N8
r-·-r;~=t=-J
i 1:~
· ~~=-+-=~-f(:v~~
!© ~-d~-----J
. ----+-
¡; ....
1 ~: -~---~-·
L.- .etjK--__J
N3 KE coruol urit a f't!Jgcomac ion, Oll!Jine hamoss, c.crtact 6

N8 ldle speed cordrol unit b Fuel pump r elay, cortad 2, temmaJTF
52912 TnroMe wtve SMtch, ICie speed/M lo8drecognbon e AC compcessot ctt.off con:rolun~ cooact 4
S2912x1 PkiQCOMEIC IOO, ~rotle va'\oti swidl d Overvol!age prolodJon reiB'/, cornoo 2
Y6 ldle spea'!l a~s!er e AC compres sor ru~ol roroot uni, eooact 2
z Comedor s!oova (soldorEKl conooctor m hamess) f't!Jgconoocl!on, tlfl9108 hamess, c.crtact 10
g EZL 1gn¡i on c'Ofl:rolunit¡N112)
Fig. 383: Function Diagram O fl dle Speed Control- E ngines 116, 117
Contact assignment of idle speed control unit (N8)
N8
Elecuooc speaóometer (A1pS) ,
roed speo-d S19'1al
r ·-.;:
1 L
(> .1~
2 K E corüolooi ¡N3), conlact 9, tompareruro Slgnal (TF)
3 AC COilllfeSsor m-c.'f c.-ontolul'lit(N6), cort&ct 4
4 Thrctile vaMI SNi dl, lu11oaóA<Ie spesd r&ognition, eonlact 1
(iclle speed rec~ion) 1 E
5 \Mum c<Jmaded to grot11d, i cfiospeed intraasas by so.tnm
•M1en Oliva m ocle engageo 'Mtl e arta¡¡ comol U!lls {sea RS 1 l.t
~
Eng~oo 1161117)
.
6
7
ltte spoeo ~ter (Y6)
ldle speed ad¡us!Dr (Y6)
L_.
8 Not BSSigllOd
9 OVervolagepro~eclon relay (1<1, K1f1 )cortact 2, vollago ,CD-00.&-tl
s~¡tenmnal15
10 EZI.. ignuon c011roi tal (N1f2, N1f3) lDtTN s¡gnal
11 Modol 10 7 Eng¡ne gOUTld (W1 1)
Mod:el 126. Balto¡y gOU!Id (W1 0)
12 Smccer loet<.out and revers11g la.mp s·,.tch (S 16f1 ) , gear

18t<l>ll1bon
F ig. 384: l dentifving ldle Speed Control Unit (N8)

Mercedes-Benz
Example engines 116, 11 7 with AC compressor
A1p7 Elecr011c do¡;1(AactJ0111Qter S29f2>c RJ.gcometloo, tlrotfe veMI svdctl

K1N OVeNolage prote.dlcn relay 1/'19 Gmund, front Ioft
M1 Starter W10 Batt&IY grotnd
N 1/3 EZUAXR 1gnilon coruol111J W11 En~e grOtlld {elecnc cablebol&d en)
N3 KE eoroot oot X11 Dlagnosbc ~~em\Tial block, temunal TD
N6 AC CCffi;l{6SSOf cu~ol corüc1111t X26 PkJ.gcomedon, 10!enor!engr¡e (12i!in)
N8 lde speed recogniloo oclirol111í X27 PkJgcomecton, staller hamoss
N16ó4 Fual punp rel!l'; X49/2 Pl.igcomedon, starter lock-oú andriM!lSIO!J lamp
S2n lgnbon Sll!r!ac S'loll!:h swttch
5 1611 Staller lod(-0\t l!ild f8VSCSIOQ lamp sv.elth Y6 lc!Oo speed a~ster
S2912 Ttr~e wtvo SMich, !de SJHl&cllful loadrorognbon b Be-d·ooc speedome!Br
Fig. 385: Wiring Diagram OfEiectronic ld1e Speed Control- Engines 116,117 Witb AC Compressor
Engine 119
On engine 1.19 the idle speed control is integrated in the KE control unit.
Example of idle speed control, engine 119.960

Mercedes-Benz
11 00
900
700 -
>
1 1
-
Start 25 Time [ s _1
Fig. 386: l dle Speed Control Graph
Diagram applies to coolant temperature of20 oc (símulated) and selector lever in position P/N.
In the warming-up phase (up to coolant temperature of 65 oc when starting) the idle speed after start is a
constant 1000 ± 100/min for a maximum of25 seconds ata coolant temperature of20 °C. Following this, idling
speed is limited dependent on coolant temperature (700 ± 50/min at coo1ant temperature of 20 °C). In normal
operation, idling speed is limited in stages as coolant temperature rises to 65o+IOO _50 /min (with selector lever
in position P/N.
The idling speed after start of 1000 ± 100/min is lowered immediately when a Drive mode is engaged or the id le
speed contact opens. This function remains inhibited if a subsequent engine start is performed within the next
20 minutes after switching off the engine. Exception: Battery has been disconnected or KE control unit
unplugged in the meantime.
Example engine 119 with AC compressor

Mercedes-Benz
.r--·-·-·-·-·-·-·-W·-·-·-·-·--·-·-·-·
()
...
.J
GES
12
t 4 ICI \& 11 ,. j
Lr*! .1!1
5~
.1!1
~
•
b e
FFX4
.11{
e •
J(1
' l
ve 81112 8211
8 1112 Coo!art lempera..tur e sensor X 11í4 Test coq¡iog roroegnc>Sts, puise ra."Bdout
K112 OvetVoltage protectJon relay (1 ~Pill
M1 Staner X2212 Fti.gcomocion, actomatJc .-ll/lSI111SStonlengme (8-Pifl)
N16 EZl lgrlioo coniol u1111 X261.2 Pki-gcomecton, angina separallon poli! (30-~)
N3 KE conrol Ulll X27 Pkigcomedon, startor hamess (~Pill
N15 Eilg11e sys!Oms con'rolurd YS ki& speed ad¡us1er
5211 lgnbon slaf!aJ s'l'.lll:h Z7 COJlllector s!oeve,t811Tlflai87E
S1611 stador lock-ot! and reve151ng lam¡> s...,.lth Roed speed sa!J)al from mútlimcbon block
GES
52912 Thro:lle "'!Wc S'Mtdl, de speedlfUI IoadrOGOgl1tion B To ignlbon startor s'l'.ltdl, lllm'lnal15
52912x1 Pkigcomocion, tlro~ vafve swtch b To EZL/Al<R l!lfllbon cO!irol ~ni
W3 Groond, at frort te.'twheelloose Qgríion c01l) e Groond, VIB comedor sloew, camshaft shelding
W11 Eilg:11e ground (o!ernc cabloboled on) To .,st!unert ciJslDr flathomelor)
d
W16 Componert compartment groond
X4 Temunal block, 00m1nal30, fuseandrelayboxArlilltlOr
(2-Pifl)
X4110 Termmal blod<, blrnlnai30J30UI61e.4!7l (~PlJl)
Fig. 387: Wiring Diagram OfElectronic Idle Speed Control- Engine 119 With AC Compressor
Location of idJe speed adjuster, example engine 119

Mercedes-Benz
Y6 kl& speoo ad)Jsler

za Shapwhose
29 &adlel
Fi~. 388: Identifyin~ IdJe Speed Ad juster Components
Engine 117.968
The bypass between the shaped hoses (arrow) is open on engine 117.968 (approx. 4 mm).
Mercedes-Benz
Fig. 389: ldentifying Idle Speed Ad juster
Idle speed adjuster
84 89 88 86 87 85
64 SpfVlg
b
as DI~
-
SS Annann shaft 89 knpadplete
a6 Sc!onO!d e Almtet
B7 Armatu-e b AlfOOlet
Fie. 390: Section View Of Idle Speed Adjuster
The impact plate (89) is opened to d1e maximum by the spring (84) in the absence ofpower supply to the
solenoid and with the ignition switched on. When the engine is nmning, a current of 700 - 1000 mA flows
through the solenoid (86). This produces a magnetic field and the armature (87) is pulled into the solenoid (86)
to such an extent until the air throughput at the impact plate produces the correct idle speed.
If the load on the engine is increased as the result of an additional consumer ( e.g. power steering at fulllock),
idle speed drops. This is recognized by the idle speed control vía the TD/ TN engine speed signal. The current
through the solenoid is reduced and the magnetic field thus weakened. The impact plate opens sufficiently tmtil
the air throughput again produces the specified idling speed.
TI1e current consumption may drop below 700 mA at altitudes above 2000 m as the idle speed adjuster has to
provide a significantly greater opening cross-section at such altitudes.
- Engines with automatic transmission
The idle speed control recognizes the engagement of a Drive mode (gear recognition) when the engine is
nmning via terminal 50. When the engine is at normal operating temperature, idling speed is reduced by approx.
100 - 150/min in order to reduce the creeping tendency with a Drive position engaged. On a number of engines
idle speed in the warming-up phase is dependent on selector lever position.
Mercedes-Benz
Engine Gear recognition by

102, l03 KE control unit (N3), 25-pin, contact 16
104, 119 KE control unit (N3), 55-pin, contact 28
11 6, 117 Idle speed control unit (N8), contact 12
With selector lever in position P and N, the contact in the starter lock-out and reversing lamp switch (S16/l) is
closed_ The idle speed control recognizes ground via the starter (switch coi!). When a Drive mode is engaged,
the contact in the starter 1ock-out and reversing lamp sw itch opens_The idle speed control recognizes the
change in signal and actuates the idle speed adjuster accordingly.
NOTE: With manual transmission, the connection to gear recognition at the KE control
unit is constantly connected to ground.
Wiring diagram gear recognition
Example engine 103.984/104.980

Mercedes-Benz
r:-..- · - · - · ,
.M103 •
r::---·--·-r
4
-,
i. M10 N3 i.
i; ~~~
() i1 !1 ~-
-(>· !1
i .,... i 1 • . 1
1 i i •
H i
1
L·-·-·-·J L---·-·~
X4110
.1
i
¡_ _________J1
M1 PONS8Uo31'
M1 Satter X4 Terrnmal b!Gd<, 1Drmnal30, tusa aodrel!l'fbodrt·a nor

Nl I<E coorohnt (2-prl)
Eng¡na 103 25-pln X4!1 0 Terrnmal block, l!lrmnai30130LV61eiB7l {S..Jle'l)
Eng¡no104 55-ptn xnn PlJ gconooc•on. attomabc fransmJsSion'angme (8-p111)
N16 Eng:ne sysiBms Goni"ol unt X25112 Pllgconooclon, Jn~nodranStrussion {&pln)
5211 l¡¡nbon slarter s"Mich X27 Pllgcomecton, starter hamess (S..p111)
S 1611 Sarter lock-oú and revergng lamp s•.-.utn
Fig. 391: Wiring Diagram Gear Recognition - Engine 103.984/104.980
- Engines with AC compressor
When the AC compressor cuts in, the idle speed control is supplied with a voltage signal. The idle speed control
processes the voltage signal and actuates the idle speed adjuster. Consequently, the opening cross-section at the
ídle speed adjuster becornes larger before the compressor cuts in (time lag approx. 350 ms) so that ídle speed
remains approximatel y constant.
Engine AC compressor cut-in signa!

102 from AC compressor cut-offrelay (N6), contact 4 (terminal87Z) to the KE control unit (N3),
103 25-pin, contact 19
from the engine systems control unit (Nl6), contact 9 (terminal 87Z) to the KE control unit (N3),
103.984
25-pin, contact 19
Mercedes-Benz
104 from the engine systems control unit (N16), contact 9 (terminal87Z) to the KE control unit (N3),
119 55-pin, contact 45
116 from the AC compressor cut-off relay (N6), contact 4 (terminal 87Z) to the id le speed control
117 unit (N8), contact 3
Wirrng diagram of AC compressor cut-in signa! example engine 102.985 KAT/RUF
A.9 AC compt:essor
A9k1 ElectromagMbC clid1
A911 E/l¡Jno speed sensor
ASx1 ~ oonnoctJon, AC
compres-sor
F1 Electncal c&nh
N3 I<E c-on~ol u111t
NS AC romp~essor
a.t-off r elay
N19 /IJr ooncibonor
lsm¡¡erature sida con7ol
S31/1 A.C comp~essor S'Mtd1
....,.;, 2 swid1111g pouts
'
]1
~
o
~
~ ~
o Q
i
..y,
~!
N3
pt ~
L.-J
83'111 F1 P07--580~~
Fig. 392: Wiring Diagram Of AC Compressor Cut-In Signal- Engine 102
Wiring diagram of AC compressor cut-in signa) example engine 117.968
NS AC ccmprossCI
a.t-off reta-1
N6 kfe speod cofirol mi
N22 At1cma'ic cima~ cootol
push-btiton ccrtrol unil
S31 AC comprassor S'Mich
X26 PkJg ronnedlon, BOgYIO
hamess
Y5!1 AC comprossor
eleclromaQiltlllc ektcll
Fiº. 393: Wiring Diagram Of Af: C.omnressor f:nt-Tn Signal- Rngine 117
Mercedes-Benz
Wiring diagram of AC compressor cut-in signa! example engines 103.984/104.980/119.960
r¡¡,-·-·-t,
03
A9 AC c-ompres ser 1 1
' NS .
Ir·~]. .~
Ml1<1 ElodromsQilebc dJdl
A911 Engloo speed S91150f
A9x1 flllg coooodlon, AC .1 ~
c-ompressQf
N3 KEcootolunt
Eng¡oo 1~ 25-Pifl ! •?
! ....." !
Eng¡oos 104, 119:
55-{lln
! !
N16 Eng!oo ~ems
L·-·-·-·J
coriroluni
N19/1 Al.toma~c l8fll)Of!i'.IJre
ccrtrol push-butoo
c«trcl uni
N21 A.utQfna)c dma'B coowol
pusll-btitcn cof'ltrol unll
S31 AC CQfnjlfEtSSQf si\Ítdl
X85 PlJg conoodlon,
8ÚOfllllliC healer and
atJ!omabc !emp¡wature
cof'ltrol
Fig. 394: Wiring Diagram Of AC Compressor Cut-In Signal - Engines 103
e) Engines 102.91/96/98: beating speed
On engines 102.96/98 as of09/89 and on engine 102.910 KAT the idle speed control is supplemented by the
heating speed for heating up the catalytic converter. It is activated for a maximum of 28 seconds after each
engine start. The level ofthe heating speed is additionally dependent on the coolant temperature (see table).
Conditions for activating heating speed are:
• Idle speed contact closed.

• Selector lever in position "P" or "N".
Heating speed is deactivated if the idle speed contact opens befare 28 seconds have elapsed after engine start or
if a Drive mode is engaged.
Coolant temperature oc Heating speed 1/min Warming-up speed 1/min Idle speed 1/min
+20 1200 ± so<l) 800 ±50 -
+80 1000 ±50 (l) - 770 ± 50
(I) Maximum 28 seconds
Mercedes-Benz
d) Engines 104, 119: monitor ing actuation to idle speed adjuster
Actuation to the idle speed adjuster is switched off íf an open circuit in the wiríng, a short circuit or a
mechanical fault ofthe idle speed adjuster oran interruption in the KE <--> EZL/AKR data line is recognized.
The idle speed adjuster opens as the result of spring force and opens the emergency running cross-section (fast
ídling). In order to prevent the idling speed rising, the ignítion tíming is retarded in such a way that idle speed
íncreases only to an ínsígníficant extent.
e) Engine 119: battery voltage-dependent idle speed increase
Engine speed is raised by approx. 100/min depending on the battery voltage when the Drive mode is engaged in
order to boost the charging capacíty of the altemator.
Function
The idle speed increase ís actívated provided the following conditions exist:
• Coolant temperature between 60 oc and 11 O oc

• Selector lever in Drive position
• Battery voltage < 12.5 volts for at least 20 seconds.
• Engine speed once above 900/min.
The id le speed increase ís switched off once:
• Selector lever ís moved to position "N" or "P".

• Coolant temperature exceeds 11 O°C.
• Ignítíon is switched off.
Once the actívation conditíons have been met, they remain stored in the KE control unit until the ignition is
swítched off even ífthe battery voltage has meanwhíle rísen to more than 12.5 volts.
INSTALLATION SURVEY- RA07041040001X(07.4-0001)
Engine Model Installed 1

from to
104.990 140.032 01/91 - 07/93
140.033
REMOVING AND INSTALLING DIAPHRAGM PRESSURE REGULATOR - RA07041041450X(07.4-

1450)
Operation No. of operatíon texts and operation values or standard texts and flat rates
07-1450
Mercedes-Benz
•e-Q
47 <@
1
Fig. 395: ldentifying Diapbragm Pressure Regulator Remove/lnstall Components
release through service valve (see Diagnosis Manual Engine, Volume 2, Index 3,
Fue! pressure
Testing fuel pressures and intemalleaktightness).
Vacuumhose detach, fit on.
Circlip (44) remove, install.
Diaphragm pressure
remove, insert
regulator (40)
0-rings (46, 47) replace; oil slightly to facilitate installation.
REMOVING AND INSTALLING FUEL DISTRIBUTOR WITH INJECTION V AL VES-

RA07041041451X(07.4-1451)
07-1451
Mercedes-Benz
18
Fig. 396: ldentifying Fuel Distributor With Injection Valves Remove/Install Components
release through service valve (see Diagnosis Manual Engine, Volume 2, Index 3,
Fuel pressure
Testing fuel pressures and intemalleaktightness).
Ground cable at
battery
All electrical ofwiring which runs vía the fue! distributor to the intake manifold, unplug, plug
connections m.
unbolt, bolt on.
Fuel feed and return
lines NOTE:
Do not unbolt fuel feed and return lines for testing the injection valves.
Vacuumline from pressure regulator, detach, fít on.
Fue! distributor (17) carefully pull out of intake manifold together with injection val ves, insert.
Injection valves test (Diagnosis Manual Engine Volume 2).
unplug, plug in.
Plug connections
(arrow) NOTE:
Do not unplug the connectors ( arrow) for testing the injection valves.
Insulating sleeves examine, replace ifnecessary (07.4-6572).
Mercedes-Benz
Injection valves remove, install (07.4-6520).

LH control unit fault
read, erase ifnecessary (see Diagnosis Manual Engine, Volume 2, Index 0).
memory
REMOVING AND INSTALLING PROTECTIVE GRILL AT AIR MASS SENSOR- RA07041041452X

(07.4-1452)
Preceding work:
Removing and installing air mass sensor (07.4-1453)
07-1452
82/2
• 70
G'- ~S-8-0 . -:-s-----,

1
Fig. 397: Identifying Protective Grill At Air Mass Sensor Remove/Install Components
Circlip (7 1) remove, install.

Protective grill (70) take off, insert.
REMOVING AND INSTALLING HOT WIRE AIR MASS SENSOR- RA07041041453X(07.4-1453)
07-1 453
Mercedes-Benz
o-··
31
Fig. 398: ldentifying Hot Wire Air Mass Sensor Remove/lnstall Components
Plug connection (B 2/2 x 1) at hot wire air mass sensor (B2/2), detach, fit on.
Slacken knurled nut.
Hose clips (32) slacken, tighten.
Hot wire air mass sensor
remove, install.
(B2/2)
check; renew ifnecessary.
Connection hose (31) Pay attention to installed position (arrow) connecting hose (31)/hot wire air
mass sensor (B2/2).
read, erase if necessary (see Diagnosis Manual Engine, Volume 2, Index 0).
memory
REMOVING AND INSTALLING LH RESISTANCE TRIMMING PLUG- RA07041041459X(07.4-

1459)
07- 1459
Mercedes-Benz
Fig. 399: ldentifying LB Resistaoce Trimming Plng
unplug, plug in. Pay attention to position.

. . . Pay attention to notes.
LH res1stance tnmmmg "'
l 11 (Rl?/2) LD.oanallrl
P Uo The LH resistance trimming plug must be resealed after installing with the
sealing pliers 124 589 O1 37 00 and the embossing set 124 589 24 63 OO.
read, erase if necessary (see Diagnosis Manual Engine, Volume 2, Index 0).
memory
NOTE: Assignment of resistance trimming plug position <--> complaint see Diagnosis
Manual Engine, Volume 2, lndex 3.
All vehicles (except USA/California) have a resistance trimming plug for adapting the various injection maps.
Vehicles with KA T have a green resistance trimming plug, vehicles without KAT have a white resistance
trimming p1ug.
60anaerl
On vehicles with KAT and national version ¡gj it is not permitted to install a white resistance trimming plug
otherwise the air pump for air injection will run constantly and the air pump will be damaged as a result.
Special tools
Mercedes-Benz
t24 S89 01 3T 00
07
l24 589 ~· 63 00
07
REMOVING AND INSTALLING COOLANT TEMPERATURE SENSOR- RA07041041462X(07.4-

1462)
Operation No. of operation texts and operatíon values or standard texts and flat rates
07-1462
Mercedes-Benz
.
~ 1
IP07-<0734-57 --1
Fig. 402: Identifying Coolant Temperature Sensor Remove/Install Components
reduce. To do this, open cover of coolant expansion tank,

Pressure in coolant circuit
elose.
Coolant temperature sensor plug
unplug, plug in.
connection (X59/2)
Coolant temperature sensor (Bll/2) unscrew, screw m.
Seal (arrow) renew.
Coolant leve! check, top up if necessary.
read, erase if necessary (see Diagnosis Manual Engine,
Volume 2, Index 0).
REMOVING AND INSTALLING INTAKE AIR TEMPERATURE SENSOR- RA07041041465X(07.4-

1465)
Operatíon No. of operatíon texts and operation values or standard texts and flat rates
07-1465
Mercedes-Benz
Fi~. 403: Identifyin~ lntake Air Temperature Sensor
Electrical connector at intake a ir temperature

unplug, plug in.
sensor (B 17/7)
0-ring check, renew ifnecessary.
Intake air temperature sensor (B 17/7) tum to left, withdraw, insert, turn to right.
read, erase if necessary (see Diagnosis Manual Engine,
Volume 2, Index 0).
REMOVING AND INSTALLING LH CONTROL UNIT- RA07041041470X(07.4-1470)
Operation No. of operatíon texts and operatíon values or standard texts and flat rates
07-1470
Mercedes-Benz
Fig. 404: ldentifying LB Control Unit Remove/Install
Ignition switch off

Cover of LH control unit (N3/ 1), remove and install.
LH control unit (N3/1) withdraw with special tool140 589 01 33 00, insert.
LH control unit fault memoryread, erase ifnecessary (see Diagnosis Manual Engine, Volume 2, Index 0).
Special tools
REPLACING OXYGEN SENSOR- RA07041045303X(07.4-5303)
07-5303
Mercedes-Benz
Fig. 406: ldentifyiog Oxygen Sensor
detach, fit on.
Oxygen sensor plug connection NOTE:

(G3/2xl)
• Turn un ion nut to the left as far as stop --> open
• Turn union nut to the right as far as stop --> lock
unscrew, screw in. Special tool 000 589 71 03 OO.
Iostallation instructioo
Oxygen sensor (G3/2) Coat thread of oxygen sensor (G3/2) with hot lubricating paste, Part
No. 000 989 88 51.
Tightening torque 50 - 60 Nm as reference vaiue.
test (see Diagnosis Manual Engine, Volume 1, Testing, adjusting
Lambda control
engine).
read, erase ifnecessary (see Diagnosis Manual Engine, Volume 2,
Index 0).
Spec.ial tool
000 589 71 03 00
83
Fig. 407: ldeotifyiog Special Tool (000 589 71 03 00 83)
REMOVING AND INSTALLING FUEL FILTER- RA07041045563X(07.4-5563)

Mercedes-Benz
07-5563
~51
57
P07·0634-57
Fig. 408: ldentifying Fuel Filter Remove/lnstall Components
.&oanae-rl
Pay attentíon to safety ínstructíons!

Overpressure in fuel tank reduce by openíng pressure cap, closing.
Ground cable to batte1y dísconnect, connect.
Protective box ( 69) detach, attach.
Fuel suction hose (53) and fuel pressure hose (52) pinch with clamp (51) 000 589 40 37 00, slacken
clamp.
Hollow screw (59) at fuel filter (55), unscrew, screw in. Collect
remaining fuel.
Tigbtening torque 26 Nm as reference value.
Copper seals (62) renew.
Fuel pressure hose (52) at fuel filter (55), unscrew, screw on. Collect
remaining fuel.
Screws ( arrows) at mounting bracket (57) slacken, tigbten.
Detach fuel pressure hose (52) for thís purpose,
Mercedes-Benz
attach.
Fuel filter (55) remove, insert with plastic sheet (56).
Examine plastic sheet (56); renew ifnecessary.
&oanaor!
Always install plastic sheet (56) between fuel filter

(55) and bracket (57)! The plastic sheets ofthe fuel
pumps (M3ml, M3m2) and ofthe fuel filter (55)
must project on both sides ofbracket Direct contact
of fuel pump with bracket results in contact
corrosion.
Leaktightness of all connections examine with engine running.
Special tool
000 589.40 37 00
00
The fuel pump pack is located 011 the tight ahead of the r ear axle 011 the frame floor looking in direction of
traveL
Fig. 410: ldentifying Fuel Pump Pack
REMOVING AND INSTALLING FUEL PUMPS- RA07041045750X(07.4-5750)

Mercedes-Benz
Both fu el ptunps
07-5750
Fuel pump 1
07-5713
Fuel pump 2
07-5714
A. Removing and installing fuel pump 1 (M3ml)
Jr-'1
Fig. 411: ldentifying Fuel Pump 1 (M3m1) Removellnstall Components
&.oanaerl
Pay attentíon to safety instructíons!

Overpressure in fuel tank reduce by opening pressure cap, closing.
Cover (69) take off fit on. Tnstallation nosüion see 07.4-5770
Mercedes-Benz
clamp.
Cap nut (54a) at fuel pump 1 (M3ml) unscrew, screw on.
Electric cables offuel pump 1 (M3m1) disconnect, connect. Pull off protective caps for this
purpose, fit on.
Positive cable M4 connection thread.
Negative cable M5 connection thread.
Hose clip at fuel suction hose (53) slacken, secure.
Fuel suction hose (53) press off, fit on.
Screws (arrows) at bracket (57) slacken, tighten. Detach fuel
pressure hose (52) for this purpose, attach.
Fuel pump (M3ml) remove, insert with plastic sheet (56). Pay attention
to spacer piece (65).
&.oanaerl
It is essential to insert plastic sheet (56) between

fuel pump (M3ml) and bracket (57). The plastic
sheets ofthe fuel pumps (M3m1 , M3m2) and ofthe
fuel filter (55) must project on both sides ofthe
bracket. Direct contact of a fuel pump with the
bracket results in contact corrosíon.
Leaktightness of all connections examine with engine running.
Special tool
000 589 40 3 7 0 0
00
B. Removing and installing fuel pump 2 (M3m2)

Mercedes-Benz
t;Ls1
M 3m2
P07-0636-5i7
Fig. 413: ldentifving Fuel Pump 2 (M3m2) RemovellnstaU Components
&Dan<~er!
Cover (69) take off, fit on. Installation position see 07.4-5770
clamp.
Cap nut (54a) unscrew at fuel pump 1 (M3ml ), screw on. Collect
remaining fuel.
Cap nut (54b) Tightening torque 26 Nm as reference value.
unscrew at fuel pump 2 (M3m2), screw on.
Screws (arrows) at bracket (57) slacken, tighten. Detach fuel
Electric cables at fuel pump 2 (M3m2) disconnect, connect. Pull off protective caps for this
purpose, fit on.
Mercedes-Benz
Posítíve cable M4 connectíon thread.

Negative cable M5 connection thread.
Fuel pump 2 (M3m2) remove, insert with plastic sheet (56). Detach fuel
líne (61) from fuel pump 1 (M3ml) for thís
purpose, fit on. Pay attention to spacer piece (65).
Examine plastic sheet (56); renew ifnecessary
&oanQer!
Always install plastic sheet (56) between fuel pump

(M3m2) and bracket (57)_ The plastíc sheets ofthe
fuel pumps (M3ml , M3m2) ando the fuel filter
(55) must project on both sides ofthe bracket
Direct contact of the fu el pump wit the bracket
results in contact corrosion.
Fuelline (61) press off fuel pump 2 (M3m2), fit on.
Leaktightness of all coooections examine with engine runníng.
Special tool
000 58B 40 37 00
00
Fi~. 414: Id entifvin ~ Special Tool (000 589 40 37 00 00)
REMOVING AND I NSTALLING FUEL PUMP PACK - RA07041045770X(07.4-5770)
07-5770
Mercedes-Benz
&Lst
M3m2
P07-0636-57
Fig. 415: Identifying Fuel Pump Pack Remove/Install Components
Lt.oanaer!
Pay attention to safety instmctions!

Grotmd cable at battery disconnect, connect.
Cover (69) take off, fit on.
clamp.
Electric cables of fuel pumps (M3ml , M3m2) disconnect, connect. Pull off protective caps for this
purpose, fit on.
NOTE:
Positive cable M4 connection thread. Negative
cable M5 connection thread.
Hose clip ( arrow) slacken at fuel suction hose (53), tighten.
Fuel suction hose (53) at fuel pump 1 (M3ml) press off, fit on. CoUect remaining fue!.
Fuel pressure hose (52) slacken at fuel pump pack, tighten.
Fuel pump pack detach at rubber block (58), attach.
Leaktightness of all connections examine witb engine nmning.
Mercedes-Benz
SpeciaJ tool
000 589 40 37 00
00
The fu el pump pack ís located on the right ahead of the rear axle on the frame floor lookíng in directíon of
travel.
REPLACING CHECK VALVE FOR FUEL PUMPS- RA07041045820X(07.4-5820)
Operation No. of operatíon texts and operation values or standard texts and flat rates
07-5820
A. Replacing check valve at fuel pump 1 (M3m1)

Mercedes-Benz
P07-0637-57A
Fig. 418: ldentifving Valve At Fuel Pump 1 (M3m1) Remove/lnstall Components
&Dan<~er!
clamp.
Cap nut (54a) at fuel pump 1 (M3ml) unscrew, screw on.
Screws (anows) at bracket (57) slacken, tighten. Detach fuel
Check valve (63) remove, install. Collect remaining fue l.
&oanaer!
Always install plastic sheet (56) between fuel pump
(M3ml) and bracket (57). The plastic sheets ofthe
fuel pumps (M3ml, M3m2) and ofthe fuel filter
(55) must nroiect on hoth sides ofthe bracket.
Mercedes-Benz
Direct contact of a fuel pump with bracket results

in contact corrosion.
Copper seals (62, 62a) renew.
Leaktightness of all connections examine with engine runníng.
Special tool
000 589 40 37 00
00
The fu el pump pack is located on the ríght ahead of the rear axle on the frame floor looking in directiion
oftravel.
B. Replacing check valve at fue) pump 2 (M3m2)

Mercedes-Benz
P07-0637-57
Fig. 421: Identifving Valve At Fuel Pump 2 (M3m2) Removellnstall Components
&.oanqer!

Fuel suction hose (53) and fuel delivery hose (52) pinch with clamp (51) 000 589 40 37 00, slacken
clamp.
Fuelline (60) remo ve and install. Collect remaining fuel.
Check valve (63) remove and install. Collect remaining fuel.
Copper seal ( 62a) renew.
Leaktíghtness of all connections examine with engine running.
Special tool
Mercedes-Benz
000 589 dO 37 00
00
The fuel pump pack is located on the right ahead of the rear axle on the frame floor looking in directi!on
oftravel.
Fig. 423: ldentifving Fuel Pump Pack
REMOVING AND INSTALLING RUBBER BLOCKS FOR FUEL PUMP PACK- RA07041045860X
(07.4-5860)
07-5860
Mercedes-Benz
P07.,0638-S7 ~
Fig. 424: ldentifying Rubber Blocks For Fuel Pump Pack Remove/Install Components
Cover (69) unscrew, screw on.

Rubber block (58) detach from shoulders, fit jn; renew if necessary.
The fuel pump pack ís located on the right ahead ofthe rear axle on the frame floor lookíng in direction of
travel.
Mercedes-Benz
REMOVING AND INSTALLING INJECTION VAL VES- RA07041046520X(07.4-6520)
Preceding work
Removing and installing fuel distributor with injection valves (07.4-1451)
07-6520
. 1
14----(§)
1
1...____.
l
Fig. 426: ldentifying lnjection Valves Remove/Install Components
Plug connections unplug, plug in.

pull off at injectíon valves, fit on.
Anti-twist lock (12) &oanqerl
Anti-twist lock must engage in four-sided lug (arrow) at injection valve (Y62).
Inj ection valves (Y62) withdraw from fuel distributor, insert.
0 -rings (14) replace, oil slightly to facilitate ínstallation.
NOTE: As of 09/92 modified injection val ves have been used. The fuel outlet (a) has
Mercedes-Benz
been converted from 4 to 2 holes to achieve improved fuel preparation.
Y62
P07-5441-1 3
Fig. 427: ldentifying Fuel Outlet Boles Oflnjection Valve
As a result of the arrangement of the boles, 2 jets are formed when the fuel flows out wbich spray the fuel in the
fmely atomized flow onto both injection valves_
P07-5475-15
Fig. 428: ldentifying Fuel Spray

Mercedes-Benz
RENEWING ISOLATING SLEEVES AND RUBBER RINGS (FOR INJECTION VAL VES) -
RA07041 046572X(07.4-6572)
Preceding work
Removing and installing fuel distributor with injection valves (07.4-1451)
07-6572
P07.()736--57
Fig. 429: ldentifying Isolating Sleeves And Rubber Rings
Isolating sleeves (35) withdraw from intake manifold, press in.

0-rings (arrow) replace, oil slightly to facilita te installation.
PROGRAMMED REPAIRS- RA0704104PROOX
07.4 Electronically controlled gasoline injection system (LH)
Complaint:
Mercedes-Benz
Output of fault code 4 and 10 at LH control unit
Cause/Remedy:
If fault 4 or 1Ois displayed in the pulse readout, the stored fault should be confmned with the check:
l. On!off ratio output with ignition ON

2. On/off ration output engine idling.
If no fault is confirmed in the onloff ratio output, the fault should be ignored and erased in the LH controltmit.
Tbis relates only to the control unit with part no. 009 545 098 32 .
FAULTCHART
Pulse readout Fault type
4 Aír mass sensor signal
10 Idle speed recognition of EFP control unit
Complaint:
Engiue cuts out wbeu idliug, if steering is operated wheu AC compressor on
Cause/Remedy:
l. Power steering pump witb opening pressure of 125 bar installed.
Install power steering pump with opening pressure of 105 bar, standard as of 06.91.
2. Insufficient idle speed air.
Clean actuator in the area ofthe throttle valve. Exchange Tempomat cruise control/idle speed control unit
(N4/3) and LH control unit (07.4-1470 and 30-1272).
Allocation Part no. as ofvehicle ident end no.
LH 014 545 61 32 1A067 579
TPM/LLR AG 4-speed 140 545 67 32 1A061 052
TPM/LLR AG 5-speed 140 545 68 32 1A064 968
Complaint:
Output offault code 6 at base moduJe (N16/1)
Cause/Remedy:
Mercedes-Benz
Iffault 6 is displayed in the pulse readout at the base module (Nl6/ l), check whether the AC compressor cuts in
when the air conditioner is switched on.
If the AC compres sor is operating properly, ignore the stored fault and erase it in the base module.
NOTE: Fault 6 is also stored if the engine cuts out when the air conditioner is on.
Fig. 430: ldentifying Base Module
Complaint:
Engine cuts out when stationary when a Drive position is engaged or when parking
Cause/Remedy:
Moisture (corros ion) in the plug connection of starter lockout switch/gearbox wiring harness.
Pulse readout: EFP control unit 6 or 2 and 6 ABS/ASR control unit 30
Check starter lockout switch for corros ion. If necessary, replace starter lockout switch and transmission wiring
hamess. Starter lockout switch is identified with white dot (27-130) .
Complaint:
Protective grill of air mass sensor damaged
Cause/Remedy:
Replace protective grill part no. 000 090 00 45 (07.4-1452).
&oan<ler!
Mercedes-Benz
Hot wire of air mass sensor must not be damaged otherwíse premature damage wilJ occur or hot wire will bum
out.
Complaint:
Engine is difficult to start when cold after operating auxiliary heater, vibrates when idling and/or cuts
out
Cause/Remedy:
LH control unit does not recognize auxiliary heater operation.
NOTE: This relates to all vehicles up to vehicle ident end no. 1A092 141 .
Replace LH control unit, part no. 014 545 61 32 as ofproduction code 269.03 (07.4-1470).
Complaint:
Poor throttle response in warming-up phase and/or engine backfires into intake manifold
Cause/Remedy:
Inlet valves coked.
Unplug LH resistance trimrning plug and plug into position 3.
TECBNICAL MODIFICATIONS- RA0704104TAOOX
07.4 Electronically controlled gasoline injection system (LH)
Designation Nature and reason for modification Production Op.No.

breakpoint
0-ring at injection valve made of material more
lnjection valve 06/91 -
resistance to cold temperatures
Injection valve Diameter of insulating sleeve reduced by 1/1 Omm 07/91 -
Software revision, improved cold starting
LH control unit
properties
01/92 -
Fu el outlet has been converted from 4 to 2 boles to 07.4-
lnjection valve 09/92
improve fuel preparation 6520
Conversion offuel filter from 0.5 liter, was 0.6
Fuel filter
üter, except@ and Gulf States
02/93 -
LH resistan ce trimrning 07.4-
Note re color coding 06/91
connector 1459
VEIDCLE FEATURES - RA0704FLH0004X(07 .4-0004)

Mercedes-Benz
Engine 104.990 119.970 119.971 119.974 120.980

KA T/without KAT/without KAT/without KA T/without KAT/without
Version
KAT KAT KAT KAT KAT
Model 140.032 140.050 140.042 124.036 140.056
140.033 140.051 140.043 140.057
LH designation LH LH LH LH LH
Compression
10 10 10 10 10
ratio
Ignition system EZL EZL EZL EZL EZL
LH resistance White inscription White inscription White inscription White inscription White inscription
trimming plug KATIECE KAT/ECE KAT/ECE KAT/ECE KAT/ECE
lgnition system
resistance Green inscription Green inscription Green inscription Green inscription Green inscription
trimming and partno. and part no. and partno. and part no. andpart no.
coupling
One temperature One temperature One temperature One temperature One temperature
Coolant sensor one four- sensor one four- sensor one four- sensor one four- sensor one four-
tempera tu re pin connection pin connection pin connection pin connection pin connection
sensor for LH control for LH control for LH control for LH control for LH control
unit unit unit unit unit
LH control unit LH control unit LH control unit LH control unit LH control unit
Fault fault memory, fault memory, fault memory, fault memory, fault memory,
recognition EZL control unit EZL control unit EZL control unit EZL control unit EZL control unit
fault memory fault memory fault memory fault memory fault memory
Accelerator
LLRLLR/TPM
control/cruise LLR/TPMEFP LLR/TPMEFP EFP EFP
EFP
control systems
Air injection withKAT withKAT (l) withKAT (I) withKAT (l) with KAT (I )
Exhaustgas x<2) X X X X
recirculation
(l) Except _
(2) Only
FUNCTION DIAGRAM- RA0704FLH0010X(07.4-0010)
A. Engine 104
Mercedes-Benz
""...,..
Fig. 431: Electronically Controlled Gasoline In jectioo System {LID Function Diagram - Engine 104
Basic version, ¡g] and ~

Mercedes-Benz
4!1 Di apiY9!J11 pressure regula~ M3m1 RJefpUI!l> 1

5ó Fuefilor M3m2 RJ el pul!l> 2
711 &M~ M16F1 Bactromc atcalerat<ll p&dal (EFP) ecmrol
75 Fuel !ank N1/3 EZl. 1911ilon conlrol umt
75 Venlva.\<9 N311 An hot WlfB {lH) conrol urnl
77 Ac lva'.ll.d cnattoef llítel N 4f1 BectroniC acc e'eratot pedal (EFP) comot tnt
B9 3
Exhoostgas reorrula on vaM! ) N 4/3 TeJ'T'PO(I'Iatcnise conioltd!e ~eed oomol unt
98 Vacuum o!omont{shil pcinlretard) 1 ) N1€t1 Basa m<Xlle {GM)
1 6
125 Alrpump l NSS Ca~ cG/Werter O"'llfh&atl1gc Ofl!Jolurd )
1 4
126 Alr sttt.tol vat.'e ) N 59 Oiagnosbc modUle )
127 1 R1íll2
NM.fetum 'Vl!ÑB {in;ectoo 81") ) EZl r&Sistance lnmmng couplilg
128 Noo.rorum V!Wo (vat:\llJm) R17f2 Alr hot wn reSistanc& lnmm~n-;¡ ~g 5 )
135 Non.retum ~e (vacu.Jm wppty? R33 CO~J-o:en!Jc~er, adcf:ów P-elfcnnanco map
136 Vacuum rosorwir aá¡usimem )
156 Exhaust moofold 515 Tr!ll1smss~en moda s>Mtcn {2nd modo)
158 Cef8lj(JC COITveltor S29/3 kilo sp oad coltact s'l.lll!:h
A1o19 Cata)¡bc romerterovo!hea5ng waminglamp 5 ¡ S 40 TBJ'T'PO(I'I!ll CIUS.B COO~ol S~~l::h
7
A1o26 CHECK ENGINE wam11glamp ' ) T1 lgriícn ootl
A9 NC C<Qffipres-sor Y313 Shftpaltrotards'Mir;'!>verwtvo 1 )
A15g1 Knock sens.or 1 Y27 ARF S'Michover v~ )
1
A16g2 Knock sans.or 2 Y32 Alr pump S'Mtthover V!!Ne l
Y33 1
82!1 Alr mass son ser 'Mih hctwwe Alr pump olaci001a:gno1c du!rh )
81 112 Coolarn IBmP-aralu9 SOOS<ll Y49 Camshaft 1Jrn1ng ar:tuator
6 Y5BI1 Rogenoraion SWíl!howr vmo
BHt/5 KATthormocO!.Clfe )
B17fl ttak& ar tem,poreture 5enscr Y62 Fu el if19'C Ion vaM!s
G3/2 Heated ox,rgen s1!llscr 1) O!t¡r f<ll votídes 'Mth KAT
K17 Aln n;e rnon relay 1 ) 1¡ Oriylorvohdas •Mthotlt KAT
K27 Fuel punp relay 3. ¡
O!tf0@)
l5 Cranksha2 P-OS~ton soo sor 4) On'y e aifomla
l511 Camshaltpcsition s.ensor s., Except@
6)
Odf0
7)
Oltf@>
Fig. 432: Engine 104 Components Reference Table
B. Engine 119
Mercedes-Benz
NT..._
Fig. 433: Electronically Controlled Gasoline In jection System (LB) Function Diagram - Engine 119
Basic version, [gJ and ~

Mercedes-Benz
40 Du;ptre9m Jl(OS~ure r~laY LS Cmnksh~ jl(lSit OO SOO SCf

55 Fuol llter L5f1 Camsha:t Jl(lSillotl S(l/lSOf
74 Fuol co<lter MJIT11 Fuelpump1
75 Fuel l!mk M 3m2 Fuelpump2
75 Y.en!valw N1.G EZl 1gnioo coolioluriit
77 A.c i va!nd dlarcolllliter N311 An ha! 'M re {LH) conlrol mt
89 El<h~~ ga~ rearrula 011 vatV& 3 ¡ N 4f1 8ec!irooic ac«Jera~ pedal (EFP) coo!rol urit
1
98 Sl'llftpoui retard V!l(WTI ~ment ) N16f1 Basem~e {GM)
1 6
d~!i
125
6
Au pump ) N 58 Cm~ e rorrverter ovemealmg corool m i )
126 /lJr sl:ntol vat.te 1 ¡ N 59 Di &!JlOSIÍC moélJie
4
)
127 Noo-telum va.Ne Ortecteo Bl') 1 ) R1812 EZl.. res•s!ance mm~t~gcoq¡tng
128 Non-tetum vzl.re !VaCIJ'Jm) R17f2 An ha! 'MnHeS!sta.nte tnmmng plug 5)
135 Non-telum va.Ne (vatu!.lm suppty) R33 CO poteni cpe'.Eir , ad<Hve p erfoonam:e map
136 Vacuum reserwn adjustm orn )
156 Elchoo 54 m oo fold 515 Transm1ssaon rooc!o swtch { 211d me efe)
158 Cetal¡tic CO/Tv'ertor 52'9.G k:e ·sp eod cortad S'Mich
6
A1o19 Catai¡(Jc CO/Tv'ertor hoallng W!lfTIJ!!91amP ¡ 5 40 Tempomat CIUIS8 cotifol SMtch
1
A1e26 CHECK ENGINEwam11gtamp ) T1 f1 9llbon coi 1
A.9 NC c:cmprassOf T1f2 lgnilioo e oi 2
1
A 16g1 Kllod< wnsor 1 Y3/3 Shilt pou t rstard S'MidiDvor vaMI l
3
A16g2 Kllock sensor 2 Y27 ARF sMtchovor vatv'e )
Y32 1
82f2 An mass sonsor"Mih Jwtwn /lJr pump SOMtdlcVer vaMI )
1
B 11f2 Coolarn temp eraltn sensor Y33 Air purnp eledromagnebc clkt.dl l
8 16!6 KAT!Mrmoc~ ¡ 6
Y49f1 Leftcamsh~ i m11g a~hla'!or
8 1717 lrta.ke air lsm¡¡eralure .sensor Y49f2 Righl ~a:msha.ft timng eduator
G3/2 He.ated ox¡~goo soosor Y58/1 Regenorotlori S';'ll!l:hover wtre
1
K 17 Au 1rjactJon relay 1 Y62 Fuel ln¡acbon vatvas
K 27 Fuol pump r elay 1) 0111.¡ 011 \'l'lhtelecs 'M~ K AT
2) 0111.¡ 011 whícles wl!iau K AT
3- )
0111.¡0 @>
4¡
s., Oril.¡ Ca!tcm1a
Except@
o)
Oril¡tCD
7)
oro¡~ @
Fi2. 434: En2ine 119 Components Reference Table (1 Of 2)
C. Engine 120
Mercedes-Benz
tJ ¡ ~ 1_~ j '~ 1 T
1 "· IP~
Be A9. u rJ.
II!!!!Jl _Mn 1 l't'V'
81~
.~~ J..rin'U ~·~
RIBI.UI!J .... 1 •r 1 e- ,A21Jb~ ~~%
itJ j1"",.
...=:::-·
"'""
----- ~-
1-
-
-~-
JJ,~ r
ll't '
1
' J.l ii·-
~~ f
~
~
lt 1
~~m
¡
·~
JI. ~ j
- ..~ ~
[- ·-·r-
"~.ro ,.
} ti YS&'sl
;~ ....,.,..
ll
-
9
-~~fl:'ll
¡1Z7
·~· ~ ri <e:::l ~ ~i
-0 -=n e =\, ¡ -
VSS JI
r,_
1111111 .
~11fi-,A ..~~~ l~~~py·r J--

Yü fL-_..
.a.. ~
'----tJ
P07-5884-11
Fig. 435: Electronicallv Controlled Gasoline In jection Svstem (LH) Function Diagram - Engine 120
Basic version, ¡g] and ~

Mercedes-Benz
40 01 epffi;ym pressure regula.~ N1111 left EZl 1g111ioo coo!Jol unt

55 Fuel iler N115 ~!ti! EZl íglloon c«troo rníl
74 Fuelcooler N312 Loftholwre (lH)comot tnt
75 FueiiMk N313 ~gtt holwu{LH)conlofunt
76 Vootvalve N411 84Kiooc atcelera:or pedal {EFP) codrol t.IUt
77 Adva~ d1arco1llliler N1&f1 Basemodtte (G.\11)
89 left ellhll~t g&s recl'rulemon vake lor rigbt bllli< oí N58/1 loft ~iác con\1lrler ovorhea'.lng cortrol uní! 0 )
cytndors ) N5812 Rl~catalpc coo<orter overheatmg cOfirol
898 Riglt e~~ gas reorcllalloovat;elor loltblri< ct Ull )
e¡.tnders )
N 59 DIBWIO'slit rTlOO.Jio 4 )
98 Shdl po¡rt {eiard vacwm e emefll
R1613 leftEZl resJStance lmlm11gpllg
125 An pump )
~:ho~:::a=~::;;;~g 5 ~
R1&!1l
An sh~oha!Ve )
1
126
R1 713
Non-cel!.m 'Vl~Ñe Qqeded a.v) ¡
127 1
Non-cetun ·.eNe ~r¡ede-d a.v) 1 ¡ R17!1l Rl!tl! lrvt wu reSistame tnrmung ~ )
127a
R3..V1 leftCO po~§ometer, adói v&peorlofmallco map
128 Non-cott.fn valve (vacwm)
~smert ¡
158 C~,t.c CQIT{efter
R3312 Rlgll COp~erilomo1er, addbw porfoonancemap
A1a19 Cat~c CQIT{efter ovamooong wamiiglamp 6 ) a<f!Usmenl )
7
A1e26 CHECK ENGIIJEwam11gtamp ) S2913 9Nid1, accelerntorpedalforcere:cogrllionAcle sp13od
A9 NC compmsscr con!Bct sNtch
A29g1 loftknod< sensor 1 S40 Tompomat cruis e cortrol S'Mtch
A29g2 leftl<nock sensor 2 S65 Transrrussaon O'vWloadprctedon swltch, bral<e band
A3()g1 Rlgli I<JY'.-ck sensor 1 81
A30g2 Rlgit l<nock sensor 2 S6511 Transmlssion overloadp;o~don s•Nich, brako band
8213 loft au mass sensorwhhot'll!re 82
T1/1 lgn!bon e~ 1 {ngli bllli< el c'fmder·s)
8214 ~gli aJ mass sensor wilh hot 'NlrB
T1/2 lgmboo col2 {lelt banl< ot c¡lindal'5)
8 11.9 Left coolantterrporaiUre sensor
Y3/3 stult poirtl retard sontohovor val<'~~ 1 )
8 11[10 Riglt coolaii roperatu¡¡e sensor
8 1&7 Y27/2 Left ARF sot.~ítchover VllNe 1 3 ~
loftKATlflll(moco~ ~
8 16.6 ~glll KAT lhormoccuple )
V27/l Rl!t' ARF ·sontcrnwer vaMI1 )
1
B17l5 leftutake a.v tempereture sensor V32 Au punp s~tchovel Vlll\>9 )
Y33 1
Rlgit 11take !llr í91Tl)era'.llro sensor Au punp aledrornagnilllc ckich )
81716
V49/1 leftcam~~ ~m~g &ekla'.Or
G3/3 loftcxygen sensor
V4912 ~ghl camshalt bmng actuator
mr4 Rlglt cx;gan sensor
K17 A!.r r~edlon relay 1 ) VSS/2 Rlglt regenora)on sw.tcho\1lf vatve
K27/1 V5813 loft regeneratJon S'Mk:hovor \Oll.o'Ve
Re!&; 1 for tue1 pumps 1 IBild 2
K2712 Relil'; 2for fuel pumj)'s 1 and 2 Y63 Len fuell'lJOCIIOn vatves
Y64 Rlglt iJ olm;adoo va)Jos
l512 loftcamsh~ pcsiion soosor
1) úm( on\1lhieles 'MtlK AT
l513 Rlglt camshalt poslbon sensor
2¡ (W¡ OII vehtcles w:hoü KAT
LS/4 leftcr~shaftpoSJbon sensor
3)
l515 Rlg!t crankshe1 posaioo sensor oro; 0 @
M3m1 Fuelpump1 4) Orf!¡ Ce!lcrma
M3m2 Fuol punp2 5)
Except@
M1613 Rlglt eledroric ac-<: ei&rator p&dá(EFP) actuator, !el
6¡
C)'indOfblock oreyQ)
M16f4 left el&ctromc at c·oleretcl pedal {E'FP) CICtJ ~r, nglt
tyindor blod<
7)
OfW®
F ig. 436: Engine 120 Components Refer ence Table
LOCATION OF COMPONENTS- RA0704FLH 0015X(07.4-0015)
A. Engine 104

Mercedes-Benz
K27 Fuel pumprelay 'N9/2 Ground, frontngtt (atheatCarrp Ulllt, rgnbon e~)
N311 lH cootol u111t X11.t4 Tf!s1 ~ng lor <iagno5ls, pulse SI!Jlai (3&-pln)
N411 Elec.OIIC eccelera<or P«fal (EFP) c;~ol Ulli X26117 P\Jg comodon, en¡¡rne sep818lon pout (36-pin)
N1611 Ba:somom.J'f! (GM) Y27 ARF sw.táloW( vat.ta
N3011 ABSIASR cortiohm Y32 An pump SWitálover vatve 1 )
3 1)
R17l2 lH reslstanoe •rnmllg plJg ) Of't¡r on vehx:les ~D1 KAT
R33 CO !)OWn,omelllr.zt:kitYe pjjrlormance map 2) ORy on vehKlos WltlOt!K AT
adjusmenl (AKVJ ) 3¡
Except@>
Fig. 437: ldentifying Electronically Controlled Gasoline Injection System (LH) Components
Location - Engine 104 (1 Of 3)

Mercedes-Benz
817f7 Hot me e1tll<e rur I&Tfll&aJure seos« Y311 Shlft potn! retard s'llltdlo''er valve
G3/2 Hea!ed ox{gen sensoc 1 ) Y58/1 Regenorabon s~-&thover \'lllve
G3/2x1 Pklgto~ion, o:>eygen seos« hea!Jng c1lll B Lino !o acb\l!i\ed dlarroel iler
(4-pil) l 1)
1 oro¡ on whicles 'Mil K AT
K 17 Au uwctJon rclay )
Mercedes-Benz
4{) DlapiTagm p{es~u-e regula'.Dr '1312 Sh:lt parí retBI!d solenotd valve
8212 Air mess sOfl·sor 'Ailh hot w• e Y33 .AJr punp eledrome_gnet¡c cU.ch 1 )
81112 C{)olllllt tomper&lue SOOSOJ Y49 Camshaftbmng actuator
l5 Crnnksnat poSI• on sensof yu.¡ F uel11¡&dlon vatv'es
l511 Camshaltpostion stmSor 1) ort¡t oo wlucles wll K AT
S65 Transtmssaon owrtoadpro!lld ooSNild'l
Fig. 439: ldentifving Electronicallv Controlled Gasoline lnjection Svstem {LH) Components
Location- Engine 104 (3 Of 3)
B. Engine 119

Mercedes-Benz
K27 Fool pump relay X11.14 Test couping 101 diagno~s. putse SJgnal f38-pln)
N3/1 LH coo~olurtt X26117 Pklg tOlliledion, engme sepam!ion pofll {36-!*1)
N411 Elec~onc acc.alora!or ~e.dal ~FP) corool uni Y27 ARF ~chovor valva
N161'1 Basemodtfn {GM) Y32 Alr pump S'Mioh:wer va.w 1 )
N3011 ABSIASR cornrol ~nt 1) 0rty oo velucles 'AIIl K AT
3 2¡
R1712 Hoh\tre roSJstant.&trimning J*Jg ¡ Oriy on vehiCies 'Mm, out KAT
R33 CO po:Sn,cpe'.sr, ad<i've ~erfcrmanw mep 3)
ed)Jstmlllt ) Ex(ept@
W9f2 Ground, lrontngtn {atheadallll uni, I!1Jb011 coil)
Fig. 440: ldentifving E lectronicallv Controlled Gasoline Injection Svstem (LH) Components

Mercedes-Benz
s11n "'-ake ar IBmpellitu'e sensor Y4 Transrrussaon mode swtchowr vallte {2nd moda)
G312 Heateú oxygen sen sor 1 1 YSB/1 Regenerebon SWIII:hover vabfo
G312x1 Pllgcomedcn, oxygen sensor(4-~) 1 ) Á To edrv&ledcharcoalfifar
1
K17 Alr ll'lledJOO relay ) 8 To eogtne
K29 TmnsmJSSion shftpoutretardrelill( 1 ) 1) Qri.¡ on whJCios v.fl KAT
Y3/3 Shit pout retard swtchover vatv& )
Locati oo - En~ne 119 {2 Of 3)
Mercedes-Benz
125 Alr punp Y312 Sl'li! pout retard solellCid Y!Wa

1
8212 Alr mes~ sensor 'Mih hot wr e Y33 Alr pump eledromegnetic cUdl )
81112 Coclam tempem!ul e s en!lor Y49/1 lelt =sh~ t mUtgad ue:or
l5 Crenllsh~ poSlion sensor Y49f2 Rlgtt camshait bmng ectualor

LS/1 Camshaft po.sibon sansO( Y62 Fuel .-.¡ectlon VaNOS
S65 Trensm1ssioo o\1!floejjpro~ucn switch 1) Oft.¡ on w lucles 'Me"! K A.T
Fig. 442: Identifving E lectronically Controlled Gasoline I njection System (LID Components
Location - Engiue 119 (3 Of 3)
C. Engine 120

Mercedes-Benz
8213 Left au mass sensor vd1 hot "Hra, poSitoned 011 n¡;t G313x1 Pllgcomcct011, let oxygllll sensor 1 ~
ot 911g;r19 G3/4x1 Pllgcometti011, nr,toxygen sensor )
82~ Rlgtt l!J' mass meter w h hot wre, po51,011ad on Ioft K 17 Au 1qedl011 relay )
otang~~a
K29 Transmrsst 011 sllft pout rotan! rela'¡
81715 Lelt ntake M tampomture sensor Y5812 Left regenerebon 1i1Mithover valva
817Al Rlglt ~take lllr te~ra\Jre sensor Y58/3 Righl reg&nerll\011 swildlovnr vll!VIll
Le.'t oxygen sensor ~
1
G313 1) Orf¡ onVI!hKies 'Mih KA.T
G314 Rlgtt oxygen sensor )

Mercedes-Benz
K27/1 Fue! pumprelaytor punp 1 am12 X1114 Tes! rouping fQ(cia91lo:sis,pulso 51g;1l!l (~pe~)
K2712 Fuol pumpreiB'flor pump 1 and 2 Y27f2 left AAF swtdlO\'!lr v<We ~
N115 Rigtt EZl ignillon camal un~ Y27f3 Riglt 1\RF SMichoVef VaMl )
N312 lattlH cootolunt Y32 An pump SMtchovor VaMl 1 )
N313 Rlgtt lH e~ unt 2 CoaxJal coonertor lor corool cable lrorn W3ñ<~aft
N411 8ad•Ofl e ¡¡ceeleralor IIO'dal {E¡:p) corooluul posabcn sensor
N1611 Basa modlte (GM) 4 Vawum comectJon
N3011 ABSI~ cortrolwt A. 8-pin coupjng
R1614 Rlglt EZl reSis!arn:etnmmng coupjng 8 8-pcn coupjn g
R3.311 Left CO p,¡¡~jome:sr , adáijve pafformancce map 1¡ Qm.¡ on vehiCies >Mtl KAT
ed;!usmort ) 2) Qm.¡ on wh!Cias 'MiiOIJi KA.T
R3312 RigH CO~enliometef, addibw pedomrallCemap
ad',l.lsmern )
T1f 1 I!Jlllíon c oil 1 (nglt barf< ol c)6ndors)
W9f2 Ground, lronlngtt (athoa~arrp oot ,tQilboo col)
Fig. 444: l dentifving E lectronicallv Controlled Gasoline Injection System (LID Components
Location - En2ine 120 (2 Of 3)
Mercedes-Benz
8213 left an mass SllflSor w~ hotwre l514 lettaari<shaltposiiJoo sensor

8214 Rlgi1111r mess S9!1SCf WIÜ'I hot '141nl l515 Rlgit aanl<slla4 poSiion sensor
811fil leftcoolantterrporerure sensor Y27n lel! ARF switd:lo'IBf VFW8
811f10 Rlgl1 ecola:t IBmperalue sensor Y2713 Rl!t' ARF swtd:lover va.\!u
817.5 lefthot wrelllake!llfterrperatne S9!lsor, posibooed Y32 An punp s... td:lovor vatve 1 )
oo n!t' ol9fl!llne Y49f1 loll camshel im11gatt.Je!or
817.5 Rlgit hct•NJ"eu'tai<e aumptlfl!Uesoosor, Y4912 Rlglt camshaft bmng actuator
poSibonecl on Ioft ol 911!JnB Y63 left tue111¡ocbon V8Nes (vams 7-1 2)
l512 lettcamshe.l po;rion sensor
Y64 Rigli l.Jeh~JE~don vatvus {vrWes 1-8)
l513 Rlglit camshalt posiboo S'9!1Sor 1) Ort; on whxles wDl K AT
Fig. 445: Identifving Electronicallv Controlled Gasoline Injection System (Lffi Components
Location- Engine 120 (3 Of 3)
Components which are allocated to tbe respective bao k of cylinders
Because of the intake manifold design, the following components which are located on the left-hand side
are allocated to the right-hand bank of cylinders and components whicb are located on the right-band side
are allocated to the left-hand bank of cylinders.
• Air mass sensor

• Intake air temperature sensor
• ARF switchover val ve
• Regeneration switchover valve
Mercedes-Benz
Location
8213 Lo~ e• mass sen90J •.vih hot wre

8 17/5 Lol hctwwe utal<e au mmperatura sensor
Fig. 446: Identifying Left Air Mass Sensor Witb Hot Wire And Left Hot Wire Intake Air
Temperature Sensor
8214 Rl9ft air ma:ss sensor 'Mth hot me

8 17/6 RlgtthotiMroutako EiiJiamperature ·sensor
Fig. 447: ldentifving Right Air Mass Sensor Wiith Hot Wire And Right Hot Wire Intake Air
Temperature Sensor
Location of switchover valves
Y27fl Lel ARf' sMichover valva
Fig. 448: Identifying Left ARF Switchover Valves

Mercedes-Benz
Y'l7f3 Rlglt ARF Sl'.lt:hover wtve
Fig. 449: ldentifving Right ARF Switchover Valves
Y5812 Ld regooera~on swlch~verv!We
Fig. 450: ldentifying Left Regeneration Switchover VaJve
Y58f3 Rlglt Hlgllflorellon swtchover veM1
Fig. 451: ldentifving Right Regeneration Switchover VaJve
LH hot wire control units (N3/2, N3/3)
Two control units are required: right LH hot wire control unit (N3/3) for cy linders 1-6 (color coding of
coupling dark green/Light green) and left LH hot wíre control unit (N3/2) for cylinders 7-1 2 (color coding
of coupling dark blue/light blue)_
Mercedes-Benz
To distinguish which control unit is responsible for the left and which for the right bank of cylinders, the
left LH hot wire control unit (N3/2) is laid to ground (ceded) at the connection ( 1.2, see Wiring Diagrams
Modell40, Volume 1).
Fig. 452: ldentifying LH Hot Wire Control Units
INFLUENCING PARAMETERS AT CONTROL UNIT- RA0704FLH0020X(07.4-0020)
A. Engine 104 (except ¡gj , ~)

Mercedes-Benz
Starlsr,
t911T111lal 50
~
' - - '
Powor gouncl (W15),

l ~ alot tom:s gound [>
BB".ery (G1) !""""' (W15/1) ~daga alld
doanng cootol
Alr mass sensor wth
hct VllfO (B2f2)
~l_J -D f-t>
Vollagill suppt,t, !Uminal
Base momio --i> 30lH, 87L, 87LH
(N1511)
I-~rase
(N1611)
mo<lJie
C>
Coolart temperatt.ro
sensor (B11f2)
f.J.r 11]6d1011 relay(K 17)
-D IOI'tf K AT, except@¡
Hotwnntaka Bir kl!ake a r tlliJ1)eriiWre
IBmporat\ra StmSQ"
(B17f7) ----D s¡gnal \J
_,Fuel purr¡~ roley (1<27)
COpo!artJomolor{R33, l _ JMnoiU<oadaptalloo
~~
L--.- Hot
>'<~re
r--. C>
\\ltloLt K AT)
~ Oxy¡¡en sensor heater
<--- - - - - - - - '1 {tH) cortrol
U1l
Hot WJ"O HlS15Iant8 kl;edJonmapadap!a!Jon 1 (N3/1) ,...,- - - - - - - - - - - - - - . ,
nnmngplug (LH, R1712) ----D 1
--¡;~ - -- --- - · ~Test co~n¡¡ lcr <ia¡¡nosts, 3l!;lln {X1114) 1
(Y5811)
'- miJillO(y . . .
Alr mass SGilSOf l'.ltlllOI

\\Ir& (8?-12)
C>
EZl 1gnt on conlitolu11t
(N113)
TNsiQrli!l -i>
Camsh~ SllllSot Slgnal
E2l. ¡gnloon cocúol lllil
(N113) ¡-o Dais IliDldlange
J _
EFP coorolum (N411)
C::.____ _,'-i:> [>
EFP cortrol uni (N411) Ido speod conrol,

-e cte speod raGQg~IIJon alld _,FuolconsuillliJOOI1ÓCellll (A1p1G)
1uo1 waiy cu1cCf dala
nten:hallQo
EFP actuator 'Shit;outro!ard SWll!:hovor valva ('(3/::J)I
orii
(M16f1) -e KAn
t~ [>
Heaíod Ol<YQ811
SQflSOf (G3f2)
1 Dii)gnosbc s od<el, ~PI1 (X11 )
--tiTostcoq:ing loráagros¡s, 38iltn (X11.14)

mem:lfy
Fig. 453: Identifying Influencing Parameters At Control Unit- Engine 104 (Except)
Enoine
b 104~
Mercedes-Benz
¡s~. Ho,t w.-e fool •llO'cbon ve~es

,temunal50 1-{> f-D
(LH, Y62)
[:::
Pcwer SJl)Und iW1S),
elcdroocs groond
Bate¡y (G1)
j- o (W 1511) --e;. ~\d.age
B/ld dBmllll!J
A11 mass ·sen SOl 'Mttl
ho:t 'MIO (82/2)
f-D coruol -C>
~
Vclla¡¡e sup~, lemrnal
Basemcdte
{N1&11) ---;:::
30lH, 87L, 87lH -{>
Bese module
(N1611)
~Sigllal 1-<>
Ccolert tempem!Ure Cool&ntte:rperwre Signal
----e: --e;.
H
sensor (811/2)
/l:lr 11jecbon relay(l< 17)
Hot wl' o uteke 111r

~~as
~
tempomnre sensor temperalure
signa!
(817n) H.:elpu~srele'{(l<27)
~goo sensor healer

Hct
All mass sensor 'Mil hot ~IJ3ke au IBflllilriWro 'M ro
'1\tfll (8212) s~gnal and llll mass 1i1911al ilHl.
-D -!> ~Rog6nermon S'Kichc~r vetve (YS&/1)
coneroluni
(NS/1)
Data ll:etchange (CAN, ~amshaft trnlng actuator i)'49)
~
EZt gnition corool un' saeGr. 15)
(N1/3) -!>
EZl •gr~ion cootroluOJI

(N113)
Da!a
-D
EFP corirol 111¡ Data llálfdlatlge inlllrchango
(CAN)
(N4/ 1),TPM corúo1 111~
{N413) --e (S>Oe Gr. 30)
f-e
4EFP cooiolunt(N4f1)
-{>
EFP actuetor
(M1SI1) --e HARF swtcro<ervaMI {Y27)
Hea!edoxygen
sensor (G312)
-t:i
Oxygen sensor Stgnal
1-í> H Fu el eonsuflllllon 11dc a'ior { A.1p1 O)
Oiay~~ostlc mO<Mc {N59)

1Shll.pont retard S'Mithover valve {Y313)
Data ltlCeichango {CAN)

_,Diagnosllt sccket, 9-!*1 (X1 1)
A..-lfl&Ciion 184J85t
ARFrttqoos.l
Faul
_,Tost ccuplmg ror ála¡J~CSIS, 38-{lln (X111'1)
memory
Mercedes-Benz
Fig. 454: ldentifying Influencing Parameters At Control Unit- Engine 104 (1 Of 2)
Engine 104 [g]

Mercedes-Benz
ISlartor,
.l&mllnal 50
1~ 4""-'""'-00""'"
!LH, Y62)
1
P<~wer gtound (W15),
a!af:tonlcs ground
J~ (W15J1)
8a2eJY{G1)
---{;::>
&wtY 'JOI:aga Air mass san sor w.t11
anddoamng hot \\lf8 (82/2)
-\> corool l-t>
Basa mod!te
(N1611)
l Votage S\Jpptf, tarmnal
30lH , 87L, 87LH
f----i> -i> Basemod!ie
--cfTN s¡gnal --{>
(N1611)
Co<llali temperatura Coolanl terrpar~ra sagnal

sensor (B1 1f2)
-{> ~ Air 11J6ctlv"fl r elay (K 17)
f'-----1>
1
Hoh~I'O U'taka !lif

IBmpMah.re sansor
(81717) ~
t l!ak 9 811 l9f'lllOI'IllJI8
Slg<tal
-i>
-el H.! el pumps r elay (l< 27)
_ , Oxygen sensor he atar

Resstooce, catat;llc
KAT thermO«KJple {81616) corMlltet overlloamg Hot
r------e: ortr<il U!1I(N58) ~ l'l<f9
{lH) c<lltrol
Ullt
-c1 Raganera~on s·t'jjdlo\191' vat~a {Y58J1)
(N3l1)
Hot-o r 9Sislanc·e Fuel m;edlon map
nnmJ1gP'Jg(lH, R1711) ade;ltallon ---{;::> Ca~ comertor owrhoamg wamng larnp
r------e: ~ (Po.1a19)
Air ma:ss sans(){ •,\ltl he! ~lake eu taf'lllera':uro

w.re (62/2) S!QIIel end 1111 mass Slgnal
__, Camsha1 11mllgactlelor (Y49i
~ -{>
E2!. tgn~oíl coo:rolunt

TN S9'lalcamsheft Da':a Jn!oochange fN1m
sensor s¡gnal dala {CAN) -e
~
EZL IQI'Iibon coreo! uni uterchange {CAN)
(N113)
--{>
-i>
EFP conrol unt(N4f1)
--{::;
EFP coruol unil (N4f1 ) ld.!e sp-eed coorol, 1dle -c-IARF sw.tchover vaM! (Y27)
s~eed r ecogn~bon and
r------e: sa!ilty fuol ru!oft da:a
uterchange -el H.lel c OOSUflllÍIOO 11dic a~r ( A 1p10 )
EFP ectuator
(M1611)
~
---{>
-1 stiftpout re!Bid s~tthover\'Bo'vo (Y3/ 3)
Healad oxygen 4
~
Oxyg011 sensor SI !Jlal Dlegic'SIIc sccl<et, 9-pll'l { X11)
sensor (G312)
- - - ~- . ... ___ ......

Faul _JTestc~ng lor díagnosís, 38-pm (X1114) 1
memory
Fig. 455: ldentifving Influencing Parameters At Control Unit- Engine 104 (2 Of 2)

Mercedes-Benz
B. Engine 119 (except [g] , ~)

Mercedes-Benz
Engine 119~
Mercedes-Benz
Engine 119 @
~
SlaliBr, Hot W'l e fuel l ftadlon \illlv'es
temunal50 l\.H, Y62)
f-t>
Pcwel gtound (V'/15),
o!o~ JOOICS ground
~ re-
Ba~&JY {G1) (W 1511) SUppt{ daga AJr mass sonSOf'Aith
he~ WJre(82!2)
anddaELl'l!ng
f-t> oornrcl f-t>
Vobge Sllpptf, rormnal
Basemodu'a lOU-i. e7l, ai'U-1
(N1611) -(::> re- Base module
4TNSI!Jial 1~
(N16/1)
e oolart tompernture Coo!anlt91Tl''Mil~ro 51!1191

sensor {81112) -e re-
HAlr l'lj()cbonralay(K1 7)
Hotmeutal<e mr
tempera'ue SOOSOf
(817/7)
-el ktake a. temperatura
Slg¡tal
~ HFuelpu!ll>S ralay(l<27)
Hot
HOxygoo sensor hoator
Alr mas s sensor 'M~ h1:t kltakeS~r t811l>8fa'l.lre >\Ira

0\lrB (8212)
----(:::>
sgnalood au mass SJ!11al
re- (LH) cCit.ra.l
un~
(N311)
~Reganll{mOO swtchO\I!t(VfiÑ8(Y5811)
Dlrta 11torchange (CAN,

HCamshalt trmng artuator (Y49)
~
EZl 1gnb on rortrol uni seeGr 15)
(N1!3)
f-t>
EZI. agn¡ton conlrol unt

EFP romo! unl (N411), ~a 11terchango
(N1B)
TPM cof'trolml {Nil/3) D ala artarchenge
----(:::> (se-eGr. 30) ---{;:
(CAN)
f-e>
EFP actua!or(M1M) _j-.c, re- ~EFP ron•olunl (N4/1)
Heat&doxyge-n sensor
H ~ SWJichoVII{ vaM3 (Y27)
(G312) Oxygen sensor SI gnal

--D f-1> HFuelcOOSIJ!1llbOOI'Idic:e:Or (A1p10)
Ol¡;gno sbt morue (N 59)

tamp
CHECK ENGI\E wamng
~Sfíiltpoirtrelards'l>ilrhovor 'Y!!Na (Y3/3)
---o (A1o26) -e
1
- !Data 11tarohange {CAN) 1 _ ,Oie!11ostk sod<ei, 9-Pil {X11)
f
1
AFI!lBdOO requeSl
1
-e
ARF reques!
FaUl _,Te"l:tccuping fof cb90(lSIS, 38-ptn o<1114)
m emofy
1
Mercedes-Benz
Engine 119 [g]

Mercedes-Benz
ISlarwr , 1LH ilolir¡edon VaNaS (Yó2)

,terrmnaiSO 1---i> 1
Power ground {\N15),
1~ olec..oocs ground
Battary(G1) 9.lpptf daga and
---{> ~~ mass senson1tth
(W 1 ~1 ) dearing coo!rol hol 'Mf& (132/2)
--{> --{>
Vo:tage s~, teJmllal

Base modtei(N16/1) lOLH, 87l and 87LH 81i1S91T1cdtl! (N16tl)
---{>
1---{>
~TNSignal 1--t>
Coolart tempernturo
sensor {81112)
Co-olallt lol'l'p«!ñ:Jre Slgtlal 4~rll,edlonrolay(l<17)
--{> ---{>
1
_ ,FtJ al puflllS relay (l< 27)

lrtake aJ: tamp"Sratue lntake aute~ allre
sens<lf (81717) --e S'!lJ'Ial -D
_ , Oxygen sensor ooaler
KAT thermocoople(816/ 6) R~Slsta.m e, cataMJc

ccrr•erter overheamg -1fa!at¡¡11c
(A1e19)
coruelter owrhflalllgw.amng lamp
--e: coorol tnt(N58) --{)
Hot
v.&re conlrol
l.llíl -t>IR&g:ollllll.IIIOO S'fllldloV!If VBMJ ty5811)
LH reSJstBllt e tnmrnng
pkl¡¡ lR17f2)
Fuel l[fedion map
~ adaptaoon ~
(LH,
N311)
1
_Jcamshañ tlrmn¡¡ actuat0{5 ty4911, Y49/2)

1
Intal< e en terrperallre EZL tgnilon cortrol umt

~r maS's sensor >Mih ho1
Sigila! e.nd air mass Stgnal {N1 /~)
'Mil! (8212)
-(> -(> Data ll'ltolchanga
(CAN)
1-i>
-[::>
8odJoniC & cetera!Of
TN SI!J!lal, c.amsh~ p"9<fal COI'ilolurl! {N<l/1)
EZli!J!lilon romo! 1.11t
(N1f3) --{>
s ~ r SIQil al and dala
ut erchange
--{>
re-
1 Fuel conSl.lmpbcn indicaiCl (A1p10)
1
BactroniC acc,olaralor ldlo spe ad c'Ofltrol, data
pooal comol IJ"It (N<l/1¡, uterchange 1despeed
-e ecognbon oodcortaclfcr Shlt pout re:ard S>Mix:hovef llaNeoiY313)
sa."uty fuol rulolf -1>
---{> -ci!Jiaglosbc sockel, 9-Pil (X11) on'off rallo oo~l

Bectromc accoleralor
padai{EFP) actualor 1
(M16l1) ----{;>
4/IW S'i\llldlo'/ BrVaNs (Y27)
H Oxygen
~
sensor si!)l'lal
' Oxygen soosor (G312) 4:estc~ng lor (iag.nos1s , 38-pl n (X1114) pulse
- ~ --~- - ---- - readoo
Faul
memor;
Fig. 458: Identifying Influencing Parameters At Control Unit - Engine 119 (2 Of2)
Mercedes-Benz
C. Engine 120 (except [g] , ~ )
LH control unit, left bank of cylinders (N3/2)

Mercedes-Benz
~
S!artllf, l d lH i.lelll'f&Cton vaM!s (Y63),
!OITTillml50 ~ders 7-1 2
-!>
P<l'.ver groond (W15)
~
Battsry(G1) lll&t tones ground
{W1511) -{>
SUpptydaga arod Lelt au mass sensor
Wilh 11ot wn {8213)
dean~ng
con!tol
Base modi.Ce
(N1611)
l VOI:age StJ~, mminal
30U-i,87l and 87lH
-e;, l-e>
~ -!>
Basemcx!!!e (N1611)
-t>J TN srgnal 1~
l ~ ccclEHt tompernlur e
sensor (811/9) Coolant ta!TpOral.lro sagnal
~ --i>
lollltllke a~rterrpera~re
sensor(B1715) lntake mr te~ iñ.lre -t:>IFtJelpufl1lS re1B'¡(K2711)
Slgllal
~ -{>
1
LO: CO~emometer leltho! _,Ol<jgan son sor h&a!er
~
(R33/1) \\Ira
4M1>ture ade;ptabon
{ody 111tlet!K AT) llHl
con7o1Uflll
(N312) -{>'Le: rageneraion s.v~chover vf!l.fe {Y5812)
lel LH reSISl~K e Fuel 1rjeál Of1 map

twnmllgplJg(R17f3) --{> ada¡lllll!on -!> -!>lll!A camshalt bmng edualor (Y4911)
1
lel BT mas> sensor wdl lntakeBJr lerrpera:Ure
hol wn (B2f3) s¡gnala.nd en mass sagnal
--e- -!> l olt EZl. 1gnt on ccnirol
unit(N1/4)
Dala Jn!Ofthange --{>

TN S !gil al, camsh~
Lo~ EZl tgnóon cortrol sensor S!gflala.nddata -!>
urd (N1/4) tltoiC hange Elel:ronc acceleralot
--e- -!> -{>
padel corrtrol m il (111411 )
lolt lH coruct un;tcodllg

IGrOI.IlldW15.'1 1--(> -!>
lo! diagnosbc sockel, '9-Pil (X11/2)
-e;, ooGI rallo ct.Cp!Ji:
EJectron;e accoleralor kle sp.ee<:t con:rol,
pedalcoruol tl!llt (N<I/ 1l data iltarchall ge,
-{>
1dle speod rec09f1ibon arod
comact for sa!etyfuel
cttcf -t>
8ect!omc a~celeralor
pedal (S:P)Ielt llrtualOI
FINA
(M16.G)
--e- memory ~Testcot.ptnglor <iagnosiS {X11f4)
p\tse raadoul
l<~A oxygen sensor

-i>IOxygoo sansor ~gnal
~
(G3/3)
Fi&. 459: Identifyin&Influencio& Parameters At Control Unit - En&ine 120 (Except)

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Eletlronc acceloralcr
--i> pedal cortrolmi (N411)
TN 51!J1al, camshafi
sensor stpnal and da!a
Rlgtt EZ1.1g11bon corool ll!!!Cchangi!
1111 (N1/5) f-r;
4FueiCOOSUITJ)ÓOO 11cjcamr (A1p10)
Electronic EKcelela!or kt& 5P81ld COOIJol,

pedalcomot tnt (N411) stíll pcirt relard s~Cl:hover vatv'o {Y3l3) (orty
data 11!erchange, KAT)
----{::
r<le speed recognilon and
cortad for safetyfuel
ct.t:of
-{> 4Rlgttdia!J10sic socke!, 9-pln (X1113)
Rlgtt olecrom oriol rabo oúpú
ac<eler!llof pedal (EFP)
aduao!or (M16í<l)
----(:;>
RIQit oxygen IOxygen sensor 51~ ~Test c0\4)1ng lor di8!J10SIS (X1 114 )
sensor {G314) ptjse raadoul
Fig. 460: ldentifving lnfluencing Parameters At Control Unit- Engine 120 (1 Of 5)
Engine 120~
LB control unit, left bank of cylinders (N3/2)

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~
S!ar!Br , l&2 LH ilellfl&eioo valv!ls {Y63)
termmal50
r-e. tylrlders 7-12
Pcwer ground (W15),
~
Baltllry{G1) elochn es ground
(W 15.'1) ro ~volageand
de&lllny con rol
lelt llll mass sensor
witll hot '~otro (8213)
1~ -t>
Vo!mge supply, IBrmnal

Basemcxiie
(N16f1) 30lH ' 87l arni87LH
--(>
~
L el coolert (Ompere\ur e
S811SOf (811/9) Caolantterrpera':!Jre S~Qflal
---{>
~
Le:t llltako llll tosrpere!ure

sensOf l51715) t nal<e an t~a'llre HFtlelpurrps relay {K2711)
----i> SJgnal ~
~leko rur tElSTpOfa'l:Jre leftho! HOJ('fgen soosorhoater

LeA lllr mass sensor wih s~gllalend ar mass SIQilal <'.!re
hot w:re (82/3) -----D ~ (LH)
conrol u11t
(N3f2) r¡l~ regenera~ en swtchoWI valva {Y58f2)
TN signa!, camsh~
le~ EZL I!Jf11l on corno! soosor signalanddata
tni(N114) iricrc hange f-c>l lel camshattomng actua101 (Y4911)
--t> ~
1
1~
left EZL 1gn¡lon cont;ol
IGrotindW15.'1 Ufl.t (N1/4)
Da'!a uterchange
(C,o\J\1 )
f-1>
Elearomc. ac~olem\01
~cOftrol mt(N4!1) ltte spoed coorol, data ~ Elec~Olllc at<·elera:O.
"-e> n'icrchange, Kili speed
r&c-ognlion and cortatt for f-e. p9def cortroiiJflll {N'II1)
sa;etv tuel wtolf
Rlgit el&elCOI'IC f-e:

acre!era!Oc' pedal {EFP)
actuatOf {M 1613)
--(>
l e!l áagnoslJc sod<et, 9-pc¡ {X11f2)
1-D on10: rabo otipt!
~
leA heated oxygen soosor Oxygen S9!1SOI51gnal
(G313)
Hte• ARF ~-vtdlover v&\oe (Y27!2)
Dlagnoslie mod!te (N59) CHECI< ENGI\E wamng 1
lamp {A1&26)
-{>
~
Oata Ílt&cchanga {C,o\J\1)

 2
On modell24.034 ¡gj , ~ , to enable the catalytic converter to heat up more rapidly, the 1 --> 2
upshift in the automatic transmission is retarded at a coolant starting temperature <40 oc as
follows:
• After a speed of 8 kmlh is exceeded for 8-13 sor up to max. 38 km/h.

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This is controlled by the LH control unit and the 1st gear starting off relay (K29/l ). The 1st gear
starting off re lay is located in the relay and fu se box in sector "E".
Fig. 495: ldentifying 1st Gear Starting Off Relay
2 -> 3 (only KAT version)
To enable the catalytic converter to more rapidly reach its operating temperature in the warming-up
phase, the 2 --> 3 upshift at idle speed and part load in the automatic transmission is retarded
between a coolant temperature of O oc up to 50 oc for not more than 15 seconds after starting. The
engine thus revs ata slightly higher speed before shifting up. This is controlled by the LH control
unit and the transmission shift point retard relay (K29).
Fig. 496: ldentifying Transmission Sbift Point Retard Relay
The control unit (N3/ l) actuates the switchover valve (Y3/3) with ground depending on the coolant
temperature, vehicle speed and time. The vacuurn element at the transmission is then pressurízed
with vacuum through the switchover valve.
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Model 140
o
d. Camsbaft adjustment (inlet camshafts)
The inlet camshafts are advanced depending on engine speed and load in order to achieve favorable
engine torque over the entire speed range.
An actuator is fitted to the camshaft adjusters which opera tes the control plunger for the
hydraulic/mechanical adjustment. The actuators are controlled by the LH control unit.
Ifthe actuators are operated, the inlet camshafts are advanced. The adjustment depends on engine
load and speed. If the selector lever is in position P or N , the adjustment is dependent only on
engine speed.
Engine speed Position of camsh aft

< 2000/min retarded (1) retarded (l) retarded (l)
> 2500/min advanced <2) advanced (2) advanced <2)
2000-4200/min - advanced (2) -
2000-4400/min - - advanced C1)
2000-4700/min advanced (l) - -
>4200/min - retarded (l) -
>4400/min - - retarded (l)
>4700/min retarded (l) - -
more than 250 km/h - advanced advanced
(l) Selector lever in Drive mode and average load.
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(2) Shift point is advanced at 3000/min in selector lever position P/N.
e. F uel cutoff in tbe event of ignition faults
To prevent the catalytic converter overheating as a result ofuncombusted fuel ifignition faults
exist, the ignition faults are detected by the EZL ignition control unit and signalled via the serial
databus (CAN) to the LH control unit. Depending on the type offault, either the fu el for the
cylinder in question (cylinder-selective) or for the cylinders ofd1e ignition circuit in question are
switched offby the LH control unit.
Cylinder-selective fuel cutoff
Misfiring is detected by means of prin1ary monitoring of the combustion voltage and combustion
time ofthe ignition spark and the fue) for the cylinder in question is cut off. Once rnisfiring no
longer exists, the fuel supply is restored if engine load has dropped below a certain level (throttle
valve almost closed) and engine speed has exceeded 2480/min (see Diagnosis Fault Memory,
Diagnosis Manua] Engine Volume 2).
lgnition circuit fuel cutoff
The following ignition faults are detected by monitoring the primary current:
• fault in output stage in the EZL ignition control unit

• fault in ignition coil and open circuit mwiring.
If these types of ignition faults exist, the fuel to all the cylinders of the ignition circuit in question is
cut off. The ignition faults are stored in the ignition control unit (see Diagnosis Fault Memory,
Diagnosis Manua~ Engine Volume 2).
f. ldle speed control
The idle speed control is operated by the electronic accelerator pedal control unit (N4/ l ). The data
required for controlling engine speed are supplied to the electronic accelerator pedal control unit by
the LH control unit through the serial databus CAN.
g. Electronic accelerator pedal
For operation ofthe electronic accelerator pedal see Group 30.
h. Diagnostics
The LH control unit feantres the following diagnostic facilities:
l . Diagnostics with fault memory
Faults which occur when the en~!ine is ruru1Ín!! are counted bv a fault counter.
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Such a fault is not stored by the fault memory unless it still exists after the engine has been
started 4 times.
Tbis avoids faults, wbich have only occurred once for example, being stored. If a fault occurs
less than 4 times, the fault counter is erased again after a certain number of starts. Faults
which prevent the engine starting or severely affect engine mnning, are stored immediately.
The fault memory is not erased when the battery is disconnected.
The stored faults can be read with the pulse counter at the diagnostic test coupling (Xll/4)
(see Diagnosis Manual Engine Volume 2).
¿Danqcrl
The engine must not be mnning and the ignition must be switched on in order to read the
fault memory.
Fig. 498: Identifying Diagnostic Test Coupling
2. On/off ratio output
Operation of the lambda control can be tested and non-stored faults wbich occur only
momentarily, can be detected by means ofthe on/offratio.
A distinction is made when reading the faults between "ignition on" and "engine idling" (see
Diagnosis Manual Engine Volume 2).
1. Emergency running program (plausibility circuit)
The LH control unit features an emergency mnning program. All the input signals are continuously
detected.
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substitute value for the implausible signaL This ensures that the injection system continues
operating practically fault-free.
If, for example, the coupling is unplugged at the coolant temperature sensor when the engine is at
normal operating temperature, the control unit detects the interruption and switches over to
emergency running mode. A slow chauge in a value is only detected by the LH control unit once
the value is implausible.
J. Data interchange vía serial databus (CAN)
Engine 104 and engine 119 (except ~)
The LH control unit (N3/ l ), electronic accelerator pedal control unit (N4/l) and ABS/ASR control
unit (N30/ l) as well as the EZL ignition control unit (Nl /3) are interlínked by a serial databus
(CAN).
CAN= Controller Area Network
The control units are interlinked in parallel by two wires.
Ibis enables additional sensors as well as inputs and outputs to be dispensed witb.
Data transfer is performed constantly in inforrnation blocks. What one control unit transmits is
received by the other control units, and vice versa.
In tbis system, the control units receive only the data whicb they require. Important data are
handled on a priority basis (see data which are transmitted vía the serial data line).
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~N 113
N3011
N411
Fig. 499: ldeotifying Data Interchange Viia Serial Databus (CAN)- Engine 104 And Engine
119 (Except
Engine~
Engine 119~
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~N 113
N1f3 EZ1...1grabon coctroh n t
N3/1 LH cMrol uril
N4/1 Eladr<10c acc o!crator pedai{EFP) <Oflllolunt
N3011 ABSIASR roruol m it
N59 Ou;gnost c modU:e
N3011
N4/1
N 59
~N 3/1
Fig. 500: ldentifying Data lnterchange Via Serial Databus (CAN)- Engine 119
Engine 120 (except ~ )

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oN 115
N1/4 Li!lt E ZL IQI'Ibon corool trit
N1/5 R!QhlEZltgriionoon..olurit
N312 LeftlH cotúol tnt
N3ll RlghtlHconrcluflJI
N3/3
N411 Electronc acceleratorpedaiiEFP) con..oluflt
N3011 ABSIASRcortrolooi
NS/2
N411
N30/1
~ N114
Fig. 501: ldentifyiog Data lnterchange Via Serial Databus (CAN)- Eogine 120 (Except
Engine120~
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¡¡~ N 116
N1!4 leltEZl i 9fllbon ccmol urlt

N1/5 RlghtEZl l 9flli onconlrolunt
N312 leltlHcomclmt
N313 R¡ghllH rolli"ol Uf'll t
1 N313
N411 E~drOf'ic acc elera'loí pedei{EFP) conro1 u11t
- 1
N3011 ABS/ASR c"Oñrol umi
N59 Dlagoosác mcdtte N312
----'- ~ N411
r---- 1 N30f1
- ...111
~
H69
- =Q N1f4
Fig. 502: l dentifying Data l nterchange Viia Serial Databus (CAN)- E ngine 120
Data which are transfer red via the databus (CAN) (except ~)
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EZL ignition control un~ (N1/3) Electronic a ccelerator peda 1(EFP) lidie
speed control una (N1/4)
trans ers trans ers
r------------------
1• engine speed • selector Jever posit!on'
1r------------------- -----------------~
1• load value Um~ 1• Economy/Standard (SIE) 1

1· KAT heatíng 1• momentary slip control 1
l. transmlssion overl oad protection on 1• throttle valve actual vaJue 1
1 1 1
1• ignition angle advance 1• lhrottle valve specified value 1
1• transmlssion switch in gear 2 1• road speed signaJ 1
11· ignition fau lts of respective cylinder l•
1
KAT heatlng on
• intake manifold absolute pressure 1• idle speed
1• full load
l•
1
Tempomat cruise cortrol on
1• stop lamp switch on
1• emergency runnJng mode
l• maximum speed
11• throttle valve compulsoi!Y ctosing
1
1 1
---------------------------------ó----· ~---~--------------------------------·
1 to 1
1 LH control unit (N3/1) 1

trans ers
r-------------------------,-------·---'--·--·---------------------------------
lt long lnjection time 1 • cortrol unit recognitlon
l• short injectíon time 1 • KAT heating
1 • air througl"plJ limit
• exhaust gas recirculatlon
• air pump
• decel fuel cutoff
• camshaft adjustment
• transmlssion shift point retard
• accelera tion enrichmert
• end of startíng
• regeneration
• ooolant temperature
• air throughplJ (air mass sensor)

• intake a Ir temperature
!._ ____________ - - - - - - - - - - - - - - - - - - - - - - - -- ------------------------------- ------·
o to
electronic accelerator pedal 1 JEZL ignitlon control unit

l(EFP) control unit 1<-l-------'-------C>I~ (N1/3) 1
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Fig. 503: Data Which Are Transferred Via Databus (CAN) (Except- Diagnostic F low Chart
Data which are transferred via the databus (~)
Shown on engine 119

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EZL ignition control unlt ~ Electronic accelerator pedal

(N 1/3) controll.llit (N4/1 )
.____-,.-1- - '1 1
1
tra nsfers transfers transfers
r----------~-----------, r-----------~------------1 r---------~----------,

:• englne speed :• selector lever posftion : 1•
1
air injection
•
1
1
:• load value llmit :• fueJ safety cutoff : : dlagnos1s request :
l.
:•
1
1
1
1
KAT heati'lg
transmission overload
protection on
1•
:.
1
:•
momentary sip control
throttle valve actua l value
throttle valve specified
:
1
:•
:
:
eXhaust gas
re circolation
diagnosis request
L_ ___________________j
:
:
:
:• ignition angle advance : value

:· transmission switch In 1• road speed signa!
l.
1
1
1 gear 2 : :. KAT heating on
1
ignftion fa ults of :. ldle speed
1 1
1 respective cyllnder :• full throttle
1
:•
1
lnta ke manifold
absoklte pressure
1
1• Tempomat oruise control
1 1
on
:• 1
l:.:•.
altitude pressure
1
• warmin g-~ stop larnp switch on
1 1
1 emergency runnng mode
1 operating 1 1
maxirrum speed
:.
1
throttle valve cornp!Jsory
1 closing to
1 1
1 l. specifted engine speed
: l.
1 1
1
1
l.
1
idle speed contaot swtch
throttle valve position
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
1 1
1 1
1 1
1 1
1 1
1 1
---------- 1 -----------~ ~ -----------l------------·
to to
l •
Fig. 504: Data Which Are Transfer r ed Via Databus (CAN) (Engine 119) - Diagnostic Flow Chart (1
Of2)
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l
to
j ___________ _
i
t.o lo
Í,--¡~;~tl~n-ltl;;,-e-l~;g--f.---~a""nt~Í-~~ljld;~if¡~;-----~
r ___________
1• ABS/ASR not operating
1• ASR operatlng properly 1 For diagnost ic 1• post-start 1
l• Tempomat cri!Jise control l module l• eXhaust gas r ecrculatlon 1
!1t off
open throttle walve
1
• oxygen sensor 1' a1
•r pump 11
1 illl>lausible 1• decel fuel cutoff 1
1 slightly 11, 1• camshaft adjiUstment 1
1• close tlYottle valve
1
coolant temperature 1
sensor lmplausible 1t transmission shfft pont
• ignitlon angle advance 1 1 retard
operating • inta ke alr 1
1 lt end of starüng
1 tempera.ture sensor 1
1 illl>lausible l• regenera tion
1, alr mass sensor l• coolant temperature
1
1 irrn
. . .. lausi'ble l•1 load
1• limit for longtine 1• inta ke air temperature
i
1
adapta tion
exoeeded
!.
1
starter operat ng
(terminal 50)
1• fault in air pump 1, fuel safety cutoff
1 switchover valve 1
l• fault In exhaust gas l
1 recirculation 1
1
1 switchover valve 1
1• fault in regeneration 1
1 switchover vaJve 1
1• fault at ca mshaft 1
1 position sensor 1
i• fault in TN signal j
l' oxyge n sensor rich, 1
1 lean 1
1 1
1 1
1 1
1 1
l1 11
1 1
L___________________ l ___________ ~------------
~ -----------t------------
transfers transfe rs
1 1
ASR control unl (N30/t) LH control unit (N3/t )
f
Fig. 505: Data Which Are Transferred Via Databus (CAN) (Engine 119) - Diagnostic Flow Chart (2
Of2)
F. Diagnostic module (California version only)

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a. General
The diagnostic module (N59) is located in the module box. It is supplied with power from the base
module (N1611). Tbe color coding is violet.
Its task is to monitor signals and systems of relevants to exhaust emissions and, if a fault is
recognized, to signal this by means ofthe CHECK ENGINE indicator lamp. At the same time, a
fault code is stored in the fault memory of the diagnostic module.
NOTE: Reading fault memory, see Diagnosis Manual Engine Volume 2 and 3.
The data required for monitoring are supplied to the diagnostic module via the serial databus
(CAN) by the following control units:
• LH control unit (N3/ l)

• EZL ignition control unit (N 1/3)
• Electronic accelerator pedal control unit (N4/l)
• ABS/ ASR control unit (N30/ l)
(see also Data wbicb are transferred by the databus (CAN))
Fig. 506: Identifying Diagnostic Module And Base Module
b. Operation of CHECK ENGINE indicator lamp
The indicator lamp (Ale26) is supplied witb voltage by the base module (Nl6/ l) and controlled
with ground by tbe diagnostic module. As a check, the bulb lights up at "ON" and for up to 30
seconds atan engine speed of about 500/ min. If no fault exists, the dliagnostic module interrupts
the ground to the bulb. The CHECK ENGINE índicator lamp goes out
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Fig. 507: l dentifying Indicator Lamp
c. Operation of fault memory
The diagnostic module features a fault memory, the contents ofwhicb are retained even iftbe
battery is disconnected.
With the ignition switched on, data which are transferred via the databus (CAN) are detected by tbe
diagnostic module.
If a fault occurs when driving, e. g. in the LH fuel injection system, a substitute value (emergency
running function) is formed in the LH control unit, the fault registered and signalled to the
diagnostic module.
If a fault occurs during two successive trips , it is stored in the fault memory after the engine is
switched off and can be read wíth the pulse counter at tbe diagnostíc socket (X 11/4) or with tbe
push-button switch and the LED (SI) at the test coupling for diagnostic module (Xll/21). At the
same time, the CHECK ENGINE indicator lan1p lights up when the engine is running until the fault
has been rectified and erased.
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-----
Fig. 508: ldentifving lndicator Lamp
d. Checking operation of systems

l. Air injection
When the engine is running and the lambda control is operating, the LH control unit fust of
all checks the electrical functions of
• oxygen sensor
• air pump switchover valve
• air pump electromagnetic clutch and signals this to the diagnostic module.
If no fault exists, the diagnostic module transmits a signal to the LH control unit which
activates the air pump.
The diagnostic module checks whether the oxygen sensor signal is thus indicating a constant
"lean". Ifthis is not the case, a fault is recognized and stored as in section e "operation of
fault memory" and the CHECK ENG INE indicator lamp lights up.
2. Exhaust gas recirculation
When the engine is running at normal operating temperature, the LH control unit checks the
electrical function of the exhaust gas recirculation switchover val ve and signals this to the
diagnostic module.
lfno fault is detected, the diagnostic module signals during a decel fuel shutoffphase (all
fuel injection valves switched off) to the LH control unit to operate the exhaust gas
recirculation switchover val ve.
The diagnostic module checks whether this causes a change in intake manifold pressure (>20
mbar). lfthis threshold was not exceeded, a fault is recognized and stored as in section e
"operation of fault memory".
Mercedes-Benz
VEIDCLE FEATURES- RA0705HFM004X(07.5-0004)
Engine 104.941 104.942 104.943 104.991 104.992

KAT / w/o KAT / w/o KAT / w/o
Version KAT / w/o KAT KAT / w/oKAT
KAT KAT KAT
Modlel 202.028 124.008/028 129.058 129.063 124.032/052
124.029/088 124.066/092
Designation HFM HFM HFM HFM HFM
Compression ratio 10 10 10 10 10
Resistance trimmiug Inscription Inscription wbite Inscription Inscription Inscription white
plug wbiteHFMMS HFMMS whiteHFMMS wbiteHFMMS HFMMS
Coolant Intake Coolant Intake Coolant Intake Coolant Intake Coolant Intake
Temperature sensor
au atr au arr arr
Fault memory Fault memory F ault memory Fault memory Fault memory
Fault recognition HFMcontrol HFM control HFM control HFM control HFM control
unit unit unit unit unit
Accelerator
LLRLLR/TPM LLRLLR/TPM LLRLLR/TPM LLRLLR/TPM LLRLLR/TPM
control/ cruise
EFP EFP EFP EFP EFP
control systems
Air injection with KAT(l) withKAT withKAT with KAT withKAT
Exhaust gas
X X X X X
recirculation
Lambda control X X X X X
(1) As of January 1994 the air pump is no longer fitted with the exception ofthe following national
verswns:
~ llJ n::s==- eT ~AP ~ [g] Q)
Engine 104.944/994 111.920 111.940 111.960 111.961

KAT / w/o KAT / w/o
Version KAT / w/oKAT KAT / w/oKAT KAT / w/oKAT
KAT KAT
Model 140.028 202.018 124.019/040 124.022/042 202.022
140.032/033 124.060/079 124.062/082
Designation HFM PMS PMS HFM HFM
Compression ratio 10 9.8 9.6 10 10
Resi stance trimming Inscription white Inscription wbite Inscription
plug HFMMS
- - HFMMS whiteHFMMS
Resistance trimming
- X X - -
coupling
Coolant Intake Coolant Coolant Intake Coolant Intake Coolant Intake
Temperature sensor
alf Intake air au arr arr
Fault recognition Fault memory Fault memory Fault memory Fault memory
HFM control PMS control Fault memorv HFM control HFM control
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unit unit PMS control unit unit unit

Accelerator
LLRLLR/TPM
control/cruise LLR LLR LLR LLR
EFP
control systems
Air injection withKAT(l) - - - ~
Exhaustgas
X - - - ~
recirculation
Lambda control X X X X X
(l) As of January 1994 the air pump is no longer fitted with the exception ofthe following national
verswns:
~ [lj ~BT ~AP ~ ¡gj Q) ~ only
FUNCTION DIAGRAM- RA0705HFM0010X(07.5-0010)
A Engine 104 HFM
Complete function HFM gasoline injection and ignition system

Mercedes-Benz
P07-5691l-59
40 Oiaptregm ¡l(OS:Stf8 regulallr M1616 kle speed ccmol (lLR) aduetcr

55 Foellitllf N3.14 HFM collrol urd
60 Mcdlia!rlgpressurn vatUIJTlt.nl N30 ABS «llirolllli
75 Fuol tanl< R 16.5 HFM re51stance lmmung pkJg
CO IJ(l-:0n~cmeltlf l
2
76 Ventvalvll R33
77 Adva)}(! charcoal hler S 1613 stanerbcKOIJlandr!Mlrsrng laiTp S'Nich, seleciOI
lnvor ~osiion re! ~ion
~ EmaustgasreorcWi!Jol'l va."v'a(@ Q)@ 3
S65 Tmnsrmssron overiosd prole.tton swtch l
orty)
T1/1 lgnlboo cotl 1 (cylnders 2 and 5)
9:8 Vac II'.Jn alomen! ter std~ri reta;dl T1/2 lgnboo coi 2lcylmfers 3 and 4)
100 Vac~t.m elemenl S l!lld E moda
T1/3 lgrilioo col 3 {cytnders 1 and 6)
125 AUDIJ!TlD
lgnboo coi 3 (cytnders 1 and fi)
125 Anpump
Y3/3 Sh~l retard swicho- vat.re 1) 3)
156 El<haust mBl'ifold
Y4 9KilchoY!lf valva, 2nd tnmsms:s1011 modo
158 Calai¡Gc COO{ertor
Y22f6 Resooaoce utal<1l m!lllllold S'illichoverva'fe
A9 AC compressor
A16 Knock senSOfS
Y27 ARF swtchovet vat.ro ¡@> Q) @> Olly)'
826 Hot lilm an mass son sor Y32 Air llUTlP S'MtchGver va!\19
8 11/3 Coolart lllmperat!.re sanso( KE, HFM, PMS Y33 f"Jr punp electromagnebc c~ng
817 h!ake air tampar..ture sensor Y49 Variable mmsha=: lim11g a1:!lla:Dr
1
G3/2 Heatod O)(fg&n S&nSOf ) Y56f1 Purgng s~'lltchover vaM!
K17 Fuel pumprelay Y62 Fu&111¡ed!cn vatve
Mercedes-Benz
Fig. 509: Vehicle Features Function Diagram- Eogine 104 HFM
Basic diagram or distributorless high voltage distribution
~
z
R18/5
S17
U/1
A16 Knock sansors 565 TransmiSsíon oYBrload!lfotadon swtch 1)

811/3 Coolart lnmp13rmue sensor K E, HFM, PMS T1/1 lgnbon e ol cyinders 2 and S
81 7 nake en mmp13rarure sensor T1/2 lgn;!IO!l eol CV'nd9ls 3 and 4
LS Crankshal pog•on san50r T1/3 lgnbon eol c,tnders 1 and 6
LS/1 Camshaft po-s~on sensor X 1114 018900SIS ~kat(16-pln)
M 16í6 kJe speed cordrol actuator 1) ~thAGcdf
NJI4 HFM eomoltnt
R1615 HFM r&Sis!ance lnrrmmg plJg
Fig. 510: Basic Diagram Or Distributorless High Voltage Distribution
Comp lete function HFM gasoline injection and ignition system

Mercedes-Benz
AG
B2/5
P07-5432-57
40 Oiaplliagm PfCSStl'e regulallr L511 Carn stlaltpos~on sensor

55 Fuel lil81 M3 Fuel pump
60 Modllalll!Hlr BSS!Jre vat UlJTl 111ft M1616 kie speoo ccnrol (LLR) attuator
75 Fuel tank N3.14 H= M ecrtrol wt
76 Vontvao'Ve N30 ABS corool un~
n Adva':ed dlaccoal ft8( R 161S H=M reSis!ance lnrmnng ~9
156 Exha1J st m6111fold Rl3 CO poten•cme:er additr•e rnap adjusf11011 {IVJI:ho\R
158 GataMJc COIM!rter KATon~Jj
A9 AG compres sor S 16/3 Stader lcd<oü androv1llsíng larrp S'Nldl, seloclof
loV9l poSiiOO 18( 0\YltiOO
A16 Knock sensor
T1/1 lgrJIJon e oi 1 ¡cytndeiS 1 al1d 4)
825 He! ifn mr mass sonsOf
T1/2 lgnbon coi 2 (cytndar 2 and 3)
8 11/3 Coolarl tomp.em!ula sensor KE, HFM, PMS
Y313 Sllttpoot ratard swiá10'N valva 1l
8 17 W.ako atr mmpam!Lra sansor
G3t2 Haa!ed olr)'gan S&nSOf Y49 Ven able camsh~ lim:ilg eü.1e~
K27 Fuel pumprelay Y5Bf1 P\Jrgng swtá1over vaMI
L5 Crenksh~ po-s~lícn sensor ,,
Y62 Fuei 11¡ecboo vat•e
'Mih KAT al1d AG orW
Fig. 511: Vehicle Features Function Diagram - Engioe 111 HFM
Basic diagram of ignition system with distributorless higb voltage distribution

Mercedes-Benz
R18/5
111618
POT-5431-57
A16 J<nod( sensor N314 HFM c<lrtrol mt

8 1113 C<lolalt lsmpemture senso; K E, HFM, PMS R4 Spari< plJgs
8 17 lrtake au tsmperatue S8/1S<lf R11l15 1-FMreSistarn:elllmmng Pkl9
LS Crenkshalpo.-s~1on sensor T1/1 I!Jiboo e<ll c:yjndiiiS 1 and 4
L511 Camsha!tposilon sens()( T1/2 lgnbon c<lil c:ytnders 2 and 3
M1816 ldle speed c<lrtrol ectualor X1114 Dlagnostíc sod<et, pt.fse Slgna1(16-PI1)
Fig. 512: Basic Diagram Of Ignition System With Distributorless High Voltage Distribution
C Engine 111 PMS
Complete function PMS gasoline injection and ignition system

Mercedes-Benz
S1ll1
X11/4
A1p6
P07-5505- 57A
36 TherfTIO.V&Ne (Gpens at 70 •e, dosa.s a1 35 'C) for LS Cra.nkshll2 pogtion sensor

luel e'«!pOJaSonc>en~cls:ystam M3 F ualpunp
40 Oiapllragm pressure r&!Jllalor M16/6 ~<te speed codrol l!..l.R) actualor
41 DI apm¡ gm pressure damper N315 PMSc-ontclunl
51 Purge 'V!Wo N4!3 Tempoma! muse cortrol (1Pfv1:Jillespeedcor0rol
55 F uel iler {llR) codrol uni
50 Mo~amgpressure \'BCwm ll!'lt N6 AC compres sor shtiolf cOftrol util
75 Fuel lank N30 ABS c«troo OOil
76 V9llt va!\le R4 Spatkplugs
77 Adva~ charcoal filar R16R Referonce resastor
82 V&wm P'P8 topressure sensor Qrtake manlold R33 CO po!aniomo!sr a"d<itrvo map a~stmonl
praswe) 5211 lgnbon!Startof SIM!th
156 Exhaust m anfold S16f1 Starter lod<Otli and revllf smg larrl) swich
156 CataMíc converter T1/1 lgnbon e oj 1 {cyirnlers 1 and 4)
159 lriake moofold T1/2 lgilbon coi 2 (cyim!ers 2 a:nd 3)
A1p5 Rpm sensor W 14 Gfoond, hyd(aúlc lllitmW'I~ng bracklll
8 11/3 Coolalt temperatura sensor KE, HFMIPMS X4f10 Te1rnínal blod< ttii1Tllllel30flei!Tilllal61
8 17 lriake 811 tomperallse sa1150r batoofy {3-Jlll)
6312 Heated oX{gen sensor X11í4 Te~ cotC)Ing for <iagnoS~s, pulse Sl~al (1 ~n)
K3f1 Par,allllal<e mlll'llfoldpreheamg{PSV) relay
X12G TeiTllmal blod(, mrmnal 15/15urrusoo {3-pCJ)cPSVl
K27 Fuel pumprelay
Y62 F ualll¡ed!oo valva
Fig. 513: Vehicle Features Function Diagram- Engine 111 PMS
Basic diagram of ignition system with distributorless high voltage distribution

Mercedes-Benz
R1GI7
D ~
- Si
z
M11Te
81813
~~------------·
Kl1$
82 Vocuum ~a toptassure sens()( R16/7 Rasrslance nnrn11g eo~

8 1113 Coolart rornpernlu'e sensor K E, HFM, PMS R4 Sparkpklgs
817 rrtaka au temperatura sensor T1/1 lgn.bon coi tylndels 1 and 4
LS Cmnkshal poSiion sensor T1/1 lgltbon coi cylndm 2 and 3
M16/6 lela sp~d c'Oftrol aduat()( X11J4 Diegnostic sod<et{16-pln)
N:W PMS con'lolunt 5 1611 Sarter lo.d<OIJ! and rowrsmg lanp switch
Fig. 514: Basic Diagram Oflguitioo System Witb Distributorless Higb Voltage Distribution
LOCATION OF COMPONENTS- RA0705HFM0015X(07.5-0015)
A Engine 104 HFM
Mercedes-Benz
P07-'6679-61
A16 Knock Sl!llSOJS T1/1 lgnbon col1 (cyind9Cs 2 and 5)

B2J5 Hot ilrn au mass sen sor T1/2 lgrlbon coi 2 (cyind9Cs 3 end 4)
8 1113 Coo!arll tempecallJr a S !II'ISOC KE, HRM, PMS T1/3 lgnbOil coi 3 (cyincf91S 1 9l1d 6)
LS CrMkshat poS! ion sOflsN Y2216 Resooanr e 1riako man¡fold sNichcwor vatve
LS/1 Camsl1att fXlSilon sensor Y27 ARF sNichoWJ valve ¡@0@ oo'y)
5 1613 Staltork>ckoot !llldreWfSing lanl> swich, selecmr
~erpoSiionracogn•on Y32 AJr ¡punp sMtcrovor valva
S65 TC!IIlsrniSSion o'Vl!floaclpro:Ocion s.-ách 3l Y33 AJr IP\JllP elodromagnebc c~ng
Y49 Vanable camsl1&1 tm111g at:b:J!ólr
Y62 J:ool ltl¡Mbon valvas
3
) "'!th AG oliy
Fig. 515: ldentifying lgnition System Components Location - Engine 104 HFM
Mercedes-Benz
Models 124, 140
Comp onents in engine compartrnent
POT-sti55-S7
817 ln!a!<e atr tsmpem!ue SEII1SO( PUrgmg w.ltchover vaM!

G3/2 Hllated o~on sensor 11 To actNaledcharcoalhl:llr
S40/2 Wd1pedal sNtdl 21 Toeng¡na
wth t<AT orfy
111th MG Oft.¡
Fig. 516: Identifying Ignition System Components Location- Models 124, 140 (1 Of2)
Comp onents in engine compartment

Mercedes-Benz
P07-50S~57
K112 Ovew~ proledloo relay CO pc:Sn•cmetsr addítrte mep adj!ls~ont2l

K27 Fuel punp r elay Shlitpoot rotllfd swxctu:wor vetve 1l
N3."1 HFM corf.rol m1 Te~ rot4Jing for diagnosas
R1515 HFM r&Sistanco tnnmmg ~ wth KAT e.ml AG or;.¡
'<'.!th ott KAT oo'y
Fi2. 517: ldentifyin2 I2nition System Components Location- Models 124,140 (2 Of2)
Model129
Comp onents in engine compartment

Mercedes-Benz
POT-6386-57
K 27 Fuel punp relay R33 CO po!.entcmelDr adcibve map aqusinert 11

N314 1-FMcomoh nt W27 Groond, m<Xlle box bracket
N4/3 Tompoma! aurse toruol (TPM) coo~olurwt X1tl4 Test couping for <iegno5ls, pulse signal
N1611 Base modle (GM) Y4 SNitd'lover valva (2nd dmtng mO<Ie)
R1615 1-FM reSJstance tnnmmg ~ Y14 En!Jlllo speed s!abil:zabon S'Mtchcvor vaM!
Y313 Sh"POOt retard sw)d'loVIlrl v!We
2) v.~ttroú KAT on.'y
Fig. 518: ldentifying Ignition System Components Location - Models 129 {1 Of 2)

Mercedes-Benz
P07-6l87-57
6 17 1/iake eir blmpOO!turo sooSOf Purgang S'Mtcllover 1/aMl

1
G3J2 Heruod oX)Igan sensor ) To arovs1&dcharcoalfilar
S<I0/2 Ckim pedal sw·am 21 To eog~no
'Mth KAT ortj
~"th MG orto¡
Fig. 519: ldentifying lgnition System Components Location- Models 129 (2 Of2)
Mode1202

Mercedes-Benz
POT-5952-57
K 1/2 OVow~e ¡Jfotadloo relay87EI87l/30a (9-pm) Test c~lng lor áagnosis, ptfse ·síg11al {38-ptn)
1
K 17 Au •fli!áloo relay Sllftpoot retald swtdlovor v!We )
K 27 Fuel punp rel~r( ~~otth KAT end AG ort.¡
N3J4 Hot n n ang¡no manegemmt (1-FM) cortrol unt l'otth MG ort.¡
R16f.i Hot Un angnemenagemert (HFM) reSistance
lniTITilng pkJg
5 40/2 ldlo speed cortrol (UR) cl.tdl pedel swtdl 2l
Fig. 520: ldentifyiog lgnition System Componeots Location - Models 202 (1 Of 2)

Mercedes-Benz
P07-59S3-S7
nal<.e au tampereue s oosor YS811 Purgmg $1\!lchover va,w

Heaied Olt)'gan sensor 1) A To arova!edchatt:oaHiter
~ltl KATort¡ B TOeotJM
Fi~. 521: Identifyin~ I~nition System Components Location- Models 202 (2 Of2)
B Engine 111 HFM
Mercedes-Benz
P07-5929-&1
A16 Knock sensoc 5 16/3 Start9flocl<ott andreYillsmg lwrp swtdl, seleclor

82!5 Hot n n ar mass sensor ~varpaSiionrecognion
8 1113 Ccolatt IDmpoo;tae senSOf KE, Hft.l, PMS 565 llllfiSITUSSIOO o\lllfloadpro!Bcion swtdl
817 lrtake !llrlempemtule sensor T1/1 lgRbon ( ot 1 (cylnders 1 and 4)
G3/2 Oxygen sensor upstraam of KAT T112 lgalion c0112 (cylinders 2 and 3)
LS Crenks.ha1 po51lon sensor Y49 Van:able camsha11imllgaci.laix
L511 Camshaíl posbon sensOf Y62 Fuef 11¡eá!On Vlltoies
M 16/6 ld!a spaed romol (llR) aduator
Fig. 522: Identifying Ignition System Components Location- Engine 111 HFM
Model 124
Mercedes-Benz
P07-5928-61
17 fuel rall
6 17 IJteka Blr I!Jmi>emlurO Sl1flSOf
40 DI aptregm press!Te regulam
625 Hot ltn au mt~SS sensor
G31Z Heatoo oX¡tgan sensor 1 )
K3l1 Par,allllake m8111fold preh!labng (PSV) reley
Y5811 Purgmg S'Mtcrover vaM!
Fig. 523: ldentifving lgnition System Components Location - Model124 (1 Of 2)

Mercedes-Benz
POT-56~57
K1/2 Ove¡yoltage PfO!ettlon rQlay R33 CO po:Sntomelef addiiiVe map aájw_,ent {'f'li11out
K27 Fuel piJTlp r illa'f KATontv)
Nl/4 HFM eottrol mt X 1114 Te~ coq¡lng for diaQflCSIS
Y3J3 1
R1615 1-FM resi~ance tnnmmg p'-'!J Sbllpoilt retard sNichOWf V!We )
1) lt\lth KAT and AG or;.¡
Fig. 524: Ideotifying Igoition System Components Locatioo - Modell24 (2 Of 2)
Model202

Mercedes-Benz
POT-5951-57
1<112 OvoN~go protadlon rol8¡87E .67t/30a (S{Hn) R1615 Hot ilme engmo managemont IHFM) r&sislailce
K27 Fuel PIITlPfBI!rl tnrmung plJ9
N3.14 Hot Un eng¡nemanagemert !1-FM) cortrol llli X1114 Te~ coq¡lng for tiagncsrs, potso flgnal (38-ptn)
Y313 Shiltpoot rotacd swtdl0119f vaNa )
Fig. 525: ldentifving lgnition System Components Location - Model 202 (1 Of 2)

Mercedes-Benz
POT-5950-57
825 Hotitn au mass sensor Y5811 Purpng s>Mtcilover vatve

17 Fuolrell A To actJvatedcharcoalfii:Bf
40 Oiapl'mgm jl{OSSU"O regula:tlf B To BO!JOO
817 k1ial<e au tBmperatu-e sollSO(
G3f2 Hea!ed OXfQOO SOOSOJ 1)
Fig. 526: Identifving Ignition System Components Location - Model 202 (2 Of 2)
C Engine 111 PMS
Mercedes-Benz
P07-6678-57
39 Ther~va.We {apeos al 70'C, dosasat 35'C)tor 8 11/3 Coolait I'Bmperature sensor KE, HI=M, PMS
luel BYCporaícn roniol sys!&m 817 lriake au llimP«atU" e sensor
40 OtaplmQill pressu-e regula:Dr LS Cra.l'lkshei pcs;t cn seo sor
41 OiaptfaQill ¡Jfessu-e damper M15/6 ~e ~eó eamrol (lLR) actuator
Arrcw SolenOKI at ltf!llOel S&!Jllern Klr recognmg IQillbOn T1/ 1 lgn¡boo coi 1 (cytndars 1 and 4)
cin:ut and alocabn¡¡ i'ljocllon valva gr~
T1/2 lgnboo Coi 2 (C'tindBIS 2 and 3)
Y62 Fuaf 11jeálon vwes
F ig. 527: Identifyi ng Ignition Systern Cornponents Loca tion - Engine 111 PMS
Model124

Mercedes-Benz
P07-S643-S7
R33 co pomn•ome!ar addillve l'!l8p a!$Jsinort {'Mihw X4110 Temunal block tonnllai30.tonnmal61
KATonM helWy (3-pfl)
W10 Ground, batte¡y
X1114 Test COI.¡)ing for áaQIIOSIS, pYise SIQnal (1S..pm)
W14 Ground, h~aúJc urllblacket
Fig. 528: ldentifying Ignition System Components Location - Model124 (1 Of 2)

Mercedes-Benz
P07-é877-57
G312 Hoated o)o/gan ·sensor N:W PMS controlurit

K1/1 OvoNc.".Bgo proteroon relll'¡ NB AC .oompressor shúO: ccrool unt
K311 Partal11take marlloldprehealllg(PSV ) relay N30 ABS cornrol un•
K17 Fuelpumprel!r¡ R16/7 PMS res!Siance nnmJngcci4JIIng
1 Ccrool uni c~ng " 1" hotty end X1114 Ta~ c~tnglor diagnoSis, pulse sagnal (16-pin)
2 COOIOI una ~ng •¿ ongme 9fld X1113 Temnnal block, tammal 15115 urnused, ~n (PSV
51 Purg~ng vatv'e lortuel avaporabcn comol syslem Mo!rcnc)
82 Vawl.lll p~e toJrtake maRfold
Fig. 529: ldentifying l gnition System Components Location - Model124 (2 O f 2)
Model 202

Mercedes-Benz
POT-6085-57
1 COOrol Ult cO<.Piíng "1" bodfend N316 Pressure 1111g1no managllment{PMS) ¡;«4Jol Ulíl
2 C<lftrol Uli c~ng "T eng¡ne end N15 Kickdo't11 Stlllol ralay
51 Purgang vat>te for fuel ovapcca!Joo coarol systam N30 ABS corfJol unt
82 VacUllll ws lo 11iaka mantold X1 114 Te~ c~ng for {jaiJIGSIS, pulse SIIJiai (38-pln)
K112 Ovotvoi!Bge Pfo!odlon rolay 87E/87l/30a (9-ptn) stJilporlt rotard swichowr vi!Ne ( AG ~~
Y4 2nd dnmgmode SWitchovervW& (AGonly)
Fig. 530: ldentifying lgnition System Components Location - Model 202
INFLUENCIN G PARAMETERS AT THE CONTROL UNIT - RA070SHFM0020X(07.5-0020)
A Engine 104 HFM

Mercedes-Benz
Sta rter lockout Selector lever AJr pump switchover valve ( Y32)
switc h ( S16/3) positlon P/N ~
AG only f-1> 1-<>
HFM
control Air pump electromagneti c coupling
urit ~ (Y33)
CO potentiome.t e r Mixture adaptation
addilive map (N3/4)
adjus1ment (R33 ) ALJtomatic
(Without KAT only) f----D f---e> 5-speed
Data tra nsfer
vía CAN transmission
<H>
data bus control unit
Knock sensors (A16) lgnition tming (N15/1)
reta rdation with
knocklng
D
f-1> combustion f--i;> Electronic
accelerator pedal
(EFP)/
Tempomat crulse
Tra nsmission lgniti on tming control (TPM}Iidle
overload protection reta rdation duiing
f<l-D speed control
switc h ( S65) AG f-e> gearshlft f--i;> <H> (LLR) control unit
only (N14/ 1)
or
CILtch pedal switch elutch depressed Tempomat cruise
(S40/2) (MG) signal, for idle
1-----t:> speed control f---e>
D control (TPM}Iidle
speed control
(LLR) control unit
(N4/3)
AC compressor AC compressor cut-

shutoff control unit f----1> in signal f--i;>
(N6)
Test coupling for diagnosis (X1114),
Faul ~ pulse signa! (1 6-pin)
memory
C>
Fig. 531: ldentifying Influencing Parameters At Control Unit- E ngine 104 HFM (1 Of 2)
Mercedes-Benz
[:::: .
~
Battery (G 1) Power ground --D TN signa! HConsumers
~ Test coupl1ng for

HFM
Overvoltage Voltage supply diagnosis, 16-pin
control
protection relay
----D ---!> unit
--D ~ (X1114)
(K1/2)
(N3/4)
1 - dFuel pump relay (1<27)
~
Hot film air mass Aír mass slgnal
Fuel injection valves (Y62)
sensor ( 8215) -i>j
---[:::. -{>
Oxygen sensor heater

--!>
1gniti on/Starter Start signa 1
switch terminal SO ----D --e>
Variable camshaft tlning actuator
___g, (Y49)
Crankshaft position Engine speed and
sensor (LS) crankshaft position
-(>
----D lgnition coll lgnition coil fo:r
actuation cylinders 2+5
--------------- --D (T111)
f--e>
Magnet segment, Recognition of
era nkshaft position lgnitlon circuk 1
sensor (LS) ----D for cylnders 2 and ---!> lgnition coll lgnitlon coil fo-r
5 actuation cylinders 3+4
--D (T112)
~
Camshaft position Recognition of cyl. [::::
sensor (LS/1) "1" for ígnition and
-D injection ---!> lgnlion coil lgnition coil for
actuatlon cylinders 1+6
--D (T113) ~
ABS control urit R oad speed signa!
(N3D)
----D ---!>
<H> ldle speed control (LLR) actuator
D (M 16/6)
e oolant temperature ....
Coolant
sensor (B 11 /3) ----D temperature signal --{> Resonance irtake manifold switchover
valve (Y22/6)
-e:
lrtake air lntake ar
temperature sensor temperature signa! Pu rging switchover vaive (Y5811)
--!> ---1>
(817 )
-e
HFM reslstance Adaptation of
trimming plug ignltion and Stliftpoint netard switchover valve
(R16/5) ----D lnjection map --e> (Y3/3)
--D (with KAT and AG only)
~
(G312) signal
Mercedes-Benz
Fig. 532: ldentifying Influencing Parameters At Cont rol Unit- Engine 104 HFM (2 Of 2)
B Engine 111 HFM
ABS oor1rol uní! Road speed signa! [:::; Pwrgíng sWitchover valve (YSS/1)
(N30 )
f-D -{>
1----t:>
HFM
Coolant temperature Coolant control Va ri able camshaft tining actuator
sensor (81113) ~ tefl1JeTature signa! ----{>
unit (Y49)
(N3f4) ~
lntake air lntake air

temperatura sensor ter11Jerature signa! Shiftpoint retard switchover valve
(8 17) f-D --{>
(Y3/3)
~ (wíth KAT and AG only)
HFM reslstance Adaptation ,of
trimming plug ignition and
(R16/5) ~ injection map ---t:>
~
Oxygen sensor Oxygen semsor
(G3/2) signal
AC cor11Jressor AC compressor cut-

shutoff control unit in signa! -{>
(N6) ~
CO potentiometer Mixture adaptation

(R33)
-D
(Without KAT only)
~
Knock se nsor (A16) lgnition timing

retardation wth
knocking ignltion
I-D -{>
Starter lockout Selector lever

switch (5 16/1) ~ posltion P/N and ---t:>
AG only 2/3
Tempomat cnl se Cruise control On

control (TPM) ~ signal ---!>
control unít (N4/2)
-·- -·- ---
Fault Test coupüng for diagnosis 16-pin
(X 11/4), pulse signa!
memory f-t>
Fig. 533: l dentifying Influencing Parameters At Con trol Unit- Engine 111 HFM (1 Of 2)
Mercedes-Benz
~
Battery (G1 ) Power ground TN signa! -ciConsumers
-t>
HFM
~ control Test couplng for
Overvoltage Voltage supply unit diagnosis 1&- pin
protectlon relay ---{> ----t> (X11/4)
(K112) ---t:: ---[> (N3/4)
Fuel pl.lllp relay (K27)

1 -t>
~
Hot film air mass Air mass signa] Partial irtake manifold pre heatlng
sensor (82/5) (PSV) relay (K3/1 )
-<>
~ ----t>
Fuel injection valves (Y62)

-{>
lgn~ion/Starter Start signal
switch termina l 50 ¡-o ----t>
Actuation lgnition coi for
ig ritíon coi cylinders 1+4
Crankshaft position Engine speed and ---{> (T111 ) --!>
sensor (l5) crankshaft position
----t>
~
Actuation lgnltlon coi for
--------------- lgrition coi
-t> (T112) -t>
cyfinders 2+3
Magnet segment Recognition of
crankshaft position lgnition circ ul 2
sensor (L5) ¡-o for cylinders 2 and -t>
3
4 1dle speed control (l l R) actuah>r
(M 16/6)
Camshaft posltion Recognition of cyl.
sensor (l511) "1" for ignlion and
-t> injectíon ----t>
Oxygen sensor heater
-{>
Fig. 534: Identifving Influencing Parameters At Control Unit- Engine 111 HFM (2 Of 2)
C Engine 111 PMS

Mercedes-Benz
Coolant temperatura Coolant ~ Fuellnjection valves (Y62)

sensor (B1113) --e temperatune signa! ---(>
1
lrtake air lntake ar

PMS
control
~O><ygeo """" heot"
temperatura sensor temperature signa! ---(> unit
1
(8 17) ~
(N3/6)
~LLR actuator (M16/6)
~
(G3/ 2) signa!
TNA signal Te.st couplng fo r
diagnosis, 1&-pln
F~heel segn1ent Engine speed and
---{> ---!> (X11/4)
vía crankshaft crankshaft position
position sensor (l5) ---(>
f---i>
TNA signal Consumers
( eg. ta cllomete r)
--------------- Recognif10n of
---{> ---!>
Magnet at flywheel ignition elre u~ "2"
segn1ent via for cylinders 2+3,
crankshaft position
sensor (l5)
f---i> alocation of ---(>
injection valve Shiftpoínt retard switchover valve
group cylinders ----(>
(Y3/3) KAT with AG only
1+4
CO potentiometer Mixture adaptation

(R33), without KAT
only ----e: ---!>
PMS reslstance Adaptatlon of

trimrring coupling ignition ancll
(R1Sn ) ---;::: injection map ---(>
ABS coi1rol unit Road spee<l signal

(N30 )
~ -f>
Starter lockout Selector lever

swítch (5 16/1) AG posíllon P/N and
only ~ 2/3 ---1>
TPM control unit e rui se control cut-

(N4/2) --e: in signal ---1>
Fig. 535: ldentifying l nfluencing Parameters At Control Unit- Engine 111 PMS (1 Of2)
Mercedes-Benz
AC compressor AC compressor cut-

Test coupfing for diagnosis, pulse
shutoff control unl in signa! ~ signai (16-pín) (X1114 )
(N S) f---t>
1
~ - ----
lntake manifold Pressure
pressure sensor
PMS Fuel pump relay (K27)

Ground, hydraulic Power ground control ~
unlt bracket (W14) ~ ~ urit
(N3/6)
Partlallntake manifold preheating
f-t> PSV relay (K311)
Terminal block tml. Vollage supply
30/tml. 61 battery (permanent Actuation of lgnition coil for
(X4/1 O) ---{;:> voltage)
f-e ignition coa cylinders 1 +4
~ (T111) --{>
Terminal block, tmi. Voltage with

15 unfused PSV/ ignition: ON Actuation of lgnition coll for
Motr,onic (X12/3)
~ ~ ignitlon coil cyllnders 2+3,
r----e (T112) ----t>
Fig. 536: ldentifving lnfluencing Parameters At Control Unit- Engine 111 PMS (2 Of 2)
HFM DESIGN AND FUNCTION- RA0705HFM0030X(07.5-0030)
HFM Gasoline Injection and lgnition System
A_ General
The HFM gasoline injection and ignition system is a further development of the LH and EZL The basic
system of the HFM electroni e gasoline injection system is a rotorless, electronically controlled injection
system. The functíons of fuel injection, ignition and idle speed control are combíned in the HFM control
unit (N3/4).
The abbreviation HFM means
HF = hotfilm
M = engine management
The principie features of the fuel injection and ignition system are:
• Hot film air mass sensor

• Electronically controlled injection valves
• Idle speed control actuator
Mercedes-Benz
• Distributorless high voltage distribution

B. Fue) supply
a. Fuel pump set
Depending on the vehicle model, the fuel pump set is equípped with one or two fuel pumps. If two
pumps are fitted, these are connected in series at the fuel end. The purnps deliver the fuel from the
fuel tank through a fuel filter into a fuel rail. The fuel pumps operate during the starting process and
so long as the engine is running. For safety reasons, they are actuated for only about 1 second with
the ignition "ON" (full running safeguard).
P0?-5749-1 3
Sho'M"' oo m<Xfel 124
Fig. 537: Identifying Fu el Pump Set
Shown on model 124
b. Actuation of fuel pump
The fuel pumps are actuated by the HFM control unit vía the fuel pump relay (K27). The rpm
recognítion for the HFM control unit is provided by the TN signa! or, if no TN signa! is recognized,
by the camshaft position sensor signa!.
Mercedes-Benz
P017-5949-1 l
Fig. 538: Identifying Fuel Pump Relav
c. Operation of Bosch fu el pump
The fuel pump is a roller-cell pump and consists ofthe fuel pump housing with rotor ring (3), the
rotor disk (1) and the rollers (2). As a result ofthe eccentric positioni.ng ofthe rotor disk (1) relative
to the rotor ring (3), a volume change occurs between the rollers during each revolution, which
produces the suction and pressure effect of the pump. The rollers are pushed to the outside as a
result of the centrifuga! force and act as a se al.
3
P07-5489-13
1 Rotor disk
2 Roler
3 Fu el ~rrp hoosmg 'Mfl rorofmg
8 Stdoo sade
b Detvery side
e Fualpr&s"Sllreless
d FuelpJGS"SlJRZBd
Fig. 539: ldentifying Bosch Fuel Pump Components

Mercedes-Benz
1 Retor disk
2 Roler
3 Fuel pumphOtJSingv.~lhrotor
nng
4 Choc k 'll!Ne
5 PI' sssure reli ef va".e
a ~d!onside
b Dalivery sl!ie
e FIJ!ll p¡essu-e!ess
d Fuel l)fessmz ed
PCI'7....,
P07-56S0-33
Fig. 540: Section View Of F u el Pump
With its delivery of at least 90 1/h at 11.5 V (current consumptiou 6 to 1O A), the fuel pump
supplíes more fuel thau the engine needs, as a result ofwhich the engiue is always supplied with
cool fuel. The excess fuel flows back iuto the tank.
In the eveut of a pressurize to more thau 8 bar (eg. as a result of constriction in the fuel feed or
return pipe), a pressure relíefvalve opens and connects the suctíon and delivery ends withín the
fuel pump, whích prevents a further rise in pressure.
When the engine iis switched off, a check valve prevents the residual pressure being reduced
through the fuel pump. This largely prevents the fom1ation ofvapor bubbles in the fuel injection
system aud improves warm starting characteristics. The check valve is located in the screw union
and can be replaced separately.
Pierburg fuel p ump
The fuel pump (M3) is a two-stage design. A side chanuel pump is located in the pump housing as
a pre-stage and an internally geared pump as the main stage. The side channel pump supplies the
fuel with a pre-pressure of 0.1 - 0.2 bar to the internally geared pump. The gas which is separated
out in the side channel pump flows back through the vent conuection (arrow) to the fuel tank.
The power consumption ofthe fuel pump (M3) is 8 - 12 A.

Mercedes-Benz
P07-8006-13
Fie. 541: Identifyine Pierbure Fu el Pump
A screw spindle pump (M3) has been fitted as of June 1994. A drive spindle (a) anda driven
spindle (b) are located in tbe fuel pump housing. These ro tate in the opposite direction to each other
and pump the fuel in the axial direction (arrow).
The current consumption is 5 to 9 A.
b M3
a
P07-659!>13
Fig. 542: Identifying Screw Spindle Pump

Mercedes-Benz
4 2 6
5 3 7
P07-6654-56
1 Driven sp in die 6 Poslive te rmina l (M4 threa d)
2 Orive spindle 7 Negative terminal (MS thread)
3 Brush spring a Fuel inlet
4 V alve plate b Fuel outJet
5 Electric motor
Fie. 543: Section View OfFuel Pump
d. Fuel ftlter
The fuel filter is a micro-filter with a paper filter element.
A damper is installed on the fuel feed side in order to avoid fuel noises. The fuel flow direction is
indicated by an arrow on the fuel filter housing.
P 07-549'{).13
Fig. 544: Section View Of Fu el Filter

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e. Fuel rail
The fuel passes through the fuel rail (17) to the injection valves (Y62). The diaphragm pressure
regulator and the pressure test connection (51) are also integrated in the fuel raiL
The pressure test connection (51) with valve is u sed for testing the fuel pressure and also for
releasing the fuel p ressure during removal and installation operations.
Shown on engíne 111
P07-6739-1 3
Fig. 545: ldentifying Fuel Rail
f Diaphragm pressure regulator
The pressure regulator (50) is installed in the fuel return ofthe fuel rail (17). It is diaphragm-
controlled overflow pressure regulator which regulates the fuel pressure between about 3.2 and 4.2
bar depending on the absolute pressure in the intake manifold. Thís control pressure cannot be
altered.
Full load operation
At fullload, no vacuum exists in the spring chamber (9), which is separated from the fuel chamber
(8) by a diaphragm (5). Ifthe set pressure is exceeded, the diaphragm (5) is forced against the
compression spring (6). The valve (3) which is attached to the diaphragm opens the passage for the
retum flow (2) and the excess fuel flows back pressureless to the fue l tank.
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A B
2
P07-6740-13
A Vah'eclosed
8 Va.\re ope:1
Fig. 546: ldentifying Diaphragm Pressure Regulator Function
Pressure ratio at fuelload
Difference in pressure between fu el pressure and intake manifold pressure is about 4.0 bar .
Schematíc presentatíon
a Fuel return to fuel tank

b Fuel preswre about 4 .0 bar
e Fuel feed from fue! pump
d lntake manifold
e lntake manifold preswre Obar
~· P07.S743-13
Fig. 547: Identifying Pressure Ratio At F uel Load
Idle speed, part load operation
The spríng chamber (9) ís connected to the íntake manifold by an íntake pipe connectíon (7). The vacuum
of the intake manifold acts via the diaphragm on the spring ( 6), as a result of which the fuel pressure is
reduced by the intak.e manifold vacuum which exists at that moment. The result is that the fuel pressure in
the fuel raíl ís dependent on the intake manifold pressure and the pressure drop through the fuel injectíon
valves is identical no matter the position of the throttle valve. As a result, the quantity of fue! injected is
determined solely by the opening time of the injection valves.
Mercedes-Benz
P07-S741-13
Fig. 548: ldentifving Diaphragm Pressure Regulator Function
Pressure ratio at part load
Difference in pressure between fuel pressure and intake manifold pressure is about 3.4 bar .
Schematic presentation
a Fuel retum to fu el tan k

b Fuel pressure approx. 4.0 bar
e Fuel feed from fu el pump
d
e
lntake manifold
lntake manifold vacuum 0.6 bar -- ..
(¿6.
P07.S744-1 3
Fig. 549: ldentifving Pressure Ratio At Part Load
Diagram of fuel pressure

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A Fuel pressure in bar

B lntake manifold vacuum in bar
ll ldle speed
Tl Par! load
Vl Full load
?07-674 2-13
Fig. 550: Diagram Of Fuel Pressure
C. Functions in the HFM control unit

a. General
Located in the component compartment, it analyzes the data regarding the engine operating state
which are supplied by the sensors, and controls essentially the fue! injection valves, the ignition
coils and the actuator for idle speed controL Voltage is supplied by the overvoltage protection relay
(Kl/2).
PO?-544 2'- 13A
Fig. 551: Identifying Overvoltage Protectioo Relay
Base injection quantity
The map ofthe base inj ection quantity is controlled by the HFM control unit depending on the
operating state of the following components:
• Engine speed
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• Air mass
• Position of resistance trimming plug
• CO potentiometer (without KAT)
b. Lambda control (KAT only)
The oxygen sensor (G3/2) measures tbe residual oxygen content (oxygen ions) in the exhaust gas.
The oxygen sensor projects into the exhaust gas flow and produces a voltage depending on the
oxygen content, which is signaled to the HFM control unit.
This voltage in the case of a rich mixture is between 500 - 1000 m V, in the case of a lean mixture
between lOO -400 m V and ata= 1 around 450 mV.
The oxygen sensor signal is required for the lambda control.
P()7-5444-13
Fig. 552: ldentifving Oxygen Sensor
c. Transmission shiftpoint retard
The transmission shiftpoint retard is controlled by the HFM control unit through the shiftpoint
retard sw itchover valve (Y3/3) to the shiftpoint retard vacuum element (see Function Diagram
Group 14, Section A).
The HFM control unit requires the following information for this purpose:
• Time after start
Mercedes-Benz
P0?-5177-13
Fig. 553: ldentifving Shiftpoint Retard Switchover Valve
Shown on engine 111
Engine 104
Transmission shiftpoint retard 2 --> 3
To enable the catalytic converter to reach its operating temperature more rapidly during the
warming-up phase, the 2 --> 3 idle throttle and part load shift in the automatic transmission is
retarded for up to not more than 90 seconds after the engine is started at a coolant temperature
between O and up to 50 oc. As a result, the engine revs up slightly more before the gearshift is
performed. Ibis sbiftpoint retard is controlled by the HFM control unit through the shiftpoint retard
switchover valve (Y3/3).
PO?-529>2-1 3
Fig. 554: ldentifying Shiftpoint Retard Switchover Valve

Mercedes-Benz
Transmission safeguard function 4 --> 5/5 --> 4 (with 5-speed automatic transmission onJy)
To protect the shift elements ofthe automatic transmission from excessive thermal stresses during
gearshifts under load in the higher rev range, a transmission overload protection is integrated in the
HFM control unit. The HFM is linked vía the CAN databus to the 5-speed automatic transmission
control unit (N5/ l ). As a result of the transmission overload protection function, ignition timing is
retarded by the HFM control unit (N3/4) to 5° CA before TDC (reduced engine torque) during the 4
--> 5 upshift for a period which is deterrnined by the 5-speed automatic transmission control unit
(Nl5/ l).
Torque reduction (4-speed AG)
For the torque reduction function, the full load ignition angle is retarded by the HFM control unit in
line with a map which is dependent on engine speed. The following pre-conditions must exist for
this function:
• Road speed <120 km/h

• Engine speed >3400 rpm
• Fullload
• <1600 m above MSL
• Engine speed
• Air mass
• Fullload
As this retardation of ignition timing also improves gearshift smoothness during the shift phase,
this measure is also used during a 5 --> 4 full throttle downshift.
The HFM control unit processes the following inforrnation for tlús purpose:
• Engine speed
• Air mass
• Signal from transmission overload protection switch (S65)
• Signal from 5-speed automatic transmission control unit (N15/ l)
Transmission overload recognition (AG only)
The transmission overload protection switch (S65) is designed as a hydraulic pressure switch and is
linked to the working pressure circuit of brake band ,B 1, of the automatic transmission. The
switching function ofthe transmission overload protection switch (S65), brake band Bl, is
dependent on the working pressure wlúch exists at ''B 1''.
Mercedes-Benz
P07-56!M-1 3
Fig. 555: ldentifying Transmission Overload Protection Switch
Opening and closing ofthe transmission overload protection switch (S65), brake band Bl , is
recognized by the HFM control unit as a shift signa!.
The shift signal is required for the following functions in the HFM control unit:
• Transmission safeguard function
Transmission overload protection
A transrnission overload protection is integrated in the HFM control unit in order to protect the shift
elements of the automatic transmission from excessive thermal stresses during load shifts at higher
revs.
The HFM control unit processes the following infom1ation for this purpose:
• Signal from transmission overload protection switch (S65)

• Engine speed
• Air mass
As a result of the transmission overload protection function the ignition timing is retarded to 5° CA
before TDC (reduced engine torque) for about 400 ms during 1 --> 2 and 2 --> 3 upshifts.
As this retardation of the ignition timing also improves the gearshift smoothness during the shifting
phase, this measure is also used for 3 --> 2 full throttle downshifts.
Emergency running mode transmission overload protection
Ifthe HFM control unit does not receive a shift signa! from the automatic transmission when the
car is being driven, whether as a result of a fault at the transmission overload protection switch
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(S65), brake Bl , or at the wiring, the HFM control unit switches into the emergency running mode.
The transmission overload protection continues operating only to a restricted extent in the
emergency running mode.
If no sbift signal is sent by the automatic transmission, the HFM control unit recognizes the start of
a gearshift as a result of a change in engine speed within a defined level.
When the transmission overload protection is operating in the emergency running mode, this may
be noticeable as a result of the temporary retardation of ignition timing at high speed.
&oanQer!
In dealing with the complaint "Misfiring at high speed", it is then necessary to check the
transmission overload protection switch (S65) and also the wiring.
Engine 111
Transmission shiftpoint retard 3 --> 4
(KAT version only)
To enable the catalytic converter to reach its operating temperature more rapidly during the
warming-up pbase, tbe idle throttle and part load shifts in the automatic transmission are retarded
for up to not more than 150 seconds after tbe engine is started at a coolant temperature between -40
oc and 100 oc. As a result, the engine revs fas ter tmtil the gearshifts are performed. The 3 --> 4 id le
throttle shift is suppressed up to 55 km/h.
d. Variable camshaft timing (inlet camshaft)
Depending on engine speed and load, the inlet camshafts are advanced in order to achieve good
engine torque over the entire engine speed range.
An actuator is attached to each of the camshaft adjusters, which operates the control plunger for the
hydraulic/mechanical adjustment. The actuators are operated by the HFM control unit. If the
actuators are operated, the inlet camshafts are "advanced". The adjustment depends on engine speed
and load. In selector lever positions P and N , the adjustment depends only on engine speed.
Example
Engine 104 governing top speed
The top speed is governed to about 250 km/h. lf this speed is exceeded, a leaner mixture is
produced and the inlet camshaft is "advanced". Camshaft adjustment (selector lever in drive
position and moderate engine load) In selector lever position P/N the shiftpoint is advanced at 3000
rpm.
Inlet camshaft adjustment (selector lever in drive position and moderate engine load)
Mercedes-Benz
Engine speed Adj ustment of cam sbaft

up to about 1200 rpm retarded
from 1200 to 4300 rpm advanced
4300 rpm or higher retarded
up to about 1500 rpm retarded
from 1500 to 4200 rpm advanced
4200 rpm or higher retarded
e. Fuel sbutoff in the event of ignition faults (KAT only)
Ifignition faults occur (50 ignitions in sequence) the injection valve ofthe cylinder(s) affected is
shut off in order to protect the catalytic converter from overheating.
Once misfiring no longer exists, the fu el supply is activated again provided:
• 255 ignitions in sequence were in order

• car was in deceleration mode
• engine speed of about 2500 rpm was exceeded
The following faults are recognized by the primary current monitor in the HFM control unit:
• Ignition output stage in HFM control unit faulty

• Ignition coil faulty or open circuit in wiring
• Short circuit (also at high voltage end)
• Spark plug faulty
The HFM control unit processes the following infom1ation for this purpose:
• Primary voltage (combustion voltage, combustion time)

• Camshaft position ignition TDC cylinder 1
• Engine speed/Recognition of ignition circuit
As a result, the fuel injection valves are shut off and are not activated again until engine speed is
< 1200 rpm.
f. Anti-jerk function (manual transmission only)
An anti-jerk function is integrated in the HFM control unit in order to suppress the tendency of cars
fitted with manual transrnission (MG) to jerk. After an engine load change, the sudden rise in
engine speed is suppressed by retarding the ignition tíming (dependent on map --> load, rpm).
The HFM control unit processes the following infonnation for this purpose:
• En1úne soeed
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• Air mass
• Gear (1st gear/not 1st gear)
Engine 104 safety fuel shutoff
(with EFP or TPM only)
The HFM control unit is hnked for the safety fuel shutoff function to switching contacts in the EFP
actuator (MI6/l) and to the TPM actuator (MI6/2), respectively_ The switching contacts supply a
positive signal to the HFM control unit when the engine is idling and also when driving_
If the throttle val ve is opened further than specified by the position of the accelerator pedal as a
result of the malfunction and if the car is not in the cruise control mode, a safety contact in the
actuator switches a ground signal via the EFP control unit (N4/1) or the TPM control unit (N4/3),
respective!y, to the HFM control unit
g. ldle speed control
Idle speed is controlled by the HFM control unit and by the idle speed control actuator (M16/6).
The idle speed control actuator (Ml6/6) comprises the throttle valve connection fitting with throttle
valve actual value potentiometer (M16/6rl) for recognizing the throttle valve position, the drive
actual value potentiometer (M16/6r2) for recognizing the servo motor position, the idle speed
contact switch (Ml6/6sl) for recognizing idle speed, and the electric servo motor (MI6/6ml) for
correcting the throttle valve position.
The HFM control unit processes the following information for idle speed control:
• Engine speed
• Throttle vaJve position
• Idle speed servo motor position
• AC compressor cut-in signal
• Clutch depressed signal, engine 104 only
Mercedes-Benz
,----------------------
i ld1e speed co.ntro1(LLR)
1
HFM actuator (M16/6)

control
unit
(N3/4)
Throttle valve actual
<l-- value potentiometer
i (M16/Sr1)
11
i Orive actual val ue

<>----1- potentiometer (M16/6r2)
1
1
11
1
1 ldle speed corltact switch
1
(M 16/6s 1)
~ 1
1
1
-----J Servo motor (M16/6nn1)

1
1
1
1
1
1 Clutch depressed signal,
-J. 1
1
engine 1 04 only
1
1
L----------------------
Fi2. 556: Idle Speed Control Commun ication Dia2ram
Function
When the ignition is switched on, the ídle speed control is activated. Before the engine is started,
the position ofthe throttle valve for idle speed is fixed by the servomotor (M16/6m1) as a function
of the coolant temperature. The servo motor is actuated in this case with a frequency between 360
and 600 Hz. The throttle valve position is signaled by the throttle valve actual value potentiometer
(M16/6rl).
Mercedes-Benz
PO7-5609--13
Fig. 557: ldentifying Servomotor Function
The HFM control unit compares actual and specifíed engine speed and determines the position of
the throttle valve at that moment via the servo motor (Ml6/6ml). The adjustment range ofthe
throttle valve for idle speed adjustment (ie. opening angle) is limited by the HFM control tmit and
is Oto 10%.
When the engine is idling and the id] e speed contact switch (M16/6s 1) is closed, 4 fixed ignition
maps are set as a function of the coolant temperature (cold or warm) and the transmission (MG or
AG). These are not influenced by the HFM resistance trimming plug.
If a difference in idJing speed exists, the id le speed control is assisted by altering the ignition
timing. The ignition timing can be advanced and retarded by up to 8°. Idle speed is continuously
controlled as a function of the coolant temperature.
The idling speeds differ according to the selector lever position. These are determined by the HFM
control unit.
Coolant temperature MG, AG selector lever position P/N AG selector lever in drive position
<0°C 1000 ± 50 rpm 800 ± 50 rpm
oc
O to 30 oc 850 ±50 rpm 700 ± 50 rpm
30 oc to 40 oc 800 ± 50 rpm 650 ± 50 rpm
>40°C 750 ±50 rpm 600 ± 50 rpm
Catalytic converter heating
The exhaust gas temperature is increased to enable the catalytic converter to reach its operating
temperature more rapidly. Each time the engine is started ata coolant temperature between about
+ 15 oc up to +40 °C, ignition timing is continuously retarded by up to 8° when the engine is idling
and selector lever in P or N for about 30 seconds, depending on the temperature, and idle speed is
increased to 1150 e 100 mm bv the idle soeed control. The increase in id le soeed is canceled as soon
Mercedes-Benz
as a drive position is selected.
In the part load range, the ignition correction angle is scanned from a map in line with coolant
temperature and load. The HFM control unit processes the following information for this purpose:
• Engine speed/crankshaft position/ignition circuit recognition
• Air mass
• Ignition counter reading
Engine speed stabilization on engines wit h AC compressor
When the AC compressor cuts in, voltage exists at pin 11 of the HFM control unit. The HFM
control unit processes the voltage level and actuates the servo motor (M16/6ml) in the idle speed
control (LLR) actuator (Ml6/6). This increases the opening cross section ofthe throttle valve
before the AC compressor cuts in so that idle speed is maintained ata practically constant level.
Throttle valve da mping function
A damping function for the throttle valveis integrated in the HFM control unit. If the throttle val ve
position is >8° opening angle, the throttle valve is closed again in the idle speed range only with a
time lag if the accelerator is suddenly released.
• Engine speed
• Throttle valv e position
• Road speed
Overheating or pinging protection
Ignition timing is retarded atan excessively high engine temperature asan overheating pinging
protection.
The pinging protection correction is activated at a coolant temperature of 100 oc and is only
effective under load.
The retardation of ignition timing is:
eg.: 100 oc --> 0° CA retarded
105 oc --> 1.4° CA retarded

Mercedes-Benz
120 oc--> 3.2° CA retarded
(The correction is dependent on engine load; the figures apply to fullload.) The HFM control unit
processes the following information for this purpose:
• Engine speed/crankshaft positionlignition circuit recognition

• Air mass
&oanQer!
The correction ofthe pinging protection and ofthe intake airare added together, ie. 120 oc coolant
temperature and 50 oc intake air temperature produce a maximum retardation of 11 oCA at full
load.
Ignitioo timing support of idle speed control
If a variation in engine speed exists, the idle speed control is supported by altering the ignition
timing.
The ignition timing can be advanced and retarded by up to 8°.
h. lntake air temperature correction
The ignition timing is corrected by the HFM control unit by being retarded as a function of intake
air temperature and "load" (engine speed and air mass).
Ignition timing is retarded only at high engine loads and begins atan intake air temperature of 35 °
C and achieves its maximum retardation at 65 °C.
Example:

65 oc --> 9.5° CA retarded
(The correction is dependent on engine load; the figures apply to fullload.)
The HFM control unit processes the following information for tlús purpose:

• Throttle valve position
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• Air mass
1. Anti-knock control AKR
The ignition maps of the HFM injection system are designed for optimal engine output. Should
knocking combustion occur under certain operating conditions, the anti-knock control integrated in
the control unit recognizes the cylinder which is knocking and retards the ignition timing
accordingl y.
Should knocking combustion occur for example as a result of fue! with low octane rating, the
mechanical vibrations produced are converted in the knock sensor into electríc signals and passed
to the HFM control unit.
• Knock sensor signals

• Camshaft position TDC cylinder 1
• Engine speed/crankshaft position/ignition círcuit recognition
The HFM control unit compares these incoming signals with the specified values stored in the
control unit. If difierences exist, the ignition timing for the corresponding cylinder in which
knocking combustion has occurred, is retarded by 3° CA immediately from the next ignition.
If the cylinder continues to knock, ignition timing is retarded by a further 3° CA. This retardation
of ignition tíming can be repeated if knockíng combustion continues unti! a maximum retardation
in line with coolant temperature is achieved (eg.: 10° CA at coolant temperature of80- 90 °C).
If knocking combustion no longer occurs, the ignition timing of the cylinder in question is
advanced in stages of0.35° CA until it is restored to the mapped value. Should one ofthe following
components fail, a retarded ignition timing dependent on coolant temperature is activated for all the
cylinders for safety reasons:
• Knock sensor
• Knock sensor analysis circuit of the antiknock control in the HFM control unit
• Camshaft position sensor (L511)
J. Coding
The HFM control unit is provided with a variant coding as of 12/93 as a phased-in measure. This
can only be conducted with the hand-held tester (automatically and manually).
The control unit has a code protection. When the code is entered, the number of the handheld tes ter
is also entered and stored. This makes it possible to determine the workshop in which coding was
performed.
Mercedes-Benz
Before removing the control unit, determine the code number by reading it with the hand-held
tester (menu point 6 variant coding). After instalJing the control unit, the code number retrieved
must be entered in the new control unit.
If it is not possible to retrieve the code number from the installed control unit, it is then necessary to
determine the vehicle version and to refer to the Parts Microfilm Group 54 for the corresponding 9-
digit code number and to enter this manually with the hand-held tester.
Pay attention to the following vehicle versions for coding:
• V ebicle model
• KAT
• Witbout KA T
• 5-speed manual transmission
• 4-speed automatic transmission
• 5-speed automatic transmission
• Tempomat cmise control
• ASR
• Controlled differential brake
• Nation version
NOTE: lf the new control unit is not required, the code should be erased.
If a control unit is not coded, engine speed is govemed to a maximum of 3200 rpm ( emergency
running mode ). Automatic recognition of the vehicle version is not possible.
k. Diagnosis
The HFM control unit has a diagnosis facility and features a fault memory. Tbe following
distinctions are made in respect of recognizing and storing faults:
• Fault exists constantly

• Fault exists for longer than 2.5 seconds
• Loose contact faults which have occurred 5 times during a journey
In the event oftbe failure of a component, eg. coolant temperature sensor, the HFM control unit
immediately switches toa substitute value orto an emergency mnning map.
This ensure that the operation of the fuel injection and ignition system as well as tbe idle speed
control are retained. Faults which no longer occur, are automatically erased after 19 journeys. A
journey is defined as follows:
• Road speed >4 km/h

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• Engine speed >700 rpm

• Engine switched off for 30 seconds
The faults are retained even after disconnecting the car battery.
The stored faults can be read and era sed with the pulse counter of hand-held tester at the test
coupling for diagnosis (X l l/4), contact 8 (see Diagnosis Manual Engine Volume 2).
NOTE: Diagnosis by means of the on/off ratio display is discontinued.
P07-5447-13
Fig. 558: Identifying Diagnosis Coupling
Resetting and re-activating memory
Memory in the HFM control unit for the following fuuctions:
• Automatic recognition of the vehicle version

• Automatic recoguition of mechanical end stop of the elo sed throttle valve
• Self-adaptation of mixture formation
The memory must be reset and re-activated after replacing the HFM control unit or after installing
the control unit from another car as a test.
Resetting and activating memory:
• Connect pulse counter (black cable contact 1, red cable contact 3, yellow cable contact 8)
• Read fault memory and erase, if necessary
• After the figure 1 appears, press start button of the pulse counter for between 6 and 8 seconds
• Switch off ignition and wait at least 2 seconds
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• Switch on ignitíon and wait at least 1O seconds before starting the engine
l. Automatic recognition of mechanical end stop of closed throttle valve
It is necessary for tbe idle speed control function that the HFM control unit detects and stores the
mechanical end stop ofthe closed throttle valve. The HFM control unit recognizes tbe throttle valve
position in this case from tbe voltage signal at the potentiometer in the idle speed control actuator.
After replacing tbe HFM control unit or the actuator, the position of the throttle valve must be re-
detected and stored (see Resettíng and re-actívating memory ofthe HFM control unit).
m. Aotomatic recognition of vehicle version
The HFM control unit recognizes tbe following versions and stores them the first time the car is
sta1ted:
• Manual/Automatic transmission
• KAT/without KAT
• F ederal/Califomia versíon
• KAT thermocouple [gJ
This eliminates the need for a variety of control units.
After replacing the HFM control unit or ínstallíng it from another car as a test, it is necessaty to
erase the stored data and to re-actívate recognition (see Resettíng and re-activating memory ofthe
HFM control unit). If re-activation is not performed, problems may occur with the fuel injection
and ignition system and with the idle speed control.
n. Self-adaptation of mixture formation (witb KA T)
The lambda control determines the ínjection time so exactly that the fuel-air ratio is always around
lambda 1.0 (corresponds to 14.7 kg air to 1 kg fuel) in all operating states. Iffaults occur as a result
of:
• unmetered air,
• wear or coking of the fuel injection valves,
• wear to the engine,
• contact resistance in the air mass sensor,
• faulty diaphragm pressure regulator,
• faulty purging switchover valve, the HFM control unit automatically performs a conection of
the mixture formation by altering the injection time. The correction parameters are constantly
calculated and permanently stored provided the followíng conditions are met:
• Coolant temperature at engine start between 15 oc up to 95 oc
• Coolant temperature when driving between 80 oc up to lOO oc
• lntake air temperature between O oc up to 50 oc
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There are two rauges in which self-adaptation is perforrned, ídle speed and at part load. The
correctiou oftoward a rich or lean mixture is in each case rnax. 25 %.
After repairs have been performed to the fuel injection system or to the engine, the HFM control
unit automatically re-adapts after about 1Oj ourneys. After a HFM control unit from another car has
beeu installed as a test or after rectifyiug the faults stated, the self-adaptation rnust be reset (see
Resetting and re-activating mernory ofthe HFM control unít).
o. Exhaust gas recirculation engine 104 (~ ¡gj ® only)
A map for the exhaust gas recirculatíon function is stored in the HFM control unit. The influencing
parameters are engine load and engine speed. Ifthe ídle speed contact is open and the coolant
temperature ís greater than 48 °C, the ARF switchover valve (Y27) is actuated by the HFM control
unit.
The HFM control unit processes the following ínformatíon for this purpose:
• Engine speed
• Air mass
• Coolant ternperature
P07-5713-13
Fig. 559: Identifying ARF Switchover Valve
p. Air injection engine 104 (with KAT only, except i ® )

Air injection is controlled by the HFM control unit. The air pump electromagnetic coupling (Y33)
and the air pump switchover val ve (Y32) are actuated by the HFM control unit in line with the
coolant temperature. Air inj ectíon is performed after the engine is started ata coolant temperah1re
between + 1O oc up to +40 °C. A ir injection is switched off at full throttle or at an engine speed
> i nOO mm AftP:r thP: P.n o-inP: i ~ "t:lrtP.cl thP: :::.ir n11mn is onP.r:ltP:cl fnr nnt mnrP. th::~n 1?0 ~P.r. oncl ~ ( ~n
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long as the lambda control is in the open-loop control mode) .
• Engine speed
• Lambda control enabling
NOTE: As a result of the more rapid heating-up of the catalytic converter, the
a ir pump is no lon9_!r fitted, with the exception of the following
national versions: llJ (Gi="er ~AP ~ ~ [g] 0
PO7-5453-1.3
Fig. 560: Identifying Air Pump Electromagnetic Coupling And Air Pump Switchover Valve
Electric air pump (M33) model202
Located below the altemator. The current consumption is max. 35 A at 12 V anda backpressure of
150 mbar.
The check valve (injected air) is no longer :fitted. The function is performed by the shutoff valve.
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P ()7-5004-1 3
Fig. 561: Identifying Electric Air Pump
The electric air pump (M33) is actuated by the HFM control unit (N3/4) via the air injection relay (K17).
P07-600.3-1 3
Fig. 562: ldentifying Air Inj ection Relay
D. Mixture formation
a. Hot film air mass sensor
The air mass inducted is detected by a hot film air mass sensor (B2/5) which is located in the intake
port between aír cleaner and throttle valve.
The air mass is required by the HFM control unit for the following functions:
• Fuel injection
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o W arming-up enrichment
o Acceleration enrichment
• Iguition
o Ignition during warming-up
o Ignitiou at full throttle
• Catalytic couverter heating
• Lambda control
• Activated charcoal filter purgiug
• Camshaft adjustmeut
• Anti-jerk function (with MG only)
• Piugiug protectiou
• Intake air temperature correctiou
P07-~44-1 3
Fig. 563: Identifying Hot Film Air Mass Sensor
Design of air mass sensor
A hot film sensor (70/ 1) is mounted in the interior ofthe measuring passage. This sensor consists of
a ceramic substrate onto which are fixed the following thick-film resistors.
• Heatiug resistor (RH )

• Sensor resistor (Rs)
• Air temperature resistor (RT )
• Compensatíon resistor (RK )
A hybrid circuit anda power module are located dowustream of the measuríng channel (70/2) in
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the electronic housing. A heat sink is attached to the outside ofthe electronic housing (70/3).
70/4
P07-543 7-1l
Fig. 564: Identifying Hot F ilm Sensor And Protective Grille
The electronic housing with measuring channel is inserted in the connection housing.
Turbulences are smoothed by the protective grille (70/4) so that a un:iiform flow of air flows around
the hot film sensor.
Function of the a ir mass sensor
The hot ftlm air mass sensor operates with a hot ftlm sensor in the inducted air flow. The resistors
(R T ), (R 1 ) and (Rs ) and also (~ ) and (R3 ) are combined to form a bridge circuit.
The heating resistor (RH) is positioned outside of the bridge. The heating current which is required
to maintain the heating resistor at a constant temperature determines the bridge voltage.
The heating resistor (RH ) and the sensor resistor (Rs ) are temperature-dependent and reduce their
resistance (NTC) as the temperature rises.
As the sensor resistor (Rs) is attached directly to the heating resistor (RH ), it adopts the latter's
temperature.
In operation, sueh a high leve! of current (IH ) is supplied to the heating resistor that it heats up to
about 160 oc above the momentary intake air temperature. When the air flow increases, the heating
resistor is cooled down as a result of which its electrical resistance rises. The current (IH ) is
adjusted in order to maintain the temperature at the heating resistor (RH ) at a constant level.
Mercedes-Benz
Ue
P07-5595-17
A lrtake au ow
B Heat
c4 Capaator
RH Heabng resastor
RS SenscrrestsiDr
RT An terrpera~r& resrstor
Rv Conlrol arnplfiet'
R1 Tnmmng restsror
R3 Tnmmng res1sfuf
T1 Troosistor
ua + Moastmgsignal +
ua - M eaS\mg sign al -
ue SJp~vollB:¡;e
w Ground
7011 Hot illn sensor
Fig. 565: Function Of Air Mass Sensor

Mercedes-Benz
The momentary air temperature is detected by the a ir temperature resistor (RT ), which al so alters
its resistance in line with the temperature. The control amplifier (Ry ) compares the current flow of
air temperature resistor CRr ) and sensor resistor (Rs ) and then influences the current supply (IH )
to the heating resistor (RH ) accordíngly in order to rnaintain the temperature difference of intake
air temperature to heating resistor temperature at a constant 160 oc. This control to a constant
temperature difference is performed within a few milliseconds.
At the test connection (UA) a change in current is tapped as a voltage drop. Dependíng on the air
mass, the heating current is between 250 and up to 800 mA. This voltage drop is the measured
variable for the iuducted air rnass for the HFM control unit.
The hot film air mass sensor has no moving parts aud causes ouly a slight flow resistance in the
intake air passage.
The benefits ofthe hot film air mass sensor compared to the hot wire air mass sensor are:
• Elimination of cleaning process

• High resistance to vibrations
Mercedes-Benz
P07-S593-15
A lrtake ¡u- ftow
8 Heet
RH Heat.lgmSistor
Rs SensOf reSistOf
R AiriBmpenrtueresistor
1
R1 Tnrnmng resastor
Fig. 566: Identifving Momentarv Air Temperature Circuit
Emergency running properties
If a fault occurs in the hot film air mass sensor, the injection time is calculated from a map ofthe
control unit using the throttle valve angle and the engine speed.
The tbrottle valve angle in this case is detected by the throttle val ve actual value potentiometer
(Ml6/6rl) in the idle speed control (LLR) actuator (Ml6/6) and passed to the HFM control unit.
b. Fuel injection valves
Injection is performed by electromagnetic injection valves (Y62). An injection valve is assigned to

each cylinder and precisely meters the fuel which is injected into the intake manifold upstream of
the inlet valve. The injection valve consists of a val ve body and the nozzle needle (56) with the
mounted armature (55). The valve body contains the field winding (53) and the guide for the nozzle
needle.
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The fuel flows through a pre-filter (51) and a drillíng in the armature to the calibrated outlet
opening (a). When the field winding is de-energízed, the nozzle needle is pressed down onto its
sealing seat by a coil spríng (54). When the field winding is excited, the nozzle needle is lifted
about 0.1 mm offits seat and the fuel is able to flow through the 2 drillings (a) with 0 0.2 mm. The
opening and closing time of the valve is less than 1 ms.
52
;:,07-061 ~1 5
Fig. 567: Section View OfFuel Injection Valve
The arrangement of the drillíngs (a) causes 2 jets to fonn when the fuel flows out, which spray the
finely atomízed fuel onto both inlet valves.
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Y62
P07-5441-13
Fig. 568: Identifying Fuel Injector Role
P07-674~1 3.
Fig. 569: Identifying Fuel Spray
The fuel injection valves are connected directly to positive and are opened by the HFM control unit
(N3/4) by means of ground pulses. The fuel injection valves are actuated in line with the firing
order (sequentially). Depending on engine load and speed, the fuel is injected more or less
upstream and, when the inlet val ves open, is inducted together with the air into the combustion
chamber.
The control unit calculates tl1e injection time in line with the operating state ofthe engine. The
quantity of fuel injected is determined by the opening time of the fuel injection valves.
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u8 = Operating vokage
u
t =Time
POl-6746--13
Fig. 570: l dentifying F uel Spray Patter n
c. Actuation of fu el metering in different oper ating states
Synchronization of injection seq uen ce
The injection sequence has to be synchronized in order to ensure correct allocation of the moment of
injection to the respective cylinder. The signal of the camshaft position sensor (L5/ l) is required in this
case for recognizing ignition TDC of cylinder l .
Synchronization is performed during the :first revolutions of the engine when it is started. The HFM
control unit processes the following information for synchronizing the injection sequence:
• Engine speed/craukshaft position

Start control
To facilitate starting the engine when cold, additional fuel has to be injected during the starting process,
in line with the coolant temperature. The increased quautity of fu el injected is achieved by extending the
injection time.
The start control begins with starting of the engine via terminal 50 and remains activated until a
temperature- related engine speed is exceeded.
The quantity of fu el required for starting is calculated from the following factors irrespective of the air
mass sensor with hot wire:
• Camshaft speed (camshaft position sensor)
• Intake manifold pressure (EZL ignition control unit)
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• Time during which engine was switched off
Post-start enrichment
After starting the engine from cold, it is necessary to enrich the mixture with additional fuel for a short
time. The fuel which precipitates on the cylinder barreis is compensated for by the enrichment, and the
engine tums smoothly.
Post-start enrichment ís dependent on:
• Coolant temperature at starting

• Time duration after start
• Position of resistan ce trimming plug
Warming-up enrichment
The precise quantity of fuel is metered to the engine in line with the coolant temperature. The inj ection
time is appropriately extended for this purpose. Warrning-up enrichment is dependent on:
• Coolant temperature during starting

• Engine speed/engine load
• Idle speedlpart load operatíon
• Position of resistance trimming pJug
Acceleration enrichment
The injection valves are actuated with additional pulses duríng acceleration to achieve throttle response.
Enri.chment is dependent on:
• Engine speedlengine load
• Speed of load change
• Position of resistance trimming plug
Full1oad enrichment
Fullload enrichment is calculated by tl1e HFM control unít above a throttle valve angle of 80°. The
opening time of the fue] injection valves is extended.
Deceleration fuel shutoff
Deceleratíon fuel shutoff is dependent on:

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• Engine speed
• Th.rottle val ve position
If deceleration fu el sh.ut-off is activated, th.e injection valves are shut off and the throttle val ve is
positioned to a.n a.ngle in line with engine speed.
The decel fuel shut-off ftmction is operational if engine speed rises above 2100 rpm ata coolant
temperature of >40 oc.
The HFM control unit recognizes "deceleration" below a speed-dependent throttle val ve position or ifthe
idle speed contact switch (M16/6s1) is closed.
The injection valves are shut off during deceleration abo ve an engine speed of >21 00 rpm.
The injection va.lves are opened aga.in as soon as engine speed is < 1700 rpm (with automa.tic
transmission) or <1500 rpm (with manual transmission).
In order to prevent a sudden rise in engine torque when fuel injection recommences after deceleration fuel
shutoff, the ignition timing is reta.rded briefly (see Function Ignition System 07.5-0035, Section A,
Deceleration fuel shutofi).
Example
Change in engine speed when fue! injection valves shut off and re-actuated.: fue! i~jection val ves shut off
> 1600 rpm, fuel injection va.lves re-actuated <1200 rpm.
Limitiog maximum engine speed
A leaner mixture is produced or fuel injection is shut off and ignition timing is reta.rded at the following
engine speeds and operating states in order to protect the engine and the dríve train. Engine speed is
govemed by the HFM control unit, which processes the following information for this purpose:
• Engine speed
• Selector lever posüion
Eogine 104
Brief governed speed for 3.5 seconds 6600+50 rpm, then continuous governed speed 6400+50 rpm.
GOVERNING MAXIMUM ENGINE SPEED

1 IRpm thresholdl
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Each 2nd injection valve in firing order off >6200 rpm

All injection valves off >6350 rpm
Each 2nd injection valve in firing order 011 (!) <6325 rpm
All i11jectio11 valves 011 <6200 rpm
(l) All injection valves are shut off
Torque converter protection
The torque co11verter is subjected to i11creased static i11temal pressure in selector lever positio11s P and N.
F or this reason, engine speed is govemed to 4000 rpm when the selector lever is in positions P and N and
vebicle speed is <5 km/h.
Drive train protection
Engine speed is govemed for a period of 1 s to 35()0 rpm if a drive position is engaged and vehicle speed
is <29 km/h in order to minimize the consequences of an "extreme start".
Engine speed of vehicles with a manual transmission is govemed to 4000 rpm at a vehicle speed of <1O
km/h.
E. Influencing parameters for control

a. Engine speed, crankshaft position, ignition circuit recognition
The information regarding engine speed, crankshaft position and ignition circuit 2 recognition for
cylinders 2 and 3 is supplied by the crankshaft position sensor (L5) to the HFM control unit in the
form of an alternating voltage. An analog-digital converter co11verts the altemating voltage in the
control unit into a square-wave signal (TN s igna!).
P07-675Q..13

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The engine speed is calculated over the period of half a crankshaft revolution.
The crankshaft position is detected from the voJtage signals ofthe 1st and 2nd segment (A).
POI -5462-13
Fig. 572: ldentifying Crankshaft Revolution 1st And 2nd Segment
Ignitíon círcuít 2 for cylinders 2 and 3 is recognized by the permanent magnet at the segment (A,
arrow).
P07-5461-1 3
Fig. 573: Locating Permanent Magnet At Segment
Engíne speed, crankshaft position, ignition circuit recognition are requíred by the HFM control unit
for the following functions:
• Fuel injection
o Base injection quantity
o Start control
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o Synchronízation of injection sequence

o Warming-up enrichment
o Fullload enrichment
o Deceleration fuel shut-off
• lgnition
o Ignition during starting
o Ignition during wanning-up
o Ignition during idling
o Ignition during fullload
o Ignition during deceleration fuel shut-off
• Idle speed control
• Catalytíc convetter heating
• Activated charcoal filter purging
• Camshaft adjustment
• Anti -jerk function (MG only)
• Anti-knock control AKR
• Partial intake manifold preheating
• Governing maximum engine speed
b. Camshaft position ignition TDC cylinder 1
The camshaft position sensor (L5/ l) produces an altemating voltage signal for each camshaft
revolution at 20° after TDC of cylinder l. This is conve1ted in the analog-digital converter into a
square-wave signal and further processed in the HFM control unit.
The camshaft position TDC cylinder 1 is required by the HFM control unit for the following
functions:
• Fuel injection
o Synchronization of ínjection sequence
• lgnition
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P07-5443- 13A
Fig. 574: Locating Camshaft Position Sensor
o Ignition during starting

o Fuel shutoff in the event of igmtion faults
o Anti-knock control
c. Road speed signa!
The road speed signa! is supplied by the ABS control unit (N30) and corresponds to the wheel
speed at the rear axle.
The road speed signal is required by the HFM control unit for the following functions:
• Fuel injection
• Transmission shiftpoint retard (AG only)
• Governing maximum propeller shaft speed
d. Coolant temperature
The NTC coolaut temperature sensor (B 1113) in the coolant circuit detects the coolant temperature
and converts it into an electrical signaL
NTC = resistance with negative coefficient. The semi-conductor resistor reduces its electrical
resistance as the temperature rises.
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P07-5443-13A
Fig. 575: ldentifying NTC Coolant Temperature Sensor
This signal is required by the HFM control unit for the following functions:
• Fuel injection
o Start control
o Post-start enrichment
• lgnition
o Ignitíon during starting
o lgnition during warming-up
o Ignition during ídling
o Ignitíon during deceleration fuel shut-off
• Id le speed control
• Catalytic converter heating
• Activated charcoal filter purging
• Transmission shiftpoint retard
• Pinging protection
• Anti-knock control AKR
• Partial intake manifold preheating
e. Intake air temperature
The intake air temperature sensor (B 17) detects the intake air temperature in the intake air flow and
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conve11s ít into electrical sígnals. These sígnals are processed in the HFM control unit and result in
a correction ofthe injection time and ofthe ígnition angle.
The intake air temperature sensor, like the coolant temperature sensor, is an NTC resistor.
The intake air temperature is required in the HFM control unit for the following functions:
• Fuel injection
o Warrning-up enrichment
• lgnition
o Intake air temperature correction
• Activated charcoal fílter purging
PG7-5460-13
Fig. 576: Identifying Intake Air Temperature Sensor
f. ldle speed recognition
The idle speed operating state is detected by the idle speed contact switch (M16/6sl) at the idle
speed control (LLR) actuator (M16/6) and passed to the HFM control unit.
Idle speed recognition is required in the HFM control unit for the following functions :
• Fuel injection
o Deceleration fuel shutoff
• Ignition
o Ignition during idling
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P07-559M3
Fig. 577: Identifying ldle Speed Contact Switch
Engine 104
When the car is moving and the clutch depressed signal is transmitted, the HFM control unit is
actuated by the clutch pedal switch (S40/2). The idle speed control is activated as a result (as for
stationary vehicle).
Po-7-5648-13
Fig. 578: ldentifying Clutcb PedaJ Switch
g. Throttle valve position
The throttle valve position is detected by the throttle valve actual value potentiometer (M16/6rl) in
the idle speed control (LLR) actuator (Ml6/ 6) and passed to the HFM control unit.
The throttle valve position is required in the HFM control unit for the following functions:
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• Fuel injection
o Base injection quantity
o Acceleration enríchment
o Fuel ]oad enrichment
o Deceleratíon fuel shut-off
• lgnition
o Ignitíon during full load
P07-5609-1 3
Fig. 579: Identifying Throttle Valve Actual Value Potentiometer
h. Adaptation of fu el injection and ignition maps with resistance t rimming plug
All vehicles (except USA) are provided with a HFM resístance trímmíng plug (Rl6/5) for adaptíng
various maps. A total of 7 adjustment positions are possible.
The HFM resistance trimming plug (R16/5) influences the following functions in the HFM control
unít:
• Ignition
• Fuel injection
o Base injection quantíty
o Warming-up enrichment P0?-5446-13
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P07-5446-13
Fig. 580: ldentifying HFM Resistance Trimming Plug
L ldle speed CO correction (without KAT)
Vehicles without KAT are fitted with a CO potentiometer (R33) for setting the idle speed
emissions level.
Tuming to the left leaner
Tuming to the right richer
Vehicles with KA T do not have any adjustment facilíty for the ídle speed emissíons level as
mixture adaptation is performed by the lambda control.
P07-5600.1l
Fie. 581: ldentifying CO Potentiometer

Mercedes-Benz
J. Battery voltage a nd voltage supply
The quantity of fuel injected is detennined by the opening times of the fu el injection valves. These
opening times are influenced by the battery voltage. The HFM control unit (N3/4) corrects the
injection time in order to maintain a constant quantity offuel injected even ifthe battery voltage
varies.
For example:
lower battery voltage = longer opening time
higher battery voltage = shorter opening time
The voltage for the HFM control unit is supplied through the overvoltage protection relay (Kl/2).
POT-5442-1 31\
Fig. 582: Identifying Overvoltage P rotection Relay
k Selector lever position (AG only)
The starter lockout switch (S 16/3) is u sed for recognizing selector lever positions PIN and also 2/3
for the HFM control unit.
The selector lever position is required in the HFM control unit for the following functions:
• Fuel injection
• Transmission shiftpoint retard
Mercedes-Benz
P07-5694-1 3
Fig. 583: Identifying Starter Lockout Switch
L Knock sensor signals
A piezo-electric structure-bome sensor is used as the knock sensor (Al6).
The vibrations of the engine block are transmitted to the piezo ceram:ic and passed in the forro of an
alternating voltage signa! along a screened cable to the HFM control unit.
NOTE: =
Piezo effect generation of voltage as a result of pressure on a
certain ceramic
P07-5722-13
Fig. 584: ldentifying Knock Sensor
The knock sensor (Al6) is attached to the engine block below the intake manifold. This fitting
location was chosen in order to detect knocking combustion at all the cylinders.
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The knock sensor signals are required for the anti-knock control (AKR).
PO 7-56{}2-1 3
Fig. 585: ldentifying Knock Sensor And Engine Block
HFM IGNITION SYSTEM DESIGN AND FUNCTION- RA0705HFM0035X(07.5-0035)
A Ignition system engine 104
NOTE: The sections which follow describe the differences compared to the
ignition system of engine 111 HFM.
Location of ignition coils and distribution of the high voltage
The ignition coíls are located at the cylínder head cover. Two spark plugs are supplíed símultaneously
with high voltage from each ignition coiL
Ignition coil Cylinders

T l /1 2and 5
T l/2 3 and 4
Tl/3 1 and 6
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P07-5448.13
Fig. 586: ldentifving lgnition Coils
lgnition coils
The three twin-spark ignition coils are actuated by the HFM control unit through a power output stage
each, switching altemately to ground. The high voltage is thus distributed by an ignition coil so that one
spark plug fires in the power stroke of the cylinder while the other spark plug fires in the exhaust stroke
ofthe cylinder offset by 360°. One crankshaft revolutionlater, the corresponding cylinders have advanced
two strokes and the spark plugs again fue, with the roles now being switched, however.
The second and third twin-spark ignition coils also generate two sparks each, offset, however, by a crank
angle of 120° in each case.
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Zyl.
1
8
i&lidi
-
e o
1111111 ,
. OI(W
P 07-5486-15
A k'lcrucbon s~ck&
B Comprassioo slrd(o
e Rcwer stroke
o Exhaust s~cl«!
E lgrrlJOO spm1<
KW Cr:enk ang!e
Fig. 587: Ignition Coils Spark Graph
The ignition coils (Tl/1, Tl/2, Tl/3) are mounted directly on a spark plug with a spark plug connector via
the secondary output (4a). The secondary output ( 4b) runs via an ígnítion cable to the other cylinder. The
guide sleeve (W) is at the same time the ground connection for the ignition coil.
Mercedes-Benz
P 07-5471-13
Fig. 588: ldentifving Ignition Coils
The primary current is limited by the HFM control unit to about 7 A. The maximum ignition voltage is
about 32 kV.
The resistance of the secondary winding must be tested between both high voltage terminals;
speci:fication 5.2 -8.5 kohms.
The resistance ofthe primary winding between terminals 1 and 15; specification 0.3 -0.4 ohms.
&.oenQer!
Primary terminals conduct voltage up to 400 V. The guide sleeve (W) must always be connected to the
vehicle ground.
&.oantter!
Persons with heart pacemakers shouJd not work on this ignition system .
B. Ignition system engine 111
lgnition coils
The ignition coils (Tl/1, Tl/2) bave two higb voltage terminals (4a, 4b). Eacb higb voltage terminal
supplies a high voltage to a spark plug each.
Tbe primary current is limited by the HFM control unit to about 7 A. The maximum ignition voltage is
about 32 kV.
&.oanaerl
Mercedes-Benz
Primary terminals conduct voltage up to 400 V. Core stack/holder must always be connected to vehicle
ground.
&oanqerl
Persoos with heart pacemaker should not work on this ignitioo system .
P07-54SS-13
Fig. 589: Identifving Ignition Coils
The ignition coil is similar in design to a transformer, the primary and secondary windíngs being isolated
from each other. The two ends of the secondary winding are eacb provided with a high voltage temlinal
and together with two spark plugs fonn a self-contained circuit. During ignition, a high voltage is
produced in the secondary winding. The ignítion sparks jump across simultaneously at both spark plugs,
one ignition spark jumpiing across from the central to the ground electrode and one ignition spark from
the ground to the central electrode. This produces a positive and a negative high voltage to grm:md at the
secondary terminals. The ignition spark in the uncompressed exhaust stroke requires only a low level of
energy so that practically the entire energy stored in the ignition coil is avaiilable for the power stroke.
Mercedes-Benz
4a
P07-5457-15
4a Second!liY ourptt. {¿)

4b SetoOndBI)I cU!pUl {-)
E lrOOCCfi!
l1 Prrmary 'Mnding
l2 Secondar¡ 'Airníng
Fig. 590: Section View Of Ignition Coil
As the secondary winding ís connected in series with both spark plugs, an open circuit ( eg. at the spark
plug connector) affects both ignition sparks. The resistance ofthe secondary winding must be tested
between both lúgh voltage tenninals.
Specification 5.2 -8.5 kohms.
The resistance ofthe prirnary winding between terminals 1 and 15, specification 0.3 -0.4 ohms.
Bene:fits ofthe distributorless high voltage distribution:
• Significantly lower electromagnetic interference level (no open sparks)

• No rotating parts
• Reductíon in noise
• Fewer high voltage connections
1 Mercedes-Benz
1 1990-2002 ENGINE PERFORMANCE Mixture Formation - REPAIR & ADJUSTMENTS- 129 Chassis
•• ~
........
~
1
L1ll
'
L2
1
..,_
~
4b S1't
P07-536E-13
1 Tennll1al 1
4a Se{ondar¡ct~l;lul (... )
4b Seoonda,¡y ootput {- )
15 Teanll1al 15
l1 Pnmar¡ Wlldlrig
l2 Secooda,¡ywindrtg
R4 SpwkpkJg
Fig. 591: ldentifying Ignition Coil Circuit Diagram
• Fewer high voltage connections
Location of ignition coils and distribution of the high voltage
The ignition coils are positioned between the intake pipes. Each ignition coil supplies two spark plugs
simultaneously with high voltage.
Ignition coil Cylinders

Tl/1 1 and 4
Tl/2 2 and 3
Mercedes-Benz
P07-5691-1 3
Fig. 592: ldentifving lgnition Coils And Distribution Of High Voltage
Note regarding testing ignition system with oscilloscope
Ifno image appears on the oscilloscope when testing with the diagnostic tester, the secondary test clamps
at the high voltage cables must be switched over at ignition coil Tl/1 from ignition cable 1 to ignition
cable 4, and at Tl/2 from ignition cable 2 to ignition cable 3.
The three twin-spark ignirion coils are actuated by the HFM control unit through a power output stage
each, switching alternately to ground. The high voltage is thus distributed by an ignition coil so that one
spark plug fires in the power stroke of the cylinder while the other spark plug fires in the exhaust stroke
ofthe cylinder offset by 360°. One crankshaft revolurion later, the corresponding cylinders have advanced
two strokes and the spark plugs again fire, with the roles now being switched, however.
The second and third twin-spark ignition coils also generate two sparks each, offset, however, by a crank
angle of 180° in each case.
Mercedes-Benz
Zyl.
'
4
A B e
P07-5412-1 3
A klducboo s~ol<:e
8 C-cm~esston sl.roke
e p,awer st"ol«!
o Exhat~st ssoke
E lgnbon spal1<
KW Crank at~giB
Fig. 593: Ignition Coils Spark Graph
Multi-spark ignition
Multiple sparks are produced in succession in the ignition timing point in order to increase smooth engine
starting at coolant temperatures of <O °C, but only up to a maximum 10° after TDC and an engine speed
up to 600 rpm.
Synchronization of ignition sequen ce
The ignition sequence is, synchronized during the flrst engine revolutions in order to achieve correct
assignment of the ignition timing point to the respective cylinder. The HFM control unit requires the
signal of the camshaft position sensor (LS/ 1) for recognizing TDC of cylinder 1, and the signal of the
crankshaft position sensor (L5) (magnet segment) for detecting ignition circuit 2 (cylinders 2 and 3).
lgnition during starting
When the engine is started and up to about 600 rpm, the ignition timing point is controlled only via the
rear edges ofthe segments at the flywbeel/driven p late by tbe crankshaft posítion sensor (L5). The
transítíon from tbe fixed ignition timing poínt to the ignition timíng point calculated in accordance with
the operating state of the engine at that moment is not made until engine speed has increased to about 800
rpm.
The followíng ínformatíon is processed in tbe HFM control unit for this purpose:
Mercedes-Benz
Ignition during warming-up
The ignition timing point is corrected in the wanning-up phase in line witb coolant temperature and
engine load.
The following information is processed in the HFM control unit for this purpose:
• Air mass
Ignition during fullload
The HFM control unit recognizes "fullload" above a fixed throttle valve angle. The HFM control unit
takes into account the "advanced" correction angle from the warming-up and heating function.
• Engine speed
• Throttle valve position
• Air mass
lgnition during idling
When the engine is idling, id le speed contact closed, 4 fixed ignition maps are set as a function of coolant
temperature and type oftransmission (manual or automatic). These are not influenced by the HFM
resistance trimming plug.
• Engine speed/cran.kshaft position/ignition circuit recognition
Ignition during decel fuel shut-off
When the injection valves are re-actuated (see Function of gasoline injection system under deceleration
fuel shut-off), tbe ignition tirning point is retarded by up to 15° CA for up to 15 ignitions in order to
prevent a sudden increase in torque when fuel injection is resumed after deceleration fuel shut-off.
Mercedes-Benz
• Engíne operating state
Mercedes-Benz
1990-2002 ACCESSORIES & BODY, CAB Throttle Control, Speed Control Systems- 129 Chassis
1990-2002 ACCESSORIES & BODY, CAB
Throttle Control, Speed Control Systems - 129 Chassis
TESTING & REPAIR

TESTING AND REP AIR WORK: P ASSENGER CARS: THROTTLE CONTROL, CRIDSE
CONTROL SYSTEM- AR30.00-Z-9104AB
ENGINE 104
Adjust throttle ENGINE 104.941 / 942 /943 /944 /991 /992 /994, AR30.10-P-
control 111.920 /940 /941 /944 /960 /961 /97 5 up to 1010D
31.8.96
Adjusting ENGINES 104.945/995 in MODEL 210 AR30.10-P-
accelerator 1010DA
control
Removing and ENGINE 104, 11 L. AR30.10-P-
installing tbrottle 3400D
control cable
Removing and ENGINE 104, 11 L. AR30.10-P-
installing 3400G
accelerator
control cable
Removing and ENGINE 104.94/99, AR30.22-P-
installing idle 111 .920/921 /94/96/970 /973 /974 /975 /977 1152D
speed control (except, 104.990)
(ISC) actuator
TESTING AND REP AIR WORK: PASSENGER CARS: THROTTLE CONTROL, CRIDSE
CONTROL SYSTEM - AR30.00-Z-9113AB
ENGINE 113
Adjusting throttle control ENGINE 112, 113 ... AR30.10-P-1010BA

Adjusting throttle control ENGINE 111, 112, AR30.1 0-P-1 O1OCA
113 ...
Adjust throttle control ENGINE 112, 113 ... AR30.10-P-10 1OGJ
Removing and installing ENGINE 111, 112, AR30.10-P-3400EA
throttle control cable 113, 119, 120, 606 ...
Removing and installing ENGINE 112, 113, AR30.10-P-3400GI
throttle control cable 612, 628 .. .
Removing and installing ENGINE 111 , 112, AR30.12-P-1321 GH
accelerator pedal 113 .. .
Removing/installing ENGINE 113, 156, AR30.12-P-1321 GZ
Mercedes-Benz
accelerator pedal 272, 273, 629, 642in

MODEL 164
Removing/installing the ENGINE 113.971 , AR30.12-P-1321RT
accelerator pedal 272.967, 642.950 in
MODEL251
Remove/install accelerator ENGINE 113, 271, AR30.12-P-1321V
pedal 272 .. .
Removing/installing the ENGTNE 113 .964 in AR30.20-P-1262GZ
electronic accelerator actuator MODEL 164.1
with flap connection
Removing/installing the ENGINE 113 in AR30.20-P-1262RT
electronic accelerator actuator MODEL 251
with tlap connection
ENGINE 119
Adjusting throttle control ENGINE 119.97 with AR30.10-P-1010EA

CODE (471a)
Acceleration slip regulation
(ASR)
Adjusting throttle control ENGINE 119.97 except AR30.10-P-1010EB
CODE (471a)
Acceleration slip regulation
(ASR)
Adjusting accelerator ENGINE 119.981/982/985 AR30.10-P-1010EC
control
throttle control cable
Removing and installing ENGINE 111, 112, 113, AR30.10-P-3400EA
throttle control cable 119 , 120, 606 ...
actuator with throttle
valve body
with throttle valve body
ENGINE 120
Mercedes-Benz
Adjusting throttle control ENGINE 120.980 /981 AR30.10-P-1010F

Adjusting accelerator ENGINE 120.982 /983, AR30.10-P-1010FA
control 606.964
Removing and installing ENGINE ll1 , 112, 113, AR30.10-P-3400EA
throttle control cable 119, 120, 606 ...
Removing and installing ENGINE 120.980 /981 AR30.1 0-P-3400F
throttle control cable
Removing and installing ENGINE 120.980/981 AR30.20-P-1262F
valve body
Removing and installing ENGINE 120.982/983 AR30.20-P-1262FA
valve body
TESTING AND REP AIR WORK: PASSENGER CARS: THROTTLE CONTROL, CRUISE
CONTROL SYSTEM- AR30.00-Z-9129AA
MODEL 129
Remove/install MODEL 124, 129, 140, AR30.12-P-1321D

accelerator pedal 170, 202,208,210, 461,
463 ...
Removing and installing MODEL 124, 129, 140, AR30.12-P-3022D
firewall pivot point with 202, 461, 463 ...
accelerator pedal lever
Remove/install electronic MODEL 129, 163, 170, AR30.20-P-1262A
accelerator actuator with 171 , 202, 203, 208, 209,
flap connection 210, 215, 220, 230, 463 ...
ADJUSTING THROTTLE/ACCELERATOR CONTROL- AR30.10-P-1010
Adjusting tbrottle control- AR30.10-P-1010BA
ENGINE 113.940 #2 in MODEL 210.070 /270
ENGINE 112.923 #2 in MODEL 129.059
ENGINE 112.943 #2 in MODEL 129.064
ENGINE 113.961 #2 in MODEL 129.068
ENGINE 113.980 #2 in MODEL 210.074/274

Mercedes-Benz
1990-2002 ACCESSORIES & BODY, CAB Throttle Control , Speed Control Systems- 129 Chassis
Model129.061
24 A cc olotiltor pedo/
Jl/ 1 #'otcnti'Omotcrtcliy lovor
'1212
2 Th1o rt1o control c.iJblc
Adjusrfng nur
1111 Adjusrtn¡¡ se row
$1617 Kfe~down swttoh
•b CTI' stop
WOT stop
P )O 10-lOOHI6
Fig. 1: ldentifying Tbrottle Control Components (Model129.061)
Model 210.070/270
24 Accolentor podo/
3111 l'otcntlomotortoliy lcv~ r
J2 Throlflc conrrol ~blo
3112 Adjusrfn¡¡ nut
3111 Adjusrfn¡¡ scrow
S 1617 KrddoWn swtto h
• CTI' stop
b wor srop
P)Q 10-4l~D - Oil
Fig. 2: ldentifying Tbrottle Control Components (Model 210.070/270)
<1 Inspecting
1 Inspect ease of operation Replace parts if
and! condition of relay necessary.
le ver (31/1) and throttle
control cable (32)
Mercedes-Benz
Adjusting
2 CTP
The re lay lever (31/1)
should be resting against
the CTP stop (a) when
accelerator is released
3 Turn adjusting nut (32/2)
suffíciently untíl relay
lever (31/1) is resting
against CTP stop (a) or
until there ís no further
accelerator pedal idle
travel
4 WOT [l] Do not opera te
Depress accelerator (24) kickdown switch {Sl6/7)
tmtil it is touching the
kickdown switch (S 1617)
5 Turn adjusting screw [l] Do not overtensíon
(32/3) until relay lever throttle control cable
(31/ 1) is resting against (32).
WOT stop (b)
<j lnspecting
6 Check WOT and CTP
setting
Adjust throttle control- AR30.10-P-1010D
ENGINE 104.941 /942/943 /944 /991 /992 /994, 111.920/940 /941 /944 /960 /961 /975 up to 31.8.96
MODIFICATION NOTES
5.9.99 Replaces SI 30/ 13 from Remove SI 30/13 from
10.10.94 your binder.
Engine 104
Shown on model124 with automatic transmission

Mercedes-Benz
24 AccolcriiiOr po<IJII
JO Thro lllo control coblo
J(l/2 Arfjusrmont nur
JOfJ Arfjusrmcnr screw
J(li$ Guido picor:
J(l/7 Sprlng loHowcr 'I''"'R
32/2 Dr~ lottflr
JV4 Llnfl rotl

JVS Bollcrilnlt
J1/6 Fulr:rum l ovor
J217 Controllovcr
J2/l Rollcr
JVP Lln~ totl Atljus·t.alllo full truottle
stop
91 Control pro ss-uro Bowrlon c~btc
91/2 Arfjusrmcnr scrow

S15t7 Klckdown sWftr:h
Fig. 3: ldentifying Adjust Tbrottle Control- Sbown On Model124 With Automatic Transmission
(Engine 104)
Engine 111
Shown on model124 with automatic transmission
24 Accoler•ror pcrt;ol
10 Throtttc control Cilblo
J(l!2 Arfju:ftmcnt nut
J(l!3 Arfju.rmcnt scrow
l OfS GUi doplcC:c
J(li7 FoNowcr !pring
1112 Dr~~g lovcr
1 214 Llnlt rotl
1 2/5 Boll er11n1t
12/6 FuJc-r um l ottct
121'1 Control lcvor
12/f Ro/ter
12/11 Ll nl! rotl (only wlth cq
31112 DrJJg lovor (only wfth cq
IV1J RcgUiiltfrlg Shilft (onlyWirh CC)
ll ArfjUSfiiOIC full mro lile Sll:lp
91 Control ptcssurc Bowtlcn c;ob/c
91/2 llfljuJtmcnt urcw
t816 Cruiso corrtrol «tuotor(onlywfm
CC)
S15t7 Kl cl<tlown swl r<:h N0ta.o:2't&Ge
Fig. 4: ldentifying Adjust Tbrottle Control - Shown On Model124 With Automatic Transmission
(Engine 111)
Left picture: closed throttle stop (arrow)
Shown on engine 104

Mercedes-Benz
Right picture: full throttle stop (arrow)
Shown on engine 104
1'30 10.o:t17-11'1
Fie. 5: Locating Closed Tbrottle Stop - Sbown On Engine 104
Fig. 6: Locating Closed Throttle Stop - Sbown On Engine 104
Loft picturo: on~ lno 111

1 Bw/1 hcod bolt
2 S¡¡J/$oc~ar
,,,. u.~ rorf

Rlght pi<lure:
JI Adjust•blo ftl/1 rhrortlf> stop
as
(In toorwc/'
Fig. 7: ldentifying Link Rod And Adjustable FuU Tbrottle Stop- Engine 111
Adjust
Ltl lgnition: OFF
1 Check condition oflink If necessary, fit new parts
rods (32/4, 32/9) and
reversíng lever (30) and
Mercedes-Benz
check for ease for

movement
2 Check play between the There must be play *BE30.10-P-1001-01A
follower spring (30/7) between the follower
and! the guíde píece spríng (30/7) and the
(30/ 5), adjust guide piece (30/5). If
necessary, adjust with the
adjustment screw (30/3)
3 Unclip the link rod (32/4) The bell crank (32/5)
on one side and check the must lie adjacent to the
closed throttle stop closed throttle stop of the
idle speed control
actuator
4.1 Clip in the link rod (32/4) Engine 104: The link *BE30.10-P-1002-01A
free from tension rod (32/4) must be set to
a fixed measurement.
Measured from baH
socket center to ball
socket center.
4.2 Set the link rod (32/4) Engine 111 : Fit the link *BE30.10-P-1002-01A
rod (32/4) free from
tension at the ball socket
(figure). Short the link
rod (32/4), to do this, tum
in the baH socket (2) two
revolutions, attach and
loek
[l] The link rod (32/4)
must be adjusted very
precisely. During this
operation, the
microswitch for smooth
idle control must be
operated (closed).
5 Idle setting on engine Engine 104:
side The roller (32/8) in the
Check settíng of control controllever (32/7) must
lever (32/7), adjust líe adjacent to the limit
stop of the slotted lever
(32/6). If necessary,
adjust the slotted lever
(32/9) with the link rod
(32/6) so that the roller
(32/8) is free from
tension adjacent to the
limit stop
Mercedes-Benz
6 Adjust control pressure W ith the control pressure

control cable (98) Bowden cable attached,
turn the adjustment screw
(98/2) tmtil the tip of the
drag lever (32/2) is at the
same height as the tip at
the slotted lever (32/6).
7.1 Check the fuU throttle Mechanical
stop, adjust transmission :
Depress the accelerator
pedal (24) with the
engine switched offup to
the full throttle stop. The
bell crank (32/5) must lie
adjacent to the full
throttle stop of the id le
speed control actuator. If
necessary, unlock the
adjustable full throttle
stop (38) by turning to
the left. Pull out the stop
bo lt slightly, lock the full
throttle stop (38) by
turning to the right.
[JJ Full throttle stop anti- Models 124, 129, 202 BT30.10-P-0003-0IA
twist protection enlarged
7.2 Automatic
transmission :
Depress the accelerator
pedal (24) w ith the
engine switched off up to
the full throttle stop at the
kick-down switch (S 16/7)
(do not operate the
kick-down switch!).
The beU crank (32/5)
must be located just in
front of the fu U throttle
stop of the idle speed
control actuator, if
necessary, adjust with the
adjustment screw (30/3).
Wl1en operating the kick-
down switch, the bell
crank must líe adjacent to
the full throttle stop.
8 Check the idle speed Accelerator pedal (24) in
Mercedes-Benz
setting on the chassis id le throttle posiüon. Play

side, adjust must be present between
the follower spring (30/7)
and the guide piece
(30/5), if necessary,
adjust the vehicle interior
with the adjusting nut
(30/2)
9 Lubricate control cable * BR00.45-Z-1 006-06A
(30) between guide (30/5)
and end element witb
corrosion protection
grease
10.1 Set the link rod (32/ 11) IZJ Only on engine 111
witb cruise control
U nclip the link rod on
one side_The control
lever (30/5) must be in
the idle speed position.
Turn the regulating shaft
(32/7) in a clockwise
direction (arrow) up to
the stop (idle speed
position)_ Turn the drag
lever (32/ 12) in a
clockwise direction, until
it lies adjacent to the
regulating shaft (32/ 13).
Now adjust the link rod
(32/ 11) so that it can
attached free from
ten sion
INSPECTION SPECIFICATIONS OF THROTTLE CONTROL

BE30.1 0-P-1001- Play of control cable mm 0.5-1.0 0.5- 1.0
Ol A between follower
spring and guide piece
at fulcmm lever
BE30.10-P-1002- Length of link rod to mm 84 -
OlA bell crank (fixed
measurement)
REPAIR MATERIALS
BR00.45-Z-1006-06A Grease A 001 989 37 51 10
Mercedes-Benz
1990-2002 ACCESSORIES & BODY, CAB Throttle Control, Speed Control Systems - 129 Chassis
Adjusting throttle control - AR30.10-P-1010EA
ENGINE 119.97 with CODE (471a) Acceleration slip regulation (ASR)
A Modol124 11 Controlprossuro8owdon c•blo 31 Adjusrfng nut

a Modt l129, uo 24 Accelar•ror pcd•l $1017 ICII:Itdown sw/fc/'1
CrQ/IIt lovor lO Or/vcr spr/ng l.ffa/1 Ell:r:tron/c •er:ciOre>r{~ 11cru•ror
2 Connocrtng tod 28 Adjustin¡¡ bolr A"ow C7P stop
7 Lo ver JO Bowctcn c•blo
• Cr•nl< levar
Fig. 8: ldentifying Adjusting Tb rottle Control Components- Engine 119.97 W ith Code
<l Inspecting
n::!rGF lgnition: OFF
1 Inspect ease of operation lf necessary replace
and condition of Bowden
cable (30) and throttle
control rods
2 Detach connecting rod
(2) at one side
3 Inspect CTP stop Crank lever must be
resting against CTP stop
(arrow) of electronic
accelerator (EA) actuator
(Ml6/1) (stop audible)
4 Attach connecting rod (2)
at one side
Adjusting control
pressure Bowden cable
(11)
5.1 Turn connecting rod (2) Left-hand steering *BE30.10-P-1001-01C
Mercedes-Benz
For this step, the tips at

the crank lever (8) and
lever (7) must be
positioned exactly
opposite when control
pressure Bowden cable is
attached. Lock nuts at
ball sockets
DJ Crank lever of right-hand BT30.10-P-0001-01A
steering/left-hand
steering standardized
5.2 Turn connecting rod Right-hand steering AR30.1 0-P-1 O10-0 l E
DJ Crank lever of right-hand BT30.10-P-0001-01A
steering/left-hand
SettingWOT
6 Ignítion: ON [l] The ignition must be
switched on otherwise the
throttle valve does not
move to wide open
throttle (WOT)
7 With engine switched off, Crauk lever (1) must be
depress accelerator pedal restiug agaiust WOT stop
(24) from iuside the car of electronic accelerator
as far as the stop at (EA) actuator (M 16/ 1)
kickdowu switch (S 1617) (stop audible); alter
switch!) flf),
(do not operate kickdown position of adjustiug nut
if uecessary.
If the throttle control
linkage is operated from
the eugine compartmeut
when the ignition is
switched on, the EA
control module switches
to emergency runuiug
mode and a fault is stored
in the fault memory.
Read fault memory
Setting CTP
8 Inspect CTP stop Driver spring (26) at
Bowdeu cable must be
making contact free of
play; alter positiou with
adjustiug bolt (32), if
necessary
9 Grease Bowden cable *BR00.45-Z-1006-06A
Mercedes-Benz
(30) with corrosion

protection grease between
end pieces and guíde
píe ce

BE30.1 0-P-1001-0 1e Length of connectíng rod mm 134
(LHS)
BE30.1 0-P-1 002-01 e Length of connecting rod mm 66
(RHS)
REPAIR MATERIALS
Number Designatio u Order number
BR00.45-Z-1006-06A Grease A 001 989 37 51 10
Turning connecting rod- AR30.10-P-1010-01E
[[] Bell crank of right-hand BT30.10-P-0001-01A

steering/left-hand steering
standardized
TEST DATA OF ACCELERATOR CONTROL

Number Desiguation Eugine 119.97
BE30.1 0-P-1002-0le Length of connecting rod mm 66
(RHS)
On models witb right-hand steering, tum connecting rod (2a) until the tips at the bell crank (8) and lever (7) are
exactly opposite each other when the control pressure Bowden cable is attached.
Fig. 9: ldentifyiug Connecting Rod, Tips Bell Crank And Lever
Adjusting throttle control- AR30.10-P-1010EB

Mercedes-Benz
ENGINE 119.97 except CODE (471a) Acceleration slip regulation (ASR)
fl30i~
A Modol124 u Flllr:rum /cvcr n Artjusrin¡¡ nut

B Modol129. 140 15 Rol/cr 40 Conncr:rlnj¡ rod
J Cr.J.nttlcvcr 24 Accclcrotor pedo/ $1617 Kic Adown JW ifc(l
2 Conncr: ring rod 25 RcstorirlJI sprlng 1116'1 Elcr:tron/c •r:r:olcr~r(E-4/ .ar:lllotor
L.cvcr 2e Orlvcr sprlng Arrow CTP stop
Cronlt levar 2V Ad}usring bo/t
'
1f Contro 1prcssurc 8owdon ~~bfc 30 Bowdcn cobla
F ig. 10: ldentifving Ad justing Throttle Control Components - Engine 119.97 Excep t Code
<) Inspecting
!GrGF Ignitiou: OFF
1 Iuspect ease of operatiou If necessary replace
andl condition of Bowden
cable (30) and tbrottle
control rods
2 Iuspect Bowden cable Driver spring (26) must
(30) be making contact free of
play; alter position with
adjusting bolt (29), if
necessary.
Setting CTP at engine
side
3 Inspect fulcrum lever Roller ( 15) must be *BE30.10-P-1003-01C
(13), adjust resting free of stress in
fulcrurn lever (13).
Adjust fulcrum lever
(13), ifnecessary, with
connecting rod (40, left-
hand, right-hand thread)
Mercedes-Benz
so that the roller (15) is

resting free of stress
against end stop. Lock
nuts at ball sockets
[[] Restoring spring between BT30.10-P-0002-01A
fulcrum lever and throttle
controllever modified
3 Detach connecting rod
(2) at one side
4 Inspect CTP stop Crankleverrnustbe
resting against CTP stop
(arrow) of electronic
accelerator (EA) actuator
(Ml6/1) (stop audible)
5 Attach connecting rod (2)
at one side
Adjusting control
pressure Bowden cable
(11)
6.1 Turn connecting rod (2) Left-band steering *BE30.10-P-1001-01C
For this step, the tips at
the crank lever (8) and
lever (7) rnust be
positioned exactly
opposite when control
¡pressure Bowden cable is
attached. Lock nuts at
ball sockets
[JJ Crank lever of right-hand BT30.10-P-0001-01A
steering/left-hand
steering standardízed
6.2 Turn connecting rod Rigbt-hand steering AR30.10-P-1010-01E
[JJ Crank lever of right-hand BT30.10-P-0001-01A
steering/left-hand
SettingWOT
7 With engine switched off, Crank lever (1) must be
depress accelerator pedal resting against WOT stop
(24) from inside the car of electronic accelerator
as far as the stop at (EA) actuator (M l6/ l)
kickdown switch (S 1617) (stop audible); alter
(do not operate kickdown position of adjusting nut
switch!) (29), ifnecessary.
Setting CTP at chassis
side
Mercedes-Benz
8 Inspect eTP stop Driver spring (26) at

Bowden cable must be
making contact free of
play; alter position with
adjusting bolt (32), if
necessary
9 Grease Bowden cable *BR00.45-Z-1006-06A
(30) with corrosion
protection grease between
endl pieces and guide
ptece

Number Designatioo E ngine 119.97
BE30 .1 0-P- 1001-01 e Lengtb of connecting rod mm 134
(LHS)
BE30.10-P- 1002-01e Length of connecting rod mm 66
(RHS)
BE30.1 0-P- 1003-01 e Length of connecting rod mm 77
to fulcrum lever
REPAIR MATERIALS
BROO .45-Z-1 006-06A Grease A 001 989 37 51 10
Adjusting accelerator control - AR30.10-P-1010EC
ENGINE 119.9811982/985
6 Ac:colcrotor control boll <:r•n~

U Ac:cclcrator pcdal
~~ A<fjmtingnut
JO Bowdcn cable
J2 Adjust"'g scro w
CIOJCd mrorrtc stop
b Wldc opon rhrortto stop
8 17 Pod•lpostrlon&cnsor
S1417 Klcl<d-n swftth
Fig. 11: Identifying Accelerator Control Components

Mercedes-Benz
Adjusting closed
throttle position
1 Check closed throttle stop Accelerator control bell
crank (6) must be making
contact w íth closed
throttle stop (a) of the
pedal position sensor
(B37). Alter adjusting
screw (32), if necessruy.
Adjusting wide open
throttle
2 With engine switched off, 111 Accelerator control
depress accelerator pedal be 11 crank (6) must be
(24) from inside the car making contact with wide
as far as the stop at open throttle stop (b) of
kickdown switch (S 1617) the accelerator position
(do not operate kickdown sensor (B37). Alter
switch!) adjusting nut (29), if
necessary.
Adjusting tbrottle control - AR30.10-P-1010F
E NG INE 120.980 /981
Dlustrated on model 140
Anglo leva r
Conne-ctrng rod
Conneclfng rod
Control tJ;~nsfcr levo r
Cont rolprcssuro ~oattol c;~b/o
trillfttfcr /evor
11;J Ac1)usrmom .scro w
14 Acco/erodor pod;~/
26 Drlvor sprfng
29 A djusrmonr nut
JO Cont rol coblo
J2 Ac(luscrmonr nut
91 Control prassure coarto/ e• blo
/MM Elocrtonlc •ccoltr•ror poda/
octu•tor
S1511 Kid rSown sWilrh
1 •
F ig. 12: Identifying Adjusting Throttle Control - lllustrated On Model140
~GF lgnition: OFF

1 Check connecting rods Replace parts if required * BE30.10-P-1001-01B
(2, 3) and control cable
(30) for easy motion and
good condition
Mercedes-Benz
*BE30.10-P-1002-01B
Idle adjustment
2 Check idle stop The angle lever (1)
should rest against the
idle stop on the electronic
accelerator pedal actuator
(M16/3) (stop audible).
Driver spring (26) should
make contact with control
cable without play.
Adjust ifnecessary with
adjustment screw (32)
3 Adjust control pressure F or this purpose, the tips
control cable (98) of the control transfer
lever (6) and control
pressure control cable
transfer lever (7) must be
positioned exactly
opposite one another with
the control pressure
control cable hooked in.
If necessary, adjust with
adjustrnent screw (lla)
F uml throttle adjustment
4 Ignition: ON ~ The ignition must be
switched on, otherwise,
the throttle flap does not
move to the full throttle
position
5 Press accelerator pedal ~ The angle lever ( 1)
(24) down to stop on should make contact with
kickdown switch (S 16/7) the full throttle stop on
from inside of car with the electronic accelerator
engine shut off (do not pedal actuator (Ml6/3)
actuate kickdown (audible stop), if
switch!) necessary adjust with
adjustment nut (29).
Ifthe control rod is
actuated from the engine
compartment with the
ignition switched on, the
control module (N4/ l)
goes to the limp-home
mode. To cancel the
limp-home mode, switch
Mercedes-Benz
off the ignition

6 Ignition: OFF
7 Accelerator pedal in idle [l] If necessary, adjust *BE30.10-P-1003-01B
position driver spring (26) play
with adjustment nut (32)
from inside of car
(30) between end
elements and guide
element with corrosion
protection grease
TEST VALUES FOR CONTROL

Number Designation Engines 120.980,
120.981
BE30.10-P-1001-01B Length of connection rod mm 173
to control transfer lever
BE30.10-P-1002-01B Length of connection rod mm 63
to angle lever
BE30.1 0-P-1 003-0IB Control cable play mm 0,5-1,0
between driver spring and
guide on transfer lever
REPAIR MATERIALS
BROO .45-Z-1 006-06A Grease A 001 989 37 51 10
Adjusting acceJerator control- AR30.10-P-1010FA
ENGINE 120.982 /983, 606.964
6 A ceo 111 raror e ontrol relay lo ver

1A Accolorarorpodal
28 Adjustíng nur
JO SOWdon cable
J2 Ad}USlinll botr
ClostJd llllorrte stop
b Wldo opon ttrrortlo Scll)¡l
BJ7 Podalpostt-ionsf111Sor
S1 al1 Klc«down swftt;h
• 831
Mercedes-Benz
Fig. 13: Identifying Adjusting Accelerator Control Components- Engine 120.982 /983
Engine 606.964
6 A«OIG rilO" QntrolfOiiY IGir'cr

24 At:ec /Gtitotpcd~l
29 A djustlng mrt
JO Sowdcn c~olc
J2 A djustlng i>c lf
Closed fllrorrto stop
o Wfdc opon ltltotllo >"foP
IIJ 7 Pcd•l posfrlo n sensor
S1af1 Klclidcwn sWfrth
St617
Fig. 14: Identifying Adjusting Accelerator Control Components- Engine 606.964
<j Adjusting
Adj usting closed
throttle
1 Check closed throttle stop Accelerator control relay
lever (6) must be
touching closed throttle
stop (a) ofthe pedal
position sensor (B37).
Alter, if necessary, with
adjustíng bolt (32).
Adjusting wide open
throttle
2 With engine switched off, [l] Accelerator control
depress accelerator pedal re lay lever ( 6) must be
(24) from inside caras far touching wide open
as stop at kickdown throttle stop (b) of pedal
switch (S 16/7) (do not position sensor (B37);
operate kickdown alter, if necessary with
switch!) adjusting nut (29)
3 Lubricate Bowden cable * BR00.45-Z-1 006-06A
(30) between end pieces
andl guide piece with anti-
corroston grease
REPAIR MATERIALS
INumber IDesignation ¡order number
RR00.45-Z-I 006-06A Gre::~se
Mercedes-Benz
REMOVING AND INSTALLING THROTTLE CONTROL CABLE - AR30.10-P-3400
Removing and installing throttle control cable - AR30.1 O-P-3400D
ENGINE 104,941 /942 /943 /944 /991 /992 /994, 111.920 /940 /941, 111.944 up to 31.8.96, 111.960 /961 /974,
111.975 up to 31.8.96
Engine 104
30 A ce ci-G~or control e ~blc

J0/ 4 PIJ~Srlc clip
lQ/5 Gulr!opl occ
JQ;/6 Rubl>cr i'Ommor
U J3 Accof.crMor control leve.r br~c:lu:t
33 Accolornor po<lo//cvor
U /1 Ro.storlnSI sprfng
AttOW Accclo~or control CJblo mount
Fig. 15: ldentifving Throttle Control Cable Components- Engine 104
Engine 111
30 A ce ctontor control e•blc

3014 PIJ~Srlccllp
301$ Gulr!op/oco
JIA'6 Rubl>cr ¡¡rommot
3113 AccclcrJtor control levar brOJC~ot
31 Accclornor po<lollovor
13/ 1 Ro.storlilg sprlng
ArtoW A ce oforator control e ~le mount
Mercedes-Benz
Fi~. 17: Identifyin~ Throttle Control Cable Components
,&. DanQer! @ Removing, installing

1 Take out guide piece First of all, pull plastíc
(30/ 5) nipple out of guide piece
2 Compress plastic clip
(30/4) and pull off
bracket of accelerator
controllever (32/3)
together with accelerator
control cable
3 Detach accelerator Model 124 release
control cable mount restoring spring (33/ 1).
(arrow) at accelerator Model129, 140, 202 take
pedallever (33) out bracket together with
expanding pin
ll1 Accelerator cable with
spring in accelerator
control cable mount. At
WOT stop, the
accelerator pedallever
travel is increased by the
spring being compressed.
This enables the
kickdown switch to
operate.
4 Press accelerator control Do not press out rubber
cable (30) out, working grommet (30/6)
from inside the car
5 Take out accelerator
control cable (30)
complete, working from
engine compartment
6 Instan in the reverse
order
7 Grease accelerator * BR00.45-Z-1 006-06A
control cable (30)
Mercedes-Benz
between guide piece

(30/5) and end piece with
anticonosion grease
8 Check accelerator AR30.10-P-1010D
control, adjust
REPAIR MATERIALS
Nomber Designation Order number
BROO. 45-Z-1 006-06A Orease A 001 989 37 51 10
Removing and installing throttle control cable- AR30.10-P-3400E
ENGINE 119.97
fi:J0 1~
14 Model12• 14 Accolor•rot pod•l tovot 3CU Rubl>crgrommor

8 Modol• 129.1410 30 Control o• blo 35 RofUtnJpring
o Control 1ovu j0/4 1'/~tlo el., J7 Holdat
10 F/xcd fOliO( 3015 Guido Atrow Control ubio mount
Fig. 18: Identifying Throttle Control Cable Components- Engine 119.97
&oanqcrl @ Removal, installation

1 Remove guide (30/5) First pull plastic nipple
ou.t of guide, do not
damage
[l] lnstallation : Ensure
that plastic nipple catches
in guide
2 Unhook control cable
(30) from controllever
(9)
Mercedes-Benz
3 Press plastíc clip (30/4)

together and remove from
fixed lever ( 1O) together
wíth control cable
4 Remove footwell
paneling
5 Unhook control cable Model124
mount ( arrow) from Unhook retum spring
accelerator pedallever (35), hook in
(14) Models 129, 140
Remove holder (37),
instan
6 Push control cable (30) [l] Do not press out
toward exterior from rubber grom.met (30/6)
passenger compartment
7 Completely remove
conn·ol cable (30) :fiom
engine compartment
8 Reinstall in opposite
order
(30) between guíde (30/5)
andl end element wíth
corrosion protection
grease
10 Check control, adjust With ASR, code 47la AR30.10-P-1010EA
Without ASR, code 47la AR30.10-P-1010EB
REPAIR MATERIALS
BR00.45-Z-l 006-06A Grease A 001 989 37 51 10
Removing and installing throttle control cable- AR30.10-P-3400EA
ENGINE 119.981 in MODEL 140.042 /043 /063
ENGINE 120.982 in MODEL 140.056 /057 /076

Mercedes-Benz
ENGINE 111.944 as of 1.9.96 in MODEL 202.025/082
ENGINE 111.975 as of 1.9.96 in MODEL 202.024/085
ENGINE 112.910 in MODEL 202.026 /086
ENGINE 112.920 in MODEL 202.029 /089
ENGINE 112.940 in MODEL 208.365 /465
ENGINE 112.921 in MODEL 210.063 /263 /081 /281
ENGINE 112.941 in MODEL 210.065 /082 /265 /282
ENGINE 113.940 in MODEL 210.070 /270
ENGINE 119.985 in MODEL 210.072 /272
ENGINE 111.947 in MODEL 210.045 /245
ENGINE 113.980 in MODEL 210.074/274
ENGINE 113.944 in MODEL 202.033/093
ENGINE 113.943 in MODEL 208.370 /470
Shown on model140
Mercedes-Benz
1990-2002 ACCESSORIES & BODY, CAB Throttle Control , Speed Control Systems - 129 Chassis
10 Fbtcd lcvcr
U A ce clcr•tor pod illlov or
10 Sowden c•l>lc
J0/4 Pl.nic clip
101e Rubl>cr grommet
JS Rcstor/rlg<spring
J7 Br•cllct
Arrow Aoccicr•tor controrublc mount
Fig. 19: Identifying Throttle Control Cable Components (Shown On Model ll 40)
Shown on model 210
10 Flxcd lovcr
JO A«ccicr.>tor conrro/ col>lc
JC!-'4 Plutic clip
10,1& Rul>bcr ¡¡rommcr
JJ Acccior.>tot pcd•IIC!Icr
J~ Restorlns¡ sprlns¡
17 Brocl'ict
Artow Ac.cDIGRtor controlc::iJblo mount
Pl!l10.oQ291-1)5
Fig. 20: Identifying Throttle Control Cable Components (Shown On Model210)
6 oanQer! @ Removing,
installing
1 Disconnect
accelerator control
cable (30) at ball
head
2 Compress plastic
Mercedes-Benz
clip (30/4) and pull

out of fixe d lever
(10) together with
accelerator control
cable
3 Remove footwell
trim
4.1 Release accelerator On engine 111 .943/944/973/975,
control cable mount 112.921 /941 , 119.981/982/985,
(arrow) at 120.982/983, 606.961:?
accelerator pedal llJ Remove bracket (37) for this purpose.
lever (33)
5 Push accelerator [[] Do not press out mbber grommet
control cable (30) to (30/6).
the outside from
inside the car
6 Take out accelerator
control cable (30) llJ Potentiometer relay lever (31/1) with
completely, spring. At WOT stop the accelerator pedal
working from the lever travel is enlarged by the spring being
engine compressed. This makes it possible to
compartment operate the kickdown switch.
order
8 Check accelerator Engine 111.944/975 up to 31.08.96 AR30.1 0-P-1 OlOD
control, adjust Engine 111 .943/973/947
Engine 111.944/97 5 as of Ol. 09.96
Engine 112.910/920/921/940/941/943: ?
manual transrnission AR30.1 0-P-10 1OC
automatic transmission AR30.10-P-
lO lOCA
Engine 113.943/944/984:?
Engine 112.923: ? 1010CA
manual transrnission AR30.1 0-P-10 1OC
Engine 112.923/943
Engine 113.940/961/980:?
lO lOBA
Engine 119.981/982/985 AR30.10-P-
lOlOEC
Engine 120.982/983 AR30.10-P-
lOlOFA
Engine 606.961 AR30.10-P-
1010HC
Mercedes-Benz
Removing and installing throttle control cable- AR30.10-P-3400F
ENGINE 120.980 /981
tnmsfor lcver
10 Fbiod lover
10 Contr olc~blc
J ()¡,¡j Pl;nriccllp
1Qf.S Guido
10/11 Rubl>cr gro mrnct
l3 A ce olorJtor pod~JI Jcvcr
JJ/1 Rcrurn sprlng
J1 Holder wlth !pro.odt>¡¡ p fn
Arrow C-on trol e Qb fo mou nt
Fig. 21: ldentifving Tbrottle Control Cable Components - Engine 120.980 /981
& oanQer! @ Removal, installation

1 Remove guide (30/5) First pull plastic nipple
out of guide
[lJ When installing
ensure that the plastic
nipple catches in guide
2 Unhook control cable
(3 0) from transfer lever
(6)
3 Press plastic clip (30/4)
together and remove from
fixed lever ( 1O) together
with control cable
4 Remove cover below
instrument panel
5 Unhook control cable For this purpose, pull out
mount ( arrow) from holder with spreading pín
accelerator pedallever (37)
(33)
6 Push control cable (30) [l] Do not press out
toward exterior from rubber grommet (30/6)
passenger compartment
Mercedes-Benz
7 Completely remove F or this purpose: ?

control cable (30) from On model140
engine compartment Remove air colJection
housing, reinstall. See
Repair instructions for
automatic heater, model
140, Operation no. 83-
140
6 Reinstall in opposíte
order
7 Lubrícate control cable [l] Control cable with * BR00.45-Z-1 006-06A
(30) between guide (30/5) spring in control cable
and end element with mount. At full throttle
corrosion protectíon stop, the accelerator pedal
grease lever motion is increased
by pressing the spring
together. This allows the
kickdown switch to be
switched
8 Check control, adjust AR30.10-P-1010F
REP AIR MATERIALS

BROO .45-Z-1 006-06A Grease A 001989 37 51 10
REMOVE/INSTALL ACCELERATOR PEDAL- AR30.12-P-1321D
MODEL 124, 129, 140, 170,202,208,210,461,

463.200 /204/206/207/208/209/220/221/224/225/227/228/230/231/232/233/240/241/300/304/307/308/3 20/321/3
Diagram left
Models 124, 463, 461
Diagram right
Motlels 129, 140, 170, 202, 208, 210

Mercedes-Benz
Fig. 22: ldentifving Accelerator Pedal Components (Models 124, 463, 461)
Fig. 23: ldentifying Accelerator Pedal Components (Models 129, 140, 170, 202, 208, 210)
Figure/ítem, etc. Work instructions

24/3, 24/1 Expanding clip or The expanding clip or
expandíng wedge pín expanding wedge pin
must engage properly
REMOVING AND INSTALLING FIREWALL PIVOT POINT WITH ACCELERATOR PEDAL

LEVER - AR30.12-P-3022D
MODEL 124, 129, 140, 202, 461, 463 (except,

Mercedes-Benz
MODEL 124, 463, 461
Shown on model 124
10 Th~lflc control CóJO/c

JJ AcceicróJCOt pcd., ltNfl.r
11.11 Rctumsptfng
J4 Flrow•ll p/vor po 1m
:W1 Bolts
Arrow l.ocldngpfll
Fig. 24: ldentifving Firewall Pivot Point With Accelerator Pedal Lever - Model 124, 463, 461
MODEL 129, 140, 202
31 Aa:oletJtor pcd•llcvcr
Jo! Firowollplvotpo/nt
:WI Rttt•fnet
Fig. 25: Identifying Firewall Pivot Point With Accelerator Pedal Lever- Model129, 140, 202
Lt. oanaer! @ Removing, installing

1 Remove/install AR30.12-P-1321D
accelerator pedal
2 Remo ve firewall pívot
point (34) together with
accelerator pedal lever
(33)
3 Pull firewall pívot point By pulling off the retainer
(34) off accelerator pedal (34/1)
lever (33) ~ On models 140,463,
461, only use the locking
ring (34/3).
ITJ Retainer for accelerator Modell40 BT30.12-P-OOOI-01A
pedallever modified
4 Install in the reverse ~ The locking pín
order (arrow) for the firewall
pivot point (34) must
engage in the bore in the
Mercedes-Benz
flfewall
<) Checking
5 Check and adjust throttle Engines 111 , 104 AR30.10-P-1010D
controllinkage
Engine 119.97 with ASR AR30.10-P-1010EA
code 471a
Engine 119.97 without AR30.10-P-1010EB
ASR code 471a
Engine 119.98 AR30.10-P-1010EC
Engine 120.980/81 AR30.10-P-1010F
Engine 120.982/83, AR30.10-P-1010FA
engine 606.964
Engine 602.983 in model AR30.10-P-1010GG
461
Engines 604.910, AR30.10-P-1010HB
605.910/960 in model
202 with automatic
transmission 722.4
Engine 605.910/960 with AR30.10-P-lOlOHC
manual transmission
717.4
Engines 605.910/960,
606.961 with automatic
transmission 722.6
REMOVING AND INSTALLING ELECTRONIC ACCELERATOR ACTUATOR WITH THROTTLE

VALVE BODY!FLAP CONNECTION - AR30.20-P-1262
Remove/install electronic accelerator actuator with flap connection- AR30.20-P-1262A
MODEL 129,163, 170, 171,202,203,208,209,210,215,220,230,463 (except, 215.376/378/379,

220.176 /876 /178 /878 /179, 230.476 /477 /479)
Mass air flow sensor removed
Shown on engine 112 in model 210

Mercedes-Benz
112 Cr-ease venlllalfon !Jite

In 8ol!s
M O.r!ng
18 IncAico m""lold
MISA ThJOtJlev.alvut:1uotor
Arrow: Ptugeonnect.ion
P3020422< 12
Fig. 26: Identifying Electronic Accelerator Actuator Components With Flap Connectioo
&oanqcrl @ Remove/install
1 Detach crankcase vent
line (1/2) from intake
manifold (19)
2 Disconnect electrical [l] Pull catch backwards.
connector ( arrow)
3 Remove bolts (8/ 1) and [l] Installation: Replace
throttle valve actuator 0-ring (8/2).
(Ml6/6)
Removing and installing electronic accelerator actuator with throttle valve body- AR30.20-P-1262E
ENGINE 119.97
Mercedes-Benz
i4 V<>euum lfn" Je G•sl<or IA15> 1 Etcccronlc ;>eco/cr¡¡ ror •c ru•ror

24• v~uum lino ll Sc:rcws IA1511X1 Plug-ln conn<:ct/on, clcClfronl c
ze V ene IK>sc 41 L.ln~"ll• rrxl •"ctclo r~rthrOftlc ••ru•ror
Jf Connec:tion hOJc 42 R'tlrurn spril>g
J2 Hose clomp
Fig. 27: ldentifying Electronic Accelerator Actuator With Throttle Valve Body- Engine 119.97
&oanqer! @ Removing, installing

1 Remove, ínstall hot-wíre AR07.41-P-1453E
aírflow sensor
2 Loosen hose clamp (32) ij] Note ínstallatíon posítion *WH58.30-Z-1002-
and remove connectíng (arrows). 06A
hose (31).
3 Undo plug-ín connectíon ~GF When replacíng the
on throttle actuator throttle actuator ensure that
(M16/ lxl) to release wire. the wiring is routed
correctly.
Wiring for electronic Model Series 124.036 up to AR30.20-P-1262-01A
accelerator pedal 06/93
Wíríng for electroni e Model Series 124.034 AR30.20-P- 1262-0I B
accelerator pedal
[JJ Routing ofwiring for Model Series 124.036 BT30.20-P-0001 -01A
electronic accelerator starting 07/93
pedal cbanged
4 Detacb linkage rod (4 1) ij] Note installation positíon
and return spring (42). of retum spring (42).
5 Unscrew vacuurn line (24, ~ Fig. 28
24a) from brake booster.
6 Pull offvent hose (29) for
positive crankcase
Mercedes-Benz
ventilation at separation
point (arrow).
7 Unscrew bolts (38). llJ Replace
microencapsulated bolts.
~ *BA30.20-P-1001-01A
8 Tilt electroníc accelerator llJ Clean joint surface and *BR00.45-Z-1010-01A
pedal throttle actuator replace gasket (36). Place
(Ml6/ l) with control-side gasket wíth Hylomar on the
throttle-body opening actuator.
upward, then rotate 1/4
tum counterclockwise to
remove.
10 Adjust throttle control With ASR Code 471a AR30.10-P-1010EA
Without ASR Code 471a AR30.10-P-1 OlOEB
8 ELECTRONIC ACCELERATOR PEDAL ACTUATOR

Number Designation Engine 119, 120
BA30.20-P-l 001-0 lA Bolt, electronic Nm25
accelerator throttle
actuator to íntake
manifold
'\
~
000 599 70 03 00
..J
RilQ WHIIICfl bl
Fig. 28: ldentifving Ring Wrench Bit (000 589 70 03 00)
CO~~RCIALLYAVAILABLETOOLS
Number Designation
REPAIR MATERIALS
BR00.45-Z-1010-01A Sealant A 001 989 25 20
Removing and installing electronic accelerator with throttle valve body- AR30.20-P-1262EA
Mercedes-Benz
ENGINE 119.981/982/985
31 Conno<ting hose
J2 Hoso clf>
Je G.as~ct
31 So/U
MIG/1 Elocttonf< •«clotaff>r••tu•tor
181811.<1 Eloctronf< •ccolor.ror•<tu•tor
connocror
Fig. 29: Identifying Electronic Accelerator With Thr()ttle VaJve Body Components
Lt. Oanqcr! @ Removal, installation

1 Remove hot film mass air AR07.07-P-1453E
flow sensor, install
2 Slacken hose clip (32) [l] Pay attention to *WH58.30-Z-1 002-06A
andl take off connecting instaUation position
hose (3 1) (arrows)
3 Unplug actuator Fold locking bar up for
connector (M16/ lx l ) this step
4 Take offvent hose (29)
5 Unscrew bolts (38) [l] Replace micro-
encapsulated bolts
~ *BA30.20-P-1001-01A
6 Take off electronic
accelerator actuator
(Ml6/l)
7 Examine gasket (36),
replace if necessary
8 lnstall in the reverse
order
~ Electronk accelerator actuator

N umber Designation Engines 119, 120
BA30.20-P- 1001 -0 lA BoEt, electronic Nm 25
Mercedes-Benz
laccelerator to intake pipe
000 SB9 70 03 00
Fig. 30: Identifying Box Wrench Socket (000 589 70 03 00)
e ommercJa·u1y availa ble tool s

Number Designation
WH58.30-Z-1002-06A 7 mm socket bexagon on flexible shaft for hose
Removing and installing electronic accelerator actuator witb throttle valve body - AR30.20-P-1262F
ENGINE 120.980/981
Left electronic pedal actuator for right bank of cylinders (Ml6/4) illustrated
Fig. 31: Identifying Electronic Accelerator Actuator With Throttle Valve Body- Engine 120.980/981
Mercedes-Benz

Remove air cleaner, AR09.10-P-1050F
install
tr::?GF Electric cable (arrow) must not chafe against
intake air shaped hose
and against fuel pipe.
Slacken cable clip at
accelerator control
mounting bracket ( 1), íf
necessary, and alter
po-sítion of the electric
cables so that cable runs
without touching. Tíghten
cable clip.
3 Accelerator control detach, attach.
linkage at electronic If necessary ?
accelerator actuator
(M16/3)
adjust accelerator control AR30.10-P-1010F
36 Gasket [l] Replace, clean sealing
sur fa ce
38 Bolts ~ *BA30.20-P-1001-01A
Bottom crankcase disconnect, fit on
breather at actuator
Purge control valve disconnect, fit on
vacuum hose at actuator
~ ELECTRONIC ACCELERATOR ACTUATOR

Number Designati o o Engines 119, 120
BA30.20-P-1001-01A Bo1t, electronic Nm 25
accelerator to intake pipe
Removing ancl installing electronic accelerator actuator witb throttle va] ve body- AR30.20-P-1262F A
ENGINE 120.982/983
Shown on left electronic accelerator actuator for right bank of cylinders (M16/4)
Mercedes-Benz
Fig. 32: Identifving Electronic Accelerator Actuator With Throttle Valve Body- Engine 120.982/983

Remove air cleaner, AR09.10-P-1050F
install
[!rGF Electric connector Must not chafe against
(Ml6/lxl) intake air shaped hose
36 Gasket [l] Replace, clean sealing
surfa ce
38 Bolts ~ *BA30.20-P-1001-01A
Bottom crankcase Disconnect, fit on
breather at actuator
Purge control valve Disconnect, fit on
vacuum hose at actuator
~ ELECTRONIC ACCELERATOR ACTUATOR

Number Designation Engines 119, 120
BA30.20-P-l 001-0 lA Bolt, electronic Nm 25
accelerator to intake pipe
REMOVING AND INST ALLING IDLE SPEED CONTROL (ISC) ACTUATOR- AR30.22-P-1152D
ENGINE 104.94/99, 111.920/921 /94 /96/970/973 /974/975 /977 (except, 104.990)

Mercedes-Benz
Loft-hmd llustrilllon. onul no 104

4111 Conn<;otfon lirrlrl¡¡
Right·hand ilustratlon shows onglno
1'11 .,.2.'70
l$13 0-rlng
M16tt Idle specd con!Tol psc) •otumr
Fig. 33: ldentifving ldle Speed Control Components
Engines 111.92/940/41/44/960/611975
f Cran~ca e vent hos..o
Fig. 34: Identifying Crankcase Vent Hose

[lJ Remove air cleauer Except engine 111.943/944/947/973/975 AR09.10-P-8031G
cross pipe, ínstall
[lJ Charge air pipe Engine 111.943/944/947/973/975
[lJ Remove resonance Engiue 104 AR09.20-P-1791D
flap, instaU
1 Crankcase vent hose Engine 111.92/940/41/44/960/611975
[lJ Pay attention to iustallation position.
Arrows must be positioned opposite
each other.
4/11 Connection fitting Engine 104
[lJ Pay attentíon to installation positíon
35/3 0 -ring [lJ lnspect, replace íf necessary. Oil to
Mercedes-Benz
facilitate installation.
M16/6 Idle speed control
(ISC) actuator
[[] Needle bearing of Engine 111.941/944/96/975 BT30.22-P-0001 -
idle speed adjuster OlA
modified

REMOVING AND INSTALLING POTENTIOMETER OF ELECTRONIC ACCELERATOR PEDAL-
RA30001 041156X(30-1156)
Fig. 35: Identifving Potentiometer OfElectronic Accelerator Pedal Componeots
Plug connection of potentiometer separate, expose, fit together.

Throttle control rods detach, attach.
Return springs detach, attach.
Fastening bolts for potentiometer (R25) remove, insert.
Throttle control check, adjust if necessary (see 30-1010).
REMOVING AND INSTALLING ACTUATOR OF ELECTRONIC ACCELERATOR PEDAL/

TEMPOMAT CRUISE CONTROL- RA30001041262X(30-1262)
Preceding work:
Removing and installing air cleaner {09-0015)
Removing and installing engine comprutment panel (61-0105)

Mercedes-Benz
30-1262
11~
,~_A
--- 116
Fig. 36: Identifying Actuator Of Electronic Accelerator Pedal/ Tempomat Cruise Control Components
Plug connection of electronic accelerator pedal unplug from coupling, plug in.
actuator (Ml6/lxl) on model124 at bracket of
diagnostic socket, on modell29 at inside right
wheelhouse
Cable of electronic accelerator pedal actuator expose.
(M16/ l)
Pushrod (21) at electronic accelerator pedal actuator detach, adjust, attach (30-1010).
(Ml6/ 1)
Fastening bolts (116, 117) remove, insert.
Electronic accelerator pedal actuator (M 16/1) remove downward. On model 124 with AC
together with bracket compressor, slacken the bottom fastening bolts for
the engine mount and raise engine.
Fastening bolts (118) remove, insert. Tightening torque 12 Nm.
Locking washer (119) release.
Fastening nut (125) remove, insert. Tightening torque 10 Nm.
Lever(E) take off, fit on.
Mercedes-Benz
Turn driveshaft of electronic accelerator pedal

actuator (Ml611) in the opposite direction ofthe
arrow against the stop, installlever (E) and secure
nut (125) with locking washer (119).
Throttle controllinkage adjust (30-1010).
Fault memory of electronic accelerator pedal read, erase (see Diagnosis Manual Engine, Volume
2).
REMOVING AND INSTALLING ACCELERATOR PEDAL- RA30001041321X(30-1321)
Removing and installing accelerator pedal- RA30001041321X(30-1321)
Operation No. of operat1on texts and work units or standard texts and flat rates: 30 -1321
A. Modell24
50~
P30.0129""'7
Mercedes-Benz
Cover below instrument panel remove, install.

Expanding clip (24a) remove, insert.
Accelerator pedal (24) pull off controllever (33), fit
on.
NOTE:
Grease pivot points and ball
sockets of throttle control
with anti-corrosion grease
000 989 87 51 1o.
B. Model129
51 24
Fi2,. 38: Identifying Accelerator Pedal Components - Model129

Retaining ring (50) pull off, fit on.
Pin (51) press out, insert.
Nuts (52) unscrew, screw on. Tightening
torque 0.5 Nm as reference
value.
Accelerator pedal (24) take off, fit on.
Mercedes-Benz
NOTE:
Grease pivot points and ball
sockets of throttle control
with anti-corrosion grease
000 989 87 5110.
Removing and Installing Accelerator Pedal- RA30001191321X(30-1321)
f'O. -DDOII- 1$
Fig. 39: Identifying Accelerator Pedal Components

Retaining ring (50) pull off, fit on.
Pin (51) press out, push in.
Tightening torque 0.5 Nm as reference value.
Accelerator pedal (24) take off, fit on.
NOTE:
Grease bearing points and ball sockets of throttle
control with anti-corrosion grease 000 989 87 51
10.
Mercedes-Benz
TECBNICAL MODIFICATIONS ENGINE 104 COMBUSTION CIS-E INJECTION-

RA3000104TAOOX
30 T brottle Control
Designation Nature and reason for modification Production Op. No.

breakpoint
ASR throttle control Relay lever on bearing bracket 10/89 -
standardized with engine 103
Connecting rod standardized with engine 04/90 -
103
ASRII Introduction of actuator potentiometer 06/90 except ~ -
and EFP control unit engine 104.980
EFP control unit Re-specification of progression 10/89 -
characteristics
Throttle Number of windings for return spring on 10/89 12/89 -
throttle valve body modified
Wire length: 50 mm
59 mm
T empomat cruise Modified rubber seal between coating 11/89 -
control connector and Tempomat cruise control
unit (installation feature: color grey,
previously black)
Throttle control Ball stud on relay lever lengthened 01/91 -
relay lever
REMOVING AND INSTALLING FIREWALL BEARING POINT WITH ACCELERATOR PEDAL

LEVER- RA30001190012X(30-0012)
Removing and Installing Firewall Bearing Point with Accelerator Pedal Lever - RA30001190012X(30-0012)
Mercedes-Benz
~l·------------- 35
,----~ 48
~J:tr-,¡m;t--~- 23
Fii:. 40: Identifyini: Firewall Bearing Point With Accelerator Pedal Lever Components

Return spring (35) detach, attach.
Bowden cable detach, attach.
Nuts (52) unscrew, screw on. Tightening torque 0.5 Nm as
reference value.
Accelerator pedal (24) wíth accelerator pedallever remove, ínsert.
(33) and fuewall bearing point (48)
NOTE:
Grease bearing points and ball sockets of throttte
Mercedes-Benz
10.
Throttle control check; adjust ifnecessary (see 30-1010).
Removing ancl installing tire waJJI pivot point witb accelerator lever- RA30001040012X(30-0012)
P30-5028-57
A Modol 124
B Model 129
F ig. 41: Identifying Fire Wall Pivot Point With Accelerator Lever Components
Cover below instrument panel remove, instaD.

Retwm spring (35) detach, attach.
Bowden cable detach, attach.
Expanding clip (54) remove, install (model 124).
Nuts (52) unscrew, screw on. Tightening torque 0.5 Nm as
reference value (model129).
Accelerator pedal (24) wíth operating lever (33) and remove, insert.
fire wall pivot point (48)
Mercedes-Benz
NOTE:
Coat pivot points and ball sockets of throttle
10.
Throttle control check, adjust if necessary (see 30-1010).
REMOVING AND INSTALLING BOWDEN CABLE- RA30001190025X(30-0025)
Removing and installing Bowdeo cable- RA30001040025X(30-0025)
Operation No. of operation texts and work tmits or standard texts and flat rates: 30 -0025
P30.5029·57
A. Model 124
B Mcx!el 129
Fig. 42: Identifying Bowden Cable Components
Bowden cable (30) detach at throttle controllever, attach. Press guide

piece (27) out of throttle control lever for this
purpose, press in.
PJastic clip (28) compress and remove from holder together with
Bowden cable (30), insert.
Mercedes-Benz

Retutm spring (35) in car inteüor detach, attach (acts as safety element).
Bowden cable (30) press out from inside car, insert. Do not press out
rubber grommet (42).
Bowden cable (30) remove complete working from engine
compartment, install.
JGrGF
If vehicle fitted with cruise control, check position
of hose clip for oil-to-water heat exchanger. The
throttle controllinkage must ha ve sufficient
clearance.
Rubber grommet (42) check, replace if necessary.
Throttle control check, replace ifnecessary (see 30-1010).
Removing an<l Installing Bowden Cable- RA30001190025X(30-0025)
Mercedes-Benz
30
Fig. 43: ldentifving Bowden Cable Components
Bowden cable (30) at tbrottle controllever (9), detach, attach.

Press guide piece out ofthrottle controllever, press
in for this step.
Plastic clip (28) compress and remove from bracket together with
Bowden cable (30), insert.
Return spring (35) in interior detach, attach (acts as retaining element).
Bowden cable (30) press out from the interior, insert. Do not press out
rubber grommet (3 1).
Bowden cable (30) take out complete from engine compartment, install.
Rubber grommet (31) check, replace if necessary.
Throttle control check, adjust ifnecessary (see 30-1010).
REMOVING AND INSTALLING ELECTRONIC ACCELERATOR PEDAL/ CRUISE CONTROL

Mercedes-Benz
ACTUATOR- RA30001190472X(30-0472)
Fig. 44: ldentifving E lectronic Accelerator Pedal/ Cruise Control Actuator Components
Cover in front of air cleaner remove, instaU.

Plug connection ofcruise control actuator (Ml6xl) on right wheelhouse, tmplug, expose cable, lay
cable, plug together (see illustration note for
arrangement).
Throttle controllinkage at cruise control actuator detach, attach.
(M l 6)
NOTE:
Since November 1989 the washers between
ru bber mount and cross bridge are no longer
fitted.
Cruise control actuator (M l 6) remove, insert.
Dlustration note
Mercedes-Benz
M18x1 Alg connec:tJon ot ause c«Doo actuator
Fig. 45: Identifying Plug Connection Of Cruise Control Actuator
REMOVING AND INSTALLING ELECTRONIC ACCELERATOR PEDAL POTENTIOMETER-

RA3000 1190566X(30-0566)
Fig. 46: ldentifving Electronic Accelerator Pedal Potentiometer Remove/lnstaU Components
Potentíometer plug connectíon unp lug, expose, plug together.

Accelerator control rods detach, attach.
Retum spring detach, attach.
Fastening bolts for potentiometer (R25) tmscrew, screw on.
ADJUSTING THROTTLE CONTROL- RA30001191010X(30-1010)
Adjusting throttle control- RA30001041010X(30-1010)
Operatíon No. of operatíon texts and work uníts or standard texts and flat rates: 30 - 1O1O
Mercedes-Benz
A. Vehicles with manual/automatic transmission and with/without Tempomat/cruise control
A. Model 124
6 Modei 12S
Fig. 47: ldentifying Adjusting Throttle Control (Vehicles With ManuaJJAutomatic Transmission
And With/Without Tempomat/Cruise Control)
Throttle controllinkage and check for ease of movement

Bowden cable and condition; renew parts if
necessary.
~GF
If vehicle fitted with cruise
control, check position of hose
clip for oil-to-water heat
exchanger. The throttle
control linkage must have
sufficient clearance.
Bowden cable (30) slacken by turning adjusting
screw (29) far enough for the
follower spring (2 6) to be
resting free of tension.
Mercedes-Benz
Com1ecting rod (2) adjust by slackening clamping

screw (1 0). Tbrottle valve
lever must be resting against
idle speed stop of throttle
valve assembly. Adjust
connecting rod (2) so that the
roller ( 15) in the fulcrum lever
(13) is resting "free of
tension" against idle speed
stop. Tighten clamping screw
(10).
Tempomat/cruise control check, correct if necessary by
setting moving throttle valve lever to
idle speed stop, detaching
connecting rod (21) at tbrottle
val ve lever and pressing
actuator lever toward engine
as far as the stop in idle
position. Adjust connecting
rod (21) so that the actuator
lever must be pulled back 1
mm from idle speed stop for
attaching.
Control pressure Bowden adjust by altering position of
cable (11) adjusting screw (lla) until the
arrow tips (e irele) are exactly
opposite.
Bowden cable (30) adjust.
a) Full throttle, manual
transmissioo
Depress accelerator pedal
slowly into full throttle
position. The throttle valve
full throttle end stop. If
necessary, release adjustable
full throttle stop (36) by
tuming to the left and
witbdraw stop pin slightly.
Lock adjustable full throttle
stop (36) in the position it has
adopted by tuming to the
right.
b) Full throttle, automatic
transmissioo
Witb engine switc hed off,
depress accelerator pedal from
Mercedes-Benz
inside car as far as the stop on

the kickdown switch (S30/2)
(do not operate kickdown
switch!).
The throttle valve lever must
be 0.5 - 1.0 mm away from full
throttle stop on throttle valve
body; set with adjusting screw
(29), if necessary.
e) ldling
When accelerator pedal is in
idle position, the follower
spring (26) must be resting
free of play; set from inside
car with adjusting nut (32), if
necessary.
Bowden cable (30) grease between end piece and
guide piece with anti-
corrosion grease 000 989 87
51 1O.
A~stable fulltlottle stop, manual lrililsmtssaoo
36
Fig. 48: Identifying Adjustable FuU Throttle Stop, Manual Transmission
B. Vehicles with automatic transmission and acceleration skid control (ASR)

Mercedes-Benz
74
53
A
52
75 51 f
S30/2 ~).SI
f\ Model 124
s Moofll 129
Fig. 49: Identifying Adjusting Throttle Control (Vehicles With Automatic Transmission And
Acceleration Skid Control (ASR)
Throttle controllinkage and check for ease of rnovement

Bowden cable and condition, replace parts if
necessary.
Bowden cable (30) slacken by altering positíon of
adjusting screw (29) until the
follower spring (26) is resting
free of tensíon.
Connecting rod (21) adjust by slackening clamping
screws at connecting rod (21)
and at the connecting rods (50
and 51). Throttle valve lever
must be resting against idle
stop of throttle valve
assembly.
Switch on ignitiou .
Mercedes-Benz
Actuator lever adopts "idle

speed position" as a result.
Now fix length of connecting
rod (21) by tightening the
clamping screw.
Switch off ignitio o .
Connecting rods (50) and (5 1) adj ust by moving lever (52)
and lever (53) to the
respective "idle speed
stop" (74 and 75) at
potentiometer (R25).
~GF
The levers must not move
away from the idle speed stops
during the adjustment.
Swivellever (8) clockwise
until connecting rod (20) is
fully pulled apart.
Pull connecting rod (50) apart
until the idle travel is
eliminated. Tighten clamping
screw.
Then, tighten clamping screw
of connecting rod (51).
NOTE:
Effective May 1990 the
connecting rod (50) can no
longer be adjusted.
Control pressure Bowden adjust by altering position of
cable (11) adjusting screw (lla) until the
arrow tips (enlarged cutout)
are exactly opposi te.
Bowden cable (30) adjust.
a) Full throttle Switch on
ignition.
With engine switched off,
depress accelerator pedal from
inside car as far as the stop on
kickdown switch (S30/2) (do
not operate kickdown
switch!). The lever (53) must
be resting against "full throttle
stop" (76) ofthe potentiometer
(R25) "free of tension"; set
with adjusting screw (29), if
necessary.
Mercedes-Benz
b) ldling Switch on ignition .

With accelerator pedal in idle
position, the follower spring
(26) must be resting free of
tension; set from inside car
with the adjusting nut (32), if
necessary.
Bowden cable (30) grease between end piece and
guide piece with anti-
corrosíon grease 000 989 87
51 10.
Adjusting Tbrottle Control- RA30001191010X(30-1010)
A. Vehicles with Automatic Transmission

Mercedes-Benz
Fig. 50: Identifying Adjusting Throttle Control <Vehicles With Automatic Transmission)

Bowden cable and condition; rep lace parts if
necessary.
Bowden cable (30) slacken by altering adjusting
driver spring (26) to be resting
free of tension.
Throttle valve lever position check.
Lever must be resting against
id le stop of throttle valve
assembly ( contact audible).
Connecting rod (2) set. Detach connecting rod (2)
at one side, check that the
lever (53) is resting against
idle stop (74). Adjust
Mercedes-Benz
connecting rod (2) so that it

can be attached free of tension
(see detail view).
Control pressure Bowden set by altering knurled screw
cable (11) (15) far enough for the arrow
tips (16) to be precisely
opposite each othe r (see
enlarged detail).
Bowden cable (30) set.
a) Full throttle
W ith engine switched off,
press accelerator pedal from
interior as far as the stop on
the kickdown switch (S 30/2)
(do not operate kic kdown
switch!). The throttle valve
fuJl throttle stop of throttle
val ve assembly (contact
audible); set with adjusting
screw (29), ifnecessary.
b) ldle speed
idle position, the driver spring
tension; set from inside car
with adjusting nut (32), if
necessary.
Bowden cable (30) grease with anti-corrosion
grease 000 989 87 51 00
between end piece and guide
p1ece.
B. Vehicles with Automatic Transmissioo and Cruise Control

Mercedes-Benz
Fig. 51: ldentifying Adjusting Tbrottle Control (Vebicles With Automatic Transmission And
Cruise Control)

Bowden cable and condition; replace parts, if
necessary.
free of tension.
Connecting rod (2) detach.
Connecting rod (21) detach at actuator (M 16).
Throttle val ve lever position check.
Lever must be resting against
id le stop of throttle val ve
assemhlv (contact audihle) .
Mercedes-Benz
Actuator lever (24) press to the right as far as the

stop, viewed in direction of
travel, then tum back 1 mm.
Com1ecting rod (21) set so that it can be attached
free of tension.
Connecting rod (2) set. Lever (53) must be resting
against idle stop (74). Set
connecting rod (2) so that it
can be attached free of
tension.
tips ( 16) to be precise!y
opposite each other (see
enlarged detail).
Bowden cable (30) set.
a) Full throttle
With engine switched off,
press accelerator pedal from
interior of car as far as the
stop on the kickdown switch
(S 30/2) (do not operate
kickdown switch!). The
throttle valve lever must be
resting against full throttle
stop of the throttle valve
assembly ( contact audible); set
with adjusting screw (29), if
necessary.
b) Idle speed
idle position, the driver spring
tension; set from interior of
car with the adjusting nut (32),
if necessary.
grease 000 989 87 51 00
piece.
C. Vehicles with Automatic Transmission and Acceleration Skid Control (ASR)

Mercedes-Benz
Fig. 52: ldentifying Adjusting Tbrottle Control (Vebicles Witb Automatic Transmission And
Acceleration Skid Control (ASR))

Bowden cable and condition; replace parts, if
necessary.
free of tension.
Idle travel rod (20) detach at potentiometer (R25).
(GrGF
Pull off idle travel rod only at
the ends (e.g. with 10 mm
open-ended wrench) as the
idle travel rod will not operate
freelv 1fhent anda nressure
Mercedes-Benz
point will then be felt at the

accelerator pedal.
Connecting rod (21) check, adjust if necessary.
a) Idle speed
Detach com1ecting rod (21) at
longitudinal throttle control
shaft (27) and move lever (53)
to idle stop (74). Switch on
ignition; this causes the
actuator lever (24) to adopt the
idle speed position. Carefully
press lever for connecting rod
(21) at the longitudinal throttle
control shaft in direction of
actuator (M16/1 ) far enough
to eliminate the existing
transmission clearances. Set
connecting rod (21) in this
position so that it can be
attached free of tension.
b) Full throttle
Press lever (53) at
potentiometer (R2 5) to full
throttle stop (76) with ignition
switched on, and hold in this
position. This causes actuator
le ver (24) to adopt fuH throttle
position. In this position, the
throttle valve lever should be
resting free of tension against
full throttle stop of throttle
valve assembly (contact
audible).
u:::rGF
Ifthe throttle vaJve lever is
resting against full throttle
stop witb a large preload wben
accelerator is at ftill throttle,
the servomotor (M16/ l) ofthe
electronic accelerator pedal is
switched off to avoid the
motor being overloaded. The
emergency driving facility is
activated (see function
description). Correct full
throttle adjustment, if
necessary, by switching off
Mercedes-Benz
ignition, slackening ball head

fastening nut at actuator lever
(24) and moving ball head
appropriately in oblong hole_
Repeat full throttle check as
before.
Idle travel rod (20) check, adjust if necessary by
switching off ignition, moving
lever (53) ofpotentiometer
(R25) to idle stop (74) and
pressing lever (52) to the right
on the driver ofthe lever (53).
Press le ver ( 6) against idle
stop (83) ofthe driver fork of
the longitudinal throttle
control shaft Now set idle
travel rod (20) at the adjusting
nut ( arrow) so that it can be
attached free of tension.
tips (16) to be precisely
opposite each other (see
enlarged detailed).
Bowden cable (30) set
a) Full throttle
Switch on ignition.
With engine not running, press
accelerator pedal from interior
of car as far as stop on
kickdown switch (S 30/2) (do
not operate kickdown
switch!). The lever (53) must
be resting against full throttle
stop (76) of the potentiometer
(R25); set with adjusting
screw (29), if necessary.
b) ldle speed
With the accelerator pedal in
the idle position, the driver
spring (26) must be resting
free of play; set from inside
car with adjusting nut (32), if
necessary.
grease 000 989 87 51 00
Mercedes-Benz
piece.
TECHNICAL MODIFICATIONS ENGINE 119 COMBUSTION KE INJECTION - RA3000119T AOOX
30 Throttle Control
Op. no. Designation Nature and reason for Production breakpoint

modification
30-0472 Cmise control actuator Disks for fitting cruise No longer fitted as of
control actuator between 11/89
rubber motmt and cross
bridge no longer provided
- Cmise control Ru bber seal between 11/89 phased-in
coding connector and
cruise control unit
modified (recognition
feature color grey,
previously black)
- ASRand EFP Implementation of 07/91
acceleration skid control
(ASR) and electronic
accelerator pedal (EFP)
FUNCTIONAL DESCRIPTION (FOR MANUAL TRANSMISSION VERSION VALID UP TOMAY

93)- RA30001240500X(30-500)
The cnüse control/Tempomat system is operational when the ignition is switched on. For actual operation,
however, the vehicle speed should be above approx. 40 km/h. Ifthe vehicle travels at the desired speed, a quick
tipping against push-button switch in direction of "accelerating- stabilizing" or "decelerating -stabilizing" is
enough to maintain this speed until the driver decides on a new speed or the system is switched off. To adapt
this fixed speed e.g. to the traffic flow, the push-button switch must be kept in position of "accelerating-
stabilizing" or "decelerating- stabilizing" until the desired speed is attained. On vehicles with a new control unit
(phased-in starting 09/86) and identified by reference resistor, quick tipping of switch in direction of
"accelerating- stabilizing" or "decelerating- stabilizing" will increase or reduce the speed by 1 km/h. In such a
case, the vehicle is accelerated and controlled atO. 7 m/s 2 . The new speed will be maintained when the switch
is released. Quick tipping of the switch in the direction of "Off" or actuation of brake pedal or clutch pedal will
switch off cruise control/ Tempomat, and the regulating system will move into idle speed posítion.
Switching off by means oftipping switch will actívate the actuator motor, which will move the regulating
system into idle speed position.
On the other hand, when switching off by depressing the brake pedal or the clutch pedal, the power flow in the
actuator is immediately intermpted by de-energizing the electromagnetic clutch and by a retracting spring
disengaging a gear wheel of the actuator gear unit. The retracting springs pull the throttle control into the idle
speed position. After switching off, the system remains operational until the ignition is switched off. If, upon
operation ofthe brake or clutch or after switching off, the push-button switch is briefly típped in the direction of
Mercedes-Benz
"memory" at a vehicle speed above approx. 40 km/h, the vehicle automatically accelerates at 1 m/s2 to the last
speed set during "stabilization". The speed set last is erased when the ignition is switched off. If the set speed is
exceeded by acceleration, e.g. when passing another vebicle, the vehicle will automatically return to the
previously set speed when the accelerator pedal is released. If the engine output is not enough for driving uphill,
the set speed will drop. It willlbe built up again as soon as the gradient declines and the speed has not dropped
to below 40 km/h or there has been no deceleration in the meantime.
If the engine brake effect is not enough when driving downhill, the set speed is exceeded and deceleration may
be required. Without braking the set speed is built up again as soon as the gradient declines.
~GF
While driving with cruise control/Tempomat do not engage the selector lever position "N" ofthe automatic
transmission, since otherwise the engine will be revving up.
Safety circuits
The speed stored last in control unit will be cancelled when the ignition is switched off. When the ignition is
switched on, the speed memory will be given the value of "O km/h".
This will make sure that when a drive is started again, e.g. after a change of driver, no unknown speed will be
stored.
The speed is constantly monitored by the control unit. Each change of speed is picked up and evaluated. On
control unit without reference resistor by means of a control stage (differentiating element), on control unit with
reference resistor by means of a computer. If a speed change is made by means of the tipping switch, the control
stage (differentiating link) together with an operation amplifier or the computer in control unit will make sure
that the specified values at switch positions "accelerating - stabilizing" of 0.7 2 m/sor at "memory" of 1 m/s 2
are maintained.
The function ofthe electromagnetic clutch in actuator ís monitored by the control unit during each braking step.
Ifthe power flow in actuator ís not interrupted when the clutch ís defective, the control unit will actívate the
actuator motor instead, which will then move the regulating linkage into idle speed position. This procedure is
registered by the control unit and the system is made inoperative until the ignition is switched off. When the
ignítion is again switched on, the system will operate nonnally until during the next braking step, under
influence of the defective electromagnetic clutch, it is again made inoperative.
When braking or clutching, the electromagnetic clutch in actuator is de- energized, the power flow is
irnmediately intenupted, since a retracting spring wíll pull a gear wheel of actuator gear unit out of mesh. The
retracting springs will pull the regulating linkage into idle speed position.
If, for example, with a defective stop lamp switch the vehicle is decelerated > 1.5 m/s 2 , this condition will be
handled on control unit without reference resistor by the control stage (differentiating element) in control unit.
The succeeding threshold value switch will actívate the actuator motor which will move the regulating linkage
into idle speed position. On control unit with reference resistor the deceleration is picked up by the computer
and the power flow in actuator is interrupted both when braking or clutching, since the electromagnetic clutch in
Mercedes-Benz
actuator is de-energized.
The period up to cutout depends on intensity of deceleration.
If for sorne reason or other the nominal speed is exceeded by more than approx. 6 km/h, the speed monitor will
react immediately. The electromagnetic clutch in actuator is de-energized, the power flow in actuator is
interrupted, the regulating linkage is moving into idle speed position. lf the speed threshold is then less than
approx. 6 km/h, e.g. the speed is now only 5 km/h more than the nominal speed, the electromagnetic clutch is
again activated and the power flow in actuator is again established.
TI1e control unit with reference resistor is protected against the input of double instructions. lf, for example, a
defective push-button switch is simultaneously putting-in the instructions "acceleration and memory", the
control unit will switch off the system until it is unlocked by switching the ignition off and on.
The cruise control/Tempomat system comprises the following components which are connected with each other
by an electric harness.
Push-button switch
Position "1" or
"2", tipp.ing = speed is stabilized.
Position "1", hold = stabilized speed is increased.
Position "2", hold = stabilized speed is reduced.
Position "3", tipping = cruise control/Tempomat is switched off.
Position "4", tipping = speed stabilized prior to switching off adjusts itself automatically ata speed above
approx. 40 km/h.
Fig. 53: ldentifving Push-button Switch

Mercedes-Benz
Cruise control amplifier
The Tempomat/cruise control (TPM) reference resistor amplifier (N4/2) compares the actual and the nominal
speed. In the event of a departure from the nominal speed, the Tempomat/cruise control (TPM) reference
resistor amplifier (N4/2) transmits corresponding control impulses to the Tempomat/cruise control (TPM)
actuator (M 16) until the actual and nominal speeds are again in accord.
Reference resistor
The Tempomat/cruise control reference resistor (R29) serves to adapt the Tempomat/cruise control (TPM)
reference resistor amplifier (N4/2) to the various vehicle models.
Fi~.54: Identifyin~ Tempom.at/Cruise Control Reference Resistor And Tempomat/Cruise Control

Reference Resistor Amplifier
Road speed sensor
The cruise control amplifier receives the actual speed impulses from the Hall-effect speed sensor (B6) or
inductive road speed sensor, transmission (L2) on the speedometer.
Mercedes-Benz
Fig. 55: Identifying Road Speed Sensor
Cruise control actuator
The Tempomat/cruise control (TPM) actuator (Ml6) receives its control impulses from the cruise control
amplifier and actuates the throttle control by way of a connecting rod.
The actuator comprises an electric motor with gear unit, an overrunning clutch, a potentiometer and an
electromagnetic clutch.
The electric motor drives the output shaft, which is provided with the overrunning clutch, by way of the gear
unit.
Fig. 56: Identifying Cruise Control Actuator
The overrunning clutch permíts e.g. with set speed acceleration by means of accelerator pedal for passing other
vehicles, without a need for operating the cruise control/Tempomat. The potentiometer reports the position of
the output shaft back to the control uní t.
The electromagnetic clutch establishes the power flow between electríc motor and output shaft by engagíng a
gear wheel. The clutch is engaged at the followíng switch positions: Accelerating - stabilizing, decelerating -
stabilizing and memory. The electromagnetic clutch is switched off by actuating the brake or the clutch, but also
when the system is switched off by means of the tipping switch (push-button switch) and when the regulating
linkage has arrived at ídling position. When the electromagnetic clutch is swítched off, the power flow is
immediately intermpted by means of a retracting spring, which pulls a gear wheel out of mesh.
On vehicles up to May 93 only Switch actuated by clutch pedal on vehicle with manual transmission
When the clutch pedal is depressed, the clutch pedal swítch, Tempomat/cruise control (TPM) (S40/l) will
interrupt the ground connection from the stop lamps to the cruise control amplifier. This immediately switches
off the cmise control, as during braking.
Mercedes-Benz
Fig. 57: Identifying Tempomat/Cruise Control Ground Connection
Relay on model201.024 (standard version)
Durmg operation of cruise control/Tempomat the relay will switch off the decel shutoff It ís painted yellow on
surface for identificatíon.
Fig. 58: Identifving Cruise Control/Tempomat Relay - Model 201.024
Relay on models 124.128/133/193/333/393 and 201.128 as of approx. 09/89 up, to approx. 06/91
Durmg operation of Tempomat/cruíse control, the Tempomat/cruíse control boost a ir cut-off relay (K 1211)
switches offthe boost air cut-off. The surface ofthe boost air cut-offrelay is painted yellow for identification.
Mercedes-Benz
l w¡oumodel 124
Fig. 59: ldentifying Tempomat/Cruise Control Boost Air Cut-Off Relay (Modell24)
lw¡oo model 201
Fig. 60: Identifving Tempomat/Cruise Control Boost Air Cut-OffRelay (Model201)
TESTING WITH ADAPTER - RA30001240504X(30-504)
Job No. of the job texts and work tmits and standard texts and flat rates
Special tool
Mercedes-Benz
126 589 05 21 00
54
Fig. 61: Identifying Special Tool (126 589 OS 21 00 54)
Pre-requisite for testing
Prior to starting test with adapter, check battery voltage (> 11 V), stop lamps and speed indication for function.
If required, recondition according to findings and also check cruise control/Tempomat prior to test for function
by means of adapter. Test cruise control/Tempomat wíth adapter only.
If other testíng and measuríng ínstruments are used, the cruise control/Tempomat unit may be destroyed. During
this test, the cruise control/ Tempomat unit is tested with the exception of the cruiise control amplifier. Faults
can be discovered by means of the adapter only with the cruise control/Tempomat constantly without functjon.
Complaints such as a temporary breakdown or peor control characteristícs ( e.g. shakíng) cannot be tested wíth
the adapter. In such cases, proceed according to notes for trouble diagnosis 30.0101-502.
If testing with the adapter indicates a faulty component, pay attention to good contact-making qualities prior to
exchanging connectors, for instance, making sure that the jacks (sockets) are not wídened. Wídened jacks
should be reshaped. Then check rejected component once again.
Prep,arations for test
l. Expose cruise control amplifier (refer to 30.0101-565).

2. Pull14-pole connector from amplifier.
3. Connect test adapter to 14-pole connector.
4. Switch on ignítíon. The LED dísplays ofthe symbols for battery, km/h and ground (if line accordíng to
wiring díagram ís ínstalled) wíll líght up, províded no fault has been detected.
@ 128581Jt!21lX» • TEIIPCIIAT
, 1,
1
7177
-t-
/ o' ·
Mercedes-Benz
Fig. 62: ldentifying Preparations For Test (1 Of 2)
5 _ Push "LED-TEST" push-button switch of test adapter and check whether all LED displays are lighting
up _If no LED display is lighting up, check connection of voltage supply and circuit connections of 14-
pole connector (refer to wiring diagrams 30.0101 -580).
@ 128589 05 21 00 11t TEJI)(JUAT
8 -e-
,Ir
lJD.T!SI'
/ ¡\ '\ 1 -,f_-
, Ir ' .
-,f:1V,
~* 2.·-t-
,J;, ..¡_
1¡\
.:t--'1'
.1 1\
Fig. 63: ldentifying Preparations For Test (2 Of 2)

•@
TESTPROGRAMSURVEY
Test step Actuation N ominal indication Possible cause of
deviation from nominal
indication
1 LED display lighting Lines wrongly
u p. connected. Lines
~ interrupted.
LED display lighting up Grounding bridge in 14-
on models with pole connector
grounding bridge. intem1pted.
~ o
LED display may light Perform test step 6.

u p.
2 Actuate cruise Respective LED display Lines intem1pted.
control/Tempomat switch lighting up. Switch defective.
(position 1-4).
3 Depress ® push-button Regulating linkage Regulating linkage and
switch. moving uniformly to accelerator pedal not
full throttle position and movmg:
remains there. Connecting rod on cruise
control actuator or on
regulating linkage not
connected.
Lines intem1pted or
wrongly connected.
Switch on clutch pedal
defective.
Mercedes-Benz
Actuator defective.
Regulating linkage and
accelerator pedal
constautly moving to-
and-fro:
Poor contacting of plug
conuectiou
hamess/actuator hamess.
l'hrottle control and
accelerator pedal not
pulled to full throttle
position:
Check contacting of lines
for actuator and amplifier
(control unit).
Actuator defective.
4 Depress ® push-button Regulating linkage not Regulating linkage
Regulating linkage at full moving immediately s.Iuggish. Actuator
throttle position. Depress into idle speed positiou defective.
brake pedal. Then release when brake pedal is
push-button switch. actuated.
5 Manual transmission Depress ® push-button Regulating linkage Lines shorted.
only switch Regulating linkage at moving immediately Switch on clutch pedal
full throttle position. Depress into idle speed position defective.
clutch pedal. Then release when clutch pedal is
push-button switch. actuated.
6 Move vehicle for at least 2 LED display flashing. Liues interrupted or
revolutions ofwheels. wrongly connected.
Sensor defective.
If no fault has shown up on previous test:
l. Test blue liue from connector cruise control actuator jack 5 to connector cruise control amplifier jack 1O
for short to ground by means of ohmmeter.
2. On amplifiers (control units) with reference resistor, test reference resistor R 29 (30.0101-506).
3. Mount new cruise control amplifier (control unit) for test drive.
Testing
Mercedes-Benz
Check voltage suppty. .

r-~·----·
:
-_-·_--_·-_-·_-_._
-- _
·-_
-·_--_
·-_
-·_
--_
·-_
-·_
--_·_
--_
·-_
- ·_
--_
·-_
- ·_
--_
·-
- -,
·--
@
!: ~~~--------------------------------------------~
TBIPCIMT
LEO display ligtting up l
.
l
Y es ~o ..
1
1
! .:
Check lines for correct comection and .!: t@
passage.
¡L_
l
__________________________ ~
l. . . -.... --·--· . ,-. . . ............................-.. . . . _. __ .,._, __. .__. __~~~~-
ab
M16
75 01 -----------------+-(•-+QS DI -- ·- ·l
0,7$ -----------------+(.--tqs' "
i- t"t..
~¡
t¡1S ...
a.~:.
;e :e~ ~ IIC lt' 0.1~11
1
d<#<:T ., .,.,
.,~W1
') 1
0.7Sbr- - - - -H•ioo-+
..-ohor
q~~ - - - +<--+
Cl'l5$•---+<•-+ __ __ _j
1 '!\¡'V ... ... 1 \ l ...
~J!.W~__l!il~li~Ql~~
... !\1~1
o~
~~~~A
_L
1 :.~:/VI -------,1,~ ~ ., . 1
~ !N4 ~ ul Í
L __.__ J 1 .
_--=....1
Fig. 64: Testing Cruise Controi/Tempomat With Adapter (1 Of 12)
Mercedes-Benz
ExllO'ple Model201 122to approx. 08185
1
¿ r----- -----------------------------------------
On ve hieles with grounding bridge test bridge
in 14-pln connector.
@ 12&6111!2100 • TBFOMAT
\'J
G o
LEO display lights up
~
·e
- / . \
0,.J. y ~ l&TESr
Yes ¡No
;~
~ Jn " '
-·· 1 1'
e @ ®
Repafr grouncling bridge in 14-pn
connector.
~~bl -----+<--1- Cl~lll

·- ·- -l
M"'6
-c: t ~l
.. O.?Sil" - - - - - +(-..fClSgn
~ t .. o ¡.:;. C¡'l!i - - ----+<•-+Qs... +-....._--t-..J-J
¡;.~ f ~!;.~ 0.'15• 1 - - - - - +<•-+c:¡sn 1
RW1
q75b r - - -+-<•-+Cl5bt 1
- 015~··
Q~... - - -+-<·-+
cp!is-" ---+-<·~ __ ___j
0,75bt
.
01~ O.i 5rlgc - - - -- ---....., l
1 ~ ~· :w ~ , ~ .. ~
~.Jl.WL.l!i.l~.llh.l~~
.a.,, A 1 ¡Á i l
.
1 -Q
.
IN4 L2¡ I.~Jl
Mercedes-Benz
Fig. 65: Testing Cnúse Controi/Tempomat With Adapter (2 Of 12)
l
Test harness and pushbutton S'Mtoh. í------·-··-·--·--·-··-·-·-·-----.. ·-·---···-·-·¡
Swtch position LEO ctsplay
j @ 1211588 05 21 00 ti 'IEIFOIIAT j
. j
Accelerate 1
Oecelerate 2 ' 11 , , j
3 8 ·t, \- ·•· .;:;:- 8
.¡.;., UD-TEST :'
~.. e
Off
Memol)l 4
"'t./ i
'il4'· j
';.J,/ ' •' ,Q 1!' i
Respectwe LEO dsplay ighti~ 14'· "~"' "' 'él j
1
Yes ~o 1-·-···-·-·-·--·-----·-·-·-----j
~
..
Check lines for correct connectlon and

passage
Renew switch.
r···-·---------------------·-·-- ------·-·-------·-·---------·--·-··--·-·-·-·-·-·--·---·-·-·-·-·--·-- ~
~~
tt~10
'\ 1 J
. '' . l
S '¡ • " "
o;rs~'rt
>
X 20 59
'-HI---0,7hw--1Fr-o+- -+f.F<~J IJwl tl -l -• wl_rl· .¡

____
_ __ __ -_ -_
r------+o+-----0,75~--------...::~
=
0.75bl
0.7Str
- "~ f
:::
" & ..
~~
& c.& ~JS .,
~ &$ & & ~ l\1'Stf
~W1
0,'1511'---+<•-+
0.1'1.. - - -1-<:64
~"'··---HI:'"-+
J~,...~ 0,7'.1br--- -------,

0.7~ 0,7'.igt/ .. - - - -- - -, 1
~.JU.!.l~~.IU!!ll~ ~~
1 ~ ~66 ... 1
¡ <A- iN4 L2¡ ~ ·~~

'::p' 1 -- . i
L.----·- ·-.J
IJ41• 11IIV3 ·- ·- .1¡'
~---·-------------·-·-·-·--·-·-·-·-·-·-·-·-·-·-·-·--·--·-·-·-·-·-·-·-·-··-·-·-·-·-·-·-·-'
Fig. 66: Testing Cnúse Control/Tempomat With Adapter (3 Of 12)
Mercedes-Benz
Test cruise cortrol actuator. r·---------------------- ------ -- --------,

Oepress pushbutton switch ® i IÍ \
! 'CJ 128589 05 21 00 • TBIPOMAT !i
Throttle cortrol and accelerator pedal are ~~~-------------------------------------- ¡
moving uniforniy to full throttle position and 1
remai n there. ¡
@ J.l'D.TBT !
!
Yes !
INo ¡
!
1
!1
JYes
!
!
1
TITottle control and accelerator pedal 1
not moving· ' '
~--------- -------------------- -- --- - -·-·----- - -~
1. Check tiTottle control.
2. Check lines for corree! connectlon
or passage (30.0101-580).
3. On vehlcles wlth manual
transmlssion, check switch on
clutch pedal for passage.
4. Renew crulse control actuator.
TITottle control and accelerator pedal
constantly moving 1<>-an~fro.
1. Check contacting of plug
connect.ion harnesslactuator
harness and harnesslcruise contrrol
amplifier (control unl).
2. Renew cruise control actuator.
TITottle control and accelerator pedal
are not pulled to full throttle position.
1. Test contacting of lines for actua tor
and for annplfier (control unit).
2. Renew actuator.
Fig. 67: Testing Cruise Control/Tempomat With Adapter (4 Of 12)

Mercedes-Benz
·-·-·--·----·--·--- ..----·-··-- .................................._. __ ........._..........._.. __ ............ _................ ___ ..._. _......_....._........_..................... _...........__ __ .........._.. ,
...
:'
!
i
i'
ab
:
''
''
''
!
1
:
:
¡
:'
!
i
1
:'
i
~ e: t ¡¡,;¡.! t" ...

o,..
0,75111
i
i'
-
lS 11'
I. .. ' lp~ •• --------~~q~+-~~~ i
1'
5.~$ 5.~5 0,1\11 --------~*-+~~,
:
~W1 i
:
!
!
r- 07!.1)11 '
1
'
O,l~bl - - - - -- - - - - - - ¡ i
01~
1
0.1~11"/911 1 ¡
i
1' !V~
~-~·
~·Jilil'..W~Jilill7~
,~. ~ 1
M ¡Á i ¡
¡
i ~ ! N4 L2~~·~ !
'----·- ·- ·- J
ISI~IIh113
._ __ .1 1
i
'
L--·--·-·--·--·-----·--·- ·--·-------------·-----·--·--·----·-----·--·-----·-------·--·--·--·--··-----·--·-------·--·---J
¡
Mercedes-Benz
Exatrple. MMel 201.122to epptox. 00/85
Check crulse controlrrempomat cutout when

br aking.
Depress pushbutton @
Actuate throttle control and accelerator pedal at
@ 126 589 05 21 00 • TBIPOIMT
fui throttle position of brake pedaL
8 e
-
· -
\. 1/
@ tamr
@'V
/ 1\
/
Throttle control and accelerator pedal moving

~ e l• • @
.Jo o @
1
illTllediately into idle speed position. Then Cil
release pushbutton switch.
Y es r o
¿
Check thrott le control for easy
opera tion.
Renew actuator.
F ig. 69: Testing C ruise Control/Tempomat With Adapter (6 Of 12)

Mercedes-Benz
Check cruise controi!Tempomat cutout durlng r----------------------------------------------

!
declutching (with manual transmission only). !
Depress pushbutton switch ®
: @ 126 589 05 21 00 • TBIPOMAT
Throiltle control and accelerator pedal at full
throttle positlonl .
l
Actuate clutch pedal. i
1
1
!
Throttle control and accelerator pedal are
.
l
1
:
immediately moving into idle speed position. !
Then rele ase pushbl<tton switch. 1
1
j
---------------------------------------------
Yes
Unes are shorted.

SWitch on ch.4ch pedal detective.

Mercedes-Benz
--------·-------------------·--·--·---------------------·--·--·---------------·------------------------·--·---------,'
''
''
E3 :
ab '
:'
''
l
1
:
''
:
X20 :'
,,.,.,, _,- - - K ''
1'
:
:
'
0,'15 bl
0.7'>0"
_.,..
r
lr
e
~
f ~ ~
&.o& Cl"'-·
§..~~ ~~§.
o,,,.
.,~Wl
1 ~llf·---~.-...
0,75oo - - -K •ro-¡.
q'l!M• - - - - - - ,K •--t
r-0 1Sb<
0.7~
,,
1 ' ~"' ~·
~.
:J
~ ' ~. ,, ~'"' ~~~ "'~ 1
Fig. 71: Testing Crnise Control/Tempomat With Adapter (8 Of 12)

Mercedes-Benz
Test h..-ness alllfstMor on tptedometer, - d r------··-·-·-·-·--·-·1
-S
indict~to r must be in cmfer
Move vehldo tor at least 2 rMWiloiiS ol i' li'\
'O
120S 05 21 ~ • l'EIIIQIIAT ¡l
!
LEO 6osptoy ftuhong

E3 ..,_.
~~
' 1
).. e
av e
... a
e
t
t@
&'IDI' i
!
i
·
Yes
1
····-·--·······--·--·-·····------···- -·-·J
i
1 OnvctKJes'MIII Híl-effec:t '""sor
(ltal\ing approx 09185) check
vohage S'4'ply (tormlnal t S) of Hal-
effec:t sen•or on black Nne of 2-pole
Hall- ol'oc:t cooncclor accordllg lo
wi""l' dial~" m (30 0 101-560)
2. Clleck lnes aoconlilg lo wilq¡
chgram
for shott cltcul. 1 n6 ntorr'4'llon.
3 Renew se,.or
Fig. 72: Testing Cnúse Controi/Tempomat With Adapter (9 Of 12)

Mercedes-Benz
---------·--·------------------·--·--·--·--·----------·--·-·--·--·-------------------------·-··--·--·--·--·--·--------,
''
1
j
l
¡ ab
''
X 5 11
M16
0,75bl ·- ·-·l
-ct
~ 1¡> ~l
.. 07~"
zs; .. .. o a.:, q7S...

~~IC
r:r d <S
t!IC!~
o' .,.. d
0.75rt 1
"'!I'"Wt
~ 0,75br·- - - + - <·.... 1
Q75go---+-<.......
r-0.7 ; t:r-
ctrnw---+-~•..,.
~~
- ·- ·J
01~
1
O,"'!ivn/Qo - - - - - - - - - , 1
1 ~.~.~~ •:- ~~~
r--u\JUU~-ld~.hb.lt~
··~bt~ ~ 1 1 J. Á]
1
L .__,__ J
~ . ¡N4 L2~._~~~~~
1
~
,_ .1 .
Fi2. 73: Testin2 Cruise Control/Tempomat With Adapter (10 Of 12)

Mercedes-Benz
Exarrple Model 201.122to approx. 08185
Disconnect test adapter.
~
Test blue fine from conneotor cn.ise controV
Tempomat jack 5 to connector amplifier (control
unit) jack 10 for short to g round.
Short to ground
No ~es
J
Recondition or renew blue llne.
ab
M16
(l7S&l
0;7!19"
·- ·- ·l
-¡
E
lS
:c~
t'~
.a
..:
o. ~ "'
"' "'
~Y: t::
q7$ ..,
0¡71)•1 1
., <:1'., d "' .,
"J~W1
rt ~1'Sbr---~r-+Q5Dt 1
r- 0,7Sbt
~::: Q~. +--.==-·--·J
~~
0,1~ O,iS '1"-'\)I ---------....,l 1
1 ,~,!v~ ,~ ,,, ,,,, ~~,~~~u~ 1
1
JA Ál
~. JUU~_nmh.l!tl~~
i ~ jN4 L2~~~~~~
Mercedes-Benz
Exe;rrple Modal 201.122to approx. 08/85
On crulse control af11'lifiers (control unls) With r---------------------------------------------------R-29--¡

reference resistor, test reference resistor (R29)
(30.0101 -506)
i í ·¡¡
Reference re sistor in orde r. !"4/2 1 rg¡ 1:
Yes
¡~
'. .
~
.6 l.
lutDEm i
-=-n '
¡No
Renew reference resistor (R29)

~ 11
!1
'
9 :i
(30.01 01-566). :' j' :'
!L._·- ·- ·- -- ----·- ·- ·- -· !
l~:~~--·----. ·--···----·. .-·--·-----...... -.......... _. . . . . . . . . . . . . . ...1
Renew cruise control amplifier.
End of test
TESTING REFERENCE RESISTOR- RA30001240506X(30-506)
Job No. ofthe job texts and work units and standard texts and flat rates
Fig. 76: ldentifying Tempomat/Cruise Control (TPM) Reference Resistor {1 Of 2)

Mercedes-Benz
Fig. 77: Identifying Tempomat/Cruise Control CTPM) Reference Resistor (2 Of2)
Tempomat/cruise control (TPM) reference resistor (R29)
Ohmmeter
Resistance values
remove, install (30-566). Production date (a). Part no. (b ), jack designation (e). For severa} reference resistors
there is no jack designation A-G. These reference resistors must be tested as shown on figure at the right.
connect (refer to table).
check (refer to table), replace Tempomat/cruise control r eference resistor (R29) ifvalues deviate.
TEST TABLE- RESISTANCE V ALUES

Part no. Connection ohmmeter to jack designation
E-G kohms E -F kohms E-B kohms E -D ohms D-H D -C ohms A- Dohms
005 545 07 501-521 26.2-27.2 1470-1530 infinity kohms < 10 infinity
32 3.21-3.27
005 545 08 501-521 26.2-27.2 1470-1530 infmity 1.98-2.02 < 10 infinity
32 kohms
005 545 09 684-712 39.4-41 1190-1230 infinity 6.52-6.78 < 10 infinity
32 kohms
005 545 10 684-712 39.4-41 1190-1230 infmity 8.28-8.62 < 10 infinity
32 kohms
005 545 11 667-695 52.4-55.2 1960-2040 infmity 2.88-3 infinity < 10
32 (1) kohms
005 545 42 98-102 19.6-20.4 592-616 infmity 3.18-3.30 infinity < lO
32 kohms
005 545 43 166-172 13-13.6 490-510 infmity 1.37-1.43 infinity < 10
32 kohms
Mercedes-Benz
005 545 44 667-695 48.9-50.9 1590-1650 infinity 1.71-1.78 infmity < 10

32 kohms
005 545 46 1660- 1720 39.4-41 1470-1530 infmity < 10 ohms infinity < 10
32
006 545 25 980- 1020 39.4-41 1470-1530 infmity 1.98-2.02 < 10 infinity
32 kohms
006 545 26 1470-1530 98-102 3570-3720 infinity 325.4-338.6 infmity < 10
32 (1) ohms
00654561 980- 1020 98-102 2940-3060 infmity 3.92-4.08 infmity < 10
32 (1) kohms
007 545 06 1080- 1120 39.4-41 1190-1230 infinity 1.92-2 ohms infinity infinity
32
007 545 12 684-712 39.4-41 1190-1230 infmity 1.92-2 k infmity infinity
32 ohms
007 545 13 501-52 1 35.8-37.2 1470-1530 infinity 2.62-2.72 infmity infinity
32 kohms
007 545 39 465-485 39.4-41 1190-1230 infmity 1.92-2 k infinity infinity
32 ohms
007 545 40 1210-1270 98- 102 2950-3070 infmity 1.3-1.36 infinity < 10
32 (1) kohms
007 545 50 684-712 39.4-41 1470-1530 infmity 6.84-7.12 < 10 infinity
32 kohms
007 545 5 1 684-712 39.4-41 1470-1530 infmity 8.91-9.27 infmity infinity
32 kohms
007 545 53 606-632 25.6-26.6 0.98- 1.02 infinity 3.93-4.09 infmity infinity
32 kohms
007 545 54 980- 1032 48.9-50.9 1960-2040 infmity < 10 ohms infinity < 10
32 (1)
007 545 55 501-521 35.8-37.2 1470-1530 infmity 3.41-3.55 infinity < 10
32 kohms
007 545 56 489-509 65.2-67.8 2380-2480 infmity 3.4 1-3.55 infinity < 10
32 (1) kohms
007 76 32 607-631 39.4-41 11 90-1230 infinity 2 .17-2.25 < lO < 10
545 kohms
009 545 15 684-712 39.4-41 1190-1230 infmity 7.35-7.65 infinity infinity
32 kohms
010 545 29 684-712 39.4-41 1190-1230 infmity 934-937 infmity infinity
32 ohms
01054530 980- 1020 25.6-26.5 11 90-1230 infinity 3.94-4.1 < 10 < 10
32 kohms
012 545 87 2380-2480 62.1-64.7 2500-2600 infmity 84.87-88.33 < 10 < 10
32 (1) (1) kohms
Mercedes-Benz
(1) These values cannot be measured with SUN DMM-5.
TEST TABLE- RESISTANCE V ALUES

Part no. Connection - ohnuneter to jack designation
E-G kohms E -F kohms E-B kohms E -D ohms D-H D -C ohms A- D ohms
014 545 30 1705-1775 39.4-41 1509-1571 infínity 84.86-88.34 infinity < 10
32 kohms
014 545 80 2274-2366 52.9-61.6 2813-2927 infínity 2.38-2.47 infínity infinity
32 (1) (l) kohms
014 545 82 772-802 24.5-25.3 980-1020 infínity 2.17-2.25 infinity < 10
32 kohms
014 545 84 637-661. 31.8-33 1402-1458 infínity 1.51-1.57 infmity < 10
32 kohms
(I) These values cannot be measured with SUN DMM-5.
COMMERCIALLY AVAILABLE TOOLS OR TESTERS, MB TESTERS (REFER TO EQUIPMENT

MANUAL)
Designation e.g. Company, order no.
Mu1timeter FJuke 23-DB, 83, 88
ITT Metrix MX 47, 50, 51 , 52
SUN DMM-5
REMO VAL AND INST ALLATION OF CRUISE CONTROL ACTUATOR- RA30001240541X(30-541)
Preceding work:
Starter removed (15-71 00) engines 102.983/990.
Engine compartment lining removed (61-0105).
A. Engine 102
Mercedes-Benz
Fig. 78: Tdentifying Cruise Control Actuator R emove!Tnstall Components - Engine 102
Battery disconnect, connect.

A ir cleaner (except engines remove, install (09/400).
with Stromberg carburetor)
Plug (1) onholder of disconnect, connect.
diagnosis socket or on holder
of ABS hydraulic unit at the
connector
Cable of Tempomat/cruíse expose.
control (TPM) actuator (M16)
Connector rod (2) on detach, attach.
Tempomat/cruise control
(TPM) actuator (M 16)
Fixing nuts (3) unscrew, screw on.
Tempomat/cruise control remove, install. On engines
(TPM) actuator (M16) with with injection system (except
holder for 102.983/990) remove
high-tension distributor cap
and distributor rotor, loasen
high-tension distributor, if
required, and tum clockwise
toward engine or remove. On
Mercedes-Benz
102.983/990 engines, extend

(TPM) actuator (M 16) frrst at
the two rear studs and remove
with the holder in downwards
direction.
Fixing bolts (4) M6 x 28 unscrew, screw on. 12 Nm.
Lock washer (6) unlock, lock.
Fixing nut (5) unscrew, screw on. 10 Nm.
Lever (A-D) remove. When installing, turn
drive shaft from
Tempomat/cnüse control
opposite to direction of arrow
against stop, mount lever (A-
D),
A Stromberg carburetor,
B 2E-E carburetor,
e Injection engines; except
102.983/990,
D Engines l 02.983/990).
Connecting rod (2) adjust {30-561).
Function test perform on road.
B. Engines 103 aod 104.980/981
Preceding work:
Air cleaner removed (09-400).
Engine compartment 11n1ng removed (61 -01 05).
Mercedes-Benz
Fig. 79: ldentifying Cruise Control Actuator Remove/lnstall Components- Engines 103 And
104.980/981

Plug (1) on modell24 at disconnect, connec t at the
holder of diagnosis socket, on connector.
model 129 on right-hand
wheelhouse or on
model201 on holder of ABS
hydraulic unit
Cable of Tempomat/cruise expose.
Connecting rod (2) on dísengage, engage.
(TPM) actuator (M16)
Fixing bolts (11) M6 x 12 and unscrew, screw on.
(8) M8 X 30
Tempomat/cruise control remove in downwards
(TPM) actuator (M16) with direction. On model 124 with
holder refrigerant compressor, loosen
lower fixing bolts for engine
mount and lift engine.
Fixing bolts (4) M6 x 28 unscrew, screw on. 12 Nm.
Mercedes-Benz
Lock washer ( 6) unlock, lock.

Fixing nut (5) unscrew, screw on, 1ONm.
Lever (E) remove. When installing, turn
drive shaft of
against stop. Mount lever (E).
Connecting rod (2) adjust (30-561).
C. Engine 111
Fig. 80: ldentifying Cruise Control Actuator Removellnstall Components- Engines 111
Battery ground cable disconnect, connect.

Starter remove, install ( 15-71 00).
Plug (1) on holder of disconnect, connect.
diagnosis socket
Cable of Tempomat/cmise expose.
Fixing bolts (3) M6xl5 tmscrew, screw on.
Mercedes-Benz
Tempomat/cruise control remove in downwards

(TPM) actuator (Ml6) with direction.
holder
Fixing bolts (4) M6x28 unscrew, screw on, 12 Nm.
Fixing nut M8xl (5) on the unscrew, screw on. 1O Nm.
drive shaft ( 11) of the
Tempomat/cruise control remove, instaH.
actuator (M16)
Tab washer (6) and setting NOTE:
lever (9) When installing the setting
Jever (9), the drive shaft (11)
of the Tempomat/cruise
control actuator (M16) must
be turned against the stop in
the opposite direction to the
arrow on the housing. The
setting lever (9) is to be
installed in this position.
Nut M8x1 (1 O) on the drive unscrew, screw on.
shaft (11) ofthe ~GF
Tempomat/cruise control Only screw nut M8x1 (10)
actuator (M16) onto the drive shaft (11) until
the threaded bolt of the drive
shaft projects 8.5 mm.
Connecting rod adjust (30-561).
D . Engine 119.960
Mercedes-Benz
Fig. 81: ldentifying Cruise Control Actuator Remove!lnstall Components- Engines 119.960

Cover in front of air cleaner remove, install.
Plug (1) on right-hand disconnect, connec t.
wheelhouse
Connecting rod (2) on disengage, engage.
Bolts (3) unscrew, screw on .
Tempomat/cruise control remove, install.
(TPM) actuator (M16) with
holder (4, 5)
Fixing bolts ( 6) unscrew, screw on, 10 Nm.
Holders (4,5) from remove, mount.
Fixing nut (8) unscrew, screw on, 10 Nm.
Lever (9) remove. When installing, tum
drive shaft of
Tempomatlcruise control
Mercedes-Benz

against stop. Mount lever (9).
Functíon test perform on road.
E. Engines 601.91/92, 602-91 and 603.91
Fig. 82: ldentifying Cruise Con trol Actuator R emove/Install Components- Engines 601.91/92,
602.91 And 603.91

Plug (1) between coolant disconnect, connect.
expansion tank and windshield
washer tank from connector
Cable ofTempomat/cruise expose.
Connecting rod (2) on dísengage, engage.
Fixing bolts (11) for shield on unscrew, screw on.
holder (1st version only)
Fixing bolts (7) M6 x 18 unscrew, screw on.
(TPM) actuator (Ml6) with
holder
Fixing bolts (4) M6 x 28 unscrew, screw on, 12 Nm.
Loek washer (6) unlock. lock
Mercedes-Benz
Fixing nut (5) unscrew, screw on, 10 Nm.

Lever (F) remove, replace rubber mount.
When installing, turn drive
shaft ofTempomat/cruise
control (TPM) actuator (Ml6)
agaínst stop. Molmt lever (F).
F. Engine 602.96
85
1
®6
~
M16
m
Fig. 83: Identifying Cruise Control Actuator Remove/Install Components- Engines 602.96

Plug (1) on holder for ABS disconnect, connect.
hydraullc unit from connector
Cable of Tempomat/cmise expose.
Tempomat/cmise control
(TPM) actuator (Ml6)
Fix in ll holts (9) M6 x 1g unscrew. screw on.
Mercedes-Benz

(TPM) actuator (Ml6) with
holder
Fixing bolts (4) M6 x 28 unscrew, screw on, 10 N m.
Fixing nut (5) unscrew, screw on, 1O Nm.
Lever (G) remove. When ins.talling, turn
drive shaft of
against stop, mount lever (G).
G. Engines 603.96/971
Preceding work:
Air cleaner removed (09-400) engine 603.96.
Mercedes-Benz
se
sé
)4
r
H
M18
~{
u1
Fig. 84: ldentifying Cruise Control Actuator Removellnstall Components -Engines 603.96/971

Cover of left-hand wheelhouse remove, install.
on modell40
Plug (1) on holder of díscom1ect, connect.
diagnosis socket, on model
140 on left of wheelhouse at
the connector
Cable ofactuator (M16) expose.
Throttle línkage and control dísengage, engage.
pressure cable
Fixing bolts (9) unscrew, screw on.
Mercedes-Benz

(TPM) actuator (M16) with
holder
Fixing bolts (4) unscrew, screw on, 12 Nm.
Fixing nut (5) unscrew, screw on, 1O Nm.
Lever (H) remove. When ins.talling, turn
drive shaft of
against stop, mount lever (H).
H. Engine 605
Preceding work:
Front engine encapsulation removed (94-531 O)
Mercedes-Benz
5
P30-5316-S9
Fig. 85: ldentifying Cruise Control Actuator Components -Engines 605

Windshield washer fluid remove, install.
reservo ir
Plug (1) in left wheelhouse disconnect, connect at
coupling.
Cable of Tempomat/cruíse expose, secure.
control actuator (TPM, Ml6)
Control cable (2) and throttle disengage, engage.
control cable (3)
Screws (4) Ml6xl5 unscrew, screw on at holder
(5) of transfer lever.
Holder (5) remove, mount.
Screws (6) of unscrew, screw on.
Mercedes-Benz
actuator (TPM, M16) with
washers and distance sleeves
actuator (TPM, Ml6)
Screws (7) M6x24 (4 off) unscrew, screw m .
Holder (8) remove, install.
Nut (10) unscrew, screw on.
Lever (11) remove. When installing, turn
drive shaft of
actuator (TPM, M 16) against
the stop in the opposite
direction to the arrow. Mount
lever (11).
Control cable adjust (30-561).
I. Engine 606
Preceding work:
Starter removed (15-71 00)
Mercedes-Benz
Fig. 86: Identifying Cruise Control Actuator Components -Engines 606
Windshield washer fluid remove, install.

reservo u
Plug (1) in left wheelhouse discom1ect, connect at
coupling_
Cable of Tempomat/cruise expose, secure.
control actuator (TPM) (M16)
Resonance suctionline (9) loosen, fold backwards (14-
1984).
actuator (TPM, M 16)
Screws (3) M6x35 of unscrew, screw on .
actuator (TPM, M 16) wíth
washers and sleeves
Mercedes-Benz
Tempomat/cruise control lift out, install from above.

actuator (TPM, Ml6)
Hexagon socket bolts (4) unscrew, screw in at two-piece
M6x18 (4 off) holder (5).
Two-piece holder (5) lift out, install from above.
Lock washer ( 6) unlock, lock
Nut (7) unscrew, screw on.
Lever (8) remove. Wben installing, tum
drive shaft of
actuator (TPM, M 16) against
the stop in the opposite
direction to the arrow.
Mount lever (8).
Resonance suction line (9) fold forwards, secure ( 14-
1984).
REMOVAL AND INSTALLATION OF PUSH-BUTTON SWITCH- RA30001240545X(30-545)
Preceding work:
Driver's side cover under instrument panel removed (68-150) .
A. Model124 up to June 93, models 129 and 140 up to February 93, 2nd version model 201 as of
approx. mid April 84
Mercedes-Benz
Fig. 87: Identifying Push-button Switch Components (Model124, Models 129 And Model 201)

V ehicle with airbag remove, install (91-660) .
Airbag unit Observe safety regulations .
Steering wheel (1) remove, install (46-0610).
Cover plate of steering remove, install.
column tube
Plug for Tempomat/cruise disconnect, connect.
control switch (S40)
Fixing bolts (2) unscrew, screw on.
Combination switch (S4) with withdraw approx. 5 cm.
switch (S40)
Cable holder (4) unclip, clip in ( deleted on
modell29).
Tempomat/cruise control detach, install at combination
switch (S40) switch (S4).
Tempomat/cruise control remove, install whilst pulling
switch (S40) up steeríng column líning (3)
on model 20 l.
Rubber grommet ( 5) at remove, install.
TPmnom::lt/rmi~P r.ontrol
Mercedes-Benz
switch (S40)
Model140 only standardize power windows
Every time the battery is (82-0605).
disconnected and connected,
Special tools
Fig. 88: Identifying Special Tool 001 589 66 21 00 00
126 589 00 10 00
4#$
Fig. 89: ldentifying Special Tool126 589 00 10 00 46
B. Model 124 as of July 93, 129 and 140 as of Marcb 93
Preceding work:
Driver's side cover under instrument panel removed {68-150) .

Mercedes-Benz
P30-5318-S9
Fig. 90: ldentifying Push-button Switch Components (Model124, 129 And 140)
Airbag unit remove, install (91-660) .

Observe safety regulations!
Steering wheel (1) remove, instan (46-061 O).
control push-button switch
(S40)
Screws (2) of contact spiral unscrew, screw m.
(3)
Contact spiral (3) remove, mount.
Screws (4) of adapter ( 5) unscrew, screw in.
Adapter (5) remove, install.
Mercedes-Benz
push-button switch (S40)

Model140 only standardize power windows
Every time the battery is (82-0605).
disconnected and connected,
Special tools
126 589 00 10 00
46
Fig. 92: ldentifying Special Tools 126 589 00 10 00 46
C. 1st version model 201 u p to approx. mid Ap ril1984
Preceding work:
Cover on left or right below instrument panel removed (68-150)

Mercedes-Benz
Fig. 93: Identifying Push-button Switch Components (Model201)

control switch (S40)
Steering wheel (1) remove, install (46-0610).
Steering column lining (3) remove, install.
Clips (6) on combination unclip, clip in.
switch (S4)
Fixing bolts (2) unscrew, screw on .
switch (S40)
Function check perform on road.
ADJUSTING CONNECTING ROD OR CONTROL CABLE- RA30001240561X(30-561)
Operation no. of the operation texts and work units and standard texts and flat rates:
A. General information
For proper operation ofTempomat/cruise control and correct adjustment ofTempomat/cruise control
connecting rod or control cable, the following points must be observed:
Mercedes-Benz
• Check for easy operation and wear ofregulating shafts, regulating lever, guide lever, ball sockets,
Bowden wire and regulating linkage. Renew worn out parts.
• Clean dirty and hard-to-move regulating assemblies.
• Lubricate all bearing points of all regulating shafts, regulating levers, joints of regulating linkage
and wire lines with an oil can.
• On ~ version vehicles only the following hydraulic fluids may be used:
Castrol DB Hydraulic Fluid
Mobil Aero HFA
Shell Aero Fluid 4
• During assembly j obs, use protective anticorrosion grease, part No. 000 989 87 15 10.
B. Engine 102 with Stromberg carburetor
Fi~.
94: ldenti fyin ~ Adjus tin ~ C on nectin~ Rod Or Cable Control (E n~in e 102 With Strom b er~
Carburetor)
IEngine bring to operating

temperature.
Mercedes-Benz
Engine allow to idle.

Ball socket (3) unlock, press off and secure.
Connecting rod (1) detach, attach at
(TPM) actuator (M 16).
Lever of Tempomat/cmise push toward engine in idling
control (TPM) actuator (M16) speed position.
Connecting rod (1) adjust approx. 1 mm or 1
revolution shorter.
C. Engine 102 with 2E-E carburetor
Preceding work:
Fig. 95: Identifying Adjusting Connecting Rod Or Cable Control (2E-E Carburetor Engine 102
Components)
V acuum hose (4) disconnect, connect.

Plug from throttle valve disconnect, connect.
actuator ( 5)
Mercedes-Benz
Throttle val ve actuator contact to ground. (Using

connection 2 electrical connection set 201
589 00 99 00).
Throttle val ve actuator contact to battery positive.
connection 8 (Using electrical connection
set 20 1 589 00 99 00).
Throttle valve actuator apply with vacuum until
plunger is fully retracted then
switch offvoltage (valve coils
are not constant current-
proof).
(Using hand vacuum pump
001 589 73 21 00).
Ball socket (3) unlock, lock.
Connecting rod ( 1) disengage, engage at
Lever of Tempomat/cruise actuator push towards engine
control (TPM) (M16) in idling speed position.
revolution shorter.
Special tools
Fig. 96: Identifying Special Tools (201 589 00 99 00 15 54)
001 589 73 21 0()

00
Mercedes-Benz
D. Engine 102 with injection system, except engines 102.983/990
Fig. 98: ldentifying Adjusting Conuecting Rod Or Cable Control (lnjection System (Engine 102)
Ball socket (3) unlock, lock

Connecting rod ( 1) detach, attach at
Throttle control move into idle speed position.
control (TPM) actuator (Ml6) speed position.
Coru1ecting rod (1) adjust approx. 1 mm or 1
revolution shorter.
E. Engines 102.983/990
Mercedes-Benz
Fig. 99: Identifying Adjusting Connecting Rod Or Cable Control (Engines 102.983/990)
1ST VERSION UP TO APPROX. 30.06.86 (ROUND ROD

Connecting rod (6) disengage, engage at reversing
lever.
revolution shorter.
2ND VERSION AS OF APPROX. 01.07.86 (PROFILATED ROD)

Hex. head screw loosen at profilated rod (6).
Lever ofTempomat/cmise raise approx. 1 mm from idle
control (TPM) actuator (Ml6) speed position and tighten
hex. screw on the connecting
rod (6) in this position.
F. Engine 103 and engines 104.980/981 with round rod
Preceding work:
Mercedes-Benz
Fig. 100: ldentifying Adjusting Connecting Rod Or Cable Control (Engine 103 And Engines
104.980/981 With Round Rod)

Connecting rod ( 1) disengage, engage at throttle
control.
Throttle control move into ídle speed positíon.
Lever of Tempomatlcmise push with connectíng rod (1)
control (TPM) actuator (Ml6) into idle speed position.
revolution shorter.
~GF
On engine 104 [g] and ~ version do not ínstall a profllated rod instead of the round rod. At full throttle
the distance between profilated rod (1) and coolant pipe is insuffícient (arrow).
Mercedes-Benz
Fig. 101: Locating Full Throttle Distance Between Proftlated Rod
G. Engine 103 and engines 104.980/981 with profilated rod
Preceding work:
Mercedes-Benz
/
/
Fig. 102: ldentifying Adjusting Connecting Rod Or Cable Control (Engine 103 And Engines
104.980/981 With Profilated Rod)
Connecting rod ( 1) disengage, engage at throttle

control.
Lever ofTempomat/cmise push with connecting rod (1)
control (TPM) actuator (M16) into idle speed pos ition.
Length of connecting rod ( 1) check, should be 1 mm
shorter. If required, remove
connecting rod ( 1) and adjust.
n::::rGF
On engine 104 [g] and ~ version, only a round rod may be installed (refer to section F).
H. Engine 111
Mercedes-Benz
Fig. 103: Identifying Adjusting Connecting Rod Or Cable Control (Engine 111)

Connecting rod (1) disengage, engage.
Lever of Tempomat/cruise push toward engine in idling
control (TPM) actuator (M16) speed position.
Connecting rod ( 1) adjust approx. l mm or 1
revolution shorter.
I. Engine 119.960
Mercedes-Benz
Fig. 104: ldentifying Adjusting Connecting Rod Or Cable Control (Engine 119.960)
Cover prior to air cleaner remove, install.

Ball socket unlock, lock.
Connecting rod (1) at disengage, engage.
control (TPM) actuator (Ml6) speed position.
Connecting rod (1) adjust approx. lmm or 1
revolution shorter.
J. Engines 601.91/92, 602.91 and 603.91

Mercedes-Benz
Fig. 105: ldentifving Adjusting Connecting Rod Or Cable Control <Engines 601.91/92, 602.91 And
603.91)
Ball socket unlock., lock at

(TPM) actuator (M l 6).
Conuecting rod ( 1) disengage, engage at
(TPM) actuator (Ml6).
Lever (2) ofTempomat/cruise push away from engine into
control (TPM) actuator (Ml6) idle speed position.
revolution shorter.
NOTE : When replacing the connecting rod (1) be su re to install only the version
with black ball heads.
These parts are available as a repair set. This means that the connecting rodl (1), the lever (2) on
Tempomat/cruise control (TPM) actuator (M16) and the ball head on the regulating lever must be
replaced simultaneously.
K. Engine 602.96
Mercedes-Benz
1
'
1
:
~--
~
:
----------~~MT~~~
Fig. 106: ldentifying Adjusting Connecting Rod Or Cable Control (Engine 602.96)
Hex. head screw (4) loosen at profllatedrod (1).

Lever of Tempomat/cmise actuator push toward engine in
control (TPM) (M16) idling speed position.
Profilated rod (1) adjust approx. 0.5 mm longer
and tighten hex. head screw
(4) in this position.
L. Engines 603.96/971
Mercedes-Benz
1
Y--
((_
1304- 13 70811
Fig. 107: l dentifying Adjusting Connecting Rod Or Cable Control (Engines 603.96/971)

Connecting rod ( 1) disengage, engage at
Tempomat/cruíse control
Lever (2) ofTempomat/cruise push ínto idle speed posítíon.
control (TPM) actuator (Ml6)
Connecting rod ( 1) adjust approx. 1 mm or 1
rotation shorter.
M. Engine 605
Mercedes-Benz
P30-5319-57
Fig. 108: Identifying Adjusting Connecting Rod Or Cable Control (Engine 605)
Controllever (1) turn clockwise until it abuts

tbe interna} idle stop.
By rotating the Bowden cable adjust the control cable (3)
adjusting screw (2) on the until the gate lever (4) has
engine side reached the idle limit stop, or
play between cable (5) and
end piece ( 6) is approx. O to l
mm.
NOTE:
Gate roller (7) must abut idle
limit stop (8) without any
play.
N. Engine 606
Mercedes-Benz
P30-5320-57
Fig. 109: ldentifving Adjusting Connecting Rod Or Cable Control CEngine 606)
Resonance suction line loosen and fold backwards,

fold forwards and secure (14-
1984).
actuator (Ml6)
Lever (2) ofTempomat/cruise push into idle speed position
control actuator (M16) in opposite direction to arrow.
revolution shorteL
NOTE:
Pay attention to ease of
movement and wear of
connecting rods, transfer
lever and ball sockets. Worn
parts are to be replaced.
Mercedes-Benz
REMO VAL AND INST ALLATION OF CRUISE CONTROL AMPLIFIER - RA30001240565X(30-565)
Preceding work:
Cover at left or right under instrument panel removed {68-150) .
A Model124
Fig. 110: ldentifying Cruise Control Amplifier Components - Model124

Connector of hamess at disconnect, connect
(TPM) amplifier (N4)
Tempomat/cruise control unscrew, screw on. If
(TPM) amplifier (N4) amplifier is defectíve, always
check the adjustment of
connecting rod.
Function test perfonn on road.
Mercedes-Benz
NOTE: A new cruise control reference resistor amplifier is being phased in. Check
reference resistor prior to subsequent use (30-506).
The new Tempomat/cruise control (TPM) reference resistor amplifier (N 4/2) has no influence either on
cabling or, as a consequence, on wiring cliagrams.
B. Model129

Cover of unit compartment, remove, instan.
right
Tempomat/cruise control disconnect, check (30-506)
reference resistor (R29) and connect.
Connector (1) ofharness disconnect, connect.
Tempomat/cruise control remove, install. If amplifier is
(TPM) reference resistor defective, always check
amplifier (N4/2) adjustment of connecting rod.
Mercedes-Benz
C. Modell40
Fig. 112: ldentifving Cruise Control Amplifier Components- Model140

Cover ( 5) of module box lift up, mount
(F23)
Gasket (4) check for damage~ when
installing, ensure correct
e
seating of gasket 4).
Tempomat/cruise control disconnect, check {30-506)
reference resistor (R29) and connect
Connector (1) ofharness disconnect, connect
Tempomat/cruise control remo ve, install using assembly
(TPM) reference resistor lever 140 589 01 33 OO. If
amplifier (N4/2) amplifier is defective, always
check adjustment of
connecting rod.
Mercedes-Benz
Special tool
14058901 3300
01
Fig. 113: ldentifving Special Tool140 589 01 33 00 07
D . Model201
Mercedes-Benz
N4 N4
N4 N4
1542-14540

Foot mat front right or left remove, install.
Foot support front right or left remove, install.
Connector of harness at disconnect, connect.
(TPM) amplifier (N4)
Tempomat/cnúse control unscrew, screw on at foot
(TPM) amplifier (N4) support (version A).
Mercedes-Benz
Fastening plate for cruise remove, install (version B).

control amplifier
Tempomat/cruise control unscrew, screw on at fastening
(TPM) amplifier (N4) plate (version B). If arnplifier
is defective, the adjustment of
the connecting rod must be
checked.
NOTE: A new cruise control reference resistor amplifier is installed on models

201.029/128. The remaining models will be phased in. Prior to reuse, check
reference resistor (30-506).
The new Tempomat/cruise control reference resistor amplifier (N4/2) has no influence either on cabling
or, as a consequence, on wiring diagrams.
REMOV AL AND INSTALLATION OF CRUISE CO NTROL REFERENCE RESISTOR-

RA30001240566X(30-566)
Preceding work:
Cover at left or right under instrument panel removed ( 68-150) .
A Modell24
Mercedes-Benz
Fig. 115: ldentifving Cruise Control Reference Resistor Components - Model 124
Tempomat/cruise control disconnect, by pushing lateral

reference resistor (R29) at retaining tongues and connect.
(TPM) reference
resistor amplifier (N4/2)
B. Model129
Mercedes-Benz
Fig. 116: ldentifving Cruise Control Reference Resistor Components- Model 129
Cover of unit compartment, remove, instalL

right
(TPM) reference
Functíon test perform on road.
C. Modell40
Mercedes-Benz
Fig. 117: ldentifving Cruise Control Reference Resistor Components- Modell40
Screws (6) unscrew, screw in_

Cover (5)of module box (F23) lift, install.
Gasket (4) check for damage, when
installing, ensure correct seat
of gasket (4).
(TPM) reference
D. Model201
Mercedes-Benz
~E~
,''1
Ft
Fig. 118: ldentifving Cruise Control Reference Resistor Components- Model 201
Floor mat front right or left remo ve, instaH.

Foot support front right or left remove, install.
Tempomat/cruise control dísconnect, by pushíng lateral
(TPM) reference
REMOVAL AND INSTALLATION OF SWITCH ON CLUTCH PEDAL (UP TO MAY 93)-

RA30001240575X(30-575)
Preceding work:
Cover at left or right under instrument panel removed (68-150) .
Mercedes-Benz
1543-14610
Fig. 119: Identifying Switch On Clutch Pedal Components
Connector at clutch pedal switch, Tempomat/cruise disconnect, connect.

control (TPM) (S40/l)
Clutch pedal switch, Tempomat/cmise control loosen and remove.
(TPM) (S40/ 1)
Function test perform on road .
LAYOUT OF CONNECTORS- RA30001240579X(30-579)
Operation no. of the operation texts and work units and standard texts and flat rates
A. Model124
Mercedes-Benz
X26 Pklg comec ion, r Hancrfeng¡n& 12-Pf'l (4 c'¡inder X33
X26 PkJgconnecion, lltanorfengine12-Pf'l (4 cy\nder X33 Pklgcomedcn, KE/Tempomatfcruse cortro1 (TPM)

mll'do s ~.p lo approx OOt.SS; 6 cyinder mode's t.p lo (1-PI'I){Ul}toapprox 08J85)
approx. 09/87)
Fig. 120: Identifving Connectors - Model124 (1 Of 2)

Mercedes-Benz
X10 ttermodum pklg coonoctor, s.1op lamp swtdl X33t4 Pllg connedon, dllch s'AI!ch'T~omatkruso
(2-Pil) COilToi(TPM)
X21 M~polntp'-'g COOn&cbon, s!Dp lamp SW!tl:h ) X5315 M~poot ~connedloo, HaProffe.cl sensorfrcad
speed Slgnal )
1
) Ody if llo correspoo!ing sagnalrs roqured lar
sevetal oplional oxtras.
Fig. 121: ldentifving Connectors- Model124 (2 Of 2)
B. Model 129
Mercedes-Benz
X3011 Pklgcom¡¡don, mJ .fimdlon bloi:k, r9!orto X33!1 Pklgconoodoo, T~e\ftrusa coo7oi (TPM), feoo
oonnedlng d!ag.ram, goup 00 ter other systams tarm r~al 1 5 (1-ptn)
Fig. 122: ldentifying Connectors - Model129
e_ Model 201
Mercedes-Benz
XSil Pklgcoroot6on, I<E!Tempomal/au1Socorool (TPM)

f2·!*1)
Fig. 123: ldentifying Connectors- Model201 (1 Of 2)

Mercedes-Benz
XS/1 Temunal blod<, 11tenof X53/.3 ~gcomec•on, H~effoctsensor/ARF {1.ptn)

X 2Q lrtoiJlleáa:a pk.lg coonoctor, stop lamp X53l4 Pk.lgcomec • on, llduc:bw soosoiiAAF (2-ptn)
s~o~ich { 2.ptn) X 53i5 M~p011t pk.ig conned!on, HaJ.ellect sensollroad
X21fJ ToiJllJnal blod<, stcplamp S'Midi'Tempomat/muse speed sagnal

conlroi(TPM) (1-Pin) X91 T81Jl1Jnal blod<, dtch poda!/TempúiTI!Il/mus o cortrol
(TPII·1){1.ptn)
X 33 ~gcomodon, KE!Tempomat/cnnse cortrol (TPM)
(1-ptn)
Fig. 124: Identifying Connectors- Model 201 (2 Of 2)
PROGRAMMED REPAIR- TEMPOMAT/CRUISE CONTROL- RA3000124PROOX
30 Throttle control, Tempomat/cruise control
30-86012 Electrical Tempomat: Engine 103 10/86 Part no. revised.

cha11ges in speed
(sawing) of approx. 2-3
Mercedes-Benz
km/h at intervals of 3-4 s.

The range of 50-80 km/h
is concerned.
Cause
Shape of gate lever.
Remedy
Install new gate lever part no. l 03 070 28 21 Production breakpoint unspecified: as of approx.
Nov 85.
a 1S: ve r:ioll
b 2ndv¡¡r;; on
Fig. 125: ldentifying 1St Version And 2Nd Version
30-86041 Electric Tempomat/cntise Models 124.125/130 up -

control can only be engaged to approx. July 85
from approx. 60 km/h.
Cause
Incorrect combination of auxiliary hamess/control unit.
Remedy
Check whether socket 14 is fitted in the coupling ofthe Tempomat control unit.
If socket 14 is fitted, control unit part no. 003 545 86 32 .
If socket 14 is missing, install control unit part no. 004 545 24 32.

Mercedes-Benz
30-8808 1 Vehicle shakes in Models 124.133/ 193/333/393

mode.
Cause
Switching instant ofboost pressure cut-out microswitch shifted dueto incorrect tbrottle control adjustment.
Remedy
Adjust throttle control.
30 Tbrottle control, Tempomat/cruise control
30-89061 Vehicle shakes when Engines 102.96/98 and

Tempomat switch is held 1O3 without ASR
in the "decelerate"
position.
Remedy
Adjust connecting rod ofthrottle control actuator approx. 2-3 mm or 2-3 rotations shorter.
30 Tbrottle control, Tempomat/cruise control
30-89101 Vehicle runs approximately Oct 90 Remedy revised -

1Okm/h abo ve the set
speed, shaking can also
occur at higher speed.
Vehicles (without ASR)
with Tempomat/cruise
control as of approx. Jan 89
Vehicles with reference resistor on Tempomat control unit are concerned.
Cause
Transition resistance at the plug pins for the reference resistor.
Remedy
Remove black rubber seal between control unit and reference resistor and install a new gray rubber seal.
Request parts from VP/PPT4.
Production breakpoint
Mercedes-Benz
Control unit wíth modified mbber seal (gray): Dec 89.
TECHNICAL REVISIONS - CRUISE CONTROL/TEMPOMAT - MODELS 124, 129, 140, 201 -

RA3000124TAOOX
Designation Type and reason for change Application

Tipping switch Tipping switch of models 124 and Middle of April 84
model 201 standardized
Control unit Reliability of interference voltage Phased-in from 12/83 to 03/84
improved
Inductive transmitter speed Improved function 03/84
Hamess Contact sleeves 1.5 mm 0 06/85
changed to copper-berylium 07/85
Hamess manufacturer 10/85
Bergmann 12/85
VDK
Reinsbagen
Krobscbub
Inductive transmitter Inductíve transmitter for speed 09/85
signa! replaced by Hall-effect
sensor
Connecting rod Engine 102.983 Profilated rods, improved 08/86
Engine 103 adjustment 09/88
Control unit Modified to IC tecbnique witb Pbased-ín starting 01 /87 to 08/88
reference resistor Model201.029 andmodel
201.128 from start of production
Hamess Suppression of decel shutoff 4-cylinder models starting approx.
eliminated on RUF and CAT 09/88 6-cylinder models starting
vebicles approx. 09/87
Connecting rod engine Longer connecting rod between 08/89
102.962/963/982 actuator and throttle valve owing
to "Partial intake pipe preheating"
Technical revisions - Cruise controJ/Tempomat- ModeJs 124, 129, 140, 201
Designation Type and reason for change Application

Actuator Washers for fasteníng between Eliminatíon date 11/89
rubber mount and cross arm
eliminated on model129.066
Control unit New gasket (color grey) between 11/89
control unit and reference resistor
Control unit New control unít for model 04/92
140.134 part no. 014 545 40 32
General Tempomat/cruíse control stíll only 06/93
Mercedes-Benz
on vehícles wíth automatic

transmission
ELECTRONIC ACCELERATOR PEDAL, TEMPOMAT CRUISE CONTROL/IDLE SPEED

CONTROL- RA3000FLH0010X(30-0010)
Electronic accelerator pedal, Tempomat cruise control/i(tle speed control- RA3000FLH0010X(30-0010)
A: Location of components
a. Engine 104
M1SJ1 ElectroniC aocelemtor pedal (EF f>) actuator N16/1 Base module (GM)
M1 6J2 Tempoma\ crulse controVidl& 5P"(I contrd (TPM/ N30/1 ABSIASR control un~
LLR) adualor X11/4 TMI coupll rg for dlagnosls. pu.tse s~naJ(38-p111)
N3/1 Hot w.re (LH) control uru t
N4/ 1 Electrotllc aooalerator pedal (EFf>) conlrot unH
N413 Tempomat Ctu!S!t COtllrO-Vidle speed Cotltrd (Tf>M!
LLR) control urut
Fig. 126: ldentifving Electronic Accelerator Pedal, Tempomat Cruise ControUidle Speed Control
Components- Engine 104
Mercedes-Benz
S16J1
$16/3
A1p8 Electcoruc SfM!édometer S16/3 Starter lockoot 1111d re\/OfSing lllfiiP SWitch, selector
Sil/1 ASD/ASR stop lamp switch lever postllOn recognltlon (only wllh EfP)
S1611 Starter loc:kout and re\l$fs11g tamp swlk:h 529/3 Id le apee<~ c:ontact SWi tch (only wllh EFP)
S40 Tempornat oru!Se control switch
Fig. 127: ldentifving Electronic Speedometer And ASD/ASR Stop Lamp Switch
b. Engine 119
Shown on model 140

Mercedes-Benz
o '
.
......._....
M1 6/1 Eleclfomc a<X:eJerator pedal (EFP) actuator N16/1 Base module {GM)
M16J2 Tempomal CfOIS<l corttollldkl s~ oonlrd (TPM/ N30/1 ABSIASR control un~
LLR) actuator V2 Diodo matrtx for eJ10kle spe6d lnetease
N3J1 Hotwire (LH)control unJl X11/4 Test couptirg for d~agnosis, pulse signaJ (38-pln)
N4/ 1 Electroruc a<X:e'lerotor pedal (EFP) control unll
N4/3 Tem:pomat crult& coriroVIdl& sp;eed contrd (TPMI
LLR) contr~ unrt
Fig. 128: ldentifving Electronic Accelerator Pedal, Tempomat Cruise ControVIdle Speed Control
Components- Engine 119
Mercedes-Benz
A1p8
S9J1
EleellOc'IJc spi!Momater
ASD/ASR &top lamp swrtch
S 1613
S2913
-
Startar tocl<cot and re~lng latn.P switch, !~&lector
le\let pcsltiOil teeognltlon (only wllh EFP)
ldle spllM oootact swllch (orCy with EFP)
S16/1 Starter lockotJt and tevetslng lamp s witch
S40 Tempomat cnJJSe control sWitch
Fig. 129: ldentifying Electronic Speedometer And ASD/ASR Stop Lamp Switch
c. Engine 120
Mercedes-Benz
M1 6/3 Electronlc acceletator pedal (EFP) aetuato.r, lelt N4/ 1 ElectronJc accelerator pedal (EF P) control W1Jt
cyllllder tlock N1611 Base mod1Jl& (GM)
M1 614 EleetroniC accelemtor pedal (I:FP) actuato.r, right N3011 ABSJASR oontrot una
c:yllnder block V2 OJode marlx for englne spee<J lnclease
N311 Hot w"l'& {LH) control unlt
X11/4 Test coupllng fotdlag11osls, ¡;ulse slgna1(38-pon)
Fig. 130: Identifying Electronic Accelerator Pedal, Tempomat Cruise ControVIdle Speed Control
Components - Engine 120
Mercedes-Benz
A1p8
S911
516/3
ElecttOllic speedometer
ASOIASR stop lamp switch
Starter lod<out ard re~ la~ switCh, selector
52913
S40
ldle S:peeCI cont11et SWitch
Tempomat crUise control switch
--
lever positlon reeognl tlon
Fig. 131: ldentifving Electronic Speedometer And ASD/ASR Stop Lamp Switch
B: Block diagram electronic accelerator pedal
a. Engine 104
Mercedes-Benz
Accelerator
pedal lever
-----------~[Bowden cable [------------~
Accelerator
co ntrol linkage
~ b
Accelerator Idle speed contact switch (52913) Output lever Thro ttle vall/e
pedal f-- - ----i> actuator
1
& lt
DC 1 5afety 1 Electronic accelerator pedal actuator (M 1611)
1 1
motor 1 contacts
1 1
1 1
1 1
1 1
Voltage supply via ignítion

starter svAtch (S2/1 )
t
Electronic acce lerator
i : Fault
Test co~ling
(X11/4)
'-e: pedal, Tempomat crulse : memory

control, k:lle speed 1
'-- -------
control urit (N4/1)
Start er locko ut
Base -·- -------------1 and reversing
module (CAN ) 1
1 lamp swltch
(N16/1)
1 (S 16J3)
L
: l
i
A/C compres.sor
LH co ntrol
u nít
I (CAN)
1
1
1
X
i
Selector lever
cutin signal (N3/1)
1
1
1
A/C compressor
pressure switch Coolant
(531 ) temperatu ra
sensor (91112)
Tempomat
cruise control
'--
switch (S4 O)
Voltage supply,
1
EZL ignition contro l T empo mat c ru ise control
unit (Nl/3) switch (fuse F3)
~ -------
i (CAN )
1
1
1
1
1 Speed sensors
(L611, L614)
Posítion sensor
(LS)
~
(CAN) ¡ABS/ASR
~Stop lamp switc h (5911)
1control unit
!<N3011)
1
?
1
1
1
f 1
1
IBrake pedal
e lectrlc wiring
transmitted m echanicallv
Mercedes-Benz
Fig. 132: Block Diagram Electronic Accelerator Pedal - Engine 104
b. Engine 119
al
eralor
---- -~~coomd~~
13) ~:le~el
or
l""'•~w.. 1
ó
oc 1
1
Sefely 1 Elt<:O-onlc ea:. le retor pedolactuotor (M1611)
contacts
lmotor 1
1
1
1
1
1 1
Voltage aupply vla i!Jlllon

sta rler~tch(S211 )
~
Eleotroolc acx:>elarator
~ Test ccupfng
- (X11/4)
:Fa~t
L.-o pedal. Tempomat crulse :memory
contrOl, id le speed 1l _______
Startar lockol.i
control u m (N411)
Base ~ -------- andreveiWlg
lamp~ldles
module
(N t6/1)
(CAN) ~ (516/1. 516/3)
1
1
J
a
~ t
r
AIC compressor
LH contrá
un4
:(CAN)
1
1 ~ r--
Selector levar
r·-
CUIInslgnal (N311) 1
1
model124 Olodl matrhc.
tngfle speed
f
NC compressor Cooánt
increase (V2)
model140
pressure swldl temperalure

(531) sensor (81 112) ljl
model124 Tempomatcnnse Additioool
control switch (540) consumen culin
-1 &l¡¡nal model140
ElL ~gntlon control

íl 1
Voltage supply Tempomat
---
unl (Nt/3) cruise control ~lch
:(CAÑ) ___
(CAN)
¡erake pedal
- - - - - eleclric wlring
translllllled mechanlcally
Mercedes-Benz
c. Engine 120
1 Mercedes-Benz
1
~-----
Accelerator IBowden cable Accelerator Throttle vatve
pedallever - ----- - - --i> control linkage (left cylinder block)
~ \1
~
~--------i>(S29!3)
"""'"~""''"'"' Out pul levar Throttle valva
actuator
1
! (rlght cytlrnder block)
- 1
1
6 r----------1
1 ~
VoUage supply via oc Safety EFP actuator oc 1 EFP actuator
lgnftion starter motor contacts (M1613) motor 1 (M16/4.)
switch 1
1
(S2/1)
~
Test coupliog
-{> (X11!4)
Base mod~e ~ EFP, Tempornat cnise

(N16/1) control, idle speed r-------- Starter lookout and
1
control unlt (N4/1) IFautlt reverslog lamp
:memory switch (S16/3)
1
!.__________
...,
-------------------,1
Serial databus (CAN) 1
1
1
1
1
<l-- J
Selector lever
~
~
1
~
Diode matrix, e ngíne
speed ilcrease (V2)
& ~ ~ -
LH control 1 CAN LH control 1 CAN
unlt 1 uníl 1
1 ______
!._ 11_ _ _ _ _
(N312) (N313) Tempomat
cruise control
sw~ch (S40 ) f
~ ~ Addltional
oonsumers outin
Coolant temperatura Coolant temperatura signal
sensor (811/9) sensor (811110}
1
Speed sensors
(L611 , Voh~e supply,
~ \1 L614) Tempomat cnise
EZL
'' CAN EZL ! CAN control switch
(fuse F3)
lgnition
4;:: control
''!...______ lgnitlon
control
1!... ______
unlt (N114) unlt (N1/5)
? ? l -
Stop lamp switch
(89/1}
Posltlon sensor Positian sensor CAN ~SIASR
(LS/4) (LS/5) ntrol unlt f<r-
1
e, e,
''
'
'
J¡ ·~~J
(N30/1)
electric wlring
y 1
Mercedes-Benz
C: Function of electronic accelerator pedal
a. General
The following functions are integrated in the electronic accelerator pedal control unit
• idle speed control

• Tempomat cruise control
• electrical, electronic engine control (electronic accelerator pedal).
All the control processes as well as the mechanical positioning movements are performed with the
electrical/electronic components in conjunction with the mechanical components. The
electrical/electronic components are provided with the necessary voltage by the base module through the
unfused terminal 87.
The following components supply signals to the electronic accelerator pedal control unit:
• base module
• ABS/ASR control unit
• LH control unit
• EZL ignition control unit
• idle speed contact switch
• electronic accelerator pedal actuator (with throttle valve body)
• stop lamp switch
• starter lockout and reversing lamp switch
• Tempomat cruise control switch
• A/C compressor cut in signal
• Data interchange via serial databus (CAN)
• Engine speed sensor
• Engine speed increase diode matrix (only on engines Mll9 and Ml20 in model 140)
The input signals are processed and monitored in the electronic accelerator pedal control unit. The
following components are actuated with the output signals:
• electronic accelerator pedal actuator (with throttle valve body)

• LH control unit
• pulse output (fault memory) vía 38-pin diagnostic socket
• Data interchange vía the serial databus (CAN)
Mercedes-Benz
The electroníc accelerator pedal facilíty as well as the íntegrated idle speed control are activated when the
ignition ís switched on. The control unít recognizes the position ofthe accelerator pedal through the set
point potentiometer in the actuator (M16/ 1, engine 120: M16/3 left bank of cylínders). The position of the
throttle valve is signalled by the actual value potentiometer in the actuator. On engine 120 the position of
the throttle valve is signalled simultaneously by the actual value potentiometer in the actuator (Ml6/4,
right bank of cylinders) to the control unit
The control unit checks the signals and determines the position ofthe throttle valve by means ofthe
output signaL
lf the accelerator pedal ís not depressed, the position of the throttle valve ís specified before sta1ting as a
functíon ofthe coolant temperature (signal from LH control unit via the serial databus).
The opening angle ofthe throttle valve is limited over tbe entire control range (from idle speed stop to
full throttle stop) by the electronic accelerator pedal control unit for idle speed controL
The position ofthe accelerator pedal (set point) is signalled from the actuator via the set point
potentiometer to the control unit for the electronic accelerator pedal facility_
The control unit assigns an output signal to tbis set point for controlling the actuator. The actuator and
thus also the throttle valve hereby adopt a position corresponding to the set point The accelerator control
linkage is connected to the output 1ever and to the internal spring capsule by a loose connection with the
throttle valve. On engine 120 the actuator (M16/4) does not have any connection to the accelerator control
linkage. The throttle valve is adjusted in this case only by tbe electrical/electronic actuation.
The opening angle of the throttle valve corresponds to the entered set point as a result of which a certain
torque ís transrnitted by the engine to the dríving wheels. Ifthe set point entered (accelerator pedal
deflection) is higher than the driving torque which can be transmitted to tbe road, this means that the
wbeels spin (slip). This slip is detected by the ABS/ ASR control unit and passed as a signal (throttle val ve
reduction) via the serial databus to the electroníc accelerator pedal control unit In addition, in order to
innnediately reduce engine torque, the ignition timing is retarded by means of a signa] from tbe serial
databus to the ignition control unit
The driving torque is continuously reduced at excessive throttle until the slip at the driving wheel drops
below a specified leveL
Features:
• Throttle valve always adjusted by the electrical/electronic facility.

• Tempomat cruise control is íntegrated in the electronic accelerator pedal control unit
b. Heating speed
If slip occurs at tbe driving wheels wben the throttle is eased back, this is likewise detected by the
ABS/ASR control unit
The signal (throttle valve íncrease) is Iikewise passed via the serial databus to the electronic accelerator
nPrbl r{)ntr{)lllnit With thic;: inf{)rrn::lh{)n thP rlrivi na t{)rnliP r::~n hP v::~riPrl e;:{) th::lt n" din {)rrnrc;: ::~t thP
Mercedes-Benz
drivíng wheels (engine drag torque control=MSR) aud thus stabilizes the lateral control ofthe vehicle.
All in aH, the electronic accelerator pedal facility enables the throttle valve to be varied between idle
speed aud full throttle or by means of ASR closed in idle speed direction or by means ofMSR briefly
opened slightly.
If excessive driving torque exists at the driving wheels (ABS control), the spiral spring in the spríng
capsule enables the actuator to move the throttle valve against the accelerator pedal position.
With an MSR control, the accelerator control (Bowden cable) permits an adjustment in the direction of
the accelerator pedal to a slight extent.
The idle travel in the actuator (between spring capsule and controllever) is an emergency drivíng facility
which allows the car to be driven with reduced engine output in the event ofthe electronics failing.
• Idle speed control is integrated in the electronic accelerator pedal control unit.
• Car can still be driven at reduced engiue output in the event of the electrics/ electronics failing.
Engíne speed is íncreased each time it is started within a certain temperature range when the engine is
idlíng (idle speed recognition) and selector lever is in position Por N (see table).
Engine Tempera tu re Time Engine speed

M104 <+20 oc approx. 20 1100 ±
seconds 100/min
M119 +20 oc - +30 o approx. 20 1000 ±
e seconds 100/min
Ml20 +20 oc- +30 ° approx. 25
e seconds + 100
850
-50
1 Mercedes-Benz
1 1990-2002 ACCESSORIES & BODY, CAB Throttle Control, Speed Control Systems- 129 Chassis
1100
1000 -
900
800 -
700
600 -
1 1
Start approx . 20
Fig. 135: Coolant Temperature And Selector Lever Position P/N Diagram
Diagram refers to 20 oc coolant temperature (simulated) and selector lever position P/N.
Shown on engine 119 in model 140
c. Engine speed increase/engine speed stabilization
Engine 104 and engine 119 in modell24 on vehicles with A/C compressor have an engine speed
stabilizer for the A/C compressor. Engine 119 in model 140 and engine 120 have an engine speed
increase diode matrix for various electrical components (e. g. A/C compressor, seat heaters, heated rear
screen).
Engine speed increase diode matrix
Wben additional electrical components are switched on, the on signal is also passed to the engine speed
increase diode matrix. T.be signal is then passed on to the electronic accelerator pedal control unit. T.his
signal is analyzed in the idle speed control assembly. The signal for increasing idle speed is only active if
no idle speed recognition exists from the set point potentiometer anda given speci:fied speed has been
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exceeded. When the vehicle next stops, the engíne then id les at a slightly increased speed. The engine
speed increase ís only cancelled once the input signal from the diode matrix no longer exísts and no idle
speed recognition is detected. Engine speed increase is not active when selector lever is in position P and
N.
Engine speed stabilization on engines witb A/C compressor
When A/C compressor cuts in, voltage ís supplied to the electronic accelerator pedal control unit or at the
Tempomat cmise controV idle speed control unit. In this case, the cut in signal is fed vía the base module
(approx. 350 ms) into the electronic accelerator pedal or Tempomat cmise controVidle speed control unit.
The control unit processes the voltage supplied and passes an appropríate signal to the set point selector.
The openíng cross section is enlarged before the A/C compressor cuts in so that idling speed remains at
an approximately constant leve l.
Fig. 136: ldentifying Engine Speed Stabilization On Engines Witb A/C Compressor
D: Block diagram Tempomat cruise controllidle speed control
a. Engine 104
1 Mercedes-Benz
1
Accele retor Bowden cable A<X:elerator-

pedallever -----------!> (M 1612) -------------!> controlllnkage
9 ~
Aocelerator Output lever Throttle vatve
pedal actuator
& ~
oc
motor
1
1
1
Safety
oontacts
¡ Tempomat orulse controflidle
speed contro l (M1612)
1
1 1
1 1
Voltage &l{lply vla lgn~ lon

starter switch (S2/1)
_L j
Tempomatcruise control!
~r-
1 FaLJt
- ~
Test couping
(X11/4)
ldle speed control unit ¡ memol)'
(N413) 1__________
Starter lockout
and reversing
Base - - - - - - - - - - - - -1 lamp switch
1"
module (CAN) 1 (81611 ),
1
(N16/1) 1- 1 auto malle
1
1
1
transmission
¿
1
NC oomprtlSSQr
LH control
unit
i (CAN)
1
1
1
Selector levar
cutln slg nal (N311 ) 1
l
1
A/C compressor Tempomat
pressure switch Coolant cruise control
(S31) temperatura Tempomat crulse clutoh pedal
sensor (811/2) oontro l switch (S40) switch (S4011)
'-- (manual
tr.ansmission)
Voltage supply,
t
Tempomat c rulse control
switch (fuse F3)
EZL lgnaion control
una (N1/3)
~ --------
¡<CAN)
'-
1
1
1 Engine speed sensors
t
Positio n sensor
( LB/1 , LB/4)
(L5)
(CAN) lABS/ASR
~Stop lamp swltcl1 (S9/1 )
1
¡oontrol unlt
l(N30/1)
1 f
1
í 1
1
electric w iring
¡s~ak-e pedal
1
... ..
Mercedes-Benz
Fig. 137: Block Diagram Tempomat Cruise Controllldle Speed Control- Engine 104
b. Engine 119 in model140

Mercedes-Benz
Acoelerator
control linkage
Ou\put lever
actuator
~
oc 1
1
Safety 1
1
Tempomat cruise controVidle
1 1
motor 1 cont.acts s.peecl contro l actuator (M 1612)
1
1
i
Voltage supply Vi a lgnhlon
starter switch (5211)
b 1
Test ooupling
(X11/4)
Tempomat cruise control/ l Fault
idle speed control urit 1 memory
(N413) 1
'-------- Starter lockout
a rnd reverslng
Base --------------1 lampswltch
module (CAN ) 1 (S16/1),
1
(N16/1) 1 automatic
1
transmisslon
1
1 X ! ~~
LH control
unit
l(CAN)
1
1
1
.... f
Selector leve r
(N3/1) 1
1
1
-
Engine speed
increase dlode
matrlx (V2)
Coolant
temperature Tempomat crulse
sensor (8 11/2)
- control switch
(S40)
9
Additional
consumers cutln
signal
Vohage supply, Tempomat

EZL lgnhlon control crulse w ntrol swítch (fuse
un~ (N1/3) F3)
.-::-----
1(CAN )
1
1
1
1 Speed sensors
1
Posftion sensor
(l6!1 , L6/4 )
(l5)
(CAN ) IABS/ASR
lcontrol urit
H Stop lamp switch (S9/1)
l(N3011)
1
1
9 1
1
1
1
¡erake pedal
.eJectdc.wiring
transmitted mechanically
Fiº. 138: Block Diaºram Temnomat Cruise Control/ldle Sneed Control - En!!ine 119 In Model 140
Mercedes-Benz
E: Fu!llction ofTempomat cruise C(}otrollidle speed control (engines 104, 119 in model 140)
The functions of
• idle speed control

• Tempomat cruise control are integrated in the control unit.
The control processes for idle speed control and Tempomat cruise control are performed with the
electrical/electronic components in conjunction with the mechanical components.
The electrical/electronic components are supplied with the necessary voltage by the base module through
unfused terminal 87.
The following components supply signals to the electronic accelerator pedal control unít:
• base module
• LH control unit
• EZL ignition control umt
• Tempomat cruise control!idle speed control actuator (with throttle valve body)
• Stop lamp switch
• starter lockout and reversing lamp switch (automatic transmission only)
• clutch pedal switch (manual transmission only)
• A/C compressor cut in signa!
• data interchange vía the serial databus (CAN)
• engine speed sensor
The input signals are processed and monitored in the Tempomat cruise control/idle speed control unit. The
following components are actuated with the output signals:
• Tempomat cruise control/idle speed control actuator (with throttle valve body)
• LH control unit
• pulse output (fault memory) vía 38-pin diagnostic socket
• data interchange via the serial databus (CAN)
The idle speed control facility is activated when the ignition is switched on. The position ofthe throttle valve
for idle speed is fixed vía the drive potentiometer by the control unit. The position of the throttle valve is
signalled by the actual value potentiometer.
The Tempomat cruise controllidle speed control unit checks the signals and determines the position of the
throttle val ve by means of the output signal. The position of the throttle valve is specified before starting as a
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function of coolant temperature (signa! from LH control unit via the serial databus). The control range ofthe
throttle valve for idle speed control (i. e. opening angle) is limited by the Tempomat cruise control/idle speed
control unit.
F: Function ofidle speed control
Id le speed is controlled by the electronic accelerator pedal control unit or by the Tempomat cruise control/idle
speed control unit. The following infonnation is required for this process:
• engine speed (TNA)

• road speed signal
• automatic transmission selector lever position
• A/C compressor cutin signal
• clutch signal (only Ml 04 with manual transmission)
• additional consumers cutin signal (engine speed increase diode matrix)
An output signal is passed to the set point selector in the idle speed control assembly as a function of the input
signal supplied. The set point selector analyzes the idle speed signal in conjunction with the other signals
received. The position controller and the serial databus (CAN) are actuated with the output signals. The signals
are checked by the monitoring device and the output stage is actuated via the release/shutoff device and the
position ofthe throttle valve thus deterrnined.
An information exchange takes place via the serial databus between the electronic accelerator pedal control
units or Tempomat cruise control/idle speed control unit, LH control unit and EZL ignition control unit.
The electronic accelerator pedal control unit or Tempomat cruise control/idle speed control unit fixes the set
speed.
If a control deviation exists, the idle speed control is assisted by the ignition control unit by altering the ignition
timing. The ignition timing can be retarded as a result up to approx. 20°.
In addition, the LH control unit is supplied with infom1ation by means of the signal from the databus from
which the LH control unit detennines the required injection time.
At idle speed and when the vehicle is stationary(road speed signal=O), the control unit automatically calculates
the air throughput inline with the operating state of the engine (e. g. coolant temperature, selector le ver
position). This ensures that optimal idling speed stability is maintained in all operating conditions. Idling speed
is controlled continuously as a function ofthe coolant temperature (see table as reference point).
Coolant Drive position without gear 1/mi n Drive position with gear 1/min
temperature oc Engine 104 Engine 119 Engine 120 IEngine 104 Engine 119 Engine 120
<O 900-1000 800-900 800-1000 800-900 750-850 700-900
>O< or= 30 900-1000 700-800 750-900 800-900 650-750 650-800
>30 < or = 40 - 650-700 750-900 - 550-650 650-800
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>40 - 650 600-750 - 500 500-650

45 750-850 - - 650-750 - -
60 700-800 - - 600-700 - -
> or =75 650-700 - - 550-650 - -
The idling speeds with and without gear differ. They are determined by the electronic accelerator pedal control
unit or Tempomat cruise control/idle speed control unit in líne with the selector lever position.
G: Notes regarding towing vebicle, test and repair work
L Pay attention to the following points in respective vehicles with ABS/ASR for the operation ítem "Testing
engine output and emissions":
o Ignition off
o Bridge between contacts 6 and 1 at test coupling (Xll/4). ABS/ASR control unit thus in diagnostic
mode.
o Ignition on, test engine output and emissions. The ABS/ASR indicator lamps light up so long as the
diagnostic mode is actívated.
o Switch off ignition. Remove bridge.
2. Actuator plug connection watertight. It must only be opened for the test operations specified in the test
program.
3. Cleaner or contact spray must not be used on the actuator plug connection.
4. Electronic accelerator pedal control unit or Tempomat cruise control/idle speed control unit is not fused.
5. Pay attention to the following points when perforrning welding work with electrical welding torch:
o Disconnect negatíve terminal of battery.
o Connect ground temtinal of welding equipment directly to the part to be welded.
6_ Should it be necessary to increase engine speed when performing test and adjustment operations on the
engine, this should be done directly at the accelerator pedal. If engine speed is increased at the accelerator
controllinkage in the engine compartment, the system will switch to emergency running and a fault will
be stored in the fault memory.
IGirGF
With ignition ON, engine running and vehicle stationary, the processor in the control unit performs
programming to the special throttle val ve angle (idle speed position) of the engine. The correction
variables are thus calculated and re-stored. It is not possible to install control units from other vehicles as
a check.
Design and operatioo of electronic accelerator pedal (ASR)- RA3000KE3A010X(30-0010)
A. General information regarding ASR
The acceleration skid control (ASR) is an automatically operating system for improving starting-off and
acceleration capability as well as vehicle stability.
Mercedes-Benz
ASR is the logical further development ofthe anti-lock brake system (ABS). Whereas the ABS prevents
the wheels locking during brake applications and thus retains the steerability and stability of the vehicle
during deceleration, ASR prevents the driven wheels from slipping when starting-off and accelerating. It
thus ensures optimal vehicle stability combined with increase traction.
The basic components ofthe ABS are supplemented for ASR by an additional hydraulic unit, a pressure
supply unit, a fourth speed sensor, enlarged electronics and the electronic accelerator pedal with control
unit, set point potentiometer and electronic accelerator pedal actuator.
In addition, the cruise control system (Tempomat) is integrated in the controllmit ofthe electronic
accelerator pedal.
Differences of ASR I and ASR JI
ASRI
• Only model126 with engine 116/117 up to approx. 02/90

• One hydraulic unit each for ASR (A8) and ABS (A7) (distinguishing feature)
• ASR pressurízing pump at pressure accumllllator
Benefits
• Improves starting-off and acceleration capability as a result of increased traction, which is

particularly beneficia! on modal split road surfaces (i. e. surfaces offering different levels of grip)
and when cornering.
• Enhances the active dynamic safety as only a wheel which is not slipping permits optirnal
propulsion without any loss in lateral control.
• Automatically adapts engine torque to the capabilities ofthe wheels to transmit the power to the
road surface ifthe driver accelerates too sharply.
• A function indicator informs the driver when the ASR control mode is operating and is a signa] to
him that he is elose to the physicallimits of his vehicle.
Mercedes-Benz
Fig. 139: ldentifying Hydraulic Unit For ASR And ABS (Distinguishing Feature)
ASRII
• AH models with 6-and 8-cylínder engines as of approx. 02/90

• Compact ABS/ASR hydraulic unit (A7/3) (distinguishing feature)
• ASR pressurízíng pump (Ml5) at brake servo unit
• ASR charge pump/ABS return pump in compact hydraulic unit
Fig. 140: ldentifying Compact ABS/ASR Hvdraulic Unit (Distinguishing Feature)
Fig. 141: Identifying ASR Charge Pump/ABS Return Pump In Compact Hydraulic Unit
The dífferences in respect of the hydraulíc components do not have any effect on the overall operatíon.
The operation/testing of the electronic accelerator pedal is identical for both ASR versions. Depending on
the engíne installed, dífferent voltage levels apply for the posítíon sensor (R25).
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NOTE: For allocation of engine - position sensor - EFP actuator - EFP control unit
refer to Diagnosis Manual Engine
Volume l.
Desigo and operatioo of electronic accelerator ¡>edal (ASR)- RA3000KE3B010X(30-0010)
B. Driving with ASR
Various symbols are provided in the instmment cluster displays for the ASR.
A1e17 ABS wamng lamp

A1e21 ASR luldlcn lndicalorlamp
A1 e22 ASR wamng lamp
L___ ·-----· ---------------------·----------------------- _::
Fig. 142: ldentifying ABS Warning Lamp, ASR Warning Lamp And ASR Function Indicator Lamp
Switching on the ignition
When the ignition is switched on (ignition starter switch in position "2 ") the ASR function indicator lamp and
the ASR warning lamp in the instrument cluster come on (bulb check) and go out when the engine is running.
Driving
When driving the ASR function indicator lamp comes on as soon as the ASR is operating. From end of the ASR
control mode the ASR function indicator lamp remains on for a further 1 second approximately. The function
indicator lamp does not come on for very brief ASR control mode.
Control mode
The ASR fimction indicator lamp indicates the ASR control mode and signals to the driver that he is close to the
physicallimits of the vehicle. This enables the driver to better adapt his style of driving to road conditions.
Warning function
If the ASR warning lamp comes on when the engine is running, this indicates a fault in the ASR or in the
electronic accelerator pedal. ASR is not operating, the ABS function is retained.
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output. The driver is aware of this from the different operating forces of the accelerator pedaL
If the ASR and ABS warning lamps come on when the e ngine is running, then:
• there is a fault in the ABS as a consequence of whích the ASR always remains deactivated.
• there is a fault in the ASR which also affects the ABS.
Both systems are then switched off
'
1
1
-------------------------------------------------------~=~~
A 1e17 ABS warnng IBill>

A1a21 ASR h.mtioo indicatorlatl1>
A 1e22 ASR warnng larrp
Fi~. 143: ldentifyin~ ARS ANS ABS Warn in~ Lamp Function
ASR snow chain switch (S76)
(ASR snow chain control with indicator lamp)
The very responsive stability-oriented control of the ASR may have a detrin1ental effect on vehicle handling
when driving in deep snow with snow chains fitted.
For this reason, a special controllogic is programmed in the control unit for the starting-off range in appropriate
situations, which can be selected by the driver by pressing the ASR snow cbain switch (slip threshold switch).
When the ASR snow chain switch is operated, the indicator lamp in the switch comes on. After an ASR control
mode lasting 50 ms, a higher input slip is permitted at the wheels, thus enabling the car to churn its way fl-ee in
the afore mentioned situations.
Mercedes-Benz
,-
'1
S78 lffJ
o
Fig.144: ldentifying ASR Snow Chain Switch
As this higher slip would ha ve a negative effect on vehicle stability, particularly at high speeds, it remains
restricted to the speed range <40 km/h. The higher input slip remaíns stored up to 60 k:rn/h and is automatícally
re-activated íf vehicle speed drops to <40 km/h. As soon as a speed of 60 km/h is exceeded, the stored hígher
slip is erased and the indicator lamp in the switch goes out.
Design and operation of electronic accelerator )leda) (ASR)- RA3000KE3C010X(30-0010)
C. Location of components
Model124
Mercedes-Benz
ElectricsiElectronic$ Hy draulics
A1e17 ABS wam11glamp A713 ABSfASR hy¡i'!l'..Jic U!ll
A1e21 ASR tmctioo 111dica~ Jamp M15 ASR prossoomg ptJrnp
A 1e22 ASR wam11glamp 80 Brakel.iJKI f8S91VOW
K 112 Overvoi:Bgo pootocllan relay87c/87l/3a (9-pin) ( son as 81 Pressure acum!.latOf
K1/ 1) 82a/82b Rll-81 bfake caipers 'Mth weartn!icator
Lo/1 lafilrort ~a s¡¡i!ad senSOJ Mechanicc
Ul/2 Rigtt liori wde ~ed soosor 20 !die i a\'91red (redurldancyrod)
l613 leftrear axle s¡¡eed sensor
l614 Rlgt roar axle speed sensor
M1 6/1 Elet~ooc eccekual:f pedal (EFP) actuaiOf
N411 Elec:rooc ac<:Bierm !)OOel (EFP) cornrol111it
N30f1 ABSIASRcomoiUillt
R25 Elec ion e ecc Bler al:f ~ (EFP) ¡poSiioo sensor
S9!1 4MATIC/ASO stop larrp swtch
S 40 Tempomat cn.t.se ccrool st.~~tc:h
V Dace'.eral! /Set
B A.ctelera\9/Set
SP ReSU'I19
A Off
S76 ASR soowcha~n S'Mich
Fig. 145: ldentifying Electronic Accelerator Pedal Components Location - Model 124
Modell26 (ASR I)
Mercedes-Benz
Moael lLb (A~t< 1}

Electri csfEiectronics Hydraulics
A1o17 ABS wa:mng Jamp A7 ABS trydraulic uni klr ASR
A1e21 ASR lll'ldlcn ll'ldtcabr lamp AB ASR trydra!Ac 111.t
A1e22 ASR warning Jamp M15 Pnssurumg punp
K1/1 Ovil!V~g.e p..-otocbon rfllay 48 Breke l nd res OIVOtr
K20 Pressun21ng punp relay 81 Pn:.sure atWITI.Ita!or
Uf1 Leftfrcn! !003 spGed sensot 828/Síb Rear btake c~po¡s v.~th weac mdíc1!!or
L6/2 Rlgtt tort axle speed sensor Me chanic s
L6l3 Loft reac axla speed sensor 20 kle raval rod {re<Uldancyrod)
L6/4 Rlg!t raer axla speo:d sensor
M1611 B&Cronc &ecelefa'm pe~al aduator
N411 Becrorec a«~leremr pedal oontolurit
N3011 ABSIASR colirt:l 1.1tl
R25 Becronc occelerm pedal pogbon sensor
5911 Stop IIIIT'p &Nich
5 40 Tempomal au~Se eortrol w.~tch
576 Sncwdlam swtch (gplhsastlold S'l'ltch)wfl
indicator lan'p
Fig. 146: ldentifying Electronic Accelerator Pedal Components Location - Model 126 (ASR 1)
Model 126 (ASR II)

Mercedes-Benz
EleetriC'S(Eiectro ni es Hydraulic s
A 1&17 ABSwam11glamp A7fJ ABSJASR ll')Qeuic oot
A 1e21 ASR i.Jncllcn llác a!Di temp M 1S ASR preSSUIZIIQ pül11>
A1e22 ASR wam11g lamp .00 Brako luid ros91VOI"
K1f1 O<arvollage protecllcn rela'{ 87E ( 7-p¡n) 81 fTBS'Sllf9 acrurrule~Dt
L6/ 1 Left frort ~ 5;l1Hld sensor 82a/82b Re arbreke cajpers wth waar 1ndicalor
l612 ~gli i"onl axle speed sensor Mechan les
L613 Left rear !llde s¡¡eed sensor 2Q kle •a·vet rod (redlndencyrod)
L6/4 Rlgttrear axla s~odsonscr
M1 611 Eleci"ont accaleralot pedal (EFP) .actualor
N4f1 El8CWOOIC accelere~Dt ~dal (EFP) coruol uní
N3M /ISSIASR conlrol tnt
R25 BIKiooc ac-coleralot pwal (EFP)poSJ&on sensor
S9f1 4MATICIASO stop lanl> sw~dl
5 4() Tompoollll OUISGCCfi'.rCI Sr.tldl
V Dacelerel!/Set
8 AcceleraleiSet
SP RestrTle
A Off
5 76 ASR SOO'IV cllain SMtdl
Fie. 147: ldentifyine Electronic Accelerator Pedal Components Location- Model126 (ASR 11)
Model 129
Mercedes-Benz
Ele ctrl.csfEI ectronic s Hydral.iics

P.1e17 ABS warnng larl1l P. 7rJ ABSIP.SR hythiÚic tnt
.0.1e21 ASR lulCion ln<ita!<lflilnl> M15 ASR pressmwgpu"l>
P.1e22 .t.SR warnng larl1l 80 Br ake luJd reseNotr
K1/2 OveNolage proluc~on relay 87E/87l./30a (9-Pfl) tH Pr essure aca~miJat<lf
(senes K111) 82al82b Re ar brake ca pers .,..th wear 1rnicator
LS/1 Left tront axiG speedsen!;Or Mechanlcs
LM RlghiiTod 8lde spaed soosor 20 lcle ~ewl rod (reduldallcyrod)
LOO lellrear 8l4e speed sensor
l614 R¡glll rear Slde speed sensor
M16J1 Electronlc aocelemtor pedal eckla!or
N4/1 Etectronic acceleralor pedal comol t.nt
N3011 ABSI ASR romo! mi
R25 Electrooc accaleralor pedalposilon sensor
S911 ASO!-'SR slOplemp s ....lth
S40 Tempomatuuse (OI'Crol swtch
V De< elerateiSet
8 Acco!ara!eiSet
SP Resune
A Off
S76 ASR SllCW chatn swlch
Fig. 148: ldentifying Electronic Accelerator Pedal Components Location - Model 129
Model201
Mercedes-Benz
E lect ric sfEiectro n les Hyd rsullcs

A1e17 ABS warnng larrp A7/3 AB SIASR hydrlllilc tnl
A1e21 ASR fuoci oomdíc:alor lam> M15 ASR Pf8SSUI1211g pufTll
A1e22 ASR warning larrp 4a Br ak& luJd re<>OIVOI"
K1/2 OvOIVolege PfO!&c~oo relay 81 Prossure acrurrulallr
Ul/1 Leftlronl Blde speced sensef 82a/82b Rear bfaf\o ca5pers ~lh wear mdíc.aíor
L612 R¡ght frCff! ll>te ~"'lOd SOilSOf M•chenlcs
Lfi/3 Left r ear al4e speed son sor 20 kle t avel rod (roC>.Jldancyrod)
L614 RlghtrelliiDde speed sensor
M1&!1 Electlooc etnlore!or pedal at~a:nr
N411 E IEh.'"llonc accolollllor podel comol tnt
Nl0/1 ABS/ 1\SR ccrtrol umt
R25 Elewom; 8(( alefator podalposllloo sensor
S9/1 ASOIASR stop lamps'lli!th
540 Tompcmatcrus:e cortrol swich
V Doalemte!Set
8 Acce'Ofa~/So!
SP RaSIJTla
A O«
S76 ASR SllCW cham swtch
Fig. 149: Identifying Electronic Accelerator Pedal Components Location- Model201
Design and operation of electroniic accelerator pedal (ASR)- RA3000KE3D010X(30-0010)
D. ASR overall function
The speeds ofall the wheels are detected and processed in the ABS/ASR control unit. Ifthe ABS/ASR control
unit detects from the speed signals that one or both driven wheels is tending to slip, the ASR control mode
commences with the brake torque control loop and the driving torque control loop.
Mercedes-Benz
The following processes are performed:
• Brake torque control loop
The slipping dríven wheel ís braked by the relevant wheel brake tmtíl ít has achíeved the most favorable
input slip range. This enables the other wheel to be optimally driven (locking differential effect).
To brake the slipping wheel, part ofthe highly pressurized brake fluid in the pressure accumulator is
passed from there via the ABS and ASR hydraulic units into the brake caliper (pressure build up).
A solenoid valve modulates the pressure flow in the brake caliper during braking torque control, in the
pressure build up, pressure holding and pressure reduction phases. During pressure reduction, the brake
fluid volume is pumped back out of the brake caliper through the returu pump into the pressure
accumulator.
This control sequence is performed for each wheel brake ofthe driven wheels individuaUy. For operation
and testing see Repair Instmctions "Brakes II, ABS/ASR Group 42".
• Input torque control loop
In order to reduce excessive input torque to achieve optímal tractíon, a signa! ínterchange is performed
through the interface between the ABS/ ASR control unit and the electronic accelerator pedal control unit.
The throttle valve position is reduced by the electronic accelerator pedal actuator relative to the
accelerator pedal position input by the driver.
The ABS/ASR control unit constantly checks whether the control functions can be cancelled, e. g. as a
result of a sud den improvement in road surface gr ip, in order to restore as rapidly as possible the input
torque specified by the driver via the accelerator pedal.
A distinction requires to be made between three control modes during ASR control:
• Control mode with one slipping driveo wbeel and vehicle speed <40 km/h with control being performed
on the basis of the driven wheel which is still gripping.
In this case, the shp threshold ofthe input torque control is relatively high. The emphasis is thus on
achieving maximum traction.
• Control mode if both driveo wbeels are slipping or if vehicle speed <40 km/b , witb control being
performed on the basis of the slipping driven wheel.
The slip threshold ofthe braking torque control in this case is still above that oftbe input torque control.
Consequently, the emphasis is on achieving maximum driving stability.
• Control mode when cornering , with vehicle speeds between approx. 20 km/h and 120 km/h (only
with ASR II) . In this case, the input torque control is activated earlier than in the two afore mentioned
control modes, depending on lateral acceleration. In this case, driving stability is enhanced when
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cornering.
A function indicator lamp informs that the ASR control mode is activated and signals to the driver that he is
approaching the physicallimits of the vehicle.
The operation of the ABS system is not impaired by the ASR as the ASR control mode is intem1pted if the
brakes are applied.
Design and operation of electronic accelerator pedal (ASR)- RA3000KE3E010X(30-0010)
E. I nput torque control loop
The input torque control loop ]s based on the electric/electronic components ofthe ABS/ASR and is
supplemented by the electronic accelerator pedaL
The electroni e accelerator pedal is composed of the following electric/electronic and mechanical components:
• Electronic accelerator pedal (EFP) position sensor (R25)

• Electronic accelerator pedal (EFP) actuator (M16/l)
• Electronic accelerator pedal (EFP) control unit (N4/ l)
• Accelerator controllinkage and accelerator pedal
• Idle travel rod (redundancy rod)
The speed signals of the speed sensors are constantly processed in the ABS/ ASR control unit to form the
following quantities:
• Input slip
• Acceleration
• Driving speed (front wheel)
• Comering detection (ASR II)
If the quantities determined exceed the specified set values, the AB S/ ASR control unit signals to the electronic
accelerator pedal control unit to ease back the throttle. As a result, the electronic accelerator pedal actuator and
thus the throttle valve are throttled back, irrespective of the movement of the accelerator pedaL
Depending on the driven speed, the input torque control commences as soon as the differential speed (deltav)
rises beyond the slip threshold ofthe input torque controL Control ofthe input torque is achieved by closing,
holding and opening the throttle valve.
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o 100 V
Slip thresholds
v = Road sp-eed
ó.v "' DlfferfiDbal speecnetweentront andrea1 'lltteels
-----· Brafc:e tOf~ ooolrol
_ _ lnpt! tOfQUe cornrol
Fig.lSO: Torgue Speed Signal Graph
Slip thresholds
Ifthe differential speed (deltav) again drops below the slip tbreshold, the tbrottle valve is opened in accordance
with the driver input.
Design and operation of electroniic accelerator pedal (ASR)- RA3000KE3F010X(30-0010}
F. Electronic accelerator pedaJ components

Mercedes-Benz
M16/1 Elecwonc acceleramr p.1ldal actuatOf R25 ElactrOilc acceterau pedal p.<JSII!cn sensoc
N411 Bettonc occeleramr ¡tedal cootol u11t 20 kle wa·~t rod (redundancy rod)
N16 EnQOle systems coolrolu111t(MAS)
Fig. 151: ldentifying Electronic Accelerator Pedal Components- Models 124, 129, 201 With Engines 103,
104
Example models 124, 129, 201 with engines 103, 104

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S16/1
A1p8 Eled· ooc speodom&:!!r 51611 Startll{"loó<Of.tandrewrsang larrp swtch

5911 Slop latll> swi dl 540 TernpOIT'tBt cnusecorCrol S'Mtdl
Fig. 152: Identifying Electronic Accelerator Pedal Components- Models 124, 129, 201 With Engines 103,
104
Example models 124, 129, 201 with engines 103, 104
Example modell26 with engines 116, 117

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N1614 S16f1 S9/1 N411
A1p8 8ocrcnc speecicmo:Sr R25 Eleclranc acce!ere~ pedal pos111on sensor·

M1611 Becionc aroelora:ot pedal ad!J!It()( S9f1 stop larrp SWlch
N4/1 BeOonc arcelera~ pedal conlrolurit S16!1 Startet lo!:koú andre'1'91sing lamp siN!II:h
N11l14 Fuel pumparldkickdo•M lwtO: relay S40 Tempoma~ aurs&cortrol S'1'1 lch
20 lcatl ~e->'91 roo {redurldancy roó)
Fig. 153: ldentifying Electronic Accelerator Pedal Components- Model 126 With E ngines 116, 117
F.x::tmniP. m ooP.I 1?.9 w ith P.n o in P. 1 19

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"11--·17
M16/1 Bed·011c eccelera'Dr pedal acruatw R25 El&cronc atceleralol pedal posibon sensor
N4f1 BeGb"onc accelermor pedal coo:rol urit 20 !die 1-8\191 rod (recluOOaocyrod)
N16 Engr~o sv.;!Bms con'"o! Wllt (MAS)
Fig. 154: ldentifying Electronic Accelerator Pedal Components- Model129 Witb Engiue 119
Design and operation of electrooic accelerator J>edal (ASR)- RA3000KE3G010X(30-0010)
G. Operation of electronic accelerator pedal
All the control processes as well as the mechanical positioning movements are performed with the
electric/electronic components in conjunction with the mechanical components.
The voltage for the electronic components is supplied via terminal 15 unfused in tbe fuse box.
The following components supplies signals to the electronic accelerator pedal control unit:
The input signals are processed and monitored in the electronic accelerator pedal control tmit The following
components are actuated with the output signals:
• Electronic accelerator pedal actuator

• ABSI ASR control unit
• Fue! numn relav
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• KE control unit
When the ignition is switched on, the electroni e accelerator pedal is operable_
The position ofthe electronic accelerator (set point) is signalled to the electronic accelerator pedal control unit
by the electronic accelerator pedal position sensor.
The position sensor additionally inputs the signal for the id le speed position vía the electronic accelerator pedal
control unit to the KE control unit for controlling deceleration fuel cutoff
This set point is assigned an output signal in the electronic accelerator pedal control unit for operating the
actuator. The electronic accelerator pedal actuator thus adopts a position corresponding to the set point
The output lever of the electronic accelerator pedal actuator is connected to the throttle valve by means of the
accelerator controllinkage_ The opening angle of the throttle val ve corresponds to the input set point, as a result
of which a certain torque is transmitted :from the engine to the driven wheels.
If the input set point ( accelerator pedal deflection) is higher than the input torque which can be transrnitted to
the road, this would mean that the wheels would spin (slip)_
• Electroníc accelerator pedal position sensor

• Electronic accelerator pedal actuator
• ABS/ ASR control unit
• Starter lockout and reversing lamp switch
• Electronic speedometer
This slip is detected by the ABS/ASR control unit anda signal (throttle valve set point) is passed to the
electronic accelerator pedal control unit
Consequently, the electronic accelerator pedal actuator and thus the throttle valve can be elosed against the
adjustrnent movement of the accelerator pedaL
The input torque is reduced ifthrottle is excessive until the slip has dropped below a specified value.
All in all, the electronic accelerator pedal device is able to close the throttle valve between idle speed and full
throttle.
If the input torque to the driven wheels is too high, the idle travel rod enables the throttle val ve to be moved in
the opposite direction of the position of the accelerator pedaL
The idle travel rod (redundancy rod) is an emergency driving device with which the car can continue to be
driven with reduced engine output in the event of the electronics failing. In addition, the electronic accelerator
pedal control uuit contains a cruise control system (Tempomat) _
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Features:
• Movement of throttle valve is always performed by means of the electric/ electronic device.
• Cruise control system (Tempomat) is integrated in the electronic accelerator pedal control unit.
• The car can continue to be driven with reduced engine output in the event of the electrics/electronics
failing.
Block diagram electronic accelerator pedal

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Retavtovor BI1C! _,..__ ldetravol rod (mrundancy

comeun¡¡ro$ ...... rod)
E:J lBowaon~
1 -----i]
Cf l n!.age
1 '
1
1
1
1
1
.......
1> r
1
1
1
1
fj,
Posllion sensor iR25) Ad1Jatot(M16/1)
------------- Sai6.')1S'Mtál
------------ ----- -------------- -------
P«e-momoter Vol;ago S!4lplf VID l gtllion Slarlolr Engu10 PoterC!omelllf SS:olysv.tll:h ~
SO¡¡nal attaiOHl~ pedal S'M!ál slgnalllroUle valVa
poS!l OO pos.bon ~
~
1
EloátCRc aocelemlor pedalcortrol tnt(N411)
<J
'-- -- """'?1
......
PoSIIon
tortrokir l~ ¡ou~ st&gll
~ 1~
1>
~
Mc,.lcmgdeVIce
-~
-
~~em~
cru se cortrol l
L>
T8ft1l0tlle!cruse Po:s!llon "R' lor Vote~ St4lllly, temunal Engr~e syslllms contol
c:oltrol S'Nlc.h (S40) theraclen&lt W\'8 30 unt(N16) Cfluolpu:np
~
S>W:thowr -----{::> rnla'f
ABS/ASR
cortrol uní lf
-
~
TDilNSigni!l
(N3011)
Staner lod<ou end
~
rovermglarnp
Stlith (S11ll1)
?
EZLIAXR tgnillon tOOi"ol 1 FuelllU!TIPS
KE contolunt Ido ;peed s...tc!Jng unt (N1/3) \J (M3rn1,M:lrn2)
(N3)
M103, 104
5ignal
M1 03, 104 ~ 1
<l-
1SoleclDr lovor
1 6
<J
Eloci'MC Roa<! speod lrullcive

;peedomotllf {A1p81 sonsor(U )modols 126,
~ - <r- 129
L_j -- Stoplarnp switch
(S9f1)
Rosd speod s>gm;l HaS. O: e« sonsO< moóels

methMICal rensrrussoon 124 , 201
___ el&c~K wmo
Fi¡:. 155: Block Dia¡:ram Electronic Accelerator Pedal

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ldle speed
When the engine is idling, the electric/electronic components are supplied with voltage when the ignition starter
switch is in position "2".
Voltage is supplied to the fuel purnp re lay (terminal 15) via the safety switch of the electronic accelerator pedal
actuator.
In conjunction with the TD/TN signal the relay picks up , as a result ofwhich terminals 87 and 30 are connected.
The fuel pumps are supplied with voltage.
The input signals from the electronic accelerator pedal position sensor and also electronic accelerator pedal
actuator are supplied to the electronic accelerator pedal control unit.
These signals are processed in the position controller and the d. c. motor ofthe electronic accelerator pedal
actuator is operated accordingly. When the accelerator pedal is depressed, the entn·e movement ofthe throttle
val ve can be utilized.
The signal interchange between the ABS/ ASR control unit and the electronic accelerator pedal control unit is
performed as for ignition starter switch position "2".
Design and operation of electronic accelerator pedal (ASR)- RA3000KE3H010X(30-0010)
H. Ignition starter switch position "2"
When the ignition is switched on (ignition starter switch in position "2") the electronic accelerator pedal device
is operational.
Voltage is supplied to the electronic accelerator pedal control unit, electronic accelerator pedal position sensor
and electronic accelerator pedal actuator.
In addition, the fuel pump relay is actuated via the safety switch ofthe electroruc accelerator pedal actuator
(voltage to tenninal 15). Voltage is supplied from it to the fuel pumps for approx. 1.5 s. In addition, voltage is
supplied vía the ignition starter switch to the Tempomat cruise control switch.
When the accelerator pedal is depressed, the adjustment movement is transmitted via accelerator control
linkage, fulcrum and relay levers to the electronic accelerator pedal position sensor.
Depending on the position ofthe accelerator pedal, the potentiometer ofthe position sensor supplies a
corresponding voltage signal to the electronic accelerator pedal control unit.
A voltage signal is llkewise input by tbe potentiometer of the electronic accelerator pedal actuator (actual
position of throttle valve).
Driving mode
When driving the throttle val ve is moved by the electric/electronic and mecharucal components. In this case, the
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desired driving speed is dependent on the position of the accelerator pedal.
Depending on the speed driven, input torque control begins as soon as the differemtial speed (a v) rises beyond
the slip tbreshold of the input torque control. Control of the input torque is achieved by closing, holding and
opening the throttle val ve.
Once the differential speed (deltav) again drops below the slip tbreshold, the tbrottle valve is opened in
accordance with the driver input signal.
The two signals from the electronic accelerator pedal actuator and the position sensor are compared in the
position controller of the electronic accelerator pedal control unit. If the signals differ, the actuator position is
adapted to the set point (position of accelerator pedal). The d.c. motor of the actuator is operated via the output
stage.
In addition, an information interchange between the ABS/ ASR control unit and the electronic accelerator pedal
control unit takes place when the ignition switched on.
The electronic accelerator pedal control unit checks whether the permissible tbrottle valve set point from the
ABS/ASR control unit is below the set point input by the driver. Ifthis set point is too large, the ABS/ASR
control unit determines the ma.ximum possible tbrottle valve opening. The signals from the electronic
accelerator pedal position sensor, electronic accelerator pedal actuator and ABS/ASR control unit as well as the
output stage are checked by the monitoring device.
Slip thresholds
.....
,.. ...
... ...-
.;o#'
-----
..-
5
-- -- _,
o 100 V
v " Roa~ speoo

l1v = Diffmerüal ·spe:e®oiwoenfrool aildr~»H 'htlllo8ls
Fi2. 156: Drivin2 Mode Speed Si2nal Graph
Driving with Tempomat cruise control

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km/h., however, in order to actívate the cruise control.
Once the vehicle is travelling at the desired speed, it is sufficient to briefly press the switch in the
"Accelerate/Set" or "Decelerate/Set" direction in order to maintain the speed until a new speed is specified by
the driver or the cruise control system is switched off.
In order to adapt this set speed, for example, to traffic flow, the switch should be pressed and held in the
"Accelerate/Set" or "Decelerate/Set" direction until the desired speed is reached .
Speed can be increased or reduced by 1 km/h each time the switch is brie:fly pressed in the "Accelerate/Set" or
"Decelerate/Set" direction in order to achieve minor changes in speed.
The road speed memory can only be incremented provided the throttle valve is not at full throttle position, and
can only be decremented provided the throttle val ve is not in the idle speed position (i. e. in the deceleration
mode).
Tn this case, the vehicle is accelerated ata controlled rate of 0.7 m/s 2 . After the switch is released, the new
speed is maintained.
Ifthe switch is briefly pressed in the "OFF" direction, or ifthe brake pedal is depressed, the Tempomat cruise
control is switched off, the accelerator control moves into the position input by the driver via the accelerator
pedal.
When the cmise control system is switched off, the actuator motor is operated and moves the accelerator control
into the idle speed position.
TI1e system remains operacional after being switched offuntil the ignition is switched off. If, after applying the
brakes or switching off the system, the switch is briefly pressed in the "Resume" direction when the car is
travelling ata speed greater than approx. 40 km/h, the car accelerates ata rate of 1 m/s 2 automatically to the
speed last fixed with "Set".
The speed last set is cancelled when the ignition is switched off. If the set speed is exceeded by depressing the
accelerator, e. g. for overtaking, the car returns automatically to the previously set speed when the accelerator
pedal is released.
If engine power is not adequate wben travelling uphill, the set speed drops. It is restored as soon as the incline
eases off and speed in the meantime has not dropped below 40 km/h or the car has not been braked.
If the engine braking action is not adequate when travelling downhill, the set speed is exceeded and it may be
necessary to brake the car. If a brake application was not necessary, the set speed is restored as soon as the
incline eases off.
o:!?'GF
When driving with the Tempomat cruise control, selector lever position "N" of the automatic transrnission must
not be engaged otberwise the engine will overrev.
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The speed last stored in the electronic accelerator pedal control unit is cancelled when the ignition is swítched
off When the ignition is switched on agaín, the speed "O km/h" ís input to the speed memory. This ensures that
no unknown speed is stored in the memory when recommencing a journey, e. g. after changing drivers. The
speed is constantly monitored lby the electronic accelerator pedal control unit. Every change in speed is detected
and analyzed by a computer.
If a speed change is performed with the Tempomat cruise control switch, the computer in the electronic
accelerator pedal control unit ensures that the specified rates of O. 7 m/s 2 in the case of switch position
"Accelerate/Set" or 1 m/s2 in the case of "Resume" are maintained.
When the cruise control is switched off, the restauration of the electronic accelerartor pedal control unit to the set
valu e of the accelerator pedal is monitored by the protection circuit in the electronic accelerator pedal control
unit.
If the vehicle decelerates > 1.5 mis 2 e. g. with a faulty stop lamp switch, the deceleration is detected by the
computer and the electronic accelerator pedal actuator closes the throttle valve with the maximum possible
positioning rate.
Design and operation of electroniic accelerator pedal (ASR)- RA3000KE31010X(30-0010)
l. Electronic accelerator pedal control unit (N4/1)
The electronic accelerator pedal control unit features two ptinted circuit boards with electronic elements.
Models 124, 129 and 201 are provided with a watertype desígn of control unit.
The housing consists of an aluminum alloy with a 35-pin multi-contact connector. The connectíon to the wiring
harness is through a 35-pin coupling, which is fixed in position with a spring clamp (arrow).
Mwol 126
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Fig. 157: Locating Electronic Accelerator Pedal Control U nit
Location of EFP control unit (N4/1)
Models 124, 129, 20 l : Right of component compartment
Model 126: Top of left footwell
Mo~ol 1 24
Fig. 158: ldentifving EFP Control Unit- Models 124
Moool 201
Fig. 159: Identifying EFP Control Unit- Models 201
Voltage is supplied by the electronic accelerator pedal control unit in ignition starter switch position "2" to the
potentiometer for the electronic accelerator pedal actuator and electronic accelerator pedal position sensor. In
addition, the signal supplied by the components are processed accordingly.
The electronic control unit is divided ftmctionally into the following assemblies:
• Position controller with input amplifier (signal processing part)

• Output stage
• Monitoring device
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(protection circuit)
• Tempomat cmise control device

• ASR signa! processing
With the exception ofthe Tempomat cruise control computer, the electronic accelerator pedal control unit
employs anaiogue technology.
Model 119
Fig. 160: ldentifying Electronic Accelerator Pedal Control Unit, Electronic Accelerator Pedal Actuator
And Electronic Accelerator Pedal Position Sensor
Position cootroller
The input signals to the position controller are reshaped, filtered and amplified in upstream signa! processing
parts. These signals are then processed accordingly in the position controller and a defmed output signal is
produced for the output stage.
Output stage
The output signa] of the position controller is passed to fue output stage and amplified at that point. In addition,
the positioning direction (idle speed direction or full throttle direction) ofthe d.c. motor in the electronic
accelerator pedal actuator is determined by the signal. The d. c. motor is actuated with a frequency of 140-160
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Hz for thís purpose.
Ifthe d. c. motor is blocked, a contínuous current is outp11t briefly. Ifblockíng persists, the output stage is
switched off by the monitoring device. The output stage is short-circuit-proof to ground.
Tempomat cruise control device
The Tempomat cruise control is integrated in the electronic accelerator pedal control unit. It is activated or
switched off as before in the case of the electric Tempomat cruise control by the Tempomat cruise control
switch.
Ifthe Tempomat cruise control switch is constantly operated <40 km/h and the car is accelerated with the
accelerator pedal beyond the safety threshold, the Tempomat cmise control ís not activated.
The Tempomat cruise control cannot be activated ifthe switch is pressed during a brake application.
When the Tempomat cruise control is set, the posítíon controller is supplied wíth an appropriate input sígnal
which specifies the position ofthe throttle valve. Ifthe driver demands a higher speed by depressing the
accelerator pedal, the Tempomat cruise control device is overridden.
If the ASR detects wheel slip in the cruise control mode, reduction in engíne output (lower speed) has priority
over cruíse control.
lf the ASR operates for longer than 3 seconds, the Tempomat cruise control is switched off.
In this case, it must be re-activated with the switch if the driver wishes to continue driving in the cruise control
mode.
NOTE: On vehicles as of 08/89 the acceleration skid control function has been modified
in combination with cruise control mode. lf wheel slip is eliminated, the cruise
control is resto red to the speed previously set provided the driver does not
request any other function.
Monitoring device
The rnonitoríng devíce performs varíous safety tasks. The following functions are checked:
• The operating ranges of the potentiometers of electronic accelerator pedal position sensor and electronic
accelerator pedal actuator.
• The wiríng to the potentiometers of electronic accelerator pedal position sensor and electronic accelerator
pedal actuator for short-circuit or open circuit.
• Operation of the safety switches in the electronic accelerator pedal position sensor and electronic
accelerator pedal actuator.
• Positioning accuracy ofthe electronic accelerator actuator, related to set position, which is specified
eíther by the accelerator pedal (electroníc accelerator pedal position sensor), Tempomat cruíse control or
by the ASR controltmit.
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• Short-circuít of output stage of d.c motor.

• Battery voltage at electronic accelerator pedal control unit. The control unit switches off if battery voltage
is below 6 V, and switches on again if voltage rises.
The function ofthe safety switch is independent ofthe electrical/electronic control function ofthe input torque
control circuit. The current through the safety switches of electronic accelerator pedal position sensor and
electronic accelerator pedal actuator is looped through the electronic accelerator pedal control unit. When
dríving or when engine idling, the fuel pump relay or the engine systems control unit (terminall5),
respectively, is thus supplied with voltage.
The safety switch in the electronic accelerator pedal position sensor closes when the accelerator is depressed
before the safety switch in the electronic accelerator pedal actuator opens. Ifthe accelerator pedal is eased back,
control is performed in the reverse order. Depending on the position of the accelerator pedal, the contact in the
electronic accelerator pedal position sensor or in the electronic accelerator pedal actuator is closed.
A switching transistor is connected additionally to the output of the electronic accelerator pedal control unit in
order to prevent any interruption to the voltage supply íf the accelerator is rapidly moved back to idling speed.
When the safety switch in the electronic accelerator pedal position sensor opens, this transistor assumes the task
of supplying the voltage to the fuel pump relay or engine systems control unit, respectively, for a maximum of
150 ms. In the Tempomat cruise control mode, the safety switch in the electronic accelerator pedal position
sensor is open, as also in the electronic accelerator pedal actuator.
The switching transistor (as already stated) performs the task ofthe safety switch ofthe electronic accelerator
pedal position sensor to enable the fuel pump or engine systems control unit relay to maintain the voltage
supply ofthe fuel pump (terminals 30 and 87 bridged tlrrough relay contact).
The safety swítches including switching transistor are also covered by the monitoring device.
Contact assignment at electronic accelerator pedal control unit

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~---------·-----------------------------------·----~
J N4/1
1 Valaga supplytoomnal15 unilsed l
1
2 Vol!age supplyt8111111el15 111llsed 1
3 El&ctrooc eccalecalor pedal &tllalcr { engme) l

4 Eloctrooc a c.: e era!or pedel atils~ {OOQIOO) 1'
S PoSllion sensor potemomater (!1QUod) ¡

6 Elaáronc scc el9ralor pedal atklalDr potemorneter {grOUild)
7 Oo nct crama cortactl
8 Engrnes 103, 104 klo spa&ds'lllll:hlng s;gnallo KE cortrol
UFil{N3)
EnQine> 116, 117, 119" Not assagnad
9 PoSIIion sensor potertrometerYOI:aga supply (•)
10 Not assjgllod
11 Gt001d, ba'larf (W10)
12 Roadspaeds¡gnal
Mooals 124,201 Hakffeúsensor {B6)
Modals 126, 129. Roed ~od 11dudlw sensor {l2)
13 sa:alys'MII:h poSl~on sensor

14 Stop lampS'IIIII:h
15 PcSllion sensor potertrometer (wper cootact Slgnal)
16 Ternpomatcruso c1ll1rol swld1 (Dece!emte , Sal)
17 Nct assign od
18 Ternpomatcruse CCfirol swtd1 (Resume)
19 Oo nct aeata cortaál
20 Eledronc eccelemtorpedalatlla!Df .{enQine)
21 Etectron;c acce!eralorpedalacllm(engma)
22 Gr001d, bata¡y (W10)
23 GtOUld, bate¡y (W10)
14 Not assiwJad
25 Nct BSSl9fl9d
26 Eleár0111c atcelere!or pedal at~a!Df potomcmeter (vol:ege
5~)
27 Nol BSSlQI'Iod --~ ------ --------------- --------- --- - - -- --~"!I!.:~~:P-. __.J
28 Electroncacce!era!crpedalacruamrpc!omomelor{w.,ar
cortact s1g11al)
29 Electrooc accelecalor pedalatlla\Dr {safat¡¡ S'Mld1)
30 fuel punp rol&ytonmnal15, conmct 9 or angrne systems
cOOI"ol mttoomnal15u, cortad 10
31 To M3S/AS< coruol tnt (l'l~ vBMI acrual valJe)
32 Ternpomatcruso cortro1 s.vtd1 (Accelerme, Set)
33 Starblf kx kot.hnd reverSJng lamp swlth,
drrve moda "R"
34 From ABS/A~ conrolunt (Uvotle VfJt(e setpoo!)
35 Ternpomatcruse cortrol s.vich (OFF)
Fig. 161: Identifying Electronic Accelerator Pedal Control Unit Contact Assignment
Road speed signal
The road speed signa! from the electronic speedometer or HaH-effect sensor (B6) is fed into the electronic
accelerator pedal control unit for the cruise control function.
It is used by the electronic accelerator pedal control unit only for the Tempomat cruise control. If no road speed
signal is received, this thus not impair acceleration and also not input torque control.
Stop lamp switch signal
When the brakes are applied, the Tempomat cruise control device is supplied with a signal change via the stop
lamp switch. This means the ground connection is interrupted. The Tempomat cruise control function is
immediately cancelled.
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The input signal ofthe Tempomat cruise control device at the position controller is cancelled. As a result of
this, the electronic accelerator pedal actuator is operated in such a way that the throttle valve is moved back to
the set value ofthe accelerator pedal.
The position of the accelerator pedal has priority. If no ground signa! is received from the stop lamp switch, the
Tempomat cruise control is switched off Neither acceleration nor input torque control is thus impaired.
Selector lever position signal
When the selector lever is moved into drive position "R", the position controller receives an input signa! from
the starter lockout and reversing lamp switch. As a result, a characteristic curve switchover is performed in the
position controller.
When reversing, the throttle valve is opened up to approx. half pedal travel. This ensures improved comfort for
reversmg.
~tA
A llTc!fe 'l'l'INe angle

B Accelflrat.or pedal !ravel
F«ward travel characteris!ic curve
RfiVBfSing cllaractenSJtic curve
Fig. 162: Selector Lever Position Signal Graph
ABS/ ASR control unit signal
An information exchange takes place (200 times per second) between the ABS/ASR control unit and electronic
accelerator pedal control unit. On the basis ofthe signa! from the ABS/ASR control unit the electronic
accelerator pedal control unit detects whether wheel slip exists and which maximum throttle valve opening is
permissible. The size of the throttle valve opening depends on the slip conditions at the driven wheels. The
throttle valve can also then be fully elo sed by means of a corresponding ASR control signal if the driver or the
Tempomat cruise control inputs full throttle.
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The ABS/ ASR control unit receives a constant flow of infonnation from the electronic accelerator pedal control
unit regarding the momentary position of the electronic accelerator pedal actuator and thus of the throttle val ve
by means ofa similar feedback signa! (throttle valve actual value).
The ABS/ASR control unit can thus check during an ASR control operation whether the electronic accelerator
pedal is following the positioning commands of the ASR device.
If a fault (no voltage supply to actuator) exists in the electroni e accelerator pedal area (no Tempomat cruise
control function), the feedback signa! disappears and the ASR system switches to fault. The ASR warning lamp
(Ale22) comes on.
NOTE: lf on vehicles as of 08/89 the accelerator pedal is first operated after ignition:
ON or when driving by being depressed to full throttle, the ABS/ASR control
unit supplies a variable throttle valve set point signal to the electronic
accelerator pedal control unit.
As a result, the electronic accelerator pedal actuator permits the full throttle position only after 2-4 seconds. In
other words, the adjustment movement ofthe electronic accelerator pedal actuator lags behind the adjustment
movement of the accelerator pedal or the input signa) of the electronic accelerator pedal position sensor. If the
accelerator pedal is repeatedly depressed to full throttle stop, the adjustment movement of the electronic
accelerator pedal actuator is again performed simultaneously to the adjustment movement of the accelerator
pedal provided no other control process exists.
Design and oper·ation of electronic accelerator pedal (ASR)- RA3000KE3J010X(30-0010)
J. Electronic accelerator pedal position sensor (R25)
Engines 103 , 104
R25 Posiion sensor

53 L &Ver
74 ldle speed stop
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Fig. 163: ldentifying Electronic Accelerator Pedal Position Sensor- Engines 103, 104
The electronic accelerator pedal posítion sensor consísts of a variable electrical resístor (potentiometer) and a
safety switch. The safety switch is designed as a double-contact switch.
Both elements are operated by the potentiometer shaft to which is attached the lever (53). The fulcrum lever is
mounted on the pín next to the potentíometer shaft.
When the ignition starter switch ís in position "2" or when the engíne ís running, the potentiometer is actuated
with a constant voltage by the electronic accelerator pedal control unit.
Engines 116/1171119
R25 Posilcn sooscr

13 Ac ce'BJatcr ccfl~olklver
16 Flkrum levar
20 Re®ndflflcy rcd
Fig. 164: ldentifying Electronic Accelerator Pedal Position Sensor- Engines 116/117/119
As a result of the adjustment movement at the accelerator peda~ the potentiometer position is altered via the
accelerator controllinkage, fulcrum lever and lever (53). A defmed variable voltage is fed back by the
potentiometer ínto the electronic accelerator pedal control unit as a function ofthe accelerator pedal positíon.
Thís signal is further processed in the posítion controller of the electronic accelerator pedal control unit. If the
accelerator pedal is not depressed (idle position), the safety switch of the test set point of the potentiometer of
the electronic accelerator pedal is open.
Voltage exists at the input síde of the safety switch if the ignition is switched on or when the engine is fUllllíng.
The swítching point ofthe safety switch is atan adjustment angle of 4-6° above idle speed stop (74).
Mercedes-Benz
100 Adj\Jstrnert sha.'t

101 Pos.Jíoo Sllnsor rofay lever
102 Hoosmgr
103 Potsn• ome!tlr
104 Sa!otys'Mtrh
105 Bol for i.Jicrum tever
Fig. 165: ldentifying Adjustment Shaft, Housing And Potentiometer
Ifthe safety switch is closed, voltage is supplied to terminal 15 at the fuel pump relay. Ifthe accelerator pedal is
moved from full tbrottle toward idle speed, the safety switch opens at approx. 6-4° before idle speed stop.
In the idle speed position, this voltage supply is performed by the closed safety switch in the electronic
accelerator pedal actuator (M16/l). The maximum current fl ow must not exceed 1 A. The switch ís not sho rt-
circuít-proofto ground.
Mercedes-Benz
R2SIVL
L:::::_LL_
R25 Eloc1JonL &e o arator po{faJ(EFP) pzysaboo sonsor

ll l~e s;p ea d C>Oflla d
Vl F uJ load ocrt..act
Fig. 166: ldentifying Electronic Acceleration Pedal Position Sensor, ldle Speed Control And Full Load
Contact
Design and operation of electronic accelerator pedal (ASR)- RA3000KE3K010X(30-0010)
K. Electronic accelerator pedal actuator (M16/1)
The electronic accelerator pedal actuator is attached to the engine block below the intake manifold by means of
a bracket.
It consists of a d.c. motor with multi-stage gear to which is attached the output lever for the accelerator control
linkage. In addition, the wiper contact for the potentiometer and the safety switch are coupled to the output
shaft.
The safety switch in this case also is designed as a double-contact switch.
When the ignition starter switch is in position "2" or when the engine is nmning, the potentiometer is actuated
with a constant voltage by the electronic accelerator pedal control unit.
Engines 103, 104

Mercedes-Benz
M1Sl1 Electronc e.ccB!oratorpodaJ(EFP) adl.~ator
Fig. 167: ldentifying Electronic Accelerator Pedal Actuator
The output signal ofthe potentiometer to the electronic accelerator pedal control unit serves as a position
feedback ofthe momentary throttle valve position. This signal is further processed in the position controUer of
the accelerator pedal control unit.
The position ofthe throttle valve is altered by the electronic accelerator pedal control unit ifthe signals differ.
The adjustment range of the electronic accelerator pedal actuator is 88-92°. The throttle valve can thus be
moved by means of the accelerator controllinkage from id le speed stop up to full throttle stop and vice versa.
Engines 116, 117

Mercedes-Benz
M1611 Elodroru; acceltii&Qr pedw(EFP) a.ctuatQf

21 Connadting rod
24 Olllputlever
Fi2. 168: ldentifyin2 Connectin2 Rod, Outjmt Lever And Electronic Accelerator Pedal Actuator
The d .c. motor features a bigh positioning rate. The total position angle is covered in approx. 120 ms wbich thus
enables a bigh positioning accuracy to also be acbieved.
Engine 119
M16/1 BodronJC acc~lamtor pode! (EFP) aciUIY.or

21 Comedngrod
24 OUpú lavar
27 l oog¡lldilal accolool!oH "Cnlrol shalt
Fig. 169: Identifying Electronic Accelerator Pedal Actuator, Output Lever And Longitudinal Accelerator
Control Shaft
¡GrGF
The rotating direction of the actuator (M 16/1) differs.
On engines 116, 117 the adjustment is made clockwise between id le speed and full throttle. On engínes 103,
Mercedes-Benz
110 113 A.rrnetuío

111 114 Potñomotor
112 115 SeJety swlid'l
Fig. 170: ldentifving Output Shaft, Step-Down Gearing, Housing And Safetv Switch
Current consumption at maximum positioning rate is approximately 8 A.
If the accelerator pedal is not depressed, the safety switch is closed. It is supplied with voltage when the ignition
starter switch is in position "2" or the engine is running and voltage is thus also supplied to terminal 15 at the
fue] pump relay. When the accelerator pedal is depressed, the safety switch opens. The switching point is
approx. 8-12° above idle speed position.
The safety switch ofthe electronic accelerator pedal position sensor (R25) now takes over the task ofvoltage
supply for the fuel pump relay_ To avoíd any swítching gap arísíng during rapid accelerator pedal movements, a
switchíng transistor performs the task ofvoltage supply for the fuel pump relay for a defined period (see 30-350
Section on monitoring device)_
The maximum current flow must not exceed 1 A. The switch is not short-circuit-proofto ground.
Mercedes-Benz
M16/1
-·~
M1&f1 Elod rooc aoceleratof padai{EFP) actuator
Fig. 171: ldentifying Electronic Accelerator Pedal Actuator Current Flow Circuit
Design and operation of electroniic accelerator pedal (ASR)- RA3000KE3L010X(30-0010)
L. Engine control
Models 124, 129, 201 with engines 103, 104

Mercedes-Benz
3 Th'olle vaJ.¡jj le-\IIIJ 50 Com&eklgrod

8 Rell'r)'lewr 51 Comoárlgrod
11 Corool proswe cable IOf 8!i!lrn~c transmss100 52 Lever
20 Comedllgrod 53 Lo'Ver
21 Conne.clllgrod 74 ldle speed stop of lo\er (53)
16 Folowtlf Sllfll9 75 ldle speed stop al ktVI!i (52)
29 Ad¡u smg saew 76 F tllll!Otf& l;top
30 Bo>Nden <able R25 Eled"ont a«elerailr pjjdaJ poSibon sellSO(
32 Adjusllllgnu poteroometor
43 Adjusmg Stft!W 53012 2nd dn1111gmode I<Jd<down S'f.ltch (S16fi)
Fig. 172: Identifying Engine Control Components- Models 124, 129, 201 With Engines 103, 104
Model126 with engines 116, 117

Mercedes-Benz
1 Ac e elerator pedal 19 Comecmgroo

3 Acce!arator pedal lewr 20 kfe _.awl rod (redundancyro{i)
4 Longltutinal a~efera!or tolirol sllaft ao¡usmg saew 21 Comecmgrod
8 Comeálng rod 21 R&turnspnng
9 ReMnspnng :n Tlwolle ~e rala¡ levar
10 Relay leWf 24 ()upú le -
11 Comecklg rod 25 Lo-dmg plata
12 Posibon sensor re!aylever 26 Comedl'lgroo
13 Fttaun levar 30 Comol ptessue e abkJ
14 Lod(flg plate M16f1 EFP actuator
15 Roler 5 1617 Kickdo'Ml sNiic:h
16 Acca•erator coniollavor
17 Rolar
Fig.173: ldentifying Engine Control Components - Model 126 With Engines 116,117
o:::rGF
On model 126 the retum springs (22 and 9) at the throttle valve relay lever and position sensor relay lever are
identical. They must not be mi xed up with the retum spring (27) at the throttle valve.
Mercedes-Benz
Fig. 174: ldentifying Return Springs Throttle Valve Relav Lever
Modell29 with engine 119

Mercedes-Benz
2 Comecmg rod 30 Bowdon cable

6 lover lllloo!JIIudmal acce!erelol comrot shaft 32 Act,Jsmgmt
9 Acc e'emtOf cont-ollever 40 Comectrlgrod
11 Cortrol pres,sura cable for at.toma: e 111111smssfOfl 41 C«med111grod
15 Adjusmgsaew 52 lovef
16 Spacef!ile'eve 53 Lsv-er
20 Redundancyrod 74 ldle ~ed stopof lewr{53)
21 Comedlngrod 76 F1.11 tuotee stop
24 AekJ a:or lever M1SI1 Elecrooc accelelallr pgdal actuator
26 Folower spmg R25 Poslbon sensor
27 lon!Jtuclnal acc elel a:or eornrol sh&"t 53012 KicX<IO'Ml sfolich
29 Ad;Jst.lg screw
Fig. 175: Identifying Engine Control Components - Model129 With Engine 119
The posítíon ofthe accelerator pedal ís input to the posítíon sensor on models 124, 129, 201 via accelerator
pedal, accelerator pedallever, Bowden cable, relay lever and connecting rod, and on model126 vía accelerator
pedal, accelerator pedallever and accelerator control linkage.
Movement ofthe throttle val ve ís then performed vía the electrical/electroníc components such as position
sensor, electronic accelerator pedal control unit and electronic accelerator pedal actuator.
The throttle valve is operated by the output lever of the electronic accelerator pedal actuator via accelerator
controllinkage and relay lever. The movement extends from idle speed stop up to full throttle stop. In the event
of a fault in the electrical/ electroníc components, movement of the throttle valve ís possíble by means of the
idle travel rod (redundancy rod) on models 124, 126 and 201 (resilient connecting rod on model129). This
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enables the car to be driven with approximately 2/3 of engine output.
Block diagram engine control Engines 103, 104, 116, 117
Posítion sensor
k Electronic
accelerator
pedal control
Electroníc
accelerator
pedal actuator
- --(>
Accelerator contro1
linkage
l unit
1
¿
1
Englnes 103, 104:
Re !ay lever and
connecting rods
ldle travel rod Relay lever
Engínes 116, 117:
--t> (redundancy rod) ---t:>
Fulcrum and accelerator
Accelerator
controllevers
pedal
1
1
~ ¿
1
1
~ 1
Accelerator Bowden cable or Throttle valve Accelerator contro1

pedallever --cJ accelerator control ~---- linkage
llnkage
_ _ electric wiring mechanical transmission
Fig. 176: Engine Control Block Diagram - Engine 103, 104, 116, 117
Engine 119
Posit lon sensor Electronic ..... .... Electronic ,.._ Accelerator control
f-----!> accelerator l<l--- --!>1 accelerator --.........- nnkage
pedal control pedal actuator
9 1
urlt 1
1
1
1 1
1
1
1
Accelerat or control llever, 1
connecting rod and 1relay
lever
~
Accelerator ldle travel rod Longitucllnal
pedal --e> (redundancy rod) ---e> accelerator control
shaft
1
~
1
1
.~ ..
1
Accele rator --<> Bowden cable Throttle Accelera tor

pedal lever valve f:r-- control
linkage
_ _ electric Wiring mechanlcal transmlssion
Fig. 177: Engine Control Block Diagram- Engine 119

Mercedes-Benz
ldle travel rod (redundancy rod)
The idle travel rod (20) is a spring-loaded accelerator control rod which connects the relay lever to the throttle
valve lever on engines 103, 104. On engines 116, 117 it connects the accelerator controllever at the position
sensor to the relay lever on the throttle valve side. On engine 119 the spring-loaded connecting rod connects the
lever at the position sensor to the lever at the longitudinal accelerator control shaft.
Engmfl'S 103, 104
Fig. 178: ldentifying ldle Travel Rod (Redundancy Rod) - Engine 103, 104
ErlQinos 116, 117
Fig. 179: Identifying Idle Travel Rod (Redundancy Rod)- Engine 116, 117
When the throttle valve is moved electrically/ electronically, the idle travel rod (20) is also operated. It performs
the following tasks:
• If the input torque at the driven wheels is too high, the idle travel rod enables the throttle valve to be
moved in the opposíte directíon of the accelerator pedal position.
This adjustment movement is assisted by the retm-n springs at the relay lever/throttle val ve and at the
throttle valve. A fixed accelerator controllinkage in olace ofthe idle travel rod is unusable as this would
Mercedes-Benz
not permit ASR control mode.
r----------------------------------------------------------,
1
1
1
1
1
'
1
!. ---- --- --------- --- --- ------ --- --------- --- ----- -~~-'-- _:
Engme119
Fig. 180: ldentifving ldle Travel Rod- Engine 119
• In the Tempomat cmise control mode the control p ressure cable of the automatíc transmíssíon is operated
from the electronic accelerator pedal actuator. This enables transmíssion downshifts to be performed at
high engine load.
• In the event of a failure or a fault in the electrical/electronic components, the idle travel rod performs
movement of the throttle valve.
This ensures tbat the car can continue to be driven, in this case approx. 2/3 of the available engíne output
can be utilized.
If the emergency nnming mode is activated, the driver detects this from the higher accelerator pedal
forces and by the ASR warning lamp coming on.
Redundancyro{i, engmes 116 , 117
Fig. 181: ldentifving Redundancy Rod - Engine 116, 117
Notes on towing as well as test and adjustment work- RA3000TPM0010X(30-0010}
Towing
Mercedes-Benz
On ASR vehicles no restrictions are necessary when towing on both axles.
Towing with a raised axle is only permissible when the ignition is switched off (in position "1 ") otherwise the
rear wheels are braked.
Test and repair work
For perfom1ance and emission testing on the brake dynamometer, the following is to be noted on vehicles with
ABS/ASR:
The ASR system must be rendered inoperative so that the rear wheels are not braked when driving onto the
brake dynamometer.
a. On vehicles with an ASR system which can be diagnosed (as of ASR III), connect socket 1 and 6 to the
test coupling (Xll/4). As a result the ABS/ASR control module is in diagnosis mode and the ABS/ASR
malfunction indicator lamp comes on.
b. On vehicles with an ASR system which cannot be diagnosed (ASR I and II), disconnect the coupling at
the EA or ASR control module.
X11J4
P00-0027-15
Fig. 182: ldentifving Connect Socket And Test Coupling
If it is necessary to increase sp eed at the engine during test and adjustment work on vehicles with ABS/ ASR,
the engine speed increase must increase directly from the accelerator pedal. If the speed is increased at the
throttle linkage in the engine compartment, limp-home mode is actuated and a fault is stored in the fault
memory.
~GF
Mercedes-Benz
With the ignition ON, the engine switched off and the vehicle stationary, programming ofthe special
mechanical throttle valve angle (idle speed position) of the engine is carried out by the computer in the control
module. The correct values are calculated and saved again. The calculation takes 90 seconds.
The plug connection of the actuator is water-tight. It may only be opened during the test work specified in the
test program. Cleaning agent or contact spray may oot be used on the actuator plug connection.
EA or CCIISC control module is not protected by fuses.
Welding work
The following points are to be observed when welding with an electrical welder:
• Disconnect negative terminal of the battery.

• Connect the ground terminal ofthe welder directly to the part to be welded.
DESIGN AND OPERATION OF ACCELERATOR CONTROL- RA3000KE30001X(30-0001)
A. General
The accelerator control connects the accelerator pedal to the throttle valve. Depending on the version, the
connection between accelerator pedal and engine :is achieved by means of a Bowden cable or a linkage
mechanism.
KE injection, EZL ignition system and automatic transmission can only operate properly if the accelerator
control is correctly set.
Adjusting accelerator control, refer to respective Repair Instructions 30-300 or 30-1010, respectively.
B. Accelerator control by meaos of Bowdeo cable
Example models 124, 201 with engine 102

Mercedes-Benz
Nas*
1 30.0090-55A
2 Connadlngroo 32 ~smgntt
8 ConnocU!groo 33 Acce!eraiOf padalle\'!!1
11 Cortrol Pf&S S\Ne e ab!e 34 f.-8'Nall p;vot P<lfl't
12 Retu"n spong 35 Retumspong
13 flfcrun l&v& 36 F uuuolle stop
15 Rolor 38 Kicl<dom swi dl
24 Acceleretor p&Oal 40 fnwal
26 Folower spmij.t!F¡)pla 41 Ccmpooert compartmont panol
27 C~pcesston spnng 42 Ru~ 9f01nl00!
28 SUppcrtilg sfe&va 42 Rubbor grommet
29 A~smg screw 52712 MKroswileílldatoltu!ll ru!D."f
30 Bowden cable
Fig. 183: Identifying Accelerator Control By Means OfBowden Cable Components
C. Accelerator control by means of linkage
Example model126 with engines 116, 117 and ASR

Mercedes-Benz
1 A.ccelefetor p&dal 17 Rolor

3 A.ccelemtOf pedalle-.w 19 Comoct.lg r<Jd
4 LOfl!Jtulinalauo!eralllf cOftrol shalt ad¡uslllg saew 20 lela iao'lll red {re<Uldancy roó)
5 l ong¡tudinal ~K«~!ora!Of cOftrol sha.'t Z1 Comect.lgrod
8 ComecU1grod 22 Rei:U'nspnng
9 Rei:U'n spnng 23 llro1118 vat>le rotayi&VOf
10 Palay le- 24 O!Jptile\'llr
11 Com aartg rod 25 lodmgplate
12 Posibon sensOf ralay levar 26 C.omecmgrod
13 Fücnmlever 30 Colirol presSU'& e able
14 lockl'lgplele M1 &'1 EFP actuatcr
15 Rcler s1an l<íd<óo•Ml swtdl
16 A.ccelemtcr coniollav er
Fig. 184: ldentifying Accelerator Control By Means Of Linkage Components
GENERAL - RA3000TPMOOOOX(30-0000)
A Literature notes
Designatioo Diagnosis manual, Repair instructions Wiring diagram volume

engine
EA, CC, ISC test Volume 3 - -
programs
Adjusting throttle control - Engine 104, 119, 120 -
and assembly work combustion LH-SFI
injection
Mercedes-Benz
- Engine 104 combustíon -

HFM-SFI injection
Electric wíríng díagrams - - Model 124, as of 10/92
Volume 1
Model129, volume 2
Modell40, volume 2
Model202, volume 1
B Abbreviations
• EA Electronic accelerator
• CC Cruise control
• ISC Idle speed control
C Control module/actuator versions
• Electronic accelerator with cruise control and idle speed control

• Cruíse control wíth idle speed control
• Idle speed control (only Model140, engine 104 LH-SFI)
D Features
Functional relationships Control module version

with Electronic accelerator Cruise control/idle ldle speed control ISC
EA speed control CC/ISC
Electric/electronic engine • - -
control
Mechanical throttle control For emergency-running • .
only
Cruíse control . • -
Idle speed control on LH-SFI • • Performed on engine
injection 104 by separate ISC
control module
Idle speed control on HFM- • • Performed by HFM-SFI
SFI injection control module
Ignition lgnition control module Ignition control module lgnition control module
on LH-SFI Integrated in on LH-SFI Integrated in on LH-SFI Integrated in
control module on control module on control module on
HFM-SFI HFM-SFI HFM-SFI
Idle speed contact switch • • -
(accelerator pedal)
Diode matrix On 8- and 12 cylínder On 8- and 12 cylinder -
engines with LH-SFI engines with LH-SFI
only only
Mercedes-Benz
Clutch pedal switch (manual • • •

transmission)
Starter lock-out and reverse • • •
lamp switch
Diagnostic module (USA • • •
only)
.-
Stop lamp switch • •
A/C compressor control • •
module or base module (cut-
in signal for A/C
compres sor)
ABS/ASR control module • - -
ABS control module - • -
LH-SFI or HFM-SFI control • • •
module
Data bus (CAN) . • •
BRIEF DESCRIPTION - RA3000TPM0002X(30-0002)
Electronic accelerator (EA) with cruise control (CC) and idle speed control (ISC)
The electronic accelerator (EA) works in conjunction with the acceleration skid regulation (ASR) and improves
the capacity for starting off and accelerating as well as driving stability.
The EA works in the drive moment control circuit and the ASR in the brake moment circuit. Both control
circuits prevent the wheels spinning when starting off and accelerating.
If the set slip threshold of the drive moment control is exceeded whilst driving i.e. one or both rear wheels spin,
the ASR/ABS control module instructs the EA control module to reduce the throttle.
Achieved by controlling tbe EA actuator, the throttle valve opening is achieved "independently" of the
accelerator pedal position
Slip threshold
Mercedes-Benz
o '100 V ZOO-..h
P 42.0235-13
v = Speoo
ó.v = Olffetonre ·speadbe.lwaontorn a11d
reenW1eol
Brake moroo11~ conr.rcl
Orwe momern cornrol
Fig. 185: Electronic Accelerator (EA) With Cruise Control (CC) And Idle Speed Control (ISC) Graph
The drive moment is thus controlled by closing, holding and opening the throttle valve.
Ifthe differential speed ( deltav) drops below the slip threshold, the throttle valve is opened in accordance
with the accelerator pedal position
A distinction is made between three control ranges in ASR/EA control mode:
a. Control mode when a driving wheel spins and the vehicle speed is < 40 km/h
Here the slip threshold of the drive moment control is higher than that of the brake moment control. In the
event of actuation, the brake moment control is thus activated first . If the driving wheel still spins
faster, the drive moment control is also activated. Priority is given to maximum traction.
b. Control mode when both driving wheels spin or ata vehicle speed > 40 km/b
In this case the slip threshold of the brake moment control is above that of the drive moment control.
Initially the throttle valve position is reduced in the event of a control. Ifthe wheels still spin faster, the
brake moment control is. also activated. Thus priority is given to maxinmm stability.
c. Control mode when cornering at vebicle speeds between approx. 20 km/h and 120 km/h
In this case, depending on the lateral acceleration, the drive moment control comes into operation even
sooner than for control mode B. Thís increases dírectional stabílíty duríng cornering.
Tncrease in slin threshold

Mercedes-Benz
In deep snow and with snow chains, the sensitive, stability-orientated control of ASR can have a
detrimental effect on the starting-off characteristics. Therefore a specific controllogic has been
programmed in for the starting off range in such situations which can be selected by the driver via the
snow chain switch (S76).
r-
_)
576 Ire 1
o
V
-
P 42-2244-13
Fig. 186: ldentifving Slip Threshold
By increasing the slip threshold, the vehicle can bite its way out in deep snow when snow chains are fitted, thus
achieving maximum traction. Por reasons ofvehicle stability, this control is only jpermitted in the speed range
up to 40 km/h.
TI1e slip thresholds are increased in stages after 50 ms control mode in the lower speed range < 40 km/h.
The increased slip threshold remains stored up to 60 kmJh, it is erased above this speed.
A greater differential speed between the front and rear wheels is permitted due to the increase in slip thresholds.
Mercedes-Benz
~· ~·-,
'1• f - - 11 1
11-' ¡í
11
&' L-~-·--
- •W- -j
~ ~-- -1
.. 1f - -- --·~------
o tb y
P4 2-0233-1:>
Slip thresholds
(v-tia bath dnve whfH!1s sptn)
Brake mofTll!ll~ control
Drr11e mcrnard cordrol
Bmke momolltcon!rol
Soow d um s~\ll!rh op!!mtt'ld
Dnve mom 9n1 c:onlrol
Sncw eh BJl s!M!rh cpi!f:Sied
v--- Vi!hide 'SI)IH!d
l:..v = Differon'llal s.p-¡¡e<fuatweonfrootand mm 'lltti!els
Fig. 187: Identifying Slip Threshold Speed Range Graph
Malfunction/function indicator
When the engine is running, the malfunction indicator lamp (A le22) indicates wbether there is a fault in the
ASR/EA system.
Models 124, 129, 140

Mercedes-Benz
P41..oo9&13A
A1e17 ABS mafulcban indicatollamp

A 1e21 ASR tlnctlon illdca~r lamp
A1e22 ASR mafulcbon indica~or lamp
Fi~. 188: Identifyin~ Malfunction lndicator Lamp
The function indicator lamp (Ale21) lets the driver know when ASR intervenes and provides a signal to the
driver that he is driving the vehicle close to its limits.
The fun ction ofthe ASR is affected by ABS as ASR control mode is interrupted when braking.
Mode l202
P42-5182-13
A 1e17 ABS mafum:bcn indicator lamp

A1e 21 ASRJEA luden mdicator tarro
A1e22 ASRIEA ma~ndion ll<icator lemp
Mercedes-Benz
Fig. 189: ldentifying Function lndicator Lamp
Fault memory
All system components are permanently monitored by the monitoring system in the EA control module and any
faults are stored in the fault memory ofthe control module. The faults can be read out via a test coupling (for
deta:ils, refer to chapter on deta.iled description).
Driving with ASR/EA
When the ignition is switched on, function indicator and malfunction indicator lamps in the instrument cluster
(bulb check) come on and go out when the engine is running.
Driving mode
In driving mode, the function indicator comes on as soon as ASR operates. After ASR control mode is
complete, the function display stays on for about another second. The function indicator does not come on
during a very brief ASR control intervention.
Control mode
The function indicator lets the driver know that control mode has been activated and signals to the driver that he
is driving the vehicle close to its physicallimits. He can thus better adapt his driving style to the prevailing road
conditions.
Data bus (CAN)
The control modules are interconnected so that information can continuously be exchanged between:
• DI/KSS ignition control module (on engines with LH-SFI i~j ection system only)
• ABS/ASR control module
• EA control module
• AT control module, 5-speed
• Diagnostic module(~ only)
• Injection system control module
Limp-home mode
In the event of faults in the EA, the systern is switched off, the accelerator pedal goes into mechanical
emergency-running operation. When the throttle is opened, it is now only operated mechanically, the throttle
valve only being able to be opened approx. 2/3.
In addition, the electronic limp-home mode is activated in the event of faults in the safety contacts, i.e. the
engine speed is limited to approx. 1200 rpm by shutting offthe fuel supply (safety fuel shut-oft). It is possible
to continue driving in both cases (refer to chapter on Individual Functions).
Mercedes-Benz
Cruise control (CC)
The cmise control function is integrated in the EA control module. It is activated or switched off vía the Cruise
control switch (S40). Using the cruise control, any speed above approx. 40 km/h can be maintained by operating
the cruise control switch.
Cruise control cannot be activated if the switch is operated during braking or the speed is < 40 km/h. The
position controUer receives an appropriate input signa! when the cruise control is set andas a result the position
of the throttle val ve is specified. If the driver requires a higher speed vía the accelerator pedal, the cruise control
system remains inoperative (refer to chapter on Individual Ftmctions).
POJ-6050-1 3
Fig. 190: ldentifying Cruise Control
ldle speed control (ISC)
The idle speed ftmction is integrated in the EA control module_ Model 140 with engine 104 LHSFI w ithout EA
or CC has a separate control module (N4/4) for idle speed controL
On vehicles with HFM-SFI injection systems without EA or CC, the idle speed control module is integrated in
the HFM-SFI injection system control module.
If idle speed deviations are detected during the specified/actual value comparison, the position controller in the
control module receives an appropriate input signal and the position of the throttle valve is now specified.
Mercedes-Benz
P30-5331-13
Fig. 191: ldentifying ldle Speed Control
LOCATION OF COMPONENTS - RA3000TPM0004X(30-0004)
Engine 104, 119, 120 with LH-SFI injection system

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P~11-57
M1 611 EA adt.Jatof
M16/2 CCASC acila1Dr
M16J3 Rí!jtacila1Dr(efl!llno lel-slde), 80Qina 120
M1614 Lel actuator (80!Jne ngli-slde), 8fl!lii'IIJ 120
N311 LH-SAcootolmodle
N4/3 EA control mcxllo
N4/4 kle speedcortrol module
N16/1 Baso modle {llM)
N30/1 ABSIASRoonlrolmodlie
N59 Olagnostlc mcxll.ile (DM), @ Oftf
S40/2 Cktch pedal s>Mtch
X1 1/4 Tog co-.._,l ng lordia¡¡oosrs {38-ptn) (pulse Slgnal)
V2 Engloo speed mcreaso <iode ma'mc (odf Modal140
'llltleng¡ne 119, 120)
Fig. 192: Locating Components- LH-SFI Injection System (1 Of 3)
Engine 104, 119, 120 with LH-SFI injection system

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S16/1
S1813
P30-500$-S7
A1pB 8ectromc sp.ee<10010tor
5911 ASDfASR stoplamp SMld1
S1&3 Stanor ~ru andreverse lerrp swtdl, seloclollovor
posit on riJ! ogn¡lion
S29f3 lde spead cOftact swt:h (oriy wfl EA)
S4ll Cruse coowolcruse controi(CC) SM!ch
V Decelomtelsal
B Accelore1lfsal
SP Resune
A Off
Fig. 193: Locating Components- LH-SFI Injection System (2 Of 3)
Engine 104, Model124 with HFM-SFI injection system

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fi11•2SSI•tSA
P30-5277-57
K1/2 OY&f\oolagil protectloll relay(9-~)
M16/1 EA ad'uator
M1 612 CC.tSC acllalor
N314 1-FM-SFi comol module
N4/ 1 E~contal moclie
N4/3 CCASC corool module
X11f4 Testc~lng lol"dla!J'IOSis (16-pín) (pulse SIQI'Ial)
Fig. 194: Locating Components - LH-SFI Injection System (3 Of 3)

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PD7•t014•1J
Pl0-527&57
A 1p8 ~odome:or (~11 hal sensor for spoed SISflal)
S911 ASDfA.SR stop lamp Sllllch
S1&f1 Starterlorl<oo!M&I'!lr se larrp switch , so!ol:!ollovar
poSiton retognlon
S29fl Jd!Q speedccl'ied S'Mtrh, accolorator pedal
S40 Cruso conrolsl'-!lth
V De eelorel&ls a1
B Accelorlt.D/soi
SP ReSlllle
A Off
Fig. 195: Locating Components - HFM-SFI Injection System (Model124)
Engine 104, Models 129, 140 with HFM-SFI injection system

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PJ0--527>57
M1611 EA aállat«
M1612 CCASC atilaloc
N4/ 1 EAcoorrolm~e
N4/3 CCASC eortrol rnoc1ile
N16/1 Base modtle (EM)
X1114 Testcoq¡ing lor dia¡JIOSIS (~n) (pulse SJgnal)
Fig. 196: Locating Components- HFM-SFI Injection System (Mode1129, 140) (1 Of 2)
Engine 104, Models 129, 140 with HFM-SFI injection system

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P30-5274-57
S9(1 ASOIASR stoplamp SMidl
S16/1 S1art!lf lod<-OI.tte\llln;e larrp s1111dl , sela1:10r levar
po51ionrec0911loo
529!3 kfe speoo cornea sWIIl:h, acceloratOf pedallody 'Mó:l
EA)
S40 Cruse coo.-<llcruso coolt<li(CC) SMtoh
V Ooc elerele!S o!
8 Aoceleca.:&tsot
S? ReSlllle
A Off
Fi2. 197: Locating Components- HFM-SFI Injection System (Model129, 140) (2 Of 2)

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P30-527~57
K1/2 Owf'f'Diago pro!eclionrelay(D-Pfl)

M 1611 EP. aduator
M1612 CCASC acilelcr
N314 HFM-SFicortrol module
N4/1 E¡>,coofrolmodlla, CC.tSC
N413 ce cocirol module
N15 Kick-d<w.n rul- au rolay
N30/1 ,6.BS/ASR ronro1 moóJe
52913 kle speed cortad swlth {Oftf wf1 EA)
X1114 Testcoq¡lng ror ála~siS {38-ptn) {pulse ggnal)
Fig. 198: Locating Components- HFM-SFI Injection System (Model 202) {1 Of 2)
Engine 104, Model 202 with HFM-SFI injection system

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P30-.5278-S7
N22 At.tormDc AJC pusl'ibU!lon corbol (!Momafc A/C)
S9/1 ASDIA.SR stoplamp SNIIdl
S16/1 Stalterlod<-ott a.ndreverse larrp sMtál, selotlor !&ver
po51lcn recogrnoo
S40 Cruse coo;oi(CC) s•.,l ldl
V Doce ernto/s et
B Accelere:etset
S? Resune
A. Off
Fig. 199: Locating Components - HFM-SFI Injection System (Model 202) (2 Of 2)
FUNCTION DESCRIPTION - RA3000TPM0006X(30-0006)
Electronic accelerator (EA)
Block diagram
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Ovecvoltage protection EA control module

relay , Models 124, 202
(power Sl.4)ply)
Base module , Models • ldle speed control
129,140, 124.034/036 (ISC)
• Power supply • ASR/EBR data
• AJC compressor cut- in • Pedal characteristic
signa ! maps (englne 120 LH-SFI or HFM-SFI
• Engine speed oriy) control module
• Vehicle speed ---!> • ldle speed sígnal
Accelerator pedaf/idle
speed contact switch limiter (englne 120 • Safety fue l shut-off
• ldle speed ldentifier
only)
• Startjng off torque
• Specifled value
limiter (engine 120
requirement, throttle valve
oriy)
EA actuator • load value
• Specifled value limltation (engine
potentlometer 120 only) EA actuator
• Actual value potentiometer
• Actuator motor
• ldle speed sa fety contact
--1> • Coupling
• S}'nchronous safety contact
Specified value • Throttle valve
ABSIASR control module f-e selection
• Specifled value 1
requirement fo r ASR/EA
control mode
• Speed signa!
Front left and rear rígtt
wheel Positlon Data bus
controHer (CAN)
Speedometet hall sensor
(Model124. engine 104
T est coupling for
HFM· SFI)
diagnosis
• Rear wheel speed signa! 1~ (pulse signa! for HiT or
Control module (LH-SFI, Monitoring pulse counter)
HFM-SI) system
• Engine speed
OL.tpL.t 1
stages
l
1
Fig. 200: Electronic Accelerator (EA) - Block Diagram (1 Of 2)

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Starte r loe k-out/ Clutch pedal switch

reverse lamp switch EA control module (MT)
• Starter look-out/reverse
• Signa!, sWitch off ce
lamp switch (AT)
A/C compressor control
• Maíntain idle speed
function > 2km/h
module, air conditioner
Models 124, 202
. Diode matrix
(Model 140 with englne
• Cut-n signa! 11 9, 120 LH-SFI only)
ce switch • ldle speed increase
• Function selection
Stop lamp switch
• Signa!, switch off ce
Data bus (CAN)
• 01/KSS control module

• ABS/ASR cortrol
module
• LH-SFI, HFM-SFI
control module
• 5-speed automati c
tra nsmission control
module
• Diagnostic modlJe
only)
(@
Fi2. 201: Electr onic Accelerator (EA) - Block Dia&ram (2 Of2)
Function
The following functions are integrated in the EA control module:

• Cruise control
• Electrical/electronic throttle control (electronic accelerator)
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In conjunction with the mechanical components, all control processes as well as the mechanical positioning
movements are performed by components of the electrics/ electronics. The EA control module receives unfused
voltage when the ignition is switched on from the base module or overvoltage protection relay.
The cruise control switch receives unfused voltage from terminal 15 (ignition).
Using the control module input signals (refer to block diagram), the output signa! which the position controller,
monitoring system and the data bus (CAN) receive is calculated in the "specified value selection" control
module. The specified value signal is compared with the actual value signal in the "position controller" control
module. In the event of deviations, the throttle valve position is adapted to the specified value (accelerator pedal
position).
In so doing, the output stage for the actuator motor is actuated via the "approvaV disconnection " system which
is downstream of the monitoring system.
At the same time, the output stage is also actuated by the safety relay. Only if the signal is available from both
systems is the actuator motor actuated and thus the position of the throttle valve determine d.
ASRcontrol
If the specified value input ( deflection of the accelerator pedal) is greater than the drive moment which can be
transmitted to the road, this means the wheels will spin (slip). This slip is detected by the ABS/ASR control
module and signalled to the EA control module as a signa! (throttle valve reduction) via the data bus (CAN). In
order to achieve an immediate reduction in torque, this signa! is transmitted simultaneously to the DI control
module and the ignition timing is briefly retarded.
The drive moment is reduced in the event of excess throttle opening until the slip at the drive wheel falls below
a set value.
In the event of excessive dríve moment at the driving wbeels (ASR control) the helical spring in the spring
capsule of the actuator permits adjustment of the throttle val ve contrary to the throttle pedal position.
EBR control
The EBR (engine brakíng regulation) is effective under the followíng conditions:
• Vehicle speed > 20 km/h to 120 km/h.

• No ASR control
• Opening angle ofthe throttle valve < 20° (set by the driver's foot).
If, when the accelerator pedal is released or during a downshift (e.g. manual) slip occurs at the drive wheels,
this is also detected by the ABS/ASR control module. The throttle valve is briefly opened (approx. 450 ms) so
that no fmther slip occurs at the rear wheels. This increases directional stability.
When the ignition is switched on, the EA system and the íntegrated idJe speed control is operative. The control
module detects the accelerator pedal position via the specified value potentiometer in the EA actuator, on the
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engine 120 the actuator for the right cylinder bank, located on the left. The position ofthe throttle valve is
signalled by the actual value potentiometer in the EA actuator.
Accelerator pedal not operated
When the accelerator pedal is not operated, the idle safety contact is "closed" and the synchronous safety
contact is "open". Both safety contacts and their signals are continuously checked by the monitoring system in
the EA control module. The control module ofthe LH-SFI or HFM-SFI injection is actuated by the output
signal of the monitoring system. As a result the actuation of the injection valves is guaranteed o ver the entire
speed range via the safety fuel shut-off. In the absence of a signal, e.g. when both safety contacts are detected as
open (mechanical or high contact resistance at the contact), the LH-SFI or HFM-SFI control module actuates
the injection valves so that an engine speed of only approx. 1200 rpm is reached with the quantity of fue l.
When the accelerator pedal ís not operated, the position of the throttle valve is also determined as a function of
the instantaneous coolant temperature before starting.
Throttle control
The throttle linkage is connected to the throttle by means of a loose connection vi a the drive lever and the
interna! spring capsule.
On the engine 120, the EA actuator is "not" connected to the throttle linkage or the left cylinder bank (located
on the right ofthe engine).
The throttle valve is adjusted here only by means of electric/electronic actuation.
Emergency running system
(refer to chapter on Individual Functions)
Fault memory
(refer to chapter on Individual Functions)
Information is continuously exchanged between the ABS/ ASR, LH-SFI or HFM-SFI, EA control modules and
the DI/KSS ignition control module and the Diagnostic module(~ only) via the data bus (CAN). The data
bus ís also checked by the monitoring system.
Accelerator pedal operated
By operating the accelerator pedal, the control movement is transmitted to the specífied value potentiometer in
the actuator via the floor-type accelerator pedal, Bowden cable and throttle linkage. Depending on the
accelerator pedal position, an appropriate voltage signal is input to the EA control module by the specified value
potentiometer.
The slip signal at the drive wheels is signalled to the EA control module vía the data bus (CAN). In ASR mode,
the torque is reduced by closing the throttle until no further slip occurs.
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In EBR mode the torque is increased by briefly opening the th.rottle (approx. 450 ms) until no further slip
occurs.
Overall, the th.rottle valve can be adjusted between idle and full th.rottle or closed in tbe direction of idle by ASR
or brie:fly opened slightly by EBR using the EA system. The opening angle for idle control is limited by the EA
control module over the entire adjustment range ofthe throttle valve (idle to ful l tbrottle stop).
Cruise control (CC)
The following signals are processed in the cmise control section of the EA control module for the parameters of
cruise control control:
• Push-button switch
• Engine speed
• Speed of left front and rear wheel (Model124, engine 104 HFM-SI, left front wheel and hall sensor
signal, speedometer)
• Th.rottle valve position
• Clutch switch (MT only)
The cruise control ftmction can only be activated by operating the switch (S40) ata speed above 40 km/h. The
cruise control switches off if tbe brake or clutch pedal are operated.
P07 -6050-13
Fig. 202: Identifying Cruise Control Switches
To maintain directional stability, the speed signal from the left rear wheel is measured in addition to the speed
signa! of the left front wheel. On Modell24, engine 104, signal of the left front wheel and the hall sensor signa!
from the speedometer.
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When the cruise control is switched off, the return of the throttle val ve to the specified value of the accelerator
pedal is monitored by the safety circuit in the electronic accelerator control module.
If, for example, when the stop lamp switch is defective, the vehicle decelerates > 1.5 m/s 2 , the deceleration is
recorded by the computer and the actuator closes the throttle val ve at the highest speed possible.
When the cruise control is set, the position controller in the EA control module receive an appropriate input
signal. As a result the position of the throttle valveis specified, recorded by the actual value potentiometer of
the throttle valve and signalled to the EA control module. If the driver requires a higher speed via the
accelerator pedal, the cruise control remains inoperative.
If ASR detects drive slip during cruise control mode, the reduction of engine output (lower speed) has priority
over cruise control mode. If ASR operates for more than 0.5 ms, cruise control is switched off In this case the
system has to be reactivated vía the switch if further cruise control mode is required.
Monitoring and limp-home systems
Ifthe max. differential speed between the left front wheel and the left rear wheel (EA) is exceeded for more
than 0.5 s, the cruise control is switched off by the CCIISC control module.
The synchronous safety contact must be bridged by means of the switching transistor in cruise control mode.
Inadmissible acceleration is now detected by monitoring the speed and acceleration plausibílítíes, and the cruise
control is switched off
Maximum differential speed
up to 149 km/h 3 km/h
above 150 km/h 5 km/h
Fault memory
(refer to chapter on individual functions)
Cruise control/idle speed control (CC/ISC)
Block diagram
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OvervoHage protection CC/ISC control module

refay
Models 124, 202
(pow er supply)
Base module
Cruise cortrol
Models 129, 140
!elle speed control LH·SFI or HFM-SFI
• Voltage supply control module
• AC compressor cut-n • ldle speed signa!
signal
1-----t:l-• Safety fuel shut-off
• Engine speed
ce s witch Specified value
selection
• Function selection
Accelerate/Set
Oecelerate/Set
Resume
Off
ISC actuator -
EA actuator
• Orive actual value Poslion Data bus
controller • Actuator motor
potentiometer
• Clutch
• Throttle valve actual
·---(:: • Throttle vafve
value potentiometer
• ldle speed contact
• Safety contact
ABSIETS control
module
• Speed signa!
l eft front and rear wheel --1> Monitoring
- system
Speedometer hall
sensor
(M odel 124, engine 104
HFM-SFI)
• Speed signaJ
Rear wheel
LH·SFJIHFM-SFJcontrol
module
• Englne speed
Fig. 203: Cruise Control/Idle Speed Control (CC/ISC)- Block Diagram (1 Of 2)

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Control m odule (HFM- Clutch ped al switch

SFI) CCIISC control module (MT)
• Engine speed • SWitch off CC signal
Starter lock-out/ • Maíntain idle speed
reve:rse lamp switch function > 2mlh
• Selector lever poslion Diode matrix
detection (AT) (Model 140, engíne 11 9,
AJC c ompress or cont ro l 120 LH-SFI only)
module • ldle speed increase
Models 124, 202 --e>
• Cut-n slgnal
Stop lamp switch
• Switch off CC signal
Data bus (CAN)

• 01/KSS switch urit
• LH-SFI, HFM-SFI
control module
• 5-speed transmission
automatic control
module
• Dlagnostlc module (@
only)
Fig. 204: Cruise Control/Idle Speed Control (CC/ISC)- Block Diagram (2 Of 2)
Function
The following functions are integrated in the CC/ISC control module
• Cruise control
The Cruise control function can only be activated at a sp eed above 40 km/h by operating the switch. The cruise
control swi tches off if the brake or clutch pedal are operated. T o maintain vehiele stability, the speed signal
from the rear axle and, in vehicles with electronic traction support (ETS), that of the left rear wheel is measured
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in addition to the speed signal of the left front wheel.
If the differential speed between the front and rear wheel is too high, cruise control is switched off after
0.5 S.
Maximum differential speed
up to 149 km/h 3 kmlh
above 150 km/h 5 km/h
If, for example, a stop lamp switch is defective and the vehícle decelerates > 1.5 m/s2, the deceleratíon is
recorded by the computer and the actuator closes the throttle valve at the highest positioning rate possible.
When the cruise control is switcbed on, tbe control module input signals (refer to block diagram) are used to
calculate the output signa} which tbe position controller, the monitoring system and the data bus (CAN) receive
in the "specífied value selection" control module.
In so doing, the output stage for the actuator motor is actuated vía the approvalldísconnection system which is
downstream of the monitoring system
The position is fed back by the drive actual value potentiometer and the throttle valve actual value
potentiometer.
If the driver requires a higher speed via the accelerator pedal when the cruise control is switched on, the cruise
control remains inoperative.
The idle speed contact and the safety contactare located in the CC/ISC actuator. Normally the contact is always
closed. The idle speed contact is closed when the accelerator pedal ís not operated and opened when the throttle
is opened.
Normally (when driving) the safety contact is always closed. If it is "open", in the event ofa fault, (e.g. dueto
an inadmissible throttle opening), the "safety fuel shut-off' is triggered by the injectíon system control module
and the engine speed is limited to approx 1200 rpm.
In cmise control mode the safety contact is brídged by means of the swítching transistor. Inadmissible
acceleration is detected by monitoring the speed and acceleration plausibilities and the cruise control is
swítched off.
Fault memory
( refer to chapter on individual functions)
ldle speed control
(refer to chapter on idle speed control)

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ldle speed control (ISC)
Block diagram for ISC with separate control module
(engine 104, Modell40 only wíthout EA or CCIISC)

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Base module ISC control module

• Power supply
• AJC compressor cut-in
signa!
• Engine speed
Specifled val ue
ISC actuator selectlon
• Orive drive actual value LH-SFI control module
potentiometer
• ldle speed slgnal
• Throttle valve actual
value potentlometer
• Jcile speed conta el
ABS control module
• Rear axle speed signa ! 7
Starter lock-out/ Posltlon Data bus
reverse lamp switch ccmtroDer
• Selector lever posllon
detection (AT)
Clutch pedal swítch EA actuator
(MT) • Actuator motor
• Maintain idle speed • Clutch
functi on > 2 kmfh --t • Throttle valve
Diode matrix
• ldle speed ncrease Monitorlng
- system
Test coupling for

Output Fault diagnosis
stage memory t---lf----1--1...,'>~ (pulse signal for HHT or
pulse counter)
Data bus (CAN)

• DIIKSS switch unit
• ABSJASR control
module
e LH-SFI, HFM-SFI
control module
• 5-speed transmission
at.tomatie control
module
• Dia gnostie module (@
oriy)
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Fig. 205: ldle Speed Control (ISC) - Block Diagram
Function
When the ignition is switched on, the idle speed control system is operative. Befo re starting, the position of the
throttle valve for idle is specified via the actuator motor depending on the coolant temperature.
Depending on the input signals shown, refer to block diagram, an output signal is transmitted to the specified
value selection in the idle speed control module. It evaluates the idle speed signal in conjunction with other
adjacent signals. The position controller and the data bus (CAN) is actuated by the output signals. The signals
are checked by the monitoring system and the output stage actuated via the approval/ disconnection system.
The ISC control module compares the actual and specified engine speed and determines the required position of
the throttle valve vía the actuator motor. The position of the throttle valve is recorded by the actual value
potentiometer in the actuator and signalled to the ISC control module.
The adjustrnent range of the throttle val ve for idle adjustment ( e.g. opening angle) is limited to max. 10° by the
control module.
Support of idle speed control by the ignition system
If there is an engine speed control deviation, the id le speed control is supported by varying the ignition timing.
Idle speeds with and without gear engagement vary. They are determined according to the selector lever
position and the coolant temperature via the EA, CC/ISC or ISC control module.
Engine speed increase or stabilization
a) Speed stabilization on engines with A/C compressor
When the A/C compressor cuts in, the EA, CCI ISC or ISC control module receives a cut-in signal. The control
module processes the applied voltage and transmits an appropriate signal to the specified value selection. The
cross.-section of the opening becomes larger before the A/C compressor cuts in so that the idle speed remains
almost constant in the process.
b} Speed stabilization on vehicles witb automatic transmission (AT)
The signal is evaluated when the drive position is engaged. This results in a changeover of characteristics. Tbis
signal is then passed on to the specified value selection. In this way, the throttle valve is opened toa varying
extent due to the characteristic in force when the accelerator pedal is deflected. A gentle progression is thus
achieved for each selector lever position.
e) Increasing engine speed to generate beat
In order to bring the catalytic convertor more quickly to operating temperature, the speed is increased for
approx. 20 seconds after each starting operation when coolant temperatures are below +20°C and a recognized
idle speed signa! and selector lever position P/N.
1 Mercedes-Benz
1 1990-2002 ACCESSORIES & BODY, CAB Throttle Control, Speed Control Systems- 129 Chassis
Engine Temperature Time Engine speed

M 104 <+ 20°C approx. 20 seconds 1100 ± 100/rpm
M 119 +20°C -+ 30°C approx. 20 seconds 1000 ± 100/rpm
M 120 +20°C - + 30°C approx. 20 seconds 850 + 100 -50
n tmn]
1100
1000 -
900
800 -
700 -
600 -
1 1
Start ca. 20
Oiagram appte s toa oooloot toiTJl era\JriO of w·c (Simwat&d) and saledor levl!f posibcn Pt-1.
ShO!M'l on ol)fjoo 119 Íl Modol 140.
Fi~. 206: Selector Lever Position Coolant Temperature Graph
d) Speed increase on engines witb diode matrix
(Model140, engine 119, 120 LH-SFI only)
In order to achieve a higher charge current at idle speed> the engine speed is increased from 550 rpm to 650 rpm
under certaín conditions.
The control module receives a signal via the diode matrix when auxiliary appliances are switched on.
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The idle speed increase is activated when drive stage D, 3, 2 and 1 ís engaged when an engine speed of 900 rpm
ís exceeded and one or more ofthe following applíances are switched on:
• Dipped beam (except in the case of day-driving light)

• Blower on stage 3 or higher in the case of automatic heater control
• Heated rear window Automatic air
P54-1845-13
Fig. 207: ldentifving Diode Matrix, Speed Increase (Footwell Right)
• window
• Automatic air conditioning
• Left and ríght auxiliary fans
• Front or rear seat heating on stage 2
The idle speed increase ís swítched offwhen dry stages P, R or N are engaged anda coolant temperature of > or
= l10°C.
CHARGE CURRENT
Engine speed Generator speed Charge current
550/rpm 1595/rpm 47 A
650/rpm 1885/rpm 65 A
2180/rpm 6300/rpm 120A
e) ldle speed increase dependent on battery voltage
(Models 129 and 202 with engine 104)
In order to increase the charge current of the generator, tthe id le speed ís increased to approx. 650 rpm under the
followimz oneratinQ conditions:
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• Battery voltage < 12.3 V

• Selector lever position "D"
• Coolant temperatme 40 - ll0°C
If these conditíons are met, the idle speed remains at the increased leve! after exceedíng 900 rpm when the
engine speed reduces.
Detection and adaptation of mecbanical end stop of throttle valve
The control module detects and adapts the end stop (ídle speed stop) when the ignition is switched on. The time
for this is approx. 45 s. The detectíon is effected by the throttle valve being drawn onto the end stop by the
actuator motor integrated in the actuator.
The throttle valve position is recorded by the actual value potentiometer, transmitted to the control module and
stored there.
The control module then calculates from these values the position of the throttle valve for idle speed.
INDIVIDUAL FUNCTIONS - RA3000TPM0008X(30-0008)
Overvoltage protection relay
Models 124, 202
• Supplies the EA or CC/ISC control module or on engine l 04 the ISC with unfused voltage.
K111 OveNol!ago pcotectJon
P30..5182-13
Fig. 208: ldentifying Overvoltage Protection Relay - Models 124, 202
Base module
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• Supplíes the EA or CC/ISC control module or on the engine 104 the ISC wíth unfused voltage.
Additional outputs :
• Engine speed
• A/C compressor cut-in signa!
P30-5l31-1 3
Fie. 209: Identifyine Base Module - Models 124.034/036, 129, 140
Accelerator pedal/tbrottle control
• Operates mechanically the specified value sensor in the actuator and thus specifies the required throttle
valve position (on EA). Wíth CC/ISC or ISC the throttle valve ís operated.
Applies to EA on1y
The position of the accelerator pedal is input to the EA actuator via accelerator pedal, accelerator pedallever,
Bowden cable, transfer lever and connecting rod. On engines 104 and 119, the mechanical actuation takes place
at the actuator Ml6/ l , and on engíne 120 at the actuator Ml6/3. The actuator Ml6/4 ís only actuated
electrically.
The throttle val ve ís then adjusted vía the electrícal/electroníc components such as the electronic accelerator
control module and actuator.
The specified value potentiometer is operated by the output lever of the actuator vía the spring capsule. The
throttle valve is operated vía the d. c. motor in the actuator dueto signa! processing in the control module. The
adjustment travel ranges from the idle stop to the full throttle stop.
In the event of a fault in the electrical/electronic components, the throttle valve can be adjusted via the spring
capsule. This ensures that the vehícle can be dríven wíth approx. 2/3 engíne output in the case of engínes 104
and 119 aud approx. 1/3 engine output in the case of engíue 120.
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Accelerator pedal idle speed contact switch
• Signals the idle position ofthe accelerator pedal to the EA actuator.
The idle speed contact switch {S29/3) is open at idle_ When the throttle ís opened, initially the ídle speed contact
switch closes before a specified value can be changed at the actuator via the control system.
P30-2130-1l
Fig. 210: ldentifying Idle Speed Contact Switch
EA actuator
• Operates the throttle valve via an actuator motor and coupling
The following are integrated in the actuator:
• Specified value potentiometer

• Actual value potentiometer
• ldle speed safety contact
• Synchronous safety contact
• Actuator motor
• Coupling
• Spring capsule with retum spring
• Throttle valve
Engine 120
Actuator for left cylinder bank (located on right of engine).
!Gf'"GF
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This actuator has no mechanical actuation but is only actuated electrically by the EA control module .
The adjustment range ofboth actuators is 8°- 90° in each case.
The foUowing components are included in the actuator:
• Actual value potentiometer 1

• Actual value potentiometer 2
• d.c. motor
• Coupling
• Tbrottle valve
• Retum spring
Specified value potentiometer
• Signals the position of the accelerator pedal to the EA control module
When the ignition is switched on or the engine is running, the specified value potentiometer is actuated by a
constant voltage from the EA control module. The potentiometer position is changed vía the tbrottle linkage by
means of adjustment movement at the accelerator pedal. A defined, variable voltage ís transmítted back to the
EA control module by the potentiometer, depending on accelerator pedal position. Tbis signal is processed
further in the position controller of the control module.
Actual value potentiometer
• Signals the position of the throttle val ve to the EA control module
When the ignition is switched on or the engine is running, the potentiometer is actuated with a constant voltage
from the EA control module. The output signal of the potentiometer to the control module is used as a position
feedback of the instantaneous tbrottle valve position.
This signal is processed further in the position controller of the control module. The position of the throttle
valve is varied by the control module in the event of deviating sígnal values.
Actual value potentiometer 2
(engine 120 only. Actuator ofleft cylinder bank, located on the right ofthe engine)
In principie, the function of actual val ue potentiometer 2 is identical to that of actual val ue potentiometer of the
actuator ofthe right cylinder bank. Adjustment is made electrically by the EA control module. The signa! ftom
the monitoring system is checked and is compared with the signal of the other actuator.
Actual value potentiometer 3
(Engine 120 only. Actuator of left cylinder bank, located on the right ofthe engine)
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In principie, the function of actual value potentiometer 3 is identical to that ofthe actual value potentiometer of
the actuator ofthe right cylinder bank. The signa! is used as a position feedback of instantaneous throttle valve
position. This signal is also processed by the position controller and checked by the monitoring system.
Safety contacts
a. Idle speed safety contact
Signals the idle position ofthe throttle valve in the actuator to the EA control module. The idle safety
contact is integrated in the lever which is permanently connected to the throttle valve. When the ignition
is switched on or when the engine is running, a stabilized voltage is applied to the input side. The id] e
safety contact is closed when the accelerator pedal is not operated (idle position).
The signal is checked via the monitoring system. Ifthe signal evaluation is in order, an output signal to
the LH-SFI or HFM-SFI control module takes place which then releases the actuation ofthe fuel pump.
The switching point of the idle safety contact is 2 to 3° of adjustment above the idle stop. With the
adjustment from full throttle towards idle, the idle safety contact closes at 4° of adjustment before the idle
stop.
b. Synchronous safety contact
Signals the driving position of the throttle valve.
The synchronous safety contact is open when the accelerator pedal is not operated. It closes when the
accelerator pedal is operated. The switching point is approx. 4 o above the idle position.
The signa! is also checked via the monitoring system. The LH-SFI or HFM-SFI control modules are
actuated as for the idle safety contact.
c. Safety fuel shut-off
Shuts off the fuel supply in the event of faults in the actuator contacts.
Normally a safety contact is always closed. If both contacts are open in the event of a fault, the LH-SFI or
HFM-SFI control module receives a fault signa! from the monitoring system in the EA or CCIISC control
module. This signal triggers the safety fuel shut-off, the engine speed being limited to approx. 1200 rpm.
In cnüse control mode, the synchronous safety contact is bridged by means of a switching transistor. Here
an inadmissible acceleratíon is detected by monitoring the speed and acceleration plausibilities and the
cruise control is switched off.
Actuator motor
• Adjusts the tbrottle valve to the position specified by the control module.
The actuator motor is actuated by the control module vía the output stage with 140 to 160 Hz. As a result, the
throttle valve can be adjusted from idle to fuU throttle (8-90° adjustment angle) via multi-stage gearing. The d.c.
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motor has a high adjustment speed.
The complete degree of adjustment is covered in approx. 120 ms. The power consumption at the maximum rate
of adjustment is approx. 12 A
Coupling
• Makes the connection between the actuator motor and the throttle valve.
The coupling is actuated from the monitoring system in the EA control module with a pulsed voltage signal (2
kHz) . The maximum current value is 2.6 amperes.
The monitoring system switches offthe coupling in the event of a failure ofthe eMectrical/ electronic control
functions. The connection is released and the throttle valve can be adjusted mechanically. It is thus possible to
continue dríving with reduced engine output (limp-home mode).
Engine 120
There is no mechanical connection between the actuator for the left cylinder bank: (located on the right ofthe
engine) and the accelerator pedal.
In the event of faults in the electrical/electronic control function, the throttle valve can no longer be opened via
the accelerator pedal.
CC/ISC actuator
• Operates the throttle valve via the actuator motor and coupling.
• Drive actual value potentiometer

• Throttle valve actual value potentiometer
• Idle contact
• Safety contact
• Actuator motor
• Coupling
• Throttle valve
The adjustment range ofthe actuator is 8-90°. As a result, the throttle valve can be adjusted from idle speed to
full throttle stop and vice-versa via the throttle linkage.
Between idle speed and full throttle the throttle valve is operated purely mechanically via the accelerator pedal
lever.
Drive actual value potentiometer

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• Signals the position ofthe drive (actuator motor) to the CC/ISC control module.
Throttle valve actual value potentiometer
• Signals the position of the throttJe valve to the CCIISC control module.
ldle contact
• Signals the idle speed position from the actuator to the CCIISC control module.
Safety contact
(once only)
• Signals inadmissible throttle openings to the CC/ISC control module during cruise control mode.
Actuator motor
• At idle or during cruise control mode, adjusts the throttle valve to the position specified by the control
module.
The actuator motor is actuated by the control module via the output stage with 140 to 160Hz and adjusts the
throttle valve via multi-stage gearing.
Adjustment range
Idle speed range 8-12°
Cruise control range 8-90°
The power consumption at maximum rate of adjustment is approx. 12 A.
Coupling
• Makes the connection between actuator and throttle valve.
The coupling is actuated by the monitoring system with a pulsed voltage signal (2kHz) from the CCIISC
control module. The maximum current is 2.6 A.
ISC actuator
• Operates the throttle valve via actuator motor and coupling.
• Drive actual value potentiometer

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• Throttle valve actual value potentiometer

• Idle speed contact
• Actuator motor
• Coupling
• Throttle valve
Drive actual value potentiometer
• Signals the position of the drive (actuator motor) to the ISC control module.
Throttle valve actual value potentiometer
• Signals the position of the throttle val ve to the ISC control module.
Idle speed contact switch
• Signals the idle speed position of the throttle valve to the ISC control module.
Actuator motor
• Adjust the throttle valve to the position specified by the control module.
The actuator motor is actuated by the control module via the output stage with 140 to 160Hz and adjusts the
throttle valve via multi-stage gearing.
Adjustment range 4-8°
Coupling
• Makes a connection between actuator motor and tbrottle valve.
The coupling is actuated with a pulsed voltage signal (2 kHz) from the ISC control module. The power
consumption at max. rate of adjustment is approx. 12 A.
EA, CCIISC control module
• Controls the position of the throttle val ve depending on the input signals.
Individual functions
• Power supply
• Specified value selection
• Pedal characteristic maps
• ASR/EBR signal processing
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• Antí-squat control
(engine 120 only)
• Load value limitation
(engine 120 only)
• Maximum speed limiter (engine 120 only)

• Speed selection
• Position controller
• Output stage
• Monítoring and emergency-runníng systems
• Safety relay
• Data bus (CAN)
• Cruise control
• Fault memory/diagnosis
Voltage supply
When the ignítion is switched on, the following components are supplied with voltage from the EA control
module:
• Specified value potentíometer

• Actual value potentíometer
• d.c. motor
• Coupling
• Cruise control switch
• Idle speed contact switch
• Safety contacts
In addition, for the left actuator on engine 120, located on the right of the engine are:
• Actual value potentíometer 2

• Actual value potentíometer 3
• Coupling
• d.c. motor
Specified value selection
The following signals are input:

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• Idle speed requirement

• Accelerator pedal requirement
• ASR/EBR requirement
• Maximum speed requirement
• Cruise control requirement
The signals are evaluated and the signal with the highest priority determined with the specified computer
program. The position controller and the monitoring sys tem are actuated by the output signal.
Ifthe specified value signal dev iates from the actual value signal, the D. C. motor is actuated via the output stage
and the throttle val ve position is changed. The adjustment continues until the specifíed and actual value agree.
At the same time the information available in the specifted value selection are signalled to the data bus. It
transmits it to the following components:
• DI/KSS control module (onLH-SFI only)

• ABS/ASR control module
• LH-SFI or HFM-SFI control module
• 5-speed automatic transmission control module
• Diagnostic module(~ only)
A signal is also sent directly to the LH-SFI or HFM-SFI control module by the nominal value selection. In
conjunction with other information available from the LH-SFI or HFM-SFI control module, the period for
actuation of the injection valves is calculated at idle speed.
Pedal characteristic maps
(Accelerator pedal or cruise control requirement) The accelerator pedal position is input to the EA control
module by the specified value potentiometer of the actuator. In addition, the following signals are also
processed:

• Engine speed
The appropriate characteristic map is actuated depending on the signals applied. Thus the output signal is
transmitted on to the nominal value selection via the maxirnum value selection. There the signal is compared
with others. The signal with the highest priority takes precedence and determines the position of the throttle
valves via the position controller and the output stage. At the same tirne, the signals are checked by the
monitoring system.
The pedal characteristic maps are designed to achieve throttle valve opening limitations at which the max. drive
moment is still achieved.
ASRJEBR signal processing

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The ASRIEBR data are transmitted to the EA control module by the ABS/ASR control module via the data bus.
The data are updated every 1O ms.
The ASR data are input to the minimum value evaluation and the EBR data in the maximum value evaluation.
The output signa! calculated during this process is input to the nominal value selection and evaluated with the
other signals (idle speed control signal). The signal wíth the highest príority takes precedence and controls the
position controller and thus the throttle valve via the output stage.
If no ASR/EBR signal or Cruise control signal is applied, the accelerator pedal position, or the idle speed
control when the accelerator pedal is not operated, determine the position of the throttle valve.
Anti-squat control (engine 120 only)
To protect the driveline, the EA control module controls the engine output moment below a speed threshold of 5
km/h toa particular limiting moment depending on the selector lever position D, 3, 2 or R. To effect this, the
throttle valve is moved back towards the accelerator pedal position.
Load value limitation (engine 120 only)
The EA control module receives a load value limítation signal from the ignítion control module via the data bus.
The signal is effective, if for example the fault "knock sensor defective" or "camshaft sensor implausible" is
detected in the ignition control module. This results in the ignition being retarded whereby only a particular
opening angle ofthrottle valve is permitted by the EA.
Maximum speed limitation (engine 120 only)
The maximum speed is limited to 250 km/h. When this speed is exceeded, the throttle valve is closed
irrespective of the accelerator position.
Speed signal
After signal processing, the speed signal from the front left and rear left wheel speed is fed to the EA control
module by the ABS/ ASR control module. On modell24, engine 104 HFM-SFI, front left wheel speed and
speedometer hall sensor signal.
The selector lever position is input by the starter lockout and reverse switch. The signals are evaluated,
processed and transmitted at the data bus (CAN) and the cruise control and idle speed system.
Position controller
Various input val ues are calculated to give an output value in the specified value selection unit. This output
value is input to the position controller where it is compared to the actual value ofthe throttle val ve position. In
the event of deviations, corrections are made untíl the specified and actual value are the same.
Output stage
The output signal ofthe position controller is transmitted to the output stage and amplified there. Thís sígnal
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furthermore determines the direction of adjustment (idle speed or full throttle direction) ofthe d_c_motor in
the actuator during idle speed and cruise control mode_ A t the same time the output stage is actuated by the
monitoring system vía the safety relay.
Both signals are compared in this process. Ifthe signals are identical, the d. e motor is actuated ata frequency of
140 to 160 Hz_ The clutch is also monitored by the monitoring system_
Monitoring and limp-bome mode
Safety functions are fulfilled by the monitoring system. Limp-home mode operates in the event of faults in the
system (e.g ifthe throttle valve ís opened more than specified by the accelerator pedal and cruíse control is not
in operation)_
With mecbanicallimp-home mode the output stage of the clutch and the actuator motor is switched off The
throttle valve can then only be adjusted mechanícally vía the accelerator pedal so that 2/3 engíne output on
engines 104 and 119 and 1/2 engine output on engine 120 are available (e.g. in the event of errors in the
accelerator pedal idle speed contact switch)_
With electronic limp-home mode the engine speed is limited to approx_ 1200 rpm via the injection system by
controlling the fuel supply (safety fuel shut-off) (e.g. in the event offaults in the idle speed or synchronous
safety contact)_
The following functions are monitored:
• The operating ranges of the drive actual value potentiometer and throttle val ve actual value potentiometer
• The cables to the drive actual valve potentíometer and the throttle valve actual value potentíometer are
checked for short-circuit or open-circuit
• The function of the safety switch in the actuator
• The positional accuracy of the actuator, related to the specified position which is specified either by the
idle speed control or by the cruise control
• Short-circuit in the output stage ofthe d.c. motor
• Battery voltage at the electronic accelerator control module
• Selector lever position of the automatic transmission
• Speed signa} from the front left and rear left speed sensors
• The functions of the stop lamp switch
• TNA engine speed signa!
Safety relay
This is actuated by the monitoring system vía the "Approval/disconnection" control module ífthe output signa!
is approved due to the signals applied. Both components control the output stage for the actuator motor. The
coupling in the actuator is actuated by the monitoring system at the same time_
Data bus (CAN)

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(refer to chapter on data bus)
ldle speed control
This is performed by the EA or CC/ISC control module. On vehicles with LH-SFI injection system, without EA
or CC/ISC, a "separate" control module is responsible for idle speed controL
(For ftmction, refer to chapter on ISC Function Description)
Cruise control
The cmise control ftmction is integrated in the EA control module.
(For function, refer to chapter on CC/ISC Function Description)
Fault memory/diagnosis
All system components are monitored by the monitoring system in the EA, CCIISC control module. Faults are
stored in the fault memory of the control module and are retained after the battery is disconnected.
The stored faults can be read out and erased at the test coupling for diagnosis (Xll/4) using the hand-held tester
(HHT) or the pulse counter (for fault chart with details offault codes, refer to Diagnosis Manual, Volume 3)
ABS/ ASR control module
• Specified value requirement for throttle valve position in ASR or EBR mode, irrespective of accelerator
pedal posítion.
• Speed signal for EA or CC/ISC control module.
Specified value requirement for throttle valve position in ASR or EBR mode, irrespective of accelerator
pedal position
Every 10 ms information is exchanged between the ABS/ASR control module and the EA control module via
the data bus (CAN).
From the shape of the signa! from the ABS/ ASR control module, the EA control module detects when ASR or
EBR intervenes and determines which maximum throttle valve opening is permissible. Irrespective of the slip
conditions at the drive wheels, the throttle val ve can be completely closed or briefly opened to a limited extent
by means of an appropriate ASR/EBR control signa!.
With the ASR control signa], it can also be closed if full throttle is specified by the driver or by the cmise
controL By means of a similar type of feedback signa! (throttle valve actual value) the EA control module
informs the ABS/ASR control module continuously about the instantaneous position of the throttle valve. The
ABS/ASR control module can thus check whether the EA follows the position commands ofthe ASRIEBR
system during ASR/EBR control mode. If a fault exists in the area of the EA (without cmise control function)
(actuator without voltage supply), the feedback signal diisappears and the ASR switches to "fault". The ASR
m::~l fun r.tion in cl ic.::~tor l::~mn (A 1e22) c.omes on
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Speed signaJ for EA or CC/ISC control module
• Speed sensors indicate speed to EA, CC/ISC control module via ABS/ASR control module.
Allocation :
for CC/ISC: Speed sensor from left (L6/ 1) and speed sensor rear axle (L6)
P42-524M3
Fig. 211: ldentifying Speed Sensor From Left
P3&5690-13
Fig. 212: ldentifying Speed Sensor Rear Axle
E ngine 104 HFM-SFI, Model124
The speed signal for the rear w heels is not output from the ABS/ASR control module but picked up by a hall
sensor on the speedometer and! is u sed for the cruise control function as well as idle speed control.
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Q
A1p8
p 30-5332-13
Fig. 213: Identifving Speed Signal- Engine 104 HFM-SFI, Model124
ASRJEA : Front left (L6/1) and rear left speed sensor (L6/3).
The speed signals recorded by the speed sensors of tbe wheels or the speed sensor of the rear axle (witb
CCIISC) are input to the ABS/ ASR control module and transmitted by this to the EA or CC/ISC control
module.
Tbe speed signals are required for
• Cmise control
• Maximum speed limitation (engine 120)
P 42-5187-1 3
Fig. 214: Identifving Rear Left Speed Sensor

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HFM-SFI injection system control module
• Supplies the EA or CC/ISC control module with an engine speed signal

• Receives the idle speed signal from EA or CC/ISC.
• Activates the safety fuel shut-off during limp-home mode
Starter lockout and reverse lamp switch
• Signals the selector lever position on automatic transmission to the EA control module or CC/ISC or ISC.
When engaging the drive position, the signa] is evaluated. As a result the characteristic map is changed over.
This signa! is then passed on to the specified value selection.
S16/1
916/3
Pl0-5333-13
Fi2. 215: Identifyin2 Starter Lockout And Reverse Lamp Switch
A/C compressor control module
(Air conditioner)
• Signals to the EA control module or CCIISC or ISC that the refrigerant compressor has been switch on.
When the refrigerant compressor is switched on, the control module receives a switch-en signal. On the models
129 and 140 this is from the base module, on models 124 and 202 from the A/C compressor control module.
The control module processes the applied voltage and transmits an appropriate signal to the specified value
selection. The opening cross section increases before the refrigeration compressor cuts in so that the idle speed
can be kept approximately colltstant.
Cruise control switch
• Signals the driver's requirements to the EA or CC/ISC control module

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When the CC switch (S40) is operated, the EA or CC/ISC control module can receive the followíng commands:
• Accelerate/Set
• Decelerate/Set
• Resume a Off
P07-6Q5Q-13
Fig. 216: ldentifying Cruise Control Switch
Control contact switch
This is closed when the switch is operated. The control contact is monitored in the EA or CCIISC control
module. The cruise control cannot be switched on in the absence of a control signa! when the switch is operated.
The cruise control can also be switched off in the absence of a control signal.
Stop lamp switch/clutch pedal switch
• Signals to the EA or CCIISC control module whether the brake or clutch is operated.
When the brak:e or clutch is operated, the cmise control system receives a change in signal. The cruise control
function is cancelled immediately.
The input signa! of the cruise control system is cancelled at the position controller. As a result, the actuator is
actuated so that the throttle val ve is moved back to the specified value by the accelerator pedal. The position of
the accelerator pedal has priority. Opening the throttle and also controlling the drive moment are not impaired.
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S8J1
P07-6004-1 3
S9!1 stop larrp swi dl, 4-ptn
Fig. 217: ldentifying Stop Lamp Switch/Clutch Pedal Switch
Diode matrix
(Model l40 only, engine 119, 120 LH-SFI up to the end of92)
• Signals the switching on of auxiliary appliances to the EA or CCIISC control module
The idle speed is increased from 550 rpm to 650 rpm under certain conditions to achieve a higher charge current
at idle speed.
Id le speed increase is activated when drive stages D 3, 2 and 1 are engaged, if an engine speed of 900 rpm has
been exceeded, one or more of the following appliances are switched on:
• Dipped beam (except wiith day-driving light circuit)

• Blower stage 3 or higher on automatic heater control
• Heated rear screen
• Automatic climate control
• Left and right auxiliary fans
• Seat heater stage 2, front or rear
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P54-2B45-13
V2 Dlodomalnx
Fig. 218: Diode Matrix
The idle speed increase is switched offwhen drive stages P, R or N are engaged and when the coolant
temperature is > or = 11 0°C. The EA or CC/ISC control module is actuated by the appliances via a diode
matrix. The diode matrix prevents backflows to the other connected appliances if one or more appliances are
switched on.
CHARGE CURRENT
Engine speed Generator speed Charge current
550 rpm 1595 rpm 47A
650 rpm 1885 rpm 65A
2180 rpm 6300 rpm 120A
Data bus (CAN)
The following control modules are interconnected using the data bus (CAN = Controller Area Network)
• DI/KSS ignition control module (on engines with LH-SFI injection system only)
• ABS/ ASR control module
• EA, CC/ISC or ISC control module
• 5-speed automatic transrnission control module
• DM Diagnostic module (~ only)
• Injection system control module (LH-SFI or HFM-SFI)
The control modules are interconnected by two cables.
As a result, additional sensors as well as inputs and outputs can be dispensed with on the control module. Data
is constantly transferred in information blocks. If one control module transmits, the other control modules
rP.r.PivP :lnn v ir. P. vP r~:l ThP. r.nntrnl mnnn I P.~ nn lv rP.r.Pivt> thP rl:ltll w h ir.h thPv r P.n n ir P. Tmnnrt:lnt rJ;:¡t;:¡ MP
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transmitted as a priority (refer to data which are transmitted vía the serial data line). If a limp-home function
exists as a result of a fault indication, the function is retained by the data bus.
~N 113
N3011
N411
N16f1-
NSO
'N311
P07-5011-17
N1!3 Dt CMJOI modtlle
N3/1 lliSR coo~olme<hte
N:!l/1 EA ~-cn!rol mOIÍ'J11!·
N15/1 5-sp~ed atdom !ñc tmn:.m SSJOn e ordrol module
Nl0f1 A.BS.fASR con~olmod'ttcf!
N59 OM Dia;gnosticmodule (@ ooM
F ig. 219: Data Bus (CAN) System
Transmission data (CAN)
(shown on vehicle with LH-SFI injection system)

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01control mo-;',;;
{LH-Sfl injection s~lem onM
.~ rEA control module
j
l
tranl.s transLs
r -Englne
'•
j - - - ,• :•r----------~---------
_speed Sele<lor lwer posrtion
!o Load value lmhtlon 1• ! Sof~ty fucl shut-ofl
lo Heatlng CAT 1 :o Englne frietlon lor(JI~
!•: Tn~nsmlsslon overload
protectlon on
,
1 :•
! conlrcl (EBR)
ThrOIIIe valve actual valuc
:• AdVane~ ongle adj.Jstmert 1 1• Thtottle valve reqúremenl
lo Transmlsslon sv.tch on 2nd 1 ! (specifled value)
: ~ar 11• Speed :slgnal
lo 1 lo .-------..,
r
I!J!Iion fauJ In the CAT heatlng on
! respec!Ne 'Yfnder ¡ !• ldle speed
¡S.speed automa1ic 1
¡transmission eortrol •
Absollte pressure in ntake 1 Full tlrálle C>imodule 1'0---
1 1
! !
.!
1
'
'
1
1
'''
1
! 1
i
' 1
¡
: 1
! 1
¡ i!
i 1!
o ntake o full tlrcttle r-!> module
tnllrlfold o Crulse conlrol on
t Mitudc prenwe • Stop lamp swlch on
• Warm·up n operation • l nl¡>-hame mode
o Ma>dmJm speed
o forted closuee of throttJc
vawe
o En¡ine specffied Sl'Ced
o tdle speed econtoet switch
o ThrcttJe vtlve posl
___T ____ ----------r---------

10 to
1 1
Fig. 220: Transmission Data (CAN) System

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lo
1
to to
l
to
r-~--------------------b-,
1• ABS/ASR not in operation
r--------~---------T ___________ j ____________ ,
ilt lo~ 1njec1ion 1• Control m.odule detection 1
1• ASR functioning correct~ penod 1• CAT heating 1
1
1• Cruise control off 1• Short injection i• Air flow lmitation 1
• Open throttle valve slightly 1 period !• Exhaust gas recircUiation 1
1• Glose throttle valve 1 1• Air pump 1
l• Adva nce ang.l e a d]ustment '--------------- ----4, deceleration fu el shLt-off 1
1 n operation ¡•1 Camshaft ad]ustment
1
J
1 1• Transmission shift pont 1

1 1 retard 1
1
1 ¡, Acceleratíon enrichment i
1: Startíng complete 1
1 Purging 1
1 i• Coolant temperature 1
l•1 Air flow (air mass sensor)
¡• lntake air temperature
1• Oetection - camshaft
1 sensor
1
• Sta rte r operating
1
1
1
1
' ----------- ~------------

-----------,.-----------J
transmits transmits
ASR cont rol module LH-SFl or HFM·SFl contro l

module
I
Fig. 221: Transmission Data (CAN) System
r
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WIRING DIAGRAMS - RA300Al240580X(30-580)
Wiring diagrams - RA300A1240580X(30-580)
A. General
These repair instructions only include wiring diagrams for the models 124 and 201 up to 08/89 or model
year 89. Wiríng diagrams for models 129 and 140 as of09/89 or model year 90, refer to the file "Electric
wiring diagrams". A new cruise control amplifier with reference resistor is installed in the models
201.029/128.
On the other models it will be phased in.
The new cruise control amplifier has no influence on the cabling and therefore also not on the wiring
diagrams.
N4
N4 CIUISG ronlrol .a¡npliElf
~H.ü.llftttüb
1 -or 1
1 'o/ 1
L--- -- ·- ·- · -·J
1544 • 14~48
Fig. 222: Identifying Cruise Control Amplifier
R29
N4t2
R29
CIUISQ coolrolampUerv.~th referooce reSist~
Cnise coolrcl rofurllfl('6 re~islllr
N4~
r ~!
1 1
~#WJL•~
.H . lrl ~it~
1 {)
.1 't" l.
1
L.- ·- -·-·--·- ·- ·- ·- -·J

tM4·1112fr
Fig. 223: ldentifving Cruise Control Amplifier With Reference Resistor And Cruise Control
Reference Resistor
Wiring diagrams- RA30011240580X(30-580)

Mercedes-Benz
B. Model124 with automatic transmission
Models
124.020/0801120/ 180, 124.125/ 130 up to vehicle ident. end no. A 087383 (except ~)
124.133/ 193/333/393 up to approx. 08/88
b a
q,n_,,,..,., ________-+4
CI'IS lit
~ f 0.7Ssw/ rt- ws
1: • t i
i :.1 •tl 1\'IS-
~~tiC f.l ~ O.'IS•I
.,. <r d
cr "'a
W11 o. ,str- ---Hr-.4-

o.?Sg• ----H~•""
--- - f-f'.--..
0,7\
r-~7Silf :::=:>f O,?Ssw~J

-••
- 0.7Stw W '1 I -- - 0 , 7 S t>r
.,. ,... . O,?S i"'t•
86~
1 f.~ ""~ . \~ \1 ~ , ......
'"
L.::~::J
B6 t~aJ.effeet sp&ed se~!IOr W1 Ma•n ground (beñl nd ln:Mtument cltr$tet)

M1 6 e lUiSe control actu ator ){20 Connector, s1op lamp S\~lch
N4 CnJJse conllol ampldler XS315 Multipoint connectos. HaJ-effeet sensor
S9 Stop larrlp swllc h a On 'fu &e S teflnlnal 15
S40 b
S40 Crulse oonllol swllch b On N7 lamp m<>n~ toring dev.ce, hne>"Up 15
V DocaJeratQJS(~
B Aooeleratelset
se RestJJnB
A Off
Mercedes-Benz
Fig. 224: Automatic Transmission- Wiring Diagrams (1 Of 8)
Models 124.023/026/03 up to approx. end of08/85
b a
X33
-o.75w~ ~D75 w-' - e
n----------------------~~bl----------------------~(~4
,....-++-------0.1~ tw/tl-w,.----------------------IK•I...f
r-------Q~-------------------~[~~
. . - - - - - - - - - tl.1'.1., - -- - - - - - - - - 1f-OIIo-+
W1t-l---- 0,7hr - ----+-<•"'""'+q5bt

r - - - - - -- - -- - 0,75ge Q">ge-t--------'
.....--- - - - - - - - O,?lisw----H'-...~
1 '~""~ - ~"'''- _,,~,'-'""'~ ~A

r-u.lili1L~J!i1Uil!l!~
1 1
o,15br-.....aw
r = _O,'I'ibr - - ' 1
1
0,75 !J'I(.lo
1
W~l-l-,9--,g.-~::'"-~~~l
... t
! ~ ¡N4 X5315
1 _ ,_ _ j
--12MOI2
B6 Hal-effect speed sensor W1 Main ground {behlnd i'lstrument cluster)

M1 6 Crulse COiltrol aetuator X20 Connector. stop tamp S\Yitcn
N4 Crulse oontrol arrpliller X33 Connector. CIS.Eicrulse contrd (1pole)
Sil Stop lamp swrtch X5315 Mullipomt connector. Hal-effect sensor
S4() Crulse COilttol swrtch a On fuse S lelmJnal 15
V Decelerate/set b On N7 Jamp monttonng devlce, Jine-up 15
B Acx:eleratetset e On N3 control unlt tn]ectlon system llne-up 6
SB Resume
A Off
Models
124.021/23 as ofapprox. 09/85 RUF/CAT up to approx. 08/88,

Mercedes-Benz
124.026/03 as ofapprox. 09/85 RUF/CAT up to approx. 08/87,
124.043/083 RUF/CAT up to approx. 08/88, 124.090 and 124.2 RUF/CAT up to approx. 08/87
b a
4-t--- o.~r.•wl'r1..-lo -----+-------------f-.J

o---+0-
L ~
x 2o sg
...C:~· ~
0,75-lrt· ..
l ~1
0.7hwJn -.o o - - - - -- - -- .....:........c:~. _ _
j
Q X26
- 0.7!> -..5
~ 0.15 w• - -- - e
~nbt
; ~l~swln--ws
t: S. f
~ i.l ¡;, 5. ¡ (I"IS-
~~~
<:r a <' ~~~ 0,:1!>••
W1 1 o,7':1t..-----Hc.;....+
o;r.;oe - - - - H: --J
0,75 o w - - --1-C•'"-1
0,7S sw~
l-"'
,. - -. 4±D
a
O, 75 t" :==:::::::>~ W
~07~~ ,
W 1 1
1--- - O,l5l><'-
''"'~
o,niJ'III•
1 ~ ·~ ~· ~~~ ·-~~..¡ ·~ - ~~ :- ~ ~
~X 53~ B6!L§UI
L::.____::J
B6 i'iaJ.e tle<:t speed s&nsor W1 Ma•n ground (behlnd lnstrument cluslftr)

M16 CruJse oontrol adualot X20 Comedor, stop lamp swllch
N4 CruJse oonttol ar'!llliflcr X26 Comcctor lnt&rlor/ergi ne, 12· pole
S9 Stop lamp switch X53/5 Multlpojnt connec1or, tial -effe<:t sensor
S40 Crul$e oonttot swílch a On fusa 5 lruminal 15
V Deceleratetset b On N7lamp monltoong cleviee, l~p 15
B Acoeteral@/sel e On N3 oonliol UJll t lnjectbn system llne- up 6
SB Resume
A Off
Fig. 226: Automatic Transmission - Wiring Diagrams (3 Of 8)
Models
124.021/023/043/083 RUF/CAT as ofapprox. 09/88, 124.026/03/09 and 124.2 RUF/CAT as ofapprox. 09/87,
Mercedes-Benz
124.128/ 133/ 193/333/393 as of approx. 09/88 up to 08/89
r· ;.::.-
. r- - '_,-~ '1~-
L 1
1
S40
b
r-------+-----o·:;15•""'"-"'-
L
e
'§"""""'-"• --------+Cl--~rt:-t...
- - - ----+--'
-:~ S9
''1
J 1
"' '' o'n '-----o.~·""""• ·--------~~<-t::!!:...___Jj
I r ~
~~-~T~f.~9~~~i~~==ll'_~~---_-_------------------------~
~~M----------~~~:
~:a~q$~ 1---M-~__6_
. _,
rlt-------- ~Xawlri -w• -· Q.59 " - i - - - - - .
.-------~~-----------.w_.L""7"'*CI""' .• nJ
....¡ ::S tt-~ ~ ~!!
r------------ c,?Sw-----+4::~~:-+qs.,- ~~
r-+-- -- - - - -- --O,l!iJIO
r+-- - -- -- - - - -D,15ow ~
~
14$-it:::====
(l'ó¡¡o-f--~
·- -
a ---o.?S.,...M ·., - - ---.
W11-l- - o:IS~• ----,
r------0~~~-----~~~~~
R29 X53f5
"9- • N4/2
I U S-Utlll
B6 Hal-4tffeet speed sensor W1 Maln ground (behlnd lnstt ument cluster)

M16 Crulse ooottol aduator X20 Coonector. Slop lamp switch
N4!2 CruJse oonitol aJll)l~ler wlth referen<:e rescstor X5315 Multipomt ooone<:tor, HaJ-effect sensor
R21l Crulse oonttol refetence msiSlor a On fu~ 5 tennlnal 15
sg stop lamp swlch b On N7 lamp mon1tonng devJOe, hOfMJp 15
S40 Crulse ooolfol swdch
V Deeeleratefs«
B Aooelcrate/set
SB Resume
A Off
Models 124.026/030 ~ 1986,

Mercedes-Benz
b o
X20 S9
_j
f:"lX26
r---0,>'5 w~ --"'1~
.."- -o,, ,.,. _____ c
rt-------------~~·1----------------+--~~~
r-t-1------- o.~ ...,, -.. ,---------+--+C,.~
W l lt --- -- - 0,75---+----it-e:•-+
.-------------------o.?'JO~---t--Ht'--t
~------------------- ~~ ·~---+--~~+ ~~::::::::::~J
B6 HaJ..e ffect $poed sen~ W1 Main ground (behlnd n W\Jrn!lfll elu!ltat)

M1 6 Crulse control aduator X20 Comeetor, stc>p lamp switch
N4 Crulse control a~iller X26 Comeetor nterlor/e~lne, 12- pole
59 Stop lamp swrteh X53/5 Multlpo1nt oonnector, Hal -effect sen$()(
$40 Crulse eontrol sw <tch a On fustt S tt!llllmaJ 15
V DeceJerale/sfll b On N7 lamp mooltonng devJCe, hn8-<.1p 15
B Acceleratef&et e On N3 control unl t in]eetion system lifl&.up 6
SS Resume
A Off
Models 124.026/030/050/090 ~as of 1988

Mercedes-Benz
L
....---· - . , b a
'j~,i~S40 x~o s
~• -... I1
.¡ r -- - -- - ; - - -...o:r>IWh'I•YI .'l'S$wlrl-..l-===:¡===tr;~
. ~ ..,.- ..___
. r,!E9
... 1
'-----075swlrt-ws --+----~'(..ol-~-'·
111 n
, !1!'
~~
~.-+-·
'~ ~li--1~~ ~~~.......
~ ~1 1
lrfff~~:d____ ~" bl ---------f-l¡...::(•:~
[A:" Q5bl l M1~ l
,......,f-------0..7~aw/rt-wo ~
1 QSe• +-----.J .
......!.~qs-
,----- - -Q"WJ- ---------+-+o • _..... n 1
'ISvl 1-i ~ · :~ Q5rt- ~
r------ - - - -0.7Sbr---t-...¡..ti)li-+q5111-! ~ !!
rt---~------- O,l~sw
O, 'lSqcr--' 1 jJ _¿;:¡:
1-.r--
Q!lc¡p
QS...., 1
...__ _ __
1
- 0,7S swln•\'l - - - - .
W1f o.7~tw ---...,
.-----0.:1'5~~-----KK-ffi.;
R 29 X53/5
~~ 1 ~ ~~ 1
! o - + !
86U: ~ ll
B6 HalH!ffect speed senliOJ' W1 Mail ground (behlnd 11strumert c\Jster)
M16 Cruose oontfol actuator X20 Connector. stop IM'Ip s~tch
N4f2 Crulse oonltol amplifler with refereooe resistor X26 Coonector lnt&rior/engine, 12-pole
R29 CruJse control reference reslstor X53/S MuJIJI)Oinl connector, Hal-effect sensor
S9 Stop lamp swdch a 01\J fuse 5 lermlnal15
S40 Cruise control swltch b Qn, N7 lamp monlloring device, llne-up 1S
V Déeeleratelset e Qn¡ N3 control unlt mjecuon sy!item line-tJp 6
B Aocelemlelsel
SB Resume
A Off
Fig. 229: Automatic Transmission- Wiring Diagrams {6 Of 8)
Models 124.125/130 as ofvehicle ident end no. A 187384 and models 124.185/190/330
Mercedes-Benz
O,'IS bl
~ i 0,1Ssw l.n -w~
e~ .!.
-
i ¡¡
ea g, ¡ ~15 ...
~S§ ~§~ 0,1\VI
W11 o,nt..- ----H(.-+

0,75g• ---~(.......
O,?Ss w----+-tl~-.¡.
a 0.7Sow~t-
•l
D,7St>r - - - l W1
W11-I--- 0.7Sbr
1 ,!\ .. ~~ •!\·~·~
··~ ~'-"""' 1
o.n ¡rolgt
. - - - - 1gnJ9* ffif*,
86¡
X5315
L.::._ .:J
B6 HaJ.effect s.peed sensor W1 MaJ11 ground (behind lnstrumert clu'Sie!)
M16 CrtJISe control actuator .)(20 Conooc tor, siop tamp switch
N4 CruiSe control ampllfier XS315 Mulllpolnt connector, Hal -effect sensor
S9 Stop lamp swtch a On fuse S termlnal1S
54() CruiSe control swrtch b On N7 lamp morit<Ning devlCe, hn<t-Up 15
V Decelemte/set
B Aocl!lemte/set
SB Resutne
A Off
Fig. 230: Automatic Transmission - Wiring Diagrams (7 Of 8)
Models124.1 33/193 ~ 1987

Mercedes-Benz
¡ ·----;.:..._-·-.
Wlf.T\Is40 b a
~ ttlr r
..r (\'11111
- ~:•
.:=""' i
lS t. .. e. :§. ¡
O.?!i•w lrt
cps..,.
·w•
----+--+-C:~-fCISws+.......f-N--'
~~§ ~§& O.Tho - - - - t - - 4 - (...~QSII
W1J o;r~ tor--1¡--f...(,'-'+

0,'15~---11--t-<•-t
0,7'>ow --+-+"(•--t
-Q15bo 7lw1
l r 0)517
0,75 Cllllg.
1 ~~·~~ -:~~:-·~ ~:y.:~~~-: •.'.~·:--~ - ~ 1
· .~
X5315
aei
L.:: . _.~
86 Hakffed speitd sen~ W1 Ma.n groond (behlnd n stnJment cluster)

M16 Cnu~;e OOl'l\101 aetuatOf X20 ComectOf, stop lamp swlioh
N4 CtuJSe OOl'l\101 arrpliller X53/S Multlpolnt connector, HaJ -effect sensor
S9 Stop 1amp swrtch a On fuse 5 tetmlnal 15
S40 CruJse control $ W tdl b On N7 tamp monitoring devloe. 111\e-up 15
V OeceJemteJset
B Aa:elerate/sel
SB Resume
A Off
BELL CRANK OF RIGHT-HAND STEERING/LEFT-HAND STEERING STANDARDIZED-
BT30.10-P-0001-01A
ENGINE 119.974 ##as of001451 as of1.7.91, 119.971 ##as of001504 as of1.7.91, 119.970 ##as of
00~.:1~.:1 !lC: nf 1 7 Ql
Mercedes-Benz

E ngine LBS Transmission Engine E ngine Prod. Prod. Nature and Reference/Remar ks
11 9.974 001 45 1 01.07.9 1
119.97 1 001 504 01.07.91
11 9.970 003484 01.07 .9 1
Since 07/91 the bell cranks (8) of right-hand steering/left-hand steering have been standardized.
A l'rcllious vcrslon B
8 F'rc.sc.nt t~cr.sion
Fig. 232: Identifying Previous Version And Present Version
RETURN SPRING BETWEEN F ULCRUM LE VER AND ACCELERATOR CONTROL LEVER

MODIFIED - BT30.10-P-0002-01A
E NGINE 119.975 ## as of 005900 as of 1.8.91,
119.971 ## as of 011673 as of 1.8.91,
119.970 ## as of 025738 as of 1.8.91

Engine LBS Transmission Engine Engine Prod. Prod. Nature and Reference/Remarks
11 9.975 005900 01.08 .9 1
11 9.97 1 011673 01.08.91
11 9.970 025738 01.08.9 1
Since 08/91 the diameter for the retum spring between fulcrum 1ever and accelerator controllever has been
modified.
ANTI-TWIST LOCK OF WOT STOP ENLARGED- BT30.10-P-0003-01A
Models 124, 129, 202
ENGINE 104.941/942/943/944/991/992/994. 111.92#/940/941/944/960/961/975 #O as of 1.7.95

Mercedes-Benz
Anti-twist lock 1.5 mm enlarged in order to prevent it being incorrectly installed in the motmting bowl at the car
en d.

MB 129 Eng

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Mercedes-Benz

1990-2002 HVAC Air Compressor, Belt Orives- 129 Chassis

Air Compressor, Belt Orives - 129 Chassis

TESTING & REPAIR

Remove!install generator ENGINE 104, 111, 112, AR13.22-P-5700EA

Remove/install poly-V-belt ENGINE 112, 113 ... AR13 .25-P-3200R

Remove/install generator ENGINE 104, 111 , 112, AR13.22-P-5700EA

REMOVING AND INSTALLING POLY V-BELT- AR13.22-P-1202

Removing and installing poly V-belt- AR13.22-P-1202AO

ENGINE 120 in MODEL 129, 140

Fig. 1: Locating Poly V-Belt

Remove, instaD poly V-belt- AR13.22-P-1202B

ENGINE 112.945 in MODEL 463.232 /233 /244 /209 /245 /250

ENGINE 112 in MODEL 129, 163

ENGINE 113.982 in MODEL 463.246/243

Shown on engine 112

Fig. 2: ldentifying Poly V-Belt Remove/lnstall Components- Shown On Engine 112

tensioning device for

Fig. 3: l dentifying Externa! Torx Set (001 589 76 09 00)

POLY V-BELT RUNNING DIAGRAM- AR13.22-P-3902

Poly V-belt running diagram - AR13.22-P-3902-02AO

Running diagram with air pump

Poly V-belt 1ength 2585 mm 8 grooves, as of 04/1996 6 grooves

1 Tonsionlng pu/lcy {Without groovets)

Fig. 4: Polv V-Belt Running Diagram

Running diagram with 2nd generator in place of air pump

Poly V-belt length 2523 mm 8 grooves, as of04/ 1996 6 grooves

1 Trmslonlng pulloy {WithoutgroovcsJ

Fig. 5: Polv V-Belt Running Diagram

Running diagram of]Joly V-belt- AR13.22-P-3902-02B

6-groove single-belt drive, without AC compressor

6-groove single-belt drive, with AC compressor

REMOVE/INSTALL POLY-V BELT TENSIONING DEVICE- AR13.25-P-3200B

ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250

ENGINE 112 in MODEL 129, 163, 211.061 /261 /065/265

ENGINE 113.982 in MODEL 463.243/246

Shown on engine 112

• Oanaer! Belt tensiOnmg d ev1ce

OlM belt tensíoner to tapped 1

· Dangorl Bel t tenswmng d ev1ce

~GF Tum the ignition key briefly into position 3.

3. Check poly-V-belt (27) for signs of damage.

Fig. 9: Locating Mark On Poly-V-Belt

REPAIR & ADJUSTMENTS

Viscous fan clutch removed (20-3120).

1st version witb externa! damper

A E lfls\elootger (13) auf Madclerung 11) = Kodnppemomen U!lgespamt

Bolt ( 16) slacken approx. 1/4 - 1/2 turns.

lsecuring bolt of tensioning de vice 75

000 589 1 o99 01

Fig. 11: ldentifving Special Tool (000 589 10 99 01)

Fan shroud removed (20-3400)

Viscous fan clutch removed (20-3120) .

13-1 202 - 13-400 1

2nd version witb internal damper as of September 1994

Fig. 13: Identifying Service Label

Use oftensioning device with .internal damper (2nd version)

104.941 lO 004 059

104.941 12 034 967

104.942 10 005 790

104.942 12 048 697

104.943 10 000 901

104.943 12 003 621