intake and exhaust, manifolds, emission control system 14 - … info/servizna... · 2014. 5....

Intake and exhaust, manifolds, emission control system 14

14 Intake and exhaust manifolds, emission control system

Job No.

Recognition features In vehicles in national version (USA) ................. ....... 14 - 001Function of emlsslon control system ................................ ....... 14-050Testing heated oxygen sensor malfunction indicator lamp ................. ........ - 116Removal and Installation of catalytic converter ......................... ........ - 200Removal and lrSstallation of intake manifold and replacing gasket ............ ........ - 450Replacement of preheating flange .................................. ........ - 452Replacement of Intake manifold ................................... ........ - 455Testing panlal Intake manrfold heating (PMP) .......................... ........ - 456Removal and Installation of intake manifold bottom section, replacing gasket .... ........ - 460Removal and lnstallatlon of exhaust manifold .......................... ........ - 470Testing exhaust gas recirculation (EGR) (USA) 1991 .................... ........ - 475General InstructIons for vehicles with catalytic converter (KAT) ............. ........ - 487Disposing of catalytic converters ................................... . . . . . . . . - 489

14 1

14-001 Recognition features of vehicles in national version USA

Information plate for emissions control system oncross member in front of radiator. This plate liststhe engine code data as well as the principalengine setting data.

The engine code data are given in a lo-position code.

Example: H MB 2.3 V 6 F A 13 H MB

Model yearH=1986 J=1987etc.

Manufacturer codeMercedes-Benz

Displacement2298 cm3

2.3 V 6 F A 13

Vehicle classV = car with gasoline engine

Type of fuel supply6 = mechanical injection

Catalytic converter versionF = 3-way catalytic converter incombination with lambda control

At manufacturer’s disposalA = Federal and California

Check digit

Tourist version IVehicles in tourist version are equipped with afactory installed catalytic converter as ofapproximately 05 88.

Color code of information plate:Background color red. lettering silver.

Vehicles must be equipped with catalyticconverters for Importation into the USA.

THIS YEHlCLf COHFCMS TO U S f P b,A&ULAlIOYS APPLICABLE 101981 MOOEL YEARSEW HOTOR EHICLES

P14-0038-13

1

1 4 . 0 9 2 4 - 0 0 1 . 2

14-050 Function of emission control system

A. National version @ with catalytic converter

a) Generalb) Function dlagramsc) CFI control moduled) Lambda controle) Oxygen sensor9 Catalytic converters

a) General

The function of the emissions control system forthe basic and national versions is described inthe sections below (b to f). Specific nationalvariations are listed in the respective section.The vehicle features are listed in the Op. No.07.3-004 .

Notel Vehicles with engines in Standard version

can be converted to open-loop catalyticconverter (Op No. 14480). An exception tothis are vehicles with engine 102.983Standard.

l Vehicles in the basic version ROF can beconverted to KAT (closed-loop). Seeinstallation instructions for optionalequipment for conversion measures.

Model 201 Volume 2 Group 14

l In the case of vehicles in the basic versionKAT with engines 102.96198 as of 09/89,RUF mode is no longer possible.

b) Function diagrams

Engines 102 962 NV KAT RUF 09/83-09;85@engine 11)2.961 (2.3) @ 1985;86 engine 102.985

52

N3

158

1 MIX: .‘b2 :.:.1:131 LJmt

2 60 :C, m-r- 31 %:alve (white)3 Ch!‘::f I+ ,w,e AJ th integrated restnctor12 Irlldii? ‘11.1 fc c15 Futc .1 str tx.tcr50 Fuel -ar k51 Ver-: :a3 I.‘+:52 Ch i”:oal ~:a1 Ser53 Retjcw-a:lon valve79 50-C tie*rrovalve (red)156 ExP;lJst -nanWd156 Ufl~~+x~ :a:alyW converterBll!3 Conl,~~ !errze’atLre sensorG3/2 He,ilza o.xv;el sensorG3/2xl Ox, ;-i‘ -oa:i’1g ml plug connecttonG3l2x2 Ox:, ~;di‘ Z’lSZr signal plug connection

N3S5/2S27f2s29/1w5WlOYlabmt

CFI control moduleOlstnbutor (breakerless)Deceleration fuel shutoff mlcroswltchFull load detectlon throttle valve switchEngine groundBattery groundElectrohydraullc actuatorAir admIssIon line (engine compartment)Fuel pump relay, contact 2Idle speed air valve, contact 2Fuel pump relay, contact 7, terminal 87

14.0924-050 2

Engine 102.985 @ 1991

14055577 576777879899294

158Ale2682B6B1 l/2

B17/1821

G3/2K3/1

Mrxture control unrtDraphragm pressure regulatorFuel filterFuel accumulatorFuel tankVent valveCharcoal canrsterRegeneratron valve70°C thermovalveExhaust gas recrrculatron valveInjectton valveDeceleratron valve (only with manualtransmrssron)Underflcer catalytic converterCHECK ENGINE malfunctron Indicator lampArr flow sensor potentiometerHall-effect speed sensorEngme coolant temperature sensor (DIICFII:! E-E),4-pmIntake arr temperature sensorExhaust gas recrrculatron (EGR) temperaturesensor (Californra only)Heated oxygen sensorIntake air preheatmg (PMPI relay

K29L5M3N1/2N3N6N16/3R812R16llS25/13S27’2S29l2TlYlY5/1

Y6Y8

Transmrssron shaft pomt retard relayCrankshaft position sensorFuel pumpIgnition control moduleCFI qectron system control moduleCompressor shutoff control moduleFuel pump relay moduleintake manrfold preheating (PMP)Reference resistor60°C temperature switch (PMP)Deceleratron fuel shutoff microswrtchFull load/idle speed detection throttle valve switchIgnrbon co11Electrohydraulrc actuatorAir conditioning compressor electromagneticclutchIdle speed arr valveStart valve

C Arr admrssron

14.0924-050:3

c) CFI control module (N3)

The CFI control module is installed on the rightof the component compartment behind thebattery.

Caution!When ignition IS on or when the engine isrunning, do not detach coupling at CFI controlmodule as the CFI control module may bedamaged by voltage or current peaks.

N3 CFI control moduleR 17 Reference resistor

NoteSurvey of CFI control modules, see 07.3-250and 07.3-003.

CFI control module versionWhen the igrlltlon IS switched on, a certaincurrent exists at the electrohydraulic actuatorand a certain on off ratio is output at the lambdatest output (see 07.3-i 21). The CFI controlmodule has two Iqection programs (with/withoutlambda controls. The respective program isactivated by the resistance trimming plug. For@ reference resistors are installed . For @1988 and 199 1 the reference resistor isintegrated in the CFI control module.

Version 1 Injection program 1 Resistance trimming plug

KfIT 1 With lambda control IKATI I

14.0924+?504

CFI control module KAT/RoF version withdiagnosis by measuring on/off ratioThe CFI control module detects faulty inputsignals and passes a fault message to thelambda test output. The fault message can beread at the diagnostic connector with the lambdatester. The faults detected are short circuit andopen circuit.

A certain on/off ratio is assigned to each fault.The output of fault messages has priority overoutput of the lambda control signal. If the lambdacontrol is not operational (e.g. heated oxygensensor temperature too low), the readout is 50%(control mode/constant readout). If the lambda isswitched on, the readout fluctuates around amean value. If several faults occur simul-taneously, the fault which corresponds to thelowest on/off ratio is always displayed. Thiscontinues until all the faults have been rectified.An assignment of on/off ratio and possible causeof fault is summarized in the respective testprogram (07.3-l 21).

Plausibility circuitryThe signals which the peripheral componentsfeed into the CFI control module arecontinuously monitored. If the composition of thesignals is not longer logical, the electroniccontrol automatically forms a substitute value(emergency running property) for the implausiblesignal.

14.0924450/5

CFI control module KAT version with faultdlagnosls by measuring on/off ratio and faultstorageThe injection program for the RijF mode is nolonger provided In the CFI control module.

Two possibilities exist in the CFI control unit fordetecting and outputting faults which occur in thesystem.

The fault tables with the listing of the individualfaults are described in the test program07.3-121, Section “E” and “F” respectively.

On/off ratio with engine runningThe faults whrch exist at that moment and aredetected are displayed by measuring the on/offratio. The faults are not stored and can only bedisplayed immediately by measuring the on/offratio at the diagnosis socket (Xl 1).

Diagnostic trouble code (DTC) memoryFaults which occur and are detected whendriving are stored In the CFI control module andcan be output at the diagnostic connector(Xl l/4) with the impulse counter scan tool.

The battery must not be disconnected in themeantime, otherwise the stored DTCs areerased. Loose contacts are also recognized ascodes and stored. The CFI control modulecannot be replaced by other versions.

Note @ 1988/l 991 CaliforniaOn Board diagnosis system (see 07.3-121,Section “F”).

14.092445Oi6

d) Lambda control

The CFI control module performs the followingfunctions: monitoring heated oxygen sensor,signal amplification and calculation from the inputsignals the output signal for the electrohydraulicactuator. The current level with lambda controlfluctuates between approx. -10 to + 10 mA.

The lambda control is not operative during thefollowing operating conditions, i.e. control mode:

l heated oxygen sensor not operational ordefective

l deceleration with decel fuel shutoff0 wide open throttle operation0 acceleration enrichmenta starting at below + 15 “C up to approx.

+ 40°C - 70°C engine coolant temperature(depending on version).

e) Heated oxygen sensor (G3M)

The heated oxygen sensor is installed in thefront exhaust pipe or in the exhaust manifold(engine 102.96/98 as of 09/89). The oxygensensor is heated in order to create a constantoperating temperature. The heating element ofthe oxygen sensor is energized via terminal 87of the fuel pump relay module and is heated solong as the fuel pump is running.

Arrangement in front exhaust pipe I / p,.-2117 - 13

14.092445oi7

Note: fuel pump relay module as of 01190Fuel pump and kick-down shutoff relay (N16/4)with additional connector for oxygen sensorheater. Oxygen sensor (G3/2) is heated onlyfrom +2O”C engine coolant temperature(07.3-165).

Arrangement in exhaust manifold

The outer electrode IS exposed to the exhaustemissions, the inner electrode is exposed toatmosphere. The active part of the heatedoxygen sensor IS a ceramic body which consistsprimarily of zlrconlum dioxide. It is coated on thesurface with a gas-permeable platinum layer, aswell as with an addltional protective layer on theexhaust side.

1 Sensor houslng2 Protective tube slot3 Heating element4 Sensor ceramic

At operating temperature the ceramic materialconducts the oxygen ions. The different oxygenportion between exhaust gas and atmosphereproduces a voltage in the heated oxygen sensor.

At operating temperature (~300 “C) the oxygensensor supplies a voltage signal to the controlmodule.Voltage >450 mV rich mixtureVoltage <450 mV lean mixture

14 0924-05018

As a result of the rapid voltage jump with lambda(A) = 1, the exhaust composition can be rapidlymonitored and the fuel/air mixture correctedwithin a narrow control range.

A Rich fuel/air mixtureI3 Lean fuel/air mixture

e) Catalytic converters

I

The Sway catalytic converters are installed inthe exhaust system upstream of the mufflers.The following versions are installed:

Up to 08189Pre- and underfloor catalytic converter.

As of 09189 underfloor catalytic converter (pre-catalytic converters no longer installed).

Underfloor catalytic converter

Pre-catalytic converter

14.0924-050/9

The catalytic con\/erters consist primarily ofthree main parts:Carrier material of high-strength ceramic or hightemperature-resistant stainless steel, also knownas the monolith (ceramic flexibly mounted onwire mesh). Intermediate layer for enlarging thesurface. Catalytically active layer ofplatinumkhodlum.

1 Fabric2 Wire mesh3 Monolith

FunctionThe exhaust gases flow through the catalyticconverter and come into contact with the noblemetals. Oxidatton converts carbon monoxide(CO) into carbon dioxide (CO4 and hydro-carbons (HC) Into water (H20) and reductionconverts the oxldes of nitrogen (NO,) intonitrogen (Nz). The cntical factors for this processare the temperature and the residual oxygencontent in the exhaust gas. The catalyticprocess, i.e. the chemical reaction, commencesfrom approx. 25O’C. Excessively hightemperatures result in thermal overload.

Oxygen is requtred for the oxidation of CO andHC. The reduction of the oxides of nitrogenoccurs in an oxygen-deficient atmosphere.

The fluctuation between oxygen-low and oxygen-rich exhaust gas IS achieved by altering thefuel/air mixture. The ratio of the fuel/air mixture isdesignated wtth lambda (A), in which A< 1indicates a rich mixture, A > 1 a lean mixture.

A Rich fuel/air mixtureB Lean fueVair mwdure

14 0924-050/l 0

.~.___5.~.~~.

The fluctuation of the oxygen portion of theexhaust gas is controlled by the oxygen sensor.The three exhaust elements stated can only bechemically converted in the catalytic converterby means of these oxygen fluctuations.

Vehicles fitted with the catalytic converter andoxygen sensor must only be operated withunleaded fuel. Lead additives in the fuel aredeposited on the chemically reacting surface ofthe catalyst and the oxygen sensor, renderingthe system ineffective.

B. National version @ with exhaust gas recirculation

a) Generalb) Function diagrams

l Engine 102.9610*US 19&t/85

l Engine 102.96@ 1984-1986@ 1984-1987

l Engine 102.9820a 198!386@ 1985-1987

c) Function of exhaust gas recirculationd) Function of componentsh) @ 1991

14.0924-050/11

a) General

Exhaust gas reclrculatlon (EGR) reduces theoxides of nitrogen (NOx).

Fuel evaporation control system @ reduces theemission of fuel vapors to atmosphere (47-200).

Exhaust gas recirculationPart of the exhaust gases is returned through theexhaust gas recirculation valve to the intakemanifold during certain engine operating states inorder to reduce the oxides of nitrogen in theexhaust gas.

The low-oxygen exhaust gases are mixed in theintake manifold with the fresh, oxygen-richmixture. The portion of fresh mixture is reducedas a consequence and less oxygen is thusavailable in the combustion process. Thequantity of recirculated exhaust gases isdepende_nt on the throttle position and on theengine coolant temperature. The drivingcharacteristics of the vehicles are not influencedby exhaust gas recirculation.

@ 1991 engtne 102.985: testing exhaust gasrecirculation, see 14-475.

14.0924+50112

c) Function of exhaust gas recirculation (EGR)

The exhaust gases are recirculated at an enginecoolant temperature above approx. 40°C andwith the throttle contacting the closed throttleposition stop or wide open throttle stop.

When the throttle is contacting the closedthrottle or wide open throttle position stop, thecontrol module (N37) switches voltage to theswitchover valve (Y27). The signal for this ispassed to the control module (N37) by theWOTCTP switch (S2912).

The switchover valve (Y27) switches over andadmits air to the EGR valve (60, connection A),which causes the latter to close.

If the throttle is moved into a position betweenclosed and wide open throttle, the signal fromthe WOTCTP (S29/2) to the control module(N37) is switched off. This interrupts the voltagesupplied to the switchover valve (Y27).

14.0924-050113

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._............................................

As a result, the swltchover valve (Y27) switchesintake manifold vacuum to the EGR valve (60,connection A). At the same time, more or lessair is admitted through the vacuum control valve(73) to the EGR valve (60, connection B),depending on the throttle position. The EGRvalve (60) opens partially or fully.

d\ Function of comDonents

Exhaust gas recirculation valve (60)Atmospheric pressure which is admitted througha orifice (arrow) constantly acts via the shutoffdiaphragm (1 j in the diaphragm chamber.

1 Srl~toff diaphragm2 PC? zlaphragm3 Wcrk r-3 diaphragmA C~ITX:IO~ (red), to switchover valve0 Cc,llec:lon (brown), to switchover valve

If intake manifold vacuum is acting throughconnection A (red) in the diaphragm chamberbelow the shutoff diaphragm (l), the latter ispressed down against the spring force. The EGRvalve opens If air is admitted at the same time tothe diaphragm chamber through the workingdiaphragm (3 ).

PO7-0320.15

Noteinner diameter of gasket for exhaust gasrecirculation valve at exhaust manifold enlargedas a result of modification of shape.

A Previous versionB Present version

A B

’ 0 a?_.,,Vacuum control valve (73)When the engine is at idle, the vacuum controlvalve reduces the intake manifold vacuum to aconstant level. If the throttle is opened, the camdisk (2) is moved in the direction of the arrow.The reduced vacuum at connection (6) is furtherreduced, as a result of which the EGR valveopens.

12345676A0

CFlF2F3

HousingCam diskLeverSpring retainerSleeveSealing dtsksDiaphragmTubeIntake manifold connectionDamper connection, exhaust gasrecirculation valveAir guide housing COnneCtIOnConical springPre-tensioning springCompression spring

I A 6

-Fl

Vacuum damper (9) with restrictorThis prevents the EGR valve opening or closingsuddenly. A restrictor is fitted in the connection

(gn).

14.0924-050115

Wide open throttle/closed throttle positionswitch (WOTICTP) (S2W2)It switches the control signal for switching off theEGR when the throttle is in the closed throttleand wide open throttle position.

X56 T-irotfle body switch plug connectionijr = gveen‘,‘JS = wllte

40°C thermovalve (36a, color code black)It opens from a coolant temperature of approx40°C and then allows the intake manifoldvacuum to pass.

1 B~f~~etal plate: 0-rf-CJA :o crleck valve0 :o In:ake manifold

Switchover valve (Y27)Fitted to the bulkhead in the enginecompartment. The swttchover valve is energizedwhen the throttle valve is in the idle and fullthrottle position and switches over toatmospheric air admission.

Check valve (44)It prevents the Intake manifold vacuum at theexhaust gas recirculation valve dropping as thethrottle valve increasingly opens further.

Cylindrical or stepped version possible.

A = V dcuum inlet

bl WS SW bl SW

14.0924-05Oi16

Control module (N37)It switches through or switches off the voltagefzr Ye switchover valve depending on thecontrol signal from the throttle valve switch.

Model 124

h) @ 1991 engine 102.985

Function4217879

80

818994123

diagram of exhaust gas recirculationIntake manrfoldExhaust gas recrrculation linePurge valve for fuel evaporatron control systemThermovalve for fuel evaporatron control system,opens at 70°C closes at 35°CThermovalve for exhaust gas recrrculatron, opensat 70% closes at 60°CAutomatrc transmrssionExhaust gas recrrculatton valveTime-delay valve (manual transmissron only)Throttle body assembly

NlI2230 0

158

156 Exhaust manrfold158 Purge linea Purge Ime to charcoal canister821 Exhaust gas recrrculatron temperature sensorN1/2 ignitron control module

Lrne color codebr brownSW blackw s whrteVI vrolet

14.0924-050’17

NoteTesting exhaust gas recirculation, see 14-475.

The vacuum which exists at the exhaust gasrecirculation valve (89) differs according to thethrottle position.With the thermovalve (80) open, the vacuumcontrols the exhaust gas recirculation valve (89),as a result of which the exhaust gas recirculationvalve opens pamally or fully and exhaust gasesare thus passed through the exhaust gas recircu-lation line (21) into the intake manifold (4).

The time-delay valve (94) on vehicles withmanual transmlsslon prevents the exhaust gasrecirculation valve (89) opening too rapidly.

Exhaust gas recirculation is performedl in partial ioad mode:

a) with rlslrig engine coolant temperatureabove + 70’ C

b) with dropping engine coolanttemperature up to +6O”C

No exhaust gas recirculation is performeda when idling and at wide open throttle0 at engine coolant temperature below + 60°C

Exhaust gas recirculation temperaturesensor (821), California onlyInstalled in the exhaust gas recirculation only.Tightening torque 23-28 Nm. The temperature ofthe recirculated exhaust gases is registered bythe temperature sensor. See diagram forresistances.

14.0924450118

If the exhaust temperature drops below approx.120°C during operation, no exhaust gasrecirculation is performed. This is detected as afault by the CFI control module and stored.In addition, the CHECK ENGINE malfunctionindicator lamp lights up(see 07.3-121, Section F).

DiagramExhaust gas temperature resistanceat exhaust gas recirculation temperature sensor

14.0924450/19

14-116 Testing heated oxygen sensor malfunction indicator lamp @

Al Instrument clusterAle10 Heated oxygen sensor malfunction indicator lampAle26 CHECK ENGINE malfunction lndlcator lampKl,l Overvoltage protectlon relay

Oxygen sensor change malfunction indicatorlamp, model 201.024, model year 1984/85Legislation prescribes that the oxygen sensormust be replaced once after 30 000 miles or, inthe case of Canada vehicles, after 50 000 km.This is indicated by an “02 sensor” malfunctionindicator lamp (AlelO) in the instrument cluster(Al) lighting up.

Description of functionThe odometer of the speedometer produces avoltage via a magnetic field when 30 000 milesor 50 000 km, respectively, is reached. Thedownstream electronics detects this voltage andswitches on the malfunction indicator lamp in theinstrument cluster.

N3a

CFI control moduleTo CFI control module (N3)contact 1

After the heated oxygen sensor has beenreplaced, the malfunction indication deviceshould be deactivated by removing the bulb.Partially remove instrument cluster and install forthis purpose.

14.0924-l 16.1

Heated oxygen sensor malfunction indicatorlamp, model years 1986, 1967, 1968 and 1991Federal versionA failure of the oxygen sensor is indicated by the“02 sensor” malfunction indicator lamp (Al) inthe instrument cluster (AlelO) lighting up (1988and 1991 Federal: Inscription: “CHECKENGINE” (Ale26).The malfunction indicator lamp is actuated by theCFI control module, contact 15 (1991 Federal :CFI control module, contact 23).

“CHECK ENGINE” malfunction indicatorlamp Model year 1988,1991 California versionThe “CHECK ENGINE” malfunction indicatorlamp (Ale26) lights up if an exhaust componentfails (On Board Diagnostic System, see 07.3-121, Section F). The malfunction indicator lampis actuated by the CFI control module, contact23.

Test condition0 Battery voltage 11-14 V

Wiring diagrams (07.3-l 28).

Key to symbols

[_I Multimeter--c Contact

7ConnectorGround

q Multimeter direct voltage measuringmode

q Multimeter resistance measuringmode

14.0924-l 1612

Test step/Test scope

1.0Test malfunctionindicator lamp(AlelO)(Al e26)

2.0Voltage supply ofmalfunctionindicator lamp

A.I 986:87x38Federal

B.1988 California1991

3.0CFI controlmodule (N3)cable tomalfunctionindicator lamp

A.I 986/87/88Federal

B.1988 California1991

Tester/Test connection

Visual inspection

Ale10Ale26 cableNge * _L

Ale26 cablert/bl -=@- _I _k’ge) ‘)

Ale10cable N3gribl *x- 1 5

Al 826cable N3bl/ws -+k- 23(grlgn) ‘)

OperationRequirement

Ignition: ONEngine: start

Ignition: ONCabledisconnected

Ignition: ONCabledisconnected

Ignition: OFFCabledisconnected

Ignition: OFFCabledisconnected

Specification

Malfunctionindicatorlamp(AlelO) or(Al e26)lights upbriefly

11-14 v

11-14 v

<l a

<lQ

Possible cause/Remedy

Malfunction indicator lampdefective.Remove malfunctionindicator lamp, test, replaceif necessary

Open circuit malfunctionindicator lamplover-voltage protectionrelay (Kl/l)

Open circuit malfunctionindicator lamp I CFIcontrol module (N3)

Open circuitcable (AlelO) -+ (Kl/l)contact 2.Open circuit cable (Klil)contact 2 -+ (N3)contact 1

Open circuit cable (Ale26)-+ (Kl/l) contact 6.cable (Ale26) + CFIcontrol module (N3)contact1

Open circuit

Open circuit

‘1 1988 Cahforma

14.0924-l 1613

Special tool

Commercially available tester

Multimeter 0.Q. Sun, DMM-5

14.0924-1164

14-200 Removal and installation of catalytic converter

Cover (2b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, install. Pay attention to install position.Heated oxygen sensor (G3/2) . . . . . . . . . . . . . . remove, install (07%258) not on vehicles with

heated oxygen sensor in exhaust manifold.

NoteBefore installing oxygen sensor, the thread mustbe coated with hot lubricating paste, Part No.000 989 88 51.

Bolts (1) of flanged joint at exhaustmanifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . unscrew, screw on.Side support (10) at transmission . . . . . . . . . . . . remove, install.Rubber rings for exhaust system . . . . . . . . . . . . detach, attach.Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . remove, install complete (49-l 00).Flanged joints (arrow) . . . . . . . . . . . . . . . . . . . . detach and remove catalytic converter.

14.0924-200/l

Note IEngine 102.96 985: A deflector ring (arrow) hasbeen installed for Improved support of the pre-catalytic converter (monolith) (noise reduction).

Production breakpoint: 05166

14-450 Removal and installation of intake manifold and replacing gasket

Preceding work:Removal and installation of mixture control unit with air guidehouslng (07.3-225).

Fuel lines .............................

Bracket for starter cable ..................

Electric wiring, vacuum lines ...............

Supporting bracket (2) for intake manifold ......

Engine lifting lug ........................

Fastening nuts (23) and bolt (19) ............Intake manifold (10) .....................

Intake manifold gasket (12) . . . . . . . . . . . . . . . .

Throttle control linkage ...................

Idlespeed . . . . . . . . . . . . . . . . . . . . . . . . . . . .

unscrew, screw on.

unscrew, screw on.

take off, fit on.

unscrew, screw on.

unscrew, screw on.

unscrew, screw on. Use washer (22).take off, clean. Check flange surfaces withstraightedge; dress on dressing plate ifnecessary.

replace. Replace light alloy gasket forpreheating flange on engines with partial intakemanifold preheating (14452).

install, check, adjust if necessary (30-300).

set (07.3-l 00).

14.0924450/l

14-452 Replacement of preheating flange

Preceding work:Removal and rnstallation of intake mamfofd and replacinggasket (14450).

Intake manifold gasket (12/l ) ............... replace.Electric coupling for intake manifold preheating . . unplug, plug in.Preheating flange (11) .................... take off, replace.Light alloy gasket (110) .................. replace.

14 0924452/l

14-455 Replacement of intake manifold

Preceding work:Removal and Installation of intake manlfoid (14450)

Replacement

Unbolt all parts on the removed intake manifoldwhich are able to be unbolted and install ontonew intake manifold with new gasket.

14.092445511

14-456 Testing partial intake manifold preheating (PMP)

Engine 102.9W98 KAT as of 09189

K3/1 Intake mamfold preheater relay moduleR&2 Intake mamfold preheaters25/13 60 “C temperature switch11 Preheating flange1 l/l Cylinder head-PMP gasket

1212/l92AB

Intake manifoldPSV-Intake mamfold gasketInjectorModel 124 (non-USA)Model 201

Test ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . perform only in the case of engine runningfaults, e.g. engine bucks up to 60°C enginecoolant temperature.

14.0924-456:1

All electrical accessories ............

Battery voltage ..................

Multimeter (range “A”) .............

Special tool

Commercially available tester

. . . . switched off.

. . . . . 11-14 v.

. . . . . connect with current clamp to intake manifoldpreheating cable (R812) at preheating flange.

Multimeter e.g. Sun, DMM-5

Key to symbols

[=jy Multlmeter

--c Contact

7ConnectorGround

+=@- Multlmeter direct voltage measuringmode

-=@+ MultImeter resistance measuringmode

NoteIf the specified value of a test step, e.g. step 2,is in order, it IS not necessary to perform teststep 2.1.

Test step: Tester/ OperationTest scope Test connection Requirement

1.0Cable

Connect multimeter(range “A”) withcurrent clamp tointake manifoldpreheater cable(R8/2) at preheatingflange

Detachconnector atengine coolanttemperaturesensor(S25i13) andconnect toground. Startengine.

Specification

l-2 s afterend of start~21 A


1. Current consumption>5 ~21 A:replace preheatingflange (11) (14-452)

2. Current consumption< 5 A: intake manifoldpreheater relay module(KW), wiring

14.092445612

Test stepiTest scope

. . . . . . . . . . . . . . . . . . .1.2

. . . . . . . . . . . . . . . . . . . . . . .1.3

. . . . . . . . . . . . . . . . . . . . . . . .1.4


Wll K3/11 +9+-s

(9) ‘)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wll K311_I_ q-4

(10) ‘)

. . . . . . . . . . . .._.................K3/1 R8121-c* B--(7) ‘)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K3/1 s251135-c * )_(11) ‘)

OperationRequirement

Ignition: ONRelaymodule (K3/1)disconnected

. . . . . . . . . . . . . . . . . . . . . . .ignition: ONRelay (K3/1)disconnected

. . . . . . . . . . . . . . . . . .Ignition: OFFRelaymodule (K3/1)disconnected,coupling at(R8/2)disconnected

. . . . . . . . . . . .._.........Ignition: OFFRelaymodule (K3/1)disconnected,coupling at(S25/13)disconnected

Specification

11-14 v

. . . . . . . . . . . . . . . . . . .11-14 v

. . . . . . . . . . . . . . . . . . .Cl n

. . . . . . . . . . . . . . .._..<l z2


Model 201:Open circuit from (Fl)terminal 30 + (K3/1)contact 3

. . . . . . . . . . . . . . . . . . . . . . . . . .._...............Model 201:Open circuit from (Fl)coupling U, contact 2-D (K3/1) contact 4

. . . . . . . . . . . . . . . . . . . . . . . . . .._...............Open circuit

,............................,..........,..Open circuit

l) Contact assignment for engine 102.96/98

14.0924456/3

Model 201Engine 102.!% 98

q75S Wbl I- 0,75br 1

- L,rt/gn

K3/1 f?8/2 S25/13P14-0014-3s

Operating principleA preheating flange I,PTC element) is fittedbetween intaktt rnanlfold and cylinder head inorder to achl;ve preheating of the mixture duringthe warming-tip phase. A relay module (K3il)and a 60°C engine coolant temperature switch(S251’13) are required for heating the preheatingflange.

Model 124 shown

If the engine IS started at an engine coolanttemperature < 6O’C. tne preheating flange isenergized by the relay module (K311).

As the temperattire at the preheating flangerises, the current flow IS reduced constantly(PTC element1 un:~l the temperature switch(S25/13) interrupts the ground connection to therelay module iK3 11 at an engine coolanttemperature of approx. 60°C.

Model 201

14.0924-456 4

1 Q-460 Removal and installation of intake manifold bottom section,replacing gasket

Throttle control linkage ...................

Vacuum lines ..........................

Return hose for power steering .............

Coolant hose for thermostat housing .........

Throttle body assembly (123) ...............

Engine mounts .........................

Intake manifold bottom section (18) . . . . . . . . . .

Intake manifold gasket (20) . . . . . . . . . . . . . . . .

unbolt, bolt on, adjust (30-300).

take off, refit.

model 201, loosen, tighten.

model 201, remove, fit on. Check coolant level.

unscrew fastening nuts, screw on.

loosen both and raise engine with inspection pitlift.unscrew fastening nuts, screw on, press downand remove.

replace.

Caution!When replacing the intake manifold bottomsection, unscrew all the parts which can beunscrewed on the removed bottom section andfit to the new bottom section. The M8 X 22 studbolts in the intake manifold bottom section aswell as the two M8 x 85 hexagon bolts must beinstalled with sealing compound.

Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . set (07.3-l 00).

140924460/l

14-470 Removal and installation of exhaust manifold

P14-0126-55

Exhaust system ........................ partially remove, install (49-l 00).

Exhaust nuts .......................... at exhaust manifold, unbolt, bolt on.Exhaust manifold ....................... take out.

Exhaust manifold ....................... install with new gaskets.

Caution!The angled metal tabs or the beads (arrow)must be facing the exhaust manifold.

I P14-2104-13

14092447011

Notes

Exhaust manifold studsStuds of a higher quality (10.9) (previously 8.8)are used for attaching the exhaust manifold tothe cylinder head.

Identification: black bonderized (was yellowchromatized).

Production breakpoint: 04184

Model Engine Engine end No.manual transmission

Engine end No.automatic transmission

201.024 102.961 068090 040901

Engine 102.96/98Stability increased by strengthening ribs (arrows)on exhaust manifold between cylinders 2 and 3,3 and 4.

Production breakpoint:Engine 102.985 approx. 05/86



201.024 @ 102.985 003769 034688

14092447Ol2

Engine 102.985Exhaust manifold made of modified materialReason: crack prevention

Production breakpoint: 09/88



201.028 102.985 027063 076715

Exhaust manifold gaskets at cylinder headEngine 102.985Installation of asbestos-free soft material gasketto provide better sealing.

Exhaust manifold/cylmder head gasketA Prewous versionB Modified version (soft material)

I PI4 - ma0 - 13

Production breakpoint: 05/89



031907 079148

14.Q924-47Ql3

Engine 102.98/98 KAT as of 09/89Heated oxygen sensor (G312) installed in rearsection of exhaust manifold.

Remove, install heated oxygen sensor(see 07.3-258).

G3/2 Heated oxygen sensor

@ 1991 engine 102.985The heated oxygen sensor (G312) is locatedclose to the engine in the exhaust manifold. Thisenables it to reach its operating temperaturesooner.The exhaust gas recirculation valve (89) ispositioned at the rear part of the exhaustmanifold.

14.09244701'4

14-475 Testing exhaust gas recirculation (EGR) @ 1991

PIN-0070-55A

79

69

Thermovalve, opens at + 70°C,closes at + 60°CExhaust gas recirculation valve

621 Exhaust gas recirculation temperature sensor(California only)

Connection diagram(California only)001 CFI control module

connector002 Test cable003 Multimeter004 Contact boxN3 CFI control module

14.0924475/l

Teststep

1.0

. . . .2.1

Test scope

Function ofmonitoringsignal(Californiaonly)


&

7 + 22

I Operation/ Possible cause/RemedyRequirement

Engine atoperatingtemperature,4000iminapprox.1 minute

No exhaust gasrecirculationTemperature sensor faultyWiring.

EGR valve(69)(static)

. . . . . . . . . . . . .EGR valve(69)(dynamic)

. .Vacuumsupply forEGR valve

Ignition: OFFVacuum testerconnected to EGRvalve

. . . . . . . . . . . . . . . . . . . . . . .Engine idling

. . . . . . . . . . . . . . . . . . . . . . . .Vacuum testerconnected todetached vacuumline

APPLY500 mbarvacuum

Detachvacuum testerat EGR valve

. . . . . . . . . . . . . . . . . .APPLY500 mbarvacuum atEGR valve,..........._...........,Engine sppeed> 4000/min

EGR valveshouldcloseaudibly

. . . . . . . . . . . .Engineshould runroughly

,................approx.500 mbar

Replace EGR valve.

~..........................................Replace EGR valve.

. . . . . . . . . . . . . . . . . . . . . . . . .Check arrangement ofvacuum lines (seefunction diagram),replace thermovalve.

Thermo-valve (79)a) shiftpoints

. . .b) Leak-tightness

Connect vacuumtester to angleconnection, applyvacuum

.,,.....,.......,,._.,...........Connect vacuumtester straightconnection

Engine coolanttemperature

>70 “C

X60 “C

. . . . . . . . . . . . . . . . . . . . . . .APPLY500 mbarvacuum

Passage

Nopassage

. . . . . . . . . . . . . . . . .Vacuummust notdrop

Replace thermovalve.


~.................I........................


14.092447512

Special tools

124 58907 21 oc

201 589 00 99 C

Hand vacuum

0 -1000 mbar

DO1 589 73 21 00 201 589 13 21 00

Commercially available tools or testers

Designation e.g., Make, Order No.

124 58900 21 00 124 509 33 63 00

Multimeter Sun, DMM-5

Engine tester Bosch, MOT 002.02

14 0924475.3

14-487 General instructions for vehicles with catalytic converter (KAT)

Tow-starting or jump-startingTow-starting or jump-starting with anotherbattery can be performed when the engine iscold and the catalytic converter system hascooled down. Repeated attempts at startingshould be avoided, however. If the engine is atnormal operating temperature and does notstart immediately, do not make any furtherattempts to start the engine in order to protectthe catalytic converter system.

MisfiringIf misfiring occurs, the pre-catalytic convertersare particularly at risk as fuel/air mixture isconverted in the hot catalytic converter. Thepre-catalytic converters may thus be subjectedto excessive thermal stresses. If misfiringoccurs frequently, the engine may only beoperated for a short time at low load. The causeof the problem should be immediately repaired.In cases of doubt, the catalytic converter shouldbe examined for thermal damage after rectifyingthe problem at the ignition system.

Checking the catalytic converter system forthermal damageIf excessive thermal stresses occur, the pre-catalytic converters sustain damage first. Thiscan be checked by visual inspection with theexhaust system removed. Complaints regardingperformance after engine running problemsindicate excessive thermal stress of thecatalytic converter. Residues of the moltencatalytic converter block the exhaust pipe.

Driving on the roller dynamometerThe pre-catalytic converter becomes red-hotmore rapidly at high loads because of thegreater heat dissipation. This is no reason forconcern.

Fuel additivesThese are not recommended for vehicles fittedwith catalytic converters. Only the specifiedquality of fuel may be used.

Use of leaded fuelIf leaded fuel has been inadvertently used, thefunction of the lambda control should bechecked. If the sensor is damaged, it must bereplaced. If the emission level exceeds <OS%CO, the complete catalytic converter systemshould be replaced.

Engins oilsThe same oil recommendations (approvedproducts, oil change intervals, etc.) as forvehicles without catalytic converter apply tovehicles fitted with catalytic converter.

Obnoxious odorsDeposits of sulfur elements from the fuel in thecatalytic converter may result in the formation ofhydrogen sulfide. Even minute concentrations ofhydrogen sulfide are extremely obnoxious,although not harmful to health.

14.0924487/l

Risk of fire (parking on premises)The surfaces of the under-floor catalyticconverters in our vehicles fitted with closed-loopcatalysts are thermally insulated to ensureeffective cleaning of the exhaust gases in alloperating conditions. Provided the engine isoperating correctly, no higher temperaturestherefore occur than with conventional mufflersystems. Excessive temperatures occur only if(e.g. as a result of faults in the ignition orinjection system) uncombusted fuel/air mixturepasses into the catalytic converter.

14.0924487/2

14-489 Disposlng of catalytic converters

Catalytic converters must not be disposed of asscrap. The catalytic converter contains valuablenoble metals which can be recycled.

Details regarding return addresses and exchangeprices are available at an authorized Mercedes-Benz dealer.

14.092448911

lectrical system, engine 1

15 Electrical system - engine

Job No.

Notes regarding work on transistorized ignition system ........................... 15 - 505Function of distributor ignition system (DI) .................................... 15 - 510Function of the breakerless transistorized ignition system (TSZ) ..................... - 512Testing ignition point .................................................... - 515Analyzing oscilloscope images ............................................. - 525Replacing spark plugs ................................................... - 530Removal and installation of ignition or high voltage distributor ....................... - 535Testing distributor ignition system (DI) ........................................ - 540Testing breakerless transistorized ignition (TSZ) ................................. - 542Testing ignition advance in warm-up phase (only TSZ) ............................ - 543Retrofitting corrugated hoses for ignition cables ................................. - 547

15 1

15-505 Instructions regarding work on transistorized ignition system

A. Safety precautions

increased requirements of modern engines inrespect of the ignition systems and the desire forfreedom from maintenance have led to thestandard use of electronic ignition systems.

As a rule, the ignition capacities of electronicsystems are higher than those of conventionalsystems; further increases in capacity are likely.Consequently, electronic ignition systemsoperate in a power range which may behazardous if contact is made with live parts orterminals (see warning plate).

Warning plate In engine compartment

For this reason, the following safety precautionsshould always be observed when performingwork on electronic ignition systems (distributorignition, TSZ):

l Before performing work at cranking speed,e.g. testing compression or adjusting valveclearance, switch off ignition and detachcontrol lead (arrow) at control module or plugprotective connector Part No.102 589 02 21 00 into the diagnosticconnector.

Gefghrliche HochspannungyVorsicht bei Arbeiten an derZtindanlage

Danger! High voltageObserve caution when workingon the ignition system

Danger! Haute tensionAttention lors de travaux ausysteme d’allumage

PlS-0241-13

TSZ ignition control module

15 0924-5051

l Persons with heart pacemakers should notwork on such ignition systems.

l Do not grasp or detach any components ofthe ignition system at cranking speed orwhen the engine is running.

tgnltion control module

l Perform removal and installation work on theignition system or connection and discon-nection of sensors at ignition cables onlywhen the engine is not running and theignition is switched off.

l No adapters or plug-in sensors which aremetallically blank to the outside may beinstalled in the ignition cables (e.g. cylinder1).

. Instructions for avoiding damage to ignition system

The control module connectors may onlybe unplugged and plugged in when theignition is switched off in order to avoiddamage to the ignition and TSZ controlmodules.Do not connect a test lamp to terminal 1 ofthe ignition coil.Terminals 1 and 15 of the ignition coil mustnot be short circuited to ground, e.g. as ananti-theft protection.The threaded pins of the ignition coil havedifferent diameters (M5 and M6) to eliminatethe risk of incorrect polarity.Install only genuine ignition system parts.Do not operate ignition system at startingspeed unless all the ignition cables are fullyconnected.

15 092440512

l The high voltage side of the ignition systemmust have a load of at least 2 kR (distributorrotor 1 kR, distributor cap per terminal 1 kQ)to avoid damage to the ignition and/or TSZcontrol modules. Do not install 5 k!Jdistributor rotors for interferencesuppression.

l The following work must not be performed atstarting speed or when the engine isrunning:- holding ignition cable 4 at a distance to

ground- unplugging spark plug connector- unplugging ignition cable 4 at ignition coil.

l The ignition control module is coated on therear with heat-conducting paste to improveheat dissipation and covered with a heat-conducting protective film. The protectivefilm must not be removed.

l If the short-circuit protection (cylindercomparison) is operated and the enginestops, the test cannot be performed with thistester.

l A load of not more than 28 kV may beapplied to the ignition coil when performingthe separate ignition coil test in order toavoid damaging the coil.

l If it is necessary to test the ignition sparkwhen rendering roadside assistance, thismust only be done with a spark plug at acylinder ignition lead. Ensure a good contactto ground of the spark plug.WARNING! Risk of shock!

C. lnstructlons for use of engine testers

l Connect and disconnect voltage clamp toignition cable 4 and trigger clamp to ignitioncable of cylinder 1 only when the engine isnot running and the ignition is switched off.

15.0924-50513

15-510 Function of distributor ignition system (DI)

Function diagram of distributor ignition system (DI)Engine 102.9858112 Engine coolant temperature sensorGt BatteryL5 Crankshaft posltlon sensorNl:Z Ignition control moduleR4 Spark plugsR16 Reference reslstorS5l3 High voltage distnbutor

s2912

TlXl 1

Full throttle/tdle speed detectlon throttle valveswitchlgnltron co11Dlagnostlc connector/terminal block termmal TD

1 Segments on driver disk2 Vacuum line

Engines 102.96/98 as of 09189The intake air temperature sensor (B17il)supplies its temperature values to the ignitioncontrol module (intake air temperature sensor forCFI system no longer equipped).

15.0924-51041

Components and function

ignition control module (N1/2)

Ground point W3Front left wheelhouse Ground (-)

I I

Transmission overloadprotection switch(S65) (only engines102.98399 wtthautomatictransmlsslon)

Engtnes 102.983199

-4 Shift operationsI=+

Ignitioncontrolmodule(Nli2)

Dwell and ignitiona n g l e c o n t r o l+1

+controls

c

Ignition coil

supplies

&,

controls

1

Tachometer,fuel pump relay,compressor shutoffcontrol module,CFI control module,etc.

The ignition control module is located on the leftwheelhouse panel.

It is installed with heat conducting paste toimprove heat dissipation. When exchanging thispart, the protective film must not be removed.The film does not impair heat dissipation. Theignition control module contains amicrocomputer, a pressure sensor and thepower output stage.

The ignition maps for typical load/engine speedranges and a fixed idle speed ignition map arestored in the microprocessor of the ignitioncontrol module.

The ignition control module detects themomentary operating state of the engine fromvarious input signals. Engine speed andcrankshaft position are sensed by the positionsensor.

The optimal ignition point for this operating stateis output from the stored ignition maps byanalyzing all the input signals.

2 .

1 Vacuum connection2 Coaxial connector for control lead from posItIon sensor3 Sensor connector 4-pin

1 Engine coolant temperature sensor2 Wide open throttle/closed throttle postion switch3 Reference resistor4 Vacant (lead ends in wiring harness)

or intake air temperature sensor4 Supply connector 4-pin

15 = Terminal 1516 = Ignition coil terminal 1TD = TD signal31 = Ground

15.0924-5 1013

The output end stage actuated by the micro-computer switches the primary current of theignition coil between terminals 16 and 31(4-pin supply connector).

The familiar functions of dwell angle control,primary current cutoff and primary currentlimiting are still contained in the ignition controlmodule.

The speed-dependent TD signal is generated inthe ignition control module (15-512).

When the engine is started and up to approx.450:min the ignition point is controlled only viathe segment edges of the flywheel. Only whena certain engine speed is reached (approx.460Imin) is a transition made from the fixedignition point to the ignition point calculated forthe momentary operating state.

In the warming-up range, various ignition mapsare inhibited depending on coolant temperaturein order to reach the operating temperature asrapidly as possible.

At idling speed and when decelerating a fixedignition map is specified when the idle contactof a throttle valve switch is closed. This isinfluenced neither by the temperature sensor,the intake manifold vacuum nor by thereference resistor.

NoteIf an interruption of the engine coolanttemperature sensor occurs (resistance 00 Q)Bosch ignition control modules depart from thefixed idle speed curve and select a certainignition point in the map, i.e. the ignition point isadvanced.

At full load, the ignition point is determined bythe full load ignition curve. The ignition controlmodule detects full load from the intakemanifold vacuum and engine speed inputsignals.

At full load, the ignition point is advanced(higher engine torque), taking into account theknock limit.

On engines 102.983199 two full load ignitioncharacteristic curves are stored. The ignitionpoint is determined as follows depending on theswitch position of the intake air temperaturesensor:- By the advanced ignition characteristic

curve below +25 “C intake air temperature.- By the retarded ignition characteristic curve

above +25 “C intake air temperature.

15.0924-51 oi4

On engines 102.96/98 as of 09:‘89 with intakeair temperature sensor, the ignition point isretarded as the Intake air temperature rises. Inaddition, an lgnrtron map is stored both forautomatic and manual transmission. Thesemaps are activated by the reference resistor.

The ignition points of certain ignitioncharacteristic curves can be altered with thereference resistors. depending on the operatingstate.

Two maps for the following operating modes arestored in the ignition control module:

l For operation with catalytic converter (isactivated via reference resistor).

The national version @ has a fixed resistancereference resistor.

NoteThe ignition control module for engine 102.983Standard has only one map. The ignition pointIS altered for leaded and unleaded premiumgrade fuel with a special resistance trimmrngplug (inscription EZL and digits l-7).

If the engine coolant temperature exceeds 90“C or 100 “C (depending on version), certainignition characteristic curves are retarded tocounteract a further temperature rise (boilingprotection correctton).

On engines 102.96:98 as of 09;88 up to 08,89the use of the boiling protection correction hasbeen advanced from 100 “C to 90 “C enginecoolant temperature. From a coolanttemperature of 90 “C the ignition point isretarded. The maximum retardation of 5” WA isalready reached at a coolant temperature of100 "C.

Engines 102.996/98 as of 09189The use of the boiling protectron correctionbegins from 100 “C.The retardation correction is:100 “C + retarded 2” CKA (crank angle)110 “C -+ retarded 4” CKA120 “C + retarded 5” CKA

AThe correction of the boiling protection and ofthe intake air are added, i.e. 120 “C coolanttemperature and 50 “C intake air temperatureproduce a maximum retardation of 12” CKA.

Safety measures at control moduleA safety retardation is automatically performedin the event that one or several sensors of theignition system fail in order to protect theengine.

15.0924-510:'5

The Ignition point test must be performed at anengrne coolant temperature between 75 “C and90 ‘C because of ‘he boiling protectroncorrection as the ignition point is altered outsideof this temperature range. To avoid an incorrectmeasurement of the ignition point, unplugconnector for the engine coolant temperaturesensor and feed in 320 12 ( = 80 “C enginecoolant temperature) with the resistance decade.

Engines 102.96:9881112 Engine coolant temperature

sensorWl 1 Engine ground

Flywheel disk with segments

Two segments offset 180” (A) are installed tothe flywheel or to the flexplate.

As the segments pass the position sensor theyproduce an alternating voltage as a result ofInduction.

Flywheel (manual transmlsslon)

15.0924-51016

Flexplate with rtng gear(automatic transmission)

Position sensor (L5)To activate the ignition control module, theposition sensor (L5) detects the crankshaftposition and the engine speed.

The position sensor is installed on the crankcaseabove the starter flange.

The coil body projects to just before thesegments at the driver plate. Segment positionand engine speed are sensed without contacts.

When the engine is rotating an alternatingvoltage is produced in the position sensor as aresult of induction. The peak value of the voltage(U,) is approx. 1.5 volts at starter speed. Asengine speed increases, the voltage rises(U, approx. 3 volts at 1200/min.).

15.0924-51 on

NoteMeasure peak value of voltage (U,) with theoscilloscope.

The crankshaft setting is detected from thevoltage as follows:

The front edge of the segment produces anegative voltage signal.The rear edge of the segment produces apositive voltage signal.

The engine speed is determined by measuringthe period.

The alternating voltage of the position sensor ispassed along the control lead (coaxial lead) toterminal 7 at the ignition control module. Thelead is a single-core cable and the screening isused as a second lead.

If the ignition control module does not receive asignal from the position sensor, the completeignition system is inoperative, e.g. an interruptionof the sensor coil can cause this.

The resistance of the position sensor betweenterminal (7) and (31d) is 680-1200 Q.

Notes regarding damage segments ormechanical damage to position sensor:l Alternating voltage of position sensor below

specification.l Alternating voltage signals of individual

segments vary greatly.l No alternating voltage signal.

Position sensor voltage signalt1 1 st segmentt2 2nd segmentd Penod for one crankshaft revolution

31d

P15-0240-13

15.0924-51018

Wide open throttle/closed throttleposition (WOTICTP) switch (S29M)When the closed throttle contact of a WOTCTPswitch is closed (accelerator not depressed), thefixed idle speed/deceleration ignitioncharacteristic curve is activated. The switchingsignal passes through the WOTCTP switchconnector (S29/2xl) and the 4-pin sensorconnector (contact 2) to the ignition controlmodule.

Engine coolant temperature sensor (Bl l/2)Temperature sensors are equipped with 2-pin or4-pin (from approx. 09189) connections.

The temperature signal passes along thegreen/black cable at the 4-pin sensor connector(contact 1) to the ignition control module.The engine coolant temperature sensor ispositioned at the front at the cylinder head.

NoteNTC = resistor with negative temperaturecoefficient, i.e. the resistance is less in the warmstate.

2-pin engine coolant temperature sensor(Bl l/2)The engine coolant temperature sensor has twoNTC resistors, each with a single-pin connection.One NTC for CR and one NTC for the distributorignition system.

Engines 102.96198561 l/2 Engine coolant temperature

s8nsor

15.0924-51019

4-pin engine coolant temperature sensor(Bl l/2)It integrates two separate temperature sensors(NTC) which do not have any electricalconnection to the housing of the engine coolanttemperature sensor.

One temperature sensor is for the distributorignition system (contacts 1 and 3) and one forthe injection system (contacts 2 and 4).The connector of the engine coolant temperaturesensor is designed so that it can be plugged inin any position. The two temperature sensors arearranged diagonally.

Engines 102.96/‘9881 112 Engine coolant temperature

sensor

15.0924-51 Oil 0

. . . .iiii

Pin assignment of coupling:1 = Ignition temperature sensor2 = CFI temperature sensor3 = Ground W3, front left wheelhouse4 = CFI control module ground

Notes regarding testEngine coolant temperature sensor (61 l/2)When testing the engine coolant temperaturesensor, measure the resistances 2 x diagonallyand compare. The resistances of thecharacteristic curves are identical with those ofthe previous version.

An electronic switch is incorporated in the intakeair temperature sensor which interrupts theconnection between terminal 2 and terminal 3(ground) at temperatures 125 “C . Continuityexists between the two terminals below thistemperature.

At terminal 1 the voltage for the electronic switchis supplied from terminal 15 via fuse 10.

1 Voltage supply2 lgnltion control module3 Ground

15.0924-51 Oil 1

b) Engines 102.96/98 KAT as of 09/89The intake air temperature sensor installed onCFI now supplies its temperature values throughthe sensor connector contact 4 to the ignitioncontrol module. The resistance of thetemperature sensor (NTC) becomes smaller asthe temperature rises.

From an intake air temperature of 32 “C thergnrtion point is retarded and reaches itsmaximum at 50 “C.e. g.: 32 “C -+ retarded lo CKA

40 “C -+ retarded 5” CKA50 “C + retarded 7’ CKA

Engines 102.96;98El1 711 Intake air temperature sensor

Reference resistorTwo different types of reference resistors areinstalled:

a) Variable resistance trimming plug (R16).b) Reference resistor (R161’1) with fixed

resistance @.

Model 124 shownR 16 Reference resistor

15.0924-510: 12

b) Reference resistor (R16A)The reference resistor @16/l) has a fixedresistance. The fixed resistances differ depend-ing on Part No. as follows (see 15-515 forassignment):

Model 201

Part No. Resistance

000 540 22 81 220 n

000 540 25 81 I 1300 n

000 540 26 81 I 2400 Q

A certain ignition map is activated in the ignitioncontrol module with the reference resistor@16/l).

Perform resistance measurement for testing thereference resistor (R16il) at the ignition controlmodule between sensor connector (contact 3)and ground.

High voltage distributor (W3)The singular task of the high voltage distributoris to distribute the ignition voltage. It is thereforeno longer possible to set the ignition point.Activation and adjustment of the ignition pointare performed by the position sensor and theignition control module.

Interference suppression resistors: At distributorcap per terminal 1 kQ, spark plug connector1 kQ, distributor rotor 1kQ.

The distributor cap is attached to the highvoltage distributor with M-6 special bolts.The special cap for long-range interferencesuppression is mounted on the cap and attachedwith two metal stars.

Ignition coil (Tl)The ignition coil is matched to the ignition controlmodule to achieve a higher ignition energy. Theprimary current can be further boosted as aresult of the high switching capacity of theignition control module. The primary winding isdesigned as a very low impedance (0,3-0,6 Sz)for this purpose.Stall current cutoff and primary current limitingenable the ignition coil to be operated withoutballast resistor. Consequently, current limiting bythe ballast resistor is eliminated. If the maximumprimary current flows without limit in the ignitioncoil (e.g. stall current cutoff defective), theignition coil is damaged after a short time by thehigh level of heat developed.

For distinguishing:The ignition coils of 4- and 6-cylinder engineswith distributor ignition systems are identicalIdentification: yellow type plate.The ignition coils cannot be interchanged withignition coils for a-cylinder engines (identification:green type plate).Pay attention to Part No. when exchanging.

P15-2139-13

Pay attention to instructions regarding work onelectronic ignition systems (16-505).

15.0924-510114

15-512 Function of the breakerless transistorized ignition system (TSZ)

Gl

P15-0422-35

GlNl/lR4

BatteryTransistorized ignition (TSZ) control moduleSpark plugs

S5/2Tlx11

Breakerless distributorIgnition coilDiagnostic connector/terminal block terminal TD

NoteInstallation survey of engines with breakerless Only a 4-pin connector is plugged in at the smalltransistorized ignition system (TSZ), see transistorized control module (distinguishing07.3-004. feature to ignition control module).

15.0924-512/l

Components and function

transistorized control module (NW)

ignition starterswrtch (S21)termrnal 15

Inductron sensor Indtstnbutor

Voltage supply ( + )

I I

transistorizedcontrolmodule(Nl/l)

The transistorized control module is located onthe left wheelhouse panel. It is designed inspace-saving hybrid technology.

1 lgnrtion co112 transrstorized control module3 Terminal block terminal TD4 Diagnostic connector

Dwell angle controlStall current cutoffPrimary current limiting

controls

cIgnition coil

+supplies

1

I

controls

ITachometer,fuel pump relaymodule,compressor cutoffcontrol module,CFI control module,etc.

15 0924-512/2

Pin assignment at transistorized controlmodule

l Green control lead from induction sensor indistributor (coaxial connector).

0 4-pin round connector with terminals 15, 31,16 and TD.

The electronic functions of primary currentlimitation and stall current cutoff in thetransistorized control module enable the seriesresistors in the primary current circuit to beeliminated. Consequently, a higher ignition coilprimary current and higher ignition capacity arepossible.

The transistorized control module is activated byinduction sensor in the distributor.

The optimal capacity of the ignition system isachieved by the dwell angle control in thetransistorized control module. The dwell angle iscontrolled within the control range so that thesame primary current is always achievedapproximately in every operating state, i.e. atdifferent battery voltages and engine speeds.

As a result of the elimination of the seriesresistors, the primary current is cut off by thetransistorized control module (stall current cutoff)when the engine is not running and the ignitionis switched on. The primary current is connectedonly once a certain pulse sequence is generatedby the induction sensor in the distributor.

The maximum primary current of the ignition coilis determined by a current limiter in thetransistorized control module.

150924-51213

The current limitation (c) can be recognized onthe oscilloscope when the engine is at idle.Current limitation is no longer visible from anengine speed of approx. 2000imin.

The power output stage switches the primarycurrent of the ignition coil between terminals 16and 31. In addition, the power output stageperforms the task of limiting the primary current.

a Opening angleb Dwell angleC Current limltlng

TD signal

The transistor engine speed (TD) signal isproduced in the transistorized control module.This is an engine speed-dependent square-wavesignal.

The engine speed is detected by the number ofsquare-wave signals per minute.

When performing tests, the On time (t, e.g. 70%of the individual square-wave pulses is measuredas dwell angle in degrees or as on’off ratio inpercent (related to period, d).

The TD signal can be measured:

l with the dwell angle tester or on/off ratiotester in percent and degrees.

l with the voltage meter 6 volts up to 12 voltsdirect voltage.

d-100%99

P15-0215-13

l with the oscilloscope - square-wave signals.

15.0924-51214

NoteNo TD signal exists If a short to ground ispresent at the connected equbment or at thediagnostic connectorterminal block terminal TD(Xl 1). To locate the problem, detach cableconnection (arrow). Rectify short to ground inthe respective circuit.

The following electronic components have a TDconnection, e.g.:Tachometer, CFI control module, fuel pump relayand compressor cutoff control module.

Ignition distributor (S5/2)

l The induction sensor is installed in thedistributor. It produces an alternating voltageup to approx. 100 volts for actuating thetransistorized control module.

The alternating voltage passes along thegreen control cable (coaxial cable) to theignition control module. The cable is asingle-wire lead. The screening is used as asecond lead.

l Engine speed-dependent ignition advance byflyweights. Load-dependent ignition advanceby vacuum (above approx. 60 “C coolanttemperature).

l Interference suppression resistors: distributorrotor 1 kQ (code number Rl, on rotor),distributor cap 1 kQ per cylinder.

15.0924-5 12:5

Ignition coil (Tl)

The ignition coil is matched to the ignition controlmodule and designed for a higher ignitioncapacity. Identification: yellow sticker.

The ignition coil must on no account be replacedby one of the previous ignition coils.

Distinguishing features from previous ignitioncoils are:l The safety plug in the cover of the ignition

coil.l A higher dome.0 Cable connection at terminal 1 with

M5 thread.0 Cable connection at terminal 15 with

M6 thread.

A 5.5 mm opening (arrow) which is sealed with aplug is located in the cover of the ignition coil.This cover detaches if an pressure as a result ofsevere heat formation is produced in the ignitioncoil by a defective output stage in the controlmodule. The ignition coil is provided with a covercap to prevent uncontrolled escape of the plugor of the sealing compound.

Ignition cablesThe partially screened spark plug and angleddistributor connectors are designed for highignition voltage.

An interference suppression resistor of 1 kS2 isinstalled in the spark plug connectors. These canbe unscrewed (M3 thread).

15-515 Testing ignition point

Preceding work:

A. Vehicles with TSZ ignition system

Gl BatteryNl/l Transistorized ignition (TSZ) control moduleR4 Spark plugsS5l2 Breakerless distributor

Tlx11030

Ignition coilDiagnostic connector/terminal block terminal TDEngine tester with oscilloscope

Engine tester with oscilloscope (030) . . . . . . . . . connect to diagnostic socket (Xl 1).

Safety precautions . . . . . . . . . . . . . . . . . . . . . . observe (15-505). Selector lever in position P orN. Apply parking brake.

Ignition point . . . . . . . . . . . . . . . . . . . . . . . . . . test at specified engine speed with or withoutvacuum (see table).

15.0924-5 1511

Ignition point .......................... set by turning distributor. Then re-test.

Flywheel vacuum advance ................. test at specified engine speeds (see table).

Commercially available testersEngine tester (engine speed, dwell angle, ignition angle,oscilloscope, voltmeter

e. g. Bosch, MOT 002.02Sun, 1019

Z) basic versionI

DistributorBosch No.

lnition1

Engine

I102.961

hint (TS

Typeoffue13)

installedvalue ofignttionpoint in“CKABTDC atstartingspeedwithoutvacuum

Vacuumadvanceof ignrtiorpoint in“CKABTDC at

1

8

8

n

Installedvalue ofignitronpoint in“CKABTDC alstartingspeedwithoutvacuum

withouvwithvacuum

45001min

at idle at idle45001min

27without

8-123 237 002 0843 237 002 059

3 237 002 105

Jn-eaded

Jn-eaded

8-12102.985 27without

See next page for footnotes.

int(TSIType of:uel 3,

basic versionmEngine Distributor

Bosch No.Vacuumadvanceof ignitiopoint in“CKABTDC al

Test and settingdata ‘) of ignitiorpoint in “CKABTDC 2 1without/withvacuum

Ignition point advancen “CKA (crank angle)before TDCNithout vacuum

45001min

at idle at idle 15001min

3000/min

45001min

102.9611984

Jn-eaded

0 237 002 094 5with

24-28’)

D 237 002 098102.961102.985as of1983

10-14 22-26’) 14-l 8*) 5In 98 RON) If norm :ompressron engines are opera d wfth fue of less tha mm. 88 IN) or fow-compressfon engmes wftn

less than 92 RON (mtn. 82 MON), the fgnftron pofnt should be retarded and adapted to the octane number of the fuel used. Areference value for this adlustment IS: retard rgnrtion point by l-2 O CKA per 1 RON. The maxfmum retardatfon must notexceed 6” CKA.The Ignition correction should be entered by hand on the “engfne setting data” Information plate.Thrs results m reduced oerformance and increased fuel consumption. In addition, the engfne must not be operated at full load.The full rgnftron advance snould be reset as soon as fuel of the soecffied octane number IS again avaflable.

2) Test at 3500/min.3) Vehicles wfth catalytfc converter must be ooerated wfth unleaded fuel.4) This value must be ldentfcal with and wrthout vacuum when engine at normal ooeraring temperature: cneck lgnltlon advance In

warming-up phase If necessary (15-543).

15.0924-5153

8. Vehicles with distributor ignition system (DI)

PlS-0424-59

81112 Engrne coolant temperature sensorB17ft Intake air temperature sensorGl BatteryL5 Crankshaft posrtron sensorN1/2 lgnrtron control moduleR4 Spark plugsR16 Reststance trimmrng plug (EZL)S5l3 High voltage drstributor52912 Wide open throttle/closed throttle posttron switch

S65

Tlx11

12030

Transmissron overload protection swatch(only engines 102.983199)lgnrtion coilDiagnostic connector/termrnal block termrnal TD

Segments at flywheel/driver diskVacuum lineEngine tester with oscilloscope

15 0324-5t 514

Engine tester with oscilloscope (030) . . . . . . . . . connect to diagnostic socket (Xl 1).

Safety precautions . . . . . . . . . . . . . . . . . . . observe (15-505). Selector lever position P orN. Apply parking brake.

Ignition point . . . . . . . . . . . . . . . . . . . . test at a engine coolant temperature for approx.80 “C with or without vacuum at specifiedengine speed (see table).

Engine 102.96/99 KAT as of 09189Detach engine coolant temperature sensor(El l/2) and intake air temperature sensor(I31 70 ) for test.

Following the test, the DTC memory must beerased (see 07.3-121, section “D”). Useimpulse counter scan tool 124 589 19 21 00 forthis or unscrewi screw on negative pole terminalor battery.

NoteThe ignition point cannot be set. If the ignitionpoint is incorrect, test distributor ignition system(DI) (15-540).

Radio with codeFollowing repairs to the vehicle which involvedisconnecting the battery terminals, the radiomust be made operational again by entering thecode number. The CODE card must be availablewhen repairs are performed.

15.0924-515:5

Engine dersion ProductionbreakpointModel year

Ignition controlmodulePart No.alternatively

Enginespeed1 :min

Resistancetrimming plugsetting, typeof fuel ‘)

Ignition Ignitionpoint pointin “CKA in “CKABTDC / BTDC

without withvacuum vacuum

1986,1987 004 545 57 32004 545 59 32

Referenceresistor750 n

18-22 3, 29-33 3,

-+-14-18 14-18

102.983

102.985

dling

1987/l 988 005 545 30 32005 545 32 32

3200

Idling 18-12 18-12

102.985 1989 007 545 47 32 5)6)007 545 48 32 5)6)

3200 2 3 - 2 7 139-43

dling

3200

8-12 8-l 2

010 545 59 32010 545 60 32

Referenceresistor1.3 kR(man. transm.)2.4 kS2(aut. transm.)

22-26 ‘) 139-43 ‘)102.985

dling 8-12 8-12

I) Manual transmlsslon.2) Automatlc transmlsslon.3) Intake atr temperature sensor connector dlsconnected.4) Resistance tnmmlng plug positjon results from setttng.5) These lgnltlon control units may also be tnstalled In vehicles pnor lo 08188. In th1.s case the Ignition point values are altered as

shown in the table. The resstance trimmmg plug setting “7” IS no longer permitted for these lgnltlon control umts.6) Test lgnltlon point at 80 “C coolant temperature by unplugging the temperature sensor connector 61 l/2 and feedIng In 320 Q

with resistance decade between green/black cable (coolant temperature sensor coupltng 4-pin, contact 1) and engine ground.7) Vehicles with catalytic converter must be operated with unleaded fuel.8) Reference resistor (resistance 0~ Q) not fitted to vehicles with tgnltlon control urxt 003 545 70 32.9) For testing, detach the Intake air temperature sensor and coolant temperature sensor connectors. Test tgnltion point at 80 “C

coolant temperature by feedlng In 320 R with resistance decade between contact 1 at 4-pin connector and engine ground.

Notelgnltlon control unit with Ignition map for manual and automatic transmission (actuated by different EZL resistancetrimming plugs), bolllng point correctlon (max. 5 “CKA), intake air correction (max. 7 “CKA) and safety retardation (6 “CKA)In the event of open clrcult 10 reference resistance trimming plug.

15.0924-515:6

Special tools

124 569 09 63 OC

Commercially available testersEngine tester (engine speed, dwell angle, ignition angle, 8. g. Bosch, MOT 002.02oscilloscope, voltmeter) Sun, 1019

NoteThe ignition point test must be conducted at anengine coolant temperature between 75 “C and90 “C because of the boiling protectioncorrection as the ignition point alters outside ofthis temperature range. To avoid an incorrectmeasurement of the ignition point, detachconnector for the engine coolant temperaturesensor and feed in a resistance of 320 Sz (=80°C engine coolant temperature) with theresistance decade.

Engines 102.96/98Bl l/2 Engine coolant temperature sensorWl 1 Engine ground

15.0924-515n

Pin assignment of Cpin engine coolanttemperature sensor (B1112):1 = Ignition temperature sensor2 = CFI temperature sensor3 = Ground W3, front left wheelhouse4 = CFI control module ground

Engines 102.96/98 KATas of osiasBl l/2 Engine coolant temperature sensorB17/1 Intake ar temperature sensor

EZL KE

EZL

t 5.0924-515!8

15-525 Analyzing oscilloscope images

Description of oscilloscope image

Good image

NotePrimary current limiter (7) is only operative up toapprox. 2000Imin.

0 %Pl5-0004-57

Ignition voltage lineIgnition voltageCombustion periodCombustion voltageCombustion voltage line

6 Decay process7 Primary current limiting6 Opening section9 Closing section (dwell angle)

15 0924-52511

Good image

1. Secondary parade

[WI

P ls-ooo5-57

15.0924-52512

Good image

2. Secondary grid

15.0924525/3

Good image

3. Secondary single image

IS

5

15.0924-52514

Good image

4. Secondary single image

[WI2 0

lo

0

%,

15.0924-52515

Good image

5. Primary parade

[VI400

2.og

0

P 15-ooo9-57

15.0924-525/6

Good image

6. Primary single image

15.0924-52517

Good image

7. Blipping throttle

Test requirement: Repeatedly accelerate engineto approx. 3000/min by blipping throttle.

Notel As a result of the acceleration process,

several cylinders are recorded in turnaccording to the firing sequence, 8. g. imageexample (1 st 3rd 4th 2nd, 1 st 3rd 4th 2nd,etc.)

l The ignition voltage rises uniformly at all thecylinders during the acceleration phase. Theignition voltage rise must not exceed6 kV.

CkUl 1

P15-0011-57

i 5.0924-52518

Good image

8. Primary current limitation

NotePrimary current limitation may occurintermittently at individual or at all cylinders atengine speeds above 2000/min with and withoutload.

15.0924-52519

Fault image

9. Ignition voltage too high/combustion periodshorter.

Test requirement: May occur at any enginespeed with or without load.

CauseSpark plug electrode gap too large; additionalspark gap at secondary side; fuel/air mixture toolean.

P 1s-aot3-57

15.0924-525110

Fault image

10. Ignition voltage too low/combustion periodlonger.


CauseSpark plug electrode gap too small;fuel/air mixture too lean;compression loss.

[kVlI

.

I

.

I

.

I

I

I-

.

P 15-001447

15.0924-525/l 1

Fault image

11. Decay process too high

Test requirement: Accelerate engine repeatedlyto approx. 3000/min by blipping throttle or runengine under load on roller dynamometer.

CauseFuel/air mixture at one cylinder too lean.

NoteIf engine running is rough (does not run on allcylinders) after start, the engine should beswitched off at operating temperature andrestarted after a lengthy period (approx.30 minutes) to obtain a better diagnosis.It is essential to pay attention to testrequirement when repeating the startingoperation.

AWarning!Problem may only occur briefly.

[kVl

P 15-QQ1.5-57

15.0924-525/l 2

Fault image

12. Decay processes too high.

Test requirement: Accelerate engine repeatedlyto approx. 3000imin by blipping throttle or runengine under load on roller dynamometer.

CauseFuel/air mixture on all cylinders too lean.

P15001657

15.0924-525113

Fault image

13. Higher combustion voltage > 1.5 kV at singlecylinder.


CauseSoot, oil, lead deposits on spark plug.Too high ohmic resistance at secondary side.

[kUl1

P 15-QQ17-57

15.0924-525114

1

Fault image

14. Higher combustion voltage > 1.5 kV at allcylinders.


CauseToo high ohmic resistance at secondary side.

crl a

i- r/

P 15-0018-57

15.0924-525115

Fault image

15. Ignition voltage < 8 kV at terminal 4

Test requirement: Starting speed.

CauseIgnition coil

NoteEngine does not start

[kvl10

c

C

i-

loo 80 60 40 20 0 ii. P ,E.-%l19-51

15.0924-525116

Fault image

16. Ignition voltage < 6 kV at single cylinder

Test requirement: Starting speed

CauseIgnition coil


c kV1

15.0924-525117

Fault image

17. No decay process

Test requirement: Starting speed

CauseIgnition coil or ignition control module.


15.0924-525118

Fault image

18. Too few decay processes


CauseIgnition coil or ignition control unit

[WI20

10

0

I

.

I

.

I

.

I

.

I--

.

1

PlS-OO22-57

15.0924-525119

Fault image

19. Too few decay processes.


CauseIgnition coil or ignition control module.

23

13

C

15.0924-525120

15430 Replacing spark plugs

Spark plug connector . . . . . . . . . . . . . . . . . . . . loosen by turning to left and right and pull off.Blow out recesses with compressed air.

Ignition cables . . . . . . . . . . . . . . . . . . . . . . . . . clean, when installing, ensure the ignition cablesare correctly laid.Firing sequence: l-4-3-2

Spark plugs . , . . . . . . . . . . . . . . . . . . . . . . . . . remove, install, use only approved spark plugwrench (with Nm limiter “B”).A 102589020900B 16258901 0900C Vehicle tool

Installation noteInstall only approved spark plugs with taperedseat (a).Tightening torque 20 Nm.

15.0924-530/l

1 s-535 Removal and installation of ignition or high voltage distributor

Precedmg work:-

Tl s5/3 s29/2 81711mew m?65

Distributor cap . . . . . . . . . . . . . . . . . . . . . . . . . unscrew, screw on.With TSZ, vacuum line and sensor cable (2) . . . . detach at distributor, fit on.Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . set to ignition TDC of No. 1 cylinder by aligning

markings on distributor rotor (3) and distributorhousing (1). In addition, the pointer (8) on timingcase cover must be above the TDC mark ofvibration damper (arrow).

Caution!Crank engine only in direction of rotation.

Distributor mounting (5) . . . . . . . . . . . . . . . . . . . loosen. Remove distributor.

15.0924-535/l

Installation . . . . . . . . . . . . . . . . . . . .

Sealing disc and distributor rotor (3) . .

Screw (5) ..................... . . . . . . . tighten.

Ignition cables ................. . . . . . . . Install. Firing sequence l-4-3-2

. . . . . . . set engine to ignition TDC by aligning thepointer (8) on timing case cover exactly to TDCmark of vibration damper.

. . . . . . . install at distributor. Align distributor rotor tomarking on housing. Insert distributor.With EZL ignition system, align screw in middleof oblong hole (pay attention to note).With TSZ ignition system, set ignition point(15-515).

NoteIt is not possible to set the ignition point on theEZL ignition system by turning the high voltagedistributor. The ignition point is determined bythe Ignition control module. Test distributorignition system, if necessary (15-540).

If the engine has been cranked with thedistributor removed, set ignition TDC of No. 1cylinder (05-215).

15.0924-53512

15-540 Testing distributor ignition system (III)

Preceding work:Testing, adjusting engine (07.3-l 10)

Precondition for testSpark plugs, Ignition cables, distributor rotorand distributor cap in proper mechanical andelectrical order.

Test e. g. by visual inspection, measuringresistance and ignition oscilloscope.

P15-0424-59

Connection diagram for engine tester with oscilloscope

Bll!Z Engme coolant temperature sensor617/l Intake air temperature sensorGI BanefyL5 Crankshaft postlon sensor

N1/2R4R16

lgnltlon control moduleSpark plugsReference reslstor

15.0924-540/l

s513 High voltage distnbutors29/2 Wide open throttle/closed throttle posItIon switchTl lgnttlon co11x11 Dlagnostlc connector/terminal block termmal TD

1 Segments on flywheel/driver disc2 Vacuum line030 Engine tester with oscllloscooe

NotePay attention to the safety precautions(15-505) when performing work on the ignitionsystem. Switch off ignition when unplugging andconnecting the connectors at the Ignition controlmodule.

The test is split up into two sections:

A. Engine not runningThe basic functions of the ignition system aretested in this section.

Special tools

I1245890963001 i 201 589 00 99 001

Commercially available testers

B. Engine runningFault sources in the ignition advance or at theappropriate components may affect the handlingof the vehicle.

If a complaint is received regarding the handlingof the vehicle, first of all test the ignitionsystem. Then, continue troubleshooting at theCFI system.

Multimeter e. g. Sun, DMM-5Fluke, Multimeter 23Hermann, Avometer 2003

Engine tester e. g. Hermann, Datascope 9800Bosch, MOT 301:400Sun, 2110BEAR, D AC E

15.0924-54032

Test data

Resistances (test data from O-100” C)

Position sensor coil resistance(terminals 7 and 31d) ninsulation (terminal 7 and ground) kR

Drstributor cap per terminal, ndistributor rotor,spark plug connector

660-l 2002 200

700-l 300

Voltages, engine not running, ignition switched on

Terminals 15 and 31 (contacts 5 and 2 diagnostic connector) Battery voltage

Between termrnals 1.5 and 1(contacts 5 and 4 diagnosis socket) V 0

4-pin round connector terminals 15 and 31

4-pin round connector terminals 16 and 31

V 1 Battery voltage

V Battery voltage

Dwell angle

Ignition point at starter speed in ’ CKA ITDC 220

Test ignition points with engine running (15-515).

15.092&540:3

A. Engine not running

NoteIf the specified value of a test step, e. g. teststep 1 .O, is in order, continue immediately withtest step 2.0.

If the specified value of step 1.0 is not in order,it is then necessary to continue with step 1 .l.

key to symbols:+=@@- Multimeter direct voltage modeq Multimeter resistance mode-O-_ Oscilloscope

- c ContactConnector

T Ground

On/offratioreadout


1.0VoltageSUPPlY

2.0Crankshaftpositionsensor L5

Test connection

N11231 d-J=@+- 15

L531d _c+@+-- 7

Operation/Requirement

Ignition: ON

Ignition: OFFDetachcrankshaftposition sensorconnector atIgnition controlmodule.

Specifi-cation

Batteryvoltage


Test wiring and contactsaccording to wiring diagram(from battery via ignitionlock to Ignition controlmodule).

Replace crankshaft positionsensor (LS).

15.0924-54014

On/offratioreadoui

. .


,............,....2.2Insulation ofsensor coil

3.0Dwell angle

4.1Stall currentcutoff

. . . . . . . . . . . . . . . . . .4.2Ignition coilprimary Tl

Test connection

L531d _t---o*_- 7

,....

---cL

. . . . . . . . . . . . . . . . .L5

q-7

Engine tester

Cir. 1 GCir.

. . . . . . . . . . . . . . . . . . . . . . . . .Tl

Cir. 1 *Cir.


Detachcrankshaftposition sensorconnector atIgnition controlmodule.Engine: Start

. . . . . . . . . . . . . . . . . . . . . .Detachcrankshaftposition sensorconnector atIgnition controlmodule.

Engine: Start

Ignition: ON

Engine: Start

. . . . . . . . . . . . . . . . . . . . ..(

Ignition: OFFUnscrewwiring atignition coil.

Specifi-cation

seediagram

1200 kR

9O-49”or1 o-54%

IV

3V

>ov. . . . . . . . . . . . .3.3-3.6 R


Signal too small/no signal:replace position sensor.Different voltage height:test segments. ReplaceIgnition control module.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace crankshaft positionsensor.

Dwell angle not totolerance:replace Ignition controlmodule. No dwell angle:test stall current cutoff.

Replace Ignition controlmodule and ignition coil.

Test wiring and contactsfrom Ignition control moduleto ignition coil or replaceIgnition control module.Replace ignition coil.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace ignition coil.

15.0924-54015

On/offratioreadout


5.0Primarycurrent

6.0Primarycurrentlimiting

7.0Ignitionvoltage atterminal 4ignition coil

. . . . . . . . . . . . . . ..~7.1Ignitioncableterminal 4

. . . . . . . .7.2Distributorrotor

. . . . . . . . . . . . .7.3Distributorcap

Test connection

Engine tester

Scope image:primary parade

Engine tester

Scope image:Secondaryoverlap

Engine tester

Scope image:Secondary parade

. . . . . . . . . . . . . . . . . . . . .Tl s5i3Cir. 4 * Cir. 4

. . . . . . . . . . . . . . . . . . . .Distributor

rotor*

Middle Peak

. . . . . . . . . . . . . . . . . . . . . . .s5i3*

Cir. 4 Carbon

Dperation/qequirement

!ngine: Start

%gine: Start

fngine: Start

. . . ..t..........gnition: OFFDetach ignition:able terminalt at ignition:oil anddistributor cap.

. . . . . . . . . . . . . . . . .gnition: OFFqemovedistributor cap.

. . . . . . . . . . . . . . . . .gnition: OFFDistributor cap,emoved anddetach ignition:able terminal1.

Specifi-cation

>200 v

seediagram

r0 kV

..,......,.....Cl52

,...,,...,.....700-1300 szandvisualinspec-tion

,........,.....700-1300 Qperterminalandvisualinspec-tion


Replace Ignition controlmodule.

Replace Ignition controlmodule.

Test ignition cable terminal4, distributor rotor,distributor cap and ignitioncoil.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..__....._...Replace ignition cableterminal 4.

. . . . . . . . . . . . . . .._..............._...._.....Replace distributor rotor.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace distributor cap.

15.0924-54016

On/offratioreadou


7.4Ignition coilsecondaryTl

8.0Ignitionvoltage atsinglecylinder

. . . . . . . . . . . . . .8.1Ignitioncable withspark plugconnector

. . . . . . . . . . . . .8.2Spark plugs

Test connection

TlCir. 4 ++ Cir. 1

Engine tester

Scope image:Secondary paradeHigh voltage clampat cylinder ignitioncable (e. g. cylinder3)

,,..........,,,.................*

Ignition Sparkcable plug

connector

. . . . . . . . . . . . . . . . . . . . . ..f..Visual inspection


Ignition: OFFUnscrewcables atIgnition coil.

Engine: Start

..,...................~Ignition: OFFDetach ignition:able withspark plugconnector atspark plug anddistributor.

..,,...................gnition: OFFqemove spark3lug.

Specifi-:ation

3-13 kQ

>6 kV

. . . . . . . . . . . .flectrodeJapI.8 mm


Replace ignition coil.

Test distributor cap,distributor rotor,ignition cables with sparkplugs.

.,,..........,,,..........................Replace ignition cable withspark plug connector.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._........Replace according tocondition.

Test A completed.

15.0924-540/7

B. Engine running

Pay attention to safety precautions (15-505).

On/offratioreadoui

Test step1Test scope

1.0gnition point

. . . . . . . . . . . . .1.1qeference*esistor[R16)

. . . . . . . . . . . . . . . .1.1.1Referenceresistor(Rl6)

,..................1.1.2Cables andcontacts

Test connection

Ingine tester

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N112

1. **3Sensor

connector4-pin

..,,...........................R16

zdle-++-

A Z

. . . . . . . . . . . . . . . . . . . . . . . . .316 Nli2-_c **3

Sensorconnector

4-pin


Engine: Testat normaloperatingtemperature atspecifiedspeeds andwith/withoutvacuum.

. . . . . . .._.............Ignition: OFFDetach sensorconnector atIgnition controlmodule. Payattention toassignmentengine/referenceresistor.

.,........,,..........Ignition: OFFDetachreferenceresistor.

. . . . . . . . . . . . . . . . . . . . . .Ignition: OFFDetachreferenceresistor.Detach sensorconnector atIgnition controlmodule.

Specifi-cation

see table(15-515)

,.............depend-ing onreferenceresistorsetting,see table

. . . . . . . . . .see table

. . . . . . . . . . .>lsZ

>l R


Reference resistor, coolanttemperature sensor,WOTCTP switch, vacuumadvance, transmissionoverload protection(102.983199).

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reference resistor, cables,contacts.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reference resistor

. . . . . . . ..t..............................Replace cables or contacts.

Test negative cable to Wl 1or WlO, replace.

15.0924-54018

On/offratioreadou


1.2Enginecoolanttemperaturesensor(Bl li2)

. . . . . . . . . . . . .1.2.1Enginecoolanttemperaturesensor(B1112)

. . . . . . . . . . . . . .1.2.2Cables andcontacts

. . . . . . . . . . . . .1.3WOTCTPswitchclosedthrottlepositiondetection

Test connection

-L_N1/2*)-1

Sensorconnector

4-pin

. . . . . . . . . . . . . . . .Bl l/2

;ot-(2-pzGreen/black

cable

B1112

. . . . . . . . . . . . . .B1112

blackcable

N112

connector4-pin

. . . . . . . . . . . . . . . . . . . . . . . . . . .s2912x

2 , * -1


Ignition: OFFDetach sensorconnector atIgnition controlmodule

. . . . . . . . . . . . . . . . . . . . . .Ignition: OFFDetach sensorconnector atIgnition controlmodule

,.....................,Ignition: OFFDetachconnector attemperaturesensor andsensorconnector atIgnition controlmodule.

. . . . . . . . . . . . . . . . . . . . . .Ignition: OFFDetachconnector(S2912x).

Specifi-cation

at80 “C290-360 Rfurthervalues,seediagram

. .._..........

measure2 x dia-gonally. . . . . . . . . .<l ff?see note

. . . . . . . . . . . . .Idleposition:< 1ROtherpositions:x)


Coolant temperature sensor(B1112)Cables, contacts.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace coolanttemperature sensor (B1112)(07.3-251).

Replace coolanttemperature sensor (B1112)(07.3-251).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace cables or contacts.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set or replace WOTCTPswitch. Open circuit.

15.0924-54019

Onioffratioreadoul


Cables andcontacts

. . . . . . . . . . . . . . .._..1.4Vacuumadvance

. . . . . . . . . . . . . . .1.5

Test connection

SensorzonnectorI-pin

. . . . . . . . . . . . . . .Engine tester

3ld -c-o->

N3- 13


Ignition: OFFDetach sensorconnector atIgnition controlmodule andCFI controlmodule.

. . . . . . . . . . . . . . . . . . . . . .Engine: normaloperatingtemperature,speed1500imin.Detachvacuum hoseat Ignitioncontrolmodule.

Connectvacuum hoseat Ignitioncontrolmodule.

. . . . . .._..............Detachcrankshaftposition sensorconnector atIgnition controlmodule.Engine: Start

Specifi-cation

. . . . . . . . . .Ignitionooint?etarded

Ignitionoointadvancec

. . . . . . . . . . . . .seejiagram

Js 2 1v


Replace cable or contact.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vacuum hose leaking.Connection at intakemanifold blocCFld.Pressure sensor in Ignitioncontrol module faulty.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Different voltage heights:Test segments (visualinspection)Replace flywheel/driver discwith segments.

15.0924-540/l 0

On/offratioreadou

. . . . . . . .


1.6Transmis-sionoverloadprotection,only engine102.983199withautomatictransmission

. . . . . . . . . . . .1.6.1Transmis-sionoverloadprotectionswitch(S65)

Test connection

N112-L. -++-4

Sensorconnector

4-pin

. . . . . . . . . . . . . . . . . .S65

_-=@-,


Depressparking brake.Pay attentionto safetyprecautions.Engine: StartIdle speedselector leverposition: “D”

Selector leverposition:“P” or “N”

. . . . . . . . . . . . . . .Detachconnector attransmissionoverloadprotectionswitch S65.Depressparking brake.Pay attentionto safetyprecautions.Engine: StartIdle speedselector leverposition “D”

Selector leverposition:“P” or “N”

Specifi-cation

< lsz

lJ


Transmission overloadprotection switch (S65)CablesContacts

Transmission overloadprotection switch (S65)CablesContacts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace transmissionoverload protection switch(S65).

Replace transmissionoverload protection switch(S65).

15.0924-540/l 1

On/offratioreadout


1.6.2Zables andzontacts

2.0Iwell angle

3.0iigh voltagelistributorjdistributor‘otor

Test connection

565 Nli2- c +YY-4

Sensorconnector

S65A*

4-pin

- L

Engine tester

disual inspection


Ignition: OFFDetachconnector attransmissionoverloadprotectionswitch (565)and Ignitioncontrol module(N1/2).

Ignition: OFFDetachconnector attransmissionoverloadprotectionswitch (S65)and Ignitioncontrol module(N112).

Engine speed3200/min,normaloperatingtemperature.Detach sensorconnector atIgnition controlmodule andvacuum line.Engine: Start

Ignition: OFFRemovedistributor cap.

Specifi-cation

< lsz

27-54”

;:-60%




Replace Ignition controlnodule.

Distributor cap,distributor rotor has cracks,nterference suppressionpesistors faulty.

15.0924-540112

On/offratioreadout

. . . . . . . .


3.1Distributorcap

. . . . . . . . . . . . . . . .3.2Distributorrotor

4.0Scopeimages

Test connection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Distributor

rotor*

Middle Peak

Scope imagesParadeOverlapRaster


Ignition: OFFRemovedistributor cap.

. . . . . . . . . . . . . . . . . . . . . . .Ignition: OFFRemovedistributor cap.

Engine: StartAt idle.

Specifi-cation

700-1300 Rperterminal

. . . . . . . . . . . . .700-1300 Randvisualinspec-tion

seescopeimages15-525


Replace distributor cap.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace distributor rotor.

Ignition coilDistributorIgnition cablesSpark plugs

Test B completed.

15.0924-540/l 3

Crankshaft positionsensor signal LSt1 1 st segmentt2 2nd segmentd Per& for one crankshaft

revolutionUs Voltage (2 1V)

Crankshaft position sensor connector L5Test resistance or voltage signal betweenconnection 7 and 31d.

, - 3 1 d

P15-0240-13

J(kV)lo-

~- Schliel3 .I

4 5 4QC 3 5 ’ 3 0 ‘ 2 5 2 0 ’ 153 10 5 ” 8 Zyl.1 I I I L I/ I 1

9 0 8 0 ’ 7 0 ‘ 6 0 5b 40’ 3 0 ’ 2 0 10; 4 Zyl.1 -1 I I I /

6 0 5 0 ‘ 4 0 3 0 2 0 m 6 Zyl.

P15-0244-55

Current llmlting

15.0924-540114

Notes regarding testEngine coolant temperature sensor (61 l/2)

Diagram of coolanttemperature sensor (I31 l/2)

4-pin engine coolant temperature sensor

Pin assignment of connector:1 = Ignition system temperature sensor2 = CFI temperature sensor3 = Engine ground at intake manifold for DI4 = CFI control module ground

NoteNational version @ 1988 without connectordesignations.

When testing the engine coolant temperaturesensor, measure the resistances 2 x diagonallyand compare.

2oooo

10000Bocae.ooo40003000

EZL KE

EZLKE

Note regarding ignition distributorImproved distributor rotor with polyamid bush.

Production breakpoint: January 1989

Model Engine Engine end EngineNo. manual end No.transmission automatic

transmission

201.024 102.962 211498 108898201.028 102.985 30070 78183

15.0924-540:16

s513 S 2912 817/i B1112

w 3IIb d

o,xg”:5* --&-0,75gnisw 10,75suige--+-C,5gn

R,:a,

Distributor ignition system wiring diagram, engines 102.96:98 KAT as of 09;89

81112817/lL5N1/2R16S5i3S29l2S29/2xl

Engine coolant temperature sensor (DKFI)Intake air temperature sensor (DI)Crankshaft postton sensorTranslstortzed lgnltlon control module (DI)Reference resstor (DI)High voltage dlstnbutor

TlW3WlOWllx11

Wide open throttle/closed throttle postlon switchWide open throttle/closed throttle posItIon switch fplug connectlonlgnitlon c o i l

Ground, front left wheelhouse (ignltlon coil)

Battery groundEngtne ground (electric cable bolted on)Diagnosis socket’terminal block terminal TD

h

To CFI control module contact 13To CFI control module contact 7 (ground)To CFI control module contact 5To CFI control module contact 21Voltage supply terminal 30Model 201: to fuse 13 wa electrical centerconnector S. contact 11Voltage supply terminal 15, unfusedModel 201: electrlcal center connector S,contact 4Equipment with terminal TD (e. g. tachometer,fuel pump relay, CFI control module, compressorcutoff control module)

z Connector sleeve (soldered connector in wiringharness)

15.0924-540! 17

15-542 Testing breakerless transistorized ignition (TSZ)

Precedmg work:Testing, adjusting engme (07.3-l 10)

Precondition for testSpark plugs, ignition cables, distributor rotorand distributor cap in proper mechanical andelectrical condition.

Test e. g. by visual inspection, measuringresistance and ignition oscilloscope.

Connection diagram for engine tester with oscilloscope

Gl Battery S512Nl/l Transrstonzed ignltlon (TSZ) control module T lR4 Spark plugs Xl 1

030

Breakerless dlstnbulorlgmtlon co11Dtagnostlc connector/terminal block termmal TDEngine tester with oscilloscope

15 0924442 1

NotePay attention to the safety precautions(15-0505) when performing work on the ignitionsystem. Switch off ignition when unplugging andconnecting the contacters at the TSZ controlmodule.

Special tool

1201 589 00 99 00)

Commercially available testers

Multimeter e. g. Sun, DMM-5Fluke, Multimeter 23Hermann, Avometer 2003

Engine tester e. g. Hermann, Datascope 9800Bosch, MOT 3011400Sun, 2110BEAR, D AC E

Test data

Resistances (test values at approx. 20 “C)

Ignition coil primary (terminals 1 and 15) n 0.5-0.9

Ignition coil secondary (terminals 1 and 4) kQ IS-16

Induction sensor Coil resistance(terminals 7 and 31d) nInsulation (terminal 7 and ground) k!J

Distributor cap per terminal, szdistributor rotor,spark plug connector

600f 100> 200

700-l 300

15.0924-54212

Voltages, engine not running, ignition switched off

Terminals 15 and 31 (contacts 5 and 2 diagnostic connector)

Between terminals 15 and 1(contacts 5 and 4 diagnostic connector) V

Dwell angle

At starter speed 17-34”

Battery voltage

15.092444213

national vers

Distributor3osch No.

nition oint ITSi

Engine Type-Ifue13)

iol

-----IInstalledvalue ofignitionpoint in“WAbeforeTDC atstartingspeedwithoutvacuum

nTest and settingvalue ‘) ofgnition point in“CKA BTDC + 1tiithout;withJacuum

un-leaded

1

Vacuumadvanceof ignitiorooint in“WA3TDC at

Ignition advance in “CKPBTDCkthout vacuum

1.5001nin

idling 1500;min

3000:’min

15001nin

Idling

38 RON

102.9611984

102.961102.985as of1983) If normi

5 with ?4-28*)19-252)

22-26*)

I 237 002 094

I 237 002 098 14-l 8*)

I with fuc?I c)f less thar mm. 88 I IN) or low-compressron engrnes wrtnsd and adapted to the octane number of the fuel

:ompressron engines are operafuel of less than 92 RON (min. 82 MON), the lgnrtron pornt should be retarused. A reference value for thus adjustment IS: retard rgnrtron pornt by 1 - 2” CKA per 1 RON. The maxImum retardabon mustnot exceed 6” CKA.The lgnrtlon correctlon should be entered by hand on the “engine settrng data” InformatIon plate.The result IS reduced power output and increased fuel consumptron. In addrtron, the engrne must not be operated at full load.The full ignltlon advance should be re-set as soon as fuel of the specified octane number IS agaln avallable.

2) Test at 3500imln.3) Vehicles wtth catalytic converter must be operated with unleaded fuel.4) This value must be identrcal at normal operatrng temperature of engrne with and wrthout vacuum: test ignrtron advance In the

warmrng-uo phase if necessary (15-543).

NoteIf the specified value of a test step, e. g. teststep 1.0, is in order, continue immediately withtest step 2.0.

If the specified value of step 1.0 is not in order,it is then necessary to continue with step 1.1.

Key to symbols:q Multimeter direct voltage modeq Multimeter resistance mode-O_ Oscilloscope

--x ContactConnector

T Ground

On/offratioreadout


1.0Voltagesupply

2.0Inductionsensor

. . . . . . . . . . . .2.1Insulation ofsensor coil

3.0Dwell angleof (TDsignal)

Test connection

Nl!l31 -(-++- 15

Connector31d J++- 7

. . . . . . . . . . . . . . . . . . . . . . . .Sensor coil

_l-*_

Engine tester


Ignition: ON

Ignition: OFFDetachinductionsensorconnector atTSZ controlmodule (greencable).

. . . . . . . . . . . . . . . . . . . . . . .Detachinductionsensor cableconnector atdistributor.

Engine: Start

Specifi-cation

Batteryvoltage

600 Sz+100 !A

. . . . . . . . . . . . . . .2200 kR

7-34”


Test cables and contactsaccording to wiring diagram(from battery via ignitionlock to TSZ controlmodule), ground connection(W3).

Replace induction sensor.Test cables and contactsfrom TSZ control module todistributor.

. . . . . . . . . . .._......_.......................Replace induction sensor.

Dwell angle not totolerance:replace TSZ controlmodule. No dwell angle:test stall current cutoff.Pay attention to notes onTD signal (15-512).

15.0924-54215

On/offratioreadout


4.0Stall currentcutoff

. . . . . . . . . . . . . . . . . .4.1Ignition coilprimary Tl

5.0Primaryvoltage

6.0Primarycurrentlimiting

7.0Ignitionvoltage atterminal 4ignition coil

. . . . . . . . . . . . . . . . . . . .7.1Ignitioncableterminal 4

Cir. 1 &Cir.

. . . . . . . . . . . . . . . . . . . . . . . . . . .Tl

Cir. 1 *Cir.

Engine tester

Scope imagePrimary parade

Scope imageSecondaryoverlap

Engine tester

Scope imageSecondary parade

. . . . . . . . . . . . . . . . . . . . . .Tl 332Cir. 4 * Cir. 4


Ignition: ON

Engine: Start

. . . . . . . . . . . . . . . . . . . . . . . .Ignition: OFFUnscrewcables atignition coil.

Engine: Start

Engine: Start

Engine: Start

. . . . . . . . . . . . . . . . . . . . . . . .Ignition: OFFDetach ignitioncable terminal4 at ignitioncoil anddistributor cap.

Specifi-cation

>ov,..............0.50.9 51

seediagram

ha kv

. . . . . . . . . .<l Q


Replace TSZ controlmodule and ignition coil.

Test cables and contactsfrom TSZ control module toignition coil or replace TSZcontrol module.Replace ignition coil.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace ignition coil.

Replace TSZ controlmodule.

Replace TSZ controlmodule.

Test ignition cable terminal4, distributor rotor,distributor cap and ignitioncoil.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace ignition cableterminal 4.

15.0924-54216

On/offratioreadou

...........

Test stepiTest scope

7.2Distributorrotor

. . . . . . . . . . . . . . .7.3Distributorcap

. . . . . . . . . . . . . . . . . .7.4Distributorcap/rotor

. . . . . . . . . . . . .7.6Ignition coilsecondaryTl

8.0Ignitionvoltage atsinglecylinder

,.....,.............8.1Ignitioncable withspark plugconnector

Test connection

Distributorrotor*

Widdle Peak

. . . . . . . . . . . . . . . . . . . . . . . . . .S5l2

Cir. 4 * Car-bon

. . . . . . . . . . . . . . . . . . . . . . . .Asual inspection

,....................,.,.....,.

Zir. 4 + Cir. 1

Engine tester

Scope imageSecondary paradeiigh voltage clampat cylinder ignition:able (e. g. cylinder3)

. . . . . . . . . . . . . . . . . . . . . . . .-=@-

gnition Spark:able plug

connector


Ignition: OFFRemovedistributor cap

. . . . . . . . . . . . . . . . . . . .Ignition: OFFDistributor capremoved anddetach ignitioncable terminal4.

. . . . . . . . . . . . . . . . . .Ignition: OFFRemovedistributor cap.

. . . . . . . . . . . . . . . . . .Ignition: OFFUnscrewcables atignition coil.

Engine: Start

. . . . . . . . . . . . . . . . . . . . .Ignition: OFFDetach ignitioncable withspark plugconnector atspark plug anddistributor.

Specifi-cation

700-1300 aandvisualinspec-tion. . . . . . . . . . . .700-1300 nperterminalandvisualinspec-tion

. .

. .6-16 kQ

~6 kV

. . . . . . . . . . . .700-1300 a


Replace distributor rotor.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace distributor cap.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Distributor cap,distributor rotor has cracks.

. . . . ..f..................................Replace ignition coil.

Test distributor cap,distributor rotor,ignition cables with sparkplugs.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace ignition cable withspark plug connector.

15.0924-542f7

On/offratioreadou

.


3.2Spark plugs

3.0gnition point

vacuumadvance

Test connection

Visual inspection

Engine tester

. . . . . . . . . . . . . . . . .Engine tester


Ignition: OFFRemove sparkplugs.

Engine:Test at normaloperatingtemperature atspecifiedspeeds andwith/withoutvacuum.

. . . .._..................Engine:Normaloperatingtemperature,speed approx.1500:min.

Detachvacuum hose.Fit on vacuumhose.

Specifi-:ation

3ectrodgapI.8 mm

see table

. . . . .gnitionIoint,etarded

gnitionIointidvance

possible cause/Remedy

Replace according tocondition.

Setting of vacuum advanceIgnition advance in warm-upchase(15-545).

. . . . . . . . . . . . . . . . . . . . . . . . . . .Vacuum hose leakingConnection at intakemanifold blocked.Vacuum unit faulty.Distributor faulty.

15.0924-54218

U(kV)

L

i5I

I t__ SchlleO.j- ~ -- -

45 40. 35’ 30' 25 20' 153 10 5' 6 Zyl+ 1 I 1 I I 1/ II90 80 70' 60 ’ 50 40 30' 20 10. 4 Zyl.I T I 160 50 40 30 20 6 Zyl.

Current hmltlng

induction sensor connectorTest resistance between connections 7 and 31d.

Test insulation of induction sensor coil to ground( 2200 kQ).

, - - - 3 1 d

PlS-0240-13

15.0924-54219

Ignition coil (Tl)If plug (arrow) pressed out, replace.

x11

TSZ wiring diagram

Nl/l5512Tlw3x11a

b

C

Transrstonzed rgnrtfon control moduleDrstnbutorlgnrtron co11Ground, front left wheelhouse (ignttion cod)

Dragnostfc connector/terminal block termfnal TDEquipment wrth termfnal TD(e. g. tachometer, fuel pump relay, CFI control module,compressor cutout control module)Voltage supply terminal 30Model 201: to fuse 13 vta electrical center coupling S,contact 11Voltage supply terminal 15, unfusedModel 201: electrical center coupling S. contact 4

r

Tl

15-543 Testing ignition advance in warm-up phase (only TSZ)

Engine 102.961 Basic Version

P15-0201-37

Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connect (16415).

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . warm up to approx. 80 “C engine coolanttemperature. Run at idle speed and take readingof ignition point.

Vacuum line . . . . . . . . . . . . . . . . . . . . . . , . . . . white/red, detach at therm0 valve (3).The ignition point must not alter.

If the ignition point alters, check whethervacuum lines are correctly laid and leaktight.Check therm0 valve. The therm0 valve shouldhave clear passage above approx. 60 “C.

15.0924-5431

Vacuum line . . . . . . . . . . . . , . . . . , . whitelred, detach at thermovalve (3) and plugthe vacuum connection at thermovalve. Theignition point must be advanced approx. 8 -12”.

If the ignition point is not advanced, checkrestrictor (1) for clear passage, check valve (2)and vacuum unit at distributor for leaktightness.

Function descriptionTo improve the perfprmance in the warm-upphase, the ignition point is advanced 8 - 12”CKA via the vacuum unit at the distributor up toa coolant temperature of approx. + 60 “C inaddition to the centrifugal advance.

Below approx. 60 “C engine coolant temperature(therm0 valve closed) the vacuum passes fromthe intake manrfold via the restrictor (1) andcheck valve (2) to the vacuum unit at thedistributor when the engine starts.

The check valve (2) ensures that the maximumvacuum IS retained at the distributor ‘(also whenaccelerating) which results in the additionalignrtion advance via the vacuum unit.

Above approx. 60 “C the thermovalve (3) opens,and the vacuum is reduced at idle speed to thethrottle valve assembly.

A restrictor (1) is installed to ensure that thevacuum for the other connected componentscannot escape through the connection at theintake manifold at idle speed.

etrofitting corrugated hoses for ignition cables

Corrugated hoses (a) 0 13 mm and(b)BlOmm . . . . . . . . . . . . . . . . . . . . . . . . . . cut to size according to table as protection

against beech martens biting through cables.Push corrugated cables (a) 0 13 mm and (b)0 10 mm approx. 10 mm together.

Spark plug connector . . . . . . . . . . . . . . . . . . . . unplug, plug in. Unscrew spark plug connectorfrom ignition cables, screw on.Push corrugated hoses onto ignition cables.

Angled connector at distributor . . . . . . . . . . . . . . unplug, plug in. Unscrew angled connector fromignition cables, screw on.Push corrugated hoses appropriate length ontoignition cables.

Length (mm)* Assignment

Corrugated hose 0 10 mm (total length approx. 1260 mm)

4 110 Ignition cable at spark plug connector2 125 Ignition cable at distributor, cylinders 1 and 41 175 Ignition cable at distributor, cylinder 21 75 Ignition cable at distributor, cylinder 31 320 Ignition cable from distributor to ignition coil

Corrugated hose 0 13 mm (total length approx. 300 mm)

10 30 1 ea. at each spark plug and angled connector* Maximum length; shorten ignition cable accordingly, if necessary.

15.0924-547/l

Parts

Designation Part No.

Corrugated hose (10 mm diameter) running meters 000 159 01 83Corrugated hose (13 mm diameter) running meters 000 159 02 83Available from: ZEG Germershelm

Time allowedBasic work:Combined work:

02-l 508/0102-l 509/O 1

Engine lubrication system 18

18 Engine lubrication system

Job No.

Oil circuit, oil pressure, overpressure and bypass valve ................... ....... 18 - 005Measuring oil consumption ....................................... ....... 1 8 - 0 2 5Removal and installation of oil filter ................................. ........ - 110Removal and installation of oil pump ................................ ........ - 210Removal and installation of oil overpressure valve ...................... ........ - 215Checking oil level indicator ....................................... ........ - 220Function of low engine oil level indicator ............................. ........ - 225

181

.,.........,......._._,__................ __I~.I~-..Y_.~.~.-YYY)YLYI

18-005 Oil circuit, oil pressure, overpressure and bypass valve, oil filter

Oil circuit

190 160

pl6 - 0 0 7 2 - 5 6

18.09-00511

P18-0073-56A

1 4 011 overpressure valve 6 0 011 pipe1 6 011 pump 1 6 0 Camshaft51 Oil filter 1 9 0 Idler gear shaft52 011 pressure gauge

PlB-5179.33A

Viscosity grades for engine oils according to SAE

Adhering to the SAE grades in accordance with ambient temperatures would result in frequent orlchanges. Consequently, the temperature ranges are merely guidelines, which can be exceeded in theupper or lower limrts for brief periods.In moderate climatic zones SAE 30 may be used from the spring on for all engine models. SAE low-40or SAE IOW-50 may be used as an all-seasons 011 for all gasoline engines.

18.09-005!2

Oil capacity in liters (approved engine oils see Service Product Specifications).

Engine (total capacity when refilling) 5,s

Engine capacity when changing oil and filter 5,o

Oil sump, max.!min. 4,8i2,8

Opening pressures of oil overpressure and oil filter element bypass valve bar gauge pressure

Oil overpressure valve in timing case cover 4,5-0,8

Oil filter element bypass valve in oil filter (difference pressure) 35

Function of oil circuit

The oil is drawn off at the lowest point of the oilsump through the strainer basket and the oilsuction pipe (7) to the suction chamber (B) andpumped into the tooth gaps, which producepressure chamber (A) as a result of theeccentric arrangement of the oil pump gears (1and 2).

To ensure that the oil remains in the tooth gapson its way from the suction to the pressurechamber, a sickle (a) is attached between bothgears in this area.

1 Inner 011 pump gear2 Outer 011 pump gear3 Oil pump cover7 Suction pipe11 M6 x30 bolt (9 off)lla Ton: bolt14 Overpressure valve15 Compression spnng16 Screw plug17 Seal22 Dnve sleeve44 Timing case cover

Pressure chamberSuction chamberDamplng chamberSickleTo 011 filter

vtie l la

0- _ - i - - 4 4

W\fa h\\\ \\ \ 1

P18-0033-35A

16.09-005 3

The teeth mesh again at the end of thepressure chamber and force the oil out of thetooth gaps.

The oil flows from the pressure chamber (A)along the feed passage (d) in the timing casecover and crankcase to the oil filter.

Pressure chamber (A) and vacuum chamber (6)are linked by the oil overpressure valve.

From an oil overpressure of approx. 4 bar, thepiston (14) of the oil overpressure valve ispushed against the force of the compressionspring (15) and opens the relief cross-section,through which part of the oil flows back to thesuction chamber (B), depending on oil pressure.

As the piston (14) is moved, the oil in chamber(C) is displaced and flows through the reliefgrooves on the outside of the piston to thesuction chamber (B).

1234567691011121314151617A0

011 filter bottom sectionReplaceable cartrrdgeConnectron fittingValve coneCompressron springSpring plateLocking nngFalter elementValve plateValve plate carrrerCompressron springValve holderCompressron springSpring plateRubber diaphragmContact-pressure plateSealFeed from 011 pumpUnfiltered 011 to mam oilgalleryFaltered oil to mam 011galleryConnectron for electrical oilpressure sensor

Oil filterThe oil coming from the feed passage (A) flowsthrough the feed and discharge hose in thecontact-pressure plate (16) into the replaceablecartridge.

As a result of the oil pressure, the rubberdiaphragm (15) is raised and the oil flowsthrough the filter element (8) from the outside tothe inside (arrows).

On the inside, the valve plate (9) is opened as aresult of the pressure of the filtered oil. The oilflows through the connection fitting (3) to thegallery (C) and on to the main oil gallery in thecrankcase.

C

D

18 09.005,4

The two check valves (9-12 and 13-16) preventthe filter cartridge from running empty when theengine is switched off and when changing thefilter.

The bypass valve (4-7) opens when thedifference pressure between dirty and clean oilside exceeds 3 bar. This is the case if the filterelement is severely fouled. The oil then flowsthrough the gallery (B) unfiltered to the main oilgallery.

When changing the filter, a slight quantity of oilflows out of the replaceable cartridge despite thecheck valves, which flows together with oil fromthe bottom of the oil filter along the galleries (Aand C) to the engine.

Oil supply of chain tensionerThe oil flows through a passage which branchesoff vertically up the way at the front of the mainoil gallery, to the cylinder head, flows in a crossgroove (arrow) to a vertical feed passage incrankcase and on to the chain tensioner.

1363738394041ab

CrankcaseChain tensioner housingThrust pinDetent spnngCompresston spnngCap nutSealFeed passage 1 .l mm dia.Restnction passage 1.2 mmdia.

1

41

40a

39

38

37

36

Lubrication of valve timingThe oil coming from the main oil gallery in thecrankcase, flows through a 4.5 mm dia. jet (A)installed in the cylinder head, and through theannular gap (arrows) direct to the longitudinalgallery (a) in the cylinder head (pressure-oriented oil feed). This oil supply system ensuresthat the oil pressure prevailing downstream ofthe oil filter depending on the operating state,always exists at the hydraulic valve clearancecompensating elements. In addition, the nozzle(A) serves as an oil return flow stop whichprevents the longitudinal passage (a) and thevalve clearance compensating elements running

dry.

I

Part of the oil flows through the restrictionpassage (g) with dia. of 2.5 mm and the twogrooves (arrows) in the rear rocker arm bearingbracket to the rear camshaft bearing and thereinto the hollow-drilled camshaft. The oil flowsthrough the camshaft to the other camshaftbearings (flow-oriented oil feed).

The rocker arm bearing points are lubricatedfrom the longitudinal passage (a) in the cylinderhead and the hydraulic valve clearancecompensating elements supplied with oil (b) fromthere through a passage in the rocker arm.

The cam lubrication is provided through the oilpipe (d) bolted to the rear camshaft bearing.

a

PO5-0160-13

r&09-005/6

Lubrication of idler gear shaft and ignitiondistributor drive

The oil flows from the front camshaft bearingthrough a cross passage to the left front cylinderhead bolt bore and from there along a crossgroove (e) to the feed passage in the crankcase.

The oil flows on to the rear bearing bush (17) ofthe idler gear shaft and through the hollow-drilledidler gear shaft (18b) to the front bearing bush(6) in the timing case cover (44).

The ignition distributor drive (18) is lubricated bysplash oil.

The cam (18d) which is press-fitted to the rearend of the idler shaft gear on engines102.9221924 (non-U.S.) and drives the fuelpump, is lubricated by the oil splash jet (13).

Oil return

Four return passages (arrows) are provided onthe righthand side of the cylinder head (lookingin direction of travel) for the oil return to thesump; part of the oil flows back through thechain box.

i 17 18dPOS-0089-13

PO,-2127-13

18.09-00517

In the crankcase, the oil flowing back is passedalong an oil collecting gallery (arrows) to the castreturn passage.From here, it flows into the oil pan.

Oil pressure and oil pressure gaugeAt normal operating temperature, the oil pressureat idling speed must drop to 0.3 bar gaugepressure.

When the accelerator is depressed, the oilpressure must immediately rise again and be atleast 3 bar gauge pressure at 3000 rpm.

The oil pressure gauge in the instrument clusteris actuated electrically by an oil pressure sensorwhich is bolted onto the oil filter housing (arrow).

FunctionWhen the ignition is switched on, the gauge inthe instrument cluster is constantly energized.Ground is applied in the gauge through thepressure sensor. As the pressure increases, theohm resistance of the pressure sensor increasesand thus alters the gauge reading.

Resistances of pressure sensor as a functionof oil pressure.

Pressure (bar) 0 1 2 3

Resistance approx. Sz 10 69 129 184

18.09-00518

Checking oil levelThe oil level depends, among other factors, onthe oil temperature and on the time for the oil toflow back after the engine is switched off. Forthis reason, do not measure oil level until approx.5 minutes after switching off the engine fromnormal operating temperature (approx. 80 “C oiltemperature).The dipstick must always be withdrawn andwiped off before checking the oil level.

To properly assess the oil level, the dipstickmust be viewed from both sides. Thedetermining factor is always the clear horizontalindication of the dipstick (arrow).

PlB-0082-15

18 09-0059

18-025 Measuring oil consumption

Special tools

NoteOil consumption should be calculated with thedipstick with millimeter graduations and therelated test sheet. It should not exceed 1.0Ii1000 km.

The procedure for measuring oil consumption isdescribed on the front of the test sheet. It isessential to properly observe this procedure.

Oil consumption indicated in mm on the dipstickshould be read off on the basis of the diagramon the rear of the test sheet in ems.

Ar CautionTo avoid any incorrect measurements, checkwhether the engine oil has been diluted with fuelbefore measuring oil consumption.

PO3-0137-17

18.09-025;l

18-110 Removal and installation of oil filter

Preceding work:Air filter removed (09-400 and 09-410).

J’ P18-0050-35A

Replaceable cartridge (1) . . . . . . . . . . . . . . . . . unbolt, bolt on, special tool103 589 02 09 00.

NoteTighten replaceable cartridge by hand, thentighten a further l/4 turns (90”) (step 2).

Plug (54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . for oil pressure sensor, detach, plug in.

Oil filter base (2) . . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, tightening torque 25 Nm (step

4).Gasket (59) . . . . . . . . . . . . . . . . . . . . . . . . . . . replace.

Sealing surfaces . . . . . . . . . . . . . . . . . . . . . . . . clean, seal main oil gallery for this step, open(step 5).

Run engine . . . . . . . . . . . . . . . . . . . . . . . . . . . check for leaks.

18.09-110/l

Special tools

(JOI 5897221 ““Ij103589020909

NoteM 102 engines are equipped with an oil filter withreplaceable cartridge (disposable filter).When changing the filter, the replaceablecartridge is unscrewed and replaced with a newone.

The initial operation and continuous operationcartridges were of different sizes up to 5188.

The housing of oil pressure sensor has beenmodified to provide adequate clearance for thespeedometer shaft.


A lnltlal operation replaceable cartridgeB Continuous operation replaceable cartndge

18.09-I 1012

Standard implementation: December 1984

Model Engine Engine end No.Man. trm. Autom. trm.

Vehicle ident end No.

Non-U.S. version vehicles 102.924 005181 001370 A 170601 F 063039102.962 016655 007928 F 063008

201.024 @ 102.985 000782 006991 F 066585

The initial operation oil filter replaceable cartridgehas been modified (same size as continuousoperation filter) to achieve standardization withengine 103.

Removal and installation

1 Remove and install air filter(09-400 and 09-410).

2 Remove and install oil filter replaceablecartridge, special tool 103 589 02 09 00.

NoteApply a light coating of oil to gasket (arrows)before installing the replaceable cartridge.

Screw on replaceable cartridge and tighten byhand.

Then tighten a further l/4 turns (90”) with thewrench socket.

18 09-11013

3 Disconnect plug (arrow) for oil pressuresensor, plug in.

4 Unscrew oil filter base section, screw on,tightening torque 25 Nm.

5 Clean sealing surfaces on oil filter andcrankcase.

For this purpose, seal the bores on thecrankcase, open (arrows).

6 Run engine, check for leaks.

18.09-11014

18-210 Removal and installation of oil pump

Preceding work:Timing case cover removed (01210).

PIE-0032-57

Oil pickup (7) with strainer basket . . . . . . . . . . . unbolt, bolt on, tightening torque 10 Nm (step

2).Gasket (12) . . . . . . . . . . . . . . . . . . . . . . . . , . . replace.

Oil pump cover (3) . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, tightening torque 10 Nm (step3).

NoteRe-install Torx bolt at the same point (for spacereasons).

O-ring (10) . . . . . , . . . . . . . . . . . . . . . . . . . . . . replace.

Oil pump gears (1 and 2) . . . . . . . . . . . . . . . . . . remove, insert, oil.

Driver sleeve (22) , . . . . . . . . . . . . . . . . . , . , . . if removed, install before fitting timing casecover.

18 09-.210/l

Special tool

NoteThe two oil pump gears (1 and 2) are arrangedeccentrically in the timing case cover (44).

The oil pump gears (1 and 2) are driven by thedrive sleeve (22) which has two faces on theouter surface for this purpose and is attached bythe central bolt to the crankshaft, which alsoholds the vibration damper or the hub with beltpulley and the crankshaft gear on the crankshaft.

The bore of the driven, externally toothed gear(1) has the identical contour as the outer surfaceof the drive sleeve.

The oil pump gears are supplied asreplacement parts only together (rotor set).

The oil pump cover (3) is attached to the rear ofthe timing case cover (44). It is fixed in place onthe timing case cover (44) with a centeringsleeve.

18 09-21012

The sealing ring (12) seals the connection fittingat the oil pump cover (oil feed) to the oil passagein the crankcase.

The jump overlock for the timing chain is alsocast onto the oil pump cover.

Oil suction pipe together with oil strainer basketis bolted to the oil pump cover (13) with a gasket

(12).

The oil suction pipe with oil strainer basket isadditionally attached by means of a bracket (8)to the main bearing cover (arrows).

The timing case cover has been modified withthe installation of the double roller timing chain(as of November 1987).The contours on the rear have been lowered.

A Previous versionI3 Present version

In addition, it has a different rib pattern on thetop. The jump overlock (i) is wider and theconnection fitting (K) longer.

18.09-21013

The drive sleeve for oil pump is manufacturedfrom sintered metal, previously from steel.

Implementation: August through December 1985

Model Engine Engine end Nos. Engine end Nos. Vehicle ident end No.Man. trm. Autom. trm.

201.024 @ 102.985 002517-003158 002505028724 F 137963- ;F 182815. End of implementation not recorded.

2 mm wider pump gears (1, 2) are installed toimprove the delivery of the oil pump.

Sue “B” previously 7.5 mmnow 9.5 mm

18 09-210.‘4


1 Timing case cover removed (01-210).

2 Unbolt oil pickup together with strainerbasket (7) bolt on. Replace gasket.

Tightening torque: 10 Nm

3 Unbolt oil pump cover, bolt on, replace O-ring (10).

Tightening torque:

Note

10 Nm

As of implementation of the flatter oil pumpcover, a Torx bolt (15) is installed for spacereasons.

Tightening torque: 10 Nm

4 Remove oil pump gears, insert, oil withengine oil for this purpose.

Caution!The oil pump gears may only be replaced as apair.

If the driver sleeve (22) has been removed, thiscan be inserted after installing the timing casecover.

18.09-210!5

5 Check oil level, adjust to correct level ifnecessary.

6 Run engine, check oil pressure and oil leaks.

l&09-210/6

18-215 Removal and installation of oil overpressure (bypass) valve

Preceding work:Removal and installation of V-belt (13-342).Removal and installation of V-belt tensioning device (13-345).

Screw plug (16) . . . . . . . . . . . . . . . . . . . . . . . . unscrew, screw on, special tool103 589 01 09 00. Tightening torque 30 Nm.

NoteScrew plug is pressurized by compressionspring. Replace seal (17).

Oil overpressure valve (14) . . . . . , . . . . . . . . , . remove, insert.

NoteCheck that oil overpressure valve is in propercondition and moves easily in timing case cover,clean bore if necessary and replace oiloverpressure valve.

With engine running . . . . . . . . . . , . . . . . . . . . . check for leaks.

18.09-2151

Special tools

001 589 72 21 00 103 58901 0900

NoteThe oil overpressure valve is installed at the side(on the left looking in direction of travel) in thetiming case cover and connects pressurechamber (A), and suction chamber (B) of the oil

pump.

14 P1storl15 Compression spring16 Screw plug17 Seal

A Pressure chamberB Suction chamber

l l a3-

P18-0033-35A

18.09.215i2

From an oil overpressure of approx. 4 bar, thepiston (14) is pushed against the force of thecompression spring (15) and opens the reliefcross-section along which part of the oil flowsback to the suction chamber (B), depending onpressure.

When the piston (14) is moved, the oil which ison the rear of the piston in chamber (C) isdisplaced and flows through the relief grooves onthe outside of piston likewise to the suctionchamber (B).

l&09-215/3

18-220 Checking oil level indicator

Model 201

Al

’ O.Sbr/vs -0

;;iX5/2

- 0,5br/ws 1

B5 S42

- I - - -.75br/gn

Wiring diagram engine oil level indicator, engine coolant level indicator, windshield washer levelindicator

Al Instrument clusterel Left turn-signal indicatore2 Right turn-signal indicatore3 High beam indicator64 Fuel reserve warning lampe5 Battery charge Indicatore6 Brake pad wear indicator lamp87 Brake fluid and parking brake indicator lampe6 Instrument lightrng811 Engrne coolant level indicator lampe12 Oil level Indicator lampel3 Windscreen washer indicator lamp

PtP2P9P7

B5S41542S43W1X5/2

Engine coolant temperature gaugeFuel gaugeOil pressure gaugeElectronrc clock/tachometer011 pressure gauge sensorEngine coolant level Indicator lamp swatchWindsshield washer level indicator lamp swatch011 level Indicator lamp swatchMain ground (behind instrument cluster)Connector, Intenor/starter 4-pin

18.09-220/l

Test data

Resistance at max. oil level

Resistance at min. oil level

Battery voltage approx. 12 V

Commercial tool

Multimeter e.g. Sun, DMM-5

NoteIf problems occur as for example:

A. Indicator lights up constantly whenengine running and oil at correct level.

B. Indicator lamp does not light up whenkey in position “2”.

C. Indicator lamp does not light up whenengine running, oil temperature ~60 “Cand oil level below “min”.

Test

A. Indicator lamp lights up constantlywhen engine running and oil at correctlevel.

Test oil level sensor. Detach connector. Testconnector to ground with multimeter.

Reading: < 1 s1

Yes No

Replace oil level sensor.

L

I I

If

18.09-22Ot2

Test cable. Remove instrument cluster for thispurpose. Test resistance with ohmmeterbetween contact 5 of 15pin connector andcontact of oil level sensor.

Reading: < 1 Q

Yes I No

Replace indicating instrument.

B. Indicator lamp does not light up whenkey in position “2” (check function).

Check operation of bulb.

Yes NoI I

f

Remove instrument cluster. Measure voltagewith multimeter at contacts 6 and 9 of the 15-pin connector.

Reading: approx. 12 V

Yes No


Modul 102 Format 1 ,O (77x58 mm)

Bild-Motiv

FoWZg-Nr.

Abgabe

Korrektur

Bild-Nr. P18-0076-13

P20-0076-13

C. Indicator lamp does not light up whenengine running, oil temperature ~60 “Cand oil level below “min”, checkfunction section “B” in order.

I 1Test oil level sensor. Detach connector for thispurpose. Test connector to ground withmultimeter.

Reading: 00 Q I

Yes No

+


I End of test I

18.09-22014

18-225 Function of low engine oil level indicator

1 instrument cluster5 lgnhon lock351 Oil level sensor

a Electronicsb 8A fuse

ComponentsOil level sensor in oil sump (351).

Indicator lamp in instrument cluster. Symbol:dripping oil can (1).

Electronics at instrument cluster (a).

GeneralThe dynamic low engine oil level indicatormonitors the oil level in the sump when theengine is running and at an oil temperatureabove 60 “C.

No indication is given below 60 “C.

The low engine oil level indicator lights up whenthe ignition is switched on (check function) andgoes out as soon as the engine is running.

The low engine oil level indicator shows a weaklight for the check function and a bright light inthe event of a fault.

18.09-22511

The oil level in the sump is detected by a float(358) with permanent magnet (359) installed inthe oil level sensor. Within the minimum range ofthe dipstick, the float opens the Reed contact(360) and a signal from the electronics in theinstrument cluster is interrupted. The indicatorlamp lights up.

27351352356359360365a

b Dscharge passage 4 mm dia.

011 sumpOil level sensor&metal snap diskFloatPermanent magnetReed contact0-nngAir admIssIon passage 8 mmdia.

The same also occurs in the event of a cableinterruption.

When the oil level drops, the indicator lamplights up first of all briefly and later shows asteady light, depending on the driving style.

To avoid unnecessary warnings in various drivingsituations, e.g. a sharp lefthand curve, theelectronics is equipped with a delay circuit. Itprevents the indicator lamp from lighting up untilan oil shortage has been signaled for 60seconds.

360361352

To avoid incorrect indications when the engine iscold (viscous oil flows back only slowly to thesump), the oil level sensor is equipped with abimetal snap disk (352). This prevents the floatchamber above the discharge passage (b)running empty at low temperatures.

18.09-22512

Switching points of bimetal snap disk

Opens at approx. 60 “C oil temperature.

Closes at approx. 30 “C oil temperature.

When changing the oil, the float chamber abovethe air admission passage (1) is filled with oil.Any subsequent faulty indications are thus notpossible.

The oil level indicator is designed so that theindicator lamp lights up just before the “min”marking on the dipstick (safety margin).

Maintenance and repair instructionsThe oil level indicator does not eliminate theneed for checking the oil level with the dipstickwhen changing the oil.

The oil level sensor (351) can be removed whenthe oil sump is installed. Drain approx. 2 liters ofengine oil for this purpose.

l&09-225/3

Engine cooling system 20

Engine cooling system

Job No.

Engine coolant circuit and engine cooling .................................... 20 - 005Draining, adding coolant - Antifreeze protection table ............................ 20 - 010Cleaning, flushing engine cooling and heating system ............................. - 015Removing oil from engine cooling and heating system ............................ - 016Checking engine cooling system for leaks ..................................... - 017Removal and installation of engine coolant thermostat ............................ - 110Removal and installation of engine coolant thermostat housing ...................... - 115Removal and installation of engine coolant pump ................................ - 2 1 0Solenoid fan coupling ................................................... - 330Removal and installation of solenoid fan coupling ................................ - 335Notes on Radiator ...................................................... - 4 1 9Removal and installation of radiator .......................................... - 420Repairing radiator ...................................................... - 425Testing radiator or expansion tank pressure cap ................................. - 430Checking engine coolant level indicator ....................................... - 440Function of engine coolant level indicator ..................................... - 445

20 1

iiiiiiiiiiiiiiiiiiii...............................................................................

20-005 Coolant circuit and engine cooling

Coolant circuit

A From thermostat houscng to radrator F Frlling line from coolant expanson tank to coolant

:From radrator to coolant pump pumpBypass line from thermostat housmg to coclant G Vent lme from thermostat housrng cap to coolantpump expansron tank

D Feed line to heater (heat exchanger) H Coolant expansion tankE Return line from heater (heat exchanger) to I Overflow hose

coolant pump

ThermostatEngine Thermostat start to open Fully open

102 87 “C 102 “C

29 59-005 1

Function

Warming-up period (engine coolanttemperature up to approx. 87 “C)The main valve (1) is closed and the bypassvalve (2) fully open. Consequently, the flow (A)to the radiator is interrupted and the coolantflows along the bypass line (C) directly to thecoolant pump (3) and from there to the engine.

Part load operation (engine coolanttemperature approx. 87 “C up to max. 102“C)The main valve (1) and bypass valve (2) aremore or less wide open depending on engineload and outside temperature. The coolant flowsboth through the radiator (A) as well as throughthe bypass line (C), depending on the position ofthe coolant thermostat.

Full load operation - High outsidetemperatures (engine coolant temperatureabove 102 “C)The main valve (1) is fully open and the bypassvalve (2) closed. All of the coolant must flowthrough the radiator and, in so doing, is optimallycooled. It is therefore incorrect to remove thecoolant thermostat in order to “improve” enginecooling.

The cooling system is vented through the ballvalve when the system is being filled andautomatically when the engine is operating.The system is vented at the cap of the coolantthermostat housing (G) along a vent line to thecoolant expansion tank.

i i

i i

P20-0025-13

20.09-005;2

20-010 Draining, adding coolant - Antifreeze protection table

Preceding work:Bottom engine compartment panehng removed(except Model 201.024).

Pressure cap (50) .

Drain plug (82) . . .

Drain plug (17) . . .

. . . . ,

. . . . .

.......

.......

P20-0024- 57

. . * . . , open in stages, close.

6T-LDo not open until coolant temperature below90 “C (step 2).

. . . . . , open, close, tightening torque 1.5 Nm(reference value, step 3).

NoteA suitable extension hose can be fitted onto theoutlet connection for collecting the coolant.

. . . . . . unscrew, insert, renew seal (la), tighteningtorque 30 Nm (step 4).

20.09-01O:l

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pour in up to marking on expansion tank, pressfiller hose down a little if necessary. Switch onheater (step 5).

Cooling system . . . . . . . . . . . . . , . check for leaks (20-017).

Special tools

] 001 589 72 21 001 124 589 15 21 001

Commercial toolAntrfreeze protection tester e.g. Ph. Gather,Prestone-W-Check (Union Carbide) 4020 Mettmann

Total filling capacities of cooling system with heater and mixing ratio of corrosionDrotectionIantifreeze aaentl) and water*) in litersModel Engine Total capacity of cooling

system with heater

1241’20 1 102 85

9,53)l) See Service Product Spectfications sheet 325.“1 See Set-we Product Speclficatlons sheet 310.3) With arr conditloning/automattc climate control.

Mixing ratioAntifreeze agent’water-37 “C -45 “C

4,25:‘4,25 4,75/3,75

4,7514,75 5,25/4,25

Notes

Disposing of coolantRefer to municipal, county and state laws.

Coolant compositionSee Factory Approved Service Product s sheet.

20.09-01012

WaterUse clean water which is not too hard.Dnnking water may frequently meet theserequirements, but not always. The content ofdissolved substances in the water may be ofsignificance for the occurrence of corrosion. Incases of doubt, the water should be analysed.

Corrosion protection/antifreeze agentsThe purpose of corrosion protectionantifreezeagent IS as follows:

- To provide adequate corrosion andcavitation protection for all components

- AntIfreeze protection- Increasing the boiling point

Approx. 50 9/o by vol. of corrosionprotectionantifreeze agent must be added tothe water. This concentration offers antifreezeprotection down to approx. -37 “C.A higher concentration IS only advantageous atlower ambient temperatures.

More than 55 9/o by vol. corrosionprotectionantifreeze agent reduces theantlfreeze protection and impairs heatdissipation.

55 9/o by vol. corrosion protection’antifreezeagent offers antifreeze protection down toapprox. -45 “C.Corrosion protectionantifreeze agent increasesthe boiling point. This means that the coolantdoes not evaporate so rapidly. Discharge ofcoolant is avoided at high coolant temperatures.Use only approved corrosion protection/antifreeze agents (see Service ProductSpecifications sheet 325.1 and 325.2).

Operational monitoring of coolantBefore the start of the cold season of the year,check the antifreeze protection of the coolant.In countries with high outside temperatures,check the corrosion protection antifreeze agentconcentration once a year.

When topping up system (after loss of coolant),ensure that the share of corrosion protection’antifreeze agent in the coolant is 50 % by vol.to provide antifreeze protection down to -37 “C.

The antifreeze protection in the coolant reducesduring engine operation. These coolants have aseverely corrosive effect.

The maximum permissible period of use for thespecified coolant in a car engine is 3 years.

Draining - filling up1 Unscrew front bottom section of noiseencapsulation, screw on.

2 Open pressure cap on expansion tank instages.

AWarning!Do not open pressure cap until coolanttemperature is below 90 “C.

3 Open drain plug (82) at the radiator, close.Tightening torque 1.5 Nm (reference value).

NoteA suitable extension hose can be fitted onto thedrainage connection (arrow) for collecting thecoolant.

Dram plug Model 124 wIthout air conditlontng

Model 124 with air conditlonmg

82 Downflow radiator dram plug Model201 (vehicles wlthout aircondltionlng, radiator 1 St version)

I 8? -1

82 Crossflow radiator dram plug Model201 (vehicles with air COndltlOnlnQ,radiator 1 st version)

20 ,J9-010 4

On Model 201 with drain system 2nd versionfit a 12 mm 0 hose approx. 1500 mm long tothe outlet connection (arrow) and run below thewheelhouse. Unscrew drain plug (82).

Downflow radtator Model 201 (vehlcieswlthout air conditiomng)Drain plug (82) on outslde lef In directlonof travel, outlet connectlon (arrow) to therear.

Crossflow radiator Model 201 (2nd version) drain plug (82) atfront right In dIrectIon of travel, accessible from nghthand flapfor towmg eye In front moulded skirt. Outlet connectlon (arrow)to the side right.

4 Unscrew drain plug (arrow) on crankcase,screw in.Tightening torque 30 Nm.

5 Fill in coolant up to the marking onexpansion tank (arrow).

NoteSwitch on heater and run engine until warm.

Close filler neck on expansion tank from acoolant temperature of approx. 60-70 “C.

I Pa-2033-13 I

I \\\ \ Pm-2029-13

20 09.Cl0 5

NoteThe filler hose can be pressed down for filling(arrow) to ensure the coolant flows more brisklyfrom the expansion tank to the radiator orengine.

6 Check cooling system for leaks (20-017).

20 c)9-010,6

20-015 Cleaning, flushing engine cooling and heating system

Preceding work:Bottom engine compartment panelling removed (01-006).Coolant drained (20-010).

18-

P20-0083- 57

Coolant thermostat ...................... remove and install positive opening part No.000 589 74 63 00, remove (step 1).

Flushing connection pipe (01) .............. install and connect tap water hose(steps 2 and 3).

Cooling system ........................ flush (steps 4 to 20 and 22).

Coolant expansion tank (7) ................ remove and install, flush out (step 21).

Cooling system ........................ check for leaks (20-017).

20 ~39-0151

Special tools

300 589 74 63 001 124 589 15 21 00

Service products

Corrosion protectionantifreeze agent 000 989 08 25

Citric acid powder (0.5 kg) 000 989 10 25

NoteHigh coolant temperatures and low heatingcapacity may also be caused among other thingsby deposits of corrosion products in the radiatoror in the heat exchanger.

The deposits can be recognized from a gelly-likemass or, when the radiator is emptied and dry,from a grey layer on the radiator connectionpipes.

In this case, the radiator and heating systemshould be cleaned with a 10% citric acidsolution.

If the cooling pipes of the radiator are completelyor partially blocked, the radiator must berenewed.

Scope of work1 Remove coolant thermostat and installpositive opening thermostat 000 589 74 63 00with sealing ring.

2009-0152

2 Connect rinsing connection pipe (01)117 589 00 90 00 with connection hose (02)between radiator and coolant hose.

3 Connect a tap water hose (03) to theflushing connection pipe (01).

4 Open pressure cap of expansion tank.

5 Set heater to “warm”.

6 On vehicles with recirculation pump, switchon recirculation pump.

This is done by switching on the ignition and:a)

b)

7

8

On vehicles with automatic heater control,lockrng the temperature selectors to the” Max” position.

On vehicles with automatic climate control,pressing the “Defrost” pushbutton.

Open vent valve of auxiliary heater.

Rinse cooling and heating system for approx.5 minutes with flowing water and engine running(approx. 2500 rpm) to flush out the remainingcoolant.

During the rinsing procedure, the cooling systemmust always be completely filled.Adjust feed quantity accordingly.

9 Allow flushing water in the radiator andcrankcase to drain out completely. Screw indrain plugs (17 and 82).

20 09.015.3

10 Dissolve 1.5 kg citric acid powder (0.5 kg,Part No. 000 589 10 25) in approx. 5 liters ofwater in a suitable vessel.

11 Pour cleaning solution into the expansiontank and top up with water to the marking onthe expansion tank.

12 Close bleeder screw of auxiliary heater.

13 Close pressure cap of expansion tank.

14 Run engine for 15 minutes at approx.2500 rpm. The flushing liquid must flow throughthe heat exchanger when performing the step(step 6).

15 Following this, drain cleaning solution.

The cleaning solution (citric acid mixture) shouldbe drained into a standard workshop oil andwater separator.

16 Open bleeder screw of auxiliary heater.

17 Flush cooling and heating system forapprox. 10 mtnutes with flowing water andengine running (2500 rpm). The flow must passthrough the heat exchanger when performingthe step (see steps 5 and 8).

18 Remove flushing connection pipe andconnect coolant hose to radiator.

19 Install normal coolant thermostat with newseal.

20 Screw in coolant drain plug at radiator (82)and crankcase (17), renew seal (18).

21 Remove and install coolant expansion tankand flush out once again separately.

NoteBecause of the pockets and recesses in thecoolant expansion tank, not all of the solution isremoved during draining.

22 On vehicles with auxiliary heater, connectplastic hose to vent valve and open valve.

23 Pour in new coolant (20-010)

24 Check cooling system for leaks (20-017).

A 6/31\

33

33

‘29

x 39-015 5

20-016 Removing oil from engine cooling and heating system

Preceding work:Engrne coolant drarned (20-O 10).Engine coolant thermostat removed (20-l 10).

P20-0024- 57

Heater controls . . . . . . . . . . . . . . . . . . . . . . . . . set to full capacity (step 1).Engine cooling system . . . . . . . . . . . , . . . . . . . fill with a 5% solution (step 2).Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . raise to normal operating temperature and run

for approx. 5 minutes (step 3).Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . drain flushing solution and fill engine cooling

system twice with fresh water, run each time forapprox. 5 minutes and drain completely (steps 5and 6).

Engine cooling system . . . . . . . . . . . . . . . . . . . check for leaks (20-017).

20.09-016;l

Special tool

I124 589 1521 001

Removing oil

NoteIt is necessary to remove oil from the enginecooling system if, for example, engine oil, gearoil in the case of an automatic transmission orhydraulic oil has got into the engine coolingsystem.

1 Set heater controls on vehicles with andwithout air conditioning to full capacity.

2 Fill the engine cooling system with a 5%solution of water and neutral cleaner or with amild alcaline cleaner, e.g. P3-Croni (supplier:Henkel) or Grisiron 7220 (supplier: FarbwerkeHoechst).

Caution!Sharply alcaline cleaners, such as P3 Standard(supplier: Henkel) must not be used on thesevehicles (light alloy radiator).

3 Warm up engine to approx. 80 “C at amoderate speed and maintain at this temperaturefor approx. 5 minutes.

4 Switch off engine and allow enginecoolingsystem to cool down to approx. 50 “C.

5 Completely drain solution.

6 Immediately after this, fill engine coolingsystem twice with fresh water, run until warm(approx. 5 minutes) and drain.

20.09-016/Z

20-017 Checking engine cooling system for leaks

Pressure cap . . . . . . . . . . . . . . . . . . . . . . , . , turn to 1st detent to release pressure. Twist offto 2nd detent and remove (step 1).

Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . check (step 2).Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 589 15 21 00, attach to expansion tank and

pressurize engine cooling system to approx. 1.4bar (step 3). Check all engine coolant andheater hoses and connection points for loss ofengine coolant. Check condrtion of hose clips,tighten if necessary (step 4).

NoteThe rllustration shows connections whrch mustbe checked for leaks when pressure-testing theengrne cooling system.

20.09-017/l

Special tool

I 124 589 15 21 00 I

Commercial tool7 mm socket wrench hexagon on flexible shaft for e.g. Hazet, D-5630 Remscheidhose clips with worm drive Order No. 426-7

Checking leaktightness1 Turn pressure cap to 1st detent and releasesystem pressure. Then turn to 2nd detent andremove cap.

Warning!Do not remove the pressure cap untilenginecoolant temperature is below 90 “C.

2 The engine coolant level must extend up tothe marking on the expansion tank (arrow).

20.09-017:'2

3 Pressurize engine cooling system to approx.1.4 bar with the tester 124 589 15 21 00.

4 Check all engine cooling and heating waterhoses and the connection points for loss ofengine coolant.

Check condition of hose clips, replace or tightenas necessary.

20.09-017i3

20-110 Removal and installation of engine coolant thermostat-

Preceding work:Drain - fill m coolant (20-010).

Cap (31) . . . . . . . . . . . . . . . . . . . . . . . . . . unscrew with connected engine coolant hose,screw on, tightening torque for light alloy cap 10Nm, plastic cap 8 Nm.

O-ring (32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . replace.Engine coolant thermostat (30) . . . . . . . . . . . remove and install.

NoteInstall the enginecoolant thermostat so that theball valve is at the highest point.

Engine cooling system . . . . . . . . . . . , . . . . , . . check for leaks (20-017).

Special tools

29 09-i lo.'1

20-l 15 Removal and lnstallatlon of engine coolant thermostat housing

Preceding work:Drain - fill in coolant (20-010).

PZO- 0026-57A

Vent line (65) ..........................

Lifting lug (22) .........................

Hose clip (38, 38a) ......................

Engine coolant thermostat housing (29) .......

Gasket (36) ...........................Engine cooling system ...................

disconnect, connect (step 2).

unbolt, bolt on. Tightening torque 25 Nm (step3).at top of bypass hose, loosen, tighten (step 4).

unbolt, bolt on. Tightening torque 25 Nm (step6).replace (step 6).

check for leaks (20-017).

20 09- 1 15il

Special tools

124 589 15 21 00 001 589 72 21 00

Commercial tool

7 mm socket wrench hexagon on flexrble shaft e.g. Hazet, D-5630 Remschetdfor hose clips with worm drive Order No. 426-7

Note ISince January 1985, Model 201 has beenequipped with a plastic engine coolantthermostat housing.

The gasket to the cylinder head is manufacturedfrom rubberized cork.

The vent line is pushed on with a hose clip;previously with hollow bolt (arrow).

P20-0069-13

A 1st versionB 2 n d verson

20.09-115 2


1 Draining - adding engine coolant (20-010).

2 Detach vent line (65) at the cap of theengine coolant thermostat housing, connect(arrow).

3 Unbolt lifting lug (22, only on engines withhydraulic oil pump), bolt on.

Tightening torque 25 Nm.

4 Loosen hose clip (arrow) at bypass hose,tighten.

5 Unbolt engine coolant thermostat housing(29), bolt on. Tightening torque 25 Nm.

6 Clean sealing surfaces, replace gasket.

7 Check engine cooling system for leaks (20-017).

20 09- 11513

20-210 Removal and installation of engine coolant pump-

Precedmg work:Drammg - addmg engme coolant (20-010).Removal and mtallatlon of V-belt (13-342).

Belt pulley (72) . . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, tightening torque of hex. socketbolt 10 Nm, Torx socket bolt 15 Nm (step 3).

Cable connector (68a) . . . . . . . . . . . . . . . . . . detach from solenoid body, plug in (step 4).Solenord body . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, pay attention to installed

position, tightening torque 10 Nm referencevalue (step 4).

Engine coolant hoses (56, 57 and 58) . . . . . . . detach, attach (step 5).Bolt (50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . for shock absorber (28), unbolt, bolt on,

tightening torque 25 Nm (step 6).Bolts (51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on. Place alternator with connected

cable to the side (step 7).Bracket (156) . . . . . . . . . . . . . . . . . . . . . . . . detach, attach by removing bolts (49, 3 off),

bolting on, tightening torque 25 Nm.

20.09-210.1

Coolant pump (1) . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, pay attention totightening torque 10 Nm. Clean(step 10).

bolt length,sealing surfaces

Note00 80 (2) if theOnly use paper gasket 102 201

timing case cover is sealed with liquid sealant.Otherwise seal engine coolant pump withsealant002 589 00 20 10.

Engine cooling system . . . . . . . . . . . . . . check for leaks (20-017).

Special tools

Commercial tool

7 mm wrench socket on flexibleshaft for hose clips with worm drive

e.g. Hazet, D-5630 RemscheidOrder No. 426-7

NoteThe pump chamber for the impeller of the enginecoolant pump is located in the timing case cover(arrow).

ComponentsThe bearing (2) of the engine coolant pump shaftand the cassette-type seal (6) are press-fit intothe engrne coolant pump housing.

1 Engine coolant pump housng2 Engtne coolant pump bearing6 Cassette-type mechanlcal seal15 Impeller68 Solenoid body68b Carrter72 Belt pulley73 Flange74 Fastening bolts75 Fan76 Angular-contact ball beanng77 Armature78 Tenslonlng pulley79 PulleyI30 Fastening bo l t

1

6

15

76

76

74

To achieve added safety for the fastening boltsof the belt pulley at the engine coolant pump,M6 X 12 Torx bolts (previously M6 x 12 hex.socket bolts) are installed. Tightening torque 15

Nm.

Produktion breakpoint: September 1985

Model Engine Engine end No.Man. trm. Autom. trm.

201.024 @ 102.985 002692 023655

20 09-210 3

The engine coolant pump housing had to bemodified with implementation of the top damperpoint of the belt tensioning device.

Modifications:a) Mounting eyes (Fig. B, 1, 2, 3) on engine

coolant pump housing lowered, size “D”18.4 mm (previously 42.4 mm), matchingM6 x 30 bolt + washer assys (previouslyM6 x 55). This creates clearance for topshock absorber of belt tensioning device (P13123).

b) Engine coolant inlet connection lowered, size“h” = 90.5 mm (previously 100.5 mm).

c) Housing wall strengthened in transition areafrom hub to housing flange (Fig. B, arrow).

d) Bottom coolant hose (radiator to enginecoolant pump) modified.Identification: Modified Part No. on coolanthose.

Bottom coolant hoseModel 124 Part No.

Manual transmission 124 501 38 82

Automatic transmission 124 501 40 82

Automatic air conditioning 124 501 39 82

20.09-21014

Model 201

Model Version Transmission Air conditioning Part No.manual automatic

201.028 201 501 66 82

Temporary installation of a cassette-typemechanical seal with modified matenal (siliconecarbide, previously ceramic).

Identification:Red dot on coolant pump housing.

2009-210 5


1 Drain cengine oolant, fill (20-010).

2 Remove and install V-belt (13-342).

3 Unbolt belt pulley for engine coolant pump.

NotePay attention to bolt versions and tighteningtorques.

Hex. socket boltsTorx socket bolts (as of 9:85)

10 Nm15 Nm

4 Disconnect cable connector (68a), plug in,unbolt solenoid body (68), bolt on (arrows).

5 Detach engine coolant hoses (56 and 57) aswell as bypass line (58), connect.

20.09-210 6

6 Remove bolt (50) for shock absorber of belttensioning device, bolt on, tightening torque25 Nm.

7 Unscrew bolts (51) and place alternator tothe side.Tightening torque 45 Nm.

8 Unscrew bracket (156), screw on, tighteningtorque 25 Nm. For this step, remove bolts(49, 3 off), screw on, tightening torque 25 Nm.

9 Detach engine coolant pump, attach. For thisstep, remove bolts (21), bolt in, tighteningtorque 10 Nm. Pay attention to bolt length.

10 Clean sealing surfaces.

NoteA paper gasket Part No. 102 201 00 80 issupplied in the parts sector as a seal of theengine coolant pump at the timing case cover.This gasket may only be installed if it is assuredthat the timing case cover is sealed only withliquid sealant. Otherwise use sealant002 589 00 20 10.

11 Check engine cooling system for leaks (20-017).

20.09-210 7

20-330 Solenoid fan coupling

u P20-0030-57

1 Engine cmlant pump66 Solenord body6aa Connector wrth cable for solenotd body66b Carrier for solenord body72 Belt pulley wtth steel nng Insert74 socket bolt or M6 x 12 Torx bolt M6 x 12 hex.

757879a0

G

H

Fan wrth armature nngSpacer drskTensronrng diskCollar bolt

Temperature swatch for solenord fan couplrng, red100 "CTemperature swatch for solenord fan couplrng and2-stage auxrliary fan, 110 “C, red for arrconditronrng or automatrc cltmate control

20.09-330,l

General

The engines have a temperature-controlledelectromagnetic fan coupling.

It is engaged or disengaged by a temperatureswitch (100 “C, G) inserted into the sensor boxon the cylinder head.

The same function is performed on vehicles withair conditioning system or automatic climatecontrol by a 110 “C temperature switch (H).

The electromagnetic fan coupling ismaintenance-free.

FanThe fan (75) is mounted on a stud on the enginecoolant pump beartng and is attached by a collarbolt (86).

MatchingModel Engine Air conditioning/ Fan dia. No. of Capacity

Automatic climate control blades %with without

201 102.961 X 380 6 100X 430 5 100

102.985 Man. transmission x 380 6 100Autom. transmission X 430 5 100X 430 5 100

Design of electromagnetic fan couplingThe solenoid body (68) is attached to thesolenoid carrier (68b) by 3 nuts (70).

The solenoid carrier is bonded to the enginecoolant pump housing.

20 09-330 2

126

156868t172737475

Engine coolant pump houslngEngine coolant pump beanngCassette-type mechanicalsealImpellerSolenoid bodyCarrterBelt pulleyFlangeFastening boltsFan

76 Angular-contact ball beanng77 Armature78 Tenslonlng pulley79 Pulleya0 Fastening bolt

The electric cable is connected to the solenoidbody by a connector (68a).

The belt pulley is located on the engine coolantpump shafts ahead of the solenoid body.

A steel ring is inserted in the belt pulley whichattracts the armature ring on the fan when thefan coupling is engaged (arrow).

751

673

1579

80

78

76

74

77 72

20.09-330 3

The armature ring (77) and the angular-contactroller bearing (76) are installed on or in the fan,respectively.

FunctionThe fan is engaged only when the ignition isswitched on and at a engine coolant temperatureabove 98-l 02 ‘C.

A constant positive exists at the solenoid body

(68).

Below a engine coolant temperature of 98-102“C, the fan is switched off and only rotates as aresult of the airstream or as a result of thebearing friction.

Minus is engaged at a engine coolanttemperature of not more than 102 “C throughthe temperature switch (G or H) at the sensorbox.

The armature (76) is attracted by the solenoidbody (68) and presses against the end face ofthe belt pulley.

The fan is now rigidly connected to the beltpulley and rotates in line with the engine coolantpump speed.

If the engine coolant temperature drops below93-98 “C, the temperature switch opens andthe armature (76) is lifted off the belt pulleyby the leaf springs.

On vehicles equipped with automatic airconditioning, the fan and the electric auxiliary fanare engaged by a double-contact relay which isactivated by the triple temperature switch (H).

20 09.330:4

2 0 - 3 3 5 Removal and installation of solenoid fan coupling

Preceding work:Removing and !nstalling V-belt (13-342).

75w

o-74

‘72

u[__-j-’ P20-0032-57

Belt pulley (72) . . . . . . . . . . . . . . . . . . . . . . . . . unbolt, bolt on, tightening torque hex. socketbolts 10 Nm, hex. Torx bolt 15 Nm(step 2).

Cable connector (68a) . . . . . . . . . . . . . . . . . . . . detach from solenoid body, plug in (step 3).Solenoid body (68) . . . . . . . . . . . . . . . . . . . . , . unbolt, bolt on, pay attention to installed

position, tightening torque 10 Nm (referencevalue, step 4).

NoteThe carrier (68b) for the solenoid body isbonded to the engine coolant pump, do not pulloff. Stick on loose carriers with adhesive001 989 47 20.

20.09-3351

Special tool

0 0 1 5 8 9 7 2 2 1 O C

NoteHex. Torx bolts (M6 X 12) are fitted instead ofhex. socket bolts to achieve greater securityagainst slackening or fracturing of the belt pulleyfastening bolts.

Standard implementation: September 1985

Model Engine

201.028 @ 102.985

Engine end No.Man. trm. Autom. trm.

002692 023655


1 Remove and install V-belt (13-342).

2 Unbolt bet? pulleybolt on.

Tightening torques:Hex. socket boltsHex. Torx bolts

for engine coolant pump,

10 Nm15 Nm

2 0 69-335 2

3 Detach cable connector (68a) from solenoidbody, plug in.

4 Unbolt solenoid body (68), bolt on, payattention to installed position, tightening torque10 Nm (reference value).

NoteThe carrier for the solenoid body is bonded tothe engine coolant pump housing. Attach loosecarrier with adhesive 001 989 47 20.

20 09435 3

20-419 Notes on radiator

Fan cowl/Fan

Radiator/Fan

PZO-0070-13

DPO3- 0130 -15

Installation measure for radiator, fan and fan cowl

Model Engine Distance “a” from fan toradiator, approx. mm

201.024 102.961201.028 102.985 36

‘) Fan cowl I 24 500 05 55 (2nd version) on vehicles with manual transm6son.

Distance from fan to cowl,approx. mm

A B C

22 28 20

Radiator expansion tankThe expansion tank is attached to the rightwheelhouse.

Different radiators are installed depending on thevehicle equipment.

On vehicles with air conditioning.automaticclimate control, crossflow radiators (B), arrows,are installed.

Radiator with air conditioning,‘automatic climatecontrol

Radiator block:: Width ,,B” = 410mmHeight A-t” = 388 mmDepth ,,T” = 42 mm

A

20.09-4 19;2

Fan cowlThere are different fan cowl versions dependingon the various radiator design.

Version “A”On vehicles without air conditioning (narrowradiator non-USA vehicles).

Version “B”On vehicles with air conditioning (wide radiator).

20 09.419,3

20-420 Removal and installation of radiator

Precedmg work.Dratmng and addlng coolant (20-101).

Engine coolant hose (8 and 10) ............. at radiator, detach, attach (step 1).

Fan cowl(2) . . . . . . . . . . . . . . . . . . . . . . . . . . . detach and place over fan (step 2).

Clip (5) .............................. on vehicles without air conditioning, remove,install (step 3).

Transmission oil lines (12) . , . . . . . . . . . . . , . . . on vehicles with automatic transmission, detach,attach. Pinch lines with clamp 000 589 51 21 00(step 4).

Retaining clips

Engine cooling

Oil level . . . .

(7) . . . . . . . . . . . . . . . . . . . . . . . remove and install and lift out, insert radiator(step 5).

system . , . , . . . . . . . . . . . . . . . check for leaks (20-017).

. . . . ., ., .., . . . . . . . . . . . . . . . in automatic transmissron, adjust to correct level(Op. No. 27- 010).

20 09-420.1

Special tools

124 589 15 21 0

Commercial tool

7 mm wrench socket on flexible shaft for hose e.g. Hazet, D-5630 Remscheidclips with worm drive Order No. 426-7

1 Detach engine coolant hoses at radiator,attach.

2 Pull off clips (6), install and place fan cowlover fan.

3 On vehicles without air conditioning’automatic climate control, remove clips (5) onfront of radiator, insert.

20.09-429 2

4 On vehicles with automatic transmission,detach oil cooler lines, attach, pinch with theclamps 000 589 40 37 00.

5 Remove retaining clips (7) for radiator, fit onand lift out, insert radiator.

6 Check engine cooling system for leaks(20-017).

7 Adjust 011 level In automatic transmission tocorrect level (27- 010).

20 00420 3

20-425 Repairing radiator

1 Radiator honeycomb2 Tube bottom3 Top water tank4 Bottom water tank5 Gasket6 Cooling lubes7 Fins

Special tool

P20 - 0071-3s

1 124 589 15 21 001

Commercial tool

7 mm wrench socket with flexible shaft for hose e.g. Hazet, D-5630 Remscheidclips with worm drive Order No. 426-7

20 09-425 1

NoteLight alloy radiators with plastic water tankscannot be repaired by soldering.

The different sealing compound versions andthe priming liquid are combined in a repair kit,Part No. 123 989 00 20.

Because of the different access possibilities tothe radiator (e.g. more difficult in thehoneycomb than at the water tank), sealingcompounds are available in diluted andundiluted form.

Designation

Priming liquid

Undiluted sealing compound

Diluted sealing compound

Application

Preparation of primer

For sealing easily accessrble points

For sealing difficult-to-reach points(e.g. on side of cooling tubes)

Sealing compound and priming liquid can be Fractured or torn fastening straps, tears at thekept for approx. 1 year provided they are always connection fittings or splintering cannot besealed airtight after use. repaired.

Priming liquid which has become cloudy shouldnot be reused.

The following individual parts or points in thecoolant circuit can be sealed with the sealingcompound:

On heavy metal radiators with plastic watertanks, soldering may be performed on thehoneycomb only up to a distance of 20 mmfrom the water tank otherwise the gasket (5)and the water tank (3 and 4) WIII be damaged asa result of the high soldering temperature.Leaks which are closer to the water tank, shouldbe sealed only with the sealing compound.a)

b)

c)

d)

e)

f)

Plastic water tanks (3 and 4).

Heavy metal water tanks (holes up to1.5 mm dia.).

Light and heavy metal cooling tubes (6).

Tube bottom (2).

Beaded collar (connection point betweenradiator honeycomb and water tank).

Heat exchanger of heater system.

It is not necessary to remove the radiator forsealing. In this case, it is sufficient to drain thecoolant and after sealing the cooling system, topressure-test with the tester (1.0-l .2 bar gaugepressure).

20 G9-4252

The priming liquid IS easily combustiblesafety regulations, Hazards Class Al).

(observe

Acetic acid is released until the sealingcompound has completely set. For this reason,avoid skrn contact. Clean affected areasimmediately with soap and water. Rinse out eyeswith water. Consult a doctor, if necessary.

Sealing

1 If it is not possible to locate the leak pointproperly when the radiator is installed, removeradiator (20-420).

2 Clean radiator.

3 Plug hose connections with the shop-madecaps.

P20- 0 0 8 2 - 1 3

Parts required for the top hose connection:15 2 clips L36-46, Part No. 916026 03600016 Piece of hose, Part No. 201 501 38 6217 Reducer made of two tubesA 35 mm 0B 39mm0C 12mm 0

Parts required for the bottom hose connection:18 2 clips L36-46, Part No. 916026 03600019 Piece of hose, Part No. 201 501 38 8220 Cap from a tubeA 35 mm 0B 39mm0

L

18 1 9 18 20I I

P20-0072-13

20 09-425.3

4 Seal connections of transmission oil coolerwith plastic caps or plugs from old oil cooler line.To do this, cut off the oil cooler lines just behindthe nipple and close by soldering.

5 Connect tester to radiator.

6 Place radiator in a water bath.

7 Pressurize radiator with the tester and checkwhere air bubbles rise.

8 Mark leak point.

9 Remove radiator and release pressure.

10 Blow radiator dry with compressed air.

11 Clean point to be sealed with a commercialcleaner (e.g. Tri or cleaner’s naphtha). Alwaysclean more than the point to be sealed (e.g.approx. 20-30 mm beyond the ends of cracks).

It is not necessary to remove the paint. Followingthis, blow the radiator dry at the affected pointwith compressed atr.

There must not be any dust or grease residuespresent after performing the step.

12 Apply a very thin and even coat of primingliquid with a brush.

In the same way as for cleaning, apply thepriming liquid beyond the point to be sealed.Pour the quantity of priming fluid required for therepair into a separate vessel to avoid theremaining priming fluid in the container beingcontaminated.

20 09-42514

AWarning!Observe safety instructions!

13 Allow priming liquid to dry for approx.10 minutes at room temperature.

14 Position radiator so that the sealingcompound cannot run off the point to be sealed.

15 Depending on accessibility, apply diluted orundiluted sealing compound. Use a brush,spatula or similar to spread the sealingcompound.

Caution!Ensure that no air is entrapped in the compoundwhen applying and spreading it.

As for cleaning and priming, apply the sealingcompound beyond the point to be sealed. Ifthere are several leakage points at the beadedcollar (arrows), it is recommended to seal thebeaded collar all-round.

Seal leaks in the honeycomb from both sides.

After completion of the sealing operation,immediately close tube. Acetic acid is releaseduntil the sealing compound is completely set.Avoid skin contact. Clean affected pointsimmediately with soap and water. Rinse out eyeswith water. Consult a doctor, if necessary.

16 Place radiator down, or position upright, forat least 3 hours to allow sealing compound todry. Depending on the quantity of sealingcompound applied and on the size of the pointsealed, it may take up to 24 hours at roomtemperature for the sealing compound to setcompletely to form a durable elastic joint.

20.09-4255

17 Pressure-test radiator in water bath forapprox. 5 minutes at 1.5 bar gauge pressure.

If there are still leaks present, repeat sealingoperation as from step 7.

18 Remove tester and plugs.

19 After re-installing radiator, check enginecooling system for leaks (20- 017).

20 09425 6

20-430 Testing radiator or expansion tank pressure cap

Double connection . . . . . . . . . . . . . . . . . . . , . . attach 000 589 77 63 00 to tester

P20 - 0063 - 33

Pressure cap

Overpressure

124 589 15 21 00, remove (step 1).

. . . . . . . . . . . . . . . . . . . . . . . . . . fit onto double connection (step 2).

valve . . . . . . . . . , . . . . . . . . . . . . test opening pressure by pumping (step 3).See table for test pressure.

Vacuum valve . . . . . . . . . . . . . , . . . . . . . . . . . test. It must be resting against rubber seal, mustrise easily and spring back after being released(step 4).

Pressure cap

Code number I 120

Overpressure valve opens at bar gaugepressure

newpressure cap

1,2+0,1

usedpressure cap

1,2-0,l

Special tools

000 589 77 63 O(

NoteReplace pressure cap if corrosion is present onradiator or expansion tank cap.

Testing overpressure valve r I1 Attach double connection to tester.

2 Fit pressure cap onto double connection.

3 Test the opening pressure by pumping.

Testing vacuum valve4 The vacuum valve (arrow) must be restingagainst the rubber seal, must rise easily andspring back after being released.

P20-0074-13

20-440 Checking engine coolant level indicator

Model 201

i i 1C b d O,Sbr/ws 1

Wiring diagram engine oil level indicator, coolant level indicator, windshield washer level indicator

A l Instrument clusterel Left turn-signal fndfcatore2 Rrght turn-sfgnal Indicatore3 Hugh beam Indicatore4 Fuel reserve warnrng lampe5 Battery charge Indicatore6 Brake pad wear lndrcator lampe7 Brake fluld and oarkrng brake rndtcator lampe6 Instrument liqhtmqe l l Cooant ievei ndrcator lampet2 011 eve1 ndlcator law?13 W,?xnleld wasner lndlcaror ampPl C,;olant ~e~~erat’Jre gaUgeD2 F .er gauge07 E eciror~: clocktachometer

hlh2

B5S41S42s43WIX5/2

b

C

3

Warning busszerAcoustfc turn-sgnal indicator011 pressure gauge sensorCoofant level rndrcator lamp switchWIndshIeld washer level Indicator lamp swatch011 level Indicator lamp swatchMarn ground fbehind Instrument cluster)Connector, InterIorstarter 4-ptn

E!ectncal center connector contact 15 termrnal 15unprotectedElectrical center connector D contact 2 terminali 5 fuse aE!ectrical center connector D co1 tact 6 alternatorfermrnaf 61

20.09-44OV

Test data

Resistance at coolant level sensor at “max” coolant level

Resistance at coolant level sensor at “min” coolant level approx. 5 R

Battery voltage approx. 12 V

Commercial tool

MultImeter e.g. Sun, DMM-5

Note

If problems occur such as:

A. Indicator lamp lights up constantly whenengine running and coolant at correctlevel.

6. Indicator lamp does not light up whenkey in position “2”.

C. Indicator lamp does not light up whenengine running and coolant below “min”level.

Test

A. Malfunction indicator lamp lights upconstantly with engine running andcoolant at correct level.

Test coolant level sensor. Detach connector.Connect both pins to multimeter and testresistance.

Reading: a) fI

-4-i -ml/,\ L-l

t c

20 09-440 2

Test cable. Remove instrument cluster. Testcontact 12 of the 15 pin connector to groundwith multimeter.

Reading: m Q

Yes


L J

End of test

8. indicator lamp does not light up whenkey in position “2”.

Test function of bulb.

Yes No

! c

Remove instrument cluster. Measure voltagewith multimeter at contacts 6 and 9 of the 15-pin connector.


Yes

Replace Indicating instrument.

t--a--P20-0068-13

I

I I 1 I

._-_-!5vP20-0076-13

End of test

‘G 09 UC 3

C. Indicator lamp does not light up whenengine running and coolant below“mln” level. Check function section “8”in order.

I-

Test coolant level sensor. Detach connector.Connect both pins with multimeter and testresistance.

Reading: approx. 5 Q

I.

Yes

Test cable. Connect multimeter with 2-pinconnector of coolant level sensor (browncable) and battery positive.


Yes pzgi&qJump coolant level sensor connector. Indicatorlamp should light up when key in position “2”.

End of test

P20-0071-13

PZO-0078-13

20 OS-JJi 4

20-445 Function of engine coolant level indicator

550 Engme coolant levelsensor550a Lockmg ring551 Float5 5 2 O-rmg

General

P20-0062-35

The dynamic engine coolant level indicatormonitors the engine coolant level in theexpansion tank when the engine is running.

When the ignition is switched on, the enginecoolant level indicator lights up (check function)and goes out as soon as the engine is running.

The engine coolant level indicator shows a weaklight for the check function and a bright light if afault exists.

Componentsl Engine coolant level sensor (550) in

expansion tank.

l Indicator lamp in instrument cluster.Symbol: radiator.

.x09-445! 1

The engine coolant level sensor has two lugs ofdifferent width which fit into approprrate slots onthe expansion tank (arrows) to ensure that it isnot incorrectly installed.

It is pressed into the expansion tank and sealedwith an O-ring (552). Remove locking ring towithdraw engine coolant level sensor.

FunctionWhen the ignition is switched on (key position 2),the indicator lamp shows a weak light and goesout when the engine is running (function checkof bulb).

The engine coolant level in the expansion tank issensed by a float (551) with permanent magnetwhich is attached to the engine coolant levelsensor.

From a certain engine coolant level on, thecontact is closed and the indicator lamp lights

up.

Depending on the driving style, the indicatorlamp will light up briefly at first and then latershow a steady light. If the indicator lamp lightsup, top off engine coolant.

20 G9-445 2

Engine suspension 22

Engine suspension

Job No.

Function of hydraulic engine mounts ........................................ 22 - 210Removal and installation of front engine mounts ................................ 22 - 211Removal and installation of rear engine mount ................................. 22 - 212

22.‘1

22-210 Function - hydraulic engine mounts

456

710

a Dtaphragm chamberb Top chamberC Bottom chamber

Engine mountDiaphragmPlastic disk with annularpassageRubber stop plateRubber mount

P22-0018-35

All parts of the engine suspension aremaintenance-free.The hydraulic engine mounts differ in theirbearing capacity on left and right.

To avoid accidental interchange, the Part No. isstamped on the housing.

The engine mounts are filled with a glycolmixture.

The two chambers (b and c) provided in theengine mount are linked by an annular passagein the plastic disk (6), through which the liquidflows into the respective chamber depending oncompression or extension. As a result, adamping function takes place simultaneously inthe annular passage.

Air is admitted to and released from thediaphragm chamber (a) in the top chamberthrough two passages (4 mm dia.) (arrow).

A rubber stop plate (7) connected to the base ofthe bearing and which limits the engineamplitudes, is located in the bottom chamber

(c)a

22.09-21011

22-211 Removal and installation of front engine mounts

Preceding work:Engme compartment penelling removed (01-006).

Hex. socket bolts (43a) . . . . . . . . . . . . . . . . . . . at bottom, unscrew, screw on, 40 Nm (step 1).

Both hex. bolts (44) . . . . . . . . . . . . . . . . . . . . . at top, unscrew, screw on, 55 Nm and take offheat guard (45), fit on (step 2).

Fan cowl (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . detach, attach, place over fan (step 3).

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . raise with engine hoist, remove engine mounts(steps 4 and 5).

NoteWhen inserting engine mounts, ensure they areproperly located.

22 09-211 1

Special tool

Commercial toolEngine hoist No. 3188 self-locking e.g. Backer, Herder Str.

D-5630 Remscheid

Note 1Since February 1989 (phased-in to seriesproduction) 2 mm higher engine mounts havebeen installed. In addition, recesses (arrow) havebeen provided on the bottom of these enginemounts and lugs on the engine crossmembers.This enables the engine mount to be installedfree of tension.

The modified engine mount has been installed asa standard feature as of August 1989.

The modified engine mounts can also beinstalled on vehicles manufactured prior to thisdat.Ensure that the engine mounts are installed freeof tension.

Engine mounts of the previous and the modifiedversions must not be installed in combination.

22.09-211 2


1 Unscrew hex. socket bolts (43a) for bottomengine mounts, bolt on, tightening torque 40 Nm.

Hex. socket bolt, right

Hex. socket bolt, left P22-5021-

2 Unbolt both top engine mount fastening bolts(44), tightening torque 55 Nm.

3 Detach fan cowl, attach and place over thefan.

4

lug

Attach cables of engine hoist to front lifting(arrow) and raise engine with a crane, lower.

22 09.211,3

5 Remove engine mounts, insert. Ensure theyare properly located.

22.09-21114

22-212 Removal and installation of rear engine mount

65Nm

1 I23& 27

25Nm8

35NmP22-0019-57

:rossmember (13) . . , . . . . . . . . . . . . . . . . . . . unbolt, bolt on.Bolt (23), M8 25 NmBolt (27), Ml0 35 Nm (step 1)

Engine mount (15) . . , . . . . . . . . . . . . . . . . . . . remove and install, Ml2 nut 65 Nm (step 2).

Special tools

22.09-212/l


1 Unbolt crossmember (13), bolt on. Raisetransmission slightly for this step.Tightening torques: Bolt (23) 25 Nm

Bolt (27) 35 Nm

2 Remove nut (17), screw on, detach enginemount (15), attach.Tightening torque 65 Nm.

NoteInstall the shapedside is facing up.

washer (21) so that the open

22.09-212'2

Accelerator control, cruise control 30

30 Accelerator control

Job No.

Adjusting throttle control ................................................ 30 - 300Removal and installation of accelerator pedal lever with firewall bearing ............... 30 - 315Removal and installation of Bowden cable .................................... 30 - 325Removal and installation of accelerator pedal .................................. 30 - 330Lubricating throttle control linkage and throttle control shafts ....................... 30 - 335

3Oil

30-300 Adjusting throttle control

Preceding work:

a) 0 Vehicles with automatic transmission0 Vehicles with RHD version0 Vehicles with manual transmission

NoteVehicles with manual transmission and LHDversion are fitted with a variable wide openthrottle stop to improve the response andadjustment characteristics. See section “b” forsetting and use.

Throttle control linkage and Bowden cable . , . . check for ease of movement and bending.Replace linkage or Bowden cable, if necessary.

Setting closed throttle position stopBowden cable (30) . . . . . . . . . . . . . . . . . . . . . . detach at fulcrum lever (13).

Roller (15) in fulcrum lever (13) . . . . . . . . . . . . . must rest free of tension against end stop.

Throttle body . . . . . . . . . . . . . . . . . . . . . . . . . . check. Throttle body must rest against idlespeed stop.

Set closed throttle position stop . . . . . . . . . . . . . set the fulcrum lever (13) with the connectingrod (2) so that the roller (15) is resting free oftension against end stop. A play of max. 0.5 mmmay exist between roller (15) and fulcrum levertrack.

Cautlon!The roller (15) must run centered in the fulcrumlever (13). Correct or replace parts if necessary.

Checking, setting wide open throttle stopBowden cable (30) . . . . . . . . . . . . . . . . . . . . . . attach at fulcrum lever (13).

Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . with engine switched off, move slowly into wideopen throttle position or, if automatictransmission fitted, down to stop at kickdownswitch (38).The throttle body lever must be touching wideopen throttle stop when performing this step.Set wide open throttle stop at adjusting screw

(28).Adjustlng Bowden cableNipple (26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . must be resting free of tension against

compression spring (27) and the microswitch(S2712) must be operated.

Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . adjust in footwell with adjusting nut (32).Recheck idle speed and wide open throttlestop, adjust if necessary.

NoteWith ignition switched on and lambda testerconnected, an on/off ratio of 20 % must beindicated at wide open throttle (only CFI controlmodules with diagnostics via on/off ratio).

Adjusting control pressure cable (11) forautomatic transmission

a) Control pressure cable with metal ballsocket:

Detach Bowden cable and press back, then pullforward again until the stop is felt. Attach controlpressure cable free of tension, adjust controlpressure cable with ball socket, if necessary.

b) Control pressure cable with plasticattachment:

In closed throttle position, the adjusting pointermust be aligned with the annular groove (arrow)of the adjusting screw (015). Set adjustingscrew, if necessary.

Vehicles with cruise control

Check whether the actuator is resting againstclosed throttle position stop 01 the cruise control.To do this, detach pushrod (21) and press leverof actuator clockwise against idle speed stop.When attaching pushrod (21), ensure that thelever of the actuator is raised approx. 1 mm offthe closed throttle position stop. Adjust rod, ifnecessary.

30.0925-30013

b) 0 Vehicles with left hand drive version andmanual transmissionas of following Vehicle ldent End No.:

I Vehicle ldent End No.

201 A 473 115F 576 183

2

WI-0553-n

29

Throttle control linkage and Bowden cable . . . . .

Setting closed throttle po stopBowden cable (30) , . . . . . . . . . . . . . . . . . . . . .

Roller (15) in fulcrum lever (13) . . . . . . . . . . . . .

Throttle body . . . . . . . . . . . . . . . . . . . . . . . . . .

F

check for ease of movement and bending.Replace linkage or Bowden cable, if necessary.

detach at fulcrum lever (13).

must be resting free of tension against endstop.

check. Throttle body must be resting againstclosed throttle position stop.

30.0925-300/4

Setting closed throttle position stop . . . . . . . . . . set the fulcrum lever (13) with the connectingrod (2) so that the roller (15) is resting free oftension against end stop. A play of max. 0.5 mmmay exist between roller (15) and fulcrum levertrack.

The roller (15) must run centered in the fulcrumlever (13). Correct or replace parts, ifnecessary.

Setting Bowden cableBowden cable (30) . . . . . . . . . . . . . . . . . . . . . . attach at fulcrum lever (13).

Nipple (26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . must be resting free of tension againstcompression spring (27) and the microswitch(S27/2) must be operated.

Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . adjust with adjusting nut (029).

Checking, setting wide open throttle stop . . . release adjustable wide open throttle stop (36)in footwell by turning to the left and withdrawstop pin part slightly. With engine off, slowlymove accelerator pedal into wide open throttleposition until the throttle body lever is restingagainst wide open throttle stop.Accelerator pedal in closed throttle position.Engage adjustable wide open throttle stop (36)in footwell by turning to the right into theadopted position.Re-check idle speed and wide open throttlestop, adjust if necessary.

NoteWith ignition switched on and lambda testerconnected, an on/off ratio of 20 % must beindicated at wide open throttle.

30.0925-300/s

Notes

Fulcrum lever on vehicles withmanual transmissionEngine 102.985Version A was briefly replaced by version B (forautomatic transmission).Since January 1985 the fulcrum lever version Cwith modified fulcrum (arrow) has been installed(improved responsiveness of throttle control).

A First versionB Second versionC Third version

A0L0ca oTl\ o

O0

80t&a0 0

b c30

0

Production breakpoint: January 1985

Model Engine Engine End No.manual transmission

Vehicle ldent End No.

201.024 102.985 001073 F 073767

30.0925-30016

Locking washers for throttle controlLocking washers for relay lever made ofcorrosion-resistant material.

Production breakpoint: February 1988

Model Engine Engine End No.manual transmission

Engine End No.autom. transmission

067638

Accelerator pedal lever, wide open throttlestopModels 124 and 201 with LHD version andmanual transmission:fmprovement of response and adjustment facilityby converting accelerator pedal lever(extending), mounting point and wide openthrottle stop with increased pedal travel by 3” indirection of wide open throttle.

33b

36

Accelerator pedal leverModel 201Wide open throttle stop

Production breakpoint: November 1988

Vehicle ldent End No.

201 A 473 115F 576 183

30 09253OOD

30-315 Removal and installation of accelerator pedal lever with firewallbearing

Accelerator pedal (24) ....................Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bowden cable (30) ......................

Return spring (35) ......................Firewall bearing (34) .....................

Accelerator pedal lever (33) ................

Throttle control .........................

remove, install (30-330).

unscrew, screw on.

at accelerator pedal lever (33), detach, fit on.Model 201: pull off locking element, fit on.

remove, install.

unscrew, screw on.Take off together with accelerator pedal lever(33), install.

NoteWhen installing, the lug on the firewall bearingmust engage in the hole of the firewall (40)(arrow).

detach from firewall bearing (34), fit on. Pull offlocking element, fit on to perform this step.

adjust (30-300).

30.0925-315/l

30-325 Removal and installation of Bowden cable

Bowden cable (30) . . , . . . . . . . . . . . . . . . . . . . remove, install by pressing plastic ball forwardand compressing and pressing out guide piece.Remove Bowden cable by guiding it through theslot.

Plastic clips (28) . . . . . . . . . . . . . , . . . . . . . . . . compress and take out Bowden cable.Windshield wiper arm (Model 201) . . . . . . . . . . . take off. Unscrew both screws (on left and right)

which hold the cover. Withdraw plastic pins andtake out cover (pay attention to note).Not applicable as of Vehicle ldent End No.001 185.

Vacuum lines . . . . . . . . . . . . . . . . . , . . . . . . . . detach, refit.Accelerator pedal (24) . . . . . . . . . . . . . . . . . . . . remove, install (30-330).Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . detach, refit.

Locking element for Bowden cable (30) . . . . . . . remove in car interior.

Return spring (35) . . . . . . . . . . . . . . . . . . . . . . detach, attach.

30.0925-325/l

Bowden cable (30) . . . . . . . . . . . . . .

Throttle control . . . . . . . . . . . . * . . . .

. . .

. . .

Note

Model 201As of Vehicle ldent End No. 001 185 thediameter of the rubber grommet (042) in thecomponent compartment wall (041) has beenenlarged. For this reason, remove thecomponent compartment wall on vehiclesmanufactured prior to this date when replacingthe Bowden cable and enlarge the hole for theBowden cable to 32 mm 0 (productionbreakpoint November 1982).

press to the outside. Do not press out rubbergrommet (31). Take out Bowden cable completefrom the engine compartment.

NoteModel 201, up to Vehicle ldent End No.001 184: take out Bowden cable complete fromthe outside between firewall and componentcompartment wall.

adjust (30-300).

30.092%325/2

30-330 Removal and installation of accelerator pedal

Expanding clips (arrow) . . . . . . . . . . . . . . . . . . .

Accelerator pedal (24) . . . . . . . . . . . . . . . . . . . .

PO7-2367-13A

remove, install.To remove, compress expanding clips behindaccelerator pedal (24) and withdraw.When installing, ensure it engages properly.

remove by pushing accelerator pedal up andturning through 180”.Pull off accelerator pedal down the way. The lug(arrow) on the accelerator pedal lever (33) mustbe aligned with the slot in the accelerator pedal.Installation in the reverse order.

NoteThe connection from accelerator pedal lever toaccelerator pedal is maintenance-free and doesnot need to be lubricated.

30.092%33011

30-335 Lubricating throttle control linkage and throttle control shafts

Check ease of movement and wear of throttlecontrol shafts, throttle control levers, relaylevers, ball sockets, Bowden cable and throttlecontrol linkage.

After each engine wash and preservation of theengine compartment, lubricate all bearing points,all throttle control levers and joints of the throttlecontrol linkage (use anticorrosion grease PartNo. 000 989 87 51 10).

The Bowden cable is maintenance-free and doesnot need to be lubricated.

Only the following hydraulic oils may be used onmodels in USA version:

BP-Aero-Hydraulik 1Castro1 DB Hydraulik FluidEsso Univers J-13Mobil Aero HFAShell Aero Fluid 4

30.092543511

Fuel system 47

Fuel system

Job No.

Function of fuel tank with surge bowl ..........Function of fuel gauge sending unit ............Function of fuel tank ventilation ...............Removal and installation of fuel tank ...........Removal and installation of fuel gauge sending unitFunction of evaporative emission system ........Testing evaporative emission system ..........Function of fuel cooler .....................

.........................

.........................

.........................

.........................

.........................

.........................

.........................

.........................

. . 47 - 010

. . 47 - 020

. . . - 030

. . . - 100* . . - 120. . . - 200. . - 300. . . - 400

4711

47-010 Function of fuel tank with surge bowl

67 Surge bowl68 Fuel filter

7070/l

Return lineReturn jet

A surge bowl (67) with fuel strainer (68) isinstalled in the fuel tank. Its task is to reliablysupply fuel to the engine when the fuel level inthe tank is low and when driving through longcurves.When the fuel pump is running, the fuel returnjet flows along the return line (70) at high speedout of the return nozzle (70a) into the surgebowl. It entrains and carries with it into thesurge bowl the fuel around the return nozzle.

The fuel height (h) in the surge bowl ismaintained even if the fuel level in the fuel tankdrops below the height (h).

As of 1989, a cover with an approx. 20 mm 0hole is fitted additionally on the surge bowl (67).This ensures that the fuel supply of the injectionsystem is assured even if there is only a slightquantity of fuel in the tank (reserve quantity)and during high lateral acceleration.

47.092541 O/l

47-020 Function of fuel gauge sending unit

1 Wiper contact 4 Guide and contact rod2 Float 5 Reserve warning contact3 Contact plate

As the fuel level drops, the wiper contact (1) atthe float (2) detects a higher resistance, thecurrent drops and the gauge needle in theinstrument moves back.

If the fuel level drops to reserve quantity, thereserve malfunction indicator contact (5) isclosed and ground is thus connected to thereserve malfunction indicator lamp.

The reserve malfunction indicator lamp lights upwhen the ignition is switched on (checkfunction). As soon as the engine is running, itgoes out provided the fuel tank contains morethan the reserve quantity.

NoteThe reserve malfunction indicator lamp lights upwith a weak light for the check function, and witha stronger light to indicate reserve quantity.

Testing function of fuel gauge sending unit(54-256).Testing fuel gauge (54-257).

Model 201 as of 09/87The installation attitude has been modified fromapprox. 15” (deviation from vertical) to approx.5”. The gauge has been harmonized to the newattitude of the sending unit as follows:An electronic control delays the switch-on andswitch-off of the reserve malfunction indicator byapprox. 2 minutes to prevent the lamp flickeringin the transition range to the reserve indication.

47.0925420/2

47-030 Function of fuel tank ventilation

Fuel filler cap

40 Filler cap41 Seal42 Locking bar

43 Compression spnng44 Ftller neck

When an pressure of 100 - 300 mbar exists, thefuel evaporation gases are able to escapethrough the fuel filler cap (emergency ventilatione. g. if vent line crimped or vent valve defective).

NoteThe fuel filler cap is equipped with a plastic ringas a phased introduction measure to facilitateuse. The filler cap (3) slides on this ring with lowfriction and engages in both end positions.

5 0 Fuel tank51 Vent valve52 Charcoal canister5211 Cup seal

54 Central pipe5411 Fuel trap64 Vent line

The vent system consists of a central pipe (54)with fuel traps (54/l). The fuel traps prevent thefuel escaping along the vent line (64).The vent line (64) runs from the central pipe tothe vent valve (51).

Air is admitted to and released from the fueltank (50) through the charcoal canister (52) andthe cup seal (520).The fuel tank on models without fuelevaporation control system is vented directly toatmosphere by the vent valve (51).

47.09254x30/2

Function of vent valve (51)If an overpressure of 30 - 50 mbar is exceededin the fuel tank, the vent valve (4) opens and thefuel vapors flow to the charcoal canister.

NoteThe pressure in the fuel tank improves the fuelsupply and counteracts the formation of vaporbubbles.

Vent valve (51) to charcoal canister open

Vent valve opened when overpressure exists.Fuel tank vented to atmosphere (without fuelevaporation control system).

Compression spnngValve housngSpring retainerVent valveValve plateAir admission valveConnection fittingCharcoal canister connectionFuel tank connection

If a vacuum of 1 - 16 mbar is produced in thefuel tank, the air admission valve (6) opens. Airis admitted to the fuel tank of vehicles fitted withfuel evaporation control system through a sealon the left wheelhouse and through the charcoalcanister (see 47-200).

Vent valve (51) tofuel tank open

7

6

PO?-0325 15

47.Q92543Ql3

47-100 Removal and installation of fuel tank

Preceding work:

A. Removal and installation of guide funnel(on all models with catalytic emissions control system)

Guide funnel (1) . . . . . . . . . . . . . . . . . . . . . . . . remove, install by pulling out the two rivets(arrows) as far as the stolj with special tool123 589 05 33. When installing, knock in withdrift.

Caution!Ensure that no rivets drop into the fuel tankotherwise they negate the function of the surgebowl (reserve fuel quantity cannot be used).

NoteA guide funnel (1) is installed because of thesmaller dispensing pistol for unleaded fuel. Aguide funnel must be installed if the fuel tank isreplaced.

47.0925-10011

National version @Guide funnel with additional notches (arrows) tofacilitate installation.

Production breakpoint: June 1989

Model Vehicle ldent End No.A/B F

201 637121

47.0925-10012

62

62a

60a

0

P47-0073-68

47.0925-I ooc3

Fuel gauge sending unit (B4) ....

Fuel filler cap (62) ............

Seal (62a) .................

Fuel tank (SO) ...............

Cup seal (6Oa) ..............

Fuel tank panelling ...........

Feed hose (69), return hose (70),vent valve (51) ..............

WARNING!Pay attention to safety precautions. Risk ofaccident!

. . . . . . . . . remove, install (47-l 20).

. . . . . . . . . take off, fit on.

. . . . . . . . . check, replace if necessary.

. . . . . . * . . empty. Carefully pump out fuel so that no fuelremains in the tank. Capacity approx. 55 or70 litres, respectively.

. . . . . . . . . remove, fit in.

. . . . . . . . * remove, install.

. . . . . . . . . take off, fit on.

NoteCollect remaining fuel.Seal connections.Check suitability for re-use.Ensure cup seal (71) is correctly seated.Tightening torque 28 Nm.

Nuts (50b, 4 off) . . . . . . . . . . . . . . . . . . . . . . . . unscrew, screw on. Slacken tensioning screw attensioning strap (see note), tighten.

Installation instructionUse shims (50a).Tightening torque 21 Nm.

Fuel tank (50) . . . . . . . . . . . . . . . . . . . . . . . . . . remove, insert.

Fuel strainer (68) . . . . . . . . . . . .

Seal (68a) .................

Engine ....................

NotePull drain hose slightly upward and lay behindthe rim edge of fuel tank. After installing fueltank, lay drain hose correctly again. Stick sounddeadening strips (74) if necessary with MBuniversal adhesive 000 989 92 71.

. . . . . . . . . . remove, clean, check suitability for re-use,install.Tightening torque 39 Nm.

. . . . . . . . . . replace.

. . . . . . . . . . run briefly.Check connections for leaks.

47.0925-l 0014

Special tool

I001 589 72 21 00

Note

Fuel tank, Model 201 as of 09/98The contours of the fuel tank have been adaptedto the modified space conditions.Capacity approx. 55 or 70 liters, respectively,reserve quantity approx. 6.5 or 8 liters,respectively.

55-liter fuel tank of sheet steel

The 554itre fuel tank is manufactured either ofsheet steel or of plastic. Only the sheet steelversion is supplied to the @.

Repalr InstructionFuel tanks as of 09188 cannot be installed invehicles manufactured prior to this date. Theplastic fuel tank has different cup seals at therear floor and filler neck from the sheet steel fueltank.

47.0925-l 0015

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....~~.-._.~.....

47-l 20 Removal and installation of fuel gauge sending unit

Preceding work:

Model 201

Battery ground cable ..................... disconnect, connect.

Fuel tank panelling ...................... Model 201

Connector at fuel gauge sending unit (84) .....

Remove fuel tank panelling only partially.

disconnect, plug in. Secure to prevent itslipping.

Sealing flange (65) ...................... unscrew, screw on.

Fuel gauge sending unit (84) . . . . . . . . . . . . . . .

NoteIf fuel tank full, pump out approx. 8 litresbeforehand.

remove, run dry if necessary, install.Remove securing pin below adhesive strip (onlynew part).Replace seal.Tightening torque 39 Nm.

47.0925-l 20/l

Model 201 as of 09/87The installation attitude has been modified forapprox. 15” (deviation from vertical) to approx.5”. The gauge has been harmonized to the newsending unit attitude (see Group 54).

The modified sending unit (5”) may also beinstalled in place of the previous sending unit(15"), but not vice versa.

47.0925-l 20/z

47-200 Function of evaporative emission system

Function diagram of evaporative emission system

236

50

Throttte body assembly 51 Vent valveTherm0 valve (50 “C red or as of 09167 70 “C 52 Charcoal canisterblack/white) 52/l cup sealFuel tank 53 Purge valve

47.0925-20011

GeneralTo minimize the fuel vapors escaping toatmosphere, an evaporative emission system isinstalled. The fuel vapors from the fuel tank (50)are passed to the charcoal canister (52) wherethey are stored. Depending on the operatingconditions of the engine, the fuel vapors aredrawn off by means of the intake manifoldvacuum through the purge valve (53) and thethrottle body assembly and combusted in theengine.

No fuel vapors are drawn off if:l the engine coolant temperature drops below

approx. 50 “C or 70 “C, respectively(therm0 valve (as)),

l the throttle blade contacts the closed throttleposition.

FunctionIf an pressure of 30 - 50 mbar is reached in thefuel tank, the vent valve (4) opens and the fuelvapors flow to the charcoal canister.

Vent valve (51) tocharcoal canister open

1 Compression spring 62 Valve housmg 73 Spring retainer A4 Vent valve I35 Valve plate

Air admlssion valveConnection fittingCharcoal canister connect.Fuel tank connection

47.0925-20012

If a vacuum of 1 - 16 mbar is produced in thefuel tank, the air admission valve (6) opens. Airor fuel vapors are then drawn in through thecharcoal canister.

Vent valve (51) tofuel tank open

When the engine is running and the enginecoolant temperature is more than 50 “C or 70“C respectively, the intake manifold vacuumpasses through the therm0 valve to the purgevalve (connection C) when the throttle is slightlyopen.

Therm0 valve40 “C black50 “C red70 “C black with white ring

The diaphragm (4) is pulled up against the springforce from a vacuum of 20 - 35 mbar. Thepassage from connection A to 6 is opened.

Purge valve (53) open1 Compression spring4 DiaphragmA To charcoal canisterB To throttle body assemblyC Vacuum connection

1 Bimetal plate2 0-nngA To purge valveB To throttle valve assembly

- IA

47.0925-2QQl3

If the throttle is opened further, the two exhaustports (b) in the throttle body assembly, whichmerge into a common passage, are activated inturn. As a result, the fuel vapors stored in thecharcoal canister are drawn off. The activatedcarbon is regenerated.The throttle body assembly has a vacuum andan exhaust port.

NoteThe purge line to the throttle body assemblyshould be detached at the purge valve (78) andsealed when performing work such as “adjustingidle speed” or “checking, adjusting engine” toprevent the mixture being enriched from thecharcoal canister.

47.092%200:4

47-300 Testing evaporative emission system

47-0079-59

Engine oil temperature . . . . . . . . . . . . . . . . . . . approx. 80 “C.Special tool 124 589 07 21 00.

Purge switchover valve (53) . . . . . . . . . . . . . . . . detach from black line to charcoal canister andslowly increase engine speed to approx.3000/min. No extraction is performed whenengine idling. Extraction occurs as engine speedrises.

47.0925-300/l

Therm0 valve (36, in sensor block) . . . . . . . . . . .

Vacuum lines (white/black andwhite/violet/black) . . . . . . . . . . . . . . . . . . . . . . .

Vent valve (51) , . . . . . . . . . . . . . . . . . , . . . . . .

Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charcoal canister (52) . . . . . . . . . . . . . . . . . . . .

Special tools

check for clear passage.

check they are correctly connected to throttlebody assembly and to therm0 valve (36). Checkcondition.

test function.Connect tester 201 589 13 21 00 to connectionfitting to fuel tank (pressure 30 - 50 mbar,vacuum 1 - 16 mbar).

from fuel tank via vent valve (51), charcoalcanister (52, remove bulkhead if necessary),purge switchover valve (53) to throttle bodyassembly (black), check.

check. The connections to each other must notbe blocked.

47.092530012

Arrangement of components

Vent valve (51)It is fitted on at the end of the vent line of thefuel tank.

e. g. Model 201

Charcoal canister (52)a) Model 201 up to 08184, arrangement inengine compartment.The floor of the charcoal canister is air-permeable (perforated plate). If the stored fuelvapors are drawn off, the active carbon isregenerated.

53 Regeneration valveA/Arrow Extraction lineB To fuel tankC Vacuum connection

b) Model 201 as of 09184As of engines with single-belt drive, the charcoalcanister is installed in the front, left wheelhouse.The charcoal canister has a closed metal bottomand therefore has a 3rd connection (arrow) forair admission.

Repair InstructionCharcoal canister only accessible if bulkhead onleft removed.

A Extraction lineB To fuel tankArrow Air admssion line

47.092%300/3

Model 201 as of 09/87The housing of the charcoal canrster is made ofplastic (previously sheet steel). Replace steelwith steel and plastic with plastic.

If the charcoal canister IS installed in thewheelhouse, extractron and air admission linerun to the seal (52’1) which is clipped into thewheelhouse. The air admission line merges inthe annular chamber (arrow) in the middle ofwhich is connectlon (A) for the regenerationvalve.

Purge switchover valve (53)It IS fitted Into the extraction line (a) from thecharcoal canister to the throttle valve assembly.

Therm0 valve (38a)

Engines 102.96/98Installed in the sensor box on the side or on thetop of the cylinder head.

47-400 Function of fuel cooler

All models of national version

@

Model 201 as of August 198575 Fuel cooler attached to engine1, 2 Fuel return line3, 4 Engine coolant return line6 Outer pipe7 Inner popea Insulating hose9 A/C comwessor

A fuel cooler is installed to reduce the formationof vapour bubbles in the fuel system at highoutside temperatures. The fuel cooler is locatedin the coolant return line between evaporator andAC compressor.

When the engine is running, the excess fuel inthe fuel distributor flows back pressurelessthrough the fuel cooler into the fuel tank.

As soon as the A/C compressor is switched on,heat is withdrawn from the fuel by the gaseousrefrigerant which flows through the inner pipe ofthe fuel cooler.

3 2 1 6 7 8 4

47.Q925-4QQ11

Arrangement of fuel cooler, Model 201up to 08/85

1 From fuel distributor2 To fuel tank75 Fuel cooler

47.092540012

iiiiiiiiiiiiiiiiii......... . ..~ L_. ._ _._... . . . _

Exhaust system 49

Exhaust system

Job No.

Removal and installation of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 100Removal and installation of exhaust system at push-in joint . . . . . . . . . . . . . . . . . . . . . . . . 49 - 120Replacement of center and rear mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 140Replacement of exhaust support bracket at transmission . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 180

4911

49-l 00 Removal and installation of exhaust system

Preceding work:Removing and installing engine compartment panetling.

r 1

Shown on Model 124

49.0925-100/l

Exhaust system as of plug connection . . . . . . . .

Heated oxygen sensor (G312) from front exhaustpipe (2a) . . . . . . . . . . . . . . . . . . . . . . . , . . . . .

Pipe shackle (6) with Belleville spring washers (17)and self-locking nuts (23) . . . . . . . . . . . . . . . . .

Bolts (4a) . . . . . . . . . . . , . . . . , . . . . . . . . , . . .

Supporting bracket (10 or 1 Oa) with bolts (1 I),washers (12), rubber washers (14) andnuts (16) , . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front exhaust pipe with catalytic converter (2a)or front muffler (2b, 2) . . . . . . . . . . . . . . . . . . . .

remove, replace and bolt together, install(49-l 20).

remove, install (depending on version). To dothis: Separate heating coil plug connection(G3/2xl) and oxygen sensor signal plugconnection (G3/2x2) in right footwell, plugtogether.

Pull off shield (2~) fit on (open side to the rear).

Installation instructionCoat thread with paste 000 989 88 51. Ensureline is correctly laid.

remove, fit on. Tightening torque 7 Nm.

Installation instructionCheck parts, replace if necessary.

Caution!Pay attention to figure note for installingBelleville spring washers (17).

unscrew, screw in. Replace bolts (4).Tightening torque 25 Nm.Tighten flanged joint evenly.

Note Model 201 up to 09/84:Replace gasket (2~) and self-locking nuts (4b).Tightening torque 30 Nm.

remove, fit on. Tightening torque 20 Nm.

Installation instructlonCheck parts, replace if necessary.

take off, fit on.

49.0925-l 00/2

Rivet nuts (1) . . . . . . . . . . . . . . . . . . . . . . . . . . at exhaust manifold, remove, install.Knock out rivet nuts with suitable tool(e. g. bolt).

Installation instructionInstall rivet nuts with caulking bolt103 589 01 39 00 einbauen. Tightening torqueof caulking bolt 30 Nm.

Exhaust system . . . . . . . . . . . . . . . . . . . . . . , . check for leaks with engine running.

Special tools

1 103 589 01 39 00 t I001 589 66 21 00 1

A

~CautlonlInstall the Belleville spring washers at the pipeshackle so that the concave faces stand off fromeach other (as shown in illustration).

49.0925-10013

Plug connections of oxygen sensor in front offront right seat (if heated oxygen sensor screwedinto front exhaust pipe).

NoteEngine 102.96/98 KAT as of 09189 heatedoxygen sensor in exhaust manifold.

G3/2xl Oxygen sensor heating cod plug connectionG3/2x2 Oxygen sensor signal plug connection

Knock rivet nuts out of the holes in the exhaustmanifold with a suitable bolt. Screw in bolt byhand only.

Insert new rivet nut into hole of exhaustmanifold. Screw in caulking bolt and tighten to atorque of 30 Nm.

49.0925-l 00/4

Model 201 with engines 102.985 KATas of 01191As part of our policy of continuous technicaldevelopment, engines of a higher output havebeen installed in the above models. The upratedengine output is achieved as a result of amodified exhaust system.

l Two-pipe between catalytic converter orfront muffler and center muffler.

0 Pipe diameter of 55 mm (was 48 mm)between center and tail muffler.

l Volume of center muffler enlarged.


49.0925-l 0015

@ 1991 Model 201 with engine 102.985l Pre-catalytic converters omitted.l Insulation upstream of CAT.l Catalytic converter enlarged (11 I').l Suspended upstream of catalytic converter.

49.0925- l 0016

49-l 20 Removal and lnstallatlon of exhaust system at push-In joint

P49 - 0039 - 57

As shown on Model 124, Model 201 similar

Bolt (19), washers (20), spring lock washer (22),nut (23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, check, replace if necessary, fit on.

Tightening torque 25 Nm.Bolted joints, self-locking nuts (3), bolts (8) . . . . . remove, fit on.

Replace self-locking nuts (3), bolts (8).Tightening torque 20 Nm.

Rear muffler (9) . . . . . . . . . . . . . . . . . . . . . . . . remove from rubber ring (18) and take off, fit onand insert in ring.

Installation instructionCheck tail muffler (9) and rubber ring (18) forwear, replace if necessary.

49.0925-120/l

Pipe clamp (21) , , . . . . . . . . . . . . . . . . . . . . . . pull off rear muffler (9), check, replace ifnecessary, fit on.

Bolt (24) washers (20), hanger plate (25) andtensioning plate (26) . . . . . . . . . . . . . . . . . . . . take off, examine for wear, fit on.

Center muffler (7) . . . . . . . . . . . . . . . . . . . . . . take off, fit on.

Sintered seal (5), flange @a), graphiteseal (5b) . . . . . . . . . . . . . . . . . . . . . . . . . . . check suitability for reuse, replace if necessary.

Installation instructionEnsure parts are correctly installed.

Rubber buffer (13) . . , . . . . . . . . . . . . . . . . . . check for wear, replace if necessary.

Exhaust system . . . . . . . . . . . . . . . . . . . . . . check for leaks with engine running.

NoteIf necessary, clean off combustion or corrosionresidues from tapered connections of pipe (2,22) and sintered seal (5) with emery cloth.

Ensure the parts are correctly installed.

2 6 18 7 22

P49-0015-13

2 Front exhaust pipe5 Sintered seal6 Self-locking hexagon nut7 Hexagon bolt18 Flange22 Rear exhaust pipe

49.0925-l 2012

49-140 Replacment of center and rear mufflers

Preceding work:Removing exhaust system as from plug connection (49-l 20).

A. Push-flt versionsee removal and installation of exhaust system at plug connection(49-120).

Shown on Model 124, Model 201 similar

8. Welded version

New rear muffler (9n) . . .

Cut through pipe 80 mm .

Exhaust pipe clamp (21) . .

Installation . . . , . . . . . . . .

. .

. .

. . . I . . . . . 9.. .* place with plug connection exactly over theremoved exhaust system and mark pipe lengthof new rear muffler on the removed exhaustsystem.

* . . . . . . . . , . . . . from the marking (tolerance minus 10 mm) indirection of rear muffler (broken line) to maintainan insertion depth of 70 - 80 mm.

. . . . . . . . . . . . . . use for installation.

., . . . . . . . . . . . is performed similar to reair steps in (49-120).

NoteReplacement of the rear muffler is similar toreplacement of center muffler.

49.0925-14012

49-l 80 Replacement of exhaust support bracket at transmission

Preceding work:

P49-0041-57

Pipe shackle (6) with Belleville spring washers (17)and self-locking nuts (23) . . . . . . . . . . . . . . . . . remove, fit on. Tightening torque 7 Nm.

CautlonlPay attention to figure note for installingBelleville spring washers (17).

(12)Supporting bracket (10) with bolts (1 l), washersrubber washers (14) and nuts (23) . . . . . . . . . . . remove, fit on.

Tightening torque 20 Nm.

NoteCheck parts, replace if necessary.

Model 201 as of lW84Double pipe supporting bracket (10) replacessingle version (1 Oa).

49.0925-l Boil

Af Cautlon!Install the Belleville spring washers at the pipeshackle so that the concave surfaces face eachother (as shown in illustration).

49.0925-I 8012

intake and exhaust, manifolds, emission control system 14 - … info/servizna... · 2014. 5....

Documents