aN Mercedes-Benz Service Model Year 1992 Models 124.034/036 (400 E/500 E) Introduction into service Mercedes-Benz of North America, Inc© Mercedes-Benz of North America, Inc., 1992 All rights reserved. Reproduction by any means, elec tronic or mechanical, including photocopying, record- ing, or by any information storage and retrieval system Or translation in whole or partis not permitted without written authorization from the publisher, Published by Mercedes-Benz of North America, Inc. Printed in ULS.A.Preface With models 124.034.096 (400 £500 E), model line 124 has been expanded by two character- istically sporty versions. Product highlights as compared to model 424,081 (800 CE) are: Models 124.034'036 ‘© 8-cylinder engine with LH gasoline injection system, Model 124.036 ‘© Front track width increase of 37 mm, rear track width increase of 38 mm, Wide tires 22555 ZR 16, Light alloy rims 8 J x16 in new B-hole design, Fenders flared in wheel arch areas. ‘* Front and rear bumper covers adapted to modified fenders, © Fog lamps integrated into front | bumper spoiler cover. | Modifications respective to the engine, as compared to engines 119.970/971 in models 140.0501051, as well as modifications 10 the chassis and suspension, as compared to model 124.051, are detailed. Until the latest repair instructions are available (on microfiche, this Introduction Manual can be used by Mercedes-Benz service personnel to familiarize themselves with important technical details and to perform maintenance and repairs on these models. ‘All other repair instructions, adjustment values ‘and maintenance jobs not listed here can be found in existing technical literature. Mercedes-Benz Aktiongeselischatt Vertrieb Personenwagen February 1992Table of contents Vehicle and component identification Vehicle views Technical highlights Engine on 07.4 13 4 15 18 cylinder crankcase, oil pan Cylinder crankcase Oil pan Engine timing, valve train Camshafts LH gasoline injection system General information Component locations Belt drive Paly-V-belt Emission control system Electrical system ~ engine Electronic ignition with anti~knock control (EZLAKA) Alternator Engine lubrication system il pump il pressure sensor Oil dipstick guide tube Oil fiter : 10 10 " 12 19 16 7 18 20 ar at at an 20 22 30 Engine cooling system Radiator Coolant pump Visco-fan clutch Fan shroud Heater return fiting Engine suspension Engine carrier Rear engine mounts Electronic accelerator Component locations Drivetrain ar 32 33 ‘Automatic transmission Starter lock-out switch Conirol pressure bowden cable adjustment Installation survey, test and pressure values Shift points with selector lever in position *D" . Upshift delay (moder 124.034) ‘Suspension General information Front damper strut Rear shock absorbers, model 124.034 (without level control) Level control Torsion bars Cross reference - springsirubber mounts Front axle Steering knuckle arm and idler arm Wheel guidance, model 124.036 22 22. 22 22. 22 23 23 24 26 26 27 or 28 30 30 a 32 33 34 34Table of contents 35 40 a 42 46 a7 Rear axle Modified rear axle components Rear axle carrier Gear set and rear axle shaft Wheels, chassis measurement Cross reference - wheelsities’recommended tire brands Wheel bolts Tire pressures ‘Snow chains Chassis measurement (test and adjustment data) Propeller (drive) shaft Brakes Front wheel brake Rear wheel brake Brake pads, brake calipers, brake discs Tandem master brake cylinder Brake booster Brake fluid ABS Acceleration slip control (ASR il) Steering Steering gear Steering colurm jacket tube! steering spindle Steering wheel . Steering geometry, steering linkage Fuel system Fuel tank, model 124.036 Light alloy whee! (@-hole design) 35 35 36 37 7 38 38 38 39 41 42 42 43 43 43 44 46 47 47 47 48 54 Electrical system - equipment and instruments Battery Module box (F23) Control unit coordination Removal and installation of control units 36-pole test connection for diagnosis (X11/4) Instrument cluster Two-tone fanfare hors Body 49 51 53 53 85 87 60-64 Body ~ general Body shell Accident repair, use of straightening sets 82 Electrical system - body CD changer Exterior lighting Windshield wiper system, model 124.036 Interior lighting 88 Detachable body components Bumpers, model 124.036 Front fenders, model 124.036 Exterior panels, model 124.036 Trunk, model 124.036 91 Seats, restraint systems Seats Airbag Special tools 57 87 58 58 60 60 61 61 62 62 63 64Vehicle and component identification Vehicle identification 1992 (partial) 126.026 300 E 2.6 124.030 300 © 124.034 400 E 124.0 124.036 500 124.051 300 CE 124.090 300 TE Sales designation Model Engine Manual ‘Automatic Power transmission transmission _steering 400 124034119975 722.354 765.921 500 124,038 119.974 S 722.385 765.921 Component identification 1992 © (partial)Vehicle identification Vehicle identification number (VIN) ‘The following information is encoded into the VIN: Manufacturer, model, restraint system, model year, manufacturing plant and chassis end number. Example, model 600 E: WDB EA 36 XN B 123456, wos £ X NB 123456 A= Gasoline, B= Diesel, 0 = 4MATIC Restraint system D= Seat belts + SRS with driver airbag E= Seat belts + SRS with driver and front passenger airbag Check digtt Model year §—§—§ M=1991, N= 1992 Manufacturing plant" A E=Sindettingen F -H=Bremen Chassis end number 1) Manutactuing plant jeter must be specified wit the end number because smutaneous production at both plants may moan the samo end number digits are assed to wo cars.Vehicle identification Engine family designations The emission control system information plate attached to the radiator cross member also shows the engine family designation. The engine family designation identifies model year, piston displacement, version, etc. (see example on next page). Designations Engine family Version » Mode! Sales designation NMB5.0V5FA 10% A 124.034 400 € NMB 5.0 V5 FA 10 A 124,036 500 E 1) A= AN 50 states (noting Catorniay 2) For caricatan reasons, a! 119.97 engnes fall nto the 6.0 Iter engine famiy. even ithe displacement aquas only 442 hors (400 E)Vehicle identification Example: NMB 5.0.5 F A 10 > N MB 50 V5 pila a ‘Model year: m= 1991, N 992, ete. Manutas Mercer urer code’ | jes-Benz Seapament te some Vehicle class = Passenger car with gasoline engine D=Passenger car with diesel engine Type of fuel delivery’ 5 = electronic injection (LH) —_ 6 = mechanical injection 9=mechanical injection with turbocharger | Type of catalyst F'=Seway catalyst with lambda control | J=no catalyst (diesel) For manufacturer's use: A=All 60 states F= Federal Used by manufacturer for certification Check digitVehicle viewsTechnical highlights Engine Important engine data ine Compression ratio Displacement com? Boreistroke Horsepower Torque 322 hp @ 8700 rpm | 964 fib. @ 9800 rpm rig974 [100 4973 36.5165.0 240 KW@ 5700 rpm_| 480 Nm @ 3900 rpm y19.978 | 10.0 4198 9278.8 | 268hp @5700 rpm | 296 fib. @ 3900 rpm 200 KW @ 5700 rpm | 400 Nm_@ 3900 rpm 01 Cylinder crankcase, olf pan 05 Engine timing, vaive train 07.4 LH gasoline injection system 13 Belt drive 14 Emission control system 15 Electrical system ~ engine 18 Engine lubrication system 20 Engine cooling system 30 Electronic accelerator Detail modifications om cylinder crankcase. Gil pan adapted to available space. Valve timing and camshatt identification code changed, Component locations. Belt length modified Ar injection and exhaust gas recirculation (EGA). Component locations. Compact alternator 110 A with the following designation NC 14V 60/110 A. Location of oll pump suction strainer and oil level switch modified. Two-piece fan shroud. Coolant pump modified. Component locations.Technical highlights Drivetrain a 32 33 36 ‘Automatic transmission ‘Suspension Front axle Rear axle Starter lock-out switch modified. Transmission 722.3 installed. Upshift delay for model 124.034, Increased weight resulting in modifications to the following components: Damper struts, shock absorbers/spring struts, = Front and rear springs, Torsion bars. Model 124.034 Level contra! available as optional equipment. Model 124,036 Level control standard equipment, Both damper and spring struts feature extension limiting springs. Vehicle ride height lowered Model 124.036 Track widened 37 mm, Rear control arm mounts connected by additional strut. Rear axle carrier reinforced, Rear axle center piece mount. 4-arm drive pinion flange with 110 mm bolt circle diameter Rear axle shatt diameter modified with larger inner constant velocity joints. Reinforced camber linkTechnical highlights 36 40 42 45 47 54 Rear axle (continued) Wheels, chassis measurement Brakes Steering Fuel system Electrical system - equipment and Instruments Model 124.036 Rear axle hub centering flange lengthened by approx. 2mm. Track widened by 38 mm. Forged light alloy wheel in new 8:hole design. Front wheel brake with 4- and ventilated brake disc. Rear whee! brake with 2-piston catioer and ventilated dise braka. Model 124.034 Acceleration slip control (ASR) available as an option, Model 124.036 Acceleration slip control (ASR) standard equipment Steering gear 765.921 (LSL 088) Model 124.036 90 liter (23.8 gal.) fuel tank of which 11.5 liters. (3.0 gal.) are reserve. Maintenance-free battery (12 V 100 A) installed in trunk. Control units in engineicomponent compartment consolidated into module box. 38-pole test connection for diagnosis integrated into module box.Technical highlights Body 60, 61, 62, 63, 64 Body ~ general 82 Electrical system - body 88 Detachable body components 91 Seats Foliowing areas of the body shell modified: Front end, ~ Front and rear wheelhousings, = Firewall, = Tunnel, Main floor, = Rear floor, — Various supports, reinforcements and consoles, ‘Straightening sets fron Colette and Car- Bench CD changer available as an option, Model 124.036 Range of extended-reach wiper increased by 4mm Headlamp units with auxiliary high beams in place of fog lamps. Ellipsoid fog lamps integrated in trent ‘bumper cover/spoier. Model 124.038, Front bumper cover reshaped to reduce front axle ltt Front and rear bumper covers as well as side protection panels adapted to modited front and rear fender contours, Model 124.036 ‘Sport 4-place leather seating01 Cylinder crankcase, oil pan Engines 119,974'975 are identical in design to enginas 119.970/971 (models 140.081/042), with the exception of the following details. Cylinder crankcase Mounting flange for left and right engine mount arms each have two additional threaded bolt holes. A Models +24 ard 129 Mode! 140 Oil pan Upper and lower oil pan halves modified to accommodate front crossmember. Upper oil pan half made of cast aluminum, lower half made of steel ‘The shape of the oil pan gasket and baffles has been changed. Engines 119.974/975Engines 119.974/975 05 Engine timing, valve train Camshafts Modifiod camshatt identification code on left exhaust camshatt (engine 119.974 only). Valve timing in degrees of crankshaft angle at 2 mm valve lift and new timing chain Engine Camshaft identification code ® Intake valve *) Exhaust valve Intake Exhaust opens cieses | opens closes camshaft ‘camshaft after after | before before right left fight eft | TOC soc [0c Toc 119974 [7472 78 6b 30.0° oor [13.0 13.0" 75% 73M 79% 7" 119.975 [a2 80 e684 | 30.0" gs.0° [8.0° 13.0° a3 gt” 7° a5? 37 Alowabiewerance: +20" Parinn ta ony on ascend cam in Srocin Gorge ator 2 aman entfeaton number scribd on Font of Sr camshaft Bearng cual or Stared wi pant on back el cama fange 2 Camino aguster rede 4 Repo size camshaft wit © Sm larger boarng ameter.07.4 LH gasoline injection system General information In order to obtain & more accurate and more fuel efficient fuel delivery at all engine operating conditions, an electronic gasoline injection system with air mass measurement by means of a heatad wire is installed on these engines. ‘The abbreviation LH means: = Lufmassenmessung = ait mass measurement Hos Hitzdraht = hot-wire The basic system of the LH gasoline injection system is a non-engine driven, electronically controlled gasoline injection system, This system makes a direct measurement of the inducted air mass by means of a hot-wire air mass sensor. Operation of the LH gasoline injection system is described in the Introduction Marual for model 9, ‘The respective component locations for models 124.034/036 are illustrated on the following pages. Engines 119.974/975 CHECK ENGINE warning lamp (A1e26) California version model 124.034 vehicles and all model 124,036 vehicles are equipped with the CHECK ENGINE warning lamp which is activated by the diagnostic module (N59). Federal version model 124.034 yeticles are not equipped with a CHECK ENGINE warning lamp to indicate a malfunction in the Qz-sensor signal circuit gnostic module (N58) Al model 124.036 (600 E) vehicles are California version vehicles and as such, are equipped with a diagnostic module (N59) However, only the California version of model 124,034 (400 E) is equipped with the diagnostic module For a functional description of the diagnostic module, see Introduction Manual for model 140, engines 119.970/971Engines 119.974/975 07.4 Component locations CHECK ENGINE® warning lame uel oumps relay 14 conto une Elocrone accelerator contol unt Base modve Diagnostic module (Catforni version mode 124.036, al made! 124.098) xine xives xrverst yaa yer y92 Test conection for oiagnosis (impulse reacout, 3B-oie) Test connecton for diagnoste module Pushouton eth LED Unshit deay ewichover vata EQR synicnover vave Ar injocton pump swichover valve07.4 Engines 119.974/975 1777 Intake ar tengorature sensor Ya Upshit dota swichover valve G32 Heated O,-sensor Ysa Purge swicnover valve KI7 Ar ingcton relayEngines 119.974/975 07.4 B22 Ar mass sonsor with pote Yas Eloctomagnate ar action pump elven 8112 Coolant temperature sensor (4-90) ya8"1— Salenod, lah agustabie camshaft bming is CGranksnat postion sensor ‘¥49'2 _Soleno. night adusiabi camshaft bmng Ls Garshat poston sonsor Ye2——Fuolingcton vanos13 Engines 119.974/975 Belt drive Poly-V-belt Belt routing diagram Belt length 2465 mm 1 Tensonag pulleyEngines 119.974/975 14 Emission control system 195 Function diagram, air injection and exhaust gas recirculation as well as vacuum supply 40 60 89 125 126 12 128 135 156 miei mez Nis Nan Diaphragm pressure egulator Vacuum elemont Fue cooler EQR vave ‘Vacuum element, uashit dey Ar injection pump ‘ir njecton Shutoff valve (Check vale (ar injection) Check valve (vacuum) Gnock vaio (vacuum supa) Exhaust manos Blecrone accelerator actuatcr Cause contclila speed conto! actuator EZLIAKR ignition contol unt LLM conrad nit. Upshit delay switchover valve EGR sutcnover valve Air jection pune swichover valve Electramagnetc ai njecton pump cluich Purge smichover vale Active charcoal canst Consumers re8 vy ck vranspavont brown ue15 Engines 119.974/975 Electrical system - engine Electronic ignition system with antl-knock control (EZL/AKR) With the exception of individual component The functional description of the electronic locations, the EZLIAKR ignition system is, ignition system is covered in the SMS, ictentical to the system installed in engines Combustion, Engine 119, LH-injection system. 119.970:971 in model 140, Component locations Ni3_—_EZLAKR nition conte unit TH1 Ignition eal + (ght cyindar bank) Nan LH int Te cal 2 (lft cyngor bank) Nait—Ebtonic accelerator nt xn Ni6it Basa meduie xine N30’ ABSIASA conto unt A162 Reference resister (EZLIAKR) A.B Bipole connect 2 Connector. crankshat postonEngines 119.974/975 15 AI6 Knock sensors bs Crankshaft positon sensor (51 Gamshatt postion sensor sss S516 365 Lett high-votage dstnoutor Fight nigh-votage csiibuior Transmission overload protecton switch15 Alternator Compact 110 A alternator with the following designation: NC 14V 60/110 A, Charging current T Engine rpm Alternator rpm Engines 119.974/975 2180 6300Engines 119.974/975 18 Engine lubrication system Oi! pump Location of oil pump suction strainer and oil level switch changed. Oil pressure sensor The 1-pole oil pressure sensor is mounted on a stee{ cil ine. The oil pressure gauge is identical to model 124 Oil dipstick guide tube The shape of the guide tube was changed due to the modified oil pan. Oil filter The oil cooler line connections are sealed off with a plug and an O-ring since an engine oil cooler is not installed. The thermostat (cil temperature control) was deleted.20 Engine cooling system Radiator Transverse mounted radiator with 29.8 dm cooling surface with integrated transmission oil cooler on right side of radiator. Two electric auxiliary cooling fans are mounted in front of the A/C condensor. The radiator mounting console is attached with screws. Coolant pump Coolant pump iniet without air bleed fitting Visco-fan clutch cemperature was lon The fan engagemen red from 96 £4°C to 82°C. The visco-fan clutch housing was modified, thereby moving the fan 8 mm closer to the engine. The cover was adapted to the modified housing and has an open center in the front Bimotallic spring identification number: 119 200 01 22. Fan shroud The two-piece fan shroud with lateral air flaps was adapted to available space. The fan shroud is divided transversely in the middle and can be separated by removing the fan shroud ring, Heater return fitting The heater return fitting was adapted to available space on the right sear of the crankcase Engines 119.974/975Engines 119.974/975 Engine suspension Engine carrier ‘Adapted to modified installation conditions, Rear engine mounts Round rubber mounts mounted on die-cast aluminum crossmember. 2230 Electronic accelerator Component locations | i xi/4 | M761 Elecrone accelerator actuator Nig1 Base module 3M LH contd unt Naor Nar Elecronte accelerator contol uni N59 ve Diode matrix, engine gam increase xia si ior agnosis out, 28:pale)27 Automatic transmission ‘The familiar transmission type 722.3 is installe Starter lock-out switch The starter equipped with two adit (arrow) for transmission selector cognition during cruise control aperation. For test procedures, see Diagnastic Manual Engines, volume 2, section 6. Contro} pressure bowden cable adjustment A Throttle control linkage must be proj adjusted rly 1. Remove air filter. 2, Loosen hex nuts (8) on connecting rod (8) 3. Turn connecting rod (8) until the tips of the indicators ine up with one another, 4. Tighten hex. nuts (6).27 Installation survey, test and pressure values Model 124.034 124.036 Transmission type 722.354 722.365 Transmission part no, | 124 270 03 02 140 270 22 02 Vacuum modulator color | natural black’ Modulating pressure bar|s.8 40 Torque converter dia. mm [290 290 Shift points with selector lever in position “D” Model Accel. pedal [Shifts at approx. kmmin (mph) Position we [ 23 [ aoa | 453 ] 352 | 201 124.034 [Full throttle | 60 (98) | 125 (78) | 197 (128) | 722 (76) | 45 (28) | 25 (16) Kickdown | 80 (60) | 136 (@5) | 208 (130) | 186 (116) | 172 (70) | 48 (30) 124.038 [Full trots | 46 (29) | 104165) | 163(102)| 114(71) | 40 (25) | 24 (15) Kickdown 67 (42) | 112 (70) | 169 (708) | 183 (96) | 92 (68) | 98 (24)al Upshit delay vacuum eierent First goa stat colay Li contol u Kick pst Connector sleeve trina 87 (LH) oy27 Upshift delay for rapid heating of catalyst Model 124.034 In order to rapidly heat the catalyst after starting the engine, the transmission is equipped with an Upshift delay to raise the shift point for the 2-3 Upshift. Operation of the 2 ~ 3 upshift delay is described in Group 27 of the Model Year 1992 Introduction Manual for model 140. In addition, the transmission is equipped with a 1 ~2 upshift delay which is active at coolant temperatures below 40 °C, The t - 2 upshift delay occurs: © After exceeding a vehicle speed of 8 km/h (6 mph) for 8 ~ 13 seconds up to maximum (of 38 krmih (24 mph). The 1 ~ 2 upshift delay is controlied by the LH control unit and the first gear start refay (K29/t) which is located in the fuse and relay box, position “E* Note: ‘A malfunction of the 1 ~ 2 upshift delay is stored as impulse readout “29” in the LH ‘control unit's malfunction memory,32 Suspension General information Model 124.036 The vehicle ride height was lowered by 23 rm Due to the it following su: creased vehicle waight, the were modified nsion components on both models: © Torsion bars By usi nat stiffer spring and strut settings, driving stability could be f o the vehicles’ high weight vel control ig standard on model special order improved with respet performance capability and increased 124.031 option on model 1 and is avail Front damper strut Model #24.034 The tightening torque for the damper strut/steering knuckle assembly was increased to 200 Nm through the use of a larger M14x1.5 pinch-bolt (1 1k} and self-locking hex. nut (1 1u). As a result, the steering knuckle upper mounting hole diameter was increased to 14 mmand the damper strut mounting hole diameter was increased to 15 mm. The tightening torque of 110 Nm for both lower microencapsulated hex bolts (1 This reinforced damper strut mount will also be phased into production for model 124.036. ) remains unchanged.32 Model 124.036 The damper sirut is equipped with a extension limiting spring (14m), giving additional vehicle support during cornering Models 124.034/036 A harder suspension stop buffer (11h is used between the damper strut and damper strut ‘mount, the damper struts are color coded (see table). 13 Damporstut nig Pista rod 31h Buter 11m Extension tniing spring Damper strut color code Model 124.034 124.036 Number 2 8 Coior white yellow Buffer Model 124.094 124.036 Length 83 mm 70 mm Color red natural Rear shock absorbers Mode! 124.034 (without level contro!) Color code: Number: 2 Color: white Modified butter (75i) Length: 78mm Color: natural32 Level control The cil reservoir (2) is located in the front right- hand side of the engine compartment. ‘The connecting sod (7} is attached to the outer bore of the lever (Sa) on the leveling valve (3). Rear axle spring strut The rear axle spring strut, ike the front axle damper strut, has an extension limiting spring (model 124.036 only) The spring strut is color coded (See table) Spring strut color coding Model 124,034 | 124.036 Number 8 a Color white white32 Torsion bars The diameters of the front and rear torsion bars were increased (see table below). Torsion bar diameters Model Front axle Rear axle 124.034 [26.5 mm 16 mm 124.036 | 28 mm 18mm Cross reference - springs/rubber mounts For information regarding spring‘ubber mount combinations, see respective parts microfiche, group 32,33 Front axle Steering knuckle arm and idler arm Wheel guidance Model 124.03635 Rear axle Modified rear axle components © Reinforced rear axle carrier © Rear axle hub wheel centering flange lengthened by approx. 2 mim © Modified rear axle canter piece mounting (model 124.036), ‘© 4-arm drive pinion flange with 110 mm bolt —-~Reinforced camber link. circle diameter. © Track widened by 38 mm (model 124.036). ‘© Rear axle shaft diameter modified with larger inner constant velocity joints Rear axle carrier ‘The rear avle carrier was strengthened to acommodate the high engine torque and adapted to the modified frame floor. The front and rear crossmembers as well as the flexible center Piece mount were modified, Model 126.036 Model 124.09435 Gear set and rear axle shaft Mode! 124.034 124036 Rear axle center piece Ring gear dia 210 210 Ratio 2.24 2.82 Number of teeth 47:21 48:17 Gearirotor on drive pinion for ABS _ Number of teeth 43 =" Constant velocity joint flange dia. 10 110 Constant velocity joint flange type arm arm Rear axle shaft with constant Ball dia inner 23.812 23.812 velocity joint Ball dia outer [22.225 22.228 Inner bolt circle dia 102 [192 Shaft dia without ASR 25 . with ASR [32 82 Grease fil inner 150 180 quantity | @ Grease fil outer 120 120 quantity @ 1) ASA stanoard equipment, no Gear usec7 40 Wheels, chassis measurement, wheel alignment Cross reference - wheels'tires/recommended tire brands Model [Rim designation ‘Summer tires, tubeless Winter tres, tubeless Part no. Brand Tire size Brand 124.034 | Light alioy 19565815 [MICHELIN | 1956515 | CONTINENTAL 6 Vp JX 15 H2 ET 44 | o1V xv giTM+S SUPER &-hole design CONTACT Ts 750 124-401 12 02 } DUNLOP SP WINTER | | | coonyear | [ULTRA GAIP 3 PIRELLI MS. WINTER 190 | PERFOR. MANCE 124,036 | Light alloy 225155 ZA16 | PIRELLI 225195 18 | DUNLOP 8x16 H2 ET 94 600 93HM+S — |SP WINTER S-hole design SPORT DUNLOP 124 401 14.02 Dao PIRELLI MS WINTER 210 MICHELIN, PERFOR, MxM MANCE Light alloy wheel (8-hole design) Forged light alloy wheel without steel sleeves. Unlike the 8-hole wheels of model 140, the wheels for models 124.034036 are painted.40 Wheel bolts Height of head “K Bolt shank length mm | 40 40 els 124.034 and 124.036 Tire pressures For tire pressures, soe tire inflat label located on inside of fuel Snow chains ‘Snow chains with RUD-m: ble as Mercede: merchandise Mode! 124.094 Model 124.096 wit ited shank cola (row)40 Chassis measurement (test and adjustment data) Vehicte level Model Front axle Rear axie with level control vehicle at curb weight | vehicle at curb weight "" loaded (control point) mm mm mm 124.034 49° sg 12+ 27 ois Sc 12 10% 124.036, 0 “10° 9 “27+ 2 23 if “a7 102 1) Vehicle cure weight adustment values based on base pressure in damper sits 21 Adjustment values. 9) Tost valuas only. The derence o! the vehicle level between test and adjustment cbtained fom the loveling valve travel and has no effect on the conto! accuracy whe cving Front axle wheel alignment at specified vehicle level (curb weight) Model 124.034 Camber ) Wheels in straight ahead position (toe 0°) Pee Permissible difference between left and right (035°) Caster) Wheels in straight ahead position (toe 0°) 30°30'+30" _(10.50° £0.50") Measured against wheel stop 30°15'#90"_(10.25° £0.50") Permissible difference between left and right | 0°30" (0.50°) Toein or20£10" ——(0.95" £0.15) (front wheels spread with 90-110 N force) Toe-out with inner wheel turned 20° 2) a9 430" (4.00 £0.80°) ‘Maximum permissible steering angie at 40° (40.00%) inner whee! > Ball point position * Pitman arm 26.522 mm Idler arm 23.522 mm Permissible ball joint height difference 3mm between pitman and idler arms 1 Tolerance stor checking nly. out of tolerance, asst to specified valve. 2) Value glen does not nude toe. 2) Whee! angle an autsde wee! wil be 7° 10 11° less than on inside whe 8) Correcton is mas on ler arm n upward or dovenmard direction oy adsiton Note: Values in parentheses () are decimal degrees. removal of washer.40 Front axle wheel alignment at specified vehicle level (curb weight) Model 124.036 Camber # Wheels in straight ahead position (toe 0°) = pp oc + aye =. a 05" (-1,00° Permissible diference between left and right | 0°20" (0.35°) Caster ) Wheels in straight ahead position (t08 0°) 10°50' 230° (10.85 $0.50") Measured against wheel stop 10°35" #30°__(10.60° #0.50°) Permissible diference between left and right | 0°80 (0:50°) Toon i ~ [o°20'= to (0.35° £0.15") (front wheets spread with 90-110 N force) Toe-out with inner wheel turned 20° 2 —0°85'=30" (-0.90" +0.50") Maximum permissible steering angle on [40° (40.00") inner wheel 3) Ball point position 4 ~ Pitman arm 26.542 mm idler arm 23522 mm Permissible ball joint height difference 3mm betwen pitman and idler arms con by adton oF removal of washera Propeller (drive) shaft ‘Survey Model 124.084i036 Drive shaft tube dia. (mm) front 60 mm rear 60 mm Drive shaft flange bolt circle dia. (mm) 110 mmi4-arm flange Flex dise front torsionally rigid rear torsionally rigid Centering sieeve front rubber bushing rear composite bushing Centering sieave front 2.4mm installation depth (mm) rear 25.9 mm42 ABS Model 124.034 ‘The ABS system, known from model 124, was revised and modified to include the following changes. The ABS control unit (N30) is now equipped with diagnostics, Recognized malfunctions are stored in the control unit and retriaved via the 38-p0le test connection for diagnosis (impulse readout, X11/4) using an impulse counter. Malfunctions can be subsequently diagnosed with the socket box tester. For the ABS test, see Diagnostic Manual, Chassis and Drivetrain, Volume 1, Section 6.2, Model 140. Voltage is supplied by the base module (N16/1) ‘The base module (N16/1) and the ABS control unit (N30) are located in the module box. On model 124.034 with optionally available ASR, the ABS control unit (N30) is replaced by the ABSIASR contro! unit (IN30/t) Acceleration slip control (ASR !iI) Model 124.034 optional equipment Model 124.036 standard equipment ‘The acceleration slip control, known from model 129 (ASR II), has been revised and is now known as ASR Ill (3rd version). All modifications are described in the following section. Modifications to the electronic accelerator system are described in group 30 of this introduction manual42 ‘The ABS/ASR control unit was revised and modified. The ABS/ASR control unit (NSO!) is now equipped with diagnostics. Recognized malfunctions are stored in the control unit and retrieved via the 38-pole test connection for diagnosis (impulse readout, X11/4) using an impulse counter. Malfunctions can be subsequently diagnosed with the socket box tester. For the ASR test, see Diagnostic Manual, Chassis and Drivetrain, Volume 1 Section 6.2, Models 124.036, 140. Voltage is supplied by the base module (N16/1). The base module (N16/1) and the ABS/ASR control unit (N30/1) are located in the module boxSteering Steering gear Steering gear 765.921 (LSL 068) is identical to the version used in model 129, except for a ‘ower mounting position. Steering ratio = 14,0 ~ 16.0 1 Steering gear housing 4 Control vane 5 Reacton piston 2 Cover 3 Steering worm 25 Steering nut 85 Steel als 43° Pinan shat 45° Agustng sorew 50 Settiocking collar nut 51 Housing cover 71 Seve glug. 91 Automate and pay 100 Sew pugSteering column jacket tube/steering spindle An electrically adjustable telescoping steering column is installed as a standard equipment and is connected to the steering gear by a universal joint (2). To center the steering box, align the pinch slot of the steering column universal joint (2a) with the centering mark engraved on the steering box (arrows) Steering wheel (140-design) Both models are equipped with a newly designed leather covered steering wheel with airbag. Steering whee! diameter: Model 124.034 400 mm, Model 124.036 390 mm. Correct positioning of the steering whee! during installation is assured by two grooves in the hub (arrows) and by 2 mark on the steering shaft spindle. Steering geometry, steering linkage The steering linkage was modified due to the increased front axle load. The left tie rod is fitted with a hexagonal adjusting tube. The right tie rod is known from model 128.46, 47 In order to protect the steering linkage joint from high engine temperatures, a heat shield (12a) was mounted on the pitman arm, Fuel system Fuel tank Model 124.036 The capacity of the fue! tank is approx. 90 liters (23.8 gal.), of wnich approx. 11.5 liters (3.0 gal.) are re ve,54 Electrical system - equipment and instruments Battery 12 V, 100 A, maintenance-free, Bartery locaton in night sido of rink Note: Battery testing should be performed according to SMS, Repair Instructions, Group 54. Battery positive cable There are two battery positive cables having respective cross sections of 70 mm? and 10 mm®, Battery positive cable (70 mm?) With the exception of control units in the module box, all electrical consumers are supplied with voltage from the 70 mm? battery positive cable. Battery positive cable (10 mm?) Control units in the module box are supplied with voltage from the 10 mm’ battery positive cable.54 Routing of battery positive cables The 70 mm? battery positive cable runs from the battery to terminal block (X4’10). The 10 mm® battery positive cable runs from the battery directly to the module box. ‘The cables are routed inside the vehicle, along the right longitudinal frame rail 170mm? batory post 2 10 mm? battery postive cay 1 wnt batery pose cable 2 10 mam? battery postive cable X/10 Terminal block termina S030U/8re/@7L (5-00!) 70 min? battery posi 2 «mm? batery postive Terminal block (x4/10) The alternator, starter and alternator noise Suppressor are connected to the 70 mm* battery positive cable via terminal block (X4/10). Lecaton in component 2 terminal 30;30U/610/87L (S-p0l)4 54 : Electrolytic capacitor (C2) | ‘A.4700 iF electrolytic capacitor (C2) is installed for noise suppression of electrical interference from the 70 mm? battery positive cable. ‘The capacitor's positive (+) connection is made at terminal block X4/10 (70 mm? battery positive cable), and the negative (-) connection is made at ground location W162. Module box (F23) In order to protect the control units in the engine/component compartment, and fit them into @ compact area, the electronic control units are installed in a module box (F23). F209. Madiula 800 Control units in the module box (F23) are cooled by a blower motor (M2/2). Cool intake air is drawn from the passenger compartment in the glove box area and is later returned to the same area. M22 Medue bax blowar motor €2 Electrolyte capacitor (atematorrbatiry hamess 180 Suppressor) Xa/10 Terminal doce, termina’ 30/20U1610871. (S-pale)54 The blower motor (M2/2) is switched on and off by a temperature sensor integrated in the base module (N16'1), ‘The blower motor (M2/2) is switched on: © For 1.5 seconds after each engine start if the engine speed exceeds 1200 rpm. © Ifthe temperature in the module box is 2 +60 °C, The blower (M2/2) is switched off at temperatures < +55 °C. If the temperature in the module box exceeds a specified limit while driving (in spite of blower motor [M2/2] operation), the base module (16/1) diagnostics stores this information as a malfunction (impulse readout §). For further information, see Diagnostic Manual, Chassis and Drivetrain, Volume Location of control units in module box (F23) NSIT LH conta! v ait. Eleciranie accelerator contol unit 16/1 Base meoule| N3O/I_ ABS/ASR contol unt All control units and connectors in the module box are equipped with a safety feature to prevent the control unit from being plugged into the wrong connector. In addition, the control units are color coded. A color identification mark (arrow) on each contro! unit is identical to the lor of its respective connector in the module box, Several contro! units have 2 connector blocks, whereby the connector for the second connector block is darker in color than the color identification mark on the control unit54 ‘The individual connection fields in the module This, along with box are identified by number. the color-coded connectors, allows easy coor- Control unit coordination dination of the wiring hamess with the respective connection field and control unit. Control unit color mark Connection field number Identification color of hamess connector ait LH control unit 6 light green light green. 7 dark green N4it_ Electronic accelerator control 4 |light orange unit 5 | dark orange light orange | N161 Base module d black black N30'1 ABS/ASR control unit 2 light grey light grey 3 dark grey Removal and installation of control units Note: A special tool, part no. 140 $89 01 33 00, is required for the removalinstallation of control Units in the module box, Special too!54 1. Disconnect and cover battery negative terminal 2. Unscrew module box cover screws and lift off cover. 3. Place special tool on control unit (arrows) and carefully move in direction of arrow until the control unit lifts out of connector. 4. Remove special tool and pull out control unit. 5. Insert control unit by hand, paying attention to the color coding, 6. Hf necessary, press control unit completely in with special tool by placing special tool on module box frame under the ribs (arrow). Carefully move special too! in direction of arrow until resistance can be felt when control unit is fully engaged in connector. 7. Remove special tool 8. Further installation is in reverse order of removal,54 | 38-pole test connection for diagnosis (X11/4) The 38-pole test connection for diagnosis (impulse readout) is integrated into the module box (F23) and accessible after removal of a cover. Diagnosis of individual systems is covered in the respective diagnostic manuals. Terminal layout of 38-pole test connection for diagnosis (X11/4) 1 Terminal 3 (ground) w2, W18a electronics ground) 2 Supply votage tr rea 87 9 Tena 30 4 DHconvol unt, N31) * 5 Notused 5 ABSIASA cent! unt «woo 7 Blactonie accelerator conmol unit (Nt) * 8 Base modulo (NIB!) * 8-15 Not uses 16 ACC pushbuton contol unt (Nz2) 17 EZLAKR igniton comol unit 1/3)" 18-29 Not used 30. SAS contol unt (nz) 31-98 Not used Diagnostic capabity vs sonal interface lmpuisa readout (Bho ode} only54 Instrument cluster CHECK ENGINE warning lamp (A1¢26) California version model 124.084 vehicles and all model 124.036 vehicles are equipped with the CHECK ENGINE warning lamp. Federal version model 124,034 vehicles are not equipped with a CHECK ENGINE warning lamp. Electronic speedometer he speed signal for the speedometer is provided by an inductive speed sensor (L2) on the transmission Fuel level indicator Model 124.036, The fuel level indicator and the fuel level sensor were adapted to the larger fuel tank (90 liters’ 23.8 U.S. gal.) and increased reserve capacity (approx. 12 liters/3.2 U.S. gal.) Test values for fuel level sensor Model 124.036 Installed, reserve indicator ON, float at bottom: 0819, Sensor rotated 180° FULL”, float at top: indicator at 79-82 2i i ‘Two-tone fanfare horns ‘Two-tone fanfare horns are installed as standard equipment. Unlike previous models with fanfare horns, the standard signal horns and respective selection switch are not installed, He Fantare nara 1 E52. Right fog lamp ait Fantare horn 2 5482 The ellipsoid fog lamps are installed below the front bumper in the spoiler area. The ellipsoid fog lamps operate according to the projection principle in which light is not emitted through a dispersion lens but instead through a focusing lens. The advantages are a more compact assembly and an extremely sharp beam cut-off. This results in wide beam dispersion and reduced glare Repair note: Models 124.034/036 To adjust the lett or right headlamp or to replace a bulb, itis necessary to remove the engine air intake housing Air intake housing removaliastallation © Pull off hose to air filter from air intake housing. Additionally on left air intake housing, unplug connector for intake air temperature sensor. © Lift up straps on air intake housing and guide them over both catches (arrows), thereby lifting out the air intake housing to the top. Installation is in reverse order of removal.a “i 82 Windshield wiper system Model 124.036 ‘The range of the extended-reach wiper in its ‘outermost position was increased by 4 mm. Interior lighting Rear reading lamps are installed as standard equipment,88 Detachable body components Bumpers Model 124.036 ‘The front bumper cover was reshaped to reduce front axle lit by nearly one halt The fog lamps are located to the left and right of the modified front bumper ventilation slits, similar to model 129. The rear bumper cover was modified to fit the widened rear fenders. Front and rear bumpers constructed with energy absorbing foam and integrated impact absorbing bumper struts as known from previous model 124 vehicles. Front fenders Model 124.036 The front fender arches were flared outwards to acommodate wider tres.88 Exterior panels Model 124.036 The front and tear fender side protection panels as well as the rocker panel covers wera adapted to fit the modified front and rear fender contours. Trunk Model 124.036 Due to 2 larger 90 liter (29.8 U.S. gal) fuel tank, the trunk volume was decreased from 520 liters to 485 liters.91 Seats, restraint systems Seats Model 124.036 ‘Sport 4-place leather seating is installed and is available in the following interior colors: creme beige, black, blue, dark brown and grey. Due to the individual rear seating, model 124.036 is classified as a four seater only. Airbag Model 124.008 As preos, diveratbag sine as curard caper. ont passenger aba s ootoray era | Model 124.036 Driver and front passenger airbags are installed as standard equipment.; t Special tools Part number Group Category Description =~ 119 589 04 63 00 or A ( Pressure hose with angular connection 7/46" - 20 UNF | and union nut M12 x 1.5 mm for LH gasoline injection system (with tester 103 689 00 21 00), 11958008 6500 Cw) 140 589 02 63 00 o7 8 Contact module 2 LH gasoline injection system, ABSIASR, electronic accelerator system. 14059026800 a) 140 589 10 63 00 16 8 ( } 1B-pote test cable } a [98 800 15 119 589 01 09 00 18 A = Spark plug wrench 94 (18.8 mm) 175 mm long, a5" square drive, 11958901 0800 5 140 589 01 33 00 54 A Lifting fixture for removaliinstallation of control units in module box. 140 589 01 33 00)Special tools Part number Group Category Description 140 689 01 63.00 4 8 ( Contact module 1 for base module. 140 589 06 63 00 54 B Contact box for checking control units in module box. "4 589 08 63 00 4 00 5a B 140 5: Adaptor for diagnostic test connection for connecting impulse counter 124 689 19 21 00 to diagnostic test connection. "40 689 146300 34 140 889 10 33 00 64 B Spacer for removal of control units from contact box. | 140 589 08 63 00) XQ ) 129 589 00 21 00 83 B (@ ; 126-pole socket box for checking electronic systems in Conjunction with contact module. 129 689 0081 00 34