Service Manual

V-8 Engines 1986-1991

M116.96 (4.2 ltr.) & M117.96 (5.6 ltr.)
Match group index number on right to beginning of
numbers in bookmarks panel on left Group lndex

General, Technícal Data 00

Crankcase and cylinder head 01

Crankshaft assembly 03

Engine tlming , valves 05

Mechantcally/electronlcally controlled gasollne ln)ectton system (CIS-E) 07.3

Alr cfeaner 09

Beft drive 13

lntake manifold, exhaust manifold 14

Electrlcal system, englne 15

Engine lubrlcation 18

Englne coollng 20

Engine mounts 22

Throttle control 30

Fuel system 47

Exhaust system 49
lnstructions for use of service manual 00

Complete Service Manual coverage for late modal Locatlon of speciflc repair instruction s
year Mercedes-Benz vehicles requires three
individual manuals: First locate the Group No. in the Group lndex.
Individual groups are s~parated by an easily visible
Service Manual, Engine dividing page, which is followed by the job index
Service Manual. Chassis and body page. Then check the job index for the exact job
Service Manual, Heating and air conditioning required. The first page of a typical job description
looks like this:
Throughout these manuals. the vehicles are identified
by their chassis and engine numbers. These
03.7-320/1 Mounting crankshaft
numbers are made up of the first six digits of the
respective serial number. For the actuallocation of Job Title appears on - --.....J
chassis and engine numbers. see page 00-015/1. In same line as Group
case where the repair inst ructions apply to all No.

. __________
versions. only the first three digits of the respective
number are referenced. ,...--- -- - - - - -- -- - Group No.

For example, the engine type in modal 560 SEC is Subgr:~: :::
117.968. The number 117 applies to all 5.6 liter light
alloy V·8 gasolina engines with overhead camshafts
produced from 1986·91 .
11
03.7-320/ 1
Page No.

The original page formal was developed for use on

microficha. In order to use the sama originals for
printing this manual, the page numbers afways
appear on the lower left of each page.

Technical data, tightening torques and toofs are listed

at the beginning of each job.

All dimensions are in metric units. unless otherwise

indicated. Any part numbers given are only used for
identification and easier differentiation between
individual components. and are not intended for
ordering purposes.

00 . 005/1
Engine and vehicle identification 00

This manual applies to all M 116 and M 117 light alloy engines installed in the following passenger cars
from model year 1986 through 1991:

Chassis Engine
Model From To
Type Type

560 SL 1986 1989 107.048 117.967

420 SEL 1986 1991 126.035 116.965

560 SEL 1986 1991 126.039 117.968

560 SEC 1986 1991 126.045 117.968

00 . 01 o 1
Vehicle identification number locations 00

Model 107
W hen ordenng spare parts. please specofy c hassos and engone num bers.

1 Certoficatoon Tag (left door pollar)

21dentofication Tag (leh wondshoeld post)
3 Vehoc le lden tilication No.
4 Body No. and Paontwork No.
5 Engone No.
6 ln formatoon Tag
Calofornoa versoon
Vacuum lone routíng ter emossion
control system
7 Emossoon Control Tag

Model 126 sedan (coupe similar)

When ordenng spare parts, please specífy c hassis ano engone numbers.
The ollustratoon depocts the sedan . On the coupe, the ooentifocatoon plates are arranged somolarly.

1 Certoficatoon T ag (left door pollar)

21oen tílícatlon Tag (left w onoow post)
3 Vehocle ldentolícation N o.
4 Engone No.
5 Body No. ano Paontwork No.
6 Emossoon Control Tag
560 SEC. left side
7 l ntormatoon Tag
California version
Vacuum lone routing
tor emossoon control system

00-015i 1
Technical data 00

Engine
Model 107.048 126.035 126.039 126.045
Sales 560 SL 420 SEL 560 SEL 560 SEC
designation
Engine 117.967 116.965 117.968 117 968
Operation 4-cycle, electronic/ 4-cycle. electronic/ 4-cycle. electronic/ 4-cycle. electronic/
machanical gasolina mechanical gasolina machanical gasolina machanical gasolina
injec!ion sys!em with injaction system with injaction system with injection systam with
airflow sensor (CIS-E) airflow sensor (CIS-E) airflow sensor (CIS-E) airtlow sensor (CIS-E)
Number ol 8 8 8 8
cylinders
Cylinder V-shaped 90• v-shaped 90• V-shaped 90• V-shaped 90•
arrangement
Bore.'stroke mm 96.50<94.80 92.00178.90 96.50194.80 96.50194.80
Total effective 5547 4196 5547 5547
pis ton
displacament ce
Compression 9.0:1 9.0:1 9.0:1 9.0:1
ratio
Firing order 1-5-4-8-6-3-7-2 1-5-4-8-6-3-7-2 1-5-4-8-6-3-7-2 1-5-4-8-6-3-7-2
Maximum speed 6000 ±50 6000 ±50 6000 ±50 6000± 50
rpm
Engine output
(SAE)kW/rpm 17014750 15015200 17814800 17814800
(SAE net
bhp/rpm) (227!4750) (201 /5200) (238!4800) (238.'4800)
Maximum torque 380í3250 31013600 390/3500 390t3500
Nm/rpm
(net lb-ft.lrpm) (279-'3250) (228/3600) (287 3500) (287;3500}
Crankshaft 5 5 5 5
beanngs
Valva Overheadl hydraulic Overheadlhydraulic Overhead/hydraulic Ovarheadihydraulic
arrangement lifters lifters lifters lifters
Camshatt OHC. ona par OHC. ona per OHC. ona per OHC, ona per
arrangament cylinder bank cylindar bank cylinder bank cylinder bank
Oil cooling non e none none none
Cooling Coolant circulating Coolant circulating Coolant circulating Coolant circulating
pump. thermostat pump. thermostat pump, thermostat pump. thermostat
with bypass line. tan with bypass line, tan with bypass line. tan with bypass line. tan
with visco tan clutch. with visco tan c lutch, with visco tan clutch. with visco tan clutch,
tinnad tube radiator tinned tube radiator finned tuba radiator tinnad tube radiator
Lubrication Pressure lubrication Pressure lubrication Pressure lubrication Pressure lubrication
via gear type pump via gear type pump via gaar type pump via gear type pump
Oil filler Full flow filter Full flow filler Full flow filler Full flow filter
Air cleaner Ory paper cartridge Ory paper cartridge Dry paper cartridge Ory paper cartridga

00-020í 1
00 Technical data

Filling capacitles
Model 107.048 126.035 126.039 126.045
Sales designation 560 SL 420 SEL 560 SEL 560 SEC
Engine 117.967 116965 117.968 117.968
Fuel tanklreserve 85/ 115 90112.5 90112.5 90/12.5
approx. 1
Engine oil initial fi lling 8.5 8.5 8.5 8.5
approx. 1
During oil and filler 8.0 8.0 8.0 8.0
change approx. 1
Marks on dipstick 7.515.5 7 515.5 7 515.5 7.5!5 5
mavmin . approx. 1
Cooling system with 12.5 12.5 12.5 12.5
heater
approx. 1
Coolant pump maintenance- maintenance- maintenance- maintenance·
free free free free
Brake system 0.53 0.53 0.53 053
approx. 1
Automatic transmission 8.617 7 8 .617 .7 8 .6!7 7 8 .6i7.7
approx. 1 initial filli
oil change
Level control - . 3.5
approx. 1
Rear axle 1.3
hypoid gear oil SAE 90 . . .
approx. 1
MB limited slip
differential oil approx. 1 1.3 1.3 1.3
Power steering 1.4 1.2 12 1.2
approx. 1
Technical data 00

Electrlcal system
Model 107.048 126.035 126.039 126.045
Sales designation 560 SL 420 SEL 560 SEL 560 SEC
Eng1ne 117.967 116.965 117.968 117.968
Battery Volta9e 12 V 12 V 12 V 12 V
Capac1ty 92 Ah 66 Ah 92 Ah 92 Ah
Starter Bosch DW 12V DW 12V DW 12V DW 12V
l .SkW 1.5 kW 1.5kW 1.5 kW
Alternator 14 V 14 V 14 V 14 V
70 A 80 A 80 A 80 A

00-020 3
01 - 001 Engine and model survey

Engine Model Sales Output in kW Compression

designation at 1/min € : 1

116.960 107.025 380 SLC 160/5500 9.0

116.960 NV 145/5500 7.5
116.9600@ 120/4750 8.3

116.960 107.045 380 SL 160/5500 9.0

116.960 NV 145/ 5500 7.5
116.960@ 145/5500 8.3
116.9600@ 120/4750 8.3

116.961 126.032 380 SE 160/5500 9.0

116.961 NV 145/5500 7.5

116.96 1 126.033 380 SEL 160/5500 9.0

116.961 NV 145/5500 7.5
116.961@0 145/5500 8.3
116.9610@ 120/4750 8.3

116.962 107.045 380 SL 150/5250 9.4

116.962 NV 135/5500 7.5
116.962@®0 145/5500 8.3
116.9620@ 120/4750 8.3

116.963 126.032 380SE 150/5250 9.4

116.963 KAT,@ 120/4750 8.3
116.963 NV 135/5500 7.5
116.963@@)0 145/5500 8.3

116.963 126.033 380 SEL 150/5250 9.4

116.963 NV 135/5500 7.5
116.963@@0 145/ 5500 8.3
116.963 KAT,0@ 120/4750 8.3

116.963 126.043 380 SEC 150/5250 9.4

116.963 NV 135/5500 7.5
116.963 @@)0 145/5500 8.3
116.963 KAT, (V@ 120/4750 8.3

116.964 RÜF,@)0 107.047 4 20 SL 160/5200 9.0

116.964 KAT,@ 150/5200 9.0
116.964 NV 150/5200 80

01.7- 001 / 1 F3
Engine Model Sales Output in kW Compression
designation at 1/ m in e:1

116.965 RÜF,@) 126.034 420 SE 160/5200 9.0

116.965 KAT,@) 150/5200 9.0
116.965 NV 150/5200 8.0
116.965 RUF 170/5400 10.0
116.965 KAT 165/5400 10.0

116.965 RÜF,@CV 126.035 420 SEL 160/5200 9.0

116.965 KAT,@@)(D<@> 150/5200 9.0
116.965 NV 150/5200 8.0
116.965 RÜF 170/5400 10.0
116.965 KAT 165/5400 10.0

116.965 RÜF,@CV 126.046 420 SEC 160/5200 9.0

116.965 KAT,@) 150/5200 9.0
116.965 NV 150/5200 8.0
116.965 RÜF 170/5400 10.0
116.965 KAT 165/5400 10.0

117.960 107.026 500 SLC 177/4750 8.8

117.960 NV 165/4750 7.5

117.960 107.046 500 SL 177/4750 8.8

117.960 NV 165/4750 7.5

117.961 126.036 500 SE 177/4750 8.8

117.961 165/4750 7.5

117.961 126.037 500 SEL 177/4750 8.8

117.961 NV 165/4750 7.5

117.962 107.046 500 S L 170/4750 9.2

117.962NV 160/4750 7.5

117.963 126.036 500 SE 170/4750 9.2

117.963 NV 160/4750 7.5

117.963 126.037 500 SEL 170/4750 9.2

117.963NV 160/4750 7.5
11 7.963@)0 170/4750 9.2
11 7.9630@ 137/4500 8.0

1 17.963 126.044 500 SEC 170/4750 9.2

117.963 NV 160/4750 7.5
117.963@)0 170/4750 9.2
117.9630@ 137/4500 8.0

117.964 RÜF 107.046 500 SL 180/4750 9.0

11 7.964 KAT 164/4700 9.0
11 7.964 NV 170/4750 8.0

117.965 RÜF 126.036 500 SE 180/4750 9.0

11 7.965 KAT,@) 164/4700 9.0
117.965 NV 170/4750 8.0
117.965 RÜF 195/5200 10.0
117.965 KAT 185/5200 10.0

01 .7- 001 / 2 F3
 .. .. ....
...tMo.._.U.-.Wi.....~-~-~~....- M' _
, ,.,, , ,_.,,,,,..,,,,.-.~·o
.. .
._.. X ''i'))~l NoV<N>W ..., ., ,.., ,

Engine Model Sales Output in kW Compression

designation at 1/m in €:1

11 7.965 RÜF 126.037 500 SEL 180/4750 9.0

117.965 KAT,@) 164/4700 9.0
117.965 NV 170/4750 8.0
117.965 RÜF 195/5200 10.0
117.965 KAT 185/5200 10.0

11 7.965 RüF 126.044 500 SEC 180/4750 9.0

117.965 KAT,@) 164/4700 9.0
117.965NV 170/4750 8.0
117.965 RüF 195/5200 10.0
117.965KAT 185/ 5200 10.0
-·--
117.967@ 107.048 560 SL 175/4750 9.0
117.967 0 @ 173/4750 9.0

117.968 RÜF 126.039 560 SEL 200/5000 9.0

117.968 KAT,@@) 178/4800 9.0
117.9680@ 180/4800 9.0
117.968 220/5000 10.0
117.968 RÜF 220/5000 10.0
117.968 KAT 205/5200 10.0
117.968NV 200/5000 8.0

11 7.968 RüF 126.045 560 SEC 200/5000 9.0

117.968 KAT,@@) 178/4800 9.0
11 7.968 220/5000 10.0
11 7.9680@ 180/4800 9.0
117.968 RÜF 220/5000 10.0
117.968KAT 205/5200 10.0
117.968 NV 200/5000 8.0

NV = Low compression, SA = Special version. KA T = Catalytic converter

RüF = Reconverted vehticle

01.7-001 / 3 F3
01-010 Checking compression pressure

Test values with engine at operating temperatura Positiva pressure in bar

Normal compression approx. 8.5

Mínimum compression pressure 1 ) at
Low compression approx. 7.5

Permissible d ifference between the individual cylinders max. 1.5

1
) Check cyl inders for leaks if compression pressure is below m inimum.

Special tools

Compression pressure recorder with accessories 001 589 76 21 00

Adapter line for compression pressure recorder 124 589 36 63 00

Note

Check compression pressure at operating tempera·

tu re.

Check cylinders for leaks if compression pressure

is below mínimum (01- 015).

For checking, unscrew all spark plugs.

Disconnect plug connection (X27) from cable

harness and connect adapter line (01) with single·
pole coupling to plug connection (terminal 50) of
the cable harness.

Rotate the engines wit h the starter motor. Todo so,

connect the terminals specified in each case.

On veh icles with screw·type cable connectors, use

the crocodile clip with the single·pole plug instead
of the adapter line.

01.7-010/ 1 F3
Model107

On the 4-pole cable connector, disconnect ca ble

(color red/ violet) at term inal 16 and switch off
ignit ion, so that the ign ition coil and the fue l pump
are not activated. Connect terminal 30 (cable color
red) and terminal 50 (cable color violet).

Model 126

Separate plug (terminal 16, arrowl. switch off igni·

t ion so that ignit ion coil and fuel pump are not
ac t ivated.

Connect the terminals shown with arrows.

Checking

Unscrew all spark plugs.

2 Rotate engine several times to expel residue and

soot. (Selector lever: poshion N or P).

3 Press compression pressure recorder into the

spark plug hole of the cyll inder concerned.

4 For checking, rotate crankshaft approx. 8 times

at ful l thr ottle.

Check all cylinders in this manner. First move data

sheet in compression pressure recorder into new
work ing position.

01 .7- 010/ 2 F3
01-015 Checking cylinders for leaks

Data

Total pressure loss max. 25%

On valves and cylinder head gasket max. 10%
On pistons and piston rings max. 20%

Spe<:ial tools

Socket insert 27 mm, 1 /2" drive for

001 589 65 09 00
rotating the engine

1/2" drive, 80 mm long for

617 589 00 16 00
rotating the engine

Conventional tool

e.g. Bosch, EFAW 210 A

Cyli nder leak tester
Sun, CL T 228-1

Checking

Run engine up to operating temperatura.

2 Remove air cleaner.

3 Set throttle valve into fully open position.

4 Unscrew spark plugs.

5 Pull off breather hose on the cylinder head

cover (arrow).

6 Top up coolant, leaving cap off.

7 Connect cylinder leak tester with hose toa

compressed air system.

Calibrate tester.

01.7-015/ 1 F3
8 Set the piston of the cyl inder to be checked at
ignition TDC. T o do so, rota te engine at the eran k·
shaf t using the tool combination.

For rotating the engine of model 107, remove the

radiator cowling and the f an.
g .
.

Note: The vibration damper is marked with the

figures O, 90, 180 and 270 (arrowsl.

The respective pistons are in TDC position when the

marks on the vibrati on damper are adjacent to the
indicator:

Mar k Pistons at TDC

o 1 and 6
90 5 and 3
180 4 and 7
270 8 and 2

9 Screw connection hose into spark plug bore and

connect to leak tester hose.

Ensure that the crankshah does not move.

1O Note the pressure loss on the cyl inder lea k

tes ter.

11 By listening, determíne if pressure escapes

through the intake manifold, exhaust, engine
breathing system, spark p lug bore of the neighboring
cylinder or coolant filler opening.

12 Check all cylinders in the sequence of the firing

order.
o o o o o
o OO Of;_\Of;\0( .¡0
Note: There is a possibiliity tha t the pistan ring gaps o 0 ~0\~0~0
of individual pistons are directly one above the o o o o
other, so that the test resul t will be misrepresented. oo
7 154 8 6372
When in doubt, continue running the vehicle and
o
recheck cylinders for leaks at a later date.
o o o o o
of;'\Of;\Or;\O f;\0
0
o\Jo Vo~o\.:_Jo
o o o o o
01.7-015/2 F3
01-020 Evaluating cylinder bores

Conventional tool

e.g. Karl Storz GmbH, D-7200 Tuttlingen

Motoskop TW (cold light)
Cylinder illuminating lamp
with lens probe 103 26 CW (570 mm)
and lens probe 103 26 CT (2 10 mm) 1 )

1
t Required for 3rd cylinder.

Note

With a cylinder illuminating lamp it is possible to

carry out the visual check while the cylinder heads
are insta lled.

To evaluate the cylinder bore, the lens probe is intro·

duced through the spark plug bore while the respec-
tive piston is at BDC position.

To check cylinders with difficult access ( left engine

side), the lens probe 10326 CT (210 mm) must first
be introduced into the spark plug bore before con-
necting it to the extension.

Motoskop TW
12 volts and 220 volts 103-15713

After boring and honing, the cylinder running sur-

faces are treated electrolytically. The result of this
is that the piston rings and the chrome or iron-plated
light metal pistons are only in contact with the
silicon crystals (0.02 mm to 0.05 mm in size), which
provide a wear-resistant running surface. Honing
traces are not visible on these cylinder running sur·
faces.

01 .7-020/ 1 F3
When evaluating scored or streaky cylinder running
surfaces, it is often hard for t he workshop to decide
whether the damage is already serious enough to
require engine removal or repair, or whether the
marks are insignif icant. The fo llowing information
will help to make expert and correct decisions.

Note: With ..streaks in direction of land" (in direc-

tion of pisten pinl. shaft streaks or seizures are not
possible, since there is no con tact between pisten
skirt and cylinder liner. The first difference on
cylinder running surfaces is between .. optical streaks"
or .. seizure streaks" ... Optical streaks" are up to
3 mm wide and w ithout significance; wit h .. seizure
streaks" however, the cyl i nder running surface is
rough. lf there is any doubt. remove the cyl inder
head.

Brown discolorat ion (oillacquer) is a normal

occurrence with aluminum cylinder runn ing sur-
faces.

01.7- 020/2 F3
01-030 Removal and installation of engine (oil capacity)

Specified viscosity classes according to SAE

during lasting ambient temperatures
•f •e
1 ·• ·lO
) SAE 40 may be used during lasting outside temperatures
above +30 oc (+86 OF}. ·• · 20
· lO
2 ·50
) For engine oils identified on sheets 226.1 and 227.1 of
Specifications for Servl ce Products with footnote 1).
t he following applies:
SAE 5 W- 20 below + 10 °C.
...
·~
· 13
S
o
1
. 10
IS
1 20
SAE 10 W-30 ín temperate zones all seasons; i.e. up to
+30 °C.
SAE 15 W- 30 in temperate zones all seasons.
3
J A ll-season oil.

Oil capacity in liters (for approved engine oils refer to Specifications for Service Products)

New f illing {dr y engine) 8.5 1 l

Engine {total fill ing capacity)
With oil and fi !ter change 8.0

1) On vehicles with air-oil cooler 0.5 liter addi t ionally.

Tightening torques Nm

M 26 50
OH drain plug of oil pan
M 12 40

Central screw - oil filter cover Model 126 25

Anaching screw for oil filter lower part Model 107 35

Special tools

Tester for cooling system

001 589 48 21 00
and radiator or expansion tank cap

Radiator cap with hose

for leak test
JT;;
~ lf.._H_U;;oo;:;;;~iD 605 589 00 25 00

Adapter for checking radiator cap

000 589 73 63 00
in connection with tester

Conventional tool

Engine hoist size 1.5 e.g. Wilibar, D-5630 Remscheid

- -·- -·-- - - - --

01.7-030/ 1 F3
Note

On model 126, raise engine hood into 90° positi on

and engage left detent lever (arrow) .

On model 107, remove engine hood.

Remove and install engine with transmission atan

inclination of approx. 45,.

Removal

1 Drain coolant.

Caution!
The drain plugs (2) are arranged at the left and right
of the cylinder crankcase.
The lateral crankshaft bearing r;a p bo) ts (arrows)
should not be confused w ith th•· coolant drain
plugs.

2 Orain p lug left

2 Orai n p lug r ight

2 On vehicles with air conditioning or automatic

climate control, these should be drained and hoses
disconnected at t he pipe pair (arrow) (83- 516).

01.7- 030/2 F3
3 Remove radiator and tan.

4 Remove complete exhaust system.

5 Press control arm (4) off right ball head (only

model 1071.

6 Evacuate power steering pump reservoir.

7 Disconnect pressure hose on power steering.

8 Oisconnect all coolant, vacuum, oil, fue! and

electricallines and other connections leading to the
engine.

9 Unscrew cable for TDC transmitter from diagnos·

tic socket.
Remove screw (4) and pull out transmitter (3).

10 Oisconnect control shaft.

11 Unscrew attaching screws (arrow) at left and

right of engine mount.

01.7- 030/3 F3
12 Remove engine shock absorbers left and right.

Model 107

13 Attach engine hoist cables to the lifting eyes.

14 Remove rear engine cross member or bulkhead

w ith engine mount.

15 Disconnect drive shaft from t ransmission.

16 Loosen connections on t ransmission.

17 Lift out engine at an inclination of 45°.

8®
9¡> 124 :l 9 3 :.t4

lnstallation

Caution!
When installing a new engine after a previous bearing
failure, carefully flush o i l hoses, renew oil cooler.
Disassemble and clean o i l damper.

18 Check engine mounts, coolant, vacuum, oil and

fu el hoses, renew if requ ired.

01.7- 030/4 F3
Caution!
When installing the refrigerant compressor carrier
(steel version) it is important to ensure stress-free
assembly.

The carrier (steel version) must be checked for dis·

tortion. lt must rest evenly on all contact points of
the cylinder crankcase without gap. This condition
should be checked before tightening the bolts.

The bolts must be tightened in the following

sequence:

a) lnstall bolts (1 7, 6 and 5) finger·tight.

b) Tighten bolts ( 17) at engine front.

e) Tighten bolt (6) and nut (5) at side of engine.

19 1nstall and connect engine.

20 lnstall rear engine mount without tension.

Tighten set screw with 30 Nm.

21 Ensure that all drain plugs are t ight.

22 Fill in oils (exchange engines and overhauled

engines initial operation oil according to sheet 225.3
,.Specifications for Service Products"), coolant and
refrigerant.

23 Check cooling system with leak tester for leaks.

Check antifreeze capacity of coolant.

24 Connect control linkage and check funct ion.

25 Clean air filter and renew if necessary.

26 Clean air cleaner and renew if necessary.

27 Set idle speed

01 .7-030/5 F3
0 1-040 Engine b reathing sy stem - operation

The engine has a closed maintenance-free engine breathi ng system. The engine blow-by gases and cylinder crank-
case vapor s flow through the connection pipe (1) in the left cylinder head cover (in d irection of driving) to the
idle air distributor (3). A breather oríf ice of 2 mm dia. is installed in the idle air distributor.

From the breather orífice, the blow-by gases and crankcase vapors mixed with the idle air flow t hrough a distri-
bution pipe to the two idle air ducts (one duct per bank of cylinders), which are integr ated in the intake mani-
fold casting. From here the vapors and gases are directed straight into the intake pipes and further into the
combustion chambers.

From the breather connection (2) of t he right cylinder head cover the breather pipe leads directly to the clean
air side in the air cleaner.

In the lower and medium performance range, the engine is suppl ied with fresh air via the right-hand cylinder bank
by means of the intake manifold vacuum which is transmitted via the left·hand breather pipe into the cyl inder
crankcase. In other words, clean air is drawn in f rom the air cleaner vía the breather pipe.

This changes toa breathing action in the upper performance range. The blow-by gases and crankcase vapors flow
into the air cleaner, and further into the intake pipes and combustion chambers vía the air cleaner f lap.

In order to pr event fr eezing of the condensate in the breather orífice at low ambient temperatures, the idle air
distributor is coolant-heated.

2 4 3 1

Blow-by gases

Fresh air

01 .7-040/ 1 F3
01 - 112 Measuring, honing and silicon-lapping cylinder bores

Allocation Group No. Cylinder diameter Piston diameter

Engines 116.960/961/964/965

o 91 .998-92.003 91.985- 91.990

O+ 92.003-92.008 91 .990- 91.995
1 92.008-92.013 91.995-92.000
Standard size Std 92.0 dia.
1+ 92.013- 92.018 92.000-92.005
2 92.018- 92.023 92.005- 92.010
2+ 92.023-92.028 92.010-92.015

o 92.498-92.503 92.485-92.490
1st repair stage +0.5 1 ) 92.508- 92.513 92.495-92.500
2 92.518- 92.523 92.505- 92.510

o 92.998- 93.003 92.985- 92.990

2nd repair stage +1.0 1 ) 1 93.008-93.013 92.995-93.000
2 93.018-93.023 93.005- 93.01 o

Engines 116.960@ 0~, 116.961 @ 0@ ~

116.962/963

o 87.998- 88.003 87.985- 87.990

O+ 88.003-88.008 87.990-87.995
1 88.008- 88.013 87.995-88.000
Standard size Std 88.0 dia.
1+ 88.013-88.018 88.000-88.005
2 88.018-88.023 88.005-88.01 o
2+ 88.023-88.028 88.010-88.015

o 88.498-88.503 88.485-88.490
1st repair stage +0.5 1 ) 1 88.508-88.513 88.495-88. 500
2 88.518- 88.523 88.505-88.510

o 88.998- 89.003 88.985- 88.990

2nd repair stage +1 .0 1 ) 1 89.008- 89.013 88.995-89.000
2 89.018-89.023 89.005-89.01 o

1) Pistons of the repair stages are only available with t he group numbers O. 1 and 2 .

01.7- 112/ 1 F 3
Engine 117.960 up to end No. 000885

o 96.998- 97.003 96.985- 96.990

O+ 97.003- 97.008 96.990-96.995
1 97.008-97.013 96.995- 97.000
Standard size Std 97.0 d ia. 1+ 97.013- 97.018 97.000-97.005
2 97.018-97.023 97.005- 97.010
2+ 97 .023- 97.028 97.0 10- 97.015

o 97.498- 97.503 97.485- 97.490

1st repair stage +0.5 1 ) 97.508- 97.513 97.495-97.500
2 97.0 18-97.523 97.505- 97 .510

Engines 11 7.960 as of end No. 000886

117.961/962/ 963/964/965/967/968

o 96.498-96.503 96.485- 96.490

O+ 96.503- 96.508 96.490-96.495
1 96.508- 96.51 3 96.495- 96.500
Standard size Std 96.5 d ia. 1+ 96.513- 96.518 96.500-96.505
2 96.518- 96.523 96.505- 96.510
2+ 96.523-96.528 96.510-96.515

o 96.998- 9 7.003 96.985- 96.990

1st repa ir stage +0.5 1 l 1 97.008-97.013 96.995-97.000
2 97.018- 97.023 97.005- 97.010

o 97.498- 97.503 97.485- 97.490

2nd repair stage +1.0 1 ! 1 97.508- 97.513 97.495- 97.500
2 97.518-97.523 97.505- 97 .51 0

1) Pisto ns o f the repai r stages are only avail able w i th the group numbers O. 1 and 2 .

when new 0.008- 0.018

Piston clearance
wear limit 0.08

Maximum wear limit of cylinder bores in

driving or tra nsverse d irection at u pper and 0.10
lower points of return of 1st pis ton ring

01.7-1 12/2 F3
Machining tolerances

when new 0.013

Permissible deviation from cylindrical shape
wear limit 0.05

Permissible deviation from rectangular ity

0.05
with reference to cylinder height

Mean roughness (Rz) after polishing 0.001

Mean roughness (R z) after silicon-lapping 0.001 - 0.003

Permissible peak·to·valley-height (Wt) 50% of the roughness after sil icon-lapping

eylinder bore chamfer see Fig. No. 14

Conventional tools

Automatic cylinder reconditioning machine

SUNNEN eK-lO·G with honing oil filter and oil cooler

Honing head eK-3000 for 76-127 mm día.

Federal Republic of Germany:
SUNNEN honing oil MB 301 ) e.g. Hommel Handel GmbH
Donatusstrar!e 24, D- 5000 Koln 71
Prehoning, stone set e 3Q-A 53, 70 mm long2 )

Other countries :
Finish honing, stone set e 30·J 84, 70 mm long2 ) e.g. SUNNEN Products Comp.
USA-7910 Manchester
Polishing, stone set e 3Q-e 03-81 St. Louis, Mo. 63143

Stone holder for felt insert eK-30 35 Hommel Handel Export Dlvision
P.O. Box 1206
Felt insert holder set CK-3130 D-6806 Viernheim

Felt insert e 30·F 85

SUNNEN silicon paste AN -30

Box for silicon paste and

felt inserts AN·35

lnside measuring instrument (dial gauge) for 50 to 150 mm

diameter, with 0.01 m m division and spring-loaded
measuring t ip, e.g. Sunnen G RM 2125

Setting micrometer for inside measuring instrument GAM

2125 with setting range 50-200 mm, e.g. Sunnen eF-1 000 M

1 ) ln it ial filling approx . 170 liters.

2
) These stones are only availab le w ith a le ngth of 89 mm and must be shortened at the top to 70 mm using a metal saw (see
Fig. 3).

01 .7- 112/ 3 F3
Note

T he light metal cylinder bores are very sensitive to

damage, scratches and dirt and therefore should be
tr eated ver y carefully.

When honing, the cylinder bores should be matched

to the d imensions of the ex isting repa ir stage p ist ons
w it h group numbers O, 1 or 2, while maintain ing t he
specified piston clearance.

Measuring

When measuring t he cylin der bores, use a measuring

instrument with spring·loaded measuri ng t ip to pre·
vent scor e marks o n cylinder running surface through
the measuri ng point cont.act and prematu re wear of
the instrument measuring pins.
Set the self·center ing inside measuring instrument to
the cyl inder diameter before measuring, and measure
at 22-24 o e room temperature.

lnside measu ring instrument with setting m icrome te r

The aluminum surface recess ion (0.5- 1.5 pm)

between the silicon crystals can only be measured
indirectly via the mean r o ughness (Rz) after silicon·
lapping (end co ndition).

The specif ied exposed depth of the silicon crystals is

obtai ned by the tempor a:lly limited control during
silicon·lapping and the choice of silicon paste used.

Honing and silicon-lappirng

With severely scored and worn cy linder (> 0.10 mm)

etc., the cylinder bor es can be honed to t he speci·
f ied repa ir stages.
After honing, the sil icon cr ystals must rema in intact
and f lattened on the cyl inder surface.

01 .7- 112/4 F3
The honing processes (prehoning, finish honing and
polishingl must be followed by ,silicon-lapping"
according to the Sunnen process in order to expose
the silicon crystals.

Omission of the job .,silicon-lapping" invariably leads

to piston seizures.

Caution!
The following jobs must only be carried out w ith a
honing machine with honing oil filter and oil cooler.

The silicon particles must be separated from the

honing oil by filtering.

The honing oil must be cooled to a constant tempera·

tu re of 20 oC to avoid excessive heating of the
cylinder crankcase.

In o~der to obtain a good honing quality it is neces-

sary to use only the specified honing oil.

1 Set up honing machi ne CK-1Q-G.

~---··- d H O O

Carry out all honing and lapping work without

directional guide shoes.
1
..J

The protrusion of the honing stone (arrow) is

14 mm. 1

2 Cut the lower protrusion of the bronze strip on

the main guide shoe (arrow) as the recess at the
bottom of the cylinders allows only approx. 14 mm
protrusion of the honing stone.

01.7- 112/5 F3
,.,_ 1014-89~3
3 The specified stone sets of 89 mm length must be
shortened to 70 mm. Todo so, cut the hon ing stone
at the top (not the ho lder) using a metal saw.

Dimens io n a ~ 70 mm

4 Torque the crankshaft bearing cap bolts and nuts 1 2 3 4 5

in the sequence of the tightening diagram with ~
.:,2) ·6 ·
50 Nm.
tc~~q
~
!¡'~4
J 1~' ....:':"», ~

lh-
"@ "\.1§t. i
r. .,... ¡;,..
~!j~
·!
.r;¡¡vl
LtD~
1 ........

-~ '
1\$ ¡
f-~
r~~ ~~"""' . ¡ t"'"'"·i
¡"~""' 1
1-"-C"'.,

-+-·
1 .1
t L....j.
~1 Pl 11

~]
.
i
r
¡l ~
1

r @ ;·
~ ! !@~ ·
',!!/
~

'2..· :g
l-"'"'J
l:J .
~:l·6S41Q

5 Fix disassemb led and cleaned cylinder crankcase

with fitted and tightened crankshaft bearing caps
in the honing machine by means of the square steel.

6 Adjust stroke (cyl inder length) on the stroke

scale accordi ng to the table .. Prehoning".

01.7- 112/ 6 F 3
7 Adjust stone projection (arrow) with the gauge
according to the table.

8 Adjust feed (arrow) according to the table.

9 Adjust strokes per minute and revolutions per

minute according to the table.

Prehoning

Setting up of honing machine

4
Engine 116.960 116.960 2 ) ) 117.960 1 ) 117.964
116.961 116.961 2 ) 117.961 117.965
116.964 116.962 3 ) 4 ) 117.962 117.967
116.965 116.963 3 ) 117.963 117.968

Cylinder dia. setting for

92mm 88mm 96.5 mm 97mm
1st repair stage (+0.5)

Cylinder length 135 mm 135 mm 155 mm

Stroke setting 137 mm 137 mm 157 mm

Speed/ min 125

Strokes/ m in 49

Feed 4

Stone protrusion approx. 12 mm

Prehoning stone set e 30-A 53

lndication% approx. 30

Material removal/min 0.07 mm

- -..·-- - -- - - - - -
........
Feed scale/material removal 1O divisions/0.05 mm

11 Up to engine end No. 000885 cylinder d ia. 97 mm.

2 )@ 0 G)@model year 1981 .
31 Standard version and @ Q)(!)@las of model year 1982.
4
1 Onlv@0<§

01.7-112/ 7 F3
10 Prehone all cylinder bores with full honing oil
supply up to approx. 0.08 mm before the f inal
dimension, since otherwise the silicon crystals will be
torn out or damaged by the cutting pressure.

Caution!
When measuring directly after prehoning, a dimen-
sion of approx. +0.02 mm is obtained due toa rise
in temperature.

The heating-up of the cyli nder crankcase is also

dependent on the ambient temperature.

11 lnsert stone set for fine honing and cut to size

as descri bed u nder figure 3.

12 Set up honing machine according to the table

.. Fine honing".

Fine honing

Sening up o f honing machine

Engine 116 960 116.9602 ) 4 ) 117.960 1 ) 117.964 1 17.960 1 )

116.961 116.961 1 ) 117.961 117.965
116.964 116.962 3 ) 4 ) 117.962 117.967
116.965 116.963 3 ) 117.963 117.968

Cylinder dia. setting for

92.42 mm 88.42 mm 96.92 mm 97.42 mm
1st repai r stage (+0.5)

Cylinder length 135mm 135 mm 155 mm

Stroke setti ng 137 mm 137 mm 157 mm

Speed/ min 125

Strokes/ min 49

Feed 3
Stone projection approx. 12 mm

Finish honing stone set e 30·J 84

lndication% approx. 30

Material remova l/min 0.05 mm

Feed scale/ material removal 10 divisions /0.05 mm

1
) Up t o engine end No. 000885 cy linder d ia. 97.42 mm.
2
)@ 0 0@ model year 1981
3
) Standard version and <§) 0 0 @ a s of model vear 1982.
4
) Onlv @ 0 @

01.7- 112/ 8 F3
13 F ine·hone all cyl inder bores with full honing oil
supply up to approx. 0.02 mm before reaching the
final dimension.

Caution!
Measuring directly after fine·honing, a dimension of
approx. +0.01 mm is obtained as a result of tempera·
ture increase. The heating·up of the cylinder crank·
case is also dependent on the ambient temperatura.

14 Chamfer cylinder bores according to drawing

prior to ,polishing".

tO

15 For chamfering, use a suitable hand milling tool

with an angle according to the above drawing.

16 lnsert stone set for polishing.

Prior to machining, the new polishing stones should

be straightened in the narrowest cylinder bore.

01 .7-112/9 F3
17 Set u p honing machine according to the table
.,Pol ishing".

Polishing

Setting up of honing mac'hine

Engine 116.960 116.9602 ) 4 ) 117.960 1 ) 1 17.960 1 )

1 16.961 116.961 2 ) 117.961
116.964 116.962 3 ) 4 ) 117.962
116.965 116.963 3 ) 117.963
117.964
117.965
117.967
117.968

Cylinder dia. setting for

92.48 mm 88.48 mm 96.98 mm 97.48 mm
1st repa ir stage {+0.5)

Cylinder length 135 mm 135 mm 155 mm

Stroke setting 137 mm 137 mm 157 mm

Speed/ min 125

Strokes/ min 49

Feed 2

Stone projection approx. 12 mm

Polishing stone set e 30· C 03·81

lndication% approx. 30

Material remova l/min 0.01 mm

Feed scale/material removal 1O divisions/0.01 mm

1
) Up to engine end No. 000885 cylinder dia. 97.48 mm.
2
1@ 0@@ model year 1981 .
) Standard version and@ ~
3
(D <@as o f model year 1982.
Only @0(@)
4
)

18 Polish all cylinder bores with full honing oil

supp ly until the end dimension has been reached.

19 Allow cylinder crankcase to cool down.

01 .7- 112/ 10 F3
20 Measu re cylinder bores, while taking into
account the required cylinder díameter (group No.)
for the existing pistons and the specified piston
clearance.

Repolish if required.

21 Clean cylinder walls with filtered honing oil to

remove all silicon particles and to avoid scratches
dur íng the subsequent silicon·lapping process.

22 Press felt inserts (C 3Q.F 85) into the holders

CK-3130 and these into the stone holders CK-3035.

Caution!
After the felt inserts have been pressed into the
holder, remove all material which has been scraped
off in the process.

23 Set up the cylinder diameter by means of the

setting gauge.

01.7 - 112/11 F3
24 Soak felt inserts with f iltered honing oil and
insert into the honing head.

25 Cut honing oil supply.

26 Set up honing machine according to the table

.,Silicon-lapping".

Silicon-lapping

Sett ing up of honing machine

Engine 116.960 116.9601 ) 4 ) 117.960 1 ) 117.960 1 )

116.961 116.961 2 ) 117.961
116.964 116.962.1 ) 4 ) 117.962
116.965 116.9633 ) 117.963
117.964
117.965
117.967
117.968

Cylinder dia. setting for

92.50 mm 88.50 mm 97.00 mm 97.50 mm
1st repair stage (+0.5)

Cylinder length 135mm 135mm 155 mm

Stroke setting 120 mm 120 mm 140 mm

Speed/min 185

Strokes/min 73

Feed 2

Felt insert projection approx. 2mm

Felt i nsert e 30-F 85

l ndication% approx. 30

Material removal/min not measurable

Feed scale 18 divisions"" 70s running time

11 Up to engine end No. 000885 cyl inder d ia. 97.5 mm.

1
1 @00~ modelyear 1981.
31 Standard ver sion and
@ 0 0
~as of mode l year 1982.
4
1 Onlv@0@

01.7- 112/ 12 F3
27 Thoroughly stir silicon paste AN·30 and fully
coat the dry cylinder walls.

28 Likewise coat the felt inserts with silicon paste.

29 Introduce honing head with felt inserts into

cylinder bore.

30 With honing machine running, slowly turn feed

wheel to the right unti l the indicator reaches 30 %.

31 Set teed scale to 18 divisions.

The honing machine will switch off after approx.

80 seconds. The cylinder surface will then have a
dull appearance.

No honing marks will be visible.

The roughness is 0.001-0.003 mm.

32 Thoroughly clean cylinder bores of all silicon

traces using filtered honing oil anda suitable brush,
then dry.

Used silicon paste may not be reused!

01.7-112/13 F3
01-120 Machining crankcase mating surface

Data

Engine 116.96 117.96

Height .,A" of the crankcase when new 216.35-21 6.45 245.35- 245.45

Mínimum height of the n ecessary material removal 1 ) 216.20 245.20

Permissible deviation from the in longitudinal direction 0.08

parallel of the upper mating
surfaces to the crankshaft center in transverse d i rection 0.05

Permissible deviation from evenness of the upper mating surfaces 0.02

Mean roughness (R z) of the upper mating surfaces 0.006-0.016

Test pressure: water jacket with ai r under water in bar 3

Distance from piston crown to crankcase mating surface see 03- 316

Cylinder bore chamfer see Note

1
) The total mater ial removed from crankcase and cy linder head of an eng ine may not exceed 0.5 mm {see 01 - 418).

Note

After facing the surfaces, chamfer the cylinder bores.

Smooth out the lower edge of the chamfer with a
polishing stone.

lf the crankcase mating surface was remachined, the

valve tim ing has to be adjusted again (05-215).

01.7- 120/1 F3
01-122 Reconditioning of threaded bores for cylinder head bolts

Special tools

Drilling jig for threaded bores

for cylinder head bolts in 117 589 02 23 00
crankcase

Tap with guide shaft 117 589 00 70 00

Conventional tools

Hel i-Coi l tap M 10

ltem No. 0140 0100104

Heli-Coil threaded insert M 1O

Standard item No. 0130 0100025 e.g. Bollhoff & Co.. D- 4800 Bielefeld 14
(part No. 000 997 58 15)

Heli-Coil hand installer M 10

ltem No. 0150 0410000.1

Note

lf damaged threads are discovered during removal or

installation of the cylirnder head, Heli-Coil threaded
inserts part No. 000 997 58 15 must be installed for
all cylinder head bolts of the cylinder bank con-
cerned. The t hreaded inserts have a length (screwed in)
which corresponds to 2 .5 times the diameter of the
cylinder head bolts ( 14 threads).

For threads with difficult access, use an angular

drilling machine with a chuck for drills with 1O mm
diameter to avoid that the engine has to be removed.

Caution!
The threaded holes 15, 7, 1, 8 and 17 for the cylinder
head bolts M 1O x 165 on the camshaft bearings are
drilled at an angle in the crankcase.

® ® ® @>

®@
@
0 °0°0®0®
®
® @)
0 ®
®@ @
tOS.J · 75771'1

01.7- 122/ 1 F3
These threaded holes are not ver t ical to the crank-
case mating surface, bu t atan inclination of
1° 52' to the engine outside.

In order to prevent pressure poin ts on t he cylinder

ru nning surfaces dueto the relatively long Hel i·Coil
inserts, the respective core holes must be drilled
vertical! y or at 1° 52' incl ination using the drill ing
jig.

Recondi t ioning

Bolt drilling j ig onto the cylinder bank concerned.

2 Cover cylinder bores, coolant openings and chain

case (minute aluminum-silicon chips damage the
cylinder runn ing surface and the piston).

3 Using an HSS spiral drill 10 mm dia., drill core

hole approx . 37 mm deep while lubricating with
honing oi l.

Core hole diameter should be a mínimum of 1O mm

anda maximum of 10.3 mm.

4 Remove drill ing jig and blow out chips.

01.7-122/2 F3
5 Precut the Heli·Coil installation thread as deep as
possible using the tap with guide shaft section. Todo
so, lubricate the tap with honing oil.

6 Carefully blow out chips.

7 Cut Heli-Coil installation thread using Heli-Coil

tap M 1O (outside di ameter 12.0 mm), ítem No.
0140 0100104, approx. 35 mm deep, while lubri·
cating the tap w ith honing oil.

8 Carefully blow out chips.

9 Screw in oil-coated 1-feli-Coi l threaded insert (1 ),

part No. 000 997 58 15, (Heli-Coil standard item
No. 01 30 01 00025), using hand installer M 1O (2).
ítem No. 0150 0410000--1.
Todo so, screw Heli-Coil insert ( 1) with the driving
end to the front into the hand installer (2) until the
first winding projects 3 /4. Align the hand installer
over the tapped hole and screw in the Helicoil insert
(1) without pressure by turning the spindle.

Caution!
The uppermost thread must be positioned approx.
4 mm below the crankcase mating surface.

1O Screw a cylinder head bolt into the inserted

thread and check for misalignment and easy opera-
tion.

The screw-in depth should be approx. 29 mm.

Note: The driving end of the Heli-Coil threaded insert

is not removed as is usual, but remains on the threaded
insert.

01.7-122/3 F3
01-124 Reconditioning threaded bores for intermediate flange and transmission mounting

Conventional tools

Heli-Coil tap M 1O
ltem No. 0140 0100104

Heli-Coil threaded insert M 10

e.g. Béillhoff & Co., 0 -4800 Bielefeld 14
Standard item No. 0130 0100020

Heli·Coil hand installer M 1O

lte m No. 0150 0410000- 1

Note

Stripped threads for intermediate flange or trans·

mission attachment must be replaced with Heli-Coil
threaded inserts standard, item No. 0 130 0100020,
with a length equivalent to twice the diameter of the
bolts ( 11 threads).

lf stripped threads are not access ible with removed

transm íssíon or in termediate flange because of
límíted space, the engine must be removed.

Reconditio ning

1 Drill core hole approx. 27 mm deep us íng an HSS

spiral drill of 10 mm día .

The core hole díameter should be a m ínimum of

10 mm anda maximum of 10.3 mm.

2 Blow out chips.

01.7- 124/1 F3
3 Cut Heli·Coil installation thread approx. 25 mm
deep using Heli·Coil tap M 10 (outside diameter
12.0 mm), ítem No. 0140 0100104. Todo so,
lubricate tap with honing oil.

4 Blow out chips.

5 Use hand installer M 1 O, ítem No. 0150 0410000-1,

to screw in oil·coated Heli·Coil threaded insert M 10,
standard ítem No. 0130 01000020.

Caution!
The uppermost thread must be positioned approx.
2 mm below the mating surface.

6 Using an arbor, break off drive end of the threaded

bush.

7 Screw in a bolt to check inserted thread for mis·

alignment and ease of operation.

The screw· in depth should be approx. 23 mm.

01.7 -1 24/2 F3
01 - 126 Coolant preheater in crankcase (instsllation instruction)

Note

As of October 1980, t he modified screw plug

M 38 x 1.5 is installed together with an 0-ring.

The chamfer in the crankcase was changed for this

reason (2nd versionl.

When installing a coolant preheater, an 0-ring or

sealing ring t o suit the chamfer in the crankcase
should be used.

A 1st version

1204-977~
B 2nd version

01 .7- 126/1 F 3
01-210 Removal and installation of timing case cover

Tightening torques Nm

with 3 diaphragm springs 1 ) 210 - 330

Crankshaft end bolt
with 4 diaphragm springs 1 ) 370 - 400

1
) See Note 03-324.

Special tools

Oetent for counterholding crankshaft 116 589014000

Torque wrench 150-500 Nm 001 589 31 21 00

Socket insert 27 mm 001 589 65 09 00

Screwdriver for hexagon socket head

116589030700
screws 6 mm, 440 mm long

lnstalling tool for radial sealing ring

ij-::Th
~ ,! IIOOhUH
110589076100

lnstalling tool for oil dipstick guide tube 117 589 00 31 00

Conventional tool

3/4" inside to 1/2" outside square e.g. Hazet, 0-5630 Remscheid

drive adapter Order No. 1058 R 1

Notes

The timing case covers of engines 116 and 117 are

distinguished by casting number and height.

Two through-holes each for the heater return (1) and

the coolant supply (2) are arranged on the timing
case cover. These are sealed at the crankcase by
means of rubber sealing rings.

Because of the modified hole pattern for the water

pump, the timing case covers cannot be used on cast
iron engines.

01.7-210/1 F3
On engines withou t oi l cool er, t he t hread (arrowl f or
t he temperature switch o n the timing case cover
(only turbocharged engines) were changed from
M16x 1.5to M 14x 1.5.

The ti ming case cover can be removed with the

cylinder heads installed i f ca re is exercised not to
damage the cylinder head gasket.

Removal

Disconnect ground str ip from battery.

2 Drai n engine oil and coolant.

3 Remove radiator, fan cover and viscofan.

4 Rem ove alternator wi th bracket.

5 Remove distributor.

6 Remove power steering pump with pipes con-

nected and set aside.

7 Remove V·belt p ulley together with vibration

damper and hub (03- 34 2).

~
4 5 6 7 8
1

1 ~----

Crankshaft arrangement
2nd version
1 V -belt pulley
2 Bolt M 8 x 22
3 V ibration damper
4 Bolt M 18x1.5x 45
5 Oiaphragm springs (41
6 Hub
7 Radial sealing ring
8 Woodruff key
9 Timing case cover 1 1
10 Crankshaft sprocket 2 3 9 10 11
11 Crankshaft

0 1.7- 210/ 2 F3
8 Remove coolant pump (20- 210).

9 Unscrew warming·up regulator.

10 Remove oil pump (18-210).

11 Loosen oil pan upper part (with two-piece oil

pan) on crankcase, i.e. back out screws approx. 3-4
turns.

12 Orive out oil dipstick guide tube.

13 Unscrew cylinder head bolts M 8 (arrows).

14 Disconnect TDC transmitter and remove.

15 Screw out all bolts for timing case cover.

01.7- 210/3 FJ
16 Force ou t cran kshaft o il seal.

17 Take o ff ti ming case cover and remove oil pu mp

cha in from cra nkshaft sprocket.

Ca ut ion!
Do not da mage cylinder head gaskets.

lnstallation

18 Renew O·rings for sealing of water galleries.

Caution!
When renewing bushes, observe the position of the
oil groove below (a rrows l.

19 Coat sealing surface of t iming case cover wi th

seali ng com po und.

20 Grease cylinder hea d gaskets.

103- 9559

21 When f itt ing the timing case cover, insta ll the

oil pump chain on the crankshaft sprocket by means
of a bent piece of sheet metal.

22 First install cylinder head bolts M 8 .

23 For further installation proceed vice versa to

sequence o f removal.

01.7- 210/ 4 F3
01-220 lnstallation and centering of intermediate flange

Engine 117.960 with automatic transmission 722.006 up to engine end No. 001685

Data

Permissible rad ial runout deviation at the fitted collar

0.10
of the intermediate flange with a full turn

Permissible lateral runout deviation on the fitted collar

0.10
of the intermediate flange with a full turn

Fitted hole in the intermediate flange for centering dowels 12.016 to 12.043

Tightening torques Nm

Mounting bolts for intermediate flange 50

Mounting bolts M 8 for support angle

30
on crankcase

Mounting bolts M 10 for support angle

50
on intermediate flange

Pre-torque 40
Necked-down bolt for driven plate
Torque angle 90-100°

Special tools

f
Dial gauge holder
363 589 02 21 00
(2 required)

Socket insert 27 mm, 1/2" drive for

001 589 65 09 00
rotating the engine

1/2" square drive insert, 80 mm long

{c ~oo%!§~_ 10212 617 589 00 16 00
for rotating the engine

Tool for self-fabrication

Threaded pin see Fig. No. 3

01.7-220/ 1 F3
Note

lf an intermediate flange is renewed it has to be

centered.

ln termediate flange and support angle are only

installed in model 107.026 with engine 117.960 in
combination with the au t omatic transmission
722.006 up to chassis end No. 001627, and engine
end No. 001685 respectively. The hole pattern t o
mount t he t ransmission is not identical with that of
the cast·iron engines. The two mounting threads in
the crankcase (arrows) have each been moved 9 mm
further inside.

lnstallation and centering

1 Fit the intermed iate flange onto the dowel pins

(arrows) o n the cran kcase. Remove support angle.

2 Lightly tighten the two mounti ng bolts (11.

3 Screw threaded pin into the crankshaft and lock.

2 3

i
1
f--30 \
1 Hexagon nut M 12 x 1.5
2 Threaded pin 10 mm d ia.
3 Hexagon nut M 10 x 1
L - - - -- 110 - -- -=:]'"""'"'n

4 Attach dial gauge holder with dial gauge to threaded

pi n .

5 Position measuring pin on the fitted round center·

ing surface of the intermed iate flange to measure
rad ial and lateral runou t. Set dial gauge to O.

01 .7- 220/ 2 F 3
6 Turn crankshaft in direction of rotation a full turn
using the tool combination. Maximum lateral and
radia l runout is 0.1 O mm. In other words, the total
deflection of the pointer may not exceed O. 1O mm.
lf lateral runout is greater than 0.10 mm, renew
intermediate flange.

Note: When turning the crankshaft, ensure that the

measuring pin of t he dial gauge is not sticking.

7 Correct the radial runout with light taps on t he

intermediate flange.

8 Tighten mounting bolts.

Note: lf the radial runou t is greater than O. 1O mm,

remove intermediate flange.

9 Dril l both f itted holes in the intermediate flange

to 12.1 mm.

1O Repeat figures 1-8.

11 Mount supporting angle only after the ínter-

mediata ftange has been attached to the crankcase.

01 .7-220/ 3 F3
Model 107.026 with engine 1 17.960 and transmission 722.006 (W 3 B 050)
1 Oowel p in 12 x 22 mm, 2 required 7 Bolts M 6 x 25, 9 r equir ed 13 Cover
Repa ir dowel pin dia. 12.2 x 22 mm 8 Bolts M 6 x 20, 4 r equ ired 14 Circl ip 38
2 l nter mediate flange up to 9 Radial seaj ing ring 13 mm w ide, 15 Support angle right
engine end No. 001685 repa ir rad i al sea ling ri ng 16 Washer A 8, 4, 4 requ ir ed
3 Spring w asher B 10. 2 required 10.5 mm w ide 17 Bo lt M8x40
4 Bol t M 10 x 35, 2 requ i red 10 Oowel pin 6 h8 x 10, 2 requ ired 18 Bo lt M 8 x 65, 2 requi red
5 End cover 11 Bolt 19 Suppor t an gle left
6 Washer A 6, 4 , 13 r equ i red 12 Washer

01.7 - 220/ 4 F3
01-222 Removal and installation of end cover

Tightening torques Nm

Fastening screws for end cover 9

lnitial torque 30-40 Nm

Necked·dow n bolts for driven plates
Angle of rotation torque 90- 100°

Special tool

lnstallation tool for installing end cover with

1 17 589 00 43 00
pressed·in radial sealing ri ng

Note

The end cover closes the main o il gallery, so that

special care must be used during installation. Ensure
that the sealing surfaces of th e end cover and the
crankcase are without score marks.

The thr eaded holes in the crankshaft flange are

thr oughholes. With bolts removed and the engine
inclined, engine o il will run out.

Removal

1 Remove transmission (27 - 600).

Note: With the exception of engine 117.960 with

automatic transmission 722.006, the ring gear
remains on the engine when removing the trans·
mission.

2 Remove driven plates 103-410).

01.7-222/1 F3
3 Remove end cover.

A threaded hole M 8 is provided on each side to

facili tate removal of a tight ly seated end cover
(arrows).

1nstallati on

4 Carefully clean seali rng su rface on crankcase and

end cover.

5 Uniform ly coat the end cover seali ng surface with

sealing compound. lt must be observed t hat no seal-
ing compound enters the oil circuit.

6 Fill radial seal ing ri ng space between dust and

seali ng lips wit h long-l ife grease.

7 Slide end cover with radial seali ng ring over the

attached installation tool for rad ial sealing ring and
bolt on.

Caut ion !
Observe d ifferent bolt lengths.

01 .7- 222/2 F3
01-310 Removal and installation of oil pan

Oil capaeity in liters

Mo del 107 126

Oil pan max./min. 7.5/5.5

Oil filter 0.5

A ir-oil cooler 0.5 0.4

Oil dipstick color coding gentian blue light blue or grey 1 )

1
1 As of 1985.

Tightening torques Nm

M 26 50
Oi l drain plug on oil pan
M 12 40

Oil drain plug on air·oil cooler 35

··- ··-- ·- ·-·- ·-··- ·-··-·--·--···-··-- · - - - - - - -- - ·- - -- -- - -- -
Attaching screws for oi l pan
M6 11
lower part and oil pan

Special tools

Allen box wrench 13 x 14 mm 117 589 02 07 00

lnstallation tool for oil

11 7 589 00 31 00
dipstick guide tube

Note

The engines 117.960 (1st version) with intermediate

flange, up to end No. 001681, with the exception of
engine end No. 001613-001617 and 001636-001640,
were fitted with a one-p iece oil pan together with a
gasket coated on one side with graphite, similar to
the engine 117.985, however with addtional sup-
porting angles between engine and intermediate
flange.

01.7- 310/ 1 F 3
The engines 116.960 and 117.960 (2nd version) as
well as 116.962 and 117.962 are f i tted w ith the
one·piece o il pan, the engines 116.961/ 963 and
117.96 1/963 are f itted w i th t he two·piece oil pan,
both wit h integrated supporting angles, together w i th
a gasket graphi te-coa ted on one side.

The hole pattern for the o il pan of all engines 116.96

and 117.96 are identical and differ from the hole
pattern for the cast·ir on engines 116.98 and 117.98.

A protec tive bead was added in the ar ea of th e o il

drain plug at the oil pan lower part in arder to avoid
engine cracks.

lntroduction : July 1983

Engine No. 116.963 12 037 088

117.963 12 032 251

lf the refrigerant compressor carrier is bolted to t he

cran kcase during o il pan remova l and installation it
is necessary to ensure tension·fr ee assembly.

T he carrier (steel versionf must be checked for dis-

tortion. There shou ld be no gap between contact
points of t he support angle and the crankcase. This
cond ition must be verified befare at taching the angle.
The bolts must be tightened in the following
sequence:

al lnstall bolts ( 17, 6 and 5) finger-tight.

b) T ighten bolts (17) at engine front.

e) T ighten bolt (6) and nut (5) at side of engine.

01 .7- 310/ 2 F3
A. Model107

Removal

Remove fan shroud and fan.

2 Remove front axle (33- 100).

3 Remove refrigerant compressor with carrier

(83-522).

Engine 116.961 @ 1981

4 Remove support angle from transmission (1st

version engine 117.960 with intermediate flange) .

5 Unscrew bracket for oil dipstick guide tu be.

6 Unscrew oil pan and remove downwards together

with oil dipstick guide tube.

lnstallation

7 Prior to installation, use grease to attach new

gasket to the oil pan.

8 The further installation takes place in the

sequence vice versa to the removal.

01.7-310/3 F3
B. Model 126

Aemoval

1 Remove refrigerant compressor with carrier and

tensio n pulley w ithout disconnecting the pipe
assembly.

2 Remove control linkage.

3 Remove oil pan lower part.

4 Remove o il dipstick guide tube.

5 Remove oil pump.

6 Unscrew o il pan upper part.

7 Unscrew both mounting bolts for engine mounts

(arrow).

8 Loosen both engine shock absorbers at the bottom.

9 Disconnect fan shroud.

10 L ift engine w ith hoist until the oil pan can be

removed.

01.7-310/ 4 t= 3
 1nsta llat io n

11 Before the instal lation, use grease to attach a

new gasket to the oil pan.

12 Further instal lation takes p lace in the sequence

vice versa to t he removat.

Caution !
The rear mating surface of the oil pan must be lined
up with the rear mating surface of the crankcase
(arrows). lf the oil pan is not lined up with the
crankcase, this can lead to complaints of noise and
vibration.

Ensure that oil dipstick guide tubes are neither

swapped during assembly nor interchanged with
e
those of cast-iron engines. as this would result in
false oillevel readings.

They can be distinguished by means of the drawing

and table below.

A Engine 116.985, 117.986 a = 125.5 mm

B Engine 116.984, 117.985 a • 135.5 mm
e Engine 116.960/962/ 117.960/962/ a= 135.5 mm
a
964. 964/967
o Engine 116.961 /963/ 117.961 /963/ a e 125.5 mm
965, 965/968 10)3 ~ N72

01 .7- 310/5 F3
01 -41 5 Removal and installation of cylinder head

Tightening torques Nm

1st stage 30

2nd stage 60
Cylinder head bolts
Settling break at least ·1O minutes

3rd stage

Cylinder head cover screws 3

Necked-down bolts for camshaft sprockets 100

lnjection valves to cylinder head 10

1
) Each screw must first be loosened individually in t he sequence of the tightening d iagram before tigh tening to the spec ified
torque.

Special tools

Screwdriver insert 8 mm, 1 /2" drive

=n--,·[rW· 116 589 00 13 00
~
Screwdriver 6 mm,
116 589 03 07 00
440 mm long for hex. socket screws

lmpact puller for bearing bolts

116 589 20 33 00
(basic too l)

Threaded bolt M 6 x 50 116 589 01 34 00

Threaded bolt M 6 x 10 0 100 589 00 34 00

Note

The cylinder heads d iffer in the diameter ,A" of t he

exhaust ports, the basic bore ,.G" of the exhaust
valve seat rings, the different combustion chamber
and the valve seat rings as well as the casting number.

The cylinder heads cannot be used in cast-iron engines,

as the five cylinder head bolt bores do not corres-
pond.

01 .7-415/1 F3
Remove the cylinder heads only when the engine
has cooled down.

Face cylinder head mating surface only if porous or

damaged. A slightly warped mating surface will adapt
itself aga in after the cyl inder heads have been tightened.

Each cyli nder head is aligned and fixed with the

crankcase by means of two dowel sleeves and
secu red to the crankcase w ith 18 cylinder head bolts,
6 for each cylinder bore.

The cylinder head gaskets of the engines 116 and 117

differ in combustion chamber and cylinder dia meter.

The cylinder head gas kets of the engi nes 116.96 and
117.96 differ from those of 11 6.98 and 117.98 by
a diffcrent hole pattern of the 5 central cylinder
head bolt holes.

The cylinder head gaskets do not requi re retorquing.

The cylinder head bolts are no lon gar retightened

when the engine is warm.

Caution!
The cyli nder head bolts M 1O x 165, M 1O x 90 and
M 10 x 65 are 10 mm longer than for the cast·iron
engines.

The cylmder head bolts are nickel·plated (chromium

color) - prev1ously phosphated (anthracite color).
This preve nts se1zmg of the thread flanks in the
aluminum crankcase.
The washers of the cylinder head bolts were phos·
phated at the same t ime (prev iously galvanizad.
brass color). This measure provides more uni form
friction va lues when tightening the cyli nder head
bolts.

Product ion brea kpoint : November 1982

Model Engine Engine end No. Chassis end No .

107.045 116.962 011845 02 1251

107 046 117.962 001565 025013
126.032
116.963 022704 038527
126.033
126.036
117.963 018595 027517
126.037
126 043 116.963 022704 004655
126.044 117.963 018595 004152

01 .7- 415/ 2 F3
lf damaged threads are discovered during cylinder
head removal or installation, Heli·Coil threaded
inserts part No. 000 997 58 15 should be installed
for all cylinder head bolts of the respective cylinder
bank (01-122).

Removal

1 Orain coolant from crankcase at the left or

right.

Caution!
Do not confuse the lateral crankshaft bearing cap
bolts (arrows) with the coolant drain plugs (2).

Right engine side

Left engíne side

2 Remove fuel injection p ipes.

3 Unscrew injection valve retainers.

01 .7- 415/3 F3
4 Remove intake manifo ld.

5 Set engine to ignition TDC.

6 Mark camshaft sprocket and t iming chain

relative t o each other (arrow).

7 Loosen necked·down bolt of the camshaft

sprocket while holding the camshaft with an open·
end wrench (arrow).

01.7- 415/4 F3
8 Remove camshaft sprocket.

Lefthand cylinder head

9 Unscrew power steering pump and set aside with

piping connected.

10 Remove ignit ion dist r ibutor (only engine 116).

11 Remove inner sliding raíl from lefthand cyl inder

head. Todo so, pull out bearing pins by means of
the impact puller.

First remove the camshaft sprocket, then the sliding

raíl.

01.7- 415/5 F3
 Righthand cylinder head

12 Remove alternator with bracket.

13 Remove e ha in tensioner.

14 Remove anner sliding raíl.

Right and left cylinder head

15 Unscrew exhaust manifold from exhaust pipe

and cylinder head and remove. Todo so, loosen
engine mount and engine shock absorber of engine
117.96 and raise slightly.

01.7- 415/6 F3
16 Unscrew cylinder head bolts in reverse order of
tightening diagram.
@ 0 ® @
·---1,
® ®0@(:\®~®f.. ', @) ~.,
Loosen the bolts M 8 (a) with screwdriver insert
116 589 03 07 OO.
® @ 1 <D\_J0~®~@
@ ® 0 @

a Bolts M 8

Note: The following tool s are required to loosen and

t ighten the cylinder head bolts:

A llen w rench 8 x 52 mm long

Screwd r iver insert 116 589 00 13 00

17 To remove the r ighthand cylinder head, push

the tension rail with the t iming chain towards the
center of the engine so that the tension rai l is not
in the way.

18 lift out cylinder heads.

01 .7- 415/7 F 3
1nstallation

Note: On ET lspare part} cylinder heads without air

injection, the 4 holes for the air injection to the
exhaust valves (arrow) must be closed by means of
tapercd alum inum p lugs.

1053-6511/1

19 Coat tapered aluminum plugs w it h Loctite

A V X 86, part No. 002 989 87 71, and drive into
the holes in the cylinder head.

º
0
34' - -

,
5
• ~ 12,: 1 1 •
1 1_x_4 _
_1 .....
• 35--~-. .l~ ... 1x45
\014 - 9904/ '
Tapered aluminum p lugs
<( 0° 34 '
A 6 .90 mm
B 7. 33mm

20 Clean intake manifold sealing surface. Todo so.

cover the cylinder.

21 Clean mating surfaces of cylinder head and

crankcase.

Caution!
The light alloy crankcase mating surfaces must be
treated very carefully to avoid scratches and score
marks.

Clean threaded bores in the crankcase with com·

pressed a ir.

01.7 415/ 8 F 3
22 Fit new cylinder head gaskets by placing them
over the two dowel sleeves on each cylinder bank.

11 R igh thand cylinder head gasket

34 Lefthand cy línder head gasket

Caution!
The cyl inder head bolt M 1O x 165 (arrowl at the
rear camshaft bearing must be inserted prior to f itting
the cylinder heads.

The respect ive exhaust manifold is only installed

after the tightening of the cylinder head bolts has
been completed.

23 lnstall cylinder heads.

Before installing the cylinder head bolts, the thread

and the contact area of the cylinder head bolts and
the washers must be coated with oil.

Caution!
The cylinder head bolts M 1O x 165, M 1 O x 90 and
M 1 O x 65 are 1 O mm longer than those of the cast·
iron engine 1 16.98 and 117.98.

24 Tighten cylinder head bolts in the sequence of

the t ightening diagram as follows:

1st stage with 30 Nm.

2nd stage with 60 Nm.

3rd stage after 1O min utes settling break with cold

engine individua lly loosen cylinder head bolts
slightly and retorque with 60 Nm.
® ®
®o<Vo<Do®o®
@ @
25 Further installation takes place in the sequence
vice ve rsa to remova l.
®@
@
@)
@
® ® ®@ @
M>S3 · 75nn
01 .7-415/9 F3
01-418 Facing cylinder head mating surface

Data

Reference dimension H when new 59.8- 60

Minimum dimension H after material removal 59.55 1 )

in longitudinal direction 0.08

Unevenness of mating surface when new
and after machining
in transversa direction 0.0

Roughness of cylinder head mating surface 0.006- 0.014

Test pressure with air under water in bar 2

1
) The total maxi mum material removal on both cyl inde r head and cylinder crankcase o f an engine may not exceed 0.5 mm
!see 01-120).

Conventional tools

Surface grinder with m illing facility e.g. Sceledum, type RTY

for light metal surfaces Roaro u. Fi. Schio, ltaly

Knife-edge ruler approx. 500 mm long

Note

Face cylinder head mating surface only when porous

or damaged, or if an impermissible deviation of the
evenness has been measured in longitudinal direction.

Facing

Measure reference value H and note down.

2 Face cylinder head mating surface. Remove sharp

edges around combustion chamber.

3 Again measure dimension H. Determine material

removed and note down.

4 lnsert valve and measure distance between valve

stem end and cylinder head, note down.

5 Aemachine valve seats according to the material

removed from the cylinder head (05- 291 ).

6 Check valve timing (05-215).

01.7-418/ 1 F3
01-420 Pressure-testing cylinder head

Data

Test pressure with air under water in bar gauge pressure 2

Special tools

Pressure plate 117 589 00 25 00

Rubber seal (1 set = 21 gaskets) 117 589 00 25 09

Suspension device 115 589 34 63 00

Conventional tool

Electrically heated water tank e.g. Otto Dürr, 0 -71 23 Sachsenheim·Ochsenbach

Pressure-testing

Pressure-test cylinder head if cracks (coolant loss)

are suspected.

Bolt pressure plate onto cleaned cylinder head.

2 Blank off holes and connections.

3 Connect compressed air hose and regulate com·

pressed air to 2 bar.

01.7- 420/1 F 3
4 Fasten cylinde r head on suspension device and
immerse into heated water (80 °C).

5 lf air bubbles rise, determine source and mark.

01 .7- 420/2 F3
03-310 Checking, renewing and tightening connecting rod bolts

Dimensions of connecting rod bolts and connecting rod nuts

Engine 116.960 1 )/961 J ) 116.960l )/96 12 )

11 7.960/961 116.962/963
116.964/965
11 7.962/963
117.964/965
11 7.967/968

Part No. 116 038 04 71 116 038 05 71

Thread d ía. d M 10 X 1

Necked·down shank
8.4-0.1
día. e when new

Mínimum neeked·down
8.0
shank día. e

a 6.6

Dimension b 4.5

e 5.2 4.2

Length L 58.2-58.5 49.2-49.5

Conneeting rod nut height H 1 1 9

1
) Not model year 1981 national version.
2
) Only model year 1981 national version.

Tightening torque

lnitial torque 40- 50 Nm

Conneeting rod nuts
Angle of rotation torque

Tool for self·fabrication

Steel plate see F ig., item 3

03.7-310/1 F3
Note

Prior to assembly, lubricate connecting rod bolt

threads and contact surface of nuts with engine oil.

The connecting rod bolt 1 16 038 04 71 is identical

with the 3rd connecting rod bolt version of the cast·
iron engines 116.98 and 11 7. 98.

Orive out connecting rod bolts only if they have to

be renewed.

Checking

1 Prior to re-using connecting rod bolt measure

mínimum necked·down shank dia. c.

lf the minimum necked·down shank dia. e is reached,

renew connecting rod bol t.

Renewing

2 Orive out connecting rod bolts.

3 Press new connecting rod bolts into connecting

rod with approx. 45 000 N or install with hammer
and mandrel. Todo so, place connecting rod on a
ground steel p late.

Engine 116.960 1 1/ 961 1 ) 116.9602)/ 9612) 116.964

117.960/ 961 116.962/ 963 116.965
117.962/ 963 117.964
117.965
117.967
117.968

Hole
distance a 68 mm 64.6 mm
Hole b 11.5mm

~~ Not model year 1981 national version.

) On ly model year 1981 national version.

03.7- 3 10/ 2 F3
Tightening

4 Lubrícate contact surface of nuts and connectíng

rod bolt thread.

5 Tighten connecting rod nuts to 40- 50 N m initial

torque and 90-100° angle of rotation torque.

Cautionl
Tighten connecting rod bolts knocked in with a
hammer wíth an initial torque of 50-60 Nm
followed by a 90- 100° angle of rotation torque.

lt is essential that this instruction is observed, failure

todo so could result in the connecting rod nuts
coming loose.

Note: lf no angle of rotat:ion wrench is available, the

nut can also be turned in one go by the specified
angle using an ordinary socket wrench. The angle
should be observed as accurately as possible. In order
to prevent faults with the angular torque, do not use
a torque wrench when tightening according to
angular degrees.

03.7-310/3 F3
03-313 Reconditioning and squaring connecting rods

Data

Engine 116.960 1 ) 116.9602 ) 117.960 117.962

116.961 1 ) 116.961 2 ) 117.961 117.963
116.962 117.964
116.963 11 7.965
116.964 117.967
116.965 117.968

Center of connecting rod bearing bore 138.050 154.550

to center of connecting rod bushing bore
(L in Fig. ítem 5) 137.950 154.450

24.890
Width of connecting rod at connecting rod bearing bore
24.857

28.000
Width of connecting rod at connecting rod bushing bore
27.900

Basic bore f or connectin g rod bearing shells 55.619 51.619 55.619 51.619
(A in Fig. ítem 5) 55.600 51.600 55.600 51.600

Basic bore for connecting rod bushing 29.021 26.021 29.021

(a in Fig. ítem 5) 29.000 26.000 29.000

26.013 23.013 26.013

Connecting rod bushing inner dia.
26.007 23.007 26.007

Roughness of connecting rod bushing, inside 0.004

Permissible offset of connecting rod bearing bore

0.13 0.15
relative to connecting rod bushing bore

Permissible deviation from parallel of axes:

connecting rod bearing bore to connecting rod 0.06 0.07
bushing bore

Permissible runout of connecting rod bearing

0.01
bore

Permissible weight difference of the complete

4g
connecting rod within one engine

~ 1 Not model year 1981 national version.

) Only model year 1981 national version.

03.7-313/1 F 3
Tightening torque

lnitial torque 40- 50 Nm

Connect ing rod nuts
Angle of rota ti on torque 90- 100"

Conventional tool

e.g. Walter Kru pp GmbH

Connecting rod testing and
D- 5309 Meckenheim
straightening device
Model CL 6

Note

Connecting rods wh ich were overheated as a result

of bearing damage (blue d iscoloration) may not be
re·used.

Connecting rod and connecting rod cap are marked

toge ther. The connecting rod shaft shou ld not show
any transversa score marks and n icks.

Connecting rods with mach ined connect ing rod

bus hing are ava ilable as a spa re part.

Connecting rods and crankshafts with different

contact collar diamete rs may be installed together
during repairs.

When renewing connecting rods, pay attent ion to

differences in weight of connecting rods.

1 Weigh t com pensation

2 Oil hole
3 Locati ng grooves
103 -9495

03 7-313/2 F3
Reconditioning

1 Check connecting rod bolts and renew if

requ ired (03- 31 0).

R·l784

2 Check bores for connecting rod bolts.

Place connecting rod bearing cap on one connecting

rod bolt. lf connecting rod bearing cap moves down
by its own weigh t. renew connecting rod.

3 Mount connecting rod bearing cap and tighten

connecting rod nuts to 40- 50 Nm.

4 Measure connecting rod bearing basic bores. lf

basic bore exceeds the specified value or is conical,
touch up bearing cap mating surface on a surface
plate up toa maximum of 0.02 mm.

>
" L
' "IIW$2.l~

03.7- 313/3 F3
5 Press in new connecting rod bushing so tha t the
oil bores are in alignment. Pressing-in pressure at
least 2500 N.

6 Machine or ream connecting rod bushing.

7 Touch up lateral connecting rod contact surfaces

on a surface plate. 1
...J

8 Square connecting rod with connecting rod tester.

1

9 Align connecting rod bore relative to connecting

rod bushing bore (parallel alignment).

103- 1ll'7A

10 Check offset of connecting rod bearing bore

relative to connecting rod bushing bore and correct
if necessary.

03.7-313/ 4 F3
03-316 Removal and installation of pistons

Allocation Group No. Cylinder dia. Pistan dia.

Engine 116.960/961/964/965

o 91 .998-92.003 91.985-91.990
O+ 92.003- 92.008 91.990-91.995
1 92.008- 92.013 91 .995- 92.000
Standard dimension Std 92.0 dia.
1+ 92.013-92.018 92.000- 92.005
2 92.018- 92.023 92.005- 92.01 o
2+ 92.023-92.028 92.010- 92.015

o 92.498-92.503 92.485-92.490
1st repair stage +0.5 1 92.508-92.513 92.495-92.500
2 92.518-92.523 92.505-92.510

o 92.998- 93.003 92.985- 92.990

2nd repair stage +1.0 1 93.008- 93.013 92.995- 93.000
2 93.018-93.023 93.005-93.01 o

Engine 116.960@ 0@. 116.961@ 0 0 @>

1 16.962/963

o 87.998-88.003 87.985-8 7. 990

O+ 88.003-88.008 87.990-8 7. 995
1 88.008-88.013 87.995-88.000
Standard dimension Std 88.0 día.
1+ 88.013-88.018 88.000- 88.005
2 88.018- 88.023 88.005-88. o1o
2+ 88.023- 88.028 88. o10- 88. o15

o 88.498-88.503 88.485-88.490
1st repair stage +O. 5 1 ) 1 88.508-88.513 88.495-88.500
2 88.518- 88.523 88.505-88. 51 o

o 88.998- 89.003 88.985- 88.990

2nd repair stage +1.0 1 ) 1 89.008- 89.013 88.995- 89.000
2 89.018-89.023 89.005- 89.010

Engine 117.960 up to end No. 000885

o 96.998- 97.003 96.985-96.990

O+ 97.003-97.008 96.990-96.995
1 97.008- 97.013 96.995-97.000
Standard dimension Std 97.0 dia.
1+ 97.013-97.018 97.000- 97.005
2 97.018-97.023 97.005- 97.010
2+ 97.023- 97.028 97.010-97.015

o 97.498- 97.503 97.485- 97.490

1st repair stage +0.5 1 97.508-97.513 97.495- 97.500
2 97.518- 97.523 97.005- 97.51 o

1) Repair stage p istons are only available with t he group numbe rs O, 1 and 2.

03.7-316/ 1 F3
Engine 117.960 as ofend No. 000 886
117.961/962/963/964/965/967/968

o 96.498-96.503 96.485- 96.490

O+ 96.503- 96.508 96.490- 96.495
1 96.508- 96.51 3 96.495- 96.500
Standard dimension Std 96.5 dia.
1+ 96.513-96.518 96.500-96.505
2 96.518- 96.523 96.505- 96.5 10
2+ 96.523- 96.528 96.510- 96.515

o 96.998- 97.003 96.985-96.990

1st repair stage +0.5 1 97.008- 97.0 13 96.995- 97.000
2 97.01 8- 97.023 97.005- 97.010

o 97.498- 97.503 97.485-97.490

2nd repair stage +1.0 97.508-97.513 97.495- 97.500
2 97.518- 97.523 97.505- 97.510

1
) Repa ir stage pistons are only available with the group numbers O. 1 and 2.

when new 0.008- 0.018

Piston clearance
wear limit 0.08

Max. wear limi t of cylinder bores in

direction of driving or transverse direction
0.10
at the upper and lower point of return of
t he 1st piston ring

Piston weight difference within one engine 4g

03.7- 316/2 F3
Tightening torque

lnitial torque 40-50 Nm

Connecting rod nuts
Angle of rotation torque 90-100°

Special tools

Piston ring spreader 000 589 51 37 00

Piston ring clamping strap 000 589 04 14 00

Cover sleeves (2) for connecting rod and

117 589 00 98 00
connecting rod bolts during piston installation

Note

As standard, the pistons are subdivided into six

tolerance groups (group numbers). The following
information ís stamped i nto the píston crown :

1. Piston diameter e.g. 96.505

2. Piston code number e.g. 72
3. Group number e.g. 1+
4. Direction of driving arrow

a Valve recesses
b Trough diameter

The group number is also stamped into t he crankcase

mating surface.

The piston group number (e.g. 2) must correspond

with the group number of the cylinder bores (series
manufacture).

This will ensure that the piston clearance is main·

tained.

03.7-316/ 3 F3
In the event of repairs, hone cylinder bares according
to the dimensions of the ex isting pistons p lus the
pistan clearance (see table).

The pistan pins of the engines 117.967/ 968 have

diHerent inside diameters for weight compensation
purposes together with the pistan. In the case of
repairs, the pistan pins must remain w ith their
respective pistan .

Remo val

1 Remove connecting rod with piston in upward

direction. For this purpose, cover connecting rod
w ith cover sleeves to prevent damage to the cylinder
wall.

2 Remove pistan pin circ lip and push out pistan

p in.

3 Recondition connecting rod and square

(03-3 13).

lnstallation

4 On used pistons, check p istan ring gap and axial

clearance.

5 Lubricate pistan pins and connecting rod bushings.

103-10956

6 Mount pistons in such a way that the arrow points

in the direction of driving and the locating grooves
(3) in t he connecting rod are facing to the engine
outside.

1 Connecting rod contact side

3 Locating grooves

03.7- 316/4 F3
7 Push piston p in in manually.

Caution!
Do not heat piston.

8 lnsert piston p in circlip into the groove.

9 Lubricate cleaned cylinder bares, connecting rod

bearing journals, connecting rod bearing shells and
pistons.

10 Distribute piston ring gaps uniformly around the

piston circum ference.

11 Position piston ring clamping strap and intro·

duce pistons into cylinder bore with arrow in the
direction o f driving.

Todo so, f it cover sleeves to connecting rod to

avoid damage to the cylinder wall.

12 Mount connecting rod bearing caps along con·

necting rod with matching identification number
and t ighten connecting rod nuts with 40-50 Nm
initial torque and 90- 100° angle of rotation torque.

13 Rotate crankshaft and check clearance between

piston pin eye and conn9'Cting rod.

03.7-316/5 F3
14 Measure distance between p iston crown and
crankcase mating surface with the piston at TDC
. •. \

03.7- 31616 F3
03-317 Renewal of piston rings

Piston removed (03-316).

Data

Toleranee Wear limit

when new

Maximum wear limit of the eylinder bores in direction

of dr iving or transverse direction at the upper and lower 0.09
point of return of the 1st piston ring

Axial elearanee for piston rings in Groove a 0.05-0.08 0.10

Groove b 0.01 - 0.03 0.10

Gr oove e 0.01-0.04 0.06

Piston ring gap in Groove a 0.20-0.35 1.0

Groove b 0.20-0.35 0.8

Groove e 0.20-0.35 0.8

Piston clearance 0.008-0.018 0.08

Speeial toot

Piston ring spreader ~ 000 589 51 37 00

Note

lf piston rings are renewed, the eylinder wear and

the piston ring axial clearance must be measured
with new piston rings.

03.7- 317/ 1 F3
1 Remove old piston r ings; remove carbon from
piston crowns and fi ring webs.

2 Remove carbon from piston ring grooves; do not

use sharp·edged tools to prevent damage to the
groove corners.

3 Clean oil holes in the circular oil groove.

Caution!
lt is possible tha t p istons with different 2nd p iston
ring (straight tace or taper tace ring) are installed in
the same engine.

The 2nd piston r ing mus't be replaced with t he p iston

ring of identical shape, o therwise it could get stuck top

-~
in the piston ring groove.

Straight lace pista n ring

T ape r lace pista n ring

4 lnstall 3rd piston ring (oil control ring). The joint

of t he inner spiral spring must be opposite the gap of
the piston ring.

l nstall 2nd piston ring.

Observe piston ring shape.

lnstall 1st piston ring.

Caution!
The marking, TOP" on the piston r ing must be at
t he t op.

03.7- 31 7/2 F3
03-318 Checking and reconditioning of crankshaft

Data

Crankshaft Crankshaft Width of th rust Crank pin Width of

standard dimension bearing journal bearing journal diameter pins
and repair stages diameter

63.965 27.000 51.965 1 ) 47.9651 ) 50.000

Standard dimension - -- -···-- - --
63.950 27.021 51.945 47.945 50.100

63.715 51.715 1 ) 47.715 2 )

1st repair stage ---
63.700 51.695 47.695

63.465 51.465 1 ) 47.4652 )

2nd repai r stage ---
63.450 51.445 47.445
up to 27.50 up to 50.30
63.215 51.215 1 ) 47.2152 )
3rd repa ir stage ---
63.200 51.195 47.195

62.965 50.965 1 ) 46.965 2 )

4th repa ir stage - --
62.950 50.945 46.945

Permissible crankshaft journal and crank pin runout 0.0025

Permissible deviation of the connecting rod journal surface axis to the

0.01
reference axis of the crankshaft journals 1 and V, from p.arallel

Permissible radial runout of the rear crankshaft flange 3 l 0.02

Permissible axial runou t of the rear crankshaft flange 3 l 0.012

Journals 11, IV 0.07

Permissible axial runout of the
crankshaft bearing journals3 )
Journals 111 0.10

from the cylindrical shape 0.005

4
Permissible deviation of the front crankshaft journal l
from axial runout 3 ) 0.030

Permissible deviation of the bearing surfaces

from rad ial runoue) 0.02
of the thrust bearing

Fillet radii at the crank:shaft and connecting rod bearing journals 2.5- 3

Crankshaft bearing journal diameter front 31.984-32.000

Bearing surface día. for radial sealing ring rear, 99.928

ground without helix 99.874

when new 71 - 81
Scleroscope hardness of crankshaft bearing
journals and crank pins
limit value

1 1 Eng ines 116 and 117 except 2 ).

1
1 116.960/961@00 <§ 116.962/963 and 117 .962/963.
3 ) With crankshaft resting on outer crankshaft bearing journals 1 and V and one full t urn.
4
) When measuring in the installed position , eliminate end float by pressing aga inst the crankshaft journal.
5 ) Limit value should be available at least on 2/3 of journal circumference .

03.7-318/1 F3
Special tool

lmpact hardness tester (scleroscope) e • e e •'tf~

11lltolo · U:O
000 589 20 21 00

Note

During repa ir the crankshaft need not be balanced.

When checking and recon dit ioning the crankshaft

proceed according to the following diagram .

Group number for crank pin diameter (standard

dimension)

1 = 51.945-51.954 mm and 47.945- 47.954 mm

2 = 51.955- 51 .965 mm and 47.955- 47.965 mm

The stamped·in figure at bottom applies to the 1st

crank pin.

Diagram

• See section ,.Explanation on diagram".

V =Scrapping.

03.7-318/2 F3
Visual checkup
Heavy damage? - - - - -- -- yes - - - - - - V

1
no

1
Crack test•
Cracks present? - - - - - - - - yes - - - - -- V

no

1
Hardness test" - - - - - - - - no
AII bearing journals
scleroscope hardness
mínimum 60 on
2/3 of the journal
c ircumference

1
y es

MeaJre pin (journall

Dimensions in order? = no =
Check whether - - -- - - - - no - - - ----- V
regrinding is still no V
y es possible
within last - - - - - - - ves
specified repair
1
lappJg stage 4. Hardening" ------,-,--- -

1 1
Dimensional checkup Journal or pin Journal or pin
Dimensions in order? __ no with hardened without hardened
fillets fillets

yes 1
lnduction
hardening
Complete Straighten fac ilities
crankshaft crankshaft available? lnduction or
flame hardening
11 1
Grind no ves
crankshaft

11 1
Crack test 1nduc- _ _ Check hardness
Cracks showing? yes_v tion by etching"
hardening
11 1
no Relief crankshaft
at 80 °C for
11 2 hours
See Lapping
1
See Straighten·
ing of crankshaft

03.7-318/3 F 3
Explanation of diagram

Crack test

Clean cran kshaft. Bearing journals and p ins should be

free of oil a nd grease. Magnetise crankshaft and
apply fl uorescent powder (fluxing). A color pene-
trat ion method may also be used (immersion in bath
or using spray can).

Flux agent: Paint or UV·o il,

cleaning agent,
developer

Hardness test -..

···~""~...

Test hardness with impact hardness teste r

(scleroscope).

The m inimum hardness should be available on 2/ 3

of the journal and pin circumference.

Hardening

Journals and pins without hardened fillets can be

inductance hardened or flame hardened. On the
other hand, journals and pins with hardened fillets
(arrow) must always be inducta nce hardened. lf this
is not possible, scrap the crankshaft.

When hardening journals and pins without hardened

fillets, the distance A between hardened runout and
fillet rad ius (4- 5 mm) must be maintained.

The running surface for the rear radial sealing ring is

hardened and ground without helix (previously 60°
helix).

03.7- 318/4 F3
Checking the hardening results

For perfect hardening. check adjustment of harden-

ing equipment by means of metallographic etching
(gri nding).

Pertinent tests can be made with scrapped crank-

shafts.

Check hardening by etching surface of journals and

pins with a 2% solution of alcoholic nitric acid
(HN03).

No dark areas should appear on journal or pin sur-

faces.

Unhardened fillets will become dark.

Hardened fillets. on the other hand, should be as

bright as the surface of pin or journal.

A journal or pin which has al ready passed metallo·

graphic inspection may be used for compari son.

After the test. carefully wash off nitric acid with

alcohol.

Corrosion protection

Crankshafts which are not immediately installed

again should be tubricated with engine initiat
operation oil (SAE 30).

03.7-318/ 5 F3
03-320 Mounting of crankshaft

Engine removed and d isassembled.

Data

Crankshaft Crankshaft Width of crank· Crank pin Width of

standard dimension bearing journal shaft thrust diameter crank pins
and repa ir stages diameter bearing journal

63.965 27.000 51.965 1 ) 47.9651 ) 50.000

Standard size - --
63.950
---
27.021 51.945 47.945
---
50.100

63.7 15 51 .715 1 ) 47.7151 )

1st repa ir stage ---
63.700 51.695 47.695

63.465 51 .4651 ) 47.465 2 )

2nd repa ir stage -63.450
-- 51 .445 47.445
up to 27.50 up to 50.30
63.215 51.215 1 ) 47.215 2 )
3rd repa ir stage - --
63.200 51.195 47.195

62.965 50.965 1 ) 46.965 2 )

4th repair stage - --
62.950 50.945 46.945

Basic bore and bearing play Crankcase 3 ) Connecting rod

4
68.480 ) 55.6001 ) 51.600 2 )
Basic bore diameter
68.500 55.6 19 51 .619

Permissible out-of-round and conicity of basic bore 0.01 0.01

22.379
Seat width of thrust bearing shell 3 )
22.400

when new 0.025- 0.045 5 ) 0.030- 0.0555 )

Radial bearing play
wear limit 0.09 0.08

when new 0.10- 0.22 0.22- 0.38

Axial bearing play
wear limit 0.30 0.50

1
) Engines 116 and 117 e)(·Cept 2 ).
2
J 11~.960/961@0 (V~ 116.962/963and 117.962/963.
3
) Machined together with the crankshaft beari ng caps.
4
) Tolerance range índicated on crankshah bea ring cap wíth paí n t, 68.48Q-68.490 blue, 68.49Q-68.500 red .
5
) The mean value is desirable for radial bearing play.

03.7- 320/ 1 F3
Tightening torques Nm

Threaded stud in crankcase 1 ) 30

Crankshaft bearing threaded stud
Nut M 10 x 1 and lateral bolts 50

lnitial torque 40-50

Connecting rod nuts
Angle of rotation torque 90-100°

2
with 3 diaphragm springs ) 270-330
Crankshaft end bolt
1
with 4 diaphragm springs ) 370- 400

lnitial torque 30-40

Necked-down bolts for driven plates
Angle of rotation torque 90-100°

1
) Alter unscrewing, the th readed studs lose their locking effect. They may only be used once.
1 ) See Note 03-324.

Special tools

Clamping strap for piston r ings 000 589 04 14 00

Dial gauge holder for measuríng

363 589 02 21 00
crankshah end play

Cover sleeves (2) for connecting rods and

11 7 589 00 98 00
connecting rod bolts during piston installation

Note

Self-locking threaded studs are

screwed into the crankcase for
mounting of the crankshaft
bearing caps.

These threaded studs may only

be screwed in once, as the locking
compound, which is applied to
approx. 8 mm of thread length,
will become ineffective after
unscrewing the stud.

When renewing the threaded studs,

pay attention to the different
screw-in lengths and collar dia-
meters.

No Heli-Coil inserts may be used

in repair cases for the self-locking
crankshaft bearing cap studs.

03.7-320/2 F3
The five crankshaft bearing caps made of malleable
cast iron are fitted into the crankcase with a lateral
overlap of 0.01 mm.

The three center bearing caps are always bolted to

the crankcase outer walls.

The crankshaft bearing caps have been machined

together with the crankcase and are not ava ilable
as a spare par t.

Mounting of crankshaft with engine removed and

disassembled.

Following a bearing fai lure, the connecting rods

must be removed and any chips removed from the
connecting rod bores.

Carefully clean oil galleries in the crankcase, crank·

shaft. timing case cover, oil filter housing, end cover,
oil pump etc.

Check crankshaft for cracks, dimens ions and hard·

ness (03-318).

Associating crankshaft bearings, installing crankshaft

1 lnstall crankshaft beaning cap, observe marks,

1 is at the front.

The bearing caps are fitted asymmetrically, in this

way the caps can only be installed in one position.

03.7- 320/ 3 F3
2 Lub ricate nut contact area and threads, tighten
nuts with 50 Nm.

3 Lubricate thread and bolt head contact area of

lateral bolts (M 10 x 40), install with washers and
tighten with 50 Nm.

4 Measure basic bore in direction A, B and C at

two levels (conicity). Note down values.

With the basic bore wh ich exceeds the specified

value or is conical, touch up bearing cap contact
surface on a su rface plate toa maximum of
0.02 mm.

5 lnsert bearing shells, mount crankshaft bearing

caps.

Tighten nuts to 50 Nm and lateral bolts with 50 Nm.

6 Measu re bearing diameter, note down measured

values.

7 Measure crankshaft journal, then determine crank·

shaft radial bearing play.

Note: The bearing play can be corrected by using

different bearing shells, while the aim should be for
the mean value of the specified bearing play. Crank·
shaft bearing shells without color coding are thicker
than the ones with blue color coding. lt must be
observed however that th e wall thicknesses of shells
without and with color coding may overlap.

03.7- 320/ 4 F3
8 Measure width of f itted bearing journal and the
fitted bearing. Determine crankshaft axial bearing
play.

The fitted bearing shells of the repair stages are

available in oversize.

Both fitted bearing shells must be mach ined together

on both sides to the width of t he fitted bearing jour·
nal minus the axial play.

9 Coat bearing shells an d c rankshaft with engine

oil SAE 30 and fit cran kshaft.

Cautionl
Do not use bearing shells without oil hole in the
crankcase but only in t he bearing cap.

Crankcase

ViewA

Cap

2 3 4 5
Fitted bearing

03.7- 320/5 F3
1O Tighten crankshaft bearing caps with a specified 1 2 3 4 5
torque in the sequence of the tightening diagram. ~
Todo so, the thread and the bolt and nut contact
areas should be lubricated beforehand.

Nuts 50 Nm.

Lateral bolts 50 Nm.

Note: Ouality 10.9 must be used for the lateral

bearing cap bolts.

11 Measure crankshaft axial p lay (end float).

12 Rotate crankshaft by hand to check whether it

ru ns freely.

Associating connecting rod bearings and installing

connecting rods

13 Check connecting rod bolts (03-310).

14 Recondition and square connecti ng rods

(03-313).

R· 5784

15 Matching the stamped numbers. mount connect·

ing rod bearing caps. Tighten connecting rod nuts
with 40-50 Nm.

16 Measure basic bore in two directions. lf the basic

bore exceeds the specified value or is conical, touch up
bearing cap contact surface on a surface plate up toa
maximum of 0.02 mm.

17 lnsert connecting rod bearing shells, install con-

necting rod bearing caps with bearing shells and
tighten connecting rod nuts with 40-50 Nm.

03. 7-320/ 6 F3
18 Measure and note bearing diameter.

19 Measure crank pin. Determine radial connecting

rod bearing play.

Note: The bearing play can be corrected by using

different bearing shells, while the aim should be for
the mean value of the specified bearing play. Crank-
shaft bearing shells without color coding are thicker
than the ones with blue color coding. lt must be
observed however that the wall thicknesses of shells
without and with color coding may overlap.

20 Mount piston and connecting rods (03- 316).

Todo so, use cover sleeves on connecting rods to

prevent damage to the cylinder waiL

1 Connecting r od contact side

3 L ocating grooves for bea ri ng shells i().)- 9 55511

21 Lubricate bearing shells, crankshaft, pistons and

cyl inders with engine oil SAE 30. lnstall connecting
rods with pistons (03-3 16).

Observe mark ing!

22 Tighten connecting rod nuts with 40-50 Nm

initial torque and 90-100° angle of rotation torque.

03.7-320/7 F3
23 Measure axial connecting rod bearing play. Ensure
freedom of movement of connecting rods in the
pistons.

Caution!
Disassemble oil pump, clean and renew if required.
Renew oil pressure 1imiting valve. D isassemble oil
filter upper part and clean, carefully clean air-oil
cooler or renew. Unscrew and clean oil pressure
relief valve for oil filter i nsert and oil cooler bypass
valve. Disassemble and clean oil damper.

Fit initial operation oil filter insert. After 1000 to

1500 km, change engine oil and oil filter element.

Note: For repair purposes it is possible on model

107.026 with engine 117.960 to exchange the
crankshaft 1st version with the shorter crankshaft
117 031 14 01 together with an additional compen-
sation plate (10.5 mm thick) and longer (29 mm
instead of 23 mm) necked·down bolts.

1 BoltM 18x 1.5x45 11 Crankshaft bearing shell 17 Oriven plate 1.5 mm thick, 296 mm día.
2 Oiaphragm springs (4 requ ired), in crankcase 18 Oriven plate 1 mm thick, 287 mm día.
2nd version 12 Cran kshaft beari ng shell 19 Necked-down bol t for driven pi ates
3 Bolt M 8 x 22 (6 required) in bearing cap M 12 x 1.5 x 23 (8 required)
4 V·belt pulley 13 Fitted bearing shell in 20 Ring gear wi th segments
6 Víbration damper crankcase 21 Fitted bolts
7 Hub 14 Fitted bearing shell in 22 Spríng washer B 6
8 Crankshaft sprocket bearing cap 23 Nu tM 6
9 Crankshaft 15 Connecting rod bearíng shells 24 Oowel pín (only for EZL transmitter)
10 Woodruff key 16 PI ates 4.5 mm thíck

03.7-320/8 F3
03-324 Replacing front crankshaft radial sealing ring

Tightening torques Nm
1
with 3 diaphragm springs ) 270-330
Crankshaft end bolt
1
with 4 diaphragm springs ) 370- 400

Bolts. V·bel t pulley to hub 35

1 ) See Note.

Special tools

Detent for counterholding crankshaft

116 589014000
(starter flange left or r ight)

Torque wrench 3/4" drive,

001 589 31 21 00
150-500 Nm

Socket insert 27 mm, 1/ 2" drive /~ 001 589 65 09 00

~~
Sleeve for front radial sealing ring
~
~
J n~ ·UU
110589076 100

Conventional tool

Adapter 3/ 4" inside t o 1/2" e.g. Hazet. 0-5630 Remscheid

outside drive Order No. 1058 R1

Note

As of 1985. the number of diaphragm springs was

increased from 3 to 4.
For purposes of repair it is not permitted to increase
the number of diaphragm springs by adding one
addit ional diaphragm spring, but 4 new diaphragm
springs must be used.
The old version (with 3 diaphragm springs) may be
retained.
lf 4 diaphragm springs (2nd version) are used instead
of 3 diaphragm springs (1st version) during repairs,
the t ightening torque must be increased to 370-
400 Nm.

03.7-324/1 F3
Crankshaft arrangement
1st version
1V ·belt pulley
2Bolt M Bx 22
3Vibrati on damper
4BoltM 18x 1.Sx 45
SDiaphragm springs (3 required)
6 Hub
7 Radial sealing ri ng
8 Woodru ff key
9 Tlming case cover
10 Crankshaft sp roc ket
11 Crankshaft

Note

Prior to installation. the space between sealing and

dust lips of the radial sealing ring must be filled with
long·life grease acco rding to sheet 266. 2 of the
Specifications for Service Products.

Caution!
The V·belt pulley on the crankshaft is optlonall y
made of cast iron or pres:sed steel plate.

Care should be exercised not to break the cast·iron

pulley.

Crankshaft arrangement
2nd version
1 V·belt pulley
2 Bolt M 8 x 22
3 V ibratoon damper
4 Bolt M 18x 1.Sx4S
5 Diaphragm springs !4 required)
6 Hub
7 Radial seali ng ri ng
8 Woodruff key
9 T iming case cover
10 Crankshaft sprocket
11 C rank shaft

03. 7-324/ 2 F 3
Renewing

1 Remove hub, vibration damper and V-belt pulley

(03-342).

2 Force out radial sealing ring by means of a screw-

driver.

Caution!
Do not damage crankshaft and seating bore for radial
se al ing ri ng.

3 Remove burr from edge of radial se al ing ring sea t.

4 Pull in radial sealing ring by means of installation

sleeve (1). For installing, use the hexagon head bolt
( 1071 for mounting hub to crankshaft and one
diaphragm spring (106).

The radial sealing ring must be positioned at right

angles to the crankshaft journal.

Note: Hubs with running grooves from the radial

seal ing ring must be renewed.

5 lnstall hub, vibration damper and V-belt pulley

(03- 342).

The bolt M 18 x 1.5 x 45 (4) is installed with 4 dia-

phragm springs (2nd version) (see Note).

03.7-324/3 F3
03-327 Replacing rear crankshaft radial sealing ring

Necked-down bofts for driven plates onto crankshaft

Necked·down bolts, part No. 116 032 02 7l 116 052 04 71 1 )

- L
Thread O M12x1.5

when new 9.8-0.2

Necked·down
shank dia. d -------------------------------- 0
mínimum dia. 9.3

Length L 23

1) In case o f repai rs the crankshaft 1st ver sion of mode l 107.026 w ith engine 117.960 can be replaced by the shorter cr ankshaft
117 031 14 01 together w ith a compensation p late (10.5 mm th ick) and longer necked·down bolts (29 mm instead of
23mm).

Tightening torques

lnitial torque 30-40 Nm

Necked·down bolts for
dr iven pi atesto crankshaft
Angle of rotation torque

Special tool

lnstallation tool for radial sealing ring

11 7 589 00 43 00
with end cover fitted

Note

The end cover directs thle engine oil from the main
oil gallery to the two oil galleries supplying the
cylinder heads and is sealed against the crankcase by
means of sealing compound. lt is for this reason that
the radial seal ing ring should be replaced without
removing the end cover if possible.

The running surface for the rear radial se al ing ring on

the crankshaft is hardened and ground without helix.

lf the crankshaft has a groove on the running surface

of the sealing ring, a repair stage sealing ring with a
sealinglip offset to the inside should be installed.

Standard radial sealing r ing (13 mm wide).

Radial sealing ring repair stage (10.5 mm wide ) for

use with worn crankshaft.

03.7-327/1 F 3
Renewing

1 Force out radial sealing ring by means of a screw·

driver.

Caution!
Do not damage crankshaft and installation bore for
the seal ing r ing.

2 lnspect runn ing surface on crankshaft.

3 Fit mounting sleeve to crankshaft.

4 Fill rad ial sealing ring space between dust lip and
sealing lip with long-life grease according to sheet
266.2 of the Specifications for Service Products.

5 Push radial seali ng ring ove r the installation sleeve.

6 Using the installation tool, pull radial sealing ring

into the cover until it bottoms.
lt must be observed that on crankshafts with locating
dowel a corresponding bo re is provided on the
installer.

7 Measure necked·down shank of necked·down

bolts.

8 Mount dr iven pi ates in correct sequence

(03-410).

9 Tighten necked-down bolts with 30- 40 Nm and

90-100° angle of rotation torque.

03.7- 327/ 2 F3
03-342 Removal and installation of hub, vibration damper and V-belt pulley

Data

radial runout 0.3

Permissible deviation on vibration damper
lateral runout 0.5
--- -- ··---·- -···--···-···--·--------------
Tightening torques Nm
1
3 diaphragm springs ) 270-330
Crankshaft end bolt
1
4 diaphragm springs ) 370-400

Bolts, V·belt pulley to hub 35

1
) See Note 03-324.

Special tools
-----------------------------------·
Detent 116 589014000

Torque wrench 3/4" drive,

001 589 31 21 00
150- 500 Nm

Socket insert 27 mm, 1/ '2:' drive 001 589 65 09 00

Conventional tool

Adapter 3/4" inside to e.g. Hazet, 0-5630 Remscheid

1/ 2" outside drive Order No. 1058 Rl

Note

The crankshaft sprocket (10) and the hub (6) are

seated on the front crankshaft stub, lined up by
means of the Woodruff key (8). This assembly is
pressed against the cranksbaft with the bolt (4) and
the 4 diaphragm springs (5) (2nd version as of 1985).
The vibration damper (3) and the V-belt pulley ( 1)
are bolted to the hub (6) in a certain position, since
one of the six threaded holes is set off.

03.7-34211 F3
Crankshaft arrangement
2nd version
1 V-bel t pulley
2 Bolt M 8 x 22
3 V ibration dampe r
Engine 116.96 201.5 mm dia.
En gine 117.96 214 mmdia.
4 Bolt M 18 x 1.5x 45
5 Diaph ragm springs (4 required)
6 H ub
7 Radial sealing ring
8 Woodruff key
9 Timing case cover
1O Crankshaf t sprocket
11 Crankshaft

Hub, vibration damper and V-belt pulley can be

renewed without balanc ing.

The vibration dampers of the engines 116.96 and

117 .96 have a different outside d iame ter and
characteristic frequency _

The V-belt pul leys of the d ifferent engines 116.96

and 117.96 are al so different.

Note: The vibration dampe r of engines 116.960/ 96 1

@ 0 0 and ~with asymmetrical mount-
ing bore at the outer circumference was replaced
with the vibration damper 11 6 030 07 03 with
symmetrical ly arranged installation recesses as of
January 1981.

Used in:
Engine No. 116.96012 006407
116.961 12 0 11140

1st version
V ibration dampe r engine 116.96

03.7- 342/ 2 F3
Removal

1 Remove radiator, fan and V-belt.

2 Use special tool detent to locate crankshaft in

position.

3 Unscrew crankshaft and bol t.

4 Use a chisel to mark crankshaft and hub relative

to each other (arrow) so that the groove of the hub
lines up with the Woodruff key upon assembly.

5 Manually pull off vibration damper together with

V-belt pulley and hub, assisting with light taps with
a plastic hammer if necessary.

Caution!
Take care not to break the cast-iron V -belt pulley.

lnstallation

6 Mount vibration damper, V-bel t pulley and hub

bolted together as a unit.

7 For this purpose, heat the hub to approx. 50 oC

to facilita te si iding onto the crankshaft. SI ide onto
crankshaft while turning the assembly to ensure
alignment of hub groove with Woodruff key.

03. 7-342/3 F3
Cautiont
The vibration damper, the V· belt pulley and the hub
must be bolted together in a certain position.

One of the 6 bores is offset. The holes must corres·

pond accurately (see dimension 1. 73).

As opposed to cast-:ron engine, the 6 bolts M 8 x 22

for the attachment of the V·belt pulley and the
vibration dampe r are installed without spring washers.

8 lnstall the bolts M 18 x 1.5 x 45 with 4 d iaphragm

springs (2nd version) and tighten with the specified
torque (see Note 03- 324 ).

lf the vibration damper was renewed, the TDC trans·

mitter must be newly adiusted (03-345).

03. 7- 342flt F3
03-345 Checking and correcting adjustment of TDC transmitter

Special tools

Measuring pin for TDC and 20° ATDC

115 589 17 21 00
position of the engine on 1st cyli nder

Locating tool for adjusting slide 102 589 03 21 00

Socket insert 27 mm, 1/2" drive 001 589 65 09 00

1/2" drive insert, 80 mm long, for

61 7 589 00 16 00
rotating the engine

Note

With the crankshaft at 20° after TDC, the TDC trans·

mitter must be positioned exactly above the pin in
the vibration damper (arrow ).

T he adjustmen t of the T OC transmitter must be

checked and corrected

a) when renewing the T OC transmitter adjusting

slide

b) when renewing the crankshaft with hub and

vibration damper

e) when renewing the timing case cover

d) when completing partly assembled engines.

Checking

1 Loosen power steering pump, remove V·belt,

swing power steering pump to the inside.

2 On vehicles with air conditioning or automatic

clima te control, remove refrigerant compressor with
carrier.

03.7- 345/ 1 F3
3 Unscrew hex. head nu t (arrow) and pull out
TDC transmitter.

4 Screw adapter into the spark plug bore of No. 1

cylinder.

1nsert adjusting pin ( 1) into the adapter and push

down fu lly.

Note: With the cyl inder head removed, attach a

dial gauge holder to the crankcase and position dial
gauge pin on the piston crown.

5 T urn crankshaft with the tool combination until

the adjusting pin has reached its highest position.

T he piston is then at T OC .

6 Remove adjusting p in .

Clamp dial gauge in pos:i tion with a preload of

approx. 5 mm.

Rotate crankshaft and accurately adjust T OC with

the dial gauge.

Tu rn dial gauge se al e u ntil the pointer is at O.

03.7- 345/2 F 3
7 C ontinue rotating the crankshaft in direction of
rotation until the dial gauge pointer has moved back
by the value specified in the table.

8 lnsert locating too! into adjusting si ide. T he pin

of the vibration damper must engage in the slot of
the locating tool.

E ngine Measurement through

spark plug bore

116.960/ 961
Standard version 2. 99
116.964/ 965

116.960/961
@009 3.36
116.962/963

117.960/961
117.962/963 3.58
117.964/ 965

117.967/ 968 4.09

Correcting

9 Loosen adjusting si ide (arrow) and slide until the

pin engages in the locating tool.

10 Tighten adjusting slide (arrow) and remove

locating fixture.

11 lnsert TOC t ransmitter and secure (arrow).

12 Remove dial gauge.

13 Briefly turn crankshaft in direction of rotation,

then unscrew the adapter from the spark plug bore.

03.7- 345/3 F3
03-410 Removal and installation of driven plates

Necked-dow n bolts for driven plates to crankshaft

Necked·down bolts, part No. 1160320271

L- -
Thread O M 12 X 1.5

when new 9.8-0. 2

Necked-down Q
shank dia. d
mín imum día. 9.3

length L 23 29 1 )

1
) In case of r epairs the crankshaft 1st versio n of model 107.026 w ith engi ne 117.960 can be replaced by th e shorter crankshaft
117 031 14 01 together wit h a compensat ion p late (10.5 mm t hick) and longer necked·dow n b olts (29 mm instead o f
23m m).

Tightening torques

ln itial torque 30-40 Nm

Angle of rotation torqu e 90-100°

Note

The two dríven pi ates (2nd and 3rd versíon) w ith

1. 5 mm and 1. O mm thíckness díffer with regard to ·20
the outer diameter from those of the engine 117.960 -l ....
(1st vers ion) with automatic transmission 722.006
and those of the cast·iron engines with 329 mm dia.

Engínes wíth position índícator for the ignítíon (as of

1985) are equípped with a l ocatíng pín (24) and
dríven plates (17 and 18) with a bore for the locating
pin. (3rd versíon)
· 19

24
'"'""'~~---- 16
Arrangement engi ne 116.96. 11 7.96
(3rd version} '1!-1'4--··-- 17
16 Pl ate 4.5 mm thick
17 Driven plate 1.5 mm thick, 296 mm dia
18 Driven plate 1 mm thíck, 287 mm dia
19 Necked-down bolt
20 Ring gear
21 Fitted bolt
22 Spri ng washer B 6
23 Nut M 6
24 Locati ng pin

03. 7-410/ 1 F 3
The previous hole of 8 mm dia for the assembly of
the locating pin (24) was enlarged to 8.5 mm in the
platas (16).

The threaded holas in the crankshaft flange are

through·holes. With the bolts removed and the
engine inclinad, oil will run out.

Arrangement engine 116.96. 117.96

(2nd version)
16 Plata4.5mmthick
17 Oriven p lata 1.5 mm thick, 296 mm dia.
18 D riven plata 1 mm thick, 287 mm dia.
20 Ring gear
21 Fítted bolt
22 Spring washer B 6
23 Nut M 6

The arrangement of the driven platas on the engine

117.960 (1st version) with automatic transm ission
722.006 up to engine end No. 001612, as well as
engine end No. 001618-001635 and 001641-001681,
corresponds with the arrangement for cast-iron
engines.

Arrangement engíne 117.960, 1st versíon

1 Pi ate 4.5 mm
2 Oriven plate 1.5 mm, 329 mm dia.
3 Driven plate 1.0 mm, 329 mm dia.
4 =
Necked-down bolts L 23 mm

03. 7-410/2 F3
lf dur ing a repaír the shorter cranksh aft 117 03 1 14 0 1
is installed in me engine 117.960 (1st version) with
automat ic transm ission 722.006, the compensating
plate 10.5 mm th ick, part No. 116 032 03 76
(arrow) should be used instead of the front plate,
4. 5 mm mick, together with longer (L = 29 mm)
necked-down bolts (6), part No. 116 032 04 71,
(see arrangement engine 1 17.960 repair procedure
with 1st version).

Arrangement engine 117.960, repair procedure

with 1st version
1 Longitudinal compensation plate 10.5 mm
2 Driven plate 1.5 mm, 329 mm dia.
3 Driven pi ate 1.0 mm, 329 mm di a.
4 PI ate 4.5 mm
6 Necked-down bolt L; 29 mm
1033- 9576

When using me longitudinal compensation plate

together wi th the shortene d crankshaft, the driven
plate assembly must be centered with a self-fabricated
centering sleeve before tightening the necked-down
bolts.

Self-fabricated centering sleeve

03.7-410/3 F3
Note: Lighter driven plates and starter ring gears A
(version B) were installed in engines 116.962/ 963
and 117.962/963 during the period November 1982
to February 1983 andas of June 1983.

l0l2 H446

B
Designation Version A Version B

Oriven plate,
1 mm thíck 117 032 04 06 117 032 06 06
Oríven plate
1.5 mm thíck 1 17 032 05 06 117 032 07 06
Starter ring gear 1170300312 1170300412

Balancing

Crankshaft, V-belt pulley, vibration damper, dr iven

pi ates and ring gear are indiv idually balanced, and
can be renewed without additional balancing.

03. 7- 410/4 F3
Removal

Remove transm ission (27-600).

2 Unscrew necked·down bolts, spacer plates and

d riven plates with ring gear.

lnstallation

3 Measure necked· down shank. lf the specified

minimum diameter .. d" on the necked·down shank
is reached, the necked-down bolts must be renewed.

Cautionl
One of the e i!tJt mount ing bolts is offset from the
p itch circle diameter (arrow).
The driven plates must therefore be installed in a
certain position.
The hole pattems must be matched accu rately.

4 Screw in necked-down bolts and t ighten with

3Q-40 Nm ini t ial torque and 9Q-100° angle of
rotation torque.

03.7- 410/5 F3
Lighter driven pi ates and ring gears (ve rs ion B) were
installed in the period November 1982 to February
1983 andas of June 1983.

Oes,gnation Version A Version B

Onven plate,
1 mm t111ck 117 032 04 06 117 032 06 06
Onven plate.
1.5 mm th ick 1 17 032 05 06 117 032 07 06
R1n9 gear 1170300312 117 030 04 12

In the case of repair, the version A of the ring gear

must be replaced with the version B.
A

Version A
l03?-1t4C6

Version B

B. Engine 117.960 with automatic trans-

mission 722.006 (W 3 8 OSO)

Note

When removing the transmission, the ring gear remains

on the torque converter.

Ring gear with welded·on steel ringare balanced as

a unit.

03.7- 430/2 F3
03-430 Renewing ring gear

Data

Permiss ible l ateral runout of ring gear 0.3mm

Centering collar día. for driven pi ates 296.00-296.05 mm

Residual unbalance of ring gear with steel ring

A Engi nes 116.960/961/962/963,

117.960/ 961/962/963 with automatic
transmission 722.3 (W 4 A 040)
without position indicator

Note

When removing the transmission the ri ng gear rema ins

on the engine.

The ring gear and t he we lded·on steel ri ngare

bal anced together.

The ring gear (20) is vvelded to a steel ring and

bolted to the driven pi ates ( 17 and 18).

The 1. 5 mm th ick driven plate outer diameter is a

machined f i t for the centeri ng of the ring gear.

16 Plates 4 .5 mm
17 Driven p i ate 1.5 mm, 296 mm dia.
18 Driven pi ate 1 mm, 287 mm dia.
20 Ring gear
21 Fi tted bolt
22 Spring washer B 6
23 Nut M 6
1033·9075

03.7-430/ 1 F3
C. Engines 116.964/965, 117.964/965/9671 20
968 with position indicator for ignition 21
system
1 1
23
22

Note

When remov ing the transm ission the ring gear

remains on the engine. 19
- -- 30Nm.90°<í,
The ring gear (20) with 4 segments for the position '
1
indicator of the ignition system is forged from one <Dr-.
CJ>CO
NN
piece, balanced and bolted to the driven plates (17) G.'G.
and (18). 1 1

24
The 1. 5 mm thick driven pi ate outer diameter
is a machined fit for the centeri ng of the ring gear. 16
17
16 Plates
17 Driven plate 1.5 mm 18
18 Oriven plate 1.0 mm
19 Necked·down bolt
20 Ring gear
21 Bolt
2'2 Washer
23 Nut
24 Locating pin

When removing the ring gear, unscrew position indi·

cator (3) and pull out of holder (1) to avoid actuation.

Caution!
The ring gear must be mounted so that the 3. 5 mm
dia. holes (arrows ) in the ring gear and the driven
plates assume the same angular position, otherwise
a proper functioning of the ignit ion is not guaranteed.

03.7- 430/3 F3
05-211 Checking and replacing hydraulic valve clearance compensating elements

Tightening torques Nm
Bolts for cylinder head cover 3

Compensating element in cylinder head 60

Special tool

Spring compressor for valve spring 123 589 03 61 00

Note

Store compensating elements in upright position

only and do not disassemble.

Reinstall rocker arms and compensating elements

in the same place from which they were removed.

In the event of complairnts about noise, check

compensating elements as follows:

Checking

1 Place cam tip opposite rocker arm in upward

position.

2 Push with handle of a hammer against rocker

arm.

lf the ball head pressure bolt drops too fast when

compared with other pressure bofts. repface hydrau·
lic valve clearance compensating element.

05.7-211/1 F3
 3 Try to move rocker arm manually.

lf there is play, check basic position of compensating

elements (05-213).

Replacing

4 Remove rocker arm (05-230).

5 Unscrew compensating element with 24 mm

socket.

6 Lubricate threads of new compensating element,

screw in and tighten to 60 Nm.

7 lnstall rocker arm (05-230).

8 Check basic position (05- 213).

05.7-211 /2 F3
05-213 Checking and correcting basic position of hydraulic valve clearance
compensating elements

Thickness ..S" of thrust piec:es in mm Part No.

6.15 117 053 07 53

5.8 11 7 053 06 53
5.45 117 053 05 53
5.1 117 053 04 53
4.75 1 117 053 03 53
ll'l
4.4 117 053 02 53
4.05 1)$.4- 632811 117 053 01 53
3.7 117 053 00 53

Tightening torque Nm

Bolts for cylinder head cover 3

Specíal tools

Test gauge for hydraulic compensating elements 117 589 06 23 00

Spring compressor for valve spring 123 589 03 61 00

Note

The test gauge serves to find the basic position or a

plus(+) or minus (-) deviation of hydraulic e lement.

In the event of a plus(+ ) or m inus (-) dev iation,

the installation of a thinner ora thicker thrust
piece (4) perm its to reatta in the basic position.

06.7-213/1 F3
Since December 1982, the hydraulic valve clearance
compensating elements are adjusted w ith a revised
preload dimension (basic position) (previously
0.7- 1.9 mm, now 1.2-2.4 mm) .

This is achieved by adding a thicker thrust piece to

the valve spring retainer.

Production breakpoint: December 1982

Model Engine Engine Chassis

end No. end No.

107.045 116.962 013323 022708

107.046 117.962 001791 004833

126.032
116.963 025756 040889
126.033

126.036
117.963 021019 029280
126.037

126.043 116.963 025756 005329

126.044 117.963 021019 004833

The revised preload dimension is also valid for all

prev iously manufacturad engines 116 and 117, and
must be taken into account when checking and
adjusting the basic position.

Note: Checking and adjusting should be carried out

w ith the testing gauge 117 589 06 23 00 w ith
rev ised measuring groove position.

05.7 - 21 3/2 F3
Checking

1 With newly instaUed compensating element,

crank engine with starter motor for approx.
30 seconds prior to checking.

2 Cranking engine:

Model107

On 4·point cable connector, disconnect cable

terminal 16 (cable color red/purple) so that the
ign ition coil and the fuel pump are not activated.
Connect terminal 30 (cable color red) and terminal
50 (cable color purple) .

Model126

Disconnect cable plug (terminal 16, arrow) so that

the ignition coil and the fuel pump cannot be
activated. Connect terminal 30 and 50.

3 Remove load from hydraulic element to be

checked, i.e. the cam tip should point in upward
direction (arrow) .

4 Place test gauge over hydraulic element to be

tested and set measuring pin on the ball head bolt.

05.7- 213/3 F3
5 Check position of measuring groove ( 1) re lative
to the measuring edge (2):

a) The basic position is correct if the measuring 2

edge (2) is within the 1.2 mm w ide red measuring
groove ( 1 ).

b) Plus deviation (+) is indicated if the measuring

edge (2) is above the red measuring groove (1).
2
Remedy: For plus deviation (+) install thinner
thrust piece.

e) Minus deviation (-) is indicated if the measuring

edge (2) is below the red measuring groove ( 1 ).

Aemedy: For minus deviation (-) install thicker

2
thrust piece.

Corrections

6 Remove rocker arm by means of spring compres-

sor. Remove thrust piece.

05.7-2 13/4 F3
7 Measure thickness ,.S" of thrust piece.

Thrust piece thickness .,S"

Pa rt No.
in mm 1/l

6.15 117 053 07 53

L_ ··· · ~·. - --
- - 6328
5.8 1170530653
5.45 117 053 05 53
5. 1 11 7 053 04 53
4.75 11 7 053 03 53
4.4 117 053 02 53
4.05 1170530153
3.7 117 053 00 53

8 In the event o f p lus dev ia tion (+) install th inner,

in the event of m inus deviation (-) install thicker
thrust p iece.

Note: For readjustment aim for center position on

measuring groove.

9 lnstall rocker arm and repeat checkup.

05.7-213/5 F3
05-215 Checking and adjusting camshaft timing

Timing in degree {0 ) crankshaft with 2 mm valve Jift

Camshaft code number 1 ) Engine Engine lntake valve opens

left/right special version No. ATDC1 )

02/03 117.960 12° (10°)

04/05 117.961 20° {18°)

08/09 116.964 012.468/01 22° (20°)

116.965
117.962
117.963
117.964
117.965

14/15 117.963 012.406/10 18° (16°)

16/17 117 .968 012.480/01 17° {16°)

18/19 117.967 012.468/05 27° {26°)

117.968 012.468/06
012.468/14
012.468/15

20/21 116.965 21° (20°)

117.965

24/25 117.968 RÜF 17° 116°)

26/27 117.967 012.468/05

117.968 CAT 012.468/06
012.468/14 27° (26°)
012.468/15

60/61 116.960 012.406/03 12° {10°)

116.961 012.406/04
116.962 012.406/07
116.963 012.406/08

62/63 116.960 012.406/01 24° (22°)

116.961 012.406/02
116.962 012.406/05
116.963 012.406/06

70/71 116.962 012.468/03 16° !14°)

116.963 012.468/04
116.964
116.965

~) Camshaft code number :association can be taken from the spare part microfilms.
) With new timing chains anda running time of below 20 000 km, adjust the timing of the right-hand camshaft according to
the values in brackets.

05.7-215/1 F3
Tightening torques Nm

Bolts for cylinder head cover 3

Bolts for camshaft sprockets M 14 x 1.5 x 40 100

Hydraulic valve clearance compensating elements in cylinder head 60

Special tools

Spring compressor for valve spring 123 589 03 61 00

(
D ial gauge holder
~ o . ..... ......
363 589 02 21 00

Valve clearance wrench 17 mm

~' 1
116 589 02 01 00
"':~
Socket insert 27 mm i
1
''""···.,
l 001 589 65 09 00

Square d ri ve
~-10282 617 589 00 16 00

Conventional tool

e.g. Mahr, D- 7300 Essi ingen

D ial gauge A 1 DIN 878
Order No. 81 O

Note
t t 1' t
During assembly jobs it is sufficient if the marks on
0 ,0 020 030 040
the camshafts coincide at ignition TDC position of 'Ü' if 'Ü' if
1st cylinder.

Check ,.intake valve opens" on 1st and 6th cylinder

at 2 mm valve lift. 71548637 2

Checking

.(} .(} .(} .(}

.
5 6 7 8
1 Check camshaft code number on rear end of
0 0 0 0 0 0 0 0
camshafts.

05.7- 215/2 F3
... ' '
2 Remove rocke r arm ( 1) and valve clearance com·
pensating elements (2) on intake valve of 1st and
6th cylinder. lnstall valve adjusting screw (1). part
No. 116 050 11 20. on intake valve of 1st and 6th
cylinder instead of compensating elements (2).
1nstall rocker arm.

Caution!
The rocker arms and the valve clearance compensating
elements should be installed in the place from which
they were removed.

3 Rotate crankshaft (27 mm socket) until the cam

tip rests against intake val ve of 1st cylinder in up-
ward posit ion.

Rotate crankshaft in engine direction of rotation

only.

4 Turn va lve adjusting screw until rocker arm

rests free of play against camshaft heel (arrow).

5 Attach dial gauge holder to cyl inder head.

6 Clamp dial gauge witn extension pin in dial gauge

holder wíth a preload ot 3 mm.

The measuring pín should rest on the valve spring

retainer in an accurately vertical position.

7 Set the large pointer toO.

8 Rotate crankshaft until the pointers of the dial

gauge return by 2 mm to a preload of 1 mm. The
valve lift w ill then be 2 mm.

9 In th is engine position the value on the vibration

damper should be in agreement with the value
.. lntake valve opens" in the table.

1O Perform this test on the intake valve of 6th

cylinder by repeating figures 4 to 9.

05.7- 215/3 F3
Adjusting
. /~·--.,\ '
lf th e t iming must be corrected, install an offset
Woodruff key or if the chain has been elongated
too much, a new timing ·Chain.
. IJ .;
Woodruff keys are available in the following step s: ()
Offset
mm
Part No. For a
correction
.. /
..
of approx.
A

o.7 621 991 04 67 40 eran k angle

0.9 621 991 02 67 6 1/2° eran k angle
1' 1 621 991 01 67 ao eran k angle
1.3 621 991 00 67 100 eran k angle
B

An offset by one tooth on the camsha ft sprocket

resu lts in approx. 18° on the crankshaft.
lnstallation position A resu lts in eatl ier commencement of
An offset of the Wood ruff key to the right (in the opening
l nstallat io n position 8 resu l ts in la ter commencemen t of
d irection of driving) results in an earl ier commence· openi ng
ment of opening, while an offset to the left resu lts
in a later commencement of opening.

11 Mark camshaft sprockets and timing chain

relative to each other (arrow ).

12 Remove the respective camshaft sprocket.

13 Place a rag under the camshaft and remove the

Woodruff key.

14 lnsert the selected Woodruff key.

15 1nstall the camshaft sprock et w hile paying

attention to the color coding.

The wi de collar on th e camshaft sprocl<et should

tace to the camshaft (arr ow).

Do not tighten the bolt.

16 Repeat items 4 to 9.

17 Tighten bolt to 100 Nm.

18 Check basic position of hydraulic valve clearance

compensating elements and correct (05-213).

19 Complete the engine.

05.7- 215/4 F3
05-220 Removal and installation of camshafts

Timing in degree (0 ) crank angle, with 2 mm valve lift

Camshaft code number 1 ) Engine Engine lnlet valve opens

left/ right special version No. ATDC2 )

02/03 117.960

04/05 117.961

08/09 116.964 012.468/01

116.965
117.962
117 .963
117 .964
117 .965

14/ 15 117.963 012.406/ 10 18° (16°)

16/ 17 117.968 012.480/01 17° (16°)

18/1 9 117.967 012.468/05 27° (26°)

117.968 012.468/06
012.468/ 14
012.468/ 15

20/21 116.965 21° (20°)

117 .965

24/25 117.968 RÜF 17° (16°)

26/ 27 117 .967 012.468/05

117.968 CAT 012.468/06
012.468/ 14
012.468/ 15

60/61 116.960 012.406/03

116.961 012.406/04
116.962 012.406/07
116.963 012.406/08

62/63 116.960 012.406/01

116.961 0 12.406/02
116.962 012.406/05
116.963 012.406/06

70/71 116.962 012.468/03

116.963 012.468/04
116.964
116.965

~) T he association of camshaft code number can he taken from t he spare part microfilms.
) Wi t h new timing chains anda r unning time of below 20 000 k m . the t iming for the right·hand camshaft must be adjusted
according to the val ues i n brackets.

06 .7-220/1 F 3
Tightening torques Nm

Bolts for cylinder head cover 3

Bolts for camshaft sprockets M 14 x 1.5 x 40 100

1. 1n itial torqu e 30
Cylinder head bolts
2. Final to rque 60

Fastening screws for camshaft beari ngs on

50
cylinder head

Special tools

Spring compressor fo r valve spring 123 589 03 61 00

Reta ining wrench for camshafts 116 589 01 01 00

Screwd river insert 8 mm, 1/2" d rive,

000 589 33 07 00
130 mm long

Conventional tool

Screwdriver insert 8 mm, e.g. Hazet, D-5630 Remsche id

1/2" dr ive, 52 mm long Order No . 986-8

Note

Pay atte nt ion to the association of camshaft code

number relative to the r espective engine (see table).
The camshaft bearing journals can be ground, repair
stage camshaft bear ings are available (05-225) .

lf a camshaft needs to be replaced, it is necessary to

replace the co rresponding rocker arms as well.

The camshaft bearings of the engines 116.96 and

117.96 m ay be u sed on the cast iron engi nes 116.98
and 117.98.

05.7-220/2 F3
Removal

1 Remove cylinder head cover.

For this purpose disconnect fuel lines on left·hand

cylinder head cover (arrows).

2 Disconnect relay for fuel pump so that no fuel

runs out of fuel line when the engine is cranked
with the starter motor.

3 The engine can be rotated by connecting terminals

30 and 50 so that the respect ive cam tip is in an
upward position for removing the rocker arms. For
this purpose disconnect terminal 16 (arrow).

4 Remove rocker arm by means of the spring com·

pressor.

Cautionl
lf rocker arms and camshafts are not replaced,
reinstall them in the same position as before as
failure todo so would require checking of the basic
position of the hydraulic valve clearance compen·
sating elements (05-213).

5 Set piston of No. 1 cylinder to ignition TDC. so

that the Woodruff key in the camshaft (arrow)
points up.

Note: Do not rotate engine on fastening bolt of

camshaft sprockets.

05.7- 220/3 F3
6 Prise off oil pipe w ith connections (arrows) and
remove.

7 Mark timi ng chain and camshaft sprocket to·

gether with lock ing compound (arrows) .

8 Loasen bolt on camshaft sprocket wh ile holding

it with the retaining wrench.

9 Unscrew camshaft bearing screws and remove.

Note: The rear cylinder head bolts M 10 x 165 mm

(arrow) at left and right can be removed only after
the camshaft bearing has been lifted.

05.7-220/4 F3
10 Lift camshaft including camshaft bearings and
pull camshaft out of rear camshaft bearing.

lnstallation

11 Lubricate camshaft bearings and slide camshaft

into camshaft bearings.

Cautionl
Introduce cylinder head bolts M 1O x 165 mm
(arrow) at the rear camshaft bearing left and right
before mounting the camshaft bearing.

12 Lubricate cy linder head bolt threads and head

contact area.

13 Mount camshafts with camshaf t bearings.

14 Tighten cylinde r head bolts M 10 x 165 for

camshaft bearings from inside out first to 30 Nm
initial torque and then to 60 Nm final torque.

15 Tighten fastening bolts M 8 to 50 Nm.

Caution!
The camshaft should turn easily by hand.

05.7- 220/5 F3
16 When mounting the oil p.ipes, move connections
into assembly position and check the three inside
connections for unobstructed pas~-ªge of oil bores
prior·ro tapping them onto the camshaftbearings.
Replace oil pipe if oil bóres are c()~!! red up.

Caution!
Replace connections each time following re moval
from camshaft beari ngs since-otherwise the oil
pressure in the oil pipe is not assured.

17 Mount compensating washer in such a manner

that the groove below the notch engages with the
Woodruff key of the camsháft (see arrows).

18 Mount camshaft sprocket while pay ing atten·

tíon to the color coding (arrows).

Caution!
The w ide collar on the camshaft sprocket (arrow)
should faceto the camshaft.

05.7- 220/6 F3
19 Mount bolt with washer and spring washer
(arrow).

20 Tighten bolt to 100 Nm while holding the

camshafts in place with the retaining wrench.

21 lnstall rocker arm in the same position as

befo re.

Caution!
lf the rocker arms or the camshaft have been re·
placed, check basic position of hyd raulic valve
clearance compensating elements (05- 213).

22 Complete the engine.

C/5.7-220/7 F3
1 O il p ipe 8 Camshaft bearing sp rocket end 14 Washer
2 End connection 9 Camshaft bearing 2 and 3 15 Camshaft sprocket
3 Center connection 10 Camshaft bearing 5 16 Spacer ri ng right
4 Cylinder head bolt M 10 x 50 11 Camshaft bearing flywhee l 17 Compensating washer
5 Washer side 18 Woodruff key
6 Cylinder head bolt M 10 x 165 12 Bolt M 14 x 1.5 x 40 19 Camshaft right
7 Oowel sleeve 13 Spri ng washer 20 Camshaft leh

05.7-220/8 F3
05-225 Grinding camshaft bearing journals

Data

Average roughness ( Rz) of camshaft bearing journals 0.005

Permissible rad ial runou t of camshaft bearing journals b ande and

of camshaft sprocket seat when mounting camshaft in bearing 0.025
journal a and rear bearing journal e

Permissible radia l runout of camshaft base circle w hen mount ing

0.03
eamshaft in beari ng journal a and rear beari ng journal e

Bearing points ( F ig.) a b e

35.()00 49.200 49.400

Bearing día.
35.()16 49.216 49.416
St andard dimension
34.975 49. 175 49.375
Journal día.
34.959 49.159 49.359

34.900 49.100 49.300

Bearing día.
34.916 49.116 49.316
Repair stage 1
34.875 49.075 49.275
Journal dia.
34.859 49 059 49.259

34.750 48.950 49. 150

Bear ing día.
34.766 48.966 49.166
Repair stage 2
34.725 48.925 49.125
Journal día.
34.709 48.909 49.109

25.430
Bearíng bracket w idth
25.390
F it ted bearing
25.500
Journal width B
25.533

radial 0.025- 0.057 0.025-0.057 0.025- 0.057

Camshaft bearing play
axial 0070-0.143

05 .7-225/1 F3
Note

When regrind ing thrust faee of

bearing journal .. a", gr ind faee
.,S" always so that the journal
w idth .. B" and eonsequently
the ax ial p lay (e nd p lay) is
maintained.

Bearing journals are not

hardened.

Suitable repair stage eamshaft a b b e e

bearings are a va ilable for
ground eamshaft bearing
journals. 1053.7990/ 1

05.7- 225/2 F3
05-230 Removal and installation of rocker arms

Tightening torques Nm

Bolts for cylinder head cover 3

·- -- - -- ----------------------------------------- - - - - -- -- - - - - - - - - -

Special tool

1
{~--
Spring compressor for valve spring 123 589 03 61 00

Note

lnstall rocker arms in the same position from

which they were removed.

lf rocker arms are m ixed up or replaced, check basic

position of hydraulic valve clearance compensating
elements (05-213).

When installing new rocker arms al so replace the

corresponding camshaft.

1 Camshaft
2 Rocker arm
3 Hydraulic valve clearance compensating element
4 Cylinder head
5 Valve guide
6 Exhaust valve
7 Valve seat ring
8 Thrust piece
9 Valve spring retainer
10 Valve cone hall
11 O u ter valve spring
12 1nner valve spring
13 Valve stem seal
14 Rotocap

05.7-230/1 F3
Caut ion !
Wi th hydraulic valve clearance compensating elements
use rocker arm with chamfer (arrow) only.

105 - 1060-4

Rocker arms of engines 1 16 and 117 and the rocker

arms of engine 11 O m ay not be interchanged.

Removal

1 Ro tate engine so that the respective cam tip

points upwards:

Model107

On 4-point cable connector, disconnect cable

terminal 16 (cable color red/purple) so that ignition
coil and fuel pump are not ac ti vated. Connect
terminal 30 (cable color red) and terminal 50 (cable
color purple).

Model126

Oisconnect cable plug (terminal 16, arrow) so that

the ignition coi l and the fuel pump are not activated.
Connect terminal 30 and 50.

05.7- 230/2 F3
2 Remove rocker arms by means of spring com·
pressor.

lnstallation

3 Lubricate sliding and contact surface of rocke r

arm.

4 1nstall rocker arm.

Caution!
lf a camshaft ora rocker arm has been replaced,
check basic position of hydraulic valve clearance
compensating elements (05-213).

05.7-230/3 F3
05-250 Removal and installation of valve springs

Tightening torque Nm

Bolts for cylinder head cover 3

Special tools

Spring compressor fo r valve spring

b~
/ 123 589 03 61 00

t\~1
:'!?-·-

Magnetic f inger for valve cone halves 116 589 06 63 00

Conventional tool

e.g. Bosch, EFAW 210 A

Cylinder leak tester
Sun, CL T 228-1

Note

From October 1984 to January 1985 no Rotocaps

were installed on exhaust valves and from January
to May 1985 on intake valves.

Observe valve spring preload (see 05-260).

Removal

1 Remove rocker arm {05- 230).

Caution!
Reinstall rocker arms in the same place from which
they were removed.

05.7-250/ 1 F3
2 Unsc rew spark p lugs.

3 Set piston of respective cylinder to ignition TDC.

For this purpose rotate the engine w ith the tool
combination on the crankshaft.

w
.

RIOO-S9S2

Note: The numbers O, 90, 180 and 270 (arrows) are

stamped into the vibration damper.

In the following positiol'ls of markings opposite the

indicator the pístons are at TDC as follows:

Marking number Piston at TDC

o 1 and 6
90 5 and 3
180 4 and 7
270 8 and 2

4 Support valves by means of compressed air

(cylinder lea k tester).

Caution!
The valves should not be seated on the pistan crown
to prevent bending of the valves.

5 Push valve spring retaíner down by means of

spring compressor.

6 Remove valve cone halves with the magnetic

finger.

7 Remove valve spring retainer and valve spring.

8 Check valve spring, replace if necessary

(05-260).

05.7- 250/2 F3
lnstallation

9 1nsert val ve spring w ith tight coil facing cylinder

head.

10 For further installation p roceed vice versa to

sequence of removal.

~ 1

¡:
~... 2

~~
O· tM
~6
t) 7

1 Thrust p iece 08
2 Valve cone
3 Valve spring retainer
4 Outer valve spring
5 1nner valve spring
6 Rotocap
7 Valve stem seal
8 Locking ring
9 Valve gu ide intake
10 Valve guide exhaust
11 1ntake val ve
12 Exhaust valve
13 Rocker arm
14 Hydraulic valve clearance
compensating element

05.7- 250/ 3 F3
05-260 Checking valve springs and valva spring preload

Data

Valve spring Color Outside Wire dia. Length Spring force w ith preloaded
Part No. coding día. unloaded Length When new L imit value
mm mm mm mm N N

lnner spring yellow/brown

130 053 00 22 or 22.0-22.4 2.5 45 21.5 235 224-246
purple/brown

Outer spring yellow/red

110 053 01 20 or 34.1-34.5 4.75 49 30.5 863 843-902
purple/ red
-----

Checking

1n the event of repairs, check valve spring for corro·

sion prior to reusing.

In addition, check spring force at specified length

by means of a spring test scale.
lf the value is below lower limit, replace valve
springs.

In the installed condition, the valve spring force of

both valve springs on engine 116.96 amounts to
1147-1245 N and on the engine 117.96 1000-
1245 N. In order to avoid that this value is not
lower than specified on valves which have been
lowered (machined valve seats), the washer, part No.
116 990 26 40. should be placed under the Rotocap.

05.7-260/1 F3
05-270 Replacing valve stem seals

Tightening torques Nm

Bolts for cylinder head cover 3

Special tools

Spring compressor for valve spring 123 589 03 61 00

Magnet ic finger for valve cone halves 116 589 06 63 00

Conventional tool

e.g. Bosch, EFAW 2 10 A

Cylinder leak tester
Sun, CLT 228-1

Note

The valve stem seals including assembly sl eeve~ are

supplied in repair kit form.

Valve guides wh ich are worn at t he retaíning groove

for va lve stem seal must be replaced.

Caution!
Rocker arms, th rust pieces, va lve spring retainers,
valve springs, valve cone halves and Rotocaps must
be reinstalled in the same position in order to ensure
that the basic position of the hydraulic compensating
element is not c hanged.

1 Camshaft
2 Rocker arm
3 Hvdraulic valve clearance
compensating element
4 Cvlinder head
5 Valve gu ide
6 Exhaust valve
7 Valve seat ring
8 Thrust piece
9 Valve spring reta iner
10 Valve cone half
11 Outer valve spring
12 l nner valve spring
13 Valve stem seal
14 Rotocap

05.7-270/1 F3
The valve stem seals are supplied as spare part in two
versions. They must be allocated to the appropriate
valve gu ide to avoid oil leaks.

A
B
~,
1st version

Valve stem seal 116 053 00 58 with flat, brass-colored

~;
retaining spring (arrow). h
1([.•_
1 1
Use 1st version only for val ve guide without stop
collar, 5.2 mm reta ining groove distance.
11')
o
11')
1

A Exhaust 1 .i
1
8 lntake
-· ~9 - - -09 -

1st production breakpoint (1st version):

From start of production to February 1983 and
from June 1983 to November 1983

Up to engine No.

116.962 12 015193

116.963 12 028837

117.962 12 001972

117.963 12 023645

2nd production breakpoint (1st version):

June to November 1983

Engine No.

116.962 12 018054- 023705

116.963 12 033750-042895

117.962 12 002310-003139

117.963 12 028416-039773

05.7-270/2 F3
2nd version B

Valve stem seal 110 053 02 58 with round, brass-

colored retaining spring (arrow) .

Use 2nd version only for valve guide with stop collar
and with 3.3 mm retaining groove distance.

A Exhaust
B lntake

1. Production breakpoint (2nd version):

February to May 1983

Engine No.

116.962 12 015194-018053

116.963 12 028838-033749

117.962 12 001973-002309

117.963 12 023646-028415

2. Production breakpoint (2nd version):

From November 1983

Engine No.

116.962 12 023706

116.963 12 042896

117.962 12 003140

117.963 12 039774

Replacement

Remove valve springs 105- 250).

2 Remove valve stem seals with a screwdriver or

with a pair of pliers.

Caution!
Do not damage valve stem and valve guide.

05.7-270/3 F3
3 Oeburr valve stem groove.

Rep lace worn vatve cone halves and spring retainers.

4 Check Rotocap and reptace if required.

10S-139t1

5 Lubricate valve stem seals and install.

Use installatio n mandrel.

6 lnstall valve springs (05-250) .

f') 1

¡:
~' 2

~"
g. t··
~6
a 1
1 Thrust píece 08
2 Valve cone halves

~· ~10
3 Valve spring retainer
4 Oute r valve spring
5 1nner valve spring
6 Rotocap
7 Val ve stem seal
8 Locking ring
9 Valve guide intake

l!
10 Valve gu ide exhaust
11 1ntake valve 1 12
12 Exhaust valve
13 Rocker arm
14 Hydraulíc valve clearance
compensatíng element .- 105J ·180013

05.7- 270/ 4 F 3
05- 280 Checking and machining valves

Data

l ntak e 8.955-8.970
Valve stem dia.
Exhaust 8.935-8.960

l ntake 11 6.8- 117.2

Valve length
Exhaust 117.8- 11 8.2
--·---··--·------------------------···-·-··-·--···----------- -- - - - - - -- --
lntake w ithout
Sodium charge
Exhaust with

lntake with
Valve seat plating
Exhaust wi th

l ntake 1.5
When new
Exhaust 2.5
Height (h) of valve retainer
l ntake 1.0
Limit value
Exhaust 2.0

Adjusting angle (a) fo r machining of valves

Permissible ru nout on valve stem and valve seat max. 0.03

Permissib le runout on f ace of valve stem when mounted at valve stem 0.015

Conventional tools

e.g. K rupp, D- 5320 Bad Godesberg

Valve cone grinding machine
Model VS
or
e.g. Hunger, D-8000 M ünchen 55
Valve cone turning mach ine
Type VKD R 1 A, order No. 203.00.200

Note

The exhaust valves are filled with sodium!

When scrapping these valves, observe safety regula·
tions. Do not melt val ves filled w ith sodium as there
is a risk of explosion and do not use such valves for
mak ing tools (punch etc.) without f irst rem oving
the sodium fill ing.

05.7- 280/1 F3
Be careful when removing the sodium from the
valves, since sodium mix.ed with water and watery
solutions causes an extremely severe and explosive
reaction and the resulting hydrogen gas may start
a fire.

Sodium from cut or broken·up valves can be neutra·

lized in a m ixture of 2 liters of spirit of alcohol and
1 liter of water in a container in the open air.

Sodium·filled valves can be collected and sent for

neutralizing to the Garantieprüfstelle Werk Stuttgart·
Untertürk heim.

Checking and machining

1 Clean valvas and check visually.

Valves w ith a burnt valve disk, with insufficient

he ight .,h" of the valve disk and valves with worn
out or scored valve stem should be replaced.

2 Measure runout on valve stem. lf runout exceeds

0.03 mm, replace valve.

3 Machine valve seat and face of valve stem.

Observe operating instructions of machine tool and

adjusting angle.

4 Measure runout on valve seat and height .,h" of

the valve disk.

lf the limit values are reached, renew valve.

5 Machine valve seats (05-291).

Note: Observe checking valve springs and valve

spring preload (05- 260).

05.7-280/2 F3
05-285 Check ing, replacing valve guides

V alve guides

Stages Outer dia. Color Basic bore in Overlapl) Valve guide

coding cylinder head inner dia.

..
-"'
Standard di m. 14.043-14.050 grey·brown 14.03Q-14.035 0.008- 0.020
!
"' Repair stage 14.214- 14.222 red 14. 198- 14.203 0.0 11-0.024
9 .00o-9.0 15
..
::>
Standard dim. 15.043- 15.050 grey-brown 15.03Q-15.035 0.008- 0.020
"'
.t:.
X Repair stage 15.214-15.222 red t 5. 198-15.203 0.011-0.024
w
1
) The overlap must be between 0.007 and 0.025 mm.

Special t ools

.. .. .. !
Plug gauge 9 mm día. for intake and exhaust valve guide 1 17 589 03 23 00

Knock ing-out mandrel 9 mm d ia. intake and exhaust ·~') 1 10 589 02 15 00

Plug gauge for valve guide basíc bore 1 17 589 05 23 00

Reamer 14.035 mm día. intake :i o

11 589 03 53 00

Reamer 15.035 mm día. exhaust 2Zi 1 10 589 02 53 00

Broach 14.2 mm día. íntake t. . ¡v. 1 15 589 00 53 00

Broach 15.2 mm dia. exhaust 1 . 1.

o
1 1 589 00 53 00

Guide sleeve for

Engines 11 6.960/ 96 1 and 117 (i
""1
fJ[O:
_.,... H00 4 -IOStt
102 589 01 63 00

broach
intake 14.2 mm dia. Engines 1 16.962/ 963 102 589 00 63 00

Guide sleeve for broach exhaust 15.2 mm día. 1 17 589 00 63 00

l nstalling mandrel 9 mm día. intake and exhaust ~-p~

~ , 10 589 00 15 00
( 1st version) ll~t ... , , ,~

l nstalling mandrel 9 mm dia. intake and exhaust

(2nd versíon)
<IIIJj;-..-~~~í"'JiJ:n. 11004 •1 1133
11 o 589 06 15 0 0

Reamer 8.99 mm d ia. H 7 íntak e and exhaust 000 589 10 53 00

05.7- 285/1 F3
Association engines - gu ide sleeves - broaches
1

Engine Valve Valve guide Guide sleeve Broach

basic bore Part No. Page Part No.
mm

116.962/963 102 589 00 63 00 B

lntake 14.2 115 589 00 53 00
116.960/961' 102 589 01 63 00 A
117

117.96 A
Exhaust 15.2 11 7 589 00 63 00 110 589 00 53 00
116 B

Note
- - -..·- - - - - - - - - - - - - -
In the event of repairs, cylinder heads with standard
normal dimension valve guides must be f itted with
standard dimension valve guides (grey-brown). First,
ream basic bores with reamers 14.035 mm dia.
(intake) and 15.035 mm dia. (exhaust) to avoid
too great an overlap.

Basic bores in which the use of standard dimension

valve guides do not provide an adequately tight seat
(mínimum interference 0.007 mm) must be machined
with broaches for repa ir stage valve guide installa·
t ion.

The broaches must be driven through the basic bares

with a plastic hammer and the aid of guide sleeves.

05.7-28512 F3
Checking valve guides

With cylinder head removed, check valve guides by

means of plug gauge in longitud inal and transverse
d irection.

Valve guides which accept the no·go end with the

wear limit (+ 220) in its entire height (5 mm)
must be renewed.

Va lve guides which are worn outside on the valve

stem seal seat so that the valve stem seal is no longer
seated t ight ly, should also be rep laced.

Replacing valve guides

1 Knock out valve guide from combustion chamber

end by means of knock ing mand re l.

2 Check valve guide basic bore w ith plug gauge in

longitudinal and transverse d irect ion.

Basic bores into which the measuring plug can be

inserted at one point for its entire height (8 mm),
must be finished to repair stage dimensions.

lf the measuring plug cannot be inserted fully or

only in part, the basic bore for the valve guide can
be reamed to normal dimens ion for the valve gu ides.

Machining basic bore

Standard dimension
3 Ream basic bore w ith reamer 14.035 mm día. or
15.035 mm d ia. wh ile lubricating with kerosene.
Ream w ith low pressure and do not cant the reamer.

Note: Handle reamers car·e fully and put back into

protective sleeve so that the cutting edges are not
damaged.

05.7- 285/3 F3
Machining basic bore

Repair S1age
4 Remove al l soot from cylinder head and clean,
in particular the inside of the valve seat rings.

5 Remove metal chips (use stiff plastic brush or

sim ilar) from the cutting edges of the b roach prior
to use.

6 Select correct guide sleeve (refer to table). Make

sure that the guide sleeve is centered only by the
inner diameter of the valve seat ring concerned and
is not impaired with carbon residue, casting pro·
jections, in tak e and exhaust port wal ls etc.

7 Liberal ly lubricate gu ide sleeve, basic bore and

the entire broach with engine oil.

8 Introduce broach in the direction of broaching

into thc guide sleeve so that d uring the subsequent
introduction of the guide sleeve into the cylinde r
head the broach wil l enter into the bore up to the
first cutting edge. Center the sleeve in the va lve seat
ring by means of rotary movements.

9 Orive broach through the bore by means of an

aluminum mandrel approx. 130 mm long anda
p last ic hammer of approx. 250 g.
105-21801

05.7 - 286/4 F3
lnserting valve guide

10 Cool valve guide in liquid nitrogen (approx.

3 minutes) and insert.

lf no liquid nitrogen is available, heat cylinder head

in a wat er bath to approx. 80 ° C. Orive valve guide
into the cylinder head by means of the instal ling
mandrel until the locking ring contacts the cylinder
head.

11 Check valve guide for tight seat with the cylinder

head in a cooled-down condition.

12 Check inner d ia. of valve guide w ith plug gauge.

The entire go end should be introduced into the

bore.

13 lf required, ream inner dia. with reamer.

14 Check valve seats for runou t and refinish if

requ ired.

05.7-285/5 F3
05-290 Replacing valve seat rings

Engine 116.960 116.960 116.962 116.964 117.962 117.967

116.961 @0<§ 116.963 116.965 117.963 117.968
11 6.961 117.960 117.964
@0CV@ 117.961 117.965

Standard lntake 46.000-46.016 41.000- 41.016 46.000- 46.016 47.400- 47.416

dimen.
o1 Exhaust 40.000-40.016 42.000-42.016 -

Standard lntake 46.090- 46.100 41.090-41.100 46.090-46.1 00 4 7.490-47. 500

dimen.
o Exhaust 40.090- 40.100 42.090- 42.100 -
Repair 01 max. to 47.016 41.016 47.016 48.016
stage
O roughing
intake 47.300 41.300 47.300 48.700
dimension
Repair 01 max. to 40.016 42.016 -
stage
O rough ing
exhaust
d imension
40.300 42.300 -
t 10.300-10.800

H 10.390- 10.500

Overlap of valve
seat rings in 0.074-0.100
cylinder head

lntake Exhaust

Special tool

Plug gauge 9 mm dia. ' p .. . #SJ 117 589 03 23 00

Conventional tools

Cylinder head clamping device e.g. Rothenberger, 0-6233 Kelkheim

e.g. Hunger, 0-8000 München

Ring seat turning tool
Size 2. order No. 220.03.110

05.7-290/1 F3
 ----- - - -- ------------------- ----- - -- - - -
e.g. Hunger, D- 8000 München
Valve sea t turni ng tool
Type VDSNL 1/ 45/30, order No. 236.03.308

e.g. Hunger, D-8000 Mlünchen

Test set for valve seats
Order No. 216.93.300

lnternal measur ing instrument e.g. Mahr, 0 - 7300 Essl ingen

(measuring range 25-60 mm) Order No. 844

Outside m icrometer e.g. Mahr, D-7300 Essl i ngen

(measuring range 25- 50 mm) Order No. 40 S

Renewing

1 Remove old valve sea t ring by means of a ri ng seat

tu rning tool.

2 Check valve gu ides, renew if necessary (05-285).

3 Measure basic bore O 1.

A new valve seat ring standard dimension may be

used if the specified overlap is available.

05.7- 290/ 2 F3
4 Machine basic bor e repair stage O 1 w ith the
valve seat ring turn ing too l until the bore is j ust
clean.

5 Measure machined basic bore.

6 Machine valve seat ring repai r stage until the

specified overlap is attained.

7 Heat cylinder head in water bath.

8 Cool valve seat ring in liquid nitrogen.

9 lnstall valve seat ri ng with a sui table mandrel.

10 Mach ine valve seats (05-291).

05.7- 290/ 3 F3
05-291 Machining valve seats

Data lntake Exhaust

Valve seat width b 1.3-2.0 1.5-2.0

Valve seat angle a

Correction angle top {3

Correct ion angle bottom -y

Permissible runout of valve seat 0.04

Special tools

Magnetic finger for valve cone halves 116 589 06 63 00

Plug gauge 9 mm día. 1 : ;;se> 117 589 03 23 00

Conventional tools

Cylinder head clamping devíce e.g. Rothenberger, D-6233 Kelkheim

e.g. Hunger, 0 - 8000 München

Valve seat turning tool
Type VOSNL 1/ 45/30, order No. 236.03.308

e.g. Hunger, 0-8000 München

Test set for valve seats
Order No. 216.93.300

60° correct ion tool No. 13 for e.g. Hunger, D- 8000 München
correctíon angle bottom Order No. 216.64 622

Note

Clamp cylinder head into clamping

device for disassembling and
machining.

Machine valve seats with valve seat

turning tool, with valve seat
grinder or with valve seat cutter.

05.7- 291/1 F3
Machining valve seats

1 Check valve guides and replace if required

(05-285).

2 Machine valve seats (see operating instructions of

machine tool manufacturer).

Caution!
Loosen pilot only after the runout of the valve seat
has been checked (ítem 3).

Caution!
Do not turn down the bead at the lower end of the
valve seat.

3 Check runout of valve seat.

For this purpose, slide test sleeve ( 19) with dial

gauge holder (20) and d ial gauge onto the pilot (5).

5 Pilot
18 Dial gauge
19 Test sleeve
20 Dial gauge holder

05.7-291/2 F3
4 Measure valve seat width ,.b" and correct at top
w ith 15° and at bottom w ith 60° if required.

When machining w ith the Hunger turning tool, use

the 60° correction steel No. 13 for the lower valve
seat correction.

5 Observe valve spri ngs and valve spring preload

{05-260).

05.7- 291 / 3 F3
05-293 Decoking valves

Equipment

e.g. Alfred Kiircher

leutenbacher StraBe 30-40,
Sandblasting device for walnut shell granulate
D- 7057 Winnenden
Order No. 1.486.601

e.g. Eisenwerk Würth GmbH & Co.

Walnut shell granulate (25 kg) Friedrichshaller StraBe,
Gra insize 1-1.5mm D-7107 Bad Friedrichshall
Order No. 10407

Note

Transition fault during the warming-up phase on

vehicles with KA injection system can be caused
by coked-up inlet valves.

The inlet valves can be cleaned w ith a sandblast ing

device without remov ing the intake man ifold.

1 Sandb lasting device

2 Power connection cable
1220 voltsl
3 Compressed-aír connection
4 Blow·out valve
5 Compressed·air supply line
6 Granulate feed line
7 Compressed-air gun with nozzle
8 Adapter
9 Extraction line wit h plug connection
10 Extraction pipe

Clea ning proced ure

Walnut shell granulate under high pressure is blasted

on the disks of the closed inlet valves via the mount·
ing bores of the injection valves. At the same time,
the carbon residue is ex tracted together with the
granulate via t he thrott le valve pipe into the sand-
b lasting unit.

The valve disk is partly obstructed by the valve stem.

1n order to clean the obstructed part the valve must
be t urned once by 180° .

05.7-293/ 1 F3
Maintenance and filling of sandblasting device

1 After approx. 20-30 cleaning processes, shake off

the carbon p ieces on the outside of filter bag (arrow) .

2 When fitt ing the upper part , observe the marking

( M).

3 Fill the unit low er part w ith approx. 4 kg of

walnut shell granu late, grain size 1- 1.5 mm up to
the lower edge (arrow).

4 lf lumps are formed and in the case of high dust

content the granulate m<ust be renew ed because of
its inefficient cleaning effect.

Oecoking

1 Remove mixture control unit with air intake

housing.

2 Remove injection valves.

3 Remove all rocker arms and thrust pieces.

Caution!
Rocker arms and thrust pieces must be installed in
the same position from w hich they were removed.

05.7-293/2 F3
4 Cover valve area and camshaft with a cleaning rag.

5 Fit adapter {8) with open throttle valve.

6 Connect extraction line (9} to the adapter (8).

7 Place compressed-air gun (7} with nozzle in the

bore for the injection val ve. 8 last the injection val ve
for approx. 30-60 seconds.

B Blow out intake port with the blow·out valve (4)

via the injection valve bore with the extraction
switched on.

05.7-293/ 3 F3
9 Force inlet valve down by means of the valve
spring compressor 123 589 03 61 00 while turn ing
the valve by 180°.

10 Blast inlet valve for approx. 15- 30 seconds.

11 Blow inlet port with blow·out valve (4) via the

injection valve bore with the extraction switched on.

12 1nsert the extraction pipe ( 1O) vi a the thrott le

valve intake pipe and extract the remaining granu·
late from the intake manifold lower part and from
the exhaust gas recirculation line.

13 Using a light, inspect intake manifo ld lower part

and all cy linders for re sidual granu late, extract if
necessary.

14 Flush throttle va lve 1intake pipe and throttle

valve with benzine.

15 1nstall removed parts.

16 Adjust idle speed (07.3- 100).

05.7- 293/4 F3
05-310 Removal and installation of chain tensioner

Tightening torques Nm

Screws for chain tensioner on cylinder head 25

Coupling nut for chain tensioner 90

Note

The hydraulic chain tensioner is supplied with

hydraulic oil by the way of an oil duct (4) in the
cylinder crankcase front and in the cylinder head
(arrows) .

The contact pressure of the thrust bolt ( 1O) against

the tensioning rail is held constant by the check
valve (4 and 5) and the pressure limiting valve (6 and
8) together with the compression spring ( 1 1) ,
regardless of engine oil p ressure.

Venting takes p lace after the oil pressure in the

engine oil circuit has been established and the chain
tensioner is being f illed up with oil.

05.7-310/1 F3
 1 Closing nut 8 8all5 mmdia.
2 Aluminum seal ing ring A 25 x 30 9 Compression
3 B all seat r i ng spring
4 Ball 5 mm día. 10 Thrust pin
5 Ball cage 11 Compression
6 Valva d isk spring
7 0-ring 12 Housing
13 Circlip B 16

Caution!
As of June 1980, the chain tensioner has been pro·
vided w ith a reinforced flange of 17 mm (previously
12 mm).

Mount chain tensioner with 17 mm flange by means

of screws M 8 x 30 mm (previously M 8 x 25 mm).

The chain tensioner hou·sing and the closing nut

dimensions were changed.
The reason for this were cracked and leaking closing
nuts.

Chain tensioner housing: dimension 1.:r0·2 was

1.5 mm

Closing nut: dimension 15.5+ 0·2 was 14.5 mm

The part No. of the chai n tensioner has not been

changed.

Removal and installation

1 Remove fastening scr·ews and remove chain

tensioner.

2 Mount chain tensioner with a new gasket and

t ighten screws unif ormly.

The pressure pin of the chain tensioner should rest

against the tension ra il lug.

No te: In the event of repairs, replace complete chain

tensioner.

05.7- 310/ 2 F 3
05-320 Replacing timing chain

Tightening torques Nm

Mounting bolt for camshaft sprocket 100

Bolts for cylinder head cover 3

Special tools

Spríng compressor for valve spring 123 589 03 61 00

Socket insert 27 mm, 1/2" drive

001 589 65 09 00
for rotating the engine

1/2" drive insert, 80 mm long,

617 589 00 16 00
for rotating the engine

Note

A repair chain with connecting link is available fo r

repai rs.

lf only an endless timing chain is available, the chain

can be opened prior to installation by grinding off
both pins of a link and subsequent installation by
means of a connecting l ink.

The endless timing chain is installed with timing case

cover removed. Check sprockets for score marks and
pitting.

05.7-320/ 1 F3
Repair duplex chain w ith connecting link.

Engine 116.960/ 961/962/963/ 964/ 965

186 links
Engine 117.960/ 961 / 962/963/ 964/ 965/ 967 / 968
198 links

The simplex chain (in(D and@ engines 116.96

up to model year 1983) must be replaced wi t h the
duplex chain togeth er with all sprockets in the case
of repai r. The left·hand cylinder head must be
removed for this purpose.

Replacement

Remove spark plugs.

2 Remove rocker arm on right·hand camshaft

(05- 230)

Caution !
The rocker arms must be installed in the same
position f rom which they w ere removed.

3 Remove chain tensioner (05-310).

4 Cover chain box with rag and cut t iming chain by

means of chain cutting tool or grind off both pins
of one link.

05.7-320/2 F3
5 Attach new timing chain to old timing chain by
means of a connecting link wh ile removing cut·up
connecting l ink.

105· 9259

6 Slowly rotate the crankshaft by means of tool

combination in the d irect ion of rotation of engine
while simultaneously pulling up the old chain until
the connecting link comes t o rest against the upper·
most position of the right·hand camshaft sprocket.

Caution!
While rotating the crankshaf t, the tim ing chain should
always remain in mesh w i th both camshaft sprockets.

it!00-5952

7 Oisconnect old timing chain and connect new

t1mlng chain by means of a connecting link .

8 Set engine to igni tion TDC at No. 1 cylinder.

lf the markings (arrow) are not accurately lined up,

check timing (05-215).

9 Complete the engine.

Note: Remove all metal deposits from wo rn·out

sprockets and timing chains in the engine. Renew
oil filter element and engine oil.

05.7-320/3 F3
05-330 Removal and installation of tension raíl

Tightening torques Nrn

Bol t s for cylinder head cover 3

Mounting bolt for carnshaft sprocket 100

Special tools

lmpact puller fo r bearing bolt

116 589 20 23 00
(basic unit)

Threaded bolt M 6 x 50 116 589 o1 34 00

Note

The t im ing chain is guided in the cyl inder crankcase

by means of 2 slid e rails and is tensioned by the
chain tensioner via a ten~ion raíl.

The tension rail is guided by a floating p in in crank·

case and t iming case cover.

The tension rail s of engines 116.96 and 117.96 are

different in length and d iffe r in shape from those
of cast-iron engines.

The thrust p in of the tension raíl was rel ocated in an

inw ard direction and centered.

The tension railli ning (3) of all engines 116 and 117
can be re placed in the case of repairs.

Tension rai l
Engine 116.96 117.96
a= 133mm 160mm
2 Tension raíl
Engine 116.98 117.98
b= 133mm 161.5 mm
3 Lining
Engine 116 117
e• 184mm 208mm

05.7-330/ 1 F3
Removal

1 Remove slide rail in right·hand cylinder head

(only engines 116.960/ 961, 117.960/ 961).

2 Remove chain tensioner (only engines

, 16.962/963/964/965, 117.962/963/964/965/967/
968).

3 Mark right·hand camshaft sprocket and timing

chain with paint.

4 Remove right·hand camshaft sprocket.

S Unscrew closing plug (arrow).

Engine 117@

6 Cant bearing pin of tension raíl with a bolt M 8

ora screwdriver and pull out.

Note: The bearing pin is ho llow (inner dia. 8.8 mm)

anda floating fit (light sliding f it) in t he crankcase
and tim ing case cover.

05.7- 330/2 F3
7 Remove tension rail.

lnstallation

8 lnsert tension raíl between timing case cove r and

tim ing chain.

9 lnsert bearing pin and drive in fu lly.

10 lnstall closing plug w ith sealing ring.

11 Mount camshaft sprocket so that the co ll ar on

camshaft sprocket (arrow) faces toward the camshaft.

12 For further installat ion proceed vice versa.

05.7-330/3 F3
05-340 Removal and installation of slide rails

Tightening torques Nm

Bolts for cylinder head cover 3

w ith 3 diaphragm springs1 ) 270-330

Crankshaft end bolt
with 4 diaphragm sprin9s 1 ) 370- 400

Mounting bolt for camshaft sprocket 100

1
) See Note 03-324.

Special tools
- - - - - - - - - - - - - - - - - -- ---------------
lmpact puller for bear ing pin
116 589 20 33 00
(basic unit)

Threaded bolt M 6 x 50 116 589 o1 34 00

Detent
116 589 01 40 00
(starter motor flange left or right)

Torque wrench 3/ 4" dr ive,

001 589 74 21 00
150-800 Nm

Socket insert 27 mm, 1/ 2" drive 001 589 65 09 00

Conventional tool

Adapter 3/ 4" inside to e.g. Hazet, D - 5630 Remscheid

1/2" outside square drive Order No. 1058 R 1

Note

All slide rails in cylinder heads of engines 116 are

identical.

Likewise, the slide rails in cylinder heads of all

engines 117 are identical.

On the other hand, the length of the pertinent

bearing pins of light alloy engines differ from those
of cast- iron engines.

05.7- 340/ 1 F3
Slide rails in cylinder head left inside and outside

Set píston of 1st cylínder to ígnítíon TDC.

2 Remove dístributor (07.5-510).

3 Remove power steer ing pump together w íth

mounting b racket.

4 Knock out bearing p i n w ith impact puller and

remove slíde raíl.

5 When insta llíng, p ay attentíon to posítion of slide

raíl.

The bearíng p ins are dífferent from those of cast·iron

engínes.

Slide rail layout engine 116

Beari ng pin
Light alloy engines L u 46 mm
Cast-iron engines L = 56 mm

Slide rai l layout engine 117

Bearing pin
Light alloy engines L = 46 mm
Cast-iron engines L = 56 mm

05.7- 340/ 2 F3
Slide rail in cylinder head right

1 Remove alternator together w ith mounting bracket.

2 Knock out bearing pin with impact puller and

remove slide ra il.

Slide rails in crankcase

Remove timing case cover (01-210).

2 Unscrew slide raíl (87 or 79) .

The two slide rails in the crankcase differ from those

of cast·iron engines.

Cast·iron
Engine 116.96, 117.96 engine 116.98,117.98

1 Slide rail 3 Slide ra il

2 Bolt M 8 x 40 4 Bolt M 8 x 38
a 43.8 mm b 55 mm

05.7-340/3 F3
The straight slide raíl ( 1) in the crankcase is
asymmetrical (arrow) and slides onto the pins (2)
screwed into the crankcase.

1, 2 Engine 116.96and 111.96

3, 4 Cast·iron engine 116.98 and 117.98 4 '.
a 114 mm
b 26mm

Tension arm for oil pump chain

Remove timing case cover (01-210) .

2 Remove lock and re move tension arm (84).

05.7- 340/4 F3
05-434 Removal and installation of intermediate gear for distributor drive

Tightening torques Nm

with 3 diaphragm springs 1 ) 270-330

Crankshaft end bolt front
w ith 4 diaphragm springs 1 ) 370-400

Mounting bolt for camshaft sprocket 100

1
1 See Note 03-324.

Special tools

Torque w rench, single·arm, 3/ 4" drive,

001 589 74 21 00
150-800 Nm

Socket insert 27 mm, 1/ 2" drive i::&J

'~··"1
001 589 65 09 00

Detent
116589014000
( starter motor flange left or right}

Allen wrench with c ross·bar handle

, 16 589 03 07 00
6 mm, 440 mm long

Sleeve for r adial sealing ring front 11 o 589 07 61 00

Conventional tool

Adapter 3/4" inside to e.g. Hazet, 0-5630 Remscheid

1/2" outside drive Order No. 1058 Rl

Note

The bearing bushings for the distributor drive in the

crankcase have fallen away as from December 1984
and those in the timing case cover as from March
1985.

05.7-434/1 F3
Remova l

Remove timing case cover !01-210).

2 Remove slide raíl (87).

78 1nter mediate gear for d istributor drive

3 Slacken timing chain on intermediate sprock et by

turning left·hand camshaft.

4 Remove intermediate sprocket. On engine 116

this requ ires the removal of left·hand cy linder head
(01 - 415).

5 lf requ ired, pull out bearing bushing in cyli nder

crankcase and timing case cover by means of interna!
puller.

lnstallation

6 Press bearing bushing into crankcase and timing

case cover so that the lubricating groove (arrow ) is
positioned at the bottom.

7 Lubricate beari ng bushing w ith oil and insert

intermed iate sprocket.

05.7- 434/2 F3
8 Set crankshaft to ignition TDC.

Caution!
In ignition TDC position of No. 1 cylinder, the inter·
mediate sprocket should be positioned such that the
marks on the intermediate sprocket and the crankcase
are in alignment (arrow).

Engine 116

1 Driver
2 Mark on intermediate sprocket
3 Mark on crankcase
4 Aeference point for crankcase without mark

Engine 117

9 Check position of intermediate gear and correct

if required.

The marks (arrows) should be in alignment. 1f not,

distributor adjustment after installation will not be
possible.

10 For further installation proceed vice versa.

05.7-434/3 F3
05-440 Removal and installation of return sprocket

Tightening torques Nm

with 3 diaphragm springs 1 ) 270-330

Crankshaft end bolt front
with 4 diaphragm springs 1 ) 370-400

1
) See Note 03-324.

Special tools

Torque w rench, single-arm, 3/4" drive,

001 589 74 21 00
150-800 Nm

Socket insert 27 mm, 1/2" drive ¡- AJ 001 589 65 09 00

110114.• • ~)

Detent
116 589 01 40 00
(starter motor flange left or right)

Al len screwdriver with cross·bar handle

116 589 03 07 00
6 mm, 440 mm long

Sleeve for radial sealing ring front 11 o 589 07 61 00

Conventional tool

Adapter 3/4" inside to e.g. Hazet, D- 5630 Remscheid

1/2" ou tside drive Order No. 1058 R 1

Note

On engine 116 with duplex chain the intermediate

sprocket can only be renewed after removal of the
left-hand cylinder head.

The bearing bushings for the return sprock et in the

crankcase have fallen away as from Oecember 1984
and those in the timing case cover as from March
1985.

05.7-440/1 F 3
Removal

Remove timing case cover (01-210).

2 Remove slide rail (87).

3 Slacken timing chain on intermediate sprocket

(78) by turning left·hand camshaft.

4 Remove intermediate sprocket (78).

5 Remove return sprocket ( 1) .

6 lf required, pull out bearing bushing in crankcase

by means of interna! puller.

7 Pull out bearing bushing in timing case cover with

interna! puller.

lo
l 1
lb 31
1
48 30
1
29

lnstallation

8 Press bearing bushing into crankcase and timing

case cover with lubricating groove at the bottom
(arrow).

9 Lubricate bearing bushing in crankcase w ith oil

and int roduce return sprocket.

10 lnstall intermediate sprocket (05-434).

11 For further installation proceed vice versa.

05.7-440/2 F3
07.3-001 Addltlonal Deslgnatlons for Models and Components

Models and components may have ditferent versions, data and operations in connection with their
3· to 6-positioned designation (e. g. 126 or 126.034). These ditferences are identilfied by the
following additions:

Std. = Standard version (Std.).

ldentification: none

NV = Low-compression engine.
ldentification: engine data plata
(not always)
,--- Basic versions
NV KAT = Low-compression engine with cat. converter.
ldentification: engine data plata

RÜF = Engine with "multifunctional mixture

preparation and ignition system" without
catalytic converter (retrofit version).
ldentification: ECE on connector of EZL and
of CIS-E injection system.

KAT = Engine with "multifunctional mixture

preparation and ignition system" with
catalytic con verter.
ldentification: KA T on engine data plate and
on connector of EZL and of CIS-E injection
system.
Modal or
component
designation

@ = Australia version, silver plata

@) = Switzerland version, green plata, light green

for CAT version
~.- NatiOnal versions
@ = Hongkong version
= Japan version. plata in language
ldentification: 1ntormation plate 0 of country
on crossmember for
@@00@ 0 = Sweden version, blue plate, light blue
for CA T version

® = Saudi-Arabia version

@ = USA version, black plate

07.3 . 0711 . 001 ·1

 The respective modal year is indicated after the
nationality symbol of the national version. if
necessary for distinguishing.

lf no additions exist in the case of the

designation of models or components. the
respective data then applies to all the models or
components listed in the particular case.

07.3. 07 11 . 00 112
 07.3-002 Model and Components Survey

Sales Designation Model Engine

560 SL 107.048 11 7.967

420 SEL 126.035 11 6.965

560 SEL 126.039 11 7.968

560 SEC 126.045

07.3. 071 1 . 002/1

 07.3-004 Vehicle Characterlstlcs

Model 107.048
126.0391045

Engine 116.965
117.967
117.968

Compression
ratio e
1
9.0 )

EZL control unít (N1i2) refer to ill.

EZL resístance trimming Reference resistor

plug (A 16) or resistance 750 Q
trimming connector
Resistance trimming plug two pin connector with jumper
CIS-E ínjection system incorporated in wiring harness
(R17) ( < 1 Q) 2)
3
EZUCIS-E coolant two single pín connections )
temperatura sensor
(811 /2)
-Fuel dístributor
Part No. 000 074 24 13
Air flow sensor
Part No. 116 074 0314
') Compress1on rat1o IS entered next to Eng1ne No. startJng Eng1ne End No. 037
919.
2) Starting 1988 integrated in CIS-E control un.t.
3) Californ1a starting 1988 four smgle pin connections.

N1/2

15-2037-13A

N1/2 EZL control unit

07.3.0711 . 004/1
07.3-005 lnfluenclng Parameters of Mechanlcai/Eiectronlc Mixture Adaptatlon

lgn.tJon staner switch

(52/1) term1na1 15
.--·-
.......
.-·.-.-
Power supply term1nal
87E
.....
-.- ..:.-.

--.
~~;;rohydr;;;--
actuator (Y1)
--1 System pressure
1
r+
_ , Vacuum pressure

•
Overvoltage protection
relay (K l / 1) 1-
Power supply
term1na1 30a
r+
_....,.
California Controls m1xture
adaptation of ..-
Coolant temperatura Temperature signal
sensor (811 12) ---+ r+
Start-up enrichment
Post-start enrichment
Warming-up
lgn,uon control unJt TD s~gnal CIS-E
(N1 /2)/(N1 /3) f-• (TN signa!) r+ control unJt
AcceleratJOn ennchment
Full load ennchment decel tuel cutoff
(N3)
Lambda control

Air flow sensor Air flow sensor plata

potent1ometer (82)
f--+ position r+

CHECK ENGINE
ldte position/
~ Decel fuel cutoff r+ . l ndicator lamp
(A1e26}
Thronle valve sw1tch
(529/2) 1- <§ Federal only
L.,J Full thronle pos1tion
~
Electron1c Road speed signa! . A ir mjection relay
(K17)
speedometer (A 1pS) f--+ r+

EGR temperatura Temperature s1gnal

.. Fuel pump relay
(N1614)

sensor (821) f--+ r+

(California only)
-----
Diagnost1c socket
(Xtt)
On/off ratio<@
Heated 0 2 sensor 0 2 sensor signa! Federal
(G3i 2)
f--+ r+ ----- -- - --------,
On-board diagnostic system 1
¡@ Californ1a only) 1
Alt1tude correct10n Alutude sensor signal
sensor (818) r-...... r+
Diagnosllc socket (X11)
1
1
r-+ On/off ra110 1
Starter lockout and Selector lever pos1tion
1
1
backup light switch
(516/1)
-Jo r+ CHECK ENGINE indicator lamp
(A1e26) 1
1

A/C compressor A/C compressor y Test connector (X92) ~:

control unJt (N6) f--+ s1gna1 r+ _ ___ ,., ________ .,..,.,_ J

07.3.0 711 . 00511

 07.3·009 lnfluenclng Parameters of ldle Speed Control

Overvoltage protection Power supply f---+ ldle speed air valve

relay (K1 , K1 / 1)
r---+ terminal 87E --. (Y6)

,
Coolant temperatura
sensor (811 , 2) ~ signa!
Temperature
.__. 1cootrols

lgnition control unit TD signal/

,
(N1 l2)>{N1 ,3) f.--+ TN signa! ~ 1;dte speed
1
ldle speed
Throttle valve switch control unit
ldle position (N8)
(82912)
r---+ ~

Electronic speedometer Road speed signa!

(A1p8) f.--+ f-+

Starter lockout and Selector lever

backup light switch f---+ position f-+
(S16r'1)

AiC compressor control AiC compressor

unit (N6) switch on signa!
r-+ f-+

07.3 .071 , . 00911

 07.3-013 Functlon Dlagram CIS-E lnjection System

Engines 116, 11 7 wlth Exhaust Gas Recirculation

and Alr lnjection

R17/ 1D -

M)12·1333t
N16/4

1 Fuel d istr ibutor A 1e 1O lndicator lamp. 02-sensor

40 Oiaphragm p ressure r egulato r A 1p 8 Electronic s pe~ometer
55 Fuel tilter B 2 Air flow sensor position indicator
57 Fu el accum ulator B 1 1/ 2 Coolant temperature sensor (2-pin)
74 Fuel cooler B 16 Altitude correction capsule
75 Fuel tank G 3/2 0 1·sensor, heated
76 Vent valve L 5 Position indicator (crankshaft)
77 Charcoal canister M 3 Fuel pump
78 Purge vatve N 1/2 lgnition control module ¡EZLI
79 Thermo valve 50"C N 3 CIS·E conl rol u nit
89 EGR valve N 8 Electronic idle spe-ed control unit
90 Vacuum ampliher N 16/4 Fuel p ump relay
92 tnjection valve R 17/ 1 Rererence input resistor, CIS-E
125 Air pu mp S 16/1 Starter rockouttback-up light switch
126 A ir injection shutoff valve S 2912 Throtlle valve switch. idle and full load conlacts
127 Che-ck valve (air injection) tgnit ion coil
128 Check valve (vacuum) y 1 Eleclrohydraulic acluator
157 Primary catafysf y 5/ 1 Electro-magnetic cl utch, AIC compressor
158 Underll oor calalySI y 6 ldle speed air valve
y 8 Cold start valve
y 32 Switchover valve, air injection
y 33 El&ctro.magnetic clutch. air p.ump

07 .3 .071 1 -0 1311
t M1xture control unlt AtetO 02·sensor indicator lamp
40 D1aphragm pressure controller A1p8 Electron1c speedometer
55 Fuel hlter 62 A1r flow sensor pos1t1on md1cator
57 Fuel reservo~r 6tt l 2 Coolant temperatura sensor (EZUCIS·E)
74 Fuel cooler 618 Altitude correcuon capsule
75 Fuel tank G3/ 2 Heated Orsensor
76 Vent valve L5 Crankshaft pos1l10n sensor
77 Charcoal can1ster M3 Fuel pump
78 Purge valve N 112 Electron•c •QMIOn control umt (EZL)
79 so •e thermovalve N3 CIS·E control umt
89 Exhaust gas rec~rculauon valve N8 ldle speed control uM
90 Control vafve N1614 Fue! pump relay w1th klckdown cut-out
92 ln¡ect,on valve Rt711 Reference res1stor (CIS-E)
125 A1r pump S2912 Fuflloadfldle speed detecbon !hrottle valve sw1tch
t26 A1r shulOI1 valve Tt fgmt100 COII
127 Check valve (1n1ected a~r) Yt Electrohydraulic actuator
157 Flfewafl catalyt1c converter Y5f1 A/C compressor electromagnetic couphng
158 Underlloor catalytic converter Y6 ldle speed air valve
Y8 Startlng valve
Y32 Air pump sw1tchover valve
Y33 Air pump electromagnet1c coupting

07.3 071 1 . 013/2

 07.3-1 05 Testlng on/off ratio

-.
~
. '

018
r 22
')~
-·
t

~ 014

- ... ~
~
012
011
¡ -·-- · . ·~

-~ ;] 026

(~~Q#=
-~·
& :.....:-..-.-.OJ; .
==:::7

P07-008S - 61

AíC or automatic climate control . . . . . . . . . . . . . switch off.

Selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . move into position "P" .

07.3.071 1 . 10511
Testers
Extraction device (O 14)
Accelerator control
Firing point . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil temperatura
ldle speed .. ...... . .......... . .
Lambda control
Test engine running
......... .. . ..... .
......... .. .. . . .. .
connect:
Telethermometer (018) 124 589 07 21 00,
Lambda control tes ter (0 12),
Twin outlet (031),
Engine tester (026),
Trigger clamp (011 ).
position at exhaust tail pipe.
check for condition and ease of movement.
test (refer to table).
approx. 80 oc.
test (refer to table).
test (refer to table).
&
Any re-adjustment which may be necessary
may only be performed when renewing a
component of the injection system or during
repairs to the engine.
Pay attention to note.
lnstall repair kit 102 070 01 74.
Switch on all ancillaries for this step.

ldle speed, lambda control

-
Engine Model Year Compression ratio e ldle speed Lambda control

rpm Control range mA

') z¡
650 -- 100
116.965 eff. 1986 9.0 700- 1000
50
117.967
117.968
1) 1986187
Test lambda control at 2500 rpm and take average reading. Detach purge line at etectnc switchover valve for th1S step and
seal. Compare th1s read1ng with 1dle speed level. The average at 1dle speed must be greater than 5, but not more than 15,
than the level measured at 2500 rpm .
2) Starting 1988
Test lambda control at 2500 rpm and take average reading. Detach purga fine at electnc sw1tch0ver valve tor th1S step and
seat Compare th•s read1ng with •die speed level. The average at 1dle speed must not vary by more than ± 1O from the tevel
me::~sured at 2500 rpm.
Note
Cahforn•a start•ng 1988 with "On Board D•agnosucs". "CHECK ENGINE" indicator tamp must not hght up.
Sw1tch over CIS·E control urut (N3) to on!off ratio output first of all.

07.3.0711 . 105;2
 . 1on tinna
Electron1c IQnlt . po nt
Engine Model Compression Electronic Engine Resistance Firing point
Year ratio E ignition control speed in rpm trimming in ocA BTDC
unit Part No. plug
optionally
wlo with
vacuum vacuum

116.965 eff. 1986 9 .0 003 545 91 32 3500 Reference 28-32 41 - 45

resis tor
003 545 92 32 ldle speed 3-7 10- 14
750 n
117.967 004 545 53 32 3500 24 - 28 40-44
117.968
004 545 55 32 ldle speed 3- 7 10 - 14

Special tools

Lambda
control
teste r

()()() 589 1411 00 909 589 00 21 00

Commercial testers
Engine tester (engine spee d, dwell angle. ignition angla ) e. g. Bosch, MOT 001.03
Sun, Hermann

Twín outlet e. g. Hermann , ECO 53

Shop-made tool

( J
¡(~-3--------1-20--------------]f+-~1

Slugging mandrel for steel tamper proof lock

07 3.0711 . 10513
Note
The adjusting device (2) for the luel/air mixture
setting is protected against unauthorized
adjustment with a steel tamper proof lock (1).

This tamper proof lock is knocked into place with

a special tool in the lactory alter the luel/air
mixture is set and must not be removed in the
service shops.

The luel/air mixture setting may only be adjusted

when renewing a componen! ol the injection
system (e. g. fuel distributor) or when performing
repairs to the engine. In this case, the adjusting
device (2) must be renewed. 1 Steel tamper proof lock
2 AdJuSting dev1ce
3 Hex head
4 MiX1ure adJUSllng screw

The lambda control must not be tested when the

engine 1s hot, e. g. immediately after driving
sharply or alter measuring engine output on the
dynamometer.

Switch off air conditioning system or

automatic climate control. Move selector lever
ínto posit1on "P".

2 Connect testers:
Telethermometer (018) 124 589 07 21 00
Lambda control tester (012)
Twin outlet (031)
Engine tester (026)
Trigger c lamp (011)

3 Position extraction device (014) at exhaust

tail pipe.

4 Check accelerator control tor condition and

ease ol movement.

5 Test firing point (reler to table).

6 Run engine until oil temperatura approx.

80 oc.
7 Test idle speed (refer to table).

07 3.0711 . 105/4
Note
lf idle speed varíes, test electronic idle speed
control (07.3·112).

8 Test lambda control (refer to table).

Oetach purge line (arrow) to throttle valve

assembly at purga valva (53) and seal.
Press 100 % IR button on lambda control testar

Note
The reading must fluctuate during the
measurement. lf a constan! reading is indicated,
there is a fault in the lambda control, e. g.
0 2 sensor faulty. Refer to "Testing electrical
components of CIS-E injection system" (07.3-
121 ) for troubleshooting table.

California only, starting 1988

Operate push button switch (2) on test
connector (X92) for between 2 and 4 seconds.
LEO (4) flashes once (no fault stored in system).

Press push button switch (2) a second time for

between 2 and 4 seconds. CIS-E control unit is
switched over to on/off ratio output. LEO shows
a steady light.

Note
"CHECK ENGINE" indicator lamp does not light
up.
 X92

----
i
// 1
'. / V

/ .• 1 /~
·~~J
<- t / P07- 0263·33

Modal 107

1B)~®5
X92
""
~ ®
6 7
S

if ,/
/'(<~~
- ,__....., ~ -"'- '

~ :--..., ·--:/~
/---~
/
* ,' -
"' / -- , ••
~ - ~-
...., 1 '

";>:;
'\
_,...,; /

' '" . ""--e?'~

'~-
1
:, ~ ·.~ :.\·.
. •
~.~~~/ ' :
.
\~,- ~
"< ~.; < / /~
....
. - --
- ·~· ·' .....
/
'~-. _:~· / ~._ '
,, ••...,_« ----- ~
~ J

.::;-/ P07·0Z62 •33

Modal 126

9 Set lambda controL

lf, after performing repairs lo the engine or
replacing a part of the CIS-E injection system, it
is necessary to set the on1off ratio, proceed as
follows:

Remove air filter.

Strike shear-off bolts (arrow) in the middle with a

chisel punch and drill a hole approx. 6 - 8 mm
deep with a 2.5 mm twist drill.

Lt.
Do not drill through bolts as the metal chips may
cause eng1ne damage. Thoroughly remove metal
chips with a cleaning rag.

Unscrew shear-off bolts with left hand twist dril!.

07 3 .07 ! 1 . 105i6
 • ••• •••• • •••••• • "' "•'••• • .. •• ........ , .... . ........... ,.,...._.,_...... uN. o.,..,..,.,., • .,..,•..,~~''·"·"'.v.' '"'•"''

lnstall new repair kit, Part No. 102 070 01 74 by

tightening bolts untif head shears off.

Fit on air filter.

Start engine.

Push the screwdriver ( 1) through the recess in

the top section of the air filter onto the adjusting
device (2).

Push the adjusting device down with the

screwdriver against the spring force, turn it
slightfy until the hex head (3) engages in the
mixture adjusting screw (61 }.

Turn to the left for a leaner mixture - onfoff ratio

increases
Turn to the right tor a richer mixture - oníoff ratio
drops

After each adjustment, depress acceferator pedal

briefly and test for variations between 2500 rpm
and idle speed; reset it necessary.

Switch off engine.

Remove air filter.

Knock in steef tamper proot loe k ( 1) with shop-

made slugging toof with the chamfered side so
that the surface of the tamper proof fock ís flush
with, or slightfy deeper than, the bottom edge ot
the taper of the adjusting device (2).

1 Steel tamper proof lock

2 Ad¡usllng dev1ce
3 Hex head
4 Mixture ad,us!lng screw

07.3 .0711 . 105i7

 Note
Starting January 1989 the steel tamper proof
A B
loe k ( 1) is designad as a steel ball (8).
Formerly, steel cylinder (A). 8\ (]
i
!
\ 1

Standard implementation: January 1989

Model Vehicle ldent End No.
107 A 097816
126 A458731

lnstall air filler.

Reconnect purge line.

1O Test engine running by moving selector lever

into Orive position, switching on air conditioningl
automatic climate control, turning power steering
to full lock. Engine must run smoothly. lf
necessary. test electronic idle speed control
(07.3-112).

07.3.0711 . 105/6
07.3-110 Testlng , adjustlng englne

~
]~,
L~

- - - - -- - - - - - -IP07 - 0086-61

07.3.0711 . 110/1
Test sheet . ... .. . ... ... .... .... ... .... complete.
A C or automatic climate control . . . . . . . . . . . . . switch off.
Selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . move into position "P".
Testers . ... .. ... ..... .. ... ..... .. .... connect:
Telethermometer (018) 124 589 07 21 00,
Lambda control tester (012),
Twin outlet (031 ),
Trigger clamp (011),
Exhaust sensor (005) 126 589 11 63 OO.
CO analyzer (006).
Engine tester with oscilloscope (030),
Multimeter (003),
Test cable (033) 102 589 04 63 OO.
Extraction device (014) ... . .. .. . . ...... . . . position at exhaust tail pipe.
Coolant level check, adjust to correct leve!.
Engine oil level check, pay attention to condition ot oil
(visual inspection).
Air filler ... ... .. .... .... .. . .. . ....... . remove, install.
Accelerator control linkage (7) .. .... ... . . .. . check throttle valve for ease of movement and
condition. Grease bearing points. relay levers,
ball sockets.
Variable-fulcrum lever .... .. .. . ... ....... . check, adjust.
ldle stop ...... ..... . . . .... . ..... .... . check.
Full throttle stop .. . .. .. . ............... . check, adjust from accelerator pedal.
Current at actuator test with ignition switched on.
lgnition timing .. ..... .. . ........ .... • ... test, adjust (refer to tabla).
Vacuum adjustment check (refer to table).
Oil level in automatic transmission . .. . ...... . check, adjust to correct leve!.
Engine oil temperatura approx. 80 oc.
Oscilloscope image .......... ... ........ . analyze.
lntake system . . .. . ..... ............... . test for leaks by spraying.
Operation ot electrical components . . . . . . . . . . . check.
EGR valve ...... . .. .. .. .. ..... ....... . check.
ldle speed check (refer to table).

07.3.071 1 . 11012
 ldle emissions level or lambda control .. .. . . . . . test. adjust (refer to table).
For resetting, use special tools,
screwdriver (022) 000 589 14 11 00,
extractor (028) 123 589 05 33 00,
fitting mandrel (029) 123 589 00 15 OO.
Engine running ... .. . .. .. .. .. . ... ..... . . check by switching on all ancillaries.

Test and Adjustment Data

Control ranga
Engine Model Year ldle speed in rpm Lambda Control
mA

116.965 1986 ~ 100 700 - 1000 mA 1) 2)

650.
- 50

1 17.967 1986 ~ 100 700 - 1000 mA 1) 2)

650.
- 50

117.968 1986 -· 650. - 100 700- 1000 mA 1) 2)

50

1) 1986187
Test lambda control at 2500 rpm and take average reading; detach purge line at electric switchover valve for this test
and seal. Compare th1s reading with idle speed leve!. The average at idle speed must be g.reater than 5, but not
more than 15, than the leve! measured at 2500 rpm.
2¡ stan ing 1988
Test lambda control at 2500 rpm and take average reading; detach purge line at electric swuchover vaJve tor this test
and seal. Compare this reading with idle speed leve!. The average at tdle speed must not vary by more than :!:: 10
from the read•ng measured at 2500 rpm.

lgnition tlming
Eng1ne Model Year Electrontc lgnttion Engine Reference resistor lgnttion timing in •cA
Control Untt speed in before TDC
Part No. rpm
w/o vacuum wtth
vacuum

116.965 1986·91 003 545 91 32 3500 750 Q 28-32 41 - 45

003 545 92 32 Idle 3-7 10- 14

•·

117.967 1986·91 004 545 53 32 24 - 28 40-44

3500 750 Q
117.968
004 545 55 32 Idle 3-7 10- 14

0730711 . 110/3
 Version Curren! at
actuator mA

75

Speclal tools

T//
0005891411 ()() 123 5890533 ()() 123 589 ()() 15 ()() 124 589 07 21 00 201 589 ()() 99 ()()

102 589 04 63 00 126 589 11 63 ()()

Commercial testers
CO analyzer
Engine tester (engine speed, dwell angle, ignition angle, e. g. Bosch, MOT 002.02
oscilloscope, voltmeter) Sun, 1019
Lambda control testar e. g. Hermann, L 115
Multimeter e. g. Sun, OMM-5
Twin outlet e. g. Hermann, ECO 53

07.3 .0711 . 11014

 Shop-made tool
lntake pipe DIN 19534 ND 125 for air flow sensor Length approx. 500 mm
se al e. g. from ai1r filter

Note
Test and adjust lambda control with a lambda
control tester.

The lambda control or the idle emissions level

must not be testad and set when the engine is
hot, e. g. immediately after driving sharply or
after measuring engine output on the
dynamometer.

Testing, adjusting

Complete test sheet .

2 Switch off air conditioning system or

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

3 Connect testers:
Telethermometer (018) 124 589 07 21 00
Lambda control tester (012)
Twin outlet (031)
Trigger clamp (011)
Exhaust probe (005) 126 589 11 63 00
CO analyzer (006)
Engine testar with oscilloscope (030)
Multimeter (003)
Test cable (033) 102 589 04 63 OO.

07.3 .0711 . 11015

4 Position extraction device (O 14) at exhaust
tail pipe.

5 Check coolant leve!, adjust to correct leve!.

6 Check engine oil leve!, paying attention to

condition of oil (visual inspection).

7 Remove air filler.

8 Check accelerator control linkage and

throttle valve for condition and ease of
movement. Grease all bearing points and ball
sockets.

9 Engines without ASR:

Check variable-fulcrum lever, adjust. Check
whether the roller ( 15) in the variable-fulcrum
lever ( 13) is resting free of tension against the
end stop. Adjust variable- fulcrum lever ( 13) with
the connecting rod ( 1), if necessary, so that the
roller ( 15) is resting free of tension against the
end stop.

Engines with ASR:

Switch on ignition.
Relay lever potentiometer (12) must be resting
against idle stop. Accelerator control lever ( 16)
must be resting on the outer curved track of the
variable-fulcrum lever (13). Adjust accelerator
control (30-300).

07.3.0 711 . 110:6

 1073-15 374

1o Idle stop.
Check whether the throttle valve is resting
against idle stop by detaching connecting rod
(arrow). Adjust accelerator control (30·300).

Engines with cruise control only, without ASR:

Check whether the actuator is resting against
idle stop of cruise control by pressing lever of
actuator clockwise onto idle stop at cruise
control. When attaching the connecting rod (21 ),
ensure that the levar of the actuator is raised by
approx. 1 mm off the idle stop at the cruise
control. Adjust tie rod, if necessary. Adjust
accelerator control (30·300).

07 .3 .07 11. 1 1017

11 Full throttle stop
Engines without ASR:
Check full throttle stop from accelerator pedal,
adjust (30· 300).

Engines w1th ASR:

Switch on ignition. Oetlect variable-fulcrum levar
(13) fully and hold in this position. Check at
throttle valve assy. whether throttle valve is
resting against full throttle stop without linkage
being over-tensioned. Adjust accelerator control
(30-305).

12 Test voltages (battery and ignition coil):

No-load voltage
Connect voltmeter, paying attention to polarity at
battery, and take voltage reading.
Specification: 12.2 Volts

lgnition coil
Engine not running, switch on ignition. Test
voltage of terminal 15 to ground at contact 5 of
diagnostic socket.
Spec1fication: battery voltage
Test voltage diHerence between terminal 15 and
terminal 1 at contacts 5 and 4 of diagnostic
socket.
Specification: O Volts
lf the specified voltages are not reached, test
ignition system ( 15-540 or 15-541).

07.3.0711 • 110/8
 13 Test current at actuator with ignition
switched on by detaching connector at
actuator and connecting test cable 102 589
004 63 00 into circuit. Connect multimeter and
set tomA.

Version Current at
actuator mA
75

lf the specified amperages are not reached,

perform test routine (07.3- 121).

14 Test ignition timing and vacuum adjustment

(retar to table). lf the specified levels are not
reached, test ignition system (15·540 or 15·541 ).

15 Check oil level in automatic transmission.

16 Aun engine until oil temperatura approx.

80 oc.
17 Analyze oscilloscope 1image (15-525).

18 Check intake system for signs of leaks.

Before spraying, fit shop-made intake pipe to air
flow sensor. Spray all sealing points with iso-
octane DIN 51 756 or cleaning petroleum. CO
increase < 2 % .

&
Do not use commercial fuel for spraying (harmful
vapors). Pay attention to risk of tire and do not
spray onto red hot parts or parts of the ignition
system.

07.3 .071 1 . 11019

 19 Operational check of electrical components.

To determine the CIS-E control unit, switch on

ignition and measure ontoH ratio.

On.off ratio Version

100% Control unit without fault diagnosis
by measuring oni off ratio 1 )
70% CIS-E control unit with fault
diagnosis by measuring on1
oH ratio 2 )
85% @ California eff. 1988 CIS-E
control unit with fault memory for
en-board diagnosis system
1 1 Certa•n cars only at start ot series production through to
produchon date 551 in GIS-E control umt.
2) Start•ng date ol production 552 the microprocessor tor
fault detect10n •S mtegrated •n the CIS·E control un.t.

Engines with fault diagnosis by measuring

on/off ratio
Operational check of idle and full load contact.

Specifications:
ldle contact:
Switch on ignition,
on oH ratio readout 70 %.
Detlect air flow sensor plate,
ontoH ratio readout 1O %, if readout 70 % test
throttle valve switch {07.3-121}.

Full load contact:

Switch on ignition,
on,off ratio readout 70 %.
Open throttle valve fully,
ontoff ratio readout 20 %, if readout 40 % test
air flow sensor potentiometer (07.3-121 ).

07.3 .0711.110110
 Englnes wlthout fault diagnosis by
measuring on/off ratio
Start engine when at normal operating
temperatura. Engine running at idle speed.
lf readout does not flucuate, perform test routine
(07.3-121 ).

20 Check operation of exhaust gas recirculation

valve. Detach vacuum line (arrow) at EGR valve
(60), connect tester to EGR valve and pressurize
with vacuum. lf engine running does not
significantly deteriorate. renew EGR valve.
Check control mechanism, if necessary
(14-475).

21 lnstall air filler.

22 Test idle speed (refer to table) .

Note
lf engine fitted with electronic idle speed control,
idle speed cannot be adjusted. lf idle speed
varies from specification, ~est electronic idle
speed control (07.3-112).

23 Test idle emissions level (refer to table) . This

is measured at exhaust tail pipe.
Set idle emissions level (r·efer to step 24).

0 7 .3 .0 il l o l tQ; l l
 24 Test lambda control (refer to table). Detach
purge line to throttle valve assy. at purge valve
(78) and seal. Press test s1gnal selector of
Hermann lambda control tester to position 100
....._
0
1> ~. or press 100 % IR button on Bosch
rester.

Ser lambda control (refer to step 24).

Note
The readout must fluctuate during the
measurement. lf a constant readout is indicated .
there is a fault in the lambda control, e. g. 02
sensor disconnected.

Refer to "Testing electrical components of CIS-E

in1ection system" {07. 3-121) for troubleshooting
table.

Test on off rat1o of 1988·91 cars

at 2500 rpm and take average reading. Compare
th1s reading with the 1dle speed level. The
average at idle speed must not vary by more
than ± 1O from the reading measured at
2500 rpm.

Test on/off ratio of 1986187 cars

at 2500 rpm and take average reading. Compare
this reading with the idle speed level. The
average at 1dle speed must be > 5, but not more
than 15, than the reading measured at 2500 rpm.

07 3 071 1 . 1 10/ 12
25 Set idle emissions level and lambda control
(refer to table).

Withdraw security plug (4) with the extractor.

Press the screwdriver (1) through the recess on

the top section of air filter onto the adjusting
device (2). Press the adjusting device down with
the screwdriver against to the spring force, turn
it slightly until the hex head (3) engages in the
mixture adjusting screw (61).

Turn to the left for leaner mixture - oníoff ratio

increases
Turn to the right for richer mixture - oni off ratio
drops

1 Screwdriver
2 Adjus!lng devoce
3 Hex head
4 Securoty plug
61 MiX1ure ad¡usting screw

After each adjustment, depress accelerator pedal

briefly; reset, if necessary.

After adjusting, inserta blue security plug (4),

Part No. 000 997 59 86, with the fitting mandrel.

Reconnect purge line (only if lambda control

fitted).

26 Test engine running by moving selector lever

into Orive position, switching on air conditioning
systemtautomatic climate control, and turning
power steering to full lock. Engine must run
smoothly.

Q7.30711 . 1 10/ 13
 -=====·
' "' " ' '' ' " ' ' " " "' " ' ' '
=
·····=
·····=
v•••~----- ' •·••·.. , .........
------:==
""''"=·' ""='' " "=''""'''" '"""""" , ..... ., ...~• ••·.VV.
""''" '""' ......,

07.3-112 Test1ng electronic idle sp eed control

P07 -0087 ... 5i

07.3.071 1 . 11 21
Testers ............................. . connect:
Telethermometer (018) 124 589 07 21 00,
Trigger clamp (011},
Engine tester (026),
Multimeter (003),
Test cable (034) 102 589 04 63 OO.
Extraction device (014) . ................. . posttion at exhaust tail pipe.
Engine oil temperatura approx. 80 oc.
Electrontc idle speed control .............. . test (refer to table).
Operation of idle speed air valva test by briefly applying battery voltage. Must be
heard to operate.
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . test according to wiring diagram.
Engine running . . . . . . . . . . . . . . . . . . . . . . . . . test by switching on all ancillaries.

073.0711·112/2
ldle speed, current at idle speed alr valve

Engine Model Year ldle speed w/o ldle speed wlth AIC compressor
Orive position in Orive position in on, wto Orive
rpm rpm position in rpm
Control range mA

116.965 1986/87 650 • 100 500:!: 50 650:!: so

- 50
1988-91 550:!: 50
700·1000 mA
117.967 1986/87 500 :!:50
1988-91 550 :!:50
117.968 1986/87 500 :!:50
1988-91 550 ±50

Special tools

102 589 04 63 00 124 589 07 21 00 201 589 00 99 00

Commercial testers
Multimeter e. g. Sun, DMM-5
Engine testar (engine speed, dwell angle, ignition angle) e. g. Bosch, MOT 001.03

07.3.0711 . 11213
 Note
Wiring diagrams 07.3-1 28.

ldle speed control is independent of air flow

sensor potentiometer. Engine oil temperatura
approx . 80 °C, selector lever in position "P" or
"N" , AC compressor switched off and no leaks
in intake system. ldle contact, coolant
temperatura sensor and exhaust gas
recirculation operating properly.

At high altitudes ( > 2000 m) current consumption

may drop below 700 mA as the actuator requires
to open a significantly greater cross section at
such altitudes to stabilize the engine.

Road speed signa!

The test should only be performed if the
following complaint is received: "Bucking when
car running with closed throttle valve" (07.3-121 ,
Section o).

Pin asslgnment of electronlc ldle speed

control (ELR) unit (N8)

Connector
1 Electron'c speedometer (A 1p8), road speed s1gnal
2 CIS·E m¡ectlon system control unit (N3), contact 9.
temperatura signal (TF)
3 A;C compressor con trol unit (N6), contact 4
4 Tt1rottle valve sw1tch. full load!ld le speed detect1on.
contact t
5 not ass1gned
6 ldle speed a1r valve ( Y6)
7 ldle speed a1r valve (Y6)
8 not ass,gned
9 OveNoltage pro tecuon relay (K 1. K 111), contact 2,
power supply termmal 15
10 Electromc 'gmt1on EZ L control unit (N1/2 , Nl/3), TP/TN
S1gna1
t1 Model 107: Eng1ne ground (W 11)
Model 126: Battery ground (W1 O)
12 S tarter lockout and backup light sw,tch (S 16! 1), gear
detect1on

0 7. 3 07 11 . t 124
 Symbols for testers: Symbols for quantities measured with multimeter:

E3 Battery Multimeter: Measuring range Volts direct voltage

r-::: o.•...-•
~..!-!...! Multimeter Multimeter: Measuring range Ohms
Contact box Multimeter: Measuring range Amperes

Test step; Test connection Operation Spec. Possible cause/Remedy

Test scope Requirement

1.0 N8 E3 N8 11-14 V Model 107: Ground (W11) loose

Ground points 11 -<-=&- + disconnected open circuit
Model 126: Ground (W1 O) loese,
open circuit

2.0 N8 N8 11- 14 V Fuse in overvoltage protection

Power supply of 11 -<~>-9 disconnected K1t 1 faulty or not inserted, wiring
N8 lgnitlon: ON to contact 1 (terminal 30)
interrupted. ')

3.0 Connect test cable Engine idling, 700- Open circuit to idle speed air
Test curren! at (034) to idle speed without Orive 1000 mA valve (Y6), idle speed control
idle speed air air valve (Y6) position unit (N8), test TDi TN signa!
valve {Y6) ~ (07.3-12 1), idle contact (test
step 4), TF signa! (test step 5)

3.1 .
Resistance at idle
Y6
, __ ~
_2
lgnltlon: OFF 3.5-5.5 Q ldle speed air valve (Y6)

speed air valva

(Y6)

3.2 Y6 N8 lgnition: OFF <1Q Open circuit

Wiring 1-(~)-6 N8
disconnected

3.3 Y6 N8 lgnitlon: OFF <1Q Open circuit

Wiring 2 --< -=-@!- >- 6 N8
disconnected

1) MOdel 107; Control to overvoltage protecuon (K 1¡ contact 6 (termmal 15) 1nterrupted, w1nng from overvoltage protect1on (K 1¡
contacr 2 (terminal87) ro terminal btock (X51/1) tnterrupted, wtnng from term•nal block (X5 1i 1) to tdle speed
control un1t (N8) 1nterrupted.
Model 126: Control to overvoltage protection (K1 /1 ) contact 3 (terminal15) mterrupted, w1nng from overvoltage protection
(K 111) contact 2 (terminal 87E) to ;die speed control unlt (N8) contact 9 1nterrupted.

07.3.07 11 . 112/5
Test stept Test connection Operation Spec. Possible causeJReme<ly
Test scope Requirement

4.0 N8 lgnition: OFF <10 -

l<lle contact 11 -(~ )- 4 N8
disconnected
Connector at
CIS-E control
unit (N3) and
connector at
electronic
ignition control
unit coda No.
{1 - 4)
detached .

Depress 00 Pins of connector (S29f2x)

accelerator wrongly assigned, idle contact,
pedal wiring

4.1 N8 S2912X <10 Open circuit

Wiring 4 -< ....:@!- >- 1

4.2 W11 S2912x <10 Open circuit

Wiring ..L ....:@!- >- 2

5.0 N16/4 N1 6í4

TF signal disconnected
7 -<->- 8

N1614 Engine id ling 3.5-5.0 V CIS-E control unit (N3), idle

11 -<-=@!- >-- 2 speed control unit (N8),
wiring

5.1 ~ NS NS <10 Open circuit

Wiring 9 -=@!- )- 2 disconnected

5.2 N16/4 NS NS and N16/4 <1o Open circuit

Wiring 2 -< ....::@!- )- 2 disconnected

97.3 .0711 . 112/6

Test step/ Test connection Operation Spec. Possible causetRemedy
Test scope Requirement

6.0 ~ Engine idling, 11-14 V Starter lockout and backup light

Selector rever 1 ~ 16 selector rever switch (516/ 1), refer to Job No.
position position "P" 27 - 130. Contacts (X26).
(X49/2), wiring

6.1 N8 ¡,,,,,,¡ lgnitlon: OFF <1Q Open circuit

Wiring 2-(~
--
16 N8
disconnected

6.2 N8 X26 lgnitlon: OFF <1Q Open circuit

Wiring 12-<~-- 10 N8
disconnected
X26 separated

6.3 S2/ 1 X26 X26 separated <1Q Open circuit

Wiring Kl.50~>-10

6.4 S2i 1 X49;2 X49t2 < 1Q Open circuit

Wiring Kl. 50 -=-@>!- >- 5 separated

6.5 1611 X49:2 X49,2 <1Q Open circuit

Wiring 8 -< .....::@!- )- 5 separated
Connector at
(S16/ 1)
detached

7.0 N8 N8 11- 14 V AiC compressor control unit (N6)

AiC compressor 11 -(~)-3 disconnected wiring
control unit lgnltlon: ON
A/C
compressor
switched on

7.1 N6 N8 lgnitlon: OFF <1Q Open circuit

Wiring 4 -< .....::@!- )- 3 (N6), (N8)
disconnected

07.30711. 112!7
Note
Olstributor line for idle alr

Modified shape of distributor line with additional

longitudinal rib on inside (arrow) for distributing
idle air.

A 1st vers1on
B 2nd vers10n

Hose connections on left and right lengthened ,.... 1"'"-

Size C 53 mm (previously 42 mm).
· -· - r- 1-
._ ¡,....

e
Series implementation: August 1986 1074 -14 459

Model Engine Engine End No.

107.048 117.967 0 12830

126.03 116.965 025114
126.039/045 117.968 016902

07.3 .071 1 . 11 28
 07.3-120 Testing fuel pressures and internar leakage

$044~ ª

P0?-0 090-35

All fuel connections . . . . . . . . . . . . . . . . . . . . . . check for leaks.

Ease of movement of air flow sensor plata and
control plunger . . . . . . ... . .. .... .. . ... .. . check.
Pressure measuring device (043) connect.
Special tool 103 589 00 21 OO.
Double union (044) connect.
Special tool 1 02 589 06 63 OO.
System pressure test.
Lower chamber pressure . . . . . . . . . . . . . . . . . . test.
Acceleration enrichment ........... .... . .. test.
Fuel distributor and fuel pump ....... .. ... .. test tor leaks.

07.3 .071 1 . 12011

Fuel pressures in bar gauge pressure
System pressure when idling, engine 6 .2 - 6.4
cold or at normal operating temperatura
engine at normal
1
operating temperatura approx. 0.4 )

Lower chamber pressure

coolant temperatura
+ 20 oc approx. 0.5 1
)

during deceleration 6.2 - 6.4

1) Below system pressure measured previously.

Speclal tools

l 103 589 00 2 1 00 124 589 09 63 00 102 589 06 63 00 201 589 00 99 00 000 589 40 37 00

Commercial tester
Multimeter e. g. Sun, DMM-5

Note
The interna! leakage test should only be
performed if a complaint is received regarding
starting engine when !hot.

After switching off the engine, the fuel pressure

must still be 3.0 bar gauge pressure after
30 minutes.

Visual lnspectlon

Remove air filter.

2 Check all fuel connections for signs of leaks.

07.3.0711. 120i2
3 Check ease of movement of adjusting lever
(1) with air flow sensor plata (4) in air flow
sensor and of control plunger (2) in fuel
distributor.

When performing this step, datach fuel pump

ralay (N 16/4) of Model 126 in left side of
componen! compartment and briefly jumper tha
two contacts 7 and 8 to build up pressure.

Model126

On Modal 107, detach tail lamp wiring harness

connector (X18) in laft footwell below floor panel.
Briafly connect terminal 2 to terminal 30 {cable
connector next to overvoltage protection) to build
up pressure.

Modal 107

Prass air flow sensor plate {4) down by hand. An

even resistance must be felt ovar the entire
travel. No resistance should be felt when making
a rapid upward movement as the dampened
control plunger loses contact with the adjusting
lever ( 1). When performing a slow upward
movement, the control plunger (2) must follow
and maintain contact.

07.3.071 1 . 12013
4 Check control plunger in fuel distributor for
signs of leaks.

Press air flow sensor plata down fully for a short

time and hold in this position. A slight leak
quantity is permissible (illuminate, if necessary ,
with endoscope lamp).

Connect pressure measuring device.

Connect1on A Hose line to fuel d1stnbutor · lower

chamber
Connecllon B = Hose line to fuet d1Stributor - top chamber
at starting valve

Unscrew plug (arrow) on bottom chambe

fuel distributor.

&
When slackening plug, ensure that the open-1
wrench does not press against the air flow
sensor potentiometer, otherwise the
potentiometer can be damaged.

2 Connect hose line from connection "A" to

bottom chamber.

Use double union M8 x 1:M12 x 1.5.

Special tool 102 589 06 63 00 to perform this
step.

07.3 .071 1 . 120i4

3 Unscrew fuel line for starting valve at fuel
distributoro

4 Connect hose line from connection "B" to

fuel distributor o

5 Settlng of valve screws:

a) System pressure

Pressure measuring device =open valve screwo

b) Lower chamber pressure

Pressure measuring device =close valve screw o

Testlng

The system and lower chamber pressure must

be testad when the engine is runningo

Place pressure measuring device on cylinder

head covero

07 03 .0711 o 120/5
a) System pressure when engine cold or at
normal operating temperature

Engine idling.

2 Take reading of system pressure.

Specification: 6.2 - 6.4 bar gauge pressure

3 lf specified pressure is not reached or is

exceeded:

Test fuel pump (07.3- 130).

Renew diaphragm pressure regulator.

Check passage of fuel return line.

b) Lower chamber pressure when englne at

normal operating temperature

4 Take reading of lower chamber pressure.

Specified pressure at normal operating

temperatura approx. 0.4 bar below system
pressure.

lf specified pressures are not reached:

Test electrohydraulic actuator (07.3-121 ).

e) Acceleration enrichment

"Engine cold" must be simulated for testing

acceleration enrichment.

5 Valve screw closed.

6 Simulate " Engine cold" by connecting

Q decade 2.5 kQ, corresponding to approx.
+ 20 oc. between coolant temperatura
sensor connecting cable and chassis ground.

07.3.0 7 11 . 120/6
7 Start engine. Specified pressure at + 20 •e
approx. 0.5 bar below system pressure
measured previously. Sharply increase engine
speed to approx. 2500 rpm. When engine speed
is increased, lower chamber pressure must drop.

lf specification is not reached:

Test air flow sensor potentiometer (07.3-121 ).

Test current at actuator (07.3-121).

Testlng fuel system for leaks

Switch off engine. Pressure in system drops

betow the opening pressure of the injection
valves (approx. 3.4 bar gauge pressure).

2 lf pressure drops immediately to O bar gauge

pressure, renew check valve at fuel pump.

3 lf pressure drops slowly, unscrew fu el return

line (51) at diaphragm pressure regulator. No
fuel should flow on out of the diaphragm
pressure regulator (slight leak quantity is
permissible).

Lt.
lf fuel flows out of fuel return line (51), lit plug to
line.

4 Pinch leak line at fuel reservoir with clamp. lf

the pressure does not drop, renew fuel reservoir
(07.3-270).

07.3.0711 . 12017
 5 lf no leak is detected after performing
interna! leakage test. check starting valve for
leaks. This is done by removing starting valve.
Renew fuel distributor (07.3-205).

6 Oisconnect pressure measuring device.

Collect fuel with a rag.

7 Connect fuel lines. run engine once again

and check all fuel connections for signs of leaks.

8 lnstall air filter.

0 7 3 .0 7 11 . 120:8
07.3-121 Testing electrical components of CIS-E injectlon system

A. @ verslons

a) Arrangement of components
b) Without fault diagnosis by measuring oníoff ratio
e) With fault diagnosis by measuring on/off ratio
d) On-board diagnosis system California (function and test)
e) Troubleshooting table
f) Electrical test data of CIS-E injection system
g) Special tools, commercial testers
h) Connecting testers according to connection diagram
i) Pin assignment of CIS-E control unit connector (N3)
j) Test routine with contact box
1) Table of voltage levels of EZUCIS-E coolant temperatura sensor (811 12)
m) Testing 4-pole coolant temperatura sensor (811 /2)
n) Testing connector of 4-pole coolant temperatura sensor (811/2)
o) Altitude sensor table (8 18)
p) Testing decel fuel cutoff
q) Testíng road speed signal

07 3 .0711 . 121 /1
a) Arrangement of components
Model107

A 1e26 "CHECK ENGINE" warning lamp NS ldle speed control un1t

92 Air flow sensor pos1110n 1ndicator N 16/4 Fuel pump relay w1th kiCkdown cut·out
9 1112 Coolant temperature sensor (EZUCIS·E)(2·pole) S29/2x1 Connector. throttle valve sw1tch, lull load/idle
918 Altitude correct1on capsule X11 D iagnostic sockeVterminal block (C~<Cull TD)
0312 Heated 02- sensor X92 Test connection tor diagnos1s (impulse readout,
G3/ 2x1 Connector. Oz-sensor heater co11 (2-pole) 8-pole) (·--X11 /4···)
G3/ 2x2 C onnector. Oz-sensor s1gnal (1-pole) Y1 Electrohydraulic actuator (EHA )
K1 Overvoltage protection relay (5·pole) Y6 ldle speed air valve
N3 CIS·E control unit

0 7. 3 .07 1 1. 12 1i2
 Model 126

Q '1
1

K111

p@)_
A1e
0
t\lV
,,
"'

(~ ~
\~
X11
~
L------------------------------------------------------~-------..l

A1e26 "CHECK ENGINE" warnong lamp NS ldle speed control unit

82 Aor flow sensor posotoon ondicator N16/4 Fuel pump relay with kockelown cut·out
811 /2 Coolant temperature sensor (EZUCIS -E)(2 -pole) S29/2x1 Connector, throttle valve swttch, full load/odie
818 Altitude correctoon capsule X11 Diagnostoc sockeVtermonal block (corcu ot TD)
821 EGR temperature sensor X92 Test connectoon tor diagnosos (ompulse readout,
G312 Heated 02-sensor 8 -pole) (·--Xt1 /4·· ·)
G312x1 Connector, Orsensor heater cool (2-pole) Y1 Electrohydrauhc actlJator (EHA)
G3/2x2 Connector, 02-sensor sognaJ {1 -pote) Y6 ldle speed aor valve
K1/1 Overvollage protectoon relay, 87E (7·pole)
N3 CIS·E control unot

07.3.07 11 . 121/3
b) Wltho ut fault diagnosis by measurlng
onlotf ratio

Up to 12.·85 (production date 552) no fault

detection integrated in CIS-E control unit.

On these cars. it is not possible to enter the test

routine through measuring the on, off ratio.

In this case. perform the same test routine.

without % readout. Section " i". test routine with
contact box.

0 12
e) With fault diagnosis by measuring on/off
ratio ([ ,\', \ 1Í ; ~ i'¡;''·1BOSCH
.... .... ---
1
~'.~
Effect1ve 12185. faulty input signais are detected
.
..:.
/

- --...
oc e®
:.~~ :-1100
~ ]
by the CIS-E control unit (N3) and passed to the 1=
lambda test output. The faults detectad can be
output with the lambda control tester (012) at
diagnostic socket (X11 ).

~
N3
j '"
1 1
"07-0096 .. u

The fault detection facility enables various

components of the CIS-E injection system to be
tested by measuring the on!off ratio.

Detection of control units:

Connect lambda control tester.
Switch on ignition.

On:ofl ratio readout Control unit

70% with fault detection

100% without fault detection
85% California

Wiring diagrams 07.3-128.

0 7.3 .0 7 11 . 12 1/4
 d) On-board diagnosis system California Fault detectlon table
No. of Fault path
All exhaust emission-relevant components of the
flashing
CIS-E injection system and of the exhaust gas
pulses
recirculation system are monitored by the CIS-E
control unit. Malfunctions resulting from open No fault in system
circuits or failure of one of these components 2 Throttle valve switch, full throttle
are indicated by the " CHECK ENGINE" indicator contact
lamp in the instrument cluster and at the same 3 Coolant temperature sensor
time stored in the CIS -E control unit.
4 Air flow sensor potentiometer
Note 5 02 sensor
Pushbutton switch and LEO have been Not assigned
6
developed to enable customer and independent
repair facilities to specifically pinpoint the tault 7 TO signal
path in conformity with the legislation relating to 8 Altitude correction sensor
"On-board means" . A pulse counter has been
9 Electrohydraulic actuator
developed for MB wortkshop personnel which
presents a readout of the stored fault(s) on a 10 Throttle valve switch, idle contact
digital display. ,1 Not assigned
12 Exhaust gas recirculation
The control unit is switched over to onioff ratio
output for testing the lambda control by pressing
the pushbutton switch (refer to Testing lambda
control (07.3-105)).

The onloH ratio is output only alter the CIS-E

control unit has been programmed to on/off ratio
output. Otherwise the readout shows O % or
85 % , respectively, when the "CHECK ENGINE"
indicator lamp lights up, with the engine running.

A test connector (X92) with pushbutton switch

(2) and LEO (4) is provided on the component
compartment partition wall of Model 126 and oh
the lett wheel house (ill.) of Model 107. When
the pushbutton switch is operated (ignition: ON)
for between 2 and 4 seconds, the flashing pulse
output is initiated and the fault path indicated by
the number of flashes.

07.3.07 1 1 . 121/5
 Model107

Model 126

Testing on-board diagnosis with pulse

counter

Complaint:
"CHECK ENGINE" indicator lamp in instrument
cluster lights up.

Test conditions:
Battery, overvoltage protection relay and control
unit must not be disconnected prior to and
during the test otherwise the stored fault is
erased.
Battery voltage 11 - 14 Volts.

07.3.07 11 . 121 i 6
 Notes regardlng pulse readout
The digit 1 indicates that no fault is stored in the
system. All other digits are assigned to a
particular fault. lf several faults exist in the
system, the fault with the lowest pulse number is
output first.

The digits from 1 - 12 appear on the pulse

counter display.

• lf the LEO U Batt lights up after connecting

the counter, pulse counter and power supply
for pulse counter are in proper order.
• lf no further display appears during the test
after one or severa! pulse readouts (digits),
there is no further fault stored in the system.

Testlng

• Connect pulse counter according to

connection diagram.
• Sw1tch on ignition.

Note
LEO U Batt in display panel must light up; if not:

Multimeter set to Volts:

a) Test contact 1 on test connector X92 to
battery positiva (11 - 14 V).
b) Test contact 3 on test connector X92 to
contact 1 (0. 7 - 2.5 V).

07.3.0711 . 121n
001 CIS·E control unit
connector
002 Test cable
003 Multlmeter
004 Contact t:Jox
N3 CtS·E control unit P0 7- 00$3- 3S

Pulse readout

• Press start button for between 2 and 4

seconds.
• Take readout of number of pulses and note.
• Press start button once again for between 2
and 4 seconds. note any further faults. lf no
further fault is stored in the system , no
display appears after this.
• Rectify noted faults (pulse readout)
according to troubleshooting tabla by
connecting contact box according to
connection diagram.

Alter completion of flashing pulse readout, the

LEO shows a steady light. 11 the pushbutton
switch is again pressed for between 2 and 4
seconds. any further fault path stored can be
indicated. lf no further fault is detected, the
CIS-E control unit switches over to oníoff ratio
output.

07.3.07 11. 12118

 Erasing fault memory
Once a fault has been rectified without the CIS-E
control unit having been disconnected, the pulse
indicated must be erased as follows:

• After the pulse readout has been indicated

for a waiting period of 2 seconds. press start
button for 6 - 8 seconds.

Note
Each pulse indicated must be erased separately.

• No readout indicates that stored fault has

been erased.
• lf a digit ( > 1) is indicated, there are further
faults in the system.

Speclal tools

~= 1
í~~
~ · ·.
~
.' . ..--.
! ......." ,.,.,.

124 589 19 21 00 124 589 ()() 21 ()() 124 589 33 63 00 201 589 00 99 ()()

Commerclal tester
Multimeter e. g. Sun, DMM-5

0730711 . 121/9
Model 107

013
T p u1se counter
1 lgMIOn COII
X92 D •agnost1c
8·pin (11 test connector
ashtng cede) ·

Model 126

013
G 1 p u1se counter
Battery
X92 o·•agnostic test con
8·ptn (flashing code)nector.

07.3.0711 . 12 1/ 10
 Troubleshootlng table .. On-board diagnosis"
Test connection : Operation/Requirement Specification Possible causetRemedy

~ Contact box
~ M u I'ttmeter

Pulse readout 1

1No fault ;n system

¡- ¡-
Pulse readout 2
Full throttle contact lgnltlon: OFF 00

~ Connector at CIS-E control

2 -=@!- 5 unit and connector at
electronic ignition control unit
(code number 1 - 4)
disconnected

<11l Full throttle contact,

Accelerator at full throttle wiring

00
S29/2x
Detach connector S29/2x
2_ ~ _3
<11l Set or renew throttle
Accelerator at full throttle valve switch

<1 Q Open circuit

Wiring
Detach connector S29/2x
0 S29/2x
5 ..=@!- )-3

W11 S29/2x
<1 Q Open circuit
..L -=@!- )-2

Pulse readout 3
Coolant temperatura
sensor
~ lgnltlon: OFF
..,..
refer to table Coolant temperatura
sensor, wiring
7 ~ 21 Connector at CIS-E control
unit disconnected

811 /2 Detach connector at refer to tabla Renew coolant

.::@-!- temperatura sensor "1" temperatura sensor
refer to Section " m"

Connector at electronic <1Q Open circuit

Wiring
ignition control unit (code
0 811 /2
numbers 1 - 4) disconnected
21 ~ >-
<11l Open circuit
1:221 81112
7 ~ >-

07.3.0711 - 121 111

 Test connection: OperationíRequirement Specification Possible cause/Remedy

lmJGJ Contact box

l:":'::i';' l Multimeter

Pulse readout 4
Air flow sensor Engine idling at normal 4.5- 5.5 V Air flow sensor
potentlometer operating temperatura, CIS-E potentiometer. altitude
control unit connected correction sensor (refer
~ to pulse readout 8)
7 ~ 18 CIS-E control unit

lB 0.5 - 1.5 V Air flow sensor

7 ~ 17 potentiometer, CIS-E
control unit
82
lgnitlon: OFF 3.6-4.4 kQ
1- ..:@!- 3
Oetach connector at 82
82 Renew air flow sensor
Deflect air flow sensor plate Q level rises
1_ ...::@!- _2 continuously
slowly by hand
up to half of
deflection and
then drops off
again

Wiring <1 Q Open circuit

Measure at connector 82
~ 82
7 ..:@!- )- 1

SIT2I 82 <1 Q Open circuit

18 ~ )-3

0 82 <1Q Open circuit

17 ...::@!- )-2

Pulse readout 5
02 sensor
¡!m!"'" ! Engine idling at normal fluctuates 0 2 sensor, wiring
7 -=<Xr 8 operating temperature, CIS-E between
control unit connected 0.1 - 0.9 V

~ G3í2x2 Engine idling, separate 450 mV Renew 02 sensor

connector G3/2x2 and lay
7 ~ )-
connector to ground

Wiring
]]2D lgnition: OFF 00 Wiring faulty
Detach connector at CIS-E
7 -=&- 8
control unit

<1 Q Open circuit

~ G3/2x2
8 -=&-
-
07.3.0711 . 121 /12
 Test connection: OperationtRequirement Specification Possible cause/Remedy

~ Contact box
~ MI .
u trneter

Pulse readout 6
not assigned 1- 1- 1-
Pulse readout 7
TO signal

6 Engine idling at normal 6- 11 V lgnition control unit,

wiring
2 ~ 25 operating temperatura, GIS-E
control unit connected

Wiring
Open circuit
~ N8 lgnitlon: OFF <1Q
25 ~ >- 10 Disconnect idle speed control
unit N8

Pulse readout 8
Altltude correctlon sensor

lgnltlon: ON 4.6 - 5.5 V Altitude correction

7 18 CIS-E control unit connected sensor, air flow sensor
potentiometer. refer to
pulse readout 4, wiring
of CIS-E control unit

Altitude correction
~ refer to tabla
o··
-=@!- 11
u sensor. wiring
7

Wiring lgnitlon: OFF

<1 Q Open circuit
~ 818 Detach connector at 818
7 -=@!- )-3
<1 Q Open circuit
[lli2J 818
18 ~ )- 2
<1 Q Open circuit
~ 818
11 ~ )- 1

0 7.3.07 11 . 121 /13

 Test connection: Operation/Requirement Specification Possible cause1Remedy

1;¡¡¡¡;;;;; 1 Contact box

~ Multimeter

Pulse readout 9
Electrohydraulic actuator lgnition: OFF

1o
!mg:::::J
-=@!-
Connector at CIS-E control
12 unit detached
19.5 ± 1 º Electrohydraulic
actuator, wiring

Y1
1 _

Wiring
~
~
-- 2 Detach connector Y1 19.5 ± 1 Q Renew electrohydraulic
ac tuator

!22] Y1
<1 Q Open circuit
10 -=@!- )-2

Y1
<1Q Open circuit
)- 1

Pulse readout 1O
ldle contact
~ lgnltion: OFF <1Q
2 -=@!- 13 Connector at CIS-E c ontrol
unít and idle speed control
unit N8 disconnected

Depress accelerator
ldle contact, wiring

Detach connector S29/2x

S29t2x <1 Q
1_ -=@!- __ 2
Depress accelerator
00 Set or renew throttle
vaive switch

Wiring
<1Q
~ N8 Open circuit
13 --=@!- )- 4
<1Q Open circuit
N8 S29/2x
4 -( -=@!- )- 1
<1Q Open circuit
S29/2x W11
2-< -=@!- ...L

07.3.0 71 1 . 121 /14

Test connection: Operation/Requirement Specification Possible cause/Remedy

[TI¡¡:;;;;1 Contact box

~ Multimeter

Pulse readout 11
not assigned 1- ]~
Pulse readout 12
Exhaust gas reclrculatlon
temperatura sensor
[221 Run engine at normal <4.7 V Exhaust gas recirculation
~~- 19 operating temperatura for temperatura sensor,
7 ~
approx 1 min at 4000 rpm EGR valve, wiring

EGR valve retar to testing EGR

Wiring Open circuit

~ X80t3 XS0/3 separated <1Q
19 -=@!-

xao12 X80/2 separated <10 Open circuit, wiring in

order, renew EGR
temperatura sensor.

e) Troubleshooting table

Note
This test should be performed if a complaint is
received regarding engine running, e. g. rough
idle. Display fluctuates, no fault in system.

Test condition:
Battery voltage 11 - 14 V

Engine should be idling and engine oil

temperatura approx. 80 oC for measuring on/off
ratio.

07.3.0711 . 121 /1 5
 Onlotf Possible causes Scope of test Test step
ratio
in%
o No voltage or ground at diagnostic socket. Test power supply, ground and 4.0 - 4.3
Open in wiring of diagnostic socket contact diagnostic socket wiring. Test
3. Lambda testar faulty. lambda setting.
Mixture set too rich.

10 Air flow sensor potentiometer wrongly Test signal from air flow sensor 5.0 - 5. 1
connected or faulty. Possibly, fast idling potentiometer and wiring
speed. routing.

20 Full load contact wrongly connected or Test full load contact. 6.0 - 6.2
faulty. 20 % readout only if microswitch
operated.

30 Short-c irc:uit or open circuit between Test coolant temperatura 7.0- 7.4
CIS-E control unit and coolant temperatura sensor. Test wiring.
sensor or coolant temperatura sensor faulty.

40 Open circuit or short-circuit to air flow Test air flow sensor 8.0 - 8.5
sensor potentiometer or faulty. Possibly, potentiometer. Test wiring .
fast idling speed. CIS-E control unit.

50 Oz sensor not operating or faulty. Engine oil temperatura approx.

Open circuit. 80 oc.Test 0 2 sensor. Test
wiring.
9.0 - 9.3
60 not assigned - -

07.3 .0 7 11 . 121116
OnloH Possible causes Scope of test Test step
ratio
in%
70 No TD signal (open circuit) at CIS·E control Test TD signal. 10.0- 10.2
unit.

80 Open circuit or short to ground. Altitude Test altitude correction sensor 11.0- 11.3
correction sensor faulty. and wiring.

90 not assigned
...
- -
100 Lambda setting too lean. 0 2 sensor faulty Test overvoltage protection. 12.0
(short to ground). No voltage or ground at Test ground.
CIS-E control unit or CIS-E control unit Test setting of lambda control
faulty. Lambda tes ter faulty. and 0 2 sensor signal. CIS·E
control unit faulty.

f) Electrical test data CIS-E injectlon system (current at actuator mA)

Model Vears 1986- 1989
lgnttion: ON Coolant temperatura sensor Post-st art Acceleration Full load Part toad Decel fuel
ennchment enrichment at enrichment m1xture cutoff
Coolant temperatura eoolant tem -
Post-start at + 20 • e and at approx. adaptat10n
+ 20 •e (warm -up perature + 80 • e
+ 20 oc bhpp1ng 5000 rpm
base level) ReSlst· Res1stance
throttle
ance 2.3 - 2.8 kQ 290-370 Q

75 o 0±3 5-9 >20 4-6 Reading approx.

fluctu· -60
ates

07.3.0711 . 121/17
g) Speclal tools

Lambda
control
tester

102 589 04 63 00 124 589 00 21 00 124 se9 33 63 oo 201 589 ()() 99 00

909 589 00 21 00

124 589 07 21 00

Commerclal testers
Multimeter e. g. Sun, DMM-5
Twin outlet e. g. Hermann, ECO 53
Lambda control testar e. g. Bosch
KDJE-P600, 1)
Hermann, L 115
Engine testar e. g. Bosch, MOT 002.02
1) Speclallool 909 589 00 21 OO.

07.3.0711 . 121/18
 h) Connecting testers according to connection diagram

- - ..~:~::-.~:: 012

P07-ooea - ss.a

001 CIS·E control unlt connector 012 Lambda control tester

002 Test cable 033 Test cable 102 589 04 63 00
003 Multímeter N3 CIS·E control un1t
004 Contact box X11 Diagnosttc sockeVtermtnal block (ctrcvit TD)

07.3.0711 . 121/ 19
 1) Pin assignment of CIS-E control unit connector (N3)

,_,_,_,_,_,_,_,_,_,_,_,_,_,
2 3 4 5 6 7 8 9 10 11 12 13

,_,_,_,_, _,_ ,_ ,_ ,_,_,_,_,

14 15 16 17 18 19 20 21 22 23 24 25

1074-16264

Overvoltage protection relay (K 1, K 1/ 1), 15 CHECK ENGINE indicator lamp (A 1e26)

contact 2. term •nal 87E (Californ1a only)
2 Eng1ne ground (W11 ) 16 ldle speed control unit (N8), contact 12. gear
3 not assigned detect•on
4 Tnp computer plug connec tion (X61) 17 Alf flow sensor poten!lometer (82), contact 2
S Throttle valve sw1tch (S29/2), contact 3, full 18 Alf flow sensor potent•ometer (82), contact 3,
load!ldle speed detect•on alt•tude sensor {8 18), contact 3
6 not assigned 19 Exhaust gas rec~rculat10n (EGRJ temperatura
7 Ground from connector 7 is connected •nternally
to ground ol connector 2 sensor (8 21),
8 Heated 0 2 sensor (G3t2) 20 Model 126: battery ground (W1 O)
9 ldle speed control unll (N8). contact 2. Model 107: ma1n ground, right tootwell (W1 )
temperatura s•ignal (TF) 21 Coolant temperatura sensor (811 /2)
10 ElectrohydrauiiC actuator {Y1 ), contact 2 22 not ass1gned
11 A lti tude sensor (818). contact 1 23 Diagnostic socket (X 11 ), contact 3, ontoff rat10;
12 Electrohydrauhc actuator (Y 1), contact 1 CHECK ENGINE indicator lamp (A 1e26)
13 ldle speed control unit (N8), contact 4 . idle speed (California on ly)
detection 24 ldle speed control unit (N8), contact 1. road
14 A~r 1n1echon relay (K 17). contact S. 81f pump speed signal
control 25 ldle speed control unit (N8), contact 10.
TD/TN s•gnaJ

07.3 .0711 . 121120

 j) Test routlne wlth contact box

Symbols tor testers: Symbols tor quantities measured with multimeter:

~ Contact box ~ Multimeter: Range Volts OC

~ Lambda tester ....::@!- Multimeter: Range Ohms
B Battery ~ Multimeter: Range Amperes
1 --;:>] Multimeter
--< Contact

- Connector

Note
lf the on/off ratio readout is constant, first
perform test steps 1 - 3. lf the specified value of
a test step, e. g. step 4, is correct, is not then
necessary to perform the sub test step 4. 1.
Overvoltage protection relay in Model 107 with
designation .. K 1".

Onlotf Test step! Tester/ Operation/ Spec. Possible cause/Remedy

ratio Test scope Test connection Requirement
readout

- 1.0 ~ E3 lgnitlon: ON 11 - 14 V Ground terminal W11

Ground 2 ..::qr + loase, open circuit from
points N3- W11

1.1 ~ E3 11- 14 V CIS-E control unit (N3)

7 ~ + faulty

1.2 úlli2l ..::qr E3 11-14V Ground terminal W1 O

20 + (Model107, W1) loase,
open c ircuit from
N3 - W1 O (Modal 107,
W1).

- 2.0 ~ lgnltlon: ON 11- 14 V Fuse in overvoltage

Power 2 ~ 1 protection (K1/ 1),
supply from overvoltage protection
CIS-E (K 1/1) faulty or not
control unit connected, wiring to
(N3) contact 1 (terminal 30)
interrupted 1 )

~7.3.0 7 11 . 121/21
Oni oH Test step1 Testert Operation/ Spec. Possible cause/ Remedy
ratio Test scope Test connection Requirement
readout
2.1
Test wiring

2.1.1 ITill2l X35 lgnltlon : OFF 11- 14 V Model 107: Wiring loase.
Wiring from 2 ..::&-cir. 30 open circuit from
terminal 30 G1 - X35

- 2.1.2 ~ K111 Overvoltage 11 - 14 V Model107:

2 ..::&- ) - 1
protection Open circuit from
(K1 / 1) X35- K1 Contact 1
disconnected.
Model 126:
Open círcuit from
G 1 - K1 /1 Contact 1

2. 1.3 ~ N1 6/4 lgnltlon : ON 11 - 14 V Models 107, 126:

Wiring from 2 ..:&- )-9 Fuel pump without ASR
terminal 15 relay (N16/4) Open circuit from
disconnected. F1 - N16/4

wlth ASR:
Open circuit from
N4/ 1 - N 16/4

2.1 .4 F1 X26 lgnltlon: OFF < 1Q Model107:

Open circuit
Fuse 8..::@!->-

2.1.5 X26 N1 6/4 <1 Q Model 107:

13-~)-9 Open circuit

2.1 .6 F1 X26 < 1Q Model 126 wlthout ASR:

Open circuit
Fuse 7..::@!- >-1
2 . 1. 7 X26 N16/4 < 1Q Model 126 without ASR:
1- ..:.@!- )- 9 Open circuit

1) Model 126: C1rCU1t to overvoltage protection (K 111) conta<:t 3 (term1nal 15) .nterrupted, wiring from overvoltage protectton
(K1 / 1) contact 2 (terminal 87E) to CIS·E control unit (N3) contact 1 1nterrupted.
Model 107: C11cu1t to overvoltage proteciiOn (K 1) contact 6 (terminal 15) interrupted, w1nng lrom overvoltage protection
(K t ) contact 2 (term.nal 87) to term1nal block (X51/ 1) 1nterrupted, wiring from term1nal block (X51 / t} to CIS·E
control unit (N 3) .nterrupted.

07.3.071 1 . 121/22
On/off Test step/ Tester/ Operation/ Speci· Possible causetRemedy
ratio Test scope Test connection Requirement fication/
readout Function
2.1.8 N4/ 1 X89/2 <10 Model 126 wlth ASR:
30 -<-=-<§>!- r- Open circuit

2.1 .9 X8912 N16/4 < 1n Modell 126 wlth ASR:

___, ..::.@!-- r-9 Open circuit

2.2.0 ~ K1 /1 lgnitlon: ON 11 - 14 V Model 126 wlthout ASR:

2 ~ r-3 Overvoltage Open circuit from
protection N16/4 _. K1 / 1
(K111)
disconnected.

2.2.1 ~ K1 / 1 11-14 V Modem 126 wlth ASR:

2 ~ )-3 Open circuit from
F1 --• K1 / 1
2.2.2 Fl X26 lgnitlon: OFF < 1n Modem 126 wlth ASR:
Open circuit
Fuse7~>- 1

2.2.3 X26 K1 / 1 Overvoltage < 1n Model 126 with ASR:

1 -- -=@!- ) - 3 protection Open c ircuit
{K1 / 1)
discon nected.

2.2.4 ~ K1 lgnitlon: ON 11-14 V Model107:

2 ~ )-6 Overvoltage Open circuit from fusa
protection (K1) 7 _. K1 ,
disconnected. contact 6

2.2.5 i¡¡g¡;:c:: l K1 / 1 lgnltlon: OFF < 1n Open circuit from

Wiring 1 -=@!- ) - 2 K1 / 1 - N3, contact 1
terminal
87E

2.2.6 ~ X51 / 1 < , n Model 107:

1 -=@!-cir. 87 Open circuit from
X51 /1 - N3,
contact 1
2.2.7 X51/1 K1 < 1Q Model107:
cir.87~)-2 Open circuit

0 7.3.071 1 - 121/23
Ontoff Test stepi Testerf Operation/ Spec . Possibte cause/Remedy
ratio Test scope Test connection Requirement
readout

- 3.0 ~ . Test cable 102 75 mA Electrohydraulic actuator

Test current set toA. 589 04 63 00 (Y1 ), wiring, CIS-E control
at electro- connected to unit (N3), CIS-E reference
hydraulic electrohydrau- resistor (R 17/ 1).
actuator lic ac tuator
(Y1). (Y1 )
lgnition: ON
Engi ne idling fluctuates Set lambda control,
0 ± 3 mA test 02 sensor (G3/2).

3.1 ~ Disconnect 19.5 :t Electrohydraulic actuator

Electro- 10 -=@!- 12 test cable, 1Q (Y1), wiring.
hydraulic lgnltlon: OFF
actuator Connector at
(Y1 ) CIS-E control
unit (N3)
detached.

3.2 Y1 Connector at 19.5 ± Renew electrohydraulic

1- -=@!- __ 2 electrohydrau- 1Q actuator (Y1).
lic ac tuator
(Y1) detached.

- 3.3 ~ Y1 < 1Q Open circuit

10 ....:.@-!- )- 2

3.4 ~ Y1 < 1Q Open circuit

12 ....:.@!- )- 1

0 7.3.0711. 12 1124
Onloff Test stept Testar/ Operation/ Spec. Possible cause!Remedy
ratio Test scope Test connection Requirement
readout
0% 4.0 i""'"'"l X11 lgnition: OFF < 1Q Open circuit at X11 power
Wiring from 23 ~-=@!... }- 3 Connector at supply from X11 contact 6
GIS-E CIS-E control or ground at X11 contact
control unit unit (N3) 2 interrupted. Lambda
(N3) to detached. control testar faulty. Open
diagnostic circuit at Xll / 1 (Model
socket (X11) 107 only ).

4.1 !;::;::;;;; ' X11 / 1 < 1Q Model107:

'23 -<-=®~ Cir. Open circuit from
GIS-E N3 contact--+ X11 / 1,
terminal CIS-E

4.2 X11 / 1 X11 < 1Q Model107:

Cir. Open circuit from X11 / 1,
CIS-E-=@!- >- 3 Terminal CIS-E--+ X11
contact 3

4.3 02 sensor - Lambda control out-of-

02 sensor (G3/2) at tolerance (refer to test
signal normal step 9).
operating
temperatura

10% 5.0 ~ Engine idling 4.5 - Air flow sensor

Air tlow 7 ~ 18 5.5 V potentiometer (82), CIS·E
sensor control unit (N3), open
potentio- circuit from N3, contact 7
meter (82) --+ 82, contact 1

5., ~ 82 lgnttlon: OFF < 1Q Open circuit

Wiring 7 ...::@!- }- 1 Measure at
connector, air
flow sensor
poten ti ometer
(82).

07.3.0711 . 121/25
 Onl off Test step/ Tester/ Opefation/ Speci- Possible cause/Remedy
ratio Test scope Test connection Requirement fication/
readout Function
20% 6.0 rB2J lgnition: OFF 00 -
Full load 2 ~ 5 Connector at
contact CIS- E control
unit (N3) and
connector at
elect ronic
ignition control
unit code
number (1 - 4)
disconnected.

Accelerator at < 1n Pins of connector S29/2x

full throttle wrongly assigned, full load
contact, wiring.

6.1
2 __
S29/2x
~
Detach 00 -
Full load _3 connector
contact S29/ 2x.
Accelerator at < 1 n Set throttle valva switch
full throttle (S29/2) or renew, open
circuit.

6.2 .~ S29/2x < 1 Q Open circuit

Wiring 5 ~)-3

W2J S29/2x < 1 n Open circuit

2 ....::@!- )- 2

073.071 1 . 121 /26

On/off Test step/ Tester/ Operation/ Specifi- Possible cause/Remedy
ratio Test scope Test connection Requirement cation/
readout Function
30% 7.0 ~ Engine idling. At Coolant temperatura
Coolant 7 ~ 21 + 80 oc sensor (8 11/2), wiring.
temperatura coolant
sensor tempera-
(811i2) ture 0.29
-0.35 V.
Refer to
table "1"
for other
values.

7.1
Coolant
IB21 811 /2 lgnltlon: OFF
Connector at
Refer to
table " 1" .
Model 107, Model126
up to 08/87:
7 ...=@!- >-
temperatura coolant Renew coolant
sensor temperatura temperatura sensor
(811 /2) sensor (811 /2) (811 12).
disconn ected.

7.2 81112 lgnitlon: OFF Refer to Model 126 startlng

- ..::@!-
- Connector at
coolant
temperatura
table "1". 09187:
Renew coolant
temperatura sensor
sensor (811 12) (811 /2).
disconnected.
Measure
diagonally and
compare
readings w1th
tabla "1".

7.3 ~ 811 12 < 1Q Model 107, Model 126

Wiring 21 ..::@!-
- up to 08/87:
Open circuit

7.4
~ 811 /2 < 1Q Model 126 startlng
21 ..:@)!- >- 2 09/87:
Open ci rcuit
7.5 ~ 811 /2 < 1Q Model 126 startlng
7 ~)-4 09/87:
Open circuit

07.3.0711 . 121!27
Ontotf Test step/ Tester/ Operation/ Spec. Possible causetAemed y
ratio Test scope Test connection Requirement
readout
40% 8.0 ~ Engine idling. 4.5- Air flow sensor potentio-
Air flow 7 -=@!- 18 5.5 V meter (82), CIS-E control
sensor unit (N3). wiring.
potentio-
meter {82)

~ 0.5 - Air flow sensor potentio-

7 -=@!- 17 1.5 V meter (82), CIS-E control
unit (N3), wiring.

8.1 82 lgnltlon: OFF 3.6 -

Air flow 1_ ..:.@!.-- 3 Connector at 4.4 kQ
sensor air flow sensor
potentio- pote ntiometer
meter (82) (82)
disconnected.

8.2 82 Slowly deflect Q reading Renew air flow sensor

1_ -=@!- _2 air flow sensor increases potentiometer (82).
plate by hand. continuou
sly up to
half of
deflection
and then
drops off
again.
8.3 ~ 82 lgnltlon: OFF < 1Q Open circuit
Wiring 7 -=@!- )- 1 Measure at
connector, air
flow sensor
potentiometer
(82).

8.4 ~ 82 < 1Q Opern circuit

18 -=@!- )- 3

8.5 ~ 82 < 1Q Open circuit

17 -=@!- )- 2

07.3 .0 711 . 121 128

On/off Test step/ Tester/ Operation/ Spec. Possible cause/Remedy
ratio Test scope Test connection Requirement
readout
50% 9.0 ~ Engine idling, fluctuates Check 0 2 sensor (G312),
Heated 0 2 7 ~ 8 lambda sensor between wiring, CIS-E reference
sensor (G3/2) at 0.1-0.9 resistor (R17/ 1).
(G3/2) normal V
operating
temperatura.

9.1 ~ G3/2x2 Engine idling, > 450 Renew heated 0 2 sensor

Heated Oz 7 ~ >- plug mV (G3/2).
sensor connection of
(G3t2) Oz sensor
signa! (G3/2x2)
disconnected
and connector
contacting
ground.

9.2 EfiT2l lgnitlon: OFF 00 Wiring faulty

Wiring 7 ~ 8 Connector at
CIS-E control
unit (N3)
disconnected.

9.3 !±El G3/2x2 < 1 o Open circuit

8 ...:::@!-
-
60% Refer to
testing
speed signa!
Section "q".

70% 10.0 ~ Engine idling 6-12 V lgnition control unit (N1/2),

TDffN 2 ~ 25 (N1/3), wiring.
signa!

10.1 ~ X11 lgnitlon: OFF < 1o Open circuit

Wiring 25 ...=.@!- )- 1

07.3 .0711 . 121/29

Ontotf Test step/ Tester/ Operation/ Spec. Possible causetRemedy
ratio Test scope Test connection Req uirement
readout
70% 10.2 N1 /2 X11 Connector < 1Q Open circuit
TDITN (TD signal) at
.::@!- >- 1 ignition control
-<
unit (N1/2)
disconnected.

80% 11.0 ~ lgnition: ON 4.5 - Altitude correction sensor,

Altitude 7 ~ 18 CIS- E control 5.5 V air flow sensor potentio-
correction unit connected meter, refer to test step 8
sensor wiring
(818) CIS-E control unit

11. 1 ~ - Refer to Altitude correction sensor,

Altitude 7 ~ 11 table "o" wiring
correction
sensor
(818)

11.2 El 818 lgnition: OFF <1Q Open circuit

Wiring 7 ~ )-3 Detach
connector
(8 18)

11.3 LTI2J 818 <1Q Open circuit

18 ~ )-2

11.4 ~ 818 <1Q Open circuit

11 ~ >- 1

90% not assignedl

100% 12.0 - - - Refer to test steps 1, 2, 3,

9 and test on/off ratio.

07.3 .0711 . 121/ 30

1) Table of voltage levels of EZUCIS-E coolant temperatura sensor (811/2)

T emperature in oC Resistance Voltage at contact 11 Voltage at contact 21

lntake air (Volts) Coolant (Volts)
-
-20 15.7 kQ 2.85- 3.49 3.24-3.94
-10 9.2 kQ 2.50-3.06 2.84-3.47
o 5.9 kQ 2.10- 2.56 2.39-2.93
10 3.7 kQ 1.69- 2.07 1.94-2.37
20 2.5 kQ 1.32- 1.62 1.51 - 1.84
30 1.7 kQ 1.03- 1.25 1.16- 1.42
40 1.18 kQ 0.77-0.94 0.88- 1.08
50 840 Q 0.57 - 0.69 0.66-0.80
60 600 Q 0.42-0.52 0.50 - 0.61
--·
70 435 Q 0.32-0.40 0.38-0.46
80 325 Q 0.25- 0.31 0.29-0.35
90 247 Q 0.18-0.22 0.22-0.26

m) Testing 4-pole coolant temperatura

sensor (811/2)

With two ground terminals. engine ground and

CIS-E control unit ground, as well as one
terminal for the temperatura signals for CIS-E
control unit and ignition control unit. The
resistances of the characteristics are identical to
the two-pin temperatura sensor (811 /2}.

Temperatura sensor and connector are designad

(temperatura signals crosswise) in such a way
that the connector can be fitted in any desired
position.

Note
When testing the coolant temperatura sensor,
the resistances should be measured and
compared 2 x crosswise (refer to ill.).

0 7 3.0 7 11 . 12 1/31
 n) Testlng connector of 4-pole coolant
temperature sensor (611/2)

When testing the wiring from the CIS-E control

unit (contact 7 and 21 , resp.) to connector
(8 11 2). test the contacts on the connector
clockwise. Only one cable should have continuity
( < 1 Q).

o) Altltude sensor table (818)

Height Atm. pressure p Voltage
above absoluta mbar approx. Volts
MSL'm
---·-------
o 1013
- -------
4±1
1000 899 3±1
2000 795 2±1

07.3.0711 . 121/32
 p) Testing decel fuel cutoff

Test conditions:

• Road speed > 20 km1h

• Engine speed > 1440 rpm
• ldle contact of throttle valve switch
(S29x2) closed
• Enginé at normal operating temperature,
oil temperatura approx. 80 oc
• Selector lever in drive position

Test stepi Tester/ Operationi Specification Possible cause/Remedy

Test scope Test connection Requirement
Test decel fuel ~ . Connect test cable
cutoff set toA 102 589 04 63 00 to
actuator, selector
lever in position 2,
engine speed
>2500 rpm,
deceleration (throttle
valva closed)

approx.- 60 ldle contact, refer to 07.3-

mA 112. test steps 4.0- 4.2;
selector lever position
refer to 07.3-112, test
steps 6.0 - 6.5, road
speed signa! refer to
Section "q"

07. 3.07 11 • 121133

q) Testlng road speed slgnal
Refer to Section "h" for contact box connection di.agram
Test step Testerl Operation/ Specification Possible cause/Remedy
Test connection Requirement
1.0 ¡;;¡¡;::;;;! Run car on >1V Test electronic
Test road 2 ~ 24 dynamometer with speedometer, refer to
speed signal >20 kmih 54-252, wiring

, .1 N8 ~ Connector (N8) <10 Open circuit

Wiring 1 -(~ 24 disconnected

1.2 Na X26 Connector (N8) <1 o Open circuit

1 -< .....:@!-- 6 disconnected,
connector ('X26)
separated

1.3 A1p8 X26 Connector (X26) <10 Open circuit

-=@!- >- 6 separated,
-<
connector (A 1p8)
disconnected

B. Modlflcatlons and Arrangement of Coolant Temperature Sensors (811/2)

Temperatura sensor
Arrangement up to 12/85

07.3.0711 . 121 /34

 T emperature sensor
Arrangement as from O1/86

Temperature sensor
CaiJfornia starting 1988,
Federal startmg 1990

07.3.071\ . 121/35
 07.3-124 Testlng startlng devlce

038
~~~~9
a...:~
044 ~ "'''lili
li ¡; ¡; li i ¡; li
- --
ilii i i i i
i li ¡; li li li li

P07 - 0005 - SS

Testers .. . . .. ... ..... ......... .. . ... . connect:

Fuel pressures and internar leakage . ........ .
Starting valve ...... . . . . .. . ... ... . . . ... .
Post-start enrichment . . .. . ... . ......... . .
Pressure measuring device (043) 103 589
00 21 00,
Double union (044) 102 589 06 63 00,
Multimeter (003),
n decade (038) 124 589 09 63 00
Test cable {033) 102 589 04 63 OO.
test {07.3-1 20).
check for operation and leaks.
test.

07.3.0711 . 124/ 1
 Speclal tools

103 589 00 21 00 102 589 06 63 00 124 589 09 63 00 201 5$9 00 99 00 102 589 04 63 00

Commerclal testers
Multimeter e. g. Sun, DMM-5
Lambda testar
--------------------------------------- e. g. Hermann L 115

Note
Wiring diagrams (07.3- 128).

07.3.0711 . 12412
Test step Test connection Operation/ Specification Possible cause/
Requirement Remedy
1.0 Detach fuel line at 2-pole coolant
Check starting valve temperatura sensor
operation of (arrow). Remove (B 11/2):
starting starting valva and Connect Q decade i nto
valva reconnect fuel line. circuit at coolant
temperatura sensor
(811 /2) and simulate
1O kQ resistance.

4-pole coolant
temperature sensor
(B 11 /2):
Connect lambda testar to
diagnostic socket (X11 ).
Switch on ignition.
Readout 70 %. Detach
coolant temperatura
sensor connector (811/2),
readout 30 % .
Simulate 1O kQ at coolant
temperatura sensor
connector (811 /2) with
Q decade, connect into
circuit diagonally until
lambda testar indicates
70 % . Hold starting valve
in a vessel.

Start engine Starting valve Test starting valve,

must eject a finely starting valve control
atomizad spray. (07.3·1 26).

1.1 lgnltlon: OFF Starting valva Renew starting valva.

Test starting Dry off nozzle of starting must not leak.
valve for valve.
leaks

Testlng post-start enrlchment

Test data
Post-start at + 20 oc mA 5-9
End of start approx. seconds 13
Warm-up base value mA O

07.3.07 11 . 12413
 Test step/ Test connection Operation/Requirement Specification Possible cause/
Test scope Remedy
1.0 ~ Connect test cable (033)
Test current 102 589 04 63 00 to
at electro- electrohydraulic actuator
hydraulic (Y1) and multime1er.
actuator (Y1)
2-pole coolant
temperature sensor
(811/2):
Create contacts with
Q decade at coolant
temperatura sensor
(811/2) and simulate
2.5 kQ resistance.

4-pole coolant
temperature sensor
(811/2):
Connect lambda testar to
diagnostic socket (X11 ).
Switch on ignition.
Readout 70 % . Detach
coolant temperatura
sensor connector (811i 2),
readout 30 %. Simulate
2.5 kQ with Q decade at
coolant temperatura
sensor connector (811/2),
create intermediate
contacts diagonally until
lambda testar ind~cates
70%. refer to table Ground supply of
Start engine. CIS-E control unit
(N3), power supply
of CIS-E control unit
(N3) (refer to 07.3·
121, test steps 1, 2).

Coolant temperatura
sensor (811 i2) (refer
to 07.3-121, test
step 7).

Air flow sensor

potentiometer (82)
(07.3-121, test
step 8), TDITN
signal (07.3-121,
test step 10).

0 7.3 .0 7 11 . 124/4
 07.3-126 Testlng startlng valve control

«¡?
2}
i? (/fe~
UOl':!!_t

"ililiii

''''''' 038
' ' ' ' li li li
iliilililii

003
c=:o IOIOr.J
!::.\ [Jlr}(O
~ e e ~
907-009&-53

Testers ... ........... .... ... ...... ... connect:

Starting voltage
Electric cables between starting valve and
fuel pump relay . . . . . . . . . . . . . . . . . . . . . . . .
Voltage at tuel pump relay . . . . .. .. . .. . .. . . .
Multimeter (003)
Q decade (038) 124 589 09 63 OO.
test. At least 1O V in approx. 5 seconds.
test for continuity. Resistance approx. O O.
test. Contact 12 (terminal 50) at least 1O V,
contact 2 (terminal TF) 3 - 5 V simulated at
10 kQ.

07.3.071 1 . 12611
Speclal tools

124 589 09 63 00 201 589 00 99 00

Commerclal testers
Multimeter e. g. Sun, DMM-5

Note
Wiring diagrams (07.3·128).

07.3 0711 . 126/2

 Test step Testar/ Operation/ Spec . Possible cause/Remedy
Test connection Requirement

1.0 Y8 2-pole coolant

Testing starting
-< -=@!- >- temperatura sensor
valva control (811/2):
Create intermediate
contacts with Q decade at
coolant temperatura
sensor (811 12) and
simulate 1O kQ resistance.

4-pole coolant
temperature sensor
(81 112):
Connect lambda testar to
diagnostic socket (X11 ).
Switch on ignition.
Readout 70 %. Detach
coolant temperatura
sensor connector (811 /2),
readout 30 %.
Simulate 1O kQ with
Q decade at coolant
temperatura sensor
connector (8 11 /2) ,
establish intermediate
contacts diagonally until
lambda tester indicates
70 %.
Plug protective connector
Part No. 102 589 02 21 00
onto diagnostic socket.

Start engine. >10 V Fuel pump relay (N16/4),

approx. wiring TF signa! (07.3-112,
5s test steps 5.0 - 5.2).

1.1 N16/4 Fuel pump relay (N16/4) >9 V Open circuit

Voltage of 11 -<-==<Xr->- 12 disconnected . Starter (M1) -+ N16/4
terminal 50

1.2 N16/4 Y8 Fuel pump relay (N16/43) <1Q Open circuit

Wiring 4-<-=@!- >- disconnected, connector
at starting valve (Y8)
disconnected.

1.3 Y8 W11 Connector at starting valve <1Q Open circuit

..:@!- _L (Y8) disconnected.

07.3.0711 • 12613
 07.3-127 Performlng cold start

044~

Pressure measuring device,

double union (043. 044) ................ . .
Blower (053)
Cold start ............................ .
connect (07.3-120).
Special tools 103 589 00 21 00,
102 589 06 63 OO. Run engine to build up
pressure.
to cool engine (or allow engine to cool
overnight).
perform, keeping a check on pressure gauge:
lf necessary, test fuel pressures (07.3-120) or
electronic components of CIS-E injection
system (07.3-121 ).

07.3.0711 . 127/1
Speclal tools

~
~

1--- ------
103 589 00 21 00 102 589 06 63 00

Test data
Fuel pressures in bar gauge pressure

System pressure when engine idling, 6.2 - 6.4

cold or at normal operating temperatura
Engine oil temperatura approx. 80 oc approx. 0.4 1
)

Lower chamber pressure Engine not running or idling at coolant

temperatura of + 20 oc approx. 0.5 1
)

when decelerating 6.2-6.4

1) Below system pressure measured previously.

0 7.3.0711 . 127/2
07.3-128 Electrlcal wlrlng dlagrams

The following wiring diagrams of the mechanical/electronic gasolina injection system with automatic
transmission and AJC compressor are shown.

Modet Version Remark Wiring

diagram
No.
107 @ up to 1986187 1

126 2

107 @ Federal as of 1988 Separate reference resistor (R 17/1) 3

eliminated, now integrated in CIS-E
126 control unit. 4
lndicator lamp "CHECK ENGINE".
107 @ California as ot 1988 Separata reterence resistor (R17/ 1) 5
eliminated, now integrated in CIS-E
-126 control unit. -6 -
- -
lndicator lamp "CHECK ENGINE" and
on-board diagnosis. Coolant
temperatura sensor 4-pole.

Unmarked grounding points on ground engine or ground body. The ground lead trom plug 2 is
connected with plug 7 in the control unit CIS-E (N3) ..

07.3 .0712-128/1
Wiring diagram No. 1
Engine 111 1986187 model 107

P07 ~ 01?2 -$ 7

07.3.0712· 12812
 Wiring diagram No. 1
AlelO 02·sensor indocator lamp X9 Connector. termonal 30 (l·pole)
82 Aor flow sensor posotion indicator X 11 Diagnostic sockeVterminal block (corcuot TD)
811 /2 Coolant temperatura sensor (EZL!CIS·E)(2·pole) Xll/1 Doagnostic sockeVterminal block. terminal 30/CIS-
( """) E (2·pole)
818 Altotude correction capsule X18 Connector. onteroOI'Itail lamp harness
G312 Heated 02-senwr X26 Connector, onterior/engine
G3/2x1 Connector, Oz-sensor heater coil (2-pole) Y1 Electrohydraulie actuator (EHA)
G3/ 2x2 Connector. Orsensor sognal ( 1-pole) Y6 ldle speed air valva
K1 Overvol!age protection relay (5 -pole) Y8 Start valva
K17 Aor onjection relay Y32 Aor onjectoon pump switchover valve
M3/ 1 Fuel pump 1 Y33 Electromagnetic air on¡ection pump clutch
M3/2 Fuel pump 2 z Connector sleeve (solder joint in harness)
N1 /2 Electronoc ignotion control unot (EZL) a Fuse and relay box F1, fuse 6, termonal 15X
N3 CIS·E control unot b lgnitoon starter swotch S2/1. termonat 50
N6 A!C compressor control unit e Fuse and re lay box F 1. fuse 7. terminal 15
NB ldle speed control unot unprotected side
N16/4 Fuel pump relay with kickdown cut-out d Connector starter cable harness X27. jack 2
R17/1 Reference resistor (CIS-E) (starter terminal 50)
S10t 1 Left front brake pad wear sensor e Fuse and relay box F 1, fu se 12. terminal 30
S29t2 Throttle valva switch, full load/idle unprotected sida
S29/2x1 Connector, throttle valva swotch, full load/idle Terminal block X21 / 1, brake hght
Wl Maon ground (beh ind instrument cluster) swotchtelectronic speectometer
W3 Ground. left front wheel housing (at ignition coo l) g Connector X49/2 starter lockout ano back-up
W7 Ground. roght rear wheel housing on trunk light switch jack 7 (kiekdown S 16/6)
W9 Ground. at left headlamp unit m Fuse and retay box F 1. fu se 7. termonal 15
Wll Ground, engone (connectoon poont for ground n Fuse and relay box F1, fusa 12. termonal30
wires) p lnstrument cluster A 1 coupling 15·pole. jack 7
W15 Ground, electronocs (right footwell)
X4/ 10 Termonal block, termonal 30/terminal 61 (battery)
X4í 14 Terminal block. terminal 87/terminal30 (2-pole)

07 3 .0712· 12813
Wiring diagram No. 2
Engines 116, 117 1986/87 model 126

W10

T
§

07.3 .0712·128/4
Wiring diagram No. 2
AlelO 02·sensor indicator lamp X26 Connector, 1nteriorteng1ne
92 A~r flow sensor pos1tion mdicator X36 Connector, fuel pump harness (1-pole)
911/2 Coolant temperatura sensor (EZUCIS·E)(2·pole) Yl Electrohydraulic actuator (EHA)
(......¡ Y6 ldle speed atr valva
918 Altitude correction capsule va Start valva
G3t2 Heated 02-sensor Y32 Alf injection pump switchover valva
G3/2x1 Connector. 02-sensor heater coll (2-pole) Y33 ElectromagnetJC air •nJect1on pump clutch
G3/2x2 Connector, 02-sensor signa! (l·pole) z Connector sleeve (soldar JOint 1n harness)
Kl Overvoltage protection relay (5·pole) a lgnotoon coil terminal 15
K17 A1r 1n¡ection relay b Fuse and relay box F 1, fuse 7. term1nal 15
M31l Fuel pump 1 unprotected s1de
M3/2 Fuel pump 2 e Fuse and relay bolC F 1, fusa 5. termmal 15
N1 /2 Electronoc ognttion control unit (EZL) e Term1nal block X4/1, term1nal 30 (fusa and relay
N3 CIS·E control untt box)
N6 A/C compressor control unot f Fuse and relay box F1, fuse 2. term1nalJO
NS ldle speed control unit g Connector starter cable harness X27. jack 2
N16/4 Fuel pump relay with kickdown cut·out (starter terminal 50)
R17/1 Reference res1stor (CIS·E) h Connector X49/2 starter lockout and back·up
$29/2 Throttle valve switch, full loadlidle light switch ¡ack 7 (kickdown St6/7)
S29/2x1 Connector, lhrottle valve SWitCh, full load/idle lgnition starter swotch 52/1 , termtnal 50
W3 Ground, left front wheel hous1ng (at 1gnition coil) m Auxiliary fan relay (K9) ¡ack 4, terminal 86
W7 Ground, nght rear wheel housmg on trunk V Speed sognal electrontc speedometer A 1pe
W9 Ground, at left headlamp unit
W11 Ground, engine (connection pomt tor ground
Wlr8S)
X4/10 Term1nal block, termonal 30/terminal 61 (battery)
X11 Diagnost1c sockeVterminal block (circuit TO)

07.30712· 128/5
Wiring diagram No. 3
Englnes 116, 117 Federal as of 1988 model 107

VI
.---ji---"'~~- - - -++-- - - - - - -f!f..G:
,--+-- - <m•·- - - -++-- - - - ----l!·+.TI:..:
1

............. ..-- ,,j

N3

07.3.0712·12816
Wiring diagram No. 3
"CHECK ENGINE" warn1ng lamp W1 Mam ground (behind •nstrument cluster)
A1 e26
ElectroniC clockltachometer W3 Ground, left front wheel housing (at IQM•on co1l)
A1p7
A1r flow sensor posit1on •ndK:ator W7 Ground, right rear wheel hous1ng 1n trunk
82
Coolant temperatu ra sensor (EZUCIS- E)(2·pole) W10 Ground, banery
6 1112
(·· ····) W11 Ground, engine (conneclion po1nt for ground
A ltitude correct10n capsule WlrBS)
818
Fuse and relay box W15 Ground, electromcs (nght footwall)
Ft
Banery X412 Terminal block, term1nal 30 (2 -pole)
Gt
Heated Oz-senso r X413 Connector. term1naJ 30, batterytov ervottage
G312
Connector. Oz-senso r heatar coil (2 -pole) protectiOn (1-pole)
G312x1
Connector. Oz-senso r signar (1·pole) X11 Diagnostic sockeVterminal block (Cifcuit TO)
G3/2x2
Overvoltage protect10n retay (5-pole) X1 111 Diagnosbc sockeVterminal block, terminal 30/CIS·
Kt
Alf 1nJecl10n relay E (2 -pole)
K17
Starter X18 Connector, intenor/ tail lamp harness
M1
Fuel pump 1 X26 Connector. 1ntanor/eng1ne
M3/1
Fuel pump 2 X27 Connector, starter harness
M312
EtectroniC 1gmtion control unlt (EZL) X35 Termmal block. terminals 30/61 (banery) (···
N1 /2
CIS·E control uM X4/10···)
N3
NC compressor control un.t X4912 Connector. backup lannplstarter IOCk·out sw1tch
N6
ldle speecl contro l un1t Y1 Electrohydraulic actuator (EHA)
N8
Fuel pump relay w1th kickdown cut-out Y3 Kickdown valve (automattc transmiSSIOn)
N16/4
lgntiiOnlstarter sw1tch Y6 ldle speed 3Jr valve
52/ 1
Starter lock-ouVbackup lamp SWitch Y8 5tart valve
516/ 1
Kickdown switch Y32 Air injaction pump switchove r valva
516/6
" B" e ngagement sw1tch Y33 ElectromagnettC air injectton pump clutch
516/8
529/2 Thronla valva sw1tch. fulf IOad/ldle z Connecto r sfeeve (soldar )Otnt 1n harness)
Connector. thrortle valva sw1tch, full loadtidla a Lamp control un1t jack 13
S29/2x1
b Rotary hght switch
e ElectroniC speedometer

07.3.0712 -t28n
 Wiring diagram No. 4
Englnes 116, 117 Federal as of 1988 model 126

0730712· 12818
 Wiring diagram No. 4
A 1e26 "CHECK ENGINE" warn1ng lamp 529/2x1 Connector, throttle valve sw1tch, full load/idle
A1p7 Electron1c clock/tachometer W3 Ground. left front wheel housing (at ignition coil)
82 A~r flow sensor position 1ndicator W7 Ground. nght rear wheel housmg in trunk
811/2

818
,
Coolant temperatura sensor (EZUCI5·E)(2·pole)
( ......
Alt1tude correct1on capsule
W9
W10
W11
Ground, at left headlamp unit
Ground, battery
Ground, eng1ne (connectlon po1nt for ground
Fl Fuse and relay box WlfeS)
G1 Battery X4/ 10 Terminal block, terminal 30/term•nal 61 (battery)
G3/2 Heated 02-sensor X11 Diagnoshc sockevterminal block (c~rcu1t TD)
G3/2x1 Connector, 02-sensor heater corl (2·pole) X26 Connector, rntenorteng,ne
G3/ 2x2 Connector. 02-sensor s1gnal (t·pole) X27 Connector, starter harness
K1 /1 Overvoltage protection relay. 87E (7·pole) X36 Connector. fuel pump harness (1·pole)
K17 A~r 1n¡ec!lon relay X49/2 Connector. backup lamplstarter lock·out sw1tch
M1 5tarter Yl Electrohydraulic actuator (EHA)
M3/1 Fuel pump 1 Y3 Kickdown valve (automa!lc transmiss1on)
M3/2 Fuel pump 2 Y6 ldle speed air valve
N1 /2 Electronic 'gnit1on control unit (EZL) va 5tart valve
N3 CI5·E control uOI! Y32 A•r injection pump switchover valve
N6 A/C compressor control uOI! Y33 Electromagnetic air injection pump clutch
N8 ldle speed control un1t z Connector sleeve (soldar jo1nt 1n harness)
N16/4 Fuel pump relay with kickdown cut·out a Lamp control uM 1ack 13
52/ 1 lgniiiOnlstarter sw1tch b Jack electronic speedometer
516/1 5tarter lock·oUVbackup lamp swrtch
5 16/6 Kickdown switch
516/8 "8" engagement sw1tch
529/2 Throttle valve sw1tch. full load/idle

0 7.3 0712· 12819

 Wiring diagram No. 5
Engines 116, 117 California as of 1988 model 107

r-~-~
M3/1 M 3/2

~
f~¡
11 r 11 ·· , .•·. :¡ rtltV
11 . 1 l!.
bt
l
IW
l$
bf:
\~
IW

~· ' fl' ..1. ::.

W7 l W7 ;.f .l ~
u 15

"I W1S
._____,L>&í_;;.,__x•_,
a:::J

f--v scw;g. - 818

..........
B
~evr t

.,...
Q7'ib1Jt,w

~"
c n.B2
r:1 ·;.El ,_J

07.3.0712·128/10
 Wiring diagram No. 5
A1e26 "CHECK ENOINE" warning lamp WIO Oround, battery
A1p7 Electronic clockltachometer Wll Oround, engme (connection po1nt for ground
82 Air flow sensor position indicator WlleS)
81112 Coolant temperatura sensor (EZUCIS·E)(4-pole) WtS Oround, electronics (right footwell)
818 Altitude correction capsule X4/2 Terminal block, terminal30 (2-pole)
821 EOR temperatura sensor X4/ 3 Connector, terminal 30, battery/overvoltage
F1 Fuse and relay box protection (1 -pole)
01 8attery XII Diagnostic sockeVterminal block (CliCUII TD)
03/2 Heated 02-sensor XI 111 Diagnostic sockevterminal block. terminal 30/CIS-
03/2x1 Connector, 02-sensor heater coil (2-pole) E (2-pole)
0312x2 Connector, 02-sensor signa! (t ·pole) X18 Connector, interiort tail lamp harness
Kl /1 Overvoltage protection relay, 87E (7-pole) X26 Connector, interior/engine
K1 7 A ir injection relay X27 Connector, starter harness
MI Starter X35 Terminal block, terminal 301terminal 61 (battery)
M3/1 Fuel pump 1 X5111 Terminal block, terminal 871terminal 30 (2·pole)
M3/2 Fuel pump 2 X49/2 Connector, backup lamp/starter lock-out switch
Nl /2 Electron1c igmtion control umt (EZL) X80/2 Connector, temperatura sensor, EOR (reference
N3 CIS-E control unit ground)
N6 AIC compressor control uM X80/3 Connector, temperatura sensor, EOR (signa!
N8 ldle speed control uOII CIS-E)
Nl6/4 Fuel pump reray with kickdown cut-out X92 Test connection for diagnOSIS, (impulse readout,
S211 lgnibonlstarter switch 8-pole)
S16/ 1 Starter lock-ouVbackup lamp switch Yl Electrohydraulic actuator (EHA)
S2912 Throttle valve sw1tch, full loadlidle Y3 Kickdown valve (automatic transmission)
S29/2x1 Connector, throttle valve switch, full loadtidle Y6 ldle speed air valva
530/ 1 KICkdown SWitCh Y8 Start valve
S60 "B" engagement switch Y32 A ir intecbon pump switchover valve
sao Pushbutton SWitCh with LEO (California) Y33 Electromagnetic air onject1on pump clutch
W1 Main ground (behmd 1nstrument cluster) z Connector sleeve (solder ¡oint 10 harness)
W3 Oround. left front wheel hous1ng (al ignitJOn COII) a Lamp control uM 1ack 13
W7 Oround. right rear wheelhousing in trunk b Rotary light switch
e Electronic speedometer

0730712-128/11
Wiring diagram No. 6
Engines 116, 117 <§ California as of 1988 model 126

,-- -H- -Q;ñ........ . "'

.-- -1-.J--., .• -----1-·-------l:~~L ....J
2

0 7.3.0712· 128112
 Wiring diagram No. 6
A1e26 "CHECK ENGINE" warning lamp W3 Ground, left front wheelhousing (at ignition coil)
A1p7 Electronic clockltachometer W7 Ground, right rear wheelhousing 1n trunk
82 Air flow sensor position indicator W9 Ground, at left headlamp uM
811/2 Coolant temperatura sensor (EZUCIS·E)(4·pole) W10 Ground, battery
818 Altitude correction capsule W11 Ground, engine (connection point for ground
821 EGR temperatura sensor wires)
F1 Fuse and relay box X4/10 Term1nal block, terminal 30/terminal 61 (battery)
01 Battery X11 Diagnostic sockeVterminal block (circuit TD)
03/2 Heated Oz-sensor X11 14 Test connection for diagnosis, (impulse readout,
G3/2x1 Connector, 02-sensor heater coil (2·pole) 8·pole)
G312x2 Connector, 02-sensor signa! (1·pole) X11/4s1 Pushbutton switch with LEO (California)
K1 / 1 Overvoltage protection relay, 87E (7·pole) X26 Connector, interior/engine
K17 Air injection relay X27 Connector, starter harness
M1 Starter X36 Connector, fuel pump harness (1·pole)
M311 Fuel pump 1 X4912 Connector, backup lamplstarter lock·out switch
M3/2 Fuel pump 2 X8012 Connector, temperatura sensor, EGR (reference
N1 /2 Electronic ignition control unit (EZL) ground)
N3 CIS·E control un1t XS0/3 Connector, temperatura sensor, EGR (s1gnal
N6 AIC compressor control unit CIS·E)
N8 ldle speed control unit Y1 Electrohydraulic actuator (EHA)
N16/4 Fuel pump relay with kickdown cut·out Y3 Kickdown valva (automatic transmiss1on)
S211 lgn1tionlstarter switch Y6 ldle speed air valva
S16/1 Starter lock·ouVbackup lamp sw1tch va Start valve
S t 6/6 K1ckdown switch Y32 Air m¡ect1on pump switchover valve
S16/8 "8" engagement sw1tch Y33 Electromagnetic air 1nject10n pump clutch
S29/2 Throttle valva switch, full loadlidle z Connector sleeve (soldar joint in harness)
S29/2x1 Connector. throttle valve switch, fullloadl idle a Lamp control unit jack 13
b Jack, electron1c speedometer

07.3.0712·128/13
 07.3-130 Checklng fuel pump

003

~ 045

IT057

P07· 0288·55

Power consumption check. Nominal value 7-1 O ampare, (figure 1).

Use multimeter (003).
Fuel pressure in fuel tank relieve by removing cap.
Fuel return line (51) . .. ....... .... .. ... .. unscrew.
Fuel hose (041) .... .. .... ...... ... .... . fabricate and connect to diaphragm pressure
regulator.
Delivery capacity check. Nominal value 1 liter in a maximum of 40
seconds: Use measuring cup (057), stop watch
(041 ).
Delivery capacity check. Nominal value 2-4 bar pressure.
Use pressure measuring device (043)
103 589 00 21 00, connection fitting (045)
103 589 02 63 OO.

07.3.0712·1 30/1
Testing values
Fuel pump (quantity) 2

Designation EKP 6
MB part No. 002 091 59 01 ')
Bosch No. o 580 254 951
Measuring specifícations with engine stopped and a voltage on the supply
pump of at least 11 .5 volt

Rate of delivery 2) Measuring point Fuel return line after diaphragm pressure regulator

at least 1 liter in 40 seconds

Power consumption 6-1 O Ampere 3 )

'l Replacement part No. 002 091 88 0 1.
2¡ The fuel tank must be at least haff full tor measunng the rate of delive ry.
3) Pull o ff connector (G3.J2x1) heater coil oxygen sensor.

Speclal tools

103 589 00 21 00 103 589 02 63 00 201 589 00 99 00

Commerclally avallable testers

Measuring glass or measuring cup (at leas! 1 liter), stop watch
Multimeter e.g. Sun, DMM-5

Shop-made tool
Fuel hose 500 mm long
Pipe with sealing fiare
Union nut M14 X 1.5

0 7.307 12· 13012

Note
Electrical wiring diagrams see 07-128.
The fue! pump operation should be heard briefly
{approx. 1 second) when the ignition is switched
on.

A. Rate of dellvery

1 Pul! off fuel pump relay (N16/4). Set

multimeter to ampare. Cl1eck power
consumption on jack 7 (terminal 87) and jack 8
(terminal 30) .

Power consumption 6-1 O ampare. ©©©)000

806
12 10 4
A 11 9 7 5 3
2
1
lf more than 1O ampere are measured. check the
following:
©©@000
P07-0285 -1 3

a) Pull off oxygen sensor heater coil connector

(G312x1) and repeat measurement. In
models 107 and 126 this is located in the
right footwell underneath the floor panel.

Power consumption of oxygen sensor

0.5-1 .3 A, check oxygen sensor if required
(see 07.3-12 1, testing program with contact
box, impulse period d isplay 50%, test step
9.0).

b) Check fuel pressure (see section "8").

Model126

G3/2x1 Connector, oxygen sensor heater coil

G3/2x2 Connector, oxygen sensor signal

07.3.0712·13013
2 Remove electrical wiring from multimeter.
Check the fuel pump delivery rate in fuel return.
Relieve fue! pressure in fue! tank by removing
the cap. Unscrew fuel return line (51) from
diaphragm pressure regulator and plug.

50 Supply system pressure

51 Fuer return
53 Re\urn fuel distnbvtor

3 Connect shop-made fuel hose to diaphragm

pressure regulator ancl hold into measuring glass
or measuring cup.

4 Bridge jacks 7 and 8 to supply the fuel pump

with voltage.

Model 126

07.3.0712· 130/4
On model 107, pull off coupling tail lamp wiring
harness 8-pole (X18) in footwell left below floor
panel. Connect terminal 2 with terminal 30
(terminal block next to overvoltage protectíon).

Modal 107

After 40 seconds or before the measuring

glass/measuring cup run.s over, pull off contact
bridge.

Desíred value:
1 liter in a maxímum of 40 seconds with a
mínimum voltage of 11 .5 volt on the fuel pump.

5 lf the rate of delivery is less than 1 liter in 40

seconds, check the followíng poínts:

a) Check voltage on the fuel pump. Nominal

value at least 11 .5 volt.

b) Check if strainer in supply fit1ing of fuel

distributor is clogged.

e) lnspect fuellines for constrictions (squashed

lines).

d) Pinch leak-off line between fuel storage unit

and suction damper. Again check rate of
delivery. lf the specified rate ot delivery is
obtained, renew fuel storage unit.

e) Renew fuel filter.

07.3.0712· 130/5
6 lf the rate of delivery is still inadequate,
determine the detective fuel pump by means of a
pressure measurement (section " B").

7 Connect fuel return hose, lit relay.

B. Fuel pressure

Remove protective box.

2 Unscrew acorn nut trom fu el pump (M3/ 1),

connect connection fitting, part No.
103 589 02 63 00 and pressure measuring
device. part No. 103 589 00 21 00 (arrow).

3 Pull oH fuel pump relay and bridge the two

jacks 7 and 8 (terminals 30 and 87).

4 Read value off pressure gauge. The value

must be between 2 and 4 bar. lf the value is
below 2 bar. the fu el pump (M3i 1) is detective. lt
the pressure is more than 4 bar, the tuel pump
(M3/2) is detective.

5 Disconnect pressure measuring device, tit

acorn nut and tuel pump relay and check for
leaks.

6 Fit protective box.

07.3.0712 ·130/6
 07.3·135 Checklng lnjectlon valves

Preceding operation :
Removal, reinstallation of ínjectJon vatves (07.3·215)

92
11

12

13

P07•0280• 55

lnjection valvas (92) check.

Aough leak test a) Connect removed injection valvas to testar.
Bleed pressure line with opened shut-off
valva and opened union nut. Then tighten
union nut.

b) Shut-off valva open. slowly actuata hand

levar (4 s/stroke) and build up pressure toa
maximum of 1.5 bar pressure. lf a leak is
detectad on the injection valva, tha injaction
valva must be renewed.

07.3.0 712· 135/1

 Checking opening pressure .. ....... .. . . . . .
Fine leak test . . . . . . . . . . . . . . . . . . . . . . ... .
Buzzing test. evaluation of spray pattern . . ... . .
With new injection valvas. 4.3-4.6 bar pressure.
On used injection valvas. at least 3. 7 bar
pressure.
Close shut-off valve. Flush injection valve by
rapidly actuating the hand lever severa! times.
Open the shut-off valve and check opening
pressure with slow movement of the hand lever.
close shut·oH valve. Flush injection valve by
rapidly actuating the hand lever several times,
open shut-off valve and slowly build up pressure
to 0.5 bar below the previously established
opening pressure and hold. No drop must form
on the injection val ve within 15 seconds.
close shut-otf valve and flush injection valve by
actuating the hand lever several times
(0.5 s/stroke). Then reduce lever speed to
approx. 1 sl stroke. When doing so the valve
must emita buzzing sound. No drops must torm
on the valve mouth. A concentrated stream is
not permissible. One sided, atomizad spray
pattern within an overall spraying angle of
approx. 35 ° is permissible.
Spray pattern evaluation see figures.

Test values
Opening pressure of injection with new injection valves 4.3-4.6 bar pressure
valves,)
with used injection valves at least 3.7 bar pressure

,) Renew m¡ect1on valves wh1ch are outs1de the tolerance.

The 1njectlon valves can be tndividually changed w1th1n a set.

Tightening torques Nm
lnjection lines to fuel distributor (reference value) 10-12

lnjection lines to injechon valvas (reference value) 10-15

07.3.07 12· 13512

 Commerclally available testers and accessories (observe note)
Valva tester Bosch KDJE-P 400 Bosch order designation
KDJE-P 400
Nozzle tester EFEP 60 H 1 ) Bosch No. O 684 200 700
Pressure gauge 0-6 bar pressure housing dia. 100 mm Bosch No. 1 687 231 000
Ouality class 1.0
Piping Bosch No. 1 680 750 001
2
Adaptar ) Bosch No. KDJE-P 40017
1) Corresponds to the prev1ous nozzle tester. The listed pressure gauge or the pressure gauge of the pressure measuring device
100 589 13 21 00 is necessruy to test the injection valvas.
2) An adaptar is required due to the changed connection thread M 1 O x 1 of the injection valvas.

Note
The nozzle or valve testar is usad to check the
opening pressure, the buzzing, the jet and the
tightness of the injection valvas.

Before starting the injection valva test. the tank

of the testar must be filled and the device bled.
Only petroleum must be used for testing.

P07•2148-13

07.3.0712 -135/3
Spray pattern
Faulty in· . evaluation
¡ectlon valves

Orop formatlon

Stream

Spreading spray panern

Good ·ln¡ection
· valves

1
1/ 1

1/
l/t .:11
' l

/!. i/''¡1
,.-'/~:
11 1
t
1
11
1

.. 1 li ' ' ,:' i .¡ 1

_ _ _ _¿¡_:_!'¡ ,¡.1 ;· / ! ¡.
Good spray panern

07.3.07 12·13514
 ~------..--

/
Slightly one-side<l atom1zation
/

1 / i; P07-2155-1l

0 7 3.07 12 · 13515
 07.3-152 Checklng, renewlng throttle valve switch

Preceding operat1on:
Removal, re1nstallation of throttle assembly (07.3·230)

S29/2x1
,-- -----..... ~--..

P07· 0284-53 A

529/2 Thronle valve sw1tch full load/idle speed S29/2x1 Connector thronle valve sw1tch tull load/idle
recognition speed recogOI!ion

Ohmmeter .. .....•. .....•••.... ... .... set to measuring range O - oo,

Full load stop ... .. ... .. , . . . . . . . . . . . . . . . check. For this purpose push throttla valve to
fullload stop. Tha display should be O Q. Turn
the throttle valve slightly in the direction of idle
speed, tha display should indicata oo Q.
ldle spaed stop, check push throttle valva to idle speed stop. Turn
throttla valva switch until the display shows O Q.

Lift throttle valve 0.2 mm, the display should

Throttle valva switch {S29/2)
.... .... .... ...
show oo Q.
ldle speed
contact: ldle speed position approx. O Q
Full load position approx. oo Q
Full load
contact: ldle speed position approx. oo Q
Full load position approx. O Q
Part load position approx. oo Q
renew. For this purpose, remove and reinstall
both mounting screws.

Commerclally avallable tool

Multimeter e.g. Sun, DMM·5

07.3.0712· 152/ 1
 ' 'W>Y.u.'l.VV.~~. •••'-' • • • •• • • • ••'-•'- "~'"' ""''"'""~••• ....•• ,u,,,.._,,._.,,_, ,._.,, • .-~,·,,~.,,.'",,., • •• •• • •• • •• • • ,• • • •• • •, .,• '"" • "'"' • •• • •• ••• • •• •• • • •• •• • • •• •• • •• •• • •o'" 0 "

07.3-160 Conductlng fu el quantlty comparative measurement

P07- 0040-35

Flow meter position horizontally next to the vehicle.

lnjection lines . . . . . . . . . . . . . . . . . . . . . . . . . . disconnect from fuel distributor and injection
valves, reconnect. Clean connection fittings
beforehand.
Flow meter (054) connect to fuel distributor (sequence see
figure).
Fuel return line ... . ..... .. . .. .. .. .. .... . insert in filler neck of fuel tank.
Adjusting device for setting the sensor plata connect to stop lever of sensor plata (see
figure).
Relay fuel pump (N16/4) ...... .. ... .. .... . pull off and bridge jacks 7 and 8 (see figure).
Sensor plate deflect and press keys 1 to 8 for device
bleeding one after the other.
Measuring device key 1 press and hold. Deflect sensor plata by means
of the adjusting device until an idle speed
quantity of 4 cm3/min has been reached. Lock
sensor plata.

07.3.0712· 16011
 Measuring device keys 2 to 8 press one after the other and measure tlow
rates, enter on data sheet 8 20 800.99.472.00.
Maximum permissible fluctuation between the
cylinders 0.4 cmJ/min (idle speed). Then check
part and full load flow rates as described before.
For this purpose deflect sensor plate.
a) Part load 30 cm 3/min
b) Fullload 100 cm 31min
Maximum permissible fluctuation between
cylinders:
Part load 4 cm 3/min
Full load 10 cm 3 /min
lf the fluctuation is outside the tolerance, renew
fuel distributor (07.3-205).
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . run, check all fuel connections for leaks.
ldle speed . .... .. . ..... .. .. ....... .... adjust (07.3-105).

Special tool

201 589 00 99 00

Commercially available Bosch testers and accessories

Designation Order designation
Flow meter KDJE .p 300
1
Test trolley ) M 200/2 or KDJE·W 100
1) lf the test trolley is used for the tlow meter. an addit1onal angle plate is required . This can be made up or obta•ned from
a Bosch representallon.

Q7.3 0712·160f2
Notes 6 7
The measurement should be carried out with the
engine stopped. The operating condition {idle
speed, part or full load) is simulated by means of
an adjusting device on the sensor plate.

Arrangement ot fuel lines to comparative fuel

flow meter P07• 2 009· 13 A J

LOCktng sensor plate with adjusttng dev tce

Model107
Pull off coupling tail lamp cable harness (X18} in
footwell left below tloor panel. Connect terminal
2 with terminal 30 {terminal block next to
overvoltage protection). The fuel pump will be
supplied with voltage.

Model126
Pull off fuel pump relay (N16/4) and bridge the
two jacks 7 and 8 {terminals 30 and 87).
The fuel pump will be supplied with voltage.

0 7.3 .07 12· 160/3

07.3-165 Checklng fuer pump relay

003

X11

P07·0283·5U

N16/4 Fuel pump relay with kickdown cut-out X26 Connector, 1nterior/engine
X11 Diagnostic sockeVterminal block (circuit TD) 003 Multimeter
026 Engine tester

Electrical wiring diagrams (07.3-128).

Checking power consumption of fuel pump
(07.3-130).

07.3.0712 - 165/1
 Testlng

Multimeter
Jack
Plug
Bridge
Ground
Multimeter resistance measuring moda
Multimeter OC voltage measuring moda

Impulse Test step; Measuring device/ Actuation/ Set value/ Possible cause/Remedy
period Scope of Test connection Req uirement Function
display test

- 1.0 N 16/4 N1614 pulled Open circuit fu se 7,

Voltage on 9-( ~)-11 off terminal 15 ground
fuel pump con nection.
relay
(N16! 4)

N16/4 lgnition: ON 11-14 V

8-( ~)- 11

- 1.1 W1 N16/4 lgnition: OFF <1Q Open circuit.

Wiring _L ~ 11 N16/4 pulled
off.

- 1.2 F1 N16!4 lgnition: OFF <1Q Open circuit.

Wiring F1 - 7 ~)-9 N16/ 4 pulled
off.

- 1.3 N 16/4 K1i 1 lgnit ion: OFF <1Q Open circuit.

Wiring 9 -( ·. =@!- )- 3 N16/4, K1/ 1
pulled off.

- 1.4 X35 N1614 lgnition: OFF <1 Q Open circuit.

Wiring Term. 30-=@!->- 8 N16/ 4 pulled (sea
off. Note)

0 7.3.0712 · 16512
Impulse Test step/ Measuring device/ Actuatron/ Set value/ Possible causetRemedy
period Scope of Test connection Requirement Function
display test

- 2.0 N16i4 lgnition: OFF

Starting 9--< ~)---11 N16/4 pulled
signal off. Fit green
cable or
protective plug
102 589 02 21
00

Start engine 10-14 V Open circuit, ground

connection starting signal
terminal 50.

- 2.1 N16t4 X26 lgnition: OFF <1!1 Open circuit.

Wiring 12 --<...:@!- )--- 7 N16/4, X26
pulled off

- 2.2 X26 S16/ 1 lgnition: OFF <1 n Open circuit.

Wiring 7--<~>---4 X26, S16/ 1
pulled off.

- 3.0 N16/4 N16/4 pulled

TO!TN 10--(~)---11 off
signa!

-<--->- Start engine 6-12 V Open circuit.

7--< )---8

- ·-
- 3.1 N16/4 X11 lgnition: OFF <1!1 Open circuit.
Wiring 10--<~-)---1

- 3.2 X11 N1 !2 Plug A pulled <1Q Open circuit.

Wiring 1 --< ...:@!- )--- 4 off (see Fig.)

07.3.0712·165/3
Impulse Test stepl Measuring device/ Actuation/ Set value/ Possible cause/Remedy
period Scope of Test connection Req uirement Function
display test

- 4.0 X26
9 __
_L Pull off X26 as Wiring
Kickdown -=<Xr- tar as required
shutoff to connect

-- 9.

Start engine 11-14 V

lncre ase Voltage

speed up to drops
approx.
200 rpm
befo re
reaching the
max. governed
speed (approx.
5800 rpm)

- 4.1 N16/4 X26 lgnition: OFF <1Q Open circuit.

Wiring 6 -< -=@!- -- 9 N16/ 4, X26
pulled off

- 4.2 X26 S3012 lgnition: OFF <1Q Open circuit.

Wiring 9 -- -=@!- )-- 1 X26, S16/7 Kickdown switch (S 16/7)
pulled off solenoid valve automatic
transmission (Y3).

- 5.0 - Start engine Max. Check TOITN signal

Maximum and increase governed (test step 3.0)
governed spead speed Renew relay (N16/4).
speed 6000 ±
50 rpm

07.3.0712·, 65/4
 Speclal too!

201 589 00 99 00

Commerclally available tools

Multimeter e.g. Sun, DMM-5

Engine tester e.g. Bosch, MOT 001 .03

Functlon
The fuel pump relay has the following functions:
• Brief voltage supply of the fuel pumps when
switching on the ignition.

• Voltage supply of the fuel pumps during

starting and with running engine. With CAT,
additional voltage supply of the oxygen
sensor heating.

• Switching off the fuel pumps when reaching

the maximum engine speed (speed
limitation).

• Switching off the fuel pumps as soon as no

more impulses are emitted via terminal
TD/TN of the ignition control unit.

• Kickdown shutoff (test see 07.3-167).

• Starting valve activation (test see 07.3-126).

07.3.0 71 2· 165/5
 Note
On vehicles with ASA the voltage to the fuel
pump relay (N16/4, terminal 15) is supplied via
the safety circuit from the electronic accelerator
pedal (see 30-350 section E).

&
Terminal 15 is not short-circuit proof to ground
(see Checking electronic accelerator 30-365).
On sorne versions the jack 1 (terminal V) on the
fuel pump relay coupling is occupied. No plug
pin is available for this on the fuel pump relay,
which is why it is without function.

Fuel pump relay (N16/4)

The fun ction in the fuel pump relay was
increased by a separata oxygen sensor heating
in two stages:

1st version up to approx. 12/89

The fuel pump relay is equipped with an addi-
tional plug for the oxygen sensor heater with the
designation 87H. This also resultad in a changa
of the wiring connection on the relay. The acti-
vation is the same as befare, as the additional
plug 87H is connected with the plug of designa-
tion 87 by means of a bridge.

2nd version as of 01/90

From this time, the bridge between terminals
87 and 87H is no longer required. For this
purpose the control electronics in the relay have
been changed. The switch-on temperatura for
the oxygen sensor heating is + 20 oc and is
determinad by the coolant temperatura sensor.

07.3.0712· 165,6
Note
Only the new fuel pump relays are available as
parts. This means that on vehicles prior te 09189
the activation of tuel pump and oxygen sensor
heating is still effected by plug 87. The plug 87H
remams without tunction on these vehicles.

Arrangement

Model 107

The fu el pump relay N 16í4 is arranged behind

the glove compartment.
The glove compartment must be removed for
tests. Disengage the relay plug holder.

In part of the vehicles it is possible to remove a

flap in the glove compartment base.

Model126
The fuel pump relay N16/4 is arranged in the unit
compartment lett.

07.3.0712·165/7
07.3-167 Checklng klckdown switch

003 ~~ 516/7

u
! ~!
L ___ j
516/7

$ 16/7 Kickdown switchltransmission moda 003 M ultimeter

Y3 Kickdown valve (automatic transmission)

07.3.0712· 167í1
 Testlng

~
~ Multimeter
-( Jack

- Plug
Ground
Multimeter resistance measuring mode
Multimeter DC voltage measuring moda

Impulse Test step/ Measuring device/ Actuation/ Set value/ Possible cause/Remedy
period Scope of Test connection Requirement Function
display test

- 1.0 S16/7 __L lgnition: ON 11-14 V Wiring

Checking 2-(~ Coupling
kickdown S16/7 pulled
shutoff 1) off

S16/7 11-14 V Wiring.

2-( -=-~ )-4

- 1.1 X26 X49/2 lgnition: OFF <1f.l Open circuit.

Wiring 9-(~)-7 Coupling X26,
X49f2 pulled
off.

- 1.2 X49/2 S16/7 lgnition: OFF <1 n Open circuit.

Wiring 7-~>-2 Coupling
X49/2, S16/7
pullad off.

- 1.3 S16/7 Y3 lgnition: OFF <1 n Open circuit.

Wiring 4-(~ >-- Coupling
S16! 7, Y3
pullad off.

- 1.4
Wiring
S16/7 S16/8
4 -( ...::@!- >-- 1
lgnition: OFF
Coupling
<1!l Open circuit.

S16! 7, S16/8
pulled off.

1 ¡ Vehicles without 2nd driVIng program 2 ·pole k1ckdown sw1tch (voltage measurement ¡ack 1 to ground).

07.3.0712· 167/2
Impulse Test step/ Measuring device/ Actuationi Set valuei Possible causeíRemedy
period Scope of Test connection Requirement Function
display test

- 2.0 S16/7 lgnition: OFF Renew kickdown switch

Checking
kickdown
4
-- .::@!-
-- 2 Coupling
S16/ 7 pulled
(S 16/7).

shutoff off.
(S 1617)

Kickdown <1Q
switch
actuated

Not ac tuated 00

- 3.0 Y3 ...L lgnition: ON 11-14 V Renew wiring, solenoid

Checking -< -=@!- Actuate S 16/7 valve (Y3).
solenoid
valve (Y3)

- 3.1 Y3 S16/7 lgnition: OFF <1Q Open circuit.

Wiring -< -=@!- >- 4 Coupling Y3,
S16/7 pulled
off

Speclal tool

201 589 00 99 00

Commerclally available tool

Multimeter e.g. Sun, DMM-5

07.3 .0712· 167/3

.-------------------------~---------

0,75
sw
ws

\~X26
0,75
0,75
sw
1J a sw b f d e e

~
W$ t
X49/21t 2r.. el

' - - -- - - -- - 0,7Ssw/rl -----t---t-+--+------1-+---J

0,7') 0,75
r - - - - - - - - 0,7Ssw/ws -

[f
- - -t---..J gr sw
X6 ge rt
2,'>
vi

0,75 0,75 0,5 0,5

WS br br gr
bl

516/1
P27- 0110-81

0730712·1~7/4
 Wiring diagram kickdown shutoff " B" -circuit models 107, 126
Et2 Shlft pattern 111um1nat10n X49i 2 Connector, backup lamplstarter lock·out switch
L2 Vehicle speed sensor Y3 K1ckdown valve (automat1c transm1SS10n)
N16/4 Fuel pump relay with kockdown cut·out a Speedometer
St6i t Starter lock·outtbackup lamp switch b Wt Maon ground behind onstrument cluster
St617 Kockdown swotchllransmiSSion mode e Fusa terminal 15
St6/8 ··a ..
engagemem sw1tch d Back -up hght
X6 Term1nal block. termonal 58d (2·pole) e 1gn1toon starter sw1tc h
X26 Connector. onterooriengine f Starter

0 7.3.0712· 16715
07.3-205 Removal, relnstallation of fuel dlstributor

~
33 -~1 ~

·~
24 -----o

P07-000-35

Fue! supply and return lines . .. .. .. . .. . . .. . . disconnect, connect.

lnjection lines . . . . . . . . . . . . . . . . . . . .... .. . on fuel distributor and injection valves,
disconnect, reconnect. 10-15 Nm (reference
value).
Mounting screws (33) .. . .... . ........... . remove, install.
Fue! distributor (2) . . .. . ... . ........ . .. . . remove by turning backwards and forwards.
Rubber sea! (24) renew, fit dry. Carefully mount fuel distributor to
avoid disturbing the rubber seal (24).
Basic position of control piston relativa
to sensor plata .... .. . ...... . ... . ..... . . check, adjust if required.
Model 107, pul! o'ff coupling tail lamp cable
harness 8-pole (X18) in footwell leh below floor
panel.
Connect terminal 2 with terminal 30 (terminal
block. next to overvoltage protection).
Arrangement see figure.

07.3 .0712·205/ 1
 Modal 126, bridge jacks 7 and 8. Arrangement
see Fig. The fuel pump will be supplied with
voltage.
The fuel must now just stop or start flowing at
the outlet fittings for the injection lines, adjust
allocation with the idle speed mixture control
screw if required.
Engine .... .. ....... ............... . . run, check all fuel connections fo r leaks.
ldle speed ... . ...................... . adjust (07.3-100).

lnstallatlon lnstructlons
Adjust basic setting of control piston (2) by
means of the idle speed mixture adjusting
screw (61).

1 Screwdriver
2 Control piston
3 Adjusting device for lambda
controVidle spee<l em•ss•on value
4 Safety plug
61 Adjusting screw

Location

M odel107

07.3.0712· 205/2
 Model 126

07.3 .0712 · 205i3

07.3-207 Renewing seallng rlng for control piston

Preceding operatton:
Renewtng fuet dtstnbutor (07.3-205)

Position (arrow) ot screw plug measure with depth gauge and note. Mark
position with scriber to be sure.
Screw plug ( 1) . . . . . . . . . . . . . . . .. ... .. . . . remove with special tool.
Sealing ring of screw plug . . . .. . . . . . . . . ... . renew. ensure proper seat ot sealing ring.
Screw plug ( 1) ... ... ... .... ... .... ... .. screw in until the distance measured prior to
removal is obtained.
Lt.
Failure to do so will result in the control
plston assuming a wrong baslc position.
ldle speed .. .. . .... ... .... ... .... .. .. . adjust

Speclal tool

102 589 00 07 00

07.3.0712·207 ' 1
 07.3-215 Removal, relnstallatlon of lnjectlon valves

92
11

12

13

P07·0280· 55

Fuel and injection lines remove, reinstall, counterhold injection valves.

Tighten with 10-15 Nm (reference value).
Retaining clip (10} remove, mount.
Engine 116, control bearing pedestal .. . ... . . . front right, remove, reinstall.
lnjection valves (92) ....... .. .. ......... . pull out. Ensure that the insulating sleeve (12) is
not pulled out as well. lf so, renew insulating
sleeve (12) and 0-ring (13).
Rubber sealing ring ( 11 ) renew.

Note
Brass injection valves with Viton seat are
installed for improved sealing.
Production breakpoint: Phased-in 1990.

07.3.0712 ·215/1
 07.3-216 Removal , relnstallatlon ot lnsufatfng sleeve

Preceding operation:
Removat. re,nstallat,on of ,n,ectJOn valves (07.3·215)

P07 • 0281 · 5 5

Ground cable on control bearing pedestal . . . . . . rear left. disconnect, reconnect.

Shaped hose for auxiliary air ... ... .... ... .. remove, mount.
lnsulating sleeve ( 12) .... ..... ... ..... .. . with pulling pliers pull out, fit.
0-ring (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . renew.

Commercially avallable tool

Pulling pliers ZSA m1 e.g. Beru , D·7140 Ludwigsburg
Beru order No. 2 908 847 002

07.3.0 7 12 ·21611
 07.3-220 Renewing air flow sensor

Preced1ng operation:
Removal, re1nstallahon of m1xtvre control v M w1th
aJr gvide hovs1ng (07.3 ·225)

14

Air guide housing (14} . . . . ... .. . . ..... ... .
Fuel distributor (2)
unscrew from mixture control unit (25).
Renew damaged parts.
Do not use sealing compound for assembly.
Sealing is by means ot sealing lip (arrow). The
air guide housing consists of rubber. For
attachment it is buttoned into the light metal
trame.
remove , reinstall (07.3-205}.

Note
Screws of ditferent lengths are used tor attach-
ing the air guide housing to the air flow meter.
For this reason it is imperativa that the screw
removed below the air flow sensor (arrow) is
again installed in the same position. lf a longer
screw is used the air flow sensor will be dam-
aged.

07.3 .0712·220/ 1
 07.3-225 Removal, relnstallatlon of mixture control unlt

~15
~
30
P07-0049-55

Fuel and injection lines disconnect, connect. 10-15 Nm {reference

value).
Electrical wiring disconnect, reconnect.
Oiaphragm pressure regulator .. ... ... .... .. disconnect, reconnect.
Four mounting nuts for mixture control unit
suspension on rubber buffers . . . . . . . . . . . . . . . remove, mount, 9-10 Nm (reterence value).
Hose clamp ( 15) on throttle assembly . . . . . . . . . loosen, secure.
Mixture control unit (25) complete with
air guide housing lift off. tit.
Rubber buffer for attachment of air guide housing check, renew according to condition.
Engine . ... .... . .. - ..... .. .... ....... . run, check all fuel connections for leaks.
ldle speed .. .. ..... . ... . .. .... ... ... . . adjust

07.3.0712·225/ 1
Note
Screws of different length are used to attach the
air guide housing to the flow meter. For this
reason it is imperativa to ensure that the screw
removed below the air flow sensor (arrow) is
again installed in the same position. lf a longer
screw is used . the air flow sensor will be
damaged.

07.3.0712·22512
 07.3-230 Aemoval, relnstallatlon of throttle assembty
Preced1ng operat1on:
Removal. reinstallat1on of m1xture control uM w1th
air guide housing (07.3 ·225)

~15

16

529/2

P07 - 0278 - 5 7

Shaped hose (arrow) for idle speed adjuster ... . remove. mount.
Hose clamp ( 15) . . ..... .. ........ . . .... . loosen. secura.
Control linkage and return spring disconnect. reconnect.
Connector (throttle valve switch)
(S29/2x1) .. ... .. .. ... . . .. .. ... .. . . . . . . unscrew, screw on and pull out.
Vacuum connections .. . . ... .... .. .. .. ... . disconnect, refit. Ensure proper connection.
Mounting screws remove. Throttle assembly, remove. Mount with
new gasket.
ldle speed adjust.

07.3 .0712 ·230/1

a To exhaust gas rec1rculation thermovalve
b To tuel evaporat1on system thermovalve
e From purga valve
d To exhaust gas rec1rculation vacuum control valve (up to
P07 - 227S - 13
09/87 or mOdel year 1988)

07.3.0712·23012
 07.3-245 Renewlng, centerlng sensor plate and checklng and adjustlng zero
posltlon of sensor plate

Stop bracket (1) for sensor plate .... . ..... . .
Mountíng screw (2) . . . . .... .. ....... . .. . .
Sensor plate (5) .. .. . .................. .
Bore for sensor plata attachment .......... ..
ldle speed .. ........... .. .... .. ... ... .
unscrew, screw on.
heat up wíth hot aír tan and carefully unscrew
(rísk of breakíng!), screw ín 5.0-5.5 Nm.
remove, reínstall, center and check zero
posítíon (observe ínstallation instructions).
clean wíth tap M6.
adjust

07.3.0712·245/1
 Special tool

000 589 67 21 00
00

Commercially avallable equipment and tools

Hot air tan, M6 tap

lnstallation instructions
1 lnstall parts of the repair kit. lnsert sensor
plate with the inscription "top" facing up and the
washer. Lightly start micro-encapsulated
mounting screw (self-locking).

2 Center sensor plate. For this purpose build

up fuel pressure.
Model 107. pull off coupling taillamp cable
harness (X18) in footwell left below !loor panel.
Connect terminal 2 with terminal 30 (terminal
block next to overvoltage protection).

Model 126, pull off fuel pump relay (N 16/4).

Bridge jacks 7 and 8 (terminals 30 and 87) .

0 7.3 .0 7 12·24512
With a feeler gauge of approx. 0.05 mm ensure
that the sensor plata is exactly concentrical. The
sensor plate must not jam even with light lateral
pressure (bearing play eliminated).

3 Secure mounting screw with 5.0-5.5 Nm and

fit stop bracket.

4 Check sensor plate for easy operation by

manually pushing down the sensor plata. The
sensor plata must not jam. Ralease the sensor
plata, it should neither jam during the return
movement. The impact on the spring-loaded stop
should be audible. Recentar sensor plata if
required.

5 Check zero position (position of rest) of sen-

sor plata. The upper edge of the sensor plate
must be flush with the upper edge of the cylindri-
cal part (arrow) on the Venturi. A higher position
up to a maximum of 0.2 mm is permissible.

In this position a clearance of 1-2 mm should

exist when pushing the sensor plata up to the
control pistan.

07 .3 .0 712· 245/3
6 Adjust zero position of sensor plate.

a) With excessively high position, unscrew fuel

supply fitting, drive dowel pin (arrow) in
correspondingly deeper with a suitable
mandrel.

b) 11 positiOn is too low, remove mixture control

unit and drive out dowel pin from below
(07.3-225).

~
Do not drive dowel pin in too deeply. Avoid
repositioning several times in both directions as
the press seat of the pin will become inadequate.

7 Mount fuel supply fitting, stop bracket and

fuel pump relay.

8 Adjust id le speed (07 .3-1 00).

07.3 .07 12 ·24514

07.3-250 Removal, relnstallatlon of CIS-E control unlt

Model 107 Model 126 (A 17 not used)

Floor mat front righ t . . . . . . . . . . . . . . . . . . . .. ramova, rainstall.

Floor plate front right (modal 107) . ... . ... .. . ramove, rainstall.
Lateral covering front right (modal 126) .. . ... . . ramove, reinstall.
Coupling from control unit (N3) .. .... ... ... . pull off by pushing down clips.
Control unit (N3) ...... .. .. . .... .. .. . ... . pull off.

Arrangement CIS·E control unlt (N3)

Model 107
In footwall right below floor plate.

Model126
In footwall righ t behind lateral trim.

07.3.0712·25011
07.3-251 Removal, relnstallatlon of ldle speed control unlt

Model 101 Model 126

Floor mat front right (model 126) remove, reinstall.

Floor plate front right (model 126) remove, reinstall.
Glove compartment (model 107) .. ... ... .... remove, reinstall.
Control unit (NS) . . . . . . . . . . . . . . . . . . . . . . . . pull off.

Arrangement control unit (N8) for ldle speed

control

Model 107
Behind glove compartment.

Model126
In footwell right below floor plate.

07.3.0712·25111
07.3-255 Renewing electrohydraullc adjusting element

Y1
~ @
~3
~

4
© Y1

P 0 7-0050-55

Electrical coupling . . . . . . . . . . . . . . . . . . . . . . . disconnect, reconnect.

Fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting screw (3) . . . . . . . . . . . . . . . . . . . . . .
0 -ring seal (4) ..... . .......... . . ... ... .
ldle speed ... .. . ..... . . . . . . . . .. .... . . .
relieve. For this purpose loosen fuel line
between fuel distributor and starting valvc.
Collect any fuel running out with a cloth.
unscrew. screw in. Renew 0-rings (4). Observe
cleanliness of sealing surface and clean
surfaces with benzine and a lint free cloth if
required. Secure mounting screws with 3.0 ± 0.5
Nm
check, no fuel must run out with running engine.
adjust.

07.3 .0712·255/1
Commercially available tool
Screwdriver 2115-T 27 e.g. Hazet, D-5630 Remscheid

0 7.3.0712-255/2
07.3-258 Renewlng oxygen sensor

Floor mat, floor plate tront right remove, reinstall.

Covering on center tunnel .. .. . ... . . ... . .. . partly remove.
Coupling (G3/2x1 and G3t2x2) .. . ... . .. . . .. . for oxygen sensor signal (coaxial plug) and
oxygen sensor heater (2-pole), disconnect.
Línes with grommet . . . .. ... ..... .. . .... . force to the outside.
Shield . .. .. .. . ........ .. . .. .. .. .. .. . . remove, refit. Observe installation position.
Oxygen sensor (G312) .. .. . .. .. . .... . . ... . unscrew, screw in. Coat thread of oxygen
sensor with hot lubricating paste part No.
000 989 88 51 . Secure oxygen sensor
(50-60 Nm).
Lambda control check, adjust (07.3-105).

07.3.07 12·25811
07.3-268 Renewlng rubber buffer for fuel pump assembly

Protective cover (10) •................... unscrew, screw on.

Rubber buffer (35) ...................... remove, reinstall.

07.3.0712·2681
07.3-269 Removal, relnstallatlon of fuel pump assembly

Pressure in fuel tank . . . . . . . . . . . . . . . . . . . . . release by opening screw cap.

Battery disconnect, reconnect.
Protective box ( 1O) .. . . . .. .. . .. . . .. . ... . . unscrew, screw on.
Electrical wiring . . . . . . . . . . . . . . . . . ...... . disconnect, reconnect.
Fuel suction and delivery hoses (19 and 23) pinch with clamp (11 ) and remove. Special tool
000 589 40 37 00
Fuel suction, leak-off and delivery hoses
(12, 19 and 23) . .. . .. . . . . . .. .... . . ... . . unscrew, screw on .
Rubber buffer (35) remove, reinstall.

Special tool

000 589 40 37 00

0 7.3.07 12·269/ 1
07.3-270 Removal, relnstallation of fu el accumulator

P07 · 0213·55

Pressure in fuel tank . . . . . . . . . . . . . . . . . . . . . ralease by opening screw cap.

Battery .. ... ..... . ......... .... ... ... disconnect. reconnect.
Protective box (10) .... ..... .... .... ..... unscrew, screw on.
Fuel suction and delivery hoses (23, 19) . . . . . . . pinch with clamp (11) and remove. Special tool
000 589 40 37 00
Fuelline (5) ......... ... ......... .... .. unscrew from fuel storage unit (57), fuel pump
and fuel filter.
Leak -off hose (12) loosen and pull off.
Mounting screw (arrow) . . . . . . . . . . . . . . . . . . . loosen from bracket (2) and remove fuel storage
unit (57). Observe spacer ring (1) in bracket (2).
Sealing rings ....... ................. .. renew.
Engine, run check for leaks.

Speclal tool

000 589 40 37 00

07.3.0712·270/1
07.3-275 Removal, relnstallatlon of fuel fllter

"- -»><·- »«-->- -···- - - - - - - - - - - - - - - - - - - - - - - - - . .

Pressure in fuel tank . . . . . . . . . . . . . . . . . . . . . release by opening screw cap.

Battery disconnect, reconnect.
Protective box (1 O) ... ... ... ....... .... .. unscrew, screw on.
Fuel suction hose (23) and delivery hose ( 19) pinch with clamp (11) and remove. Special tool
000 589 40 37 00
Fuel line (5) ...... .. ..... .... ..... ..... unscrew from fuel tank (57), fuel filter, screw
on.
Fuel delivery hose (19) ................... unscrew, screw on.
Mounting screws (arrows) loosen from bracket (2) and remove fuel
filter (55).
Plastic sleeve (26) mount. (Observe note)
Sealing rings (9) . . . . . . . . . . . . . . . . . . . . . . . . renew.
Engine, run check for leaks.

07.3.071 2-275/1
 Special tool

000 589 40.37 00 J

Note
In order to avoid contact corrosion the fuel filter
is equipped with a plastic sleeve.
When exchanging the fuel filter ensure that the
plastic sleeve (26) is mounted between fuel filter
(55) and bracket (2). lt must protrude on both
sides of the bracket as contact corrosion could
occur it the fuel filter is in direct contact with the
bracket.

07.3.0712·2 7Si 2
 07.3-280 Removal, relnstallatlon of fuel pump

'(!Q

Pressure in fuel tank . . .. . ..... ... . ... . . . . release by opening screw cap.
Battery . . . . . . ..... . . .. ... . ... . ...... . disconnect, reconnect.
Protective box (10) .. . ... . .. . .... . .. .. . . . unscrew, screw on.
Fuel suction hose (23) and delivery hose (19) pinch with clamp and remove. Special tool
000 589 40 37 00
Fuel pump 1 (M3/ 1) remove, reinstall.
Fuel line (6) to fuel pump 2 (M3/2) .......... . disconnect, reconnect.
Electrical wiring disconnect, reconnect.
Hose clamp on fuel suction line . . . . . . . . . . . . . loosen and pull off fuel line (6).
Mounting screws (arrows) .... ..... ... ... .. loosen and remove fuel pump.
Fuel pump 2 (M3t2) . . .... ... ..... ..... .. ramove, reinstall.

07.3.0712·280/ 1
 Fuel line (5) ...... ..... ...... .... .. .... between fuel pump, fuel filler, fuel storage unit,
remove, reinstall.
Electrical wiring . . . . . . . . . . . . . . . . . . . .... . disconnect. reconnect.
Mounting screws (arrows) . . ...... . . .. . ... . loosen from bracket (2) and remove fuel pump
while forcing fuel hose oH fuel pump 1 (M3/1).
Plastic sleeve (25) mount (observe note).
Copper sealing rings (9) renew.
Check for leaks with running engine.

Special tool

000 589 40 37 00

Note
Fuel pump assembly
Arranged on the right in direction of driving in
front of the rear axle on the trame floor. A
diaphragm damper is installed in the suction side
of the fuel pumps. Owing to the higher system
pressure two fuel pumps (in series) are installed
to increase the rate of delivery.

When exchanging the fuel pumps ensure that

the plastic sleeves (25) are mounted between
fuel pumps (M3/ 1 and M3/2) and the bracket (2).
lt must protrude on both sides of the bracket as
contact corrosion couid occur with direct contact
M311 Fuel pump 1
of the fuel pump with the bracket.
M3/2 Fuel pump 2
The fuel pumps are activated vía the fue! pump 55 Fuel filler
relay (07.3-165). 57 Fuel storage un~~

07.3.07 12·28012
 Since February 1986. fuel pumps with orbital Productlon breakpoint
path have been installed . Model Engine Vehicle ident
ldentification: Bosch manufacturing date as of end No.
642.
107.048 117.967 A 045214
126.035 116.965 A 232518

126.0391045 117.968 A 232369

07.3.0712·280/3
 07.3-285 Renewlng check valve for fu el pump

Pressure in fuel tank . . . . . . . . . . . . . . . . . . . . . ralease by opening screw cap.

Battery . ... .... ... ..... ... .... .... ... disconnect. reconnect.
Protective box (1 O) .. .. ..... .... ... ..... . unscrew, screw on.
Fuel suction hose (23) and delivery hose ( 19) pinch with clamp ( 11) 000 589 40 37 00, loosen
fuel suction hose and pull off.
Renewing check valva on fuel pump 1 (M3/ 1):
mounting screw (arrow) . . . . . . . . . . . . . . . . . . . loosen on bracket (2) for fuel pump.
Fuel line (6) . .... ... ..... ... ..... ..... . disconnect, reconnect.
Acorn nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . unscrew, screw on.
Fuel pump 1 (M3/ 1) push to the left.
Check valve (32) remove, reinstall. Tightening torque 22 Nm as
reference value.
Copper sealing rings (9) renew.

07.3.0712·285/1
Check for leaks with running engine.
Renewing check valve on fuel pump 2 (M3/2):
tuel line (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . between fuel pump, fuel filter, tuel storage unit,
disconnect, reconnect.
Acorn nut . . .... .. .. .. .. . . .. .. . . . . • .. . . remove, refit.
Check valve (32) remove, reinstall. Tightening torque 22 Nm as
reference value.
Copper sealing rings (9) renew.
Check tor leaks with running engine.

Speclal tool

í 1' l
' 1

j
1

000589<03, 00

07.3.07 12·285/2
 RemovaJ, relnstallatlon of alr cleaner

Mounting nuts (5) . . . . . . . . . . . . . . . . . . . . . . . on anti-vibration mounts (6), remove, refit.

Shaped hose (8 and 11)
Air cleaner (4)
..... ... .... ..... .
for crankcase ventilation and air pump,
disconnect, reconnect.
remove, mount. Ensure proper seating of
sealing ring (7) between air flow meter and air
cleaner.

09.0712·400/1
Note
Version:
The air cleaner ís made of light metal.
The air intake is by way of a fresh air scoop and
a plastic snorkel. The fresh air scoop is attached
to the radiator.

A recess for adjusting the idle mixture is

provided in the air cleaner upper part.

Model 107
Engine 117

Mooel126
Engine 116

On engine 117.968 the air cleaner housíng is

provided with two intake scoops (double
snorkels).

Mooel126
P07 2288 13
Engine 117.968

09.0 712·400/2
 09-402 Renewlng lntake scoop

Electrical connection wire and intake air

temperatura sensor (B 17i 2) ....... . .. .. . . . . not applicable
8oth spreading clips (arrows) .............. . remove, reinstall.
Lighting unit .......... . .......... . .... . remove, reinstall (82-052).
Lighting unit . . . . . . . . . . . . . . . . . . . . . . _ . . • . adjust (82·040) .

Note
The air is drawn in vía the intake scoop (9) from
outside the engine compartment.

09.0712·40211
13-335 lnstructions concerning V-belt replacement and tensioning

Adjusting values

V·belt New V·belts Used V -belts

(width of section in mm) (KG scale on (KG scale on
measuring instrument) measuring instrument)

9.5 30 20-25
12.5 50 40- 45

Special tool

Measuring instrument (Krikit) for

,.,'~g 1 w,::.. .-!;d
__ . . .. ~~ ":'...•. 001 589 69 21 00
measuring V·belt tension

Checking V-belt condition

Replace c racked, burnt o r w orn V -belts.

Checking tension

For handling of instrument refer to operating inst ruc·

tions and Replacing and tensioning V-belts ( 13- 340).

The specified adjusting va lues refer to the KG scale

of the measuring instrument (arrow ).

13.7- 335/ 1 F3
Used V-belts

Check tension of V -belt and compare with values

named in table for used V-belts (e.g. V -belts, width
of section 9.5 mm= adjusting value 20-25).
Retension V -belt if requi red.

Mounting and tensioning of new V-belts

Proper mounting of a V-belt requires loosening of

the respective auxiliary unit or tensioning device of
V-belt to the extent that the belt can be mounted
without any special effort. In addition, the running
surface on the belt pulley should be free of burrs,
rust and dirt.

Keep free of oil, grease and chemicals. Do not use

belt wax ing compound or the like. Optimal adjust-
ment of belt tension ( for adjusting data refer to
table) as described below will eliminate any com-
plaints such as squealing V-belts and short lite.

Within the scope of maintenance jobs, mount the

V-belt prior to checking the engine and tension to
the value specified in the table for new V-belts
(e.g. V -bett, width of section 9.5 mm = adjusting
value 30) .

lf the V·belt tension is checked during final inspec-

tion or following a test drive, the measured value
should be the same as the value named in the table
for used V-belts (e.g. V -belt with width of section
9.5 mm= adjusting value 20-25). Retension V-belt
if required.

13.7-335/2 F3
13-340 Replacing and tensioning V-belt

V-belt d imensions

Engine 1 Version A
Coolant pump Alternator Refrígerant A ir pump4 )

power steering compres sor

pump

9.5x 1 1401 )
12.5 x 868 1 )
Standard 9.5x 11 502 ) 9 .5 X 920 -
12.5 X 8802 )
(2 each) 5 )

116.960 @0 9.5x1 130

9.5 X 950 12.5 X 920
116.961 1981 (2 each) 5 )

0@
1981
12.5 X 930
9.5 X 750
0@ 9.5x1 100 9 .5 X 990
1982 (2 each) 5 ) 9 .5 X 9006 )
116.962
116.963
St andard
@0 12.5 X 920
1982

116.964 12.5 X 960 7 )

116.965

9.5 X 1150 1 ) 12.5 x 868 1 )

117.960 9.5 X 11302 ) 9.5 X 10001 ) 12.5 X 9102 ) -
9.5x 11103 ) 9 .5 X 9602 ) 12.5 x920 3 )
(2 each) 5 )
Standard
9.5 X 1005 1 ) 12.5 X 910 1 )
117.961 -
9.5 X 9602 ) 12.5 X 9202 )
9.5 X 1100
(2 each) 5 )
117.962
117.963 9. 5 X 100 5 12.5 X 920 -
9.5 X 9006 )
1 17 .964
117.965
12.5x9607 ) -
117.967
117.968

1 ) 1st version
2) 2nd version
3 ) 3rd version
4
Only@@Q)(D~
!)) Special
)
lnstall d;oub le V-belts only on pairs and made by one and the same manufacturar only.
protection vehicles with 2nd alternator.
7
) Wit h Nippondenso compressor and light alloy bracket as of August 1985.

13.7- 340/1 F3
V·belt Arrangement Adjusting value (KG scale on measuring device)
New V-belts Used V-belts

A Coolant pump - power steering pump 1 ) 30 20- 25

B Alternator 35 30-35

e Refrigerant compressor 50 40-45

D Air pump 30 20-25

1
1 Oouble V -belt.

Special tools

Measuring instrument (Krikit)

001 589 69 21 00
for measuring V-belt tension

Screwdriver 10 mm for
interna! socket head bolt tension roller 117 589 03 07 00
V·belt- refrigerant compressor

Note

The measuring instrument ,.Krikit" is recommended

for testing V-belt tension.

1 Crankshaft 5 Tension roller

2 Coolant pump 6 Power steering pump
3 Alternator 7 A ir pump
4 Refrigerant compressor

Use of measuring instrument

To check V·belt tension, the measuring instrument

can be held in severa! ways:

a) With thumb and index finger at rubber loop, w ith

finger tips resting on push·button.

13.7-34012 F3
b) With index finger from above in rubber loop.

e) With index f inger laterally between rubber loop

and push -button.

Checkup

Lower indicating arm on measuring instrument.

2 Place measuring instrument on V·belt in the

center between the pulleys. T he stop of the
measuring instrument should rest laterally against
the V ·belt (arrow).

Caution!
On double belt drive, make sure that the measuring
instrument rests on one V-belt only.

3 Exert even vertical pressure on the top of t he

V·belt with the push·button until the clicking
spring disengages audibly or noticeably.

Note: Following d isengagement of click spring, do

not continue pushing with measuring instrument as
this will ind icate a wrong value.

4 Carefully lift measuring instrument off V-belt.

Avoid knocks and do not change position of
indicator arm.

13.7-340/3 F3
5 Read adjusting value on intersection of indicating
arm and upper scale (KG scale, arrow) .

The specified adjusting values refer to the KG scale

of the measuring instrument.

Replacement

Check condition ot V-belt.

Replace cracked, burnt or worn V·belts.

Cautionl
lf on a double belt drive for coolant pump and
power steering pump one of the two V·belts fails
due to wear, make sure that both V·belts are replaced
together.

lnstall only V·belts made by one and the same manu·

facturer.

V· belts as spare parts are ava ilable in pairs only.

Loosen tension devices or un its.

2 Mount V-belt without using force.

3 Tension V-belt.

Tensioning

V·belt A Coolant pump - power steering pump

1 Loosen nuts (1, 2 and 3 (pivot point]), on power

steering pump bracket.

13.7-340/ 4 F3
2 Tension V·belt with tension screw (arrow) .

3 Tighten nuts (1, 2 and 3) .

V-belt B Alternator

1 Slightly loosen fastening bolt ( 1) and nuts (2 and

3) on alternator bracket.

2 Tension V·belt w ith tension screw (4).

3 T ighten fastening bolt ( 1) and nuts (2 and 3) .

V-belt C Refrigerant compressor

Loosen fasten ing bolt (9) of tension roller (8).

2 Tension V·belt by swivell ing tension roller (8).

For t his purpose, fit an O·pen end wrench (19 mm)
on the flat ( 10).

3 Tighten mounting bolt (9).

13.7-340/5 F3
Note

Access to the attaching bolt (9) was improved by

means of a changed bracket (version 8).

This bracket is attached w ith a bolt M 12 x 1.5 x 35

(was M 12 x 1.5 x 40).

1n the event of repairs, the tension roller and the

bracket can be installed on the previous engines as
well.

As of November 1985, the bracket for the tension

rollcr is attached with an interna! socket·head bolt.
Thc inte rna! socket·head bolt must be loosened with
the 1O mm screwdriver 117 589 03 07 OO.

A 1st version
B 2nd version

V·belt O Air pump

KAT as of 1985
<§> G) 0 @as of 1981
@asof 1983

Loasen mounting bolts ( 1 and 2).

2 Tension V·belt with tension nut (3).

3 Tighten mounting bolts ( 1 and 2).

13.7- 340/6 F3
 14-001 ldentificatlon features

lnformation plate for the emission control system

on the cross member in front of the radiator.
This plate shows the engine identification data
and the most importan! engine adjusting data.

The engine identification data are coded in a 10-

digit code.

Example: H MB 5,6 V 6 FA 13 H MB 5.6 V 6 F A 13

Model year G 1986 =

H = 1987 J = 1988 K = 1989
=
L 1990 M 199 1 =
Manufacturer's code
Mercedes-Benz

Cubic capacity
5.6 liters

Vehicle class
V =Passenger car with
gasolina engine

Type of fuel supply

6 = Mechanical injection

Catalytic converter version

F = 3-way catalytic converter together with lambda control

Provided by manufacturar for free use

A = Federal and California

Check digit

14.0712·001 i 1
 Tourist version
Venicles in tourist version are equipped by t~e
manufacturer with catalytic conver:ters as of
approx. 05 88.
· Vehicles without catalytic converters are also
available upon request.

Color code of information plate:

red background. silver writing.

When imported into the US the catalytic

converters must be installed.

14.0712 ·00112
14-050 Function of emlsslon control system

A. General

The function ot the emission control system is

described in the following sections (B through
H) .

14.0 712 ·05011

B. Functlon dlagrams

Engines 116, 117 wlth Exhaust Gas Recircutatlon

and Air lnjection

N1s14 •on-13331

14.0712·050;2
Fault diagnosis by means of impulse period
measurement
The CIS-E control unit identifies faulty input
signals and issues a fault report to the lambda
measuring output. The fault report can be taken
off the diagnostic socket with the lambda tester.
Short circuit and w1nng interruption can be
identified.

A certain impulse period is allocated to each

fault. The output of fault reports has priority over
the output of the lambda control signa!. lf the
lambda control is not operational (e.g. tempera-
tura oxygen sensor inadequate). the measured
value display is 50% (control operationlconstant
display). With lambda control switched on, the
display fluctuates around a mean value. lf
severa! faults occur at the same time. the fault
corresponding to the smallest impulse period will
always be shown. This takes place until all taults
have been eliminated. An allocation of impulse
period and possible cause of the fault is
compiled in the testing program (07.3-121,
section B).

14.0712·050/7
Plausibility circuits
The signals input into the CIS-E control unit by
the peripheral components are continuously
registered.
lf the composition of the signals is no longer
log1cal, the electronics automatically form a
replacement value (emergency operation
charactenst1c) for the implaustble signal.

D. Lambda control

The CIS-E control unit handles oxygen sensor

monitoring, signal amplification and the
calculation of the output signal for the
electrohydraulic adjusting element from the input
signals. The current with lambda control is
approx. -12.5 to + 12.5 mA.

The lambda control is not operational during the

follow1ng operating conditions:

• Oxygen sensor not operational or detective.

• Coasting operation with deceleration shut-off.

• Full load operation.

• Acceleration enrichment.

• During starting process below 15 oc coolant

temperatura to coolant temperatura + 70 oc.

• After start increase > O mA (only after

starting process).

14.0712·050/8
E. Oxygen sensor

The oxygen sensor is installed in the firewall

catalytic converter or in tlhe underfloor catalytic
converter.
lt is heated in order to províde constant
operating temperatura for the oxygen sensor.
The heating element of the oxygen sensor is
provided wíth voltage via terminal 87 of the fuel
pump relay and ís heated as long as the fuel
pump is running.

Model 107

~
Fuel pump relay and kickdown shut-off (N16/4)
with additional plug for oxygen sensor heating.
Oxygen sensor (G312) is only heated from 20 oc
coolant temperatura (07.3-165).

Model 126
G312 Oxygen sensor
157 Firewall catalytic converter

14.0712·05019
 The outer electrode is exposed to the exhaust
emission while the inner electrode is exposed to
the atmosphere. The active part of the oxygen
sensor is a ceramic body mainly consisting of
zirconium dioxide. lts surface is provided with a
gas permeable platinum layer and with an
additional protective layer on the exhaust side.

P07 2289 13

1 Sensor housing
2 Slit protecttve tube
3 Heater element
4 Sensor ceramíc

At operating temperatura the ceramic material is

conductiva for oxygen ions. A voltage is created
in the oxygen sensor due to the different oxygen
content in exhaust gas and atmosphere.

Atan operating temperatura ( > 300 °C) the

oxygen sensor sends a voltage signal to the
control unit.
Voltage > 450 mV rich mixture.
Voltage < 450 mV lean mixture.

Owing to the steep voltage jump at lambda (A)

= 1 the exhaust gas composition can be rapidly B
registered and the air-fuel mixture corrected
within a narrow control range.

450

0,9 1,0 1,1-).

A Rtch aJr·fuel mtxture
B Lean air-tuel mixture

14.071 2-050110
F. Catalytlc converters

The 3-way catalytic converters are located in the

exhaust system in front of the mufflers.
The following versions are installed:
Model 107 underfloor catalytic converter
Model 126 firewall and underfloor catalytic
converters.

Model 107

Model 126

The catalytic converters consist of the following

three main parts:
Carrier material made of high-strength ceramic
or highly heat-resistant high-grade steel, also
called Monolith (ceramic flexibly mounted on wire
braiding).
lntermediate layer for surface enlargement.
Catalytically active layer made of
platinum/rhodium.

P0 7• 228 4 - 13

1 Braiding
2 W1re t:>raid1ng
3 Monollth

14.071 2-050111
Functlon
The exhaust gases flow through the catalytic
converter and during this process come in
contact with the precious metals. By oxidation,
carbon monoxide (CO) is converted in carbon
dioxide (C0 2 ) and hydrocarbons (HC) in water
(H 2 0), while nitric oxides (NO.) are converted
into nitrogen (N 2) by reduction. Decisive for this
are temperatura and the residual oxygen content
in the exhaust gas. The catalytic process, i.e.
the chemical reaction, commences from approx.
250 o C. Excessively high temperaturas lead to
thermal overloading.

Oxygen is required for the oxidation of CO and

HC. The reduction of the nitric oxides takes
place under oxygen deficiency.

The fluctuating between oxygen-deficient and

oxygen -rich exhaust gas is achieved by changing
the air-tuel mixture. The ratio of the air-fuel
mixture is called lambda (X). X <: 1 means rich
mixture . .l. > 1 means lean mixture.

A Rich a1r·ruel m1xture

B Lean air-tuel mixture '--- - - -·-·-···-·--·-·- - - - - - - = -t-

The fluctuation of the oxygen content in the

exhaust gas in tront of the oxygen sensor is
controlled. lt is only by means of these oxygen
fluctuations that the three mentioned exhaust
gas constituents can be chemically converted in
the catalytic converter.

Only unleaded fuel must be used in vehicles with

catalytic converter and oxygen sensor. Lead
additives in the fuel are depositad on the
chemically reactive surtace of the catalytic
converter and the oxygen sensor, rendering the
system ineffective.

14.07 12·050/ 12
G. Exhaust gas reclrculatlon (EGR)

In order to reduce the nitric oxides in the exhaust

gas, a part of the exhaust gases is returned into
the intake manifold vía the exhaust gas
recirculation valve under certain operating
conditions.
The oxygen-deficient exhaust gases are mixed in
the intake manifold with the fresh, oxygen-rich
mixture. As a consequence, the proportion of
fresh mixture is lowered and correspondingly
less oxygen is available for combustion . The
amount of returned exhaust gases depends on
the throttle valva position (vacuum at the throttle
valve). The driving characteristics of the vehicle
are not influenced by the exhaust gas
recirculation.

The following versions are distinguished:

a) With vacuum control valve up to 08/87
b) Without vacuum control valve as of 09/87

14.0712·050i13
 a) Wlth vacuum control valve up to 08/87

155

WS 1vilge

79 WSi br

90b P07• 0203-5$

Function diagram exhaust gas recirculation with vacuum control valve up to 08/87
M1xture control unit 90a Shut·off diaphragm
12 lntake man1fold 90b Check valve
79 Thermovalve 50 •e 123 Throttle assembly
89 Exhaust gas redrculatton valve 155 Exhaust gas recirculation line
90 Control valve 156 Exhaust manifold

Exhaust gas recirculation takes place under the

following operating conditions:
• Coolant temperatura > 50 oC
• In all load conditions except idling and full
load.

With the throttle valve closed, the EGR valve

(89) is atmospherically ventilated via a
connection on the throttle assembly (123), the
thermovalve (79) and the vacuum control valve
(90. connections 11 and 111).

lf the throttle valva is partly opened, vacuum

reaches the EGR valva vía the same way and
causing it to be opened.

14.071 2·050i 14
The control valve still maintains the exhaust gas
recirculation in the high load range (not yet full
load), although the exhaust gas recirculation
valve would already close according to its
characteristic. The bore is closed by the
diaphragm and the vacuum is maintained. In the
full load range the vacuu.m drops so that the
EGR valve is closed again.

The connection (1) on the vacuum control valve

serves to rapidly ventilate the EGR valve during
the transition from part load range to idle speed, P07 221~ t3

thus switching off the exhaust gas recirculation.

a to thermovalve exhaust gas recirculation

b to thermovatve fuel evaporation system
e from purge valve
el to vacuum control valve exhaust gas recirculation

Lb. Engine Engine end No.

The vacuum line ws/br of the exhaust gas
recirculation was temporarily fitted to the lower 116.965 000 395
connection of the throttle assembly during 117.968 000 101
production start-up. The connection is okay as of
the following engine number.

14.071 2·050/15
b) Without vacuum control valve as of 09/87
Vacuum is directly applied to the exhaust gas recirculation valve only as a function of the
thermovalve.

79

P0 1• 02&4 • 63

Function diagram exhaust gas recirculation as of 09187 or model year 1988

1 Mixture control uM 123 Throttle assembly
12 lntake man1fold 155 Exhaust gas rec~rculabon line
79 Thermovalve 50 •e 156 Exhaust manifold
89 Exhaust gas recirculation valve

14.07 12·050116
H. Air lnjectlon

Signal processing for the switching on and

switching oH ot the air pump via the relay (K 17)
is carried out by the control unit of the CIS-E
injection system.

Air injection takes place if the following

conditions are met:

• Coolant temperatura > 17 oc < 70 oc

• Engine speed < 2500 rpm

• No full load contact

• Lambda control not switched on.

Under these conditions the electromagnetic

clutch of the air pump is switched on by the
control unit CIS-E (N3) via the relay (K1 7, see
electrical wiring diagram). Via the same relay,
the change-over valve (Y32) is actuated at the
same time which in turn raleases the vacuum to
the air shut-off val ve ( 126).

The vacuum draws the diaphragm up against the

spring force, lifting the valve oH its seat. The air
drawn from the air cleaner is injected via the
shut-oH valve (126), the check valve (127) and
the passages of the timing case cover and the
crankcase into the exhaust ports of the cylinder
heads.
The air supplied via the air pump causes
a combustion of co and co2 in the catalytic
converter. The heat liberated during this process
accelerates the readiness for operation of the
catalytic converter.

14.0712·05011 7
 Note Model Engine Engine end No.
The bearings of the pulley shaft on the air pump
were reinforced. 126.035 116.965 008548
107.048 117.967 004085
Productlon breakpoint: January 1986
126.039/045 117.968 003175

14.0 71 2·0 50118

14-116 Checklng oxygen sensor fallure indlcator

Al lnstrument cluster N3 Control unit CIS -E lnje<:lion system

AlelO lnd1cator lamp oxygen sensor a To control uOII CIS -E 1n¡ect1on system (N3)
K1 /1 Relay overvoltage protect1on jack 1

Test condition
• Battery voltage 11 -1 4 V

Electrical wiring diagrams (07 .3-128).

14.0712·116/1
Explanation of symbols
~
~::L._) Multimeter Ground
Jack Mult1meter measuring mode res1stance
Plug Mulhmeter measunng modo DC voltage

Impulse Test step/ Measuring devicet Actuation/ Set value/ Possible cause,Remedy
period Scope of Test connection Requirement Function
display test

- 1.0 Visual inspection lgnition: ON Oxygen lndicator lamp detective.

Oxygen Engine: Start sensor Oxygen sensor failure
sensor failure indicator (A 1e 1O) wíthout
failure indicator voltage.
1ndicator (A1e10) Open circuit
(A1e 10) lights up Wiring (A1e10)--. (N3)
briefly. jack 15

- 2.0 Visual inspection lgnition: ON Oxygen Remove indicator lamp,

lndicator Engine: Start sensor check, renew if required.
lamp oxygen failure
sensor indicator
failure (A1e10)
indicator lights up
brlefly.

- 3.0 A1e10 Wiring

.
lgnition: ON 11-14V Open circuit
Voltage gr,bl ...=&• -'-- Wiring pulled Wiring
supply off (A1e10) ~ (K1 i 1}
oxygen jack 2.
sensor Open circuit
failure Wiring (K1 i 1)
indicator Jack 2 --. (N3)
(A1 e10) Jack 1 (a).

- 3.1 A1e10 K1 /1 lgnition: OFF < 1Q Open circuit.

Wiring rt!ge -=@!- >- 2 Wiring pulled
off

14.07 1 2 · 116!2
Impulse Test stepl Measuring device/ Actuation/ Set value! Possible cause·Remedy
period Scope of Test connection Requirement Function
display test
- 3.2 K 1.'1 N3 lgnition: OFF <1 Q Open circuit.
Wiring 2 - --< ·...:.@!- ) --·-- 1 Wiring pulled
off

- 4.0 AlelO N3 lgnition: OFF < 1Q Open circuit.

Wiring gnbl -=@!->- 15 Wiring pulled
off

Special tool

201 589 00 99 00

Commercially available tester

Multimeter e.g. Sun, DMM-5

Note
Failure of the oxygen sensor is indicated in the
instrument cluster (A 1) by a lit indicator lamp
"oxygen sensor" (A1e 10). The lamp is activated
by the control unit CIS-E injection.
The indicator lamp lights up briefly when the
ignition is switched on.

14.07 12 · 11 613
 Removal, relnstallation of catalytic converter

Cover (2b) ... . ....... . .. ... .. .. . .. .. . . remove, reinstall. Observe installation position.
Oxygen sensor (G3/2) . .... . ........ . .... . remo ve. reinstall (14-480).
Note
Befare installing the oxygen sensor, coat the
thread with the hot lubricating paste
part No. 000 989 88 51 .
Screws (1) ot flange connection on exhaust
manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . unscrew. screw on.
Lateral support (10) on transmission . . . . . . . . . . remove, reinstall.
Rubber rings (18 and 18a) for exhaust system . . . disconnect, reconnect.
Exhaust system .... . .. ... ... .... .. ..... completely remove, reinstall (49-1 00).
Flange connections (arrows) loosen and remove catalytic converter.

14.0712·200/1
 14-250 Removal , relnstallatlon of alr pump

P 14·0021·53

Connector for electromagnetic clutch (Y33) pull off. Lace out wire. On vehicles with auxiliary
heater, unscrew bracket for auxiliary heater.
Shaped hoses ( 1 and 2) . . . . . . . . . . . . . . . . .. remove, refit.
V-belt . ... . . ... . .. .... . . .. ......... . . slacken and remove.
Air pump (125) .. . .. ..... . . ... ... . ..... . remove, reinstall by removing mounting screws
(3 and 4).
V-belt instan and tension (13-340). For measuring, use
special tool 001 589 69 21 OO. Adjusting values
according to KG scale on measuring device:
New V-belts 30
Used V-belts 20-25
Electromagnetic clutch ... .. ..... .. ... .... remo ve, reinstall ( 14-260).
Special tool ........ ......... ........ .. Handling of measuring device see operating
instructions or repair instructions (13-340).

14.0712 ·250/ 1
 Special tool

001 589 69 21 00

Note Production breakpoint: January 1986

Bearings of pulley shaft reinforced. Model Engine Engine end No.
126.035 116.965 008548
107.048 117.967 004085
126.039
126.045 11 7.968 003175

14.07 12·250/2
 14·260 Remo~v~a~,~~.:_
1 relnstallatlon
______ ~_
of electromna tic clutch
- ~g~n:e:::_:.:..._____~-

. . . . . . .... . . . . ...
remove, reinstall { 1 4~~~~. Secura hex. nut
Air pump (125) F·...
Parts as shown in •9· .
d•sma ntle and reass
with 35 ::t 5 Nm.

14.0712· 260/1
 14-450 Removal, relnstallatlon of lntake manifold, renewlng gaskets

Battery disconnect, reconnect.

Mixture control unit with air gwde housing .. ... . remove, reinstall (07.3-225) .
Coolant .... ..... . .. . ... . .... . ...... . . partly drain, refill (20·01 0).
Shaped hoses (26) for auxiliary air ... .. ..... . remove, reinstall .
Electrical engine cable harness . . . . . . . . . . . .. lace out. lace in.
Longitudinal control shaft . ... ....... . ..... . remove, reinstall (30-31 0).
Bracket (1) for injection valves ... .. ..... .. . . remove, reinstall.
Bowden cable for automatic transmission .. ... . disconnect, reconnect.
Bearing bracket for control remove, reinstall.
All vacuum connections .................. . remove, reinstall. Connect vacuum lines
according to function diagram (14-050).
Exhaust gas recirculation line on exhaust gas
recirculation valva disconnect, reconnect.
Mounting screws remove, refit. Tighten screws from inside to the
outside.

14.0712 · 450/ 1
Coolant hose (2) ... .. .. .. .. . ... ....... . .
lntake manifold upper and lower parts
(10 and 18) ... . . . . .. . . .. ... . ......... .
lntake manifold gaskets ( 12)
Engine control . ... ............... . . . . . .
Leaks .. .. ... .. . .. . . ... . . . . . .. . . .. .. .
ldle speed .... ... ... .... ... .... .......
loosen.
remove, reinstall. Clean, check flange surfaces
with straightedge, machine on straightening
plate if required.
&
Upon assembly ensure that no vacuum lines
and electrical wires are jammed in .
renew.
adjust (30-300, and 30-305).
check by running engine, check fuel lines for
leaks. Check intake system, fuel distributor and
injection valves for leaks by spraying with
lso-Octane.
check, adjust.

A hose fitting with bead is installed to prevent Production breakpoint: November 1986
slipping of the vacuum line on the intake Modal Engine Engine end No.
manifold.
107.048 117.967 016953
126.035 116.065 031464
126.039/045 117.968 023518

lmproved sealing by means of gaskets made of Production breakpoint: July 1987

diHerent material. Model Engine Engine end No.

107.048 117.967 025498

126.035 116.965 045268
126.039/045 117.968 035244
14-455 Renewlng lntake manifold (lntake manifold removed)
Preced•ng operatiOn:
lntake manrfold removed (14·4.5 0)
Remaining detachable parts . o . . o .. o . . . .. . o .
lntake manifold upper part ( 1O)
lntake manifold lower part ( 18) o o o o o o o o o o o o o o
14.07 12·455/1
transfer from removed intake manifold to new
manifold. Use new gasketso
unscrew from intake manifold lower part (18)0
To do so, loo sen vacuum line tor brake booster
on intake manifold lower part, then remove
mounting screws and pull off the rubber
spacerso
install with new rubber spacers to intake
manifold upper parto
14·470 Removar, relnstallatlon ot exhaust manifold

A. Model107

P14~0011$•37

Exhaust system ..... .. ... .... ..... ... .. remove, reinstall (49-100).
Air cleaner . . . . . . . . . . . . . . . . . . ... .. .. . . . remove. reinstall (09-400).
Spark plug connector ... ...... ........ .. . remove, refit.

Exhaust manifold left

Exhaust gas recirculation valve (60) remove, reinstall. Use new gasket (6 1) during
installation.
Shield (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . remove, reinstall.

14.0712·470/1
Engine mounts . . . . . . . . . . . . . . . . . . . . . . . . . loosen, tighten with 75 Nm.
Engine shock absorber ....... .... .... ... . with bracket, remove, reinstall.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lift with pit lift.
Exhaust manifold remove, reinstall. Unscrew screws (7) and
nuts (9).
lnstall with new nuts {9) and gaskets (5).
Gaskets with metal side facing cylinder head
(see Note).
High-pressure hose for power steering .. .... . from power steering and bracket on wheel arch ,
disconnect. reconnect.

Exhaust manifold right

Coolant expansion tank ..... . .. ... .. . .... . remove, reinstall.
Shield (3) .. . .... .. .. ..... . • .. . .. .. • .. . remove, reinstall.
Exhaust manifold remove, reinstall. Unscrew screws (7) and
nuts (9).
lnstall with new nuts (9) and gaskets {5) with
metal side facing cylinder head (see Note).
Exhaust system ... .... ....... .. ..... .. . check for leaks by running engine.

A B

Note
lnstall gaskets with the metal side facing the
cylinder head.

Pt.C-2066 -13

14.071 2 ·470/2
 ws

b
e

78
WS/ VISW

P07·0a7·S 7

Function diagram air injection and exhaust gas recirculation starting 09i87
N1/2 Control unit ignltion system (EZL) 79 Thermovalve 70° C
Y32 Change-over valve air pump 80 Thermovalve so• C
a trom air cteaner 89 Exhaust gas recirculat1n g valve
b to tuel tank 123 Throttle assembly
e Venutauon 125 Air pump
1 Mixture control uM 126 A1r shut·Off valve
40 Diaphragm pressure regulator 127 Check valve (injection air)
77 Charcoal can1ster 128 Check vafve (vacuum)
78 Purge valve 129 T1ming case cover

14.07 12·05015
 C. CIS-E control unit (N3)

On model 107 the CIS-E control unit is installed

in the footwell right below the floor plate and in
model 126, in the footwell right behind the lateral
covering.

Lt.
With ignition switched on or engine running, do
not pull coupling off CIS-E control unit as the
CIS-E control unit could be damaged due to
voltage or current peaks.

MOdel 107

Model 126 (R 17 not used)

With the ignition switched on, a certain current is

available on the electrohydraulic adjusting
element while a certain impulse period is output
at the lambda measuring output (see 07.3-121).
The CIS-E control unit has two injection
programs (with;without lambda control) . The
respective program is activated by means of the
reference resistor.

14.0712 ·05016
8 · Modei12G

Spark plug connector .. remove, refit.

14.0712·4 70/3
 Exhaust manifold left
Mounting clamp (2) on transversa pipe (1) unscrew, screw on.
Shield (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . remove. reinstall.
Exhaust gas recirculation line (68) disconnect from exhaust gas recirculation
valve (60). reconnect.
Exhaust manifold (6) ... ... .. ... ... .. ... . . remove, reinstall. Unscrew screws (7) and
nuts (9). lnstall with new nuts (9) and
gaskets (5). Gaskets with metal side facing
the cylinder head (see Note).

Exhaust manifold right

Exhaust system .. . . .. . ... . .. . ... .. . .. . remove, reinstall (49-100).
Mounting clamp (2) for transversa pipe (1) unscrew, screw on.
Air cleaner remove, reinstall (09-400).
Shield (3) remove, reinstall.
Exhaust nuts (9) and bolts (7) remove, reinstall.
Exhaust manifold (4) . .... ... .. ... .... . .. . remove from below. Mount with new nuts (9)
and gaskets (5).
Metal side facing cylinder head (see Note).
Before tightening the nuts and bolts, flange on
transversa pipe.
Exhaust system check for leaks by running engine.

Note
lnstall gaskets with the metal side facing the A B
cylinder head.
Observe difference between engines
116 and 117.

A Engme 116
8 Engme 117

14 .0 7 12 -4 70 ·4
 _ _ _ Renewln
14-471 _.:.::_:::g~tr~a~ns~vverse pipe

Modei12S

14.0712 ·4 7 1/ 1
 Exhaust system .. . .. .... ...... .... .... . remove, reinstall (49-1 00).
Mounting clamp (2) on left exhaust manifold (6) . . unscrew, screw on.
Exhaust manifold (4) right . ...... .... .... . . remove, reinstall. Mount with new gaskets (5)
metal side facing cylinder head. Observe
difference between engine 116 and 117
(sea Note 14-470).
Transverse pipe ( 1) remove to the right.

14.0712·471 2
 14-472 Survey exhaust manlfolds

Model 107
Engine 117.967

left

nght

Model126
Engine 116.965
Engine 117.968

left

14 .0 7 12 · 4 72/ 1
 right

14 0712·472/2
14-475 Checklng exhaust gas reclrculatlon (EGR)

A. Exhaust gas reclrculatlon with vacuum control valve model year 1986/87

WSi bf

ws¡ge 90

P14-0017-57A

14.0712 -475/ 1
 Impulse Test stepl Measuring device/ Actuation/ Set valuei Possible cause/Remedy
period Scope of Test connection Requirement Function
display test

- 1 on EGR valve (60) pull off - -

Vacuum line
ws:br

- 2 on EGR valve (60) connect, apply switches Renew EGR valve

Vacuum 300 mbar audibly
tester (0 19) vacuum.
- 3 on EGR valve (60) connect, apply Irregular Renew EGR valve
Engine at 300 mbar engine
idte speed vacuum. operation

- 4 Pull off both Connect Coolant Renew thermovalve.

Check vacuum lines. vacuum . temperatura
function ol Connect vacuum >50 oc
thermovalve testar to inclinad open.
(79) connection. <50 oc
closed.

- 5 Connect vacuum Plug straight Coolant Renew thermovalve.

Check tester to inclinad connection. temperatura
thermovalve connection. Apply vacuum. >50 oc
(79) for vacuum
leaks remains.
- 6 Connect vacuum Start engine at approx. lf > 400 mbar are
Check tester with Y-hose operating 1500 rpm measured at 1500 rpm,
vacuum (1)partNo.117 temperatura. < 100 mbar check line assignment
control valve 078 01 45 to EGR Slowly increase approx. on throttle assembly
(90) valva speed. 3200 rpm > (see Fig.). lf set values
400 mbar are not obtained, renew
vacuum control valve.
- -

14.0712·475/2
 1 Mixture control unit AlelO 02·sensor indicator lamp
40 Diaphragm pressure controller A1p8 Electronic speedometer
55 Fuel filler 92 Air flow senSOI' position indicator
57 Fuel reservoir 911 / 2 Coolant temperatura sensor (EZUCIS·E)
74 Fuel cooler 818 Altltude correction capsule
75 Fuel tank 03/2 Heated 02-sensor
76 Vent valve L5 Crankshaft position sensor
77 Charcoal can,ster M3 Fuel pump
78 Purge valve Nl /2 Electronic ignit10n control unit (EZL)
79 50 •e thermovalve N3 CIS·E control uM
89 Exhaust gas rec~rculation valve N8 ldle speed control unit
90 Control valve N16/4 Fuel pump relay w11h kickdown cut-out
92 ln1ection valve R17/ 1 Reference resistor (CIS ·E)
125 Air pump $2912 Full load/idle speed detection thronle valve switch
126 Air shutoff valve T1 lgnition coil
127 Check valve (ln¡ected air) Y1 Electrohydraulic actuator
157 Firewall catalytic converter Y5/ 1 A/C compressor electromagnetic coupling
158 Underfloor catalytic converter Y6 ldle speed air valve
va Starting vaJve
Y32 Air pump switchover valve
Y33 Air pump electromagnetic coupling

14.0712·050/3
Func!lon diagram air tnjection and exhaust gas recirculation up to 08 87
N12 Control unn 1Qnot10n system (EZLI 79 Thermovalve
Y32 Change·over valve a•r pump 89 Exhaust gas rec~rculat1ng valve
a trom a•r cleaner 90 Control valva
b to fuel tank 123 Throttte assembfy
e ven111auon 125 A•r pump
1 M•xture control un•t 126 AJr shut·oH valve
40 0 1aphragm pressure regulator 127 Check valva (lnteCIIOn a~r)
77 Charcoal camster 128 Check valve (vacu um)
78 Purge valve 129 r,m,ng case cover

14 0712·05014
 B. Exhaust gas recirculation without vacuum control valve as of model year
1988

Note
The control valve in the vacuum line between
throttle assembly and exhaust gas recirculation
valve is no longer required as of 09/87.
The exhaust gas recirculation valve is connected
with vacuum directly only as a function of the
thermovalve.

WSJvi bt

14.0712-475/3
 Impulse Test stept Measuring devicei Actuation/ Set value/ Possible cause/Remedy
period Scope of Test connection Requirement Function
display test

- 1 on EGR valve (60) pull off - -

Vacuum line
wsl vibr
- Vacuum on EGR valve (60) connect, apply switch es Renew EGR valve
tester (019) 300 mbar audibly
vacuum.
- 3 on EGR valve (60) connect, apply Irregular Renew EGR valve
Engine at 300 mbar engine
idle speed vacuum. operation

- 4 Pull off both Connect Coolant Renew thermovalve.

Check vacuum lines. vacuum. temperatura
function of Connect vacuum >50 oc
thermovalve tester to inclinad open.
(79) connection. <50 oc
closed.
- 5 Connect vacuum Plug straight Coolant Renew thermovalve.
Check tester to inclined connection. temperatura
thermovalve connection. Apply vacuum. >50 oc
(79) for vacuum
leaks remains.

14.0712 ·4 7514
 14-478 Checklng alr lnjectlon

038
127·· 1
W$/b1

068

'
126

019

811/2 ,

K17

Note
As from 1988 modal year California, 1990 model
year Federal, the temperatura sensor coolant is
of the 4-pole type. An NTC for CIS-E and an
NTC for EZL.
8oth NTC's are independent of each other and
are grounded by the EZL ignition control unit and
the CIS-E control unit respectively.
The arrangement of the two NTC's is diagonal.

14.0 7 12 ·4 7811
 The CIS-E temperatura sensor is identified by
the following test:
Connect lambda control tester to diagnostic
socket. Pull coupling off coolant temperatura
sensor.
Switch on ignition, display shows 30%. With Q.
decade (038) srmulate 2.5 kQ (20 °C}, connect
to two opposrte 1acks of the coupling (across)
(Fig.).
At the connection CIS-E temperatura sensor the
impulse period jumps to 70%.

The air pump is only activated in the coolant

temperatura range 17-70 o C.

Test condrtron:
Coolant temperatura < 70 oc.
Pull off couplrng coolant temperatura sensor
(B 11 2). With Q-decade, simulate
2.5 kQ + 20 °C.
Electrical wiring diagrams (07.3-128).

14.0712·478/2
 Test

Explanation of symbols
~
~ Multimeter
-< Jack

-- Plug
Ground
Multimeter measuring mode resistance
Multimeter measuring mode OC voltage
Multimeter measuring mode amperage

Impulse Test step; Measuring device/ Actuation/ Set value; Possible causei Remedy
period Scope of Test connection Requir€ment Function
display test

- 1.0 - Start e ngine. Strong Check electric changa-

Air injection Pull shaped suction over valve (Y32), vacuum
hose of air on activation electromagnetic
pump off air shaped clutch (Y33).
cleaner and hose.
lightly close
with finger.

- 2.0 Connect vacuum lgnition: OFF

Vacuum tester with Pull vacuum
activation Y-hose (1). line ws/vi bl off
change-over
valve (Y32).

With Q-decade on Start engine. Air pump Vacuum lines electric

temperatura sensor Engine speed is oper- change-over valve (Y32).
coolant (8 11 12), < 2500 rpm. ational Activation air pump
simulate + 20 oc. and must (Y33) - test step 9.0.
switch off
after
approx.
60S.
Vacuum
> 500
m bar.

14 .0712·478/3
Impulse Test step/ Measuring device/ Actuation/ Set value/ Possible cause/Remedy
period Scope of Test connection Requirement Function
display test
- 3.0 K17 ...L lgnition: ON 11-14 V Wiring overvoltage
Voltage 4-< ~ protection (K 111) .
supply air
injection
relay (K17)

- 3.1 K17 lgnition: ON 11-14 V Wiring, CIS-E control

CIS-E 5-(~)-4 unit (N3).
control unit
(N3)

- 3.2 N3 K17 lgnition: OFF <1Q Open circuit.

Wiring 14-(~)-5

- 3.3 K17 K1 / 1 lgnition: OFF <1Q Open circuit.

Wiring 4 -< ..::.@!- )- 2

- 4.0 K17 K17 pulled off. 2.5-3.5 A Set values are obtained:
Power 4 -< ·=@-!.,.. >- 1 Start engine. (air Air injection relay (K17)
consumption suction CIS-E control unit. wiring.
electromag- on Above 3.5 A: renew Y33
netic clutch shaped (14-260), no current (O A):
(Y33) hose) check wiring to Y33.

-
- 5.0 K17 ...L K17 pulled off. 11-14 V Wiring .
Voltage 3-< .=~ lgnition: ON
supply air
pump

K17 K17 pulled off. 11-14 V Wiring to Y32 and Y33.

3-(....=~)-1 lgnition: ON

14.071 2·4 78·4

 Special tool

201 589 13 21 00

Commercially available tool

Engine tester e.g. Bosch, MOT 001 .03

Shop-made tool
Y-hose Part No. 117 078 01 45

Line connection on thr,ottle assembly.

&
The vacuum line ws/br of the exhaust gas
recirculation was temporarily connected to the
lower connection of the throttle assembly during
production start-up ( 14-050, section "G") .

a to thermovalve exhaust gas recirculat1on

b to thermovatve fuel evaporation system
e to purge valve
d lo vacuum control valve exhaust gas recirculation
(only vers1on ''A'')
P0 1 1175 tJ

Arrangement exhaust gas recirculation

valva (EGR).

Model 107

14 .0712·4 7515
 Model 126

Arrangement vacuum control valve (90) and

thermovalve (79).

14.07 12·475/6
Impulse Test step/ Measuring device/ Actuation/ Set value/ Possible cause/Remedy
period Scope of Test connection Requirement Function
display test

- 5.1 K17 Y32 K 17 pulled off: <1Q Open circuit.

Wiring 1 - -< ..:.@!- >- 2 lgnition: OFF Change-over valve air
pump (Y32) .

- 5.2 K17 Y33 K 17 pulled off: <1Q Open circuit.

Wiring 1 -< ....:.@!-- >- 2 lgnition: OFF Electromagnetic clutch
(Y33).

- 5.3 Y32 _L K 17 pulled off: <1Q Open c ircuit.

Wiring 1-<--=@-!- W10 lgnition: OFF

- 5.4 Y33 _L K 17 pulled off: <1Q Open c ircuit.

Wiring 1 .-<~ W10 lgnition: OFF

14.0712· 478/ 5
Special tools

201 589 00 99 00

Commercially avaUable testers

Multimeter e.g. Sun, DMM-5

Lambda control testar e.g. Hermann, L 115

Shop-made tool
Y-hose Part no. 117 078 01 45

Arrangement of components

Shaped hose ot a1r pump at side ot a1r cleaner

Y33 ElectrornagnetiC clutch

14.0 7 12·478;6
 Y32 Change·over valve a.r ,n¡ection p 07 2278 13

K 1 7 Relay a1r ,n,ectlon

14.0712 · 47817
14-487 General lnstructlons for vehlcles wlth catalytlc converter
Towing or jump-startlng
Towing or jump-starting with an externa! battery
is possible with cold engine and cooled-down
catalytic converter system. However, repeated
starting attempts should be avoided. In order to
protect the catalytic converter system, further
attempts must be stopped with the engine at
operating temperatura unless it starts
immediately.
Mlsflring
Misfiring poses a particular threat to the pre-
catalytic converters as the air-fuel mixture is
converted in the hot catalytic converter. This
could lead to thermal overloading of the pre-
catalytic converters. lf increased misfiring
occurs, the engine must only be operated for a
short period with low load. Eliminate the cause
of the damage without afelay. lf in doubt, check
the catalytic converters for thermal damage
after the faults on the ignítíon system have been
eliminated.
Checking the catalytic converter system for
thermal damage
Thermal overload first ieads to damage in the
pre-catalytic converter. This can be checked by
visually inspecting the removed exhaust system.
Performance complaints after engine troubles
point to thermal overloading of the catalytic
converter. Remains of the melted catalytic
converter are clogging the exhaust pipe.
14.0712 ·48 711
Oriving on the roller-type dynamometer
The pre-catalytic converter becomes red-hot
faster under higher load due to the increased
thermal output. This is of no consequence.
Fuel additives
These are not advisable on catalytic converter
vehicles. Ensure that only the specified fuel
quality is used.
Use of leaded fuel
lf leaded fuel was used by mistake, check the
function of the lambda control. lf the sensor is
faulty, it should be replaced. lf the exhaust value
exceeds < 0.5 % CO, the entire catalytic
converter system must be replaced.
Engine oils
The same oil recommendations (approved
products, oii change intervals etc.) apply to
vehicles with catalytic converter as for vehicles
without catalytic converter.
Smell
The deposit of sutfur constituents from the fue!
on the catalytic converter can lead to the
formation of hydrogen sulfide. Hydrogen sulfide
generates a strong smell even in smallest
concentrations, but is not harmful to health.
Fire hazard (parking In open terraln)
The surfaces of the underfloor catalytic
converters in our closed loop catalytic converter
vehicles are thermally insulated in order to
ensure an effective emission control under all
operating conditions. With correctly operating
engine. the temperaturas are therefore not
higher than on conventional muffler systems.
Excessive temperaturas are created only if
unburned air-fuel mixture enters the catalytic
converter (e.g. by a faulty ignition or injection
system).

14 .0 71 2 ·48712
15-505 lnstructlons regardlng work on breakerless transistorlzed ignition
system

A. Safety lnstructions

The increased demands of modern engines in

respect of the ignition systems and the desire
for zero maintenance have led to the standard
implementation of electronic ignition systems.

As a rule, the ignition capacities of electronic

systems are higher than those ot conventional
systems with further boosts in capacity likely in
futura. Consequently, electronic ignition systems
operate in a power range which may represent a
hazard if contact is made with live parts or
terminals (refer to warning plate).

Warn1ng plate m eng1ne compartment

For this reason, it is essential to strictly observe

the safety instructions stated below when per-
forming any work on electronic ignition systems
Gefahrliche Hochspannung!
(EZL): Vorsicht bei Arbeiten an der
Zündanlage
• Before performing any work at starting
Danger! High voltage
speed, e.g. testing compression pressure or Observe caution when working
adjusting valve clearance, switch oH ignition on the ignition system
and detach controlline (arrow) at control unit
Danger! Haute tension
or plug protective connector, Part No. Attention lors de travaux au
102 589 02 21 OO. onto the diagnostic systéme d'allumage
socket.
P15-0241-13
• Persons with heart pacemakers should not
perform any work on such ignition systems.
• Do not touch or disconnect any parts of the
ignition system at starting speed or when
engine running.

15.0713 . 505/ 1
• Perform installation work on the ignition
system or connection and disconnection of
sensors at ignition cables only when engine
not running and ignition switched off.
• Do not insert any intermediate pieces of built
in sensors with bright metallic outer surfaces
into the ignition cables. e.g. on cylinder No.
1.

B. lnstructlons for avoiding damage to lgnition system

• The control unit connectors must only be

disconnected and plugged In when the
ignitlon is switched off to avoid any dam-
age to the electronlc ignition control unit.
• Do not connect a test lamp to terminal 1 of
the ignition coil.
• Do not short termi nals 1 and 15 of the ignition
coil to ground, e.g. as an anti-theft protection.
• The threaded pins of the ignition coil have
different diameters (MS and M6) to ensure
that the poles are not incorrectly connected.
• lnstall only genuina ignition system parts.
• Do not operate ignition system at starting
speed unless the ignition components are
completely connected.
• The load at the high-voltage end of the
ignition system must be at least 2 kQ
(distributor rotor 1 kQ, distributor cap per
terminal 1 kQ) to avoid any damage to the
electronic ignition control unit. Do not install
a 5 kQ distributor rotor for interference
suppression.

15.07 13 • 505/2
• The work listed below must not be performed
at starting speed or when the engine is
runn1ng:
- Holding ignition cable 4 away from ground
- D1sconnechng spark plug connector
- Disconnecting ignition cable 4 at ignition
COl l.
• The electronic ignllion control unit is coated
w1th heat-conducting paste on the back to
improve heat d1SS1pa110n and covered over
w1th a heat-conducting protective foil. The
protective foil must not be removed.
• lf the short-circuit switch (cylinder compari-
son) is operated and the engine stops. the
test cannot be conducted with this tester.
• When performing the separata ignition coil
test. the load applied to the ignition coil must
not exceed 28 kV to avoid damaging the
ignition coil.
• lf it is necessary to test the ignition spark
when rendering breakdown assistance. th1s
must only be performed with one spark plug
at one cylinder ignition cable. Ensure good
contact to ground of the spark plug. Pay
atteni!On to nsk of electrocution!

C. lnstructlons for use of engine testers and test equlpment

• Connect and disconnect voltage sensor

clamps to 1gnition cable 4 and trigger clamps
to ignition cable of cylinder No. 1 only when
engine not running and ignition switched off.

1507 13 50513
 15-510 Functlon of electronic ignitlon system with electronlc tlmlng
adjustment (EZL)

R4

,..
'

.
'·

r tS - 0247- !!17

Function diagram of electronic ignition system with electronic timing adjustment (EZL)
811 /2 Coolant temperatura sensor (EZUCIS·E) 529/2 Throttle valve switch, full load/idle
G1 Banery T1 lgnition COII
L5 Crankshaft position sensor X11 Oiagnoshc sockeVterminal block (circuit TO)
N1 /2 Electron1c ignition control unit (EZL)
R4 Spark plugs 2 Vacuum line
R16 Aesistance trimming plug (EZL) • not usecl 3 Segments on driven plata
(A 16/ 1) reference resistor usecl on USA vehicles.
S513 High·voltage distributor

15.0713 . 51011
Arrangement of components

-
~
¿..,"

-: . ::-

. .·
..~ t
~'":
~-::

L5

$5/3 T1 R16

A1p8 Electron~c speedometer 85/3 High -voltage distributor

811 / 2 Coolant temperature sensor (EZUCIS·E) 829/2 Throttle valve swttch. fullload/idle
L5 Crankshaft posttton sensor 865 Transmission overload protectJon swttch, brake
N1 /2 Electromc tgnitlon control unit (EZL) band 81 • not u sed on USA vehtcles
R16 Reststance tnmmtng plug (EZL) · not used. T1 tgnitton coil
(R 1511) reterence res,stor u sed on USA vehtcles

15.0713.51012
The power output stage controlled by the
microcomputer switches the primary curren! of
the ignition coil between terminals 16 and 31
(4-pin supply connector).
The known functions of dwell angle control,
primary curren! cutoff and primary current
limiting are contained in the EZL control unit.
The engine speed-dependent TO signa! is
generated in the EZL control unit.
When the engine is started and up to approx.
450 rpm. the ignition timing is controlled only via
the segment edges of the flywheel. Only after
a certain engine speed is reached (approx.
460 rpm) is a transition made from the fixed
ignition timing to the ignition timing matched to
the momentary operating state.
At full load, the EZL control unit switches vía the
full load contact of the throttle valve switch to a
fixed characteristic curve.
The vacuum advance is also activated at idling
speed. i.e. there is no fixed idle speed curve.
The ignition timing advance through the
reference resistor is also active at idling speed
(without vacuum) .
When the coolant temperatura rises above
approx. 95 oc, certain ignition characteristic
curves are retardad to counter any further rise
in temperatura.

Various ignition characteristic curves are in-

hibited in the warm-up ranga depending on the
coolant temperatura. in order to reach the
normal operating temperatura as rapidly as
possible.

15.0713 . 5 1015
Oriven plate wíth segments
4 segments offset by 90° are fítted to the ríng of
the dríven plate to actívate the ignitíon system.

Position sensor (L5)

To actívate the ignitíon control unít, the posítion
sensor detects the crankshaft position and
engine speed.

The position sensor (l5) is installed on the

crankcase above the starter flange.

The coil body projects to shortly before the

segments on the dríven plate. Segment position
and engine speed are detected without physical
contact.

When the engine is turning. the induction

produces an alternatíng voltage in the position
sensor. The peak value of the voltage (Us) is
approx. 1.5 Volts at starter speed. As engíne
speed íncreases. the voltage ríses (Us approx.
3 Volts at 1200 rpm).

Note
Measure peak level of voltage (Us) wíth the
oscilloscope.

The crankshaft posítíon ís detected from the

voltage as follows:

The segment front edge produces a negatíve

voltage signal.
The segment rear edge produces a positive
voltage sígnal.

15.0713 . 5 1016
Components and tunction

EZL control unit (N1/2)

lgnt1100 Starter SWitCh

(S21) term1nal 15
[ Power supply { + )
~ ~
.... J
'J

:1
.---· Dwell a nd igM•on angle
control

1
G round point {W3)
front left wheelhouse Ground {-) ....
1··: :.
J
controls

1 : 1
1: :~
.1
1·' :,
r:' 1
•<
Crankshaft posit•on Eng•ne speed and "

sensor (L5) crankshalt poSition

:·
1
:::
1 1
F J
1 .1
t; J
lntake man•fold
Eng•ne load condition •..·
.;:
••
r
vacuum
L
r; ... ....
f:· ·::
:1
,
1
.
Coolant temperatura
Coolant temperature
...
EZL
.;·

1 •
sensor (B 1 1i 2) control unlt 1
1
l
J

Th rottle valve sw•tch

' F ull load position
{52912) 1

Reference res•stor lgmtion performance

(R1611) map adaptation
supplies

controls

D1agnostic
socket
(X11)

Tachometer.
fuel pump relay,
compressor cuto ff
control uni t, CIS·E
con1ro1 un11, etc.

15.0713. 510i3
The EZL control unit is fitted to the left
wheelhouse panel.

lt ts installed with heat-conducting paste to

dissipate heat. When exchanging this part, the
protecttve foil must not be removed. The foil
does not impair heat dissipation. The EZL
control unit contains a mtcrocomputer, a
pressure sensor and the power output stage.

1 Vacuurn connec11on
2 Coruual connector tor control hne lrom pos•hon sensor
3 4 ·sensor connector
1 Coolant temperatura sensor
2 Throttle valve sw1tch
3 EZL relerence res1stor
4 not ass1gned (cable ends on cable harness)
4 4·pln supply connector
15 Term1nal 15
16 lgM•on coll, termonal 1
TDTD 51gnal
3 1 Ground

The tgnttiOn maps for typical load/engine speed

ranges and a ftxed full load ignition characteristic
curve are stored tn the microcomputer of the
EZL control untt.

The EZL control unit detects the momentary

operating state of the engine from various input
signals. Engine speed and crankshaft position
are detectad by the position sensor.

The optimal ignition timing for this operating

state is determinad from the stored ignition maps
taking into account all the input signals.

15.0713 . 510 •4
11 1st segment
12 2nd segmenl
13 3rd segmenl Us
t4 4th segment f-..- - - -- -- - -- --,
d- - - - - -- - - --1 P1S·0234 · 33
d Period for one crankshah
revol ut•on

Engine speed is calculated by measuring the 31d

period lor one crankshaft revolution .

The alternating voltage lrom the position sensor

is passed along the control cable (coaxial cable)
to terminal 7 on the EZL control unit. This is a 7
single-core cable with the cable shield being
used as the second conductor.

11 the EZL control unit does not receive a signal

from the position sensor. the complete ignition
P15•0240•13
system is inoperable. e.g. the cause may be an
interruption in the sensor coil.

The resistance of the position sensor between

terminals 7 and 31d is 680-1200 n.

lnstructions regarding damaged segments or

mechanical damage to the position sensor:

• Alternating voltage from position sensor

below specification.
• Greatly varying alternating voltage signals
form individual segments.
• No alternating voltage signal.

15.0 7 13. 5 1017

Throttle valve switch (S29/2)
The fixed full load ignition characteristic curve is
act1vated when the fullload contact of the
throttle valve switch is closed (accelerator in full
load position). The switch signar passes through
throttle valve switch connector (S29 2x) and the
4-p•n sensor connector (contact 2) to the EZL
control unlt.

Coolant temperatura sensor (811/2)

The coolant temperatura sensor has two NTC
res•s tors each with a single-pote connection.
One NTC for CIS-E and one NTC for EZL. The
temperatura signar passes along the green.black
cable and the 4-pin sensor connector (contact 1)
to the EZL control unit. The coolant temperatura
sensor 1s positioned at the rear lef1 on the
cylinder head (A) or at the front (8).

Note
=
NTC res•stance with negat•ve temperatura
coeff•c•ent. 1.e. the resistance is less in the warm
state.
A 1St verston up to January 1986

8 2nd vers1on cffcct•ve January 1986

15.0713 · 510r8
 EZL reference resistor (R1611)

The EZL reference resistor (R 16/ 1) possesses

a fixed resistance of 750 n.

A particular ignition map in the EZL control unit

is activated with the EZL reterence resistor
(R16t 1).

Perform resistance measurement for testing the

reference resistor (R 16t 1) at the EZL control unit
between sensor connector (contact 3) and
ground.
P15- 211J$-13

Model 126
The EZL reference resistor (R 16/ 1) is located
between the fuse and relay box and attached to
the brake booster at the wiring harness.

High voltage dlstributor (5513)

The only task of the high voltage distributor is to
distribute the ignition voltage. lt is thus no longer
possible to adjust the ignition timing. The ignition
timing is activated and adjusted by means of the
position sensor and the electronic EZL control
unit.

lnterference suppression resistors: On distributor

cap per terminal 1 kQ, spark plug connector
1 kQ, distributor rotor 1 kQ.

15.0713 . 510/9
The high voltage distributor features a centrifuga!
force-dependent advance of the distributor rotor .
This ensures that, even with extreme ignition
angles. an adequate insulation gap is guaranteed
between distributor rotor and the adjacent
distributor cap electrodes. However, this
necessitates the most accurate possible
assignment (setting) between distributor rotor
and housing (approx. :! 1 o CA).

P15-2178-t3

tgnition coil (T1)

The ignition coil is matched to the EZL control
unrt to achieve a high ignition energy. As a result
of the high switching power of the EZL control
unit. the primary current can be further boosted.
For this purpose. the primary winding is
designad with a very low impedance (0.2-0.4 Q).
Closed circuit cutout and primary current limiter
enable the ignition coil to be operated without a
series resistor. Consequently, the current limiting
as a result of the series resistor is eliminated. lf
the maximum primary current flows in the P1 5 ·2139·13
ignition corl without any limit (e.g. closed circuit
current cutoH faulty). the ignition coil will be
damaged alter a short time as a result of the
intense heat which develops.

Oistinguishlng feature:
The ignition coils on 4- and 6-cylinder engines
with EZL ignition systems are identical.
ldentification: yellow type plate.
The ignition coils cannot be interchanged with
the ignition coils for 8-cylinder engines (identifi·
cation: green type plate). Pay attention to the
Part No. when exchanging parts.

Refer to the instructions for working on

electronic ignition systems (15-505) .

15.0 7 13. 51 0110

15-515 Testlng lgnltlon tlmlng

A. Vehlcles wlth EZL

R4

~-":
~~~~,\~;~~~\~~

811 12 Coolant temperatura sensor (EZUCIS-E) 529/2 Thronle valva switch, full loadlidle speed
G1 Banery detectíon
L5 Crankshaft posítion sensor T1 lgnítion c01l
N1 / 2 EZL control unít X11 Diagnostics sockeVterminal block. terminal TD
R4 Spark plugs
R16 EZL res1stance trimmíng plug - not used- 2 Vacuum fine
R1611 used on USA vehícles 3 Segments on driven plate
S5/3 High voltage distributOI'

15.0713 - 5 15/1
Engine testar with oscilloscope (030) connect to diagnostics socket (X11),
disconnect.
Safety instructions observe (15-505). Selector levar position "P" or
"N". Apply parking brake.
lgnition timing e
test at coolant temperaturas below 95 o with
or without vacuum at specified engine speed
(see table).

EZL ignition tlming

Engine EZL control unit Engine speed in lgnition timing in o CA before TDC
rpm
Resistance without with
trimming plug vacuum vacuum
position or
type of fuel

@ effective 1986
116.965 003 545 92 32 3500 Reference 28-32 41-45
003 545 91 32 resistor
idle speed 3-7 10-14
750 n

117.967 004 545 53 32 3500 Reference 24-28 40-44

117.968 004 545 55 32 resistor
idle speed 3-7 10-14
750 n

15.0 7 13 . 51 5,2
 15- 525 Analyzlng oscllloscope lmages

Descrlptlon of oscllloscope lmages

Good image

Note
Primary current limiting is only effective up to
approx. 2000 rpm.

~--~---------------------------------------------------~

[kV]
10 1
2 1

r-1
¡
1

1 0G 80 Go 40 20 o %
P15 · 0004• S 7

15.0713 . 525/ 1
Good image

1. Secondary parade

[kV]
20

10

p 15-400~7

15.0713 . 52512
Good lmage

2. Secondary raster

·····'-·- ···""··· -·'-.."··-· ·---· -··"··· -- - -- - - - - - - - - - - - - - - - -

1 1

1-~-

3 . }-·..___ .. __ _ __,. J--~

1
1
1 1
1

4 !--~--- ..----_r--~

2
¡ ~
t---
~

1 GO
..... J- ;· 1
80
1

1
Go
1 1

1
40
1

1
20
·t:rTt~ o %
, 16-0006-67

150713. 525/3
Good lmage

3. Secondary single image

.
.
.
5-
.

1
1
t 1 +-~~..o. 4
¡
1 l,.;
'
F! 1
j .
;
·4 ... srw
'
n - .e, ·.
1 OG b_ E: J.
z= i] '
; .~

p 15-0007-67

150713. 52514
Good lmage

4. Secondary single image

•'-•»•- ·····~-- -------------------------------,

[kV]
20 -

10

o 1 2 3 Sms p 1$-oOOM--$7

15.0713 . 525/5
 Good image

5. Primary parade

. - - - - -- - - - - - - - - - · - · · · -- - - -- - - - - -- - - - - - ,

[V]
400

l
1

__~
.,..__
1

P1~&-S7

15.0713 . 525/6
Good image

6. Primary single image

[V]

80 GG 2G o % p 16-0010-67

15.0713 - 52517
Good image

7. Blipping throttle

Test requirement: accelerate engine repeatedly

to approx. 3000 rpm by blipping throttle.

Note
• As a result of the acceleration operation.
several cylinders are recordad in turn
according to the firing sequence. e.g. image
example (1st. 3rd , 4th. 2nd. 1st. 3rd. 4th,
2nd etc.).
• The ignition voltage rises evenly at all
cylinders during the acceleration phase. The
rise in ignition voltage must not exceed 6 kV.

[kV]
zo J
A

15 0 7 13 . 5 25·8
Good lmage

8. Primary current limiting

Note
Primary current limiting may occur at speeds
above 2000 rpm with and without load
temporarily at individual or at all cylinders.

[kV]
20

1~ !

1 !1

o
~ ;
'
...,.)
~~.
r-j ~~
'¡
1

1 •

p 15--0012...7

15.07 13 . 525/9
Fault image

9. lgnltion voltage too highlcombustion period

shorter

Test requirement: may occur at any speed with

or w1thout load.

Cause
Spark plug electrode gap too large;
additional spark gap at secondary side;
fuel-air mixture too lean.

[kV]

1&
1
1

1
1

!
1 1

L
t? 11
1 1
1
1
1
1!
1
¡
1
1

['
y
P15-401~

15.0713 . 5251 10
Fault lmage

1O. lgnition voltage too lowtcombustion duration

longer

Test requirement: may occur at any speed with

or without load.

Cause
Spark plug electrode gap too small;
fuel-air mixture too rich;
loss of compression.

[kV]
20

10

p 1!>-0014-$7

15.0713 . 525i 11
Fault image
11 . Oecay process too high
Test requirement: accelerate engine repeatedly
to approx. 3000 rpm by blipping throttle or run
engine under load on roller dynamometer.
Cause
Fuel-air mixture at one cylinder too lean .
Note
lf engine does not run smoothly (Mt running on
all cylinders) after starting, switch off the engine
at normal operating temperatura and wait a
lengthy period (approx. 30 min) before starting
to obtain a better diagnosis.
When again starting engine, strictly observe test
requirement.
&
Fault may only occur intermittently .

..---···-···-··--·····- - - - - - - -- - - - - - - - - - - - -- - - - ,
[kV]
20

10

15.0 713. 525112

Fault image

12. Decay processes too high

Test requirement: accelerate engine repeatedly

to approx. 3000 rpm by blipping throttle or run
engine under load on roller dynamometer.

Cause
Fuel-air mixture at all cylinders too lean.

[ kV ]
20 ¡
1

1 1

i 1
1

¡: ~
¡
t:?
¿::>
1¿/
1 1
1

10 1
1
1
;
'
i
1
¡
1 j
1
i
. 1

~ ~
'
~ ~
1 ;

w
1 1

o l
J

1
!
'

ry
~ '~ -~
p 15-001S...S7

15.0713 . 525/13
Fault image

13. Higher spark voltage > 1.5 kV at single

cylinder

Test reqUtrement: may occur at any speed with

or without load.

Cause
Spark plug coated with soot, oil. lead. Too high
Ohm1c res1stance at secondary side.

[kV]
20

10

p 15-0017-67

15.07 13 o 525/ 14
Fault image

14. Higher spark voitage > 1.5 kV at all cylinders

Test requirement: may occur at any speed with

or without load.

Cause
Too high Ohmic resistance at secondary side.

15.0713. 5 25/15
Fault image

15. lgnition voltage < 8 kV at terminal 4

Test requirement: starting speed

Cause
lgnition coil

Note
Engine does not start.

[kV]
10

• 1

1 00 so 50 "10 20 o %

15.07 13. 525116

Fault image

16. lgnition voltage <6 kV at single cylinder.

Test requirement: starting speed.

Cause
lgnition coi!

Note
Engine does not start.

[kV]
1o ..
•

..
..

O·
1
p 11-4020-67

15.0713 . 525117
Fault image

17. No decay process.

Test requirement: starting speed.

Cause
lgnition coil or ignition control unit.

Note
Engine does not start.

[kV]
20 ..
.
.

.
1 1 1 1 1 1
1 1 1 1 1

1OQ 8Q 4D 20 O :·¡
/ .·
p 1$-4021-67

15.0713. 525/18
Fault image

18. lnsuHicient decay processes.

Test requirement: may occur at any speed with

and without load.

Cause
lgnition coil or ignition control unit.

[kV]
20

10

o
p 15-0022- 57

15.0713 . 525/19
Fault lmage

19. lnsufficient decay processes.

Test requirement: may occur at any speed with

and without load.

Cause
lgnition coil or ignition control unit.

[k V]
2J .
.
.
.
1e •

.
1 1 ,
1 1
' 1 T
l
'
1

1 00 8G 5~ 4~ 2: o /,
PIHD2H7

15.0713. 525120
15-530 Renewlng spark plugs

Spark plug connector slacken by turning to left and right and pull off.
fit on. Blow out recesses with compressed air.
lgnition cables clean, when fitting on, ensure cable lines are
correctly laid.
lgnition sequence: 1-5-4-8-6-3-7-2
Spark plugs . . . . . . . . . ................. . remove and install.
Tightening torque 25-30 Nm.

Special tool

11 7 sag oo os oo

15.0713 . 530/ 1
15-535 Removlng and lnstalllng high voltage dlstrlbutor

,...----- -- -- - - -- - - - - - -- - - -- - - - - -- -·- --·- - - - - --,

2 3 4

0 ~ 1-5-4-8 - 6 -3 - 7 - 2 ®
® 0
0 ®
G) 0

P 15 - 0228 - $7

Cover (7) on high voltage distributor
Oistributor cap (4) . . . . . . . . . . . . . . . . . . . . . . .
Position engine to ignition TDC of No. 1 cylinder
Sealing disc (2) and distributor rotor (3) . ... ...
Screw (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
after opening clips, remove from distributor cap,
fit on.
unscrew, screw on (arrows). Remove together
with protective cap for remota interference
suppression (6), fit on.
this is done by aligning markings on distributor
rotor (3) and distributor housing ( 1). In addition,
pointer (8) on timing case cover must be posi-
tioned above TDC mark of vibration damper (9).
remove from distributor.
slacken. Remove distributor.

15.0713. 535/1
lnstallation .. . . . .. • ..... . .. ... .. . .. . ...
Sealing disc (2) and distributor rotor (3)
Align distributor
Screw (5) . . . . . . . .. .. . ........ . . ...... .
Commercial tool
90° angle
Note
lt is not possible to set the ignition timing by
turning the high voltage distributor. The ignition
timing is determinad by the EZL'AKR control
unit.
The centrifugar force -dependent rotor advance
in the high voltage distributor does, however,
require precisely matching the distributor rotor
to the marking on the distributor housing in
order to eliminate spark discharges into the
wrong cylinder.
15.0713 . 53512
position engine to ignition TDC. This is done by
aligning pointer (8) on timing case cover exactly
on TDC mark of vibration damper.
fit onto distributor. Align distributor rotor to
marking on distributor housing. lnsert distributor.
fit on 90° angle to notch in distributor housing
edge. Align the markings on distributor rotor and
distributor housing very exactly to each other.
Lt.
When aligning, press distributor rotor slightly in
direction of rotation to eliminate any backlash.
tighten
lf the engine was rotated when the distributor
was removed. check ignition TDC of No. 1
cylinder as follows:
In ignition TDC the rocker arms at No. 1
cylinder are relieved (remove oil filler cap).
 15-540 Testing electronlc ignltlon system wlth electronlc timlng adjustment
(EZL)

Test requirement
Spark plugs, ignition parts, distributor rotor
and distributor cap in proper mechanical and
electronic condition.
Test e.g. by means of visual inspection,
resistance measurement and ignition
oscilloscope.

R4

Connection diagram for engine tester with oscilloscope

811 /2 Cootant temperatura sensor (EZUCIS -E) S29/2 Thronte valve sw1ICh, full Joad/idle
01 Banery T1 tgnition coil
LS Crankshaft posit1on sensor )( 11 01agnostJC sockeVterminal block (circu1t TO)
N1 /2 Electron'c 1gnition control unit (EZL)
R4 Spark plugs 2 Vacuum hne
R16 Res1Stance tnmm,ng ptug (EZL) - not used 3 Segments on dnven plate
R16/1 used on USA vehicles
SS/3 H1gh-voltage d1stnbutor

15.0713 . 540/ 1
Note
Pay attention to the safety instructions when
working on the ignition system (15-505). Switch
off ignition when connecting and disconnecting
the plugs at the EZL control unit.

The test es deveded into two sections:

A. Engine not running

In this section of the test, the basic functions of
the igniteon system are tested .

B. Engine running
Fault sources in the ignition advance mechanism
or at the appropriate components may influence
the performance of the vehicle.

lf complaints are received regarding

performance. first of all test ignition system .
Then, continua troubleshooting the CIS- E
injection system .

Special tools

201 589 00 99 00

15 07 13 . 54012
Commercial testers
Multimeter e.g. Sun, OMM-5
Fluke Multimeter 23
Hermann Avometer 2003
Engine tester e.g. Hermann Datascope 9800
Bosch MOT 301 1400
Sun 2110
BEAR O AC E

Test data

Resistances (test values from 0-100° C)

lgnition coi! primary (terminals 1 and 15) Q 0.2-0.4
lgnition coi! secondary (terminals 1 and 4) kQ 8-13
Position sensor resistor coils
(terminals 7 and 31d) Q 680-1 200
insulation (terminals 7 and ground) kQ ~ 200

Distributor cap per terminal, Q 700-1300

distributor rotor,
spark plug connector

Voltages (engine not running, ignition switched on)

Terminals 15 and 31 (contacts 5 and 2 diagnostics socket) V bat1ery voltage
Between terminals 15 and 1
(contacts 5 and 4 of diagnostics socket) V O
4-pin round connector terminals 15 and 31 V battery voltage
4-pin round connector terminals 16 and 31 V battery voltage

Dwell angle
At starting speed 1o -1 8 o or 1-40 %

At 3500 rpm 27°-40° or 60-90 %

15.0713 . 540/3
 lgnitlon timing
Engine EZL control unit Resistance Engine speed in lgnition point in o CA before
trimming plug rpm TDC
or trimming
without 1 with
plug position
vacuum vacuum

@ effective 1986
116.965 003 545 92 32 Reference 3500 28-32 4 1-45
003 545 91 32 resistor
750 Q idle speed 3- 7 10-14

117.967 004 545 53 32 Reterence 3500 24-28 40-44

117.968 004 545 55 32 resistor
idle speed 3-7 10-14
750 Q

lgnition timlng at starting speed in o CA before TDC 3-7

15.0713 . !?40i4
A. Engine not runnlng

Note Symbols for variables measured with

lf the specified value of a test step, e.g. step 1, multimeter
is in order. continua immediately with step 2. ~ Multimeter D.C. voltage rnode
~ Multimeter resistance mode
lf the specified value of step 1 is not in order, ~ Oscilloscope
the procedure must be continuad with step 1 . 1 .

Display Test stepí Test connection Operationi Specifi· Possible cause1Remedy

oni otf Test scope Requirement cation
factor

- 1.0 Nl/2 lgnition: ON Battery Test wiring and contacts

Power 31 -<~r-1 5 voltage according to wiring diagram
supply (from battery through
ignition lock to EZL control
unit)

- 2.0 L5 lgnition: OFF 680- Renew crankshaft position

Crankshaft 3, d -(.....::@!-)- 7 Detach 1200 Q sensor.
position crankshaft
sensor (l5) position sensor
plug at EZL
control u nit
.. ...... .... ..... .. .............. ····· ······· . . .. .... .. ..... ... .. ... ... .... ............ ....... .. ....... . ... ............ ············ · ·· · · ·· ··· · ····

15 .0713- 540/5
Display Test step! Test connection Op-eration/ Specifi· Possible causeíRemedy
on;off Test scope Requirement cation
factor

2.1 L5 Detach crank· see Signal too small/no signal:

31 d -< --<f>-->- 7 shaft position diagram Renew position sensor.
sensor plug at lnconsistent voltage peaks:
EZL control Check segments (visual
unit Us=:1V inspection).
Engine: Start Renew EZL control unit.

2.2 L5 Det ach crank- ~ 200 kQ Renew crankshaft position

lnsulation of -< ...:.@!- >-- 7 shaft position sensor.
sensor coil -L sensor plug at
EZl control
unit

3.0 Engine tester Engine: Start 1o -18 o Dwell angle not to

Dwell angla or tolerance:
1-40% Renew EZL control unit.
No dwell angle:
Test closed circuit cutoff.

4.0 T1 lgnition: ON ov Renew EZL control unit and

Closed tm. 1 ~tm.15 ignition coil.
circuit cutoff
T1 Engine: Start OV Test wiring and contacts
tm. 1 ~tm. 15 from EZL control unit to
ignition coil or renew EZL
control unit.
Renew ignition coil.
>O V
4 ., T1 lgnition: OFF 0.2-
lgnition coil tm. 1 -=-@-!-tm. 15 Unscrew 0.4 Q Renew ignítion coil.
primary (T 1) wiring at
ignition coil.

5.0 --<D-- Engine: Start 190- Renew EZL control unit.

Primary Engine tester 290 V
voltage Scope image
Parada primary

15.0 713 . 540/6

Display Test stepí Test connection Operation/ Specifi- Possible cause1Remedy
on/off Test scope Requirement cation
factor

- 6.0
Primary
--<D-- Engine: Start se e Renew EZL control unit.
Engine tester diagram
current Scope image
limiting Secondary
deviations

7.0 --CD-- Engina: Start 2::8 kV Test ignition cable

lgnition Engine tester terminal 4,
voltage at Scope image distributor rotor,
ignition coil Secondary parade distributor cap and
terminal 4 ignition coil.

7.1 T1 S513 lgnition: OFF <1Q Renew ignition cable

lgnition tm. 4 ..::.@!- tm. 4 Oetach ignition terminal 4.
cable cable
terminal 4 terminal 4 at
ignition coil
and distributor
cap.

7.2 Distributor rotor lgnition: OFF 700- Renew distributor rotor.

Oistributor ~ Remove distri- 1300 Q
rotor Middle Point butor cap. and
visual
inspec-
tion

7.3 S5i 3 lgnition: OFF 700- Renew distributor cap.

Oistributor ~ Oistributor cap 1300 Q
cap tm. 4 Carbon removed and per
contact detach terminal
ignition cable and
terminal 4. visual
inspec-
tion

7.4 T1 lgnition: OFF 8-13 kQ Renew ignition coil.

lgnition coil tm. 4 ..::.@!.. tm. 1 Unscrew
secondary wiring at
T1 ignition coil

15.0 713 . 540· 7

Display Test step; Test connection Operation/ Specifi- Possible cause/Remedy
on off Test scope Requirement cation
factor

8.0 -<D- Engine: Start >6 kV Test distributor cap,

lgnition Engine tester distributor rotor,
voltage at Scope image ignition cables with
single Secondary parade spark plugs.
cylinder High voltage sensor
clamps on cylinder
ignition cable (e.g.
cylinder 3)

8.1 -=@!-- lgnition: OFF 700- Renew ignition cable with

lgnition lgnition Spark plug Detach ignition 1300 Q spark plug connector.
cable with cable connector cable with
spark plug spark plug
connector connector at
spark plug and
distributor.

8.2 Visual inspection lgnition: OFF Electrode Renew according to

Spark plugs Remove spark gap condition.
plugs . 0.8 mm

15 0713. 54018
B. Engine running

Pay attention to safety instructions ( 15-505).

Display Test step. Test connection Operation; Specifi· Possible cause,Remedy

onioff Test scope Requirement cation
factor

1.0 Engine tester Engine: Test see table Reference resistor,

lgnition at normal coolant temperatura sensor,
timing operating throttle valve switch.
temperatura at vacuum advance.
specified rpm
and with/with·
out vacuum

- 1.1 N1 .'2 lgnition: OFF 750Q Reference resistor

EZL _j_ ...:@!- )-3 Detach sensor Wiring
reference 4-pin connector at Contacts
resistor sensor EZL control
(R16/ 1) connector unít.

1. 1. 1 R16/ 1 lgnition : OFF 750 Q Reference resistor

EZL ...:@!- Oisconnect
reference reference
resistor resistor.
(R16/1)

15.0713.- 540/9
Display Test stepl Test connection Operationi Specifi- Possible cause Remedy
on off Test scope Requirement cation
factor

- 1. 1.2 R16/ 1 N1 !2 lgnition : OFF <1 Q Renew wiring or contacts.

Wiring and -< ~ )--3 Disconnect
contacts 4-pin reference
sensor resistor.
connector Detach sensor
connector at
EZL control
unit.

R16í 1 <1 Q Test negativa cable to

...L ~ >-- ground, front left
wheelhouse (ignition coil)
(W1 1) (Model 126) or
engine ground (electric
cable bolted on) (W3)
(Modal 107), renew.
.. ..... ..... ..................... ................................. ······ ········· ········· ················ ······························· ·············
- 1.2 NV2 lgni tion: OFF at Coolant temperatura sensor
Coolant ...L. ~ >-- 1 Detach sensor 80 oc (811í2)
temperatura 4-pin connector at 290- Wiring
sensor sensor EZL control 360 Q Contacts
(811 ,2) connector unit. further
values,
se e
diagram
..... .. ... .. ·· ·········· ······ ·· · .. .. ···· ·· ·· ····· ··········· ···· ·················· ··-··· . ............... ····· ·· ············ ··· ·· ········ ···········
- 1.2.1 811 /2 lgni tion: OFF Renew coolant temperatura
Coolant
- ~ >-- Detach sensor (811 ;2).
temperatura connector at
sensor temperatura
(811 12) sen sor.

···· ·· · . .. . . . . . . . . .. . .
········· ·· ···· ········· ·· ···· . . ... . . . . .. ..... ..... .............. ... ' .. ' ' . .. . ' . .. .... ... .. .. ........ .. ... ...... ........... ...

- 1.2.2 811 12 N1 í2 lgnition : OFF <1Q Renew wiring or contacts.

Wiring and
contacts - ~ >-- 1
4-pin
Detach
con nector and
sensor te m pera tu re
connector sensor and
sensor
connector at
EZL control
unit.

············ ...... .. ........ .... ..... ............................ .................... .... ................. ...... ............................. ........ .

15.0 7 13.54011 0
Display Test step/ Test connection Operationt Specifi· Possible causeJRemedy
on off Test scope ReqUirement cation
factor

- 1.3 S29i2x lgnition: OFF Full load Set throttle valve switch or
Throttle 2_ ~ _3 Detach position: renew
valve connector <1n open circuit
switch, (S2912x) Other
fullload positions:
detection 00

(S29•2x)

1.3.2 N1.2 N3 lgnition: OFF <1Q Renew wiring or contacts.

Wiring and ( 2 ...:@-!- )- 5 Detach sensor
contacts 4-pln connector at
sensor EZL control
connector unit and CIS-E
control unit

1.4 Engine tester Engine: normal lgnition Vacuum hose leaking

Vacuum operating timing Connection at intake
advance temperatura, retardad manifold blocked
1500 rpm. Pressure sensor in EZL
Detach control unrt faulty
vacuum hose
at EZL control
unit.

Fit vacuum lgnition Vacuum hose leaking

hose onto EZL timing Connection at intake
control unlt. advanced manrfold blocked
Pressure sensor in EZL
control unit faulty
············ ...... ··· ··· ····· ·· ·· ············ ··········· . . .... . ...
· ·· · ·· · ·· · ··· · · · · · .. .. ......... .. ... . ... ······ .................. .... .
1.5 L5 Detach crank· see lnconsistent voltage peaks:
31d -<--<ir->- 7 shaft position diagram Check segments (visual
sensor inspection). Renew driven
connector at Us ~1 V plate with segments.
EZL control
unit.
Engrne: Start
............................. - ··· ·· ········ ···· ·· ··· ······ ····················· .. ··· ··· ·········· ...... ··················-·· ·-···· ·· ··· ·

15.0 7 13 . 540111
Display Test step: Test connection Operation/ Specifi- Possible cause/Remedy
on. off Test scope Requirement cation
factor

- 2.0 Engine testar Speed 27-40 ° Renew EZL control unit

Dwell angla 3500 rpm. or
Engine at 60-90%
normal
operating
temperatura.
Detach sensor
connector at
EZL control
unit and
vacuum line.
Engine: Start

15.0 713 . 540112

 Display Test stepi Test connection Operation1 Specifi· Possible cause,Remedy
on1ott Test scope Requirement cation
factor

- 3.0 Visual inspection lgnition : OFF - Distributor cap,

High voltage Remove distributor rotor has cracks,
distributori distributor cap interference suppression
distributor resistors faulty
rotor

3.1 lgnition: OFF 700- Renew distributor cap

Distributor Remo ve 1300 Q
cap distributor cap per
terminal

3.2 Distributor rotor lgnition: OFF 700- Renew distributor rotor

Distributor -=@!- Remove 1300 Q
rotor Middle Point distributor cap and
visual
inspec-
tion

4.0 Engine tester Engine: Start see lgnition coil

Scope -<D-- ldling speed scope Distributor
images Scope images images lgnition cornponents
Parad e (15-525) Spark plugs
Deviations
Raster

Crankshaft position
sensor signa! (l5)

11 1st segment
t2 2nd segment
t3 3rd segment
14 4th segment
d Penod tor one crankshaft
revoluiiOn

15.0713 . 540/13
 U(kV)
10

"-- - -- - -·- - SchlieB 4 - - - - -- -

45" 40" 35° 3Q• 25° 20° 15° 10° s• 8 Zyl.

go• so• 70° so• so• 40° 30° 20° 10° 4 Zyl.
!--- -·
600 so• 40° 30° 20° 1Q· 6 Zyl.
P15·02U•55

Currenl limillng
50000
40000
30000
20000
~
~
10000 ~ ....
8000 ,,
&000
4000
~
3000
~" t).
2000

1000 ~~ ,.
&00
"'-'!
&00

ª
a:
400
300
200
""""' '~""'"
100
eo
~-
60
40
30
20

10
- 30 - 20 o 20 40 60 80 100 120'C
P1S-0237-t$

Diagram of 4-pole coolant

temperatura sensor
{EZLICIS ·E), (8 11/2)

15.0713. 540/ 14
 0.75
9<'
rt

e
.-O.?óbrlrt - - - - - -- -..

,...------o_?~gnlsw --Q?5gn/Sw

,......----Q7~swlge--0.5gn - - -- --,

W11 1-QSb<

1--- - - - - -

Wiring diagram EZL

81112 Coolant temperature sensor (EZLICIS-E) X t1 Otagnosttc sockel/\ermtnal block (Ctrcutl TD)
L5 Crank~hatt pos111on sensor X22/ 1 Connector, transmisston overload prolect10n (2·
N l t2 Eleclrontc tgnttton control unll (EZLJ pole)
R1611 Reference reststor (EZLJ X26 Connector. tntenortengtne
$5/3 Htgh-voltage dtstnbutor
S2912 Throttle valva swttch. full roadtidle a To C IS -E in¡ectton system control unit, contact 5
Tl lgnrtton COt! b T o tdle speed control untt, contact 4
W3 Ground, left front wheel ho ustng (at rgnttJon corl) e To CIS-E tn¡ecllon system control unu, cont 21
W9 Ground. at left headlamp untt e To plug connectton X 26 on engtne. soc ket 3
Wll Ground. engrne (connectton potnt for ground (circuit 30)
WlfSS) T o plug connectton X 26 on engtne, socket 1
(CtrCUit 15}
g N ot used - ends tn wtnng harness

15.0713- 540/ 15
18-005 Oil circuit

A. Model 107

Oil circuit with air oil cooler next to radiator

Engines 116.960 (except regional version). 117.960.

Oil circuit without air oil cooler

Engines 116.960 @ 0 0 <§> 116.962/964
117.962/ 964, 117.967 @ <§>0

O il circuit with ai r o il cooler

Note

The o il circuit is p ressure-regu lated via the air oil

cooler.

18.7- 005/ 1 F3
B. Model 126

Oil circuit with air oil cooler next to radiator

(version A)
Engines 116.961, 117.961.

Oil circuit without air oil cooler

Engines 116.961 @ 0 <§ 116.963/965,
117.963/985/968 @ 0@

Oil circuit with air oil cooler in right-hand wheelhouse

(version 8)
Engines117.968 and special protection vehicles.

Oi l circui t with ai r oil cooler

Note

The oil circuit vía the air oil cooler is regu lated by
means of a thermostat and a control valve in the oil
filter.

18.7- 005/2 F3
18-010 Oil pressure, valvas in oil circuit, oil filter and thermostat (model126)

Oil pressure and oil pressure indication

At operating temperature, the oil pressure at idle

speed may drop to 0.3 bar gauge p ressu re.

During acceleration, the oil pressure should imme·

diately rise again and should reach a m ínimum of
3 bar gauge pressure at 3000 rpm.

The oil pressure indication in the instrument cluster

is electrically controlled by oi l pressure transmitter.
The oil pressure transmitter on engines in the model
107 is screwed into the flange (between oil filter
lower part and crankcase) and on the engines in the
model 126 in the oil f ilter housing lower part.

The oil pressure transmit:ter was modified in March

1980 ( improved housing seal) and in March 1981
(housing interior ventilation). In the event of repa irs
dueto a fluctuating needle of t he oil pressure indi·
cator, install only oil pre ssure transmitter starting
with production code number 3.80 (March 1980).
The production code number is stamped into the
hexagon screw connection.

Oil pressure relief valve

The oil pressure relief valve is integrated in the oil

pump cover.

Ata gauge pressure of 8 bar (up to April 1985) and

of 5.5 bar (as of April 1985). the oil from the feed
opening (A) shifts the p iston (2) against the force of
the compression spring (3).

As soon as the control edge of the piston (2) arrives

at the return flow opening (B) , the oil pressure
recedes towards t he suction side of the oil pump
(arrows).

The resulting control movements of the piston (2)

are damped by oil which f lows behind the p iston
into the damping chamber (Cl across a flat on the
p iston (arrow).

1 Oil pump housing 6 Straine r

2 Piston 7 Compensating piece
3 Compression spring A Feed opening
4 Guide pin B Return open ing
5 Pl ug C Oamping chamber

18.7-010/1 F3
Bypass valve oil filter insert

The bypass valve (3) for the oil filter insert is located
in the oil filter flange in the crankcase and leads into
the main oil gallery. When the differential pressure
between clean and dirty oil filter sides exceeds approx.
4.0 bar, e.g. when the oil filter is severely contami·
nated, this valve opens and the oil reaches the
bearing points in the unfiltered state.

Bypass valve for oil filter insert

20 Valve housing
21 Valve cone
22 Compression spring
23 Circlip

Bypass valve air oil cooler

The bypass valve (2) for the pressure-controlled air

oil cooler in the face of the crankcase opens when-
ever the flow resistance in the air oil cooler exceeds
1.5 bar gauge pressure with cold oil. The o il will
then flow d irectly to th e oil filter, bypassing the air
oil cooler.

The by pass valve is covered vía plug in the timing

case cover, or by the t i ming case cover without plug.

In the event of repairs (e.g. exchange engine) no

bypass valve should be used on vehicles w ithout air
oil cooler.

Bypass valve for air oil cooler

16 Valve seat ring
17 Valve cone
18 Compression spring
19 Valve guide 1184-7737/1

18.7-010/2 F3
Oil f ilter and t hermostat model 126

The oil filter is designed as a full f low filter. The

engine oil flows through the oil fi lter element (6)
from the outside to th e inside and continues in a
cleaned state via the r iser (8) and the duct (b) to the
main o il gallery and further to the bearings.

Vehicles w ith o il cooler :

Starting at an oil temperature of approx. 11O °C,
the thermostat ( 10) starts to move the control valve
( 11) against the force of the compression spring ( 16)
until the fina l position is reached at approx. 125 °C.

In the final position, the oil f lows via the connection

(A), an o il damper and o il hose to the air oil cooler,
is cooled down there, returns to the oil filter
housing via connection (B) and flows through the oi l
filter element from the ·o utside to the inside.

Below 11 O °C oil temperature, the oil f lows in the

oil fi lter via the short·circuit duct.

1 Center bolt 14 Valve cene return

2 Sealing ring shut·off valve
3 O il filter cover 15 Compression spring
7
4 O·ring 16 Compression spri ngl)
5 Oil filter housi ng 17 Seal oil filter element
6 Oil filter element bottom B
7 Screw fitting 1 ) 18 Seal oil fi lter element
7a Screw fitting 1 ) top 17 8
8 Riser A Uncleaned oil to the
9 Connection for electrical air oil cooler
oi l pressure transmitter B Uncleaned oil to the 16 9
10 Oil thermostat 1 ) air oil cooler 15
11 Contro l valve 1) a From the oil pump 14
To the bearings 7a
12 Va lve seat ring return b
shut·off valve e Oil return to the sump
13 Va lve retainer 13
1) Not appl icable on engines without air oil cooler. 12

Caution!
l f for any reason the air oil cooler has to be discon·
nected or the connections on the o il filter to be
blanked off, the thermostat ( 1Ol. the control valve
( 11) and the compression spring ( 16) must be re·
moved. Failure to do so will interrupt the oil supply
to the beari ngs at an oil temperature above 11O°C.

18.7-010/3 F3
18-110 Removal and installation of oil filter

A. Mode l 107

Oil filter,
engines 116.960/962 and
117.960/ 962/964/ 967

1 Center bolt
2 Sealing ring . . . . . . . . . . . . . .... •. .. . . . . Check, renew if required
3 Oil filter housing
4 O·ring . . . .. . ... ... . .. . . . . ... ...... . . Renew
5 Compression spring . . . . . . . . ... . . .. . . .. . . Observe installation position
6 Spring retainer . . . . . . . . . . . . . . ... .. . .. . For oil f ilter element
7 Oil f ilter element . . .. . .... . ..... . ..... . . Ensure use of correct oil filter element
8 Screw fitting
9 Gasket . . ...... . . .. . . . .. . . . ... .. .. . .. Renew
10 l ntermediate flange
11 Spring washer . . . . . . . . . .. . • . .... . .. .. .. 3 required
12 Internar socket head screw . .. • . . . . . . . . . . . • 3 required
13 Seal ing ring 1 )
14 Screw fitting 1 )
15 Sealing ring
16 Electric oil pressure transmi tter

1
) Not required fo r engines without air oi l cooler: 116.960@ 0 (!)<§as from 1981, 116.962/964 and
117.962/964/967.

Note

New oil fi lters are suppl ied with initial operation

filter elements which, on new engi nes, should be
u sed up to the inspection at 1000-1500 km.

18.7- 110/ 1 F3
These filter elements have a limited service lite and
must be exchanged for filter elements par t No.
000 180 05 09 if new oil filters are fitted to run-i n
engi nes.

Removal (model107)

Remove oil f ilter housi ng.

2 On engines 116.960 standard version and 117.960,

disconnect o il cooler line from intermediate flange.

3 Pu ll single-plug connection of electric line to the

oil pressure indication in the instrument cluster
from the oil pressure t ransmitter.

4 Unscrew fasten ing sc1rews for intermediate fl ange

and remove intermediat•e flange.

5 Remove remains of gasket from flange surface on

crankcase.

F irst close the openings (arrows) in such a way that

no remains of gasket can enter the oil ducts in the
crankcase.

lnstallation

6 Position intermediate flange with new gasket and

tighten fastening screws for intermediate f lange to
25 Nm.

7 On engines 116.960 standard version and 117.960,

connect oil cooler line t o intermediate flange and
t ighten coupling nut to 25 N m.

8 Plug single-plug connection of electric line to oil

pressu re indicat ion in the instrument cluster to the
oil pressure transmitter.

9 lf required, renew sealing ring of center bolt and

oil fi lter element. Position oi l f ilter housing with new
0-ri ng and tighten center bolt to 40 N m.

Note: lf compression spring with spring retainer has

been removed, reinstall part in such a way that the
spring retainer faces towards the oil f ilter element.

10 Run engine and check fo r leaks.

11 Check oil level, conrect if necessary.

18.7- 110/2 F3
B. Model 126

Oil filter, engines 116.961, 116.963, 116.965, 117.961 and 117.963, 11 7.965, 117.968

Center bolt ...... . .. ... ... . . . . ... ..... Jighten to 30 N m

2 Sealing ri ng .... . ....... . ....... . ..... Check and replace if required
3 Oil fi lter cover
4 O·r ing . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . Renew
5 Oil fi lter element . . . . . . . . . • . . . . • . . . . . . . . Ensure use of correct element
6
Oil fi lter hous ing . . . . . . . . . . . . . . • ..... ... Clean
Screw fitting 1 ) • . • • . . • • • • . • • • • • • • . • • • • .
7 Tigh ten to 40 Nm
Sealing ring1 ) • • • • • • • • • • • • • • • • • • • • • • • • •
8 Renew
9
Gasket . . . . • . . . . . . . . ... .. ........ .. .. Renew
1O Thermostat w ith control valve 1 ) . . • . • • . • . • . • . Beginning of control 11 O± 4 o C. end of control
(fully opened) 125 ± 4 ° C
11 Compression spring 1 )
12 Spring retainer 1 )
13 Compression spring
14 Valve cone ret urn flow shut·off valve
15 Valve scat ring return flow shut-off valve ...•... Tighten to 40 Nm
16 Electric oil pressure transmitter
17 Sealing ring ..... . . . . . . . . . . ..... . . . . . . . Renew
18 Spring washer ....... • ........ .. . . . . . . . 3 required
19 Hex. head bolt . . . . . . . . . . . . . . . . . . . . . . . . 3 required. tighten to 25 N m

1
) Not required on engines without air oil cooler except for subsequent installation of an oif coofer:
116.96 1 @ 0 ® @asof 1981,116.963,117.963/965/968

18.7- 110/3 F3
Note

New oil filters are delivered with initia l operation

f ilter elements which are used on new engines up to
inspection at 1OQ0- 1500 k m.

These f ilter elements have a limited service life and

shou ld be exchanged fo r f ilter elements part No.
000 180 06 09 if new oi l f ilters are attached to
run-i n engines.

Removal (model 126)

Remove oil filter cover.

2 On engines 116.961 standard version and 117.961,

unscrew both o il cooler lines on o il f ilter housing
and remove pipe elbow between oil fi lter and
damper.

3 Pull single·p lug connection of electric line for o il

pressure indication in instrument cluster f rom oil
p ressure transm itter.

4 Unscrew fastening sc rews for oil f ilter and remove

oil filte r.

5 Remove remains of gasket from flange surface on

crankcase.

First close openings (arrows) so that no remains of

gasket can enter the o il ducts in the crankcase.

lnstallation

6 Position the oil filter w ith new gasket and tighten

fasten ing screws to 25 Nm.

7 Plug single·plug connection of electric line for o il

pressure indication in instrume nt c luster onto oi l
pressure transm itter.

18 .7-110/4 F3
8 On engines 116.961 standard version and
1 17.961/968 and special protection vehicles, connect
oil cooler lines to oil filter housing and tighten
coupling nuts to 25 Nm. lnstall pipe elbow between
oil filter and damper.

9 lf requ ired, replace sealing ring of center bolt and

oil filter element. Mount oil filter cover with new
O·ring and tighten center bolt to 30 Nm.

10 Aun engine and check for leaks.

1 1 Check oillevel and correct if requ ired.

18.7-110/5 F3
18- 210 Removal and installation of oil pump

Tightening t orques Nm

Model 107 M26 50

Oil drain plugs to oil pan
Model 126 M 12 40

Oil pump to timing case cover 25

Sprocket to oil pump 28

M6 10
Fasten ing screws oil pan
to crankcase
M8 25

Fastening screws oil pan lower part to oil pan 10

Special t ools

Torque w re nch 25-1 30 N m with

001 589 66 2 1 00
plug-in ratchet 1/2" drive

Screwdriver (A IIen w rench) 5 mm, 300 mm long

116 589 02 07 00
for internal socket head se rews

Socket insert 27 mm, 1/ 2'·' drive for

001 589 65 09 00
turning the engine

Note

During oil pump change, ensure uniform number of

teeth on drive gear. l f clamp for drive chain must be
renewed, remove t iming case cover (01 - 210) .

The oi l pump compensation piece version ,.8" was

installed as standard from November to December
1982, and must be replaced w ith ve($Íon ,A" in the
case of repairs.

Hardened oil pump compensation pieces must be

A B
renewed.

From October 1985, an oil leve l transmitter has been

screwed to the oil pump. The plug connection of the
elect ric line of the oil level transmitter passes through
right-hand crankcase wall from inside to the outside
and must be sealed with a sealing ri ng.

18.7-210/ 1 F3
Removal

Drain engine oil.

2 On model107 remove oil pan (01 - 210), on

model 126 remove oil pan lower part.

3 Place compensation weight of first crank p in in

horizontal position.

2 Connection plug
3 Oil level transmitter

Model107

4 Unscrew fastening screws ( 1, 2 and 3), tilt oil

pump forwa rd, remove drive eh ain from drive
sprocket and remove oil pump.

Model126

5 Unscrew screws ( 1, 2 and 3).

6 Loasen screw (4) on drive sprocket, ti lt oil pump

toward the rear and remove the screw.

7 Push drive sprocket away from oil pump by means

of a screwdriver and remove oil pump.

8 Lift drive sprocket out of drive chain.

18.7- 210/ 2 F3
1nstallation

Model107

9 Wi th o il pump tilted forwa rd , place drive chain on

dri ve sprocket, screw in fasten ing screws ( 1, 2 and 3)
and tighten to 25 N m.

M odel126

10 Engage drive sprocket in drive chain.

11 Push oil pump onto d r ive sprocket . The dowel

sleeve in the drive sprocket should enter the recess
in the drive shaft (arrows).

12 Ti lt oil pump to the rear , screw in screw (4) and

tighten to 28 Nm.

13 Screw in fasten ing screws ( 1, 2 and 3) and tighten

to 25 Nm .

Caution!
When t ightening screw (1), secure tension spring (5)
of clamp (6) w ith a screwd river to prevent turn ing.

14 lnstall oil pan (mod el 107, 01-210) or oil pan

lower part (model 126) with new gasket and tighten
fastening screws to 10 Nm (thread M 6) or 25 Nm
(thread M 8).

15 Fill in engine oil.

16 Au n engine, check oil pressure, check for leaks.

17 Check oi l level and correct if required.

18.7- 210/3 F3
18-215 Removal and installation of oil pressure relief valve

Tightening torques Nm

Model 107 M 26 50
Oil drain plug to oil pan
Model 126 M 12 40

Closing plug (oil pressure relief

40
valve) to oi l pump cover

M6 10
Fastening screws oil pan
to crankcase
M8 25

Fastening screws oil pan lower part to oit pan 10

Special tools

Torque wrench 25- 130 Nm with

001 589 66 21 00
plug-in ratchet 1/ 2" drive

Screwdriver 5 mm. 300 mm long for

116 589 02 07 00
interna! socket head bolts

18.7-215/1 F3
Removal

Drain engine oil.

2 On model107, remove oil pan (01- 210). on

model 126. r emove oil pan lo wer part.

3 Unscrew closing plug ( 1O).

Caution!
The closing plug is under pressure from the com-
pression spring.

4 Re m ove compression spring ( 11), gu ide pin ( 12)

and piston ( 13).

lnstallation

5 lnstall p iston ( 13), guide pin ( 12) and compres-

sion spring ( 11).

6 Screw in closing plug ( 10) w ith new sealing ring

and tighten to 40 Nm.

7 l nstall oil pan (model 107, 0 1-210) or·oil pan

lower part (model 126) with new gasket and tighten
fastening screws to 10 Nm (thread M 6) or 25 Nm
(thread M 8).

8 Fill in engine oil.

9 Run engine, check oi l pressure, check for leaks.

1O Check oil level and correct if requ ired.

18.7-215/2 F3
18-220 Checking oil level indication

With complaints such as: A. Control lamp stays on with running engine and correct oil level.

B. Controllamp does not light up in key position .. 2".

C. Control lamp fa ils to light up with running engine, oil temperature > 60 °C and
oil level below .,min".

Test values

Resistance with oil level max <0.1QQ

Resistance with oil level m in ooQ

Battery voltage approx. 12 V

Conventional tool

Multimeter e.g. Sun, DMM- 5

Note

The oil level control lamp 1ights up with ignition

swi tched on (control function) and goes out as soon
as the engine runs.

Our ing the control funct ion the oil level control
lamp lights up dimly and during faults brightly.

18.7-220/ 1 F3
Checking

A. Cont rol lamp stays on with running engine and

correct o il level

Check oil level transmitter

Aemove coupling. With multimeter, check

plug connection against ground.

Display : < 0.10 fl

Yes No
1
..¡.
Aenew o il leve! transmitter .

...... ~
Check line from the plug connection to the
instrument cluster, for this purpose remove
instrument c luster. With ohmmeter, check
resistance between socket 4 of 15-pole
coupling and the disconnected socket p lug
connection (coupling).

Display:< 0.10 fl

Yes No
1

Aenew ha rness.
+
-~ ~
Aenew cluster unit (arrow) in instrument
cluster.

End of test

18.7-220/2 F3
B. Control lamp does not light up in key position
.,2" (control function)

Check function of incandescent bulb.

Y es No
1

..... ,...
Renew bulb.

~ .....
Remove instrument cluster. With multimeter
measure voltage on sockets 6 and 9 of the
15·pole coupling.

D isplay: approx. 12 V

Y es No
1

...... ....
Renew harness.

. ..... ,...
Renew indication instrument.

End of test

18.7-220/3 F3
C. Control lamp fails to light up with running engine,
oil temperature > 60 °C and oil level below .,m in".
control function secti·o n .,B" okay

-·
Check oil level transmitt er, pull off coupling.
W ith multimeter check plug against ground.

D isplay : oo !1

Y es
J No

.... .,...
Renew oi 1 level transmitter.

..... .,...
Renew indication instrument.

End o f test

18.7- 220/ 4 F3
 18-230 Removal and installation of oil level transmitter

í\81- l327$
8 9

1 Crankcase 7 Oil dipstick

2 Connection plug 8 Oil level transmi tter
3 Locking ring 9 Oil pump
4 Se al ing r ing 10 Oil pan
5 Connection cable 11 Oil pan gasket
6 Oi l dipstick guide tube 12 Timing case cover

Note

The oil level transmitter (8) is bolted to the o il pump

(9). The connection plug (2) of the connection
cable (5) passes through a bore in the crankcase ( 1)
from inside to the outside and is sealed with a
sealing r ing (4). On the outside the connection plug
is attached with a locking ring (3).

Model 107 Remove oil level transmitter with con·

nection cable and connection plug w ith oil pan
removed (01-310).

Model 126 Remove o il leve l transmitter with con·

nection cable and connection plug with oil pan
lower part removed.

18.7- 230/1 F 3
20-005 Coolant circuit and engine cooling

Coolant circuit

Engines 116.960 and 116.961 standard version

Engines 117.960 and 117.961

A From engíne to radíator G Heatíng water leed from cylínder head (intake manifold
B From radíator to coolant thermostat left) to heat exchanger
C Bypass duct H Heating water return flow duct in cyl índer crankcase
O Coolant flow from expansíon tank to radíator ríght
E Vent líne J Heat ex changer
F Overflow hose
1 Main valve coolant thermostat
2 By pass valve coolant thermostat

20.7- 005/ 1 F3
Operation

Warming-up period (coolant temperatura up to

approx. 75 °Cl

The main valve ( 1) is closed up to a coolant tempera-

tu re of approx. 75 °C and the bypass valve (2) is
fully opened. F low (8) from the radiator is inter-
rupted and the coolant flows through the bypass
duct (C) directly to the coolant pump.

Part-load operation (coolant temperatura approx.

75 °C to max. 92 °Cl

In the part·load range (engine at operating tempera·

tu re). the m ain valve ( 1) as well as the bypass val ve
(2) are more or less open depending on engine load
and outside temperatura. The coolant is directed as
a function of coolant thermostat position both vía
the radiator (A and 8 ) and the bypass duct (C).

1204·7538

Full load operation - High outside temperaturas

(coolant temperatura abo ve 92 °CI

Main val ve ( 1) is fully open. 8ypass val ve (2) closed.

Under severe engine load and high ambient tempera-

turas, the bypass duct (C} is closed not later than at
a coolant temperatura of 92 °C. The entire coolant
must flow through the radiator. lt is therefore wrong
to remove the thermostat for an .,improved" cooling
of the engine.
1204·7539

20.7- 005/2 F3
Coolant circuit (2-phase)

Engines 116.960 and 116.961 national ve rsions@ 0 0 @ 1981

Engines 116.962, 116.963, 117.962 and 117.963

F G

1204- 9641/J

A From coolant thermostat to radiator K Heat exchange r

B F rom radiator to coolant pump L Expan sion tan k
C By pass duct
D Coolant f low f rom expansion tan k to radiator 1 Ma in valve coolant thermostat
E Vent hose upper coo lant b ox to expansion tank 2 Bypass valve coolant thermostat
F Vent hose inlet conn ection (thermostat housing) to ven t 3 Cont rol bore
hose between upper coolant box and expansion tank 4 Pi n
G Overflow hose
H Heati ng water feed from cylinder head (intake manifo ld left)
to heat exchanger
Heating wa ter return duct in cylinder crankcase right

Note

On the engines 116.960 and 116.961 national versions

@ 0 0 @ 1981, the vent line (F) is installed
with effect from August 1981 .

Production breakpoint: August 1981

Engine Chassis
Model Engine
end No. end No.

107.025 003752
116.960 012479
107.045 008644
126.032
116.96 1 019965 019854
126.033

20.7-005/3 F3
lnstead of vent hose (arrow) by way of which the
cooling system has been continuously and auto·
matically vented during filling operation and also
during operation of engine, the vent screw (7) has
been used up to August 1981. This screw must be
opened for venting when filling the cooling system.
When using this vent screw, no automatic, continuous
venting of cooling system will occur.

Operation

Note: 1ndependent of coolant temperature or posi·

tion of coolant thermostat. a small quantity of
coolant will always flow through the control bore (3)
to the coolant pump. The pin (4), connected to the
wax element by means of a web, will move up and
down w ith the stroke of the wax element in the
control bore to keep the bore free of contamination.

Warming-up period (phase 1, coolant temperatura

up to approx. 84 °C)

The m ain val ve ( 1) is closed up to a coolant tempera·

ture of approx. 84 °C and interrupts the coolant
flow towards the radiator (A) and through the by·
pass duct (C). Only a small quantity of coolant will
flow through the control bore (3) to the coolant
pump during the warming-up period. This design
provides faster heating of the engine during the
warming·up period, especially in the combustion
chamber region in the cylinder head.

Part-load operation (phase 2, coolant temperature

approx. 84 °C to max. 99 °C)

In the part·load range (engine at operating tempera·

tu re) the main valve ( 1) and the bypass valve (2) are
more or less open depending on the engine load and
ambient temperatures. The coolant flows as a func·
tion of coolant thermostat position both through
radiator (A and 8) as well as bypass duct (C) to the
coolant pump.

1104-9648

20.7-005/4 F 3
Full load operation - High ambient temperaturas
(coolant temperatura above 99 °c)

Under heavy engine load and/ or high ambient tem-

peratures the main val ve ( 1) is fu lly open at a coolant
temperature of app rox. 99 °C, and the bypass va lve
(21 is closed. The entire coolant w ill now flow through
the rad iator to coolant pump (A and B). lt is there-
fore wrong to remove the coolant thermostat to
obtain an .. improved" engi ne cooling.

Coolant circuit (3-phase)

K
G

T
L
S

A From the coolant pump to the crankcase L Overflow tank (only with air conditioner/ au tomat ic
8 From the cylinder head 10 the inlet pipe and bypass d uct climate control)
C From the inlet pipe to the radiator N From cyl inder head/ intake man ifold 10 heat e><changer
O F rom the rad iator to the thermostat P Heat exchanger
E From the circulation pump to the coolant pump O Mono valve
F Aadiator A Circu lation pump electric
G Vent hose from radiator to e><pansion tank S Coolant filling hose
H E><pansion tank (in bypass circuitl with coolant level T Vent hose from in le t pipe
indication U Vent valve
J Plug w ith pressure relief and vacuum val ve 1 Main valve coolant thermostat 80 oc
K Overflow hose 2 By pass valve

20.7 - 005/5 F3
Coolant pump

with laterally arranged thermostat 80 °C in the

coolant feed from the radiator:

Operation

Coolant temperature up to approx. 80 °C

The m a in valve ( 1) is el o sed and the by pass valve (2)

fully open. The feed (D) from the radiator is ínter·
rupted and the coolant flows via the by pass duct
(B) directly via the coolant pump to the crankcase.

Coolant temperatura of approx. 80 °C up to max. e

95°C

In th e part·load range (engine at operating tempera·

tur e) the main valve ( 1) and the bypass valve (2) are
more or lcss open depending on the engine load and
ambient temperature. The coolant is directed via
both th e radiator (C and D) and also the bypass duct
as a function of the thermostat position.

1204 -753a/1

Coolant temperature above 95 °c

The main valve ( 1) is fully open and the bypass

valve (2) 1s c losed.

With heavy engine load and high ambient tempera·

tu res, the by pass duct is closed by the by pass val ve
(2) not later than ata coolant temperature of 95 °C.
The entire coolant must flow through the rad iator
to 1

(C- D). lt is therefore wrong to remove the th ermostat

for an ,. improved" cooling of the engine.
1204-7539/1

20.7 - 005/6 F3
Expansion and overflow tank

Production breakpoint: September 1984

Only for vehicles with air condit ioner or automatic

climate control.

The drain hose at the f iller neck of the expansion

tank leads to the overflow tank.
The overflow tank collects tfle coolant forced out
through the overflow hose at high ambient tempera·
tures after the engine has been switched off.

After the coolant has cooled down, t he coolant in

the overflow tank returns to the expansion tank due
to the vacuum created in the cooling system.

Coolant loss is largely eliminated in this way.

In order to prevent wrong air being drawn in at the

expansion tank cap w ith vacuum in the cooling
system, th e cap ( 1.2 bar) w as prov ided with a rubber
seal. Only this cap, part No. 123 501 02 15, may be
u sed.

Note on repairs

From the installation of the <:oolant level transmitter

the expansion tank has been reinforced and can be
used in place of the previous expansion tank together
w ith a plug w ith gasket and locking ring.

20.7-005/7 F3
Coolant level indication

T he dynamic coolant level indication moni tors the

coolant level in the expansion tank with runn ing
engine.

Components

Coolant level transm itter (550) in the expansion tank

Control lamp in instrument cluster.
Symbol: symbolic rad iator.

550a
552

550

550 Coolant level t ransmitter

550a Locki ng ri ng
551 Float
552 O·ring

Operation

With the ignition switched on (key position 2) the

controllamp lights up dimly and goes out with
running engine (function control of bulb).

The coolant level in the expansion tank is explored

by a float with permanent magnet (551) attached to
the coolant level transmitter.

As from a certain coolant level the contact is closed

and the controllamp lights up.

Depending on the driving style, the control lamp will

first light up for a short time and later on permanently.
lf the controllamp lights up, f ill up coolant.
Electrical circuit diagram see Group 54.

20.7-005/8 F3
Note on repairs

In order to avoid wrong installation of the coolant

level transmitter, it is provided w ith two lugs of
different widths, which engage in corresponding
slots in the expansion tank (arrows).

lt is pressed into the expansion tank and sealed with

an O·ring (552). To remove the coolant level trans·
mitter, remove locking ri ng.

Engine cooling

The spring·loaded cap (code number 120) serves to

establish a gauge pressu re of appr ox. 1.2 bar in the
cooling system.

Renew coolant every 3 years.

Use only approved corrosion protectíon/ ant ifreeze

agents (see Servíce Product Specifícations sheet
325.1).

Use only the Mercedes·Benz corrosion protection/

antifr eeze agent, par t No. 000 989 08 25.

For reasons of corrosion protectíon, the corrosion

protection/antifreeze agent must be filled in under
all operating conditions - even in tropical countries.

The water should be míxed w ith 40-45% by volume

of corrosion protection/ an t ifr eeze agent (correspond·
ing to antifreeze protectíon up to -30 °C). A hígher
concentration is only p ractica! with even lower
ambient temperat ures. Even at extremely low
ambient temp¡!ratures not more than 55 %by volume
of corrosion pr otect ío n/an t ifreeze agent should be
used (correspondíng to antifreeze protection up to
- 45 °C), as the ma x imum antifreeze protection has
been reached and an even greater percentage of
corrosion protectíon/antifreeze agent w ill reduce the
antifreeze pr otectíon and result in poorer heat
dissipation.

20.7-005/9 F 3
Use clean and not too hard water. Potable water
frequently meets the requirements. More accurate
specifications can be taken from the Specifications
on Ser vice Products sheet 31 O.

Caution!
Do not use any additives as these are not approved
for use in passenger car engines. They do not increase
the boiling point and offer no antifreeze protection.
1n addition, the necessary corrosion and cav ita ti on
protection is only partly obtained.

Draining and filling in coolant, see repair instructions

on mic rofil ms (20-0 1O).

When dr ivmg under full load, on mountain roads

and bumper to bumper, or following a fast ride on
an express highway with subsequent traffic con·
gestlons, or when driving in areas w ith high outside
temperaturas, the coolant temperatura indicator may
rise up to the red mark if an antifreeze of at least
- 30 °C is filled in, without causing any ejection of
coolant or faulty running of the engine.

When the engine is operated for an extended period

w1th the vehicle stopped, e.g. during a congestion,
it will be of advantage to move the selector lever of
the automatic transmission into .,N" position. This
will reduce the heat developed in the transmission
and consequently the additional heating-up of
coolant by way of the transmission oil cooler.

When coolant is lost through leaks in the cooling

system or as the result of overheating, add suitably
prepared coolant. Losses caused by evaporation can
be compensated by adding potable water.

20.7- 005110 F3
20- 01 O Draining and f illing-in of coolant - antif reeze table

Total fi lling capacities cooling system wit h heater and mi xing ratio

Antifreeze/water in liters

Model Engine Total capacity Mixing ratio antifreeze/water for

cooling system antifreeze protection up to
with heater - 30°C -45°C

107.025/045/047 116.960/962/964 12.5 5.50/ 7.00 7/5.5

107.026/046/048 117.960/962/964/ 13.5 6.00/7.50 7.5/6

967

126.032/ 033/034/ 116.961 /963/965 12.5 5.50/7.00 7/5.5

035/ 043/046

126.036/037/039/ 117.961 /963/965/ 13.5 6.00/7.50 7.5/6

044/045 968
..........·..·-.·- -- - ................,..•.•.

Tightening torques Model Nm

107 6- 10
Drain plug radiator
126 1.5-2 1 )

Drai n plugs c rankcase 25

1
) T his torque can be generated with a washer ora coin.

Conventional to ol

Antifreeze tester
Prestone VU·Check (Union Carbide)
e.g. Philipp Gather, 0-4020 Mettmann 2

R ·H89

- - - - - - -- - -- - - -- - - - - -- - -- - -------···---

20.7-010/1 F3
Self·fabricated toot

Coupl ing ( 1). part No. 002 545 49 28

approx. 1 m cable 1.5 mm1 black (b) +
approx. 1 m cab le 1.5 mm1 brown (e) -
1 cable terminal+
1 cable terminal -

a Locating groove

Note

For reasons of corrosion protection and dueto the

raising of the boiling point, the corrosion/anti f reeze
protection agent should always be used in countries
with warm climate all year round.

When renew ing or adding coolant, a concentration

of 44% by volume shou Id be aimed at, this corres-
ponds to anti freeze protectlon of - 30 °C.

lf no corros ion-antifreeze protection agent is avail·

able and only water is added, 1 % of additives
(corros ion protection oi 1), 10 cm 3 / 1 1 water must be
added.

Caution!
In order to avoid damage to light alloy components,
only corros ion-antifreeze protection agents (Speci-
fications on Service Products sheet 325.1 and 325.2)
may be used.

Model 107 with automatic climate control requires

special measures when filling in the coolant.

Draining

1 Open cap on expansion tank in stages (only

below 90 °C).

2 Unscrew drain plug in radiator.

Drain plug model 107

20.7- 010/2 F 3
 Dra in p lug mode l 126

3 Unscrew drain plug at r ight and left of crankcase.

Drain plug left

Drain plug r ight

Filling in

4 Fill in coolant slowly up to the mark on the

expansion tank (arrow ). Leave filler neck on
expansion tank open.

Expansion tanl<

Arrow ~ Coolant level cold

20.7- 010/ 3 F 3
Model 107

On vehicles with or without air conditioning system,

set both heater levers to maximum heating capacity.

On vehicles with automatic climate control, pull off

plug of elec tric supply 1in e on heating water pum p.
Connect heating water pump to battery by means of
self-made tool.
Push .,DEF" button.

Model126

On vehicles with automatic heater control, set both

temperature dials to .. Max".

Push .,DE F" button on vehicles with automatic

cl imate control.

5 Warm up engine by intermittently pressing the

accelerator until coolant thermostat opens.

For this purpose, likely open vent screw (7) on

engines 116.960and 116.961@ 0 0@
1981.

Note: Fit expansion tank cap ata coolant tempera·

tu re of approx. 60 °C.

6 Close vent screw (7) on engines 116.960 and

116.961@ 0 cv @1981 .

7 On model 107 with automatic climate control,

refit plug of electric supply line to heating water
pump.

8 Check coolant level and replenish up to specified

leve l.

Caution!
Open cap only below 90 °C coolant temperature.

20.7-010/4 F3
20- 01 5 Cleaníng coolíng and heatíng system

Total f illing capacities cooling system with heater and mi xing rat io

Corrosion·antif reeze pro tect ion agent/water in liter

Model Engine Total fill ing capacity Mix i ng ratio corrosion-antifreeze protection
cooling system wi th agent/water for antifreeze pro tection up to
heater - 30°C - 45 °C
- - -·· ·-- ---
107.025/045/ 04 7 116.960/962 /964 12.5 5.50/7.00 7/5.5

107.026/ 046/048 117.960/962/964/ 13.5 6.00/7 .50 7.5/6

967

126.032/033/034/ 116.961/963/965 12.5 5.50/7 .00 7/5.5

035/043/ 046

126.036/ 037/ 039/ 117.961 /963/965/ 13.5 6.00/7 50 7.5/ 6

044/ 045 968

Tightening torques Model Nm

107 6-10
Drain plug radiator
126

1
) Thís torque can be generated with a washer or coin.

Conventional tool

Antifreeze tester
Prestone VU·Check (Un ion Carbide)
e.g. Phi lipp Gather, 0 - 4020 Mettmann 2

R • 4 789

20.7-015/1 F3
Special tools

Flushing pipe connection with hose piece 117 589 00 90 00

~.........
Thermostat positively opened for
000 589 74 63 00
closing of bypass duct

Service products

Corrosion·antifreeze protection agent 000 989 08 25

Citric acid powder (0.5 kg} 000 989 10 25

Note

High coolant temperatures and low heating capacity

can be caused by deposits of corrosion products in
the radiator or in the heat exchanger.

The deposits can be identified as a jelly·like substance

or, with empty and dry radiator, by a grey !ayer at
the radiator connection pipes.

In this case, the cooling and heating system can be

cleaned with a 1O % citr ic acid solution.

Scope of work

1 Ora in coolant from rad iator. The coolant drain

p lug on the radiator remains open.

2 Remove thermostat and install positively opened

thermostat 000 589 74 63 00 with sealing ring.
Thus the bypass duct is closed and the flow is directed
via the radiator to t he coolant pump.

3 Connect flush ing p ipe connection 117 589 00 90 00

with connection hose (2) between radiator and
coolant hose.

4 Connect a tap water hose (3) to the flush ing pipe

connection ( 1).

1 F lushing pipe connection

2 Connection hose
3 Tapwater hose

20.7-015/2 FJ
5 Open expansion tank cap and pul l off hose to the
overflow tank.

6 Switch off circulation pump to f lush the heat

exchanger.

Todo so, switch on ignit ion and :

a) On vehicles w ith automatic heater engage both

temperature d ials to posi t ion .. Max".

b) On veh icles with automatic climate control. press

the push·button .. Defrost".

7 Open the vent valve of the supplementary heater.

8 With engine runn ing (approx. 2500/min) flush

cooling and heating system with running water for
approx. 5 minutes to flush out the remaining corro·
sion·antifreeze protection a9ent.

Caution!
uuring the flu sh ing process, the cooling system must
alw ays be fui l. Regulate additional quantity accord·
ingty.

9 Ora in ftush ing water in the rad iator completely

and screw in drain plug.

1O 1n a clean vessel, prepare a solution of 1.5 kg

citric acid powder (0.5 kg, par t No. 000 989 10 25)
and approx. 5 1 of water.

1 1 F ill the cleaning solution into the expansion

tank and top up with water to the mark on the
expansion tank.

12 Close th e vent screw of th e supplementary

heater.

13 Clase expansion tank cap.

14 Run engine for 15 m inutes at approx . 2500/ m in.

The solu t ion must now flow through the heat
exchanger (see f igure 6).

15 O rain cleaning solution.

Caution!
Dispose of the cleaning solution (citric acid mixture)
in an oil and water separator as used in workshops.

20.7- 015/3 F3
16 Open vent screw of the supplementary heater.

17 F lush cool ing and heating system with running

engine (2500/ min) for approx. 10 minutes with
running water. The water must flow through the
heat exchanger (see figures 6 and 8).

18 Remove f lushing p ipe connection and connect

coolant hose to rad iator.

19 1nstall normal thermostat.

20 Screw in coolant drain plug in radiator.

21 On vehicles with supplementary heater, connect

p lastic hose to vent valve and open valve.

22 Slowly f ill m new coolant (observe corrosion·

antifreeze protection agent) up to the mark.

a) On vehicles w ith automatic climate control press

push·button .,Defrost ". With automatic heater,
engage both temperatura selector dials in posi·
tion .,Max".

b) Warm up engine while int ermittently pressing the

accelerator pedal. At approx. 60 °C, close the
filler neck with a cap and switch supplementary
heater to imrned iate heating.

e) Vent until the thermostat opens and the coofant

runs out of the vent vafve free of bubbles. Now
cfose the vent valve.

23 Check coolant leve! below 90 °C and top up to

the specif ied leve! if required.

20.7- 015/4 F3
20- 110 Removal and installation of coolant thermostat

Coolant pump, coolant thermostat , inlet connection

Engines 116.960 and 116.961 standard version, 117.960 and 117.961

Closing plug . . .... . . . . . • . .. M 14 x 1.5. vehicles w ithout air conditioner and

automatic climate control
2 Seal ing ring. . . . . . . .. .. .. . ... ... .. .. . A 14 x 18- Cu
3 Suspension eye
4 Hex . head bolt . .. ... . ... . . . .... . . . . M 8 x 30, 25 Nm
5 Hex. head bolt ...... ......... . M 8 x 65. 25 Nm
6 lnlet connection
7 Hex. head bolt . . . . .. . .... •. .. M 8 x 85, 25 Nm
8 Washer . . . . . . . . . . . . . .. A 8, 4, 1 each
9 Seal ing ring . .. . . . . . ... . . . . . . . . . . . . . ... Check. renew if required
10 Spacer ring .
11 Coolant hose . ... . . . . . 42 X 51 X 40
12 Hose clamp. . . . .... .• . . . . . . . . ... .. L 45-35, 2 each
13 Combination screw . .... . . . . .. .. .... . . . . . M 6 x 20, 3 each, 1O N m
14 Coolant thermostat cover
15 Sealing ring .. . . .. . . .. .. . . ... . . .. ... . . . Check, renew if required

+1
16 Coolant thermostat . . . .. . ...... . . . Start of con trol 75 _ °C, end of control (fully opened)
3
max. 92 °C. Ensure correct installation position
17 Coolant pump +
2
36 T emperature switch .. . .... .. .. . . .... . • .. On: 11 O _ °C, OH: 105 ± 3 °C. Sw itches second stage
3
supplementary fan on vehicles w ith a ir conditioner or
automatic climate control
37 Sealing ring , . . . . . . . . . . . . ..... ..... , , . , A 14 .x 18- Cu
38 Temperature transm itter ... .... .. . .. . .. . . . For coolant temperature indicator in instrument cluster
1nstalled in r ight·hand cy linder head up to the end of
November 1980
39 Sealing ring ..... , ..... . . . . . . . . . . . . . . .. A 14 x 18 - Cu

20.7- 110/1 F3
Coolant pump, coolant thermostat, inlet connection

Engines 116.960 and 116.961 national versions@ 0 0@ 1981

Engines 116.962,116.963,117.962 and 117.963

1 Hex. head bolt . . . . . . . . . . . . . . . . . . . . . . M 8 x 35, 3 each, 25 Nm

2 Suspension eye
3 Temperature switch . . . . . . . . . ... ... . .. .. . For second stage supplementary fan on veh icles with
air conditioner or automatic climate control

100 °C On: 110 ~; °C, Off: 105 ± 3 °C

4 Sealing ring . . . . . . . . . . . . . .... ... .... . . A 14 x 18- DIN 7603- AL

5 Temperature transmitter . . .... . ...... . .... For cootant temperature indicator in instrument cluster
6 Seating ring. . . . . . .... .. .... . . . .... A 14 x 18- DIN 7603- AL
7 Vent screw ... Only engines 116.960 and 116.961 national versions
@ 0 0 @1981 to August 1981
8 lnlet connection
9 Washer ....... . A 8, 4, 1 each
10 Hose clamp .. L 45-35, 2 each
11 Coolant hose .... 45 X 51 X 58
12 Combination screw ..... . ..... . .. . .. .. ... M 6 x 22, 1O N m
13 Cover
14 Gasket .. ..... . .... .. . . . . . . . . . . . . .... Renew
15 Coolant thermosta't . . . . . . . . .o ••••• o • •••• Start of control 84 ± 2 °C, end of contro l (fully opened)
max. 99 °C, no vent va lve, observe installation instruc·
tions
16 Gasket ...... . ..... .. ........... o •••• Check, renew if required
19 Coolant pump
37 Closing plug .... M 14 x 1.5 AL alloy, vehicles w ithout air conditioner or
automatic climate control
38 Sealing ring ..... A 14x 18 - DIN7603-AL

20.7-110/2 F3
Coolant pump, coolant thermostat
inlet connection

Engines 1 16.964/965 standard versio n

117.964/965/967/968

1203·14589

Closing p lug . . . . . . . .. . .. . . .... .. . .. . . . M 14 x 1.5, veh icles w ithout air conditioner or auto·
matic climate control
2 Sealing ri ng . . . . . . . . . . . . . . . .. . ... . .. .. A 14 x 18- OIN 7603- AL
3 Suspension eye
4 Hex. head bolt . .. . . .. •. . . .• .. . ..... . . M 8 x 30, tightening torque 25 Nm
5 Hex. head bolt ..... . . .. . M 8 x 65, tightening torque 25 Nm
6 lnlet connection
7 Hex. head bolt .. ... .. .. .... . ... .. ..... M 8 x 85, tightening torque 25 Nm
8 Washer. . . . . . . .. . . .. A 8, 4, 1 each
9 Gasket .. . .. . . ... . .. . .. . . . . . ... ...... Check, renew if required
11 Coolant hose . . . .... . . 42 x 51 x 40
12 Hose clamp. . . . . . . . . . . . . . . . . L 45- 35, 2 each
13 Combination screw . . . . . . . . . • • . . . . . . . . . . M 6 x 20, 3 each, t ighten ing torque 10 Nm
14 Cover coolant thermostat
15 Sealing ring .... .... . . . . . . . . . . . . . . . . .. . Check, re new if requ ired
+2o
16 Coolant thermostat . .. . ... . . . .... • .. . ... Start of control 80 _ C, end of -control (fu lly openedl
2
max. 94 °C. Ensure correct installation position
. +2o + o .
36 Temperature sw1tch . . . . . . . . . • . .. ... .. .. . On: 11 0 _ C, Off: 105 _ 3 C. Sw1tches second stage
3
supplementary fan on vehicles with air conditioner or
automatic climate control
37 Sealing ring . . . . . . . . ...... .•. ...... . ... A 14 x 18- OIN 7603- AL
38 Temperature transmitter ... . .... . • •. ... . . . For coolant temperature indication in instrument cluster
lnstalled in the righ t-hand cylinder head up to the end
of 1980
39 Sealing ring .. . . . . . . . ... ... . . . .. . . . . . . . A 14 x 18 - OIN 7603 - AL

20.7- 110/3 F3
Tightening torques Nm

Cover coolant Engines 116.960 and 116.961

thermostat standard version 10
117.960, 117.961
Fastening screws
ln let connection Engines 116.960 and 116.961 national
versions@ 0 (!) @1981 25
116.962, 116.963,
117.962, 117.963

Model 107 8
Drai n plug radiator
Model 126 1.5- 2 1 )

1
) This torque can be generated with a washer or coin.

Special tools

Tester for cooling system 001 589 48 21 00

Radiator cap with hose fo r tester 605 589 00 25 00

Conventional tool

7 mm socke t inser t on flex ible shaft e.g. Hazet, D-5630 Remscheid

for hose clamps w ith worm drive Order No. 426-7

Note

For a more accurate indication of coolant tempera·

ture, the temperature transmitter has been moved
from right·hand cyl inder head into the inlet con·
nection above the coolant pump.

Subsequent conversion on older vehicles is possible.

For this purpose, install inlet connection 117 201 12 30.
The ex isting electrical 1ine from the temperature sensor
to the coolant temperature indication in the instru·
ment cluster can be used without change.

Previous installation posotion temperatura transmitter

(arrow)

20.7 - 110/4 F3
 Current installation position temperatura transmitter
(arrow)

Removal

1 Orain coolant (20-010).

Engines 116.960, 116.961 standard version,

116.964, 116.965, 117.960, 117.961, 117.964,
117.965, 117.967 and 117.968

2 Oisconnect coolant hose from cover ( 14).

3 Remove cover ( 14) and coolant thermostat.

Engines 116.960 and 116.961 national versions

@0 0 @ ·1981
116.962, 116.963, 117.962, 117.963

4 Pul l off single plug of electric lines on tempera·

ture switch (3) and on temperatu re transmitter (5).

5 Di~connect vent ho~e on connecting pipe (arrow) .

(Not required on engines 116.960 and 116.961
@ 0 0 @ 1981 to August 1981 ).

6 Loasen hose clamp ( 10), unscrew fasten ing

screws ( 1) and re m ove inlet connection (8) together
with coolant thermostat.

lnstallation

Engines 116.960, 116.961 standard version,

116.964, 116.965, 117.960, 117.961, 117.964,
117.965, 117.967 and 117.968

7 1f required, install cool ant thermostat ( 16) with

a new sealing ring ( 15) in ·such a manner that the
ball valve is on the top (arrow) . During installation,
ensure free movement of t he ball in the valve.

20.7-110/5 F3
8 lnstall cover ( 14) and tighten fastening screws
(13) to 10 Nm.

Engines 116.960 and 116.961 national versions

@00 @1981
116.962, 116.963, 117.962, 117.963

9 lf required, fit new gasket ( 16) to coolant

thermostat. lnstall coolant thermostat in inlet con·
nection (8} in such a way that the lever (50} engages
w i th pin (51) in the recess (arrow} and that the two
ends of the spring (52} engage in the retaining lugs
(dashed arrows).

10 lnstall inlet connection with installed coolant

thermostat in such a manner that the pin (51) engages
in the control bore in the cooling pump housing
(dashed arrow) .

T ighten fastening screws for inlet connection to

25 N m.

1 1 Refi t single plug of electric lines to temperature

switch and temperature transmitter and connect
vent hose.

12 Fill in coolant (20-010).

13 Check cooling system for leaks by pressure·

testing with tester ( 1 bar gauge pressure} .

20.7- 110/6 F3
20- 210 Removal and installation of coolant pump

Coolant pump, coolant t h ermost at, inlet connection

Engines 116.960 and 116.961 standard version, 117.960, 117.96 1

Closing plug . .. .. . . M 14 x 1.5, veh icles w ithout air conditioner or

au tomatic cl imate control
2 Sealing ring. ... . ...... . . .. . . . . A14x18 - Cu
3 Suspension eye
4 Hex. head bolt . . . . . .. . ...... . .. . . . . M 8 x 30, 25 Nm
5 Hex. head bolt . . . . . ...... . .. . .. . . . .. .. M 8 x 65, 25 Nm
6 l nlet connection
7 Hex. head bolt . . .. ..... . ... .. .. . ... M 8 x 85, 25 Nm
8 Washer ... . ... . . . . . . .... . . . . ... . . A 8, 4, 1 each
9 Seal ing ri ng ... .. . . Check, renew if requ ired
1O Spacer ring
11 Coolanthose ... .•... . .. . . . . . . . . . . . . . . . 42x51 x40
12 Hose clamp. . . .. . .... . . .. . . . . L 45- 35, 2 each
13 Combination screw .. . .. . .. . .... ... .. . . . . M 6 x 20, 3 each, 10 Nm
14 Cover coolant thermostat
15 Sealing ring . . ... .. .... . . ... .....
. . .. .. Check, re new if required
+1o
16 Coolant thermostat .. . .. . . .. ...... . . . • .. Start of control 75 _ C, end of control (f ul ly opened)
3
max. 92 °C. Ensure correct install ation position
17 Coolant pump
36 Temperature switch . . .. .. . . ...... . .. . .. O n: 110 ~~ °C, Off: 105 ± 3 °C. Sw itches second stage

supplementar y heater on vehicles w it h air conditioner

o r automatic climate con t rol
37 Sealing ring . .. . . ..... . . . . . . . . . . . . . . . . . A 14 x 18 --· Cu
38 Temperature transmi tter. . . ... For coolant temperature indication in instrument cluster.
lnstalled in right-hand cylinder head up to the end of
November 1980.
39 Sealing ring . . . . . A 14 x 18 Cu

20.7- 21011 F3
Fan , v•scofan
· clut eh, coolant pump

Engines 116. 960 and 116.961 stand ard version, 117. 96 O, 117.961

28 <!:0 ___..;
40
~®-
~1 22

11 eoolant pump

~"·
18 Hex. head b 1
19 Hex.headbolt
20 ot .. ...... ·• · · · · . .. ..
h"d bo11 ...... M 8 x 1352 25 N
"· h"d bo11 .. .. .. .. .. .. M 8 x m
.. . M 8 x . . '""· 25 N m
s5
21 W"h"..
22
23 G"k".. .
.. . .. .. · .. .. .
. .. ..
. . ..
. .......... M 8 O. 4 .,,h , 25 N m
24 Slid• . .. .. .. .. • .. · X 85.25 N m
2s e "" . ,.,1 .. .. . .. .. .. · .. .. .. . · A 8, 4, 1 "'"
ountemng9 with .. . . . . . . . . . ... . Renew
26 V-belt serve install . ruet1ons
27 lmpell er . . .. sealmg ring .
. .. .. . . . . . . ... . Ob
Ob
C """"" . a atiOO
atton inst
arefully e l 11 .
ÍOSt ·
ruet ions
2 ean seat for e
eaeh (dimen . ounter-ring
. s1ons ad·
mstruetions 13 -335,
, 13-340)
JUStlng value s, mstallat•on
.

28 V ·belt pulley
29
Coll ar serew M 8 X 18 4
30 Viseofan elut~~ . . . . . . . . . . . . . . . . .. Spe d , eaeh, 25 Nm
e ·eontrolled
31 Fan · · 9 blades , 460sta d d•a ., r•ght alloy
· · · · . ..
32 Spri~~ ~~s·h~; . . . .
B 6' 4 eaeh
hex h '
mm
n 6a rd up t o M a rch 1981
M 6 . x ead
20 4bolt M x 22 together wlth
33 Combina(IOn serew
• . . . 2 , eaeh 11 N
34 F
Flat shaped spnng
. · ·• · · eaeh ' m
35 an shroud
40 Adjusting pointer

20.7-210/2 F3
Coolant pump, coolant thermostat, inlet connection

Engines 116o960and 116o961 national versions@ 0 ® @ 1981

116o962, 116o963, 1170962, 1170963

1 Hex. head bolt .. ... .. o .... .... . . o . .. . M 8 x 35, 3 each, 25 N m

2 Suspension eye
+2
3 Temperature switch . . . . . o . . ... .. .. o o . . .. On: 11 O _ °C, Off: 105 ± 3 °C. switch es second stage
3
supplementary fan on vehicles w ith air conditioner or
automatic cl imate control
4 Sealing ring . . .... . .. .. . ... . . . . .. ... ... A 14 x 18- DIN 7603 - AL
5 Temperature t ransmitter . . o . . . o . . ... o o .... For coolant temperature indicatio n in instrument cluster
6 Sealing ring . . .. . . . .. . . ..... ... o o . . .. A 14 x 18- DIN 7603- A L
7 Vent screw . . o. . .. o .. . . . . . . . . o .. . . Only engines 116.960 and 116.961 national versions
@ 0) G) <§ 1981 to August 1981
8 lnlet connection
9 Washer . . . . .. o. . . . . . . . . . . A 8. 4, 1 each
10 Hose clamp . . . . . . . . .. . .. . . . . . . . . . . ... . L 45 - 35, 2 each
11 Coolant hose . .. . . . . .. . . . .. . . . ... 42 X 5 1 X 58
12 Combination screw. • • o •••••••••• • M 6 x 22, 10 Nm
••••

13 Cover
14 Gasket .... . . ... .... . . . .. . . . .. . .. .. .. Aenew
15 Coolant thermostat .. . . . . . . .... . . . . o .... Start of control 84 + 2 °C, end of control (ful ly opened)
max. 99 °C, without vent valve
Observe installation instructions
16 Gasket . . . ...... .... . . . ... . o . .. . . . . . . Check, renew if requir ed
19 Coolant pump
37 Closing plug o . ... o . . ..... .. . .. . .. M 14 x 1.5 aluminum alloy, vehicles with air condi·
t ioner or automatic c limate control
38 Sealing ri ng . • • • •• • •••• A 14 x 8 - OIN 7603- Al
••• o o •• ••

20.7-210/3 F3
Fan, viscof an clutch, coolant pump

Engines 116.960 and 11 6.961 national versions @ 0 0 @ 1981

116.962, 116.963, 117.962, 117.96 3

.-J I
~ .-J
28

~5 1
~­
~ 27

17 Hex. head bolt ... .. .... •.. . . ... M 8 x 135, 25 Nm

18 Hex. head bolt . .. .. .... •.. ....... .. ... M 8 x 65, 2 each, 25 Nm
19 Coolant pump
20 Gasket . . . . . . . . . • .... . • .. .... . ....... Renew
21 Slide ri ng seal . . . . . . . . . . . . . . . . . ....... Observe installation instructions
22 Counter·ring with sealing ring ...... •....... . Observe installation instructions
23 lmpeller . .. .. .. . .. .. . . . . . . . . •.. ... . .. Carefully clean seat for counter·ring
24 Hex. head bolt . . . . . . . . . . . . . . . . ... . . • .. M 8 x 60, 4 each, 25 Nm
25 Adjusting pointer
26 Hex. head bolt .. ... . .. . . .. • . . .. . ... M 3 x 85, 25 Nm
27 Washer .. . .. . ... . . .. ....• . . ... .. . A 8, 4, 8 each
28 V·belt pulley
29 Collar screw . . .. . ..... . .. ... . .. .. . . .. M 8 x 18, 4 each, 25 Nm
30 V·belt . . ...... . .. . . .. .. . . .. . .... . .. . 2 each (dimensions, adjusting values, installation
i nstructions 13- 335, 13- 340)
31 Viscofan clutch . . . . . ..... . . ... . ..... . . . Speed and temperature·controlled
32 Flat shaped spring .. . .... . . . . . . . . ... . .. . 2 each
33 Fan shroud
34 Fan . . ... . .... . . . .... . . .. . . . . .... . .. 9 blades, 460 mm dia., light alloy
35 Combination screw . ..... . . ..... . . .. ... .. M 6 x 20, 4 each, 11 N m
36 Spring washer . . . . . . . . . .. .. .... .. ..... . 8 6, 4 each. standard up to March 1981 together with
hex. head bo lt M 6 x 22 on engines 116.960 and
116.961 national versions @0 0 ~ 1 981

20.7- 210/4 F3
Coolant pump, coolant thermostat,
inlet connection

Engines 116.964 and 116.965 standard version,

117.964, 117.965, 117.967 and 117.968

13 12
~ 14

tJo ~ ~
~9

1203· 14589

Closing p lug ... . . .. .. . .. M 14 x 1.5, vehicles with out air condit ioner or
automatic climate control
2 Seali ng ring . . ... . . . . . . . . .. . . .. . .. A 14 x 18 - OIN 7603 - AL
3 Suspension eye
4 Hex. head bolt . . . .. . . ... .. . . M 8 x 30, 25 Nm
5 Hex. head bolt . . . .. . . . • . . .. .. . . . . . M 8 x 65, 25 Nm
6 l n let connection
7 Hex. head bolt ... .. .. .. . .. . ... ... . . ... M 8 x 85, 25 Nm
8 Washer . . ... .. .. .. . .. ... .. . . . . . .. . .. . A S, 4, 1 each
9 Gasket . . . . . . ..... . ..... • . .. .... . . . .. Check, renew if requ ired
11 Coolant hose . ... . . . . . .. . . . • .. ... .. . . . . 42 x 51 x 40
12 Hose clamp .. . .. ... . .. ... ... .. ... .... L 45-35, 2 each
13 Combination screw . . . . . . . . . . .... . .... ... M 6 x 20, 3 each, 10 N m
14 Cover coolant thermostat
15 Sealing ring . ... . ... . ..... . .. . . . .... . . . Check, renew if required
+2 o
16 Coolant thermostat . .. . .. . . . ..... . .. . . . Start of control 80 _ C. end of control (fully opened)
2
max . 94 °C. Observe correct installation position
17 Coolant pump
36 Temperature switch .... . . . .. . . . . . . . . .. . Switches on 2nd stage supplementary fan at 105 °C-
off at 98 °C, switches off refr igerant compressor at
115 °C {emergency off) - on at 108 °C
37 Seal ing ri ng . . . . . . .. . .. . . .... .. . . . . . . .. A 14 x 18 - D IN 7603 - AL
38 Temperatu re transmitter . . . . . ..... .. ..• . .. For coolant temperature indication in instrument cluster
39 Seali ng ring . . . . . .... . ... . . ..... .. .. A 14 x 18- OIN 7603- AL

20.7- 210/5 F3
Tightening torques Nm

V iscofan clutch and pulley

to coolant pump

Fastening screws Coolant pump to timing case cover 25

or crankcase

1nlet connection to coolant pump

Model 107 8
Drain plug radiator
Model 126 1.5-2 1 )

1
1 This torque can be generated with a washer or coin.

Special tools

Tester for cooling system 001 589 48 21 00

Radiator cap with hose

605 589 00 25 00
for leak tester

Socket insert 27 mm, 1/2" drive 001 589 65 09 00

Conventional tool

7 rnm hex . socket insert on flexi ble shaft e.g. Hazet. D-5630 Remscheid
for hose clamps with worm d r ive Order No. 426-7

Note

On the engines 116.962/ 963 and 117.962/ 963 the

bypass duct be low the thermostat was changed in
the coolant pump housing.

This reduces fluctuations of the temperature indica-

t ion between 80-100 °C. The opening (2 and arrow)
in the shape of a circular section was converted into
a circu lar opening w ith 30 mm d ia. ( 1 and arrow) .

This change is subsequently possible by d rilling the

web and the cast skin w ith a 3 mm drill. The alu ·
minum chips must be extracted with a vacuum
cleaner.

20.7-210/ 6 F3
Production breakpoint circular opening: August 1982

Model Eng ine Engine end No. Chassis end No.

107.045 116.962 009555 018918

107.046 117.962 001248 002196
126.032/033 116.963 017995 034984
126.036/037 117.963 014217 024413
126.043 116.963 017995 003653
126.044 11 7.963 014217 002959
·- - - - - - -- -- - --

A coolant thermostat from a 2nd manufacturer was

optionally installed in t he engines 116.962/963 and
117.962/ 963 as of August 1982.

Distinguishing features on coolant thermostat

Oesignation 1st manu factu rar 2nd manu facturer

Coolant the rmostat Wahler Behr-Thomson

Production breakpoin t: optionally as of August 1982

----- - ............

Model Engine Engine end No. Chassis end No.

107.045 116.962 009362 018804

107.046 117.962 001216 002168
126.032/033 116.963 017592 034707
126.036/037 117.963 013754 024024
126.043 11 6.963 0 17592 003562
126.044 117.963 0 13754 002893

Removal

Drain coolant (20-010).

2 Slac ken V-be lt fo r coolant and power steering

pump and re m ove ( 13- 340).

3 Re move coolant hoses between coolant pump

and upper and lower coolant tanks.

4 On model 107, unscrew fan shroud from radiator

top, lift out of the bottonn retaining straps and p lace
over the fan.

On model 126, pull off flat shaped springs (arrows),

in upwa rd d irection, lift fan shroud out of retaining
st raps at the bottom and p lace ove r the fan .

20.7-2 10/7 F3
5 Unscrew fasten ing screws (arrow) for viscofan
clutch and remove viscofan c lutch w ith fan together
w ith tan shroud.

6 Remove distributor { 15-530).

7 Onengines 116.960,116.961, 117.960and

117.961 unscrew threaded pin (arrow).

8 Remove inlet connection of coolant pump:

Engines 116.960, 116.961 standard version,

116.964, 116.965, 117.960, 117.961, 117.964,
117.965,117.967 and 117.968

lf screwed into inlet connection, pull single plug of

electric line from temperature transmitter fo r coolant
temperature indicator and f rom temperature switch
for supplementary f an. L oasen front hose clamp ( 12)
on coolant hose ( 11), unscrewfastening screws (4, 5
and 7) and remove inlet connect ion {6) with seal ing
ring and spacer ring.

Engines 116.960 and 116.961 national versions

@00@1981
116.962, 116.963, 117.962 and 117.963

Plug single plug of electric l ine from temperature

transmitter (5) and, if screwed in, from temperature
switch (3). 1f installed, disconnect vent hose on
connecting p ipe (arrow). Loasen hose clamp (10),
unscrew fastening screws ( 1) and remove inlet
connection (8) w ith sealing ring and coolant
thermostat.

9 On vehicles w ith hydropneumatic suspension,

unscrew hollow screw (5) on hydraulic oil pump
and put high pressure line (6) aside.

10 Remove vibration damper (03-342).

20.7-21 0/8 F3
11 Unscrew fasten ing scr ew s ( 1) and remove coolant
pump.

lnstallation

12 Carefully clean seal ing surfaces and install

coolant pump w ith new gasket. Tighten fasten ing
screws to 25 Nm.

13 For fur ther installat ion proceed vice versa to

items 2- 10.

Check seal or sealing r ing for inlet connection and

re new if requ ired.

Ti ghten fasten ing screw s of inlet connection and of

viscofan clutch to 25 Nm.

14 Check f iring point and adjust if requ ired

(15 - 50 1).

15 Fill in coolant (20- 0 10).

16 Check cool ing system for leaks by means of

pressure test with tester ( 1. O to 1.3 bar gauge
pressure).

20.7- 2 10/9 F 3
20-220 Reconditioning of coolant pump

T he coolant pump cannot be recond itioned. After

pressing out coo lant pump shaft wi t h compact
bear ing, the tight f it of the new compact bearing in
t he light alloy housing of the coolant pump is no
longer assured.

In the event of leaks on the coolant pump, the

sliding ring seal and the coun ter·ring with seal ing
ring can be rep laced after pulling off the impeller
(20- 225).

20.7-220/ 1 F3
20- 225 Sealing coolant pump

Specia1 too1

Pu ller for impeller 100 589 15 33 00

Self-fabricated tools

Pressing-in sleeve

Tester for tight fit of impeller

1 Flange
2 Coola nt pu mp shaft w ith compact bearing
3 Coola nt pu m p housing
4 Sliding ring sea l
5 Cou nter-ring w ith sealing ring
6 l mpeller
7 Dowel sleeve
a 5.3-5.7 mm
e Vent bares

20.7- 225/ 1 F3
Note

In October 1982 a modified sl iding ring seal was

tempora rily installed in the coolant pump.

1n the event of repairs. the parts must be installed

according to the spare parts microfilm. The sliding
ring seal must be renewed together with the counter·
ring in the impeller in th is case.

Modified slid ing ring seal 1204-10595/1

Production breakpoi nt: October 1982

Model Engine Engine end No. Chassis end No.

107.045 116 .962 010568-01137 1 020008- 0208 13

107.046 117.962 001409-001513 002344-002447
126.032/033 116.963 019968-021578 036525- 037774
126.036/037 117.963 016596--017767 026056--026924
126.043 116.963 019968-021578 004095- 004435
126.044 117.963 016596--017767 003634-003893

Disassembly

1 Pull off imp eller.

2 Cancel preload at several points by means of light

hammer blows between coolant pump housing and
sliding ring seal and push out sliding ring seal.

20.7-225/2 F3
3 Force counter-ring out of impeller.

A ssembly

4 Lightly coat housing jacket of sliding ring seal

with sealing compound and drive or press sliding
ring seal into bearing housing by means of pressing- in
sleeve.

Caut ion!
Support at bearing housing onl y and not at coolant
pump shaft.

5 Coat sealing ring on counter-r ing with brake

cylinder paste and push counter-ring with chamfered
side (arrow) into carefu lly cleaned mounting bore
of impeller.

6 By means of a chamois l eather. remove all dust

from the seali ng surface of the counter -ring and
sl íding rí ng seal.

7 Grease shaft stub of coolant pump shaft and bore

in impeller.

120-10863

8 Press on impeller while supporting the coolant

pump shaft.

20.7- 225/3 F3
9 Check impeller for tight seat. nominal torque
mínimum 35 Nm.

20.7- 225/ 4 F3
20- 320 Viscofan clutch

Viscofan clutch speed·controlled

Engines 116.960 and 116.961 standard version,

117.960, 117.961

Operation

8
1 Secondary part
2 Steel bushing
3 Oouble row angu lar ball bear ing
4 F lange shaft
5 Pin
6 Primary or drive disk
7 Supply chamber
8 Cover
9 Tension spring
1O Closing lever
11 T ransfer bore
12 Work ing gap
A Engaging p ositi on
B Oisengag íng posit ion

Up toan engine speed of approx. 4650/ m in (engines

116.960, 116.961 ) and of approx. 3850/min
(engines 117.960, 117.96 1) the fan speed increases
proport ional ly to the engine speed, during which a
fan speed of approx. 3000/m in caused by the reduc·
tion of the belt drive and by the slip in the viscofan
clutch is not exceeded. lf the engine speed increases
still further, the fan speed will drop to approx.
400- 600/min ; but a fan speed of approx. 600/min
will not be exceeded even at maximum speed of engine.

20.7-320/ 1 F 3
As soon as the engine speed drops to approx. 4100/min
(engines 116.960, 116.961) and approx. 3400/ m in
(engines 117.960, 117.961), the viscofan clutch will
engage again.

Engagement and disengagement is controlled by the

closing lever ( 10) which, at increasing speed under
influence of centrifuga! force acting against force of
tension spring (9), is gradually pushed over the
transfer bore ( 11) until that bore is completely
covered, thereby interrupting the circulation of the
viscous oil (B, cut-out position). Under the influence
of dropping speed, the effect of the centrifu ga! force
on the closing lever is gradually reduced so that the
lever can be displaced by the force of the tension
spring (9) against the centrifuga ! force, wi t h the
resul t that the transfer bore is gradually opened and
the circulation of the vi scous oil is re·established
(A, cut ·in position) .

Viscofan clutch t emperat ure and speed-controlled

Engines 116.960 and 116.961 national versions

@00~ 1981
116.962, 116.963,116.964,116.965,117.962,
117.963, 117.964, 117.965, 117.967 and 117.968

Operation

At coolant temperatures below approx. 105 °c the

bimetallic strip ( 1) push es the spring plate (3) against
the primary disk (4) by way of the pin (2). The
transfer bore (5) will then be covered and the circu-
lation of the viscous oil will be interrupted. The
viscofan clutch is d isengaged and the f an rotates
independent of the engine speed at 400-600/ min; but
the fan speed will not exceed a maximum of approx.
600/min even at maximum engine speed.

1 Bimetallic strip
2 Pin
3 Spring pi ate
4 Primary or d rive disk
5 T ransfer bore
6 Closing lever
7 Tension spring

20.7- 320/2 F3
Starting ata coolant temperature ot approx . 105 °C,
the b imetallic strip ( 1) is heated by the air flowing
th rough the radiator so that it will change its shape
and arch in an outward dir ection. The spring plate
(3) can now clear the transfer bore (5), as a resu l t
of which the circu lation of the viscous oil is estab·
lished and the viscofan clutch is engaged.

The tan now rotates up to an engine speed of appr ox.

3850/min, p roportionate to the engine speed, but
not exceeding a tan speed of approx . 3000/ min under
influence of the t ransm ission ratio of the belt drive
and of the slip in the viscofan clutch. With further
increasing engine speed, the fan clutch wi ll d isengage
and the fan w ill rotate independent of the engine
speed at 400-600/ m in, but will not exceed a maxi·
mum approx . fan speed of 600/min even at maximum
engine speed.

lf the engine speed drops t o approx . 3400/ min, the

viscofan clutch w ill again engage.

A a coolant temperature of approx. 105 °C engage· A

ment and d isengagement is controlled by the cl osing
lever (6) wh ich, at increasing speed under influence
of centrifuga! force acting against force of tension
spring (7). is gradua lly pushed over the transfer bore
(51 until the bore is completely covered, thereby
interrupting the circulation of the viscous oil (8,
cut·out position). Under influence of the d r opping
speed, the effect of the cen trifuga! force on the
c losing lever is gradually reduced so that the lever
can be displaced by the force of the tension spring
(7) against the centrifuga! force. with the result that
the transfer bore is gradually exposed and the circu·
lation of the viscous oil is re·established (A, cut·in B
position) .

With decreasing coo lant temperature the b imetallic

strip ( 1) w ill gradually cool down and its changing
shape will increasingly displace the spring plate (3)
by way of the pin (2) in the d irec tion of the primary
d isk (4) until the spring plate c loses the transfer bore
(5) not later than ata coolant temperature of approx.
95 °C. The circulation of the viscous oil is ínter·
rupted, the viscofan clutch will disengage.

Checkup

For checking th e cut·out and cut·in point of the

viscofan clutch, slowly incr ease or decrease the
engine speed.

20.7-320/3 F3
Oisengagement and engagement of the viscofan clutch
is acoustically indicated by the decreasing or in·
creasing sound of the fan speed, visually, and also by
the clearly noticeable increase or decrease of the air
f low rate.

The viscofan clutch should disengage or engage not

later than at the specified engine speeds or
coolant temperature. Replace the viscofan clutch
if it disengages or engages too late. A detective
viscofan clutch cannot be repaired with workshop
equipment.

Viscofan clutches should be transported and stored

in an upright position. For short periods- e.g. for
assembly purposes - the clutch may be set down on
the fl ange, but not on its front end. This applies
particularly to the temperature and speed·controlled
viscofan clutch, since th ere is a risk of damaging the
bracket holding the bimetallic strip which would
render the clutch unfit for use.

Speed·controlled viscofan clutch

Engines 1 16.960 and 1 16.961 standard version,

117.960, 117.961

Checking disengagement and engagement

At an engine operating temperature (75-85 °C

engine oil temperature) the viscofan clutch should
disengage or engage at the following engine speeds.

Engine Cut-out speed Cut· in speed

1/ m in of engine

116 4650 ± 100 4100 ± 100

117 3850 ± 100 3400 ± 100

20.7- 320/ 4 F3
Temperatura and speed·cont rolled viscofan clutch

Engines 116.96 0 and 116.961 nat ional versions

@ 0 ® @ 1 981 ,
116.962, 116.963, 116.964, 116.965, 117.962,
117.963, 117.964, 117.965, 117.967 and 11 7.96 8

Checking temperatura and speed·controlled engagement

Aun engine at approx. 4500/min until a coolant

temperature of 100+5 °C has been reached. Reduce
the engine speed to 3400 ~~gg/min. The viscofan
clutch should engage.

Checking speed·controlled disengagement

(coolant temperature > 100 +S ° C)

lncrease engine speed to 3850 ~~gg /m i n. V iscofan

c lutch should disengage.

Caut ion !
Whilc driving. and in addition to outside air tempera·
ture. the engine load and the driving speed play a
decisive part. At low outside air temperatures, h igh
engine load and low driving speed, the coolant tem·
perature may increase to appr ox. 110 °C before the
viscofan clutch engages.

The viscofan clutch is disengaged at coolant tem·

peratures below approx. 95 °C.

20.7- 320/5 F3
20-420 Removal and installation of radiator

lnstallation dimensions for radiator, tan and fan shroud

Model Fan distance .,a" Fan distance to fan

to rad iator, approx. mm shroud, approx. mm
A B

107 43
20 15
126 20

Aadiator/ Fan Fan shroud/ Fan

lnstallation dimensions for radiator and radiator

air-oil cooler

Model Engine 1nstallation

dimension
,a" in mm
116.960,116.962, 116.964
107 117.960,117.962, 117.964 730 ± 1
117.967
116.961 standard version
126.03 698.6 ± 4 <>
117.961
116.961 national versions
126.03 1981 . a.
700.4 ± 1.5
126.04 116.963, 116.965,
117.963, 117.965, 117.968

20.7-420/ 1 F3
Tightening torques Nm

Model 107 8
D rain plug radiator
Model 126 1.5- 2 1 )

Coupling nut lube oil hose to air·oil cooler 25

Coupling nut gear oil hose to radi ator 15

F astening screws fan shmud to rad iator Model 107 2.5

1
) This torque can be gener ated w ith a washer or coin .

Special t ools

Tester fo r cool ing system 001 589 48 21 00

Radiator cap with hose

605 589 00 25 00
fo r tester

Hose clamp 000 589 40 37 00

Conventional tool

7 mm hex. socket insert on flexib le shaft e.g. Hazet, D-5630 Remscheid

for hose clamps with worm drive Order No. 426- 7

Note

As of the end of May 1982, a rad iator w ith a core

depth (a) of 42 mm (previously 34 mm) has been
installed in the sedans and since the beginning of
August 1982 into the coupes.

On models 126.043/04 4 with air cond itioner or

automatic climate control. a mod ified condenser is
installed for space reasons.

Production breakpoint: As of May 1982

Model as o f chassis end No.

126. 032/033 031420

126.036/ 037 021 577
126.043 003564
126.044 002838

a~ 42 mm
20.7-420/ 2 F3
The modified radiator can also be installed in vehicles
with lower chassis end No. On models 126.043/044
with air conditioner or automatic climate control
only in connection with the modified condenser
(2nd version).

Modified condenser
(2nd ver sion) 1203-ft314

Previous condenser
(1st version) 1203- 11313

As of the end of August 1984, a radiator (core depth

42 mm) with improved cool ing capacity (66 cooling
tubes) (previously 44 cooling tubes) is being installed
on vehicles with energy concept. The distance from
cooling tube to cooling tube is 10 mm (was 15 mm).

This radiator can also be installed in previously

fabricated vehicles w ith energy concept.

In models 126.043/044 with air conditioner or

automatic climate control up to May 1982, a modi·
fied condenser must be installed at the same time
for space reasons.

Production breakpoint (radiator with 66 cooling tubes)

Model As of chassis end No.

126 093 902

20.7- 420/3 F3
Removal

1 Ora in coolant (20-01 O). loosen coolant hoses on

radiator and pul! off.

2 D isconnect gear oil and lube oil hoses and unscrew

from rad iator or air·oil cooler. Drain lube oil from
ai r·oi l cooler.

3 Clase open connections of oil hoses as well as

connections on radiator and cooler by means of
plastic plug.

Model 107

4 Unscrew fan shroud at the top, pull out of re·

taining brackets below and place on the fan.

5 Push hold ing springs in the direction of th e

arrow and re move.

6 Remove radiator.

Model126

7 Pull the two fl at shaped springs (arrows) out of

the fan shroud in an upward d irection.

8 Lift the tan shroud out of the lower brackets

(arrows) and place on t h e fan.

20.7- 420/4 F3
9 Pull off both flat shaped springs (arrows) in an
upward direction.

10 L1ft out radiator.

l nst allat ion

11 For instal ling proceed vice versa.

During installation, t ighten coupl ing nu ts of lube oil

hoses on the air oil cooler to 25 N m, the coupl ing
nuts of the gear oil hoses on the radiator to 15 Nm
and the fasten ing screws tor the tan shroud to the
rad iator to 2.5 N m. Counterhold when tightening
the coupling nuts.

Pay attention to the specit ied d istances of tan in

re lation to radiator and tan shroud.

12 After f illing m coolant (20-01 O) check cooling

system for leaks by pressure·testing with tester
( 1.0 to 1.3 bar gauge pressure).

20.7- 420/5 F3
20- 425 Repairing radiator

Special tools

T ester for cooling system 001 589 48 21 00

~
. . -,r .. ..... ....¡¡>
~. . ..
Radiator cap with hose ·.
605 589 00 25 00
for tester . 11~·71?•

Conventional tool

7 mm hex. socket insert on flexible shaft e.g. Hazet, D-5630 Remscheid

for hose clamps with worm drive Order No. 426-7

Note

Since light·alloy radiators with plastic coolant tanks

cannot be repaired by soldering, a seal ing compound
has been developed for t h is purpose.

This compound can al so be used to seal heavy metal

radiators {non-ferrous metal rad iators).

The seal ing compound is a p roduct on a silicone·

rubber base, which remains permanently elastic in
its final condition. T emperatur e stability from
-50 °C to + 200 °C.

Because of the varying accessibility to the radiator

(e.g. in core more difficult than on coolant tank ),
sealing compound is available in a diluted and a non·
diluted condition.

The varying sealing compound versions and the

priming fluid are combined in a repair kit, part No.
123 989 00 20.

20.7- 425/ 1 F3
Designation Purpose

Primmg fluid Preparation of the

adhesive area

Sealing compound For sealing easily accessible

non-diluted are as

Sealing compound For sealing areas with poor

diluted access (e.g. lateral ly at
cool ing tubes)

Sealing compound and priming flu id have a shelf

life of approx. 1 year if they are always closed
air-tight after use.

Turbid priming flu id should no longer be used.

The following parts or areas in the cooling system

can be sealed with sealing compound:

a) Plastic coolant tanks (3 and 4).

b) Heavy-metal coolant tanks (holes up to 1.5 mm

dia.).

e) Light-alloy and heavy-metal cooling tubes (6).

d) Tube plate (2).

e) Bead flange (connection between radiator core

and coolant tank).

f) Heat exchanger of heating system.

1 Radiator core 5 Gasket

2 Tube base 6 Cooling tubes
3 Coolant tank top 7 Gills
4 Coolant tank bottom

20.7- 425/2 F3
Damaged parts on the coolant tanks which are subject
to higher loads, such as torn or broken fastening
brackets, cracks in the fillet to the connections,
breaks and very long or large cracks on the surface
should not be repaired , since the sealing compound
can take only a very low load.

Plastic coolant tanks of Behr rad iators can be ex·

changed by means of special tools or fixtures in the
Behr radiator repai r shops or in 1nter-Radia service
stations. lf required, contac t the nearest Behr repa ir
shop o r lnter·Radia service station for this purpose
and f ind out whether such repairs are possible.

lf this is not possible, replace the radiator.

On heavy·metal rad iators with plastic coolant tanks,

soldering on the core may be performed only up to
a d istance of 20 mm fr om the coolant tank, as
o therwise the h igh solderi ng temperature will damage
the gasket ( 5) and the coolant tan k (3 or 4). Leaks
which are closer to the coolant tank should be
sealed w ith sealing compound only.

lf t he leaking ar ea cannot be clearly identified in t he

installed condition, the radi ator need not be re·
moved. In th is case it will be suHicient to drain the
coolant and to pressure-test the cooling system
after sealing.

20. 7- 425/3 F3
When hand ling priming flu id and seal ing compound,
observe the following:

The priming fluid is easily inflammable (observe

safety regu lations for dangerous materials class A 1).

Acetic acid w ill be released until the linking (setting)

of the sealing compound has been completed. For
this reason, any skin contact should be avoided.
Clean affected areas immediately with water and
soap. Rinse eyes with water and see a doctor if
necessary.

Sealing

l lf the lea k ing are a cannot be located properly in

the installed condition, r emove the radiator (20- 420)
and unscrew the air oil cooler from the rad iator.

2 Clean the radiator.

3 Glose the hose connections with self·made closing

caps.

Required parts for uppe:r hose connection:

15 2 clamps L 4Q-50, pan No. 916026 040000

16 Coolant hose, part No. 126 501 02 82
17 Reducer made of two p ipes
A 38 mmdia.
B 39 mm dia.
e 12 mm dia.

18 19 18 20
1
Required parts for lower hose connection:

18 2 clamps L 4Q-50, part No. 916026 040000

19 Coolant hose, part No. 126 501 02 82
20 Cap made from pipe
rnh
LY
A 38 mm dia.
B 39 mm día. ._._, __ ,., _jo_.. ~ ·" ... . ,.......
.'~-"~(-:;:.:-- · ~l ,i~@'t-'1~~*...~..,~.--

' -- 70 _ J \204~8.. 83

20.7- 425/4 F3
Glose overflow connection on upper coolant tank . 18 20

Required parts for inlet from expansion tank:

18 2 clamps L 28- 35, part No. 916026 028000

19 Coo lant hose, part No. 126 501 10 82
20 Cap made from pipe ~-n.
A 21 mm dia.
B 22 mm dia.
- 70 -··· ·· · - LY 1204• 84&3

4 Close connections of gear oil cooler on lower

coolant tank with plastic caps or p lugs from used
oil cooler lines. For this purpose, saw off oil cooler
l ines d irect ly behind nipple and close w ith solder.

5 Connect tester to radiator.

For leak test, pull hose from r adiator cap and attach
to r educer on the upper hose connection of the
radiator.

6 Place rad iator into a water bath.

7 Put the radiator under p r essure by means of the

tester and watch for air bubbles.

8 Mark leaking area.

9 Remove radiator and release pressure.

10 Blow radiator dry with compressed air.

11 Clean part to be sealed by means of a com·

mercially avai lable cleaning compound (e.g. Tri or
benzine). Always clean a slightly larger area than
the spot to be sealed (e.g. for cracks, approx. 20-
30 mm beyond the end of the cracks).

There is no need to remove paint. The radiator can

then be blown d ry at the respective area by means
of compressed air.

No dust or grease should remain.

20.7- 425/5 F3
12 Evenly and thinly distribute prim ing fluid with
a brush .

Similar to cleaning, apply primi ng fl uid beyond the

area to be sealed. To prevent the primi ng flu id from
becoming dirty in the container, pour the quantity
requ ~red for the repair into a separate vessel.

Caution!
When handling priming fluid, pay attention to
safety regulations. Oangerous materials class A 1,
1nflammable.

13 Allow priming fl uid to dry for approx. 10 minutes

at room temperatura.

14 Position radiator i n such a manner that the

sealing compound cannot run off the spot to be
sealed.

15 Apply diluted or non·diluted sealing compound

depend ing on accessibi lity. Use brush, spatula or the
like fo r distributing the sealing compound.

Caution!
Ourlng application and d istribution make sure that
no atr pockets w ill occur.

App ly sealing compound similar to cleaning and

prr m ing beyond the spot to be sealed. lf th ere are
several leaking points on the beaded collar (arrows),
it is reco mmended to seal the beaded collar all the
way round.

Seal leaks in the core from both sides.

At the end of the sealing procedure, clase the tube

again immcd iately. Acet ic acid w ill be liberated until
linking (setting) of sealing compound has been com·
pleted. Avoid skin contact. Clean affected areas
immediately with water and soap, rinse eyes with
water and see a doctor if required.

16 For d ry ing of sealing compound, leave rad iator

lytng or standing up for at least 3 hours. Oepending
on the quantity of sealing compound appl ied and
the size of the arca to be sealed, linking of sealing
compound into a permanent, elast ic bond will be
completed after a maximum of 24 hours at room
temperature.

20.7- 425/6 F3
17 Pressure-test the radiator in a water bath for
approx. 5 minutes at 1.5 bar gauge pressure.

lf th ere are stil l other leaks. repeat the sealing pro·

cess starting with item 8.

18 Remove tester and plugs.

19 Attach air o il cooler to radiator and tighten

fasten ing screws to 6 Nm.

20 Follow ing the installation o f radiator (20- 420)

and f illing·in of coolant (20-010), pressu re·test
cooling system with teste r ( 1 .O to 1.3 bar gauge
pressure) to check for leaks.

20.7- 425/7 F3
20-430 Checking expansion tank cap

Expansion tank cap

Part No. Code figure Pre¡sure relief valve opens at

bar gauge pressure

124 500 01 06 140 1.4 ± 0.1

Production breakpoint
as of November 87

124 501 05 15 1 ) 140 1.4 ± 0.1

Production breakpoint and
spare part as of October 86

123 501 00 15 120 1.2 .± 0.1

Production breakpoint
asofJune 1983

123 501 02 15 1 ) 120 1.2 ± 0.1

Spare part until Oct. 86

123 501 01 15 100 1.0 ± 0.2

Vacuum valve opens as of O. 1 bar vacuum

1
) Required on vehicles wi th overflow tan k.

Special tools

Tester for cool ing system and radiator cap 001 589 48 21 00

Double connection for expansion tank

000 589 75 63 00
cap to tester

20.7- 430/ 1 F3
Note

Since June 1983, a ca p wi th increased opening pres- A B

sure has been insta lled. lt can also b e installed in
previously manufactured vehicles.

The spare part cap (B) is p rovided with a spring-

loaded seal andan add itional ru bber seali ng ring and
provides a better seal al so on o lder-type expansion
tanks w ith a possibly u neven con tact surface.

On vehicles with overflow tank, a cap with higher

opening pressure ( 1.4 b ar) must be installed. ( 1.2 bar t2Q-213$3
up to October 1986, 1.4 bar as of October 1986).

The caps w ith h igher opening pressure ensure at

least 1 bar gauge p ressure in the cooling system eve n
on old er vehicles. This w ill provide increased p rotec-
tion against coolant ejection.

Checking pressure relief valve

1 Attach doub le con nector 000 589 75 63 00 to

tester 001 589 48 21 00 w it h t he ret aining c lamps.

2 Place ex pansion tank cap on t he double connector.

3 Check the opening pressure by pumping.

Checking vacuum valve

The vacuum valve (arrow) should rest aga inst t he

rubber seal, be easily lifted and snap back upon
release.

20.7- 430/2 F3
22-211 Removal and installation of front engine mount

A. Model 107

Removal

Unscrew screw (20).

2 Unscrew engine mount ( 17) from c ross member.

3 Lift engine at oil pan by means of p it lift.

Note: Use wooden base to prevent damage to the

oil pan .

4 Remove engine mount.

lnstallation

5 For installation p roceed vice versa.

6 Tighten screw (20) to 75 Nm.

Caution!
Check regulating linkage for proper function.

16~

11~
1 Nut M 6
2 Washer A 7.4
3 Cup washer 43 mm día. 1
4 Rubber buffer 36 mm día. @8
5 Shieldíng plate
6 B racket on síde member ®9

» ~
7 Engíne shock absorber, L ~ 45 mm
8 Cup washer 30 mm día.
9 Rubber buffer 26 mm día. 10
10 Bracket left
Bracket right
11 Shielding plate
...
8~
12 Engine ca rrier left 116 223 46 04
Engine carrier ríght 116 223 47 04
13 WasherAB.4 1 _j 19@
14 Screw M 8 x 45 1 't1 - -

20~
15 Screw M 8 x 60
16 Combi nation sc rew M B x 18
17 E ngine mount left ( 1 white dot)

~>002-8086
Engíne mount right ( 2 white dots)
18 Guide sleeve
19 Spring washer B 12
20 Screvv M 12 x 80

22.7-211 / 1 F 3
B. Model 126

Removal

1 Unscrew screw ( 15, arrow) f rom undersid e of

vehic le.

2 Unscrew nut ( 1) from engine shock absorber

below.

3 Lift engine at oil pan by means of pit lift.

Not e: Use wooden base to prevent damage to oil pan.

4 Unscrew screws ( 13) and remove engine mount.

lnst allat ion

5 For installation proceed vice versa.

Note: The shielding plate is located at the left .

6 Tighten screw ( 15, arrow) to 70 N m.

1 Nut M 6
2 Cup w asher
3 R ubber buff er
4 Engine carrier
5 E ngine shock absorber
6 Cup washer
7 Rubber buffer
8 Bracket
9 Washer
10 Screw
11 Nut
12 Shielding plate
13 Combination screw
14 Engine mount
15 Screw

22.7-211 / 2 F 3
22-212 Removal and installation of rear engine mount

A. Model 107

Caution!
Do not unscrew c losing pi ate ( 11 } when r emoving
engine mount (4).

Attach engine mount to closing plate without tens ion.

Upon installation of engi ne mount, ru n engine for a

short period at idle speed w ith adjusting screw loase.
T ighten adjusting screw (9) to 30 Nm with engine
stopped.

Caution!
Check regulating linkage for proper function.

1 NutM 12x 1.5 9 Adjusting screw M 8 x 75

2 Spri ng washer B 12 10 Spacer
3 Transmission f lange 11 Closi ng plate
4 Engine mount 123 240 04 13 12 Washer
5 Threaded pl ate 13 Spring washer A 8
6 Bracket 14 Screw M 8 x 32
7 Washer 8 .4 15 Washer
8 Spring washer A 8 16 Screw M 8 x 20

B. Model126

Caution!
Do not unscrew engine carrier (5) for removing
engine mount (3).

When installing the engine mou nt (3), attach w ithout

tension by means of screws (9) to the engine carrier
(5) with elongated hales.

8®
Engine mount
Engi ne carrier
H = 67-69 mm
L = 31 mm 9~ 1243 · 933 4

22.7-212/1 F 3
22-240 Removal and installation of engine shock absorber

Tightening torque Nm

Engine shock absorber attachment, hex. nut M 6 8-1 2

Not e

For loosening and tightening the lower hex. nut

apply counterhold to piston rod at f lats (arrows) for
w renc h provided for this purpose.

Observe tightening torque 8-12 Nm, do not pu ll

against the block.

A . Model 107
10() ... 13090-

Engine shock absorber left an d right

1 Remove expansion tank for removing the right-

hand engine shock absorber.

2 Remove the pressure regulator to perm it removal

of t he left-hand engine shock absorber.

3 Unscrew engine fastening screw from engine

mount and unscrew engine shock absorber.

4 Remove engine shock absorber together wi t h

bracket.

Caution!
6
During installation observe location of rubber
buffers and cup washe rs (22- 211) .

Engine shock absorber left seen from t he front

1 Nut M 6 6 Bracket on side member

2 Washer A 7.4 7 Engine shock absorber,
3 Cup washer 4 3 mm dia. L = 45 mm
4 Aubber buffer 36 mm dia. 8 Cup washer 30 mm día.
5 Shielding plate 9 Rubber buffer 26 mm d ia.
1O B racket left

22.7-24 0/1 F3
B. Model 126

Engine shock absorber leh and rig ht

During installation, observe location of rubber

buffers and cup washer s.

Engine shock absorber and layout are the same at

the left and right.

E ngine shock absorber right seen from the front

22.7- 240/2 F3
 3Q-300 Checking, adjusting accelerator control

A. Vehicles without ASR

P30- 0080 oo $5

Accelerator control linkage . . . . . . . . . . . . . . . . . check that it operates easily and is not bent.
Renew parts. if necessary.
Connecting link (5) and linkage rod (21) .... ... detach at relay lever. Check whether the throttle
valve is resting against idle speed stop.
Reattach connecting link free of tension. Adjust
to 100 mm length, if necessary (measured from
ball socket centers).
Vehicles with cruise control ... ... ..... .. ... check whether cruise control actuator (M 16) is
resting against idle stop of cruise control. This
is done by detaching linkage rod (21) and
pressing lever of actuator clockwise against idle
stop. When attaching linkage rod (2 1), ensure
that the lever of the actuator is pressed away
approx .
1 mm from the idle stop. Adjust linkage rod
(21 ), if necessary (measured from ball socket
center).

30.0714 . 300/ 1
Connecting link (22) detach.
Connecting link (1) .. ... ..... ... ... .. .. . . adjust so that the roller (15) in the fulcrum lever
( 13) is resting free of tension against end stop.
Connecting link ( 19) adjust to 163 mm and attach (measured from
center of ball socket).
Full throttle stop .. .. ... .... .... ... .... . . check. With engine swittched off, depress accel-
erator pedal (24) from inside car as lar as stop
on kickdown switch (S16i 7). The throttfe valve
lever must be resting against full throttle stop
when pertorming this step. Slacken adjusting
screw (4), if necessary, adjust accelerator
control linkage so that throttle valve lever is
resting against full throttle stop.
lf this adjustment does not result in full throttle
or idle stop, adjust linkage rod (20) to specified
length (see table). From center of ball socket to
center of damping ring.
As a check, allow accelerator pedal to slowly
move back into idle position. In this position. the
roller in the fulcrum lever must be resting free of
tension against end stop.
Control pressure cable ( 11) for automatic
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . adjust. To do this, press relay lever (23) in
direction of arrow until it is felt to touch idle stop
of automatic transmission. Attach connecting
link (22) free of tension~ adjust, if necessary.

Adjustment data in mm (measured from center of balf socket)

Model 107 126
Length of connecting link (5) from throttle
104 104
valve assembly to relay lever
Length of linkage rod (20) trom longitudinal
105 220
accelerator control shaft to accelerator pedal

Length of connecting link ( 19) from longitudinal

163 163
accelerator control shaft to fulcrum lever

30.0714 . 30012
B. Vehlcles wlth ASR

P30•0081 •57

Air filter ........ ...... .... . . .. .. . .. .. . remove.

Return springs (9, 22) check whether throttle valva· relay levar (23) is
correctly attached at potentiometer (see note
for ill.).
Locking element (14, 25) check that correctly fitted.
Connecting links (8, 11) detach at accelerator control levar ( 16) and al
fulcrum levar (13).
ldle travel rod (20) remove. This is done by pulling off accelerator
control lever ( 16) and throttle val ve re lay lever
(23) e.g. with open·end wrench.

Lh
On no account bend idle travel rod otherwise
pressure point in accelerator pedal or idle travel
rod will not move easily.

30.07 14 . 30013
Potentiometer re lay lever ( 12) must be resting against idle stop.
Accelerator control lever (16) must be resting against outer cam of fulcrum
lever (13).
Ease of movement of accelerator control lever and fulcrum lever.
check.
ldle travel rod (20) check length. To do this, lit idle travel rod (20)
onto accelerator controllever (16). In idle
position. setting size must be 3-5 mm longer
(approx. hall ball head) than the distance
between throttle valve relay lever and poten-
tiometer accelerator control lever.

&
Adjust length only at the knurled edge. The ball
sockets must not be released and repositioned.
ldle travel rod (20) lit al throttle valve relay lever (23).
Output lever (24) check. Todo this, switch on ignition. Output
lever must assume idle position. Check whether
output lever can be shifted further by hand. lf
yes. perform test routine lor electronic acceler-
ator (30-365).
Connecting link (21) ..... .. .... ....... .. . adjust length (left/right thread) so that rocker
play at throttle valve relay lever (23) in pull
direction is eliminated (throttle valve opens
immediately when potentiometer operated).
Full throttle stop ... ... .... ...... ..... ... check. To do thrs. lully deflect potentiometer
accelerator control lever ( 16) and hold in this
position. Check at throttle valve assembly
whether the throttle valve is resting against full
throttle stop (linkage not subjected to excessive
pressure). lf full throttle stop is not reached,
slacken hex. nut on ball head in output lever
(24). Operate potentiometer accelerator control
lever as far as full throttle stop and fix in posi-
tion. Pull connecting link (21) into full throttle
position and hold in this position. Secure ball
head.

30.07, 4 . 300í4
 Adjusting movement . . . . . . . . . . . . . . . . . . . . . check. With one hand, slowly deflect poten-
tiometer accelerator control lever (16) as lar as
full throttle stop and then move back into idle
position. When performing the step, check with
your other hand the adjustment movement at
connecting link (21). The actuator (M 1611) must
follow evenly (no pressure point perceptible).
Connecting link ( 11) . . . .. .. . . . . . . . . . . . . . . attach free of tension, adjust if necessary.
Connecting link (8) ... ............. ...... attach.
Full throttle stop of accelerator pedal check. Depress accelerator pedal ( 1) to full
throttle (not kickdown). Output lever (24) at
electronic accelerator actuator (M 16/ 1) assumes
'full throttle position (throttle valve must be
.resting against full throttle stop, see above).
This must not result in the accelerator control
linkage to the potentiometer being excessively
tensioned (elastic deformation). lf the linkage is
subjected to excessive pressure or full throttle
position is not reached, slacken adjusting screw
(4) and adjust longitudinal control shaft (5)
relativa to connecting link (19}.
ldle speed .. ...... .. ...... .... ... ..... check.
Air filter ........... ............ .... ... install.

Note

Vehicles with ASR and cruise control

lf driving faults occur with cruise control, perform

cruise control test routine (30·360).

~
The length of the idle travel rod may only be
adjusted at the knurled edge (arrow).

On no account, may the ball sockets be

P30•0075 •13
detached and shifted.

30.071 4 . 30015
The return springs (22, 9) on the throttle valve
relay lever and potentiometer relay lever are
identical. They must not be mixed up with the
return spring on the throttle valve.

22 Return spring
27 Throttle valve return spnng

30.0714 . 30016
 3G-310 Removing and lnstalllng engine longitudinal control shaft

----~
J á)O~~
8

\1!. ~ ~__.-:
o2 2a
8 ~

~ 16 17
P30· 0086· 5 5

A Model 107
B Mooel 126

Accelerator control rods detach and attach.

Locking element ( 1) . .. .. ..... .. ....... .. remove and install. On Model 126, taka off
spring plata ( 16) and comprassion spring ( 17).
Longitudinal control shaft {3) .. ... .... .... .. prass back and take out. When performing this
step on Modal 107, pay attention to compres-
sien spring (9), plastic bushes (2a), pivoting
balls (2) and washers (8).
Bearing points and ball sockets .... .. .. ..... graasa with Molykote-Longterm 2.
Accelerator control linkage . . . . . . . . . . . . . . . . . check, adjust (30-300).

30.0714. 310! 1
3Q-320 Removing and installing, adjusting firewall acceterator control shaft

A. Modet 107
Precedmg work:
Removmg accelerator peaal 30- 330
Removmg heater box 83-100

Connecting link with damping ring (20) press off lever ot accelerator control shaft
(14a) (14b, not used), press on.
Return spring (18) detach, attach in top hole.
Fastening bolts {19) unscrew. screw on.
Plastic bearing (13) press out up the way and take off accelerator
control shaft with bearing.
Bearing points and ball sockets grease with Molykote-Longterm 2.

30 0714 . 320>1
Accelerator pedal (24) . . . . . . . . . . . . . . . . . . . . depress as far as stop on kickdown switch
(516/7) . When doing this, the throttle valve lever
must be resting against full throttle stop. lf
necessary. correct setting by slackening screw
(4).
lf this setting does not produce full throttle or
idle stop. adjust linkage rod (20) of longitudinal
control shaft (14a) to length of 105 mm.
measured from center of ball socket to center of
damping ring.
As a check, slowly allow accelerator pedal to
move back into idle position. In this position, the
roller in the fulcrum levar must be resting free of
tension against end stop.
lf the setting described above does not produce
full throttle or idle stop, slacken hex. bolt (15) in
interior of car, press accelerator control linkage
up to full throttle stop on throttle valve assembly
and retighten hex. bolt.

30.07 14 . 32012
 B. Model126

Prece<Jing work:
Removmg accelerator pedal 30-330

~
12

~
1~

P30-0077-55

Modef 126

Return spring (22) detach and attach.

Connecting link (20) ... . . .... ..... .... ... pull off accelerator pedal lever (33), press on.
Fastening bolts (12) unscrew, screw in.
Bearing ( 13) with accelerator pedal lever (33) remove.

Accelerator pedal (24} . . . . . . . . . . . . . . . . . . . .
Lnstallatlon
Grease bearing points and ball sockets with
Molykote- Longterm 2.
depress as far as the stop on kickdown switch
(S 16/7). When doing this, the throttle val ve lever
must be resting against full throttle stop. lf
necessary, correct setting by slackening the bolt
( 4). lf this setting does not produce full throttle
or idle stop, proceed as follows:
Adjust connecting link (20) from longitudinal
accelerator control shatt (3) to accelerator pedal
lever (33) to a length of 220 mm. measured
from center ot ball socket to center of damping
ring.

30.071 4 . 320/3
30-330 Removing and installing, renewing accelerator pedal

P07 · 23 e7-t 3

Spreader clip (arrow) behind accelerator pedal, compress and

remove.
Accelerator pedal Model 107 withdraw down the way.
Accelerator pedal Model 126 push up the way and turn through 180° . Pull off
accelerator pedal down the way. The lug (arrow)
on the accelerator pedal lever must be aligned
with the slot in the accelerator pedal.
lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . .. lnstallation is performed in the reversa order.
Ensure that the spreader clip correctly engages.

The linkage from accelerator pedal lever to

accelerator pedal is maintenance-free and does
not require to be greased.

30.0714 . 33011
30-335 Greasing accelerator control llnkage and shafts

lubrícating
After each engine wash and treatment of the
engine compartment, lubricate all bearing
polnts of all accelerator control shatts,
levers, joints of the accelerator control
linkage and cables with an oil can.

Only the following hydraulic oils may be used:

BP-Aero-Hydraulic 1
Castro! DB Hydraulic Fluid
Esso Univers J-13
Mobil Aero HFA
Shell Aero Fluid 4

30.0714 . 33511
 3Q-350 Deslgn and functlon of electronlc accelerator

A. General

The acceleration slip cont rol (ASR) is an

automatic system for improving starting-off and
accelerating capability as well as driving
stability.

ASR is the logical further development of the

anti-lock system (ABS). Whereas ABS prevents
the wheels from locking when braking and thus
maintains steering control and driving stability
when braking the vehicle, ASR prevents the
driven wheels from spinning when moving off
and accelerating. The result is optimal driving
stability with enhanced traction. The ABS basic
components are supplemented for ASR by a
hydraulic unit with expanded functions. a
pressure supply unit, a fourth rotational speed
sensor, enlarged electronic control and the
electronic accelerator with control unit,
potentiometer and electronic accelerator
actuator.

In addition, the cruise control system is

contained in the control unit of the electronic
accelerator.

30.0 7 14 . 350/ 1
Benefits

• lmproves starting-off and acceleration

capability as a result of enhanced traction.
particularly beneficia! on road surfaces and
curves w1th differing levels of adhes1on.

• Enhances active dynamic safety as it is

sufftctent to have only a single wheel which
is not spinmng to achieve optimal tract1on
w1th no loss of cornering control.

• Automatically adapts engine torque to

respective adhesion capability between
wheel and road surface if the driver
accelerates too sharply.

• A function display indicates that the ASR

control has been activated and signals to the
driver that he is approaching the physical
lim1ts of the vehicle.

Driving with ASA

The 1nstrument cluster contains displays with
various symbols for the ASR.

A1e17 ASS 1nd,cator lamp

A 1e21 ASR tunct1on display
A 1e22 ASR 'nd,cator tamp

30 071 4 . 350t2
 .. _........._.. .._.._.,_,.,.,.,"...-.. ..... """""--......... .. .......................,., ....
~~- ~ _, , .........•.
- "'

Swltchlng on lgnltlon
When ígnitíon is switched on (ignition starter
switch "position 2" ), the function display and the
indicator lamps in the instrument cluster light up
(bulb check) and go out once the engine is
running.

Oriving
When driving. the function display lights up as
soon as the ASA is operating. The function
display remains on for approx. 1 s after end of
ASA control mode. lf the ASA control is
activated oniy for a very short moment. the
function display does not light up.

Control mode
The function display indicates that the ASR
control has been activated and signals the driver
that he is approaching the physical límits of his
vehicle. This enables him to adapt his driving
style better to road conditions.

Check
lf the ASA indicator lamp lights up when the
engine is running, this indicates a fault in the
ASR or in the electronic accelerator. The ASR
system is inoperable although the ABS function
is retained. lf the fault occurs in the electronic
accelerator. it is possible to continua driving with
reduced engine output. The driver notices this
from the altered operating torces of the
accelerator pedal. lf the ASA and ABS indicator
lamps light up when the engine is running, this
indicates a fault in the ABS which also involves
the ASR being deactivated as well, or in the
ASR which also affects the ABS system. 8oth
systems are switched oH.

30.0714 . 35013
Snow chain switch (S76)
(ASR slip threshold control with indicator lamp)

The responsiva. stability-oriented control of the

ASR may have a detrimental effect on starting-
S76
off behav1or 1n deep snow and with snow chains
fitted. For th1s reason. a special control logic has
been programmed into the system for the o
starting-off range in appropriate situations, which
the dnver can select by pressing the snow chain
switch. When the snow chain switch is operated.
the 1ndicator lamp in the switch lights up. Alter
approx. 50 ms continuous ASR control mode. a
higher drive slip lim1t is permitted at the wheels
to enable the vehicle to get free in the situations
indicated above. As this higher slip would have a
negativa effect on driving stability, particularly at
higher speeds. it remains limited to the speed
range < 40 km h. The higher drive slip remains
stored up to 60 km,h and is automatically
reactivated if vehicle speed drops below < 40
km h. Once vehicle speed exceeds
60 km h, the stored higher slip is erased and
the 1ndicator lamp in the switch goes out.

30.0714 . 35014
 Arrangement of components

Elec1rlcs1Eiectron ics Hydraullcs

Atet7 ABS tndicator lamp A7 ABS hydraulic unit tor ASA
At e21 ASA function display A7/3 ASA hydraulic unit
A t e22 ASA tndtcator lamp M 15 Boost pump
K 1i 1 Overvoltage protection relay 4a Brake fluid reservotr
K20 Boost pump relay 13 Pressure accumulator
L6/1 Le ft tront axle spee<:l sensor 6ai6b Aear brake caliper wtth wear tndicator
L6/2 Aight tront axle speed sensor
L6/3 Left roar axle speed sensor Mechanical parta
L6/4 Atght rear axle speed sensor 20 ldle travel rod (redundancy rod)
M1 6/1 Electrontc accelerator actuator
N4/1 Electrontc accelerator control untt
N30/ 1 ABS/ASR control u M
R25 Electronic accelerator potentiometer
$9/ 1 Stop hght switch
S40 Cruise control sw1tch
S76 Snow chatn swotch (slip threshold selector) wtth
ondocator lamp

30.0714 . 35015
B. Overall function ASR
The speeds of all the wheels are detectad in
the ABS!ASR control unit and processed. lf the
ABSI ASR control unit detects from the speed
signals that one or both driven wheels are
tending to spin, the ASR control mode is acti-
vated with the brake torque control loop and the
driving torque control loop.
The following procedures are then performed:
• Brake torque control loop
The spinning driven wheel is braked by the
relevant wheel brake until it has reached the
most favorable drive slip ranga. This
enables the other wheel to be optimally
driven (locking differential effect). The spin-
ning wheel is braked by part of the highly
pressurized brake fluid in the pressure
accumulator flowing out of the accumulator
through the ABS and ASR hydraulic units
into the brake caliper (pressure buildup). A
solenoid valve modulates the pressure flow
in the brake caliper during the brake torque
control, in pressure buildup, pressure
holding and pressure reduction. During the
pressure buildup phase. the brake fluid
volume is pumped out of the brake caliper
through the return pump into the pressure
accumulator. Th·is control sequence is per-
formed individually for each wheel brake of
the driven wheels.
30.0714 . 350/6
• Drlvlng torque control loop
In order to reduce excessive driving torque
for optimal traction, an exchange of signals
takes place along the link between the
ABSIASR control unit and the electronic
accelerator control unit.
The throttle valve position is reduced by the
actuator in contras! to the accelerator pedal
position input by the driver. A constan!
check is performed in the ABSIASR control
unit as to whether e.g. the control functions
can be cancelad as a result of a sudden
improvement in road surface adhesion in
order lo again permit the driving torque
input by the driver through the accelerator
pedal at the earliest possible moment.
A distinction is made between two control
ranges in the ASR control mode:
• Control mode for ene spinning driven wheel
and driving speeds < 40 km1h in which the
control is orientad to the driven wheel which
is still gripping. In this case, the slip
threshold of the driving torque control is
relatively high. The emphasis in this case is
on achieving maximum traction.
• Control mode if both driven wheels are
spinning or at driving speed < 40 km/h with
the control orientad to the spinning driven
wheel. The slip threshold of the braking
torque control in this case is still above that
for the driving torque control. Consequently,
the emphasis is on achieving maximum
driving stability.
C. Drivlng torque control loop

The driving torque control loop is based on the

electrical .' electronic components of the
ABS!ASR and is supplemented by the electronic
accelerator. The electronic accelerator is com-
posed of the following electrical t electronic and
mechanical components:

• Electronic accelerator potentiometer (R25)

• Electronic accelerator actuator (M 16/ 1)
• Electronic accelerator control unit (N4í1)
• Accelerator control linkage and accelerator
pedal
• ldle travel rod (redundancy rod)

The speed signals of the speed sensors are

constantly processed in the ABS circuits and
ASR microcomputers in the ABSIASR control
unit to form the following variables:

• Onve slip
• Acceleration
• Oriving speed (front wheel)

lf the variables calculated exceed certain given

specified values, the ABS/ASR control unit
signals the electronic accelerator control unit to
throttle back. As a result, the electronic
accelerator control unit and thus the throttle
valve are controlled irrespective of the amount
by which the accelerator pedal is depressed.

30.0714 . 350/7
A function display indicates that the ASR control
is activated and signals to the driver that he is
approaching the physical limit of his vehicle.

The function of the ABS is not impaired by the

ASR asan ASR control mode is interrupted by
braking.

~
Oepending on the speed driven, the braking .X
e
torque control begins as soon as the differential 10

speed between front and rear wheel (ó.v) rises

beyond the slip threshold of the braking torque
control. Braking of the relevan! rear wheel is S

controlled by building up pressure. holding

pressure and reducing pressure in the corre-
sponding rear wheel brake. Once the differential
o 100 V 200km/ h
speed (ó.v) again drops below the slip threshold.
the system switches over to pressure buildup for
a given time interval .

Slip thresholds

V Speed
ó.v = DifferentJal speed between front and rear wheel

Brak1ng torque control

Dnving torq ue control

30 07 14 . 350<8
 Drlvlng
lrrespective of road condition and direction, an lf both driven wheels are spinning or at vehicle
ASR control mode proceeds as follows: speeds > 40 km!h, the driving torque control is
superimposed on the braking torque control.
lf one driven wheel is spinning and the driving The ABSIASR control unit detects an imper-
speed is < 40 kmlh, the braking torque control missibly high slip and passes a signal to the
is superimposed on the driving torque control. In electronic accelerator control unit. The throttle
this case. the braking torque control is activated valve is moved by the electronic accelerator
first. The ABSIASR control unit detects an im- actuator against the accelerator pedal position
permissibly high slip and passes a signal to the input by the driver. As a result, the driving
solenoid valves in hydraulic unit. Thereupon, torque is reduced to the point where no slip
accumulator pressure flows into the appropriate which may impair driving stability can occur at
brake caliper so that the relevan! wheel is the driven axle. The driver may detect the
braked. As a result, the wheel running on the movement of the throttle valve by brief changes
road surface offering better adhesion is supplied in the accelerator pedal torces. The control
with torque through the differential. lf the driver movement is continuad until a wheel has
depresses the accelerator to full throttle. the dropped below the critica! slip threshold. The
spinning wheel moves into a higher slip range. remaining control cycle is tnen the same as for
The driving torque control is activated at a single spinning driven wheel.
approximately twice the slip of the braking
torque control.
The ABSíASR control unit passes a signa! to
the electronic accelerator control unit. The
throttle valve is now moved by the electronic
accelerator actuator against the accelerator
pedal position. The driving torque is reduced. As
soon as the slip has dropped below the lower
slip limit, the throttle valve is slowly opened.
This enables the maximum possible driving
torque to be transmitted to the road. lf the road
conditions changa, a renewed control cycle is
started.

30.0714 . 35019
 Accelerator --+ f ulcrum and
-+
ldle travel rod Relay lever
-+
Accelerator
control hnkage accelerator control (redunoancy roo) control linllage
le ver

+
Accelerator
+
Power supply through Accelerator Thronle valve
pedal lever
1g01tion s tarter sw1tch control linkage

Accelerator
pedal

Electron1c Electronic accelerator actuator

~~------------+---~-----~
accelerator
potentoometer

Cru1se control
swotch Fuel pumps

Veh1c1e speed
1nductove sensor
,_____. Electron1c
speedometer --
Power supply TD/TN sognal
Starter lockout or start s1gna1
Selector lever and backup
hght switch

fromlto ABS/ASR control uOit

from stop hght switch

electnc c ircu its

mechanocal transmossiOn

30.0714 . 350110
O. Electronic accelerator components

N1614 S1611 S9/1 N4/1

P30•0076 • 61

A1p8 Electronic speedometer R25 Electromc accelerator potent1ometer

M 16/1 Electron1c accelerator actuator S9/ 1 Stop light sw1tch
N4/ 1 Electronic accelerator control uM S16/ 1 Starter lockout and backup light sw1tch
N16/4 Fuel pump and kickdown shutolf relay $40 Cru1se control sw1tch
20 ldle travel rod (redundancy rod)

30.0 714 . 350111

E. Functlon of electronic accelerator
All the control processes as well as the
mechanical adjusting movements are performed
with the electrical /electronic components in
combination with the mechanical components.
The electronic components are supplied with
the necessary voltage through unprotected
terminal 15 in the fuse box. The fol!owing
components supply signals to the electronic
accelerator control unit:
• Electronic accelerator potentiometer
• Electronic accelerator actuator
• ABS/ASR control unit
• Starter lockout and backup light switch
• Cruise control switch
• Electronic speedometer
• Stop light switch
The input signals are processed and monitored
in the electronic accelerator control unit. The
following components are activated with the
output signals:
• Electronic accelerator actuator
• ABS1ASR control unit
• Fuel pump relay
When the ignition is switched on, the electronic
accelerator is activated. The position of the
accelerator pedal (set value) is signaled through
the electronic accelerator potentiometer to the
electronic accelerator control unit. An output
signa! for controlling the actuator is assigned to
this set value in the electronic accelerator
control unit.
30.0714. 350/12
The electronic accelerator actuator thus
assumes a position corresponding to the set
value. The output lever of the electronic
accelerator actuator is connected to the throttle
valve by an accelerator control linkage. The
opening angle of the throttle valve corresponds
to the input set value, as a result of which the
engine transmits a certain torque to the driven
wheels.
lf the enterad set value (accelerator pedal
deflection) is higher than the driving torque
which can be transmitted to the road, this would
result in the wheels spinning (slip). This slip is
detectad by the ABS/ASR control unit and a
signa! (throttle valva set value) is passed to the
electronic accelerator control unit. As a result,
the electronic accelerator actuator and thus the
throttle valve can be closed against the
adjusting movement of the accelerator pedal. lf
the throttle is excessive, the driving torque is
reduced until the slip drops below a fixed value.
With the electronic accelerator, it is possible to
move the throttle valva between idle speed and
full throttle or with the ASR to clase it in the idle
direction. lf there is excessive driving torque at
the driven wheels, the idle travel rod enables
the throttle valve to be moved against the
accelerator pedal position. The idle travel rod
(redundancy rod) is an emergency driving
device which enables the vehicle to continua to
be driven at reduced engine output should the
electronics fail. In addition, a cruise control
system is contained in the electronic accelerator
control unit.
Features:

• Throttle valve is always moved by the

electrical / electronic device.
• Cruise control system is integrated in the
electronic accelerator control unit.
• The vehicle can continue to be driven at
reduced engine output in the event of a
failure of the electrics i electronics.

30.0714 . 350i13
Block dlagram of electronlc accelerator

Accelerator --+ Fulcrum and Retay rever

-+
Acceterator
control lonkage accete rator control (reóundancy red) control tinkage
rever -.r 1
1
1

Accelerator
+
pedal rever Power supply through Accererator Throttle valve
ignitoon starter swotch control lonkage
+ +
Accelerator
pedal

Electronoc !•------+-----~ Electronoc accelerator actuator

accelerator

'--po..,t_e_n_t•o_m_e-te_r_ _..__ _..r __ ~ ,....,,.- ~.~

.1 + - - - - -- - - - - - '
C ruose control 1
SWitCh 1 - - - - - - - - - - + '' 1 Fuer pump retay Fuel pumps
1 l
1:
Vehocle speed Electronoc
i
1, .
onductove sensor f-+ speedometer
t Electronic
acceterator
1' control unot
1·
r Power supply TD signal or
Starter lockout l'' start sognal
Selector rever and backup J:i:
f-• light swotch r
f:
t

fromlto ABSIASR control unot

____]-
trom stop toght swotch

electric cables

mechanocal transmossoon

30.0 714 . 350i14

 F. lgnltion starter switch "positlon 2"
When the ignition is switched on (ignition starter
switch " position 2"), the electronic accelerator
is activated . Power is supplied to the electronic
accelerator control unit, electronic accelerator
potentiometer and to the electronic accelerator
actuator. In addition, the fuel pump relay is
activated through the safety switch of the
electronic accelerator actuator (voltage at
terminal 15). Voltage is supplied from it to the
fuel pumps for approx. 1 s. In addition. the
cruise control switch is supplied with voltage
through the ignition starter switch.
When the accelerator pedal is depressed, the
adjusting movement is transmitted through the
accelerator control linkage, fulcrum and relay
lever to the electronic accelerator potentiometer.
Depending on the accelerator pedal position, the
potentiometer inputs a corresponding voltage
signal to the electronic accelerator control unit.
30.07 14. 350/1 5
A voltage signal is likewise input by the
potentiometer of the electronic accelerator
actuator (actual position of throttle valve). 8oth
signals are comparad in the position controller
of the electronic accelerator control unit. lf these
signals vary, the actuator position is adapted to
the set value (position of accelerator pedal). In
addition, when the ignition is switched on. an
exchange of information occurs between the
ABSIASR control unit and the electronic
accelerator control unit.
The electronic accelerator control unit checks
whether the permissible throttle valve set value
of the ABSIASR control unit is below the set
value input by the driver. lf this set value is too
large, the ABSIASR control unit determines the
maximum possible throttle valve opening.
The signals from the electronic accelerator
potentiometer, electronic accelerator actuator
and ABS/ASR control unit are checked by the
monitoring device. The output stage is also
checked by the monitoring device.
Block diagram of electronic accelerator ignition starter switch "position 2"/ldling/driving

Accelerator Fulcrum and _+ ldle travel rod ______ , Retay lever Accelerator
pedal lever accelerator (redundancy rod)
r--- control linkage
... control tever
+
'---- ---, Accelerator Throttle valve
control linkage
Accelerator

1 pedal 1
control
hnkage ,

j ...--:_ _ 1

~-__,____,
Relerence polent•ometer (R25)
• Voltage supply
through 19 01t10n
starter sw1tch
L Actuator (M 16i 1)

Potent•ometer Safety sw• tch Eng1ne Potent•ometer Safety switch

s•gnal. acceleralor signa!, thronte
pedal POSitiOn valve posttion

. - - - - --··-
Cru•se POSitoon "R" lor Power supply Fuel pump relay
'--+---i""~ COntrOl $WI\Ch charactenst•c term•nal 30 t---t~ (N16/4)
- curve sw•tchover

ABSIASR
+ TD s•gnal

conlrol unlt Starter IOCkOut

(N 30/1) and backup loght
SWitCh +
EZL control Fuet pumps

+ unit (Nl /2) (M3m1, M3m2)

Selector
lever
l Electron1c lnóuctive speed
Brake pedal Brake lamp Brake speedometer sensor (l2)
--+ SWitCh ($9i1) f-tlo sognal r - - - - - l (A 1p8) 1+-
' - -·-
Speeó s•gnat
- - - - - - mechan•cal lransm•SSJOn - - - electric cables

30 0714 . 350: 16
ldle speed
At idle speed, the electrical 1 electronic com-
ponents are energizad when the ignition starter
switch is in "position 2". The fuel pump relay
(terminal 15) is energizad through the safety
switch of the electronic accelerator actuator. The
relay picks up in combination with the TDtTN
signal, as a result of which terminals 87 and 30
are linked. The fuel pumps are energizad. The
input signals from the reference potentiometer as
well as from the electronic accelerator actuator
are supplied to the electronic accelerator control
unit. These signals are processed in the position
controller and the O.C. motor of the electronic
accelerator actuator is controlled accordingly.
When the accelerator is depressed, the entire
travel of the throttle valve c an be utilized. Signals
are exchanged between the ABSIASR control
unit and the electronic accelerator control unit as
for ignition starter switch "position 2".

Driving mode
In the driving mode, the throttle valve is adjusted
by the electrical r electronic and mechanical
components. The desired driving speed in this
case depends on the position of the accelerator
pedal. >
<1

Dependent on the speed driven. the driving 5

torque control is activated as soon as the
differential speed (ilv) rises above the slip
threshold of the driving torque control. The
driving torque is controlled by closing, holding o 100 V 200km/h

and opening the throttle valve. Once the

differential speed (llv) again drops below the slip
threshold. the throttle valve is opened according
Slip thresholds
to the accelerator pedal input from driver.
V Speed
tw D1fferential speed between front and rear wheel

Brak1ng torque control

Dnv1ng torque control

30.0714 . 350!1 7
Driving with cruise control
The cruise control is operational as soon as the
ignition is switched on. The vehicle must be
traveling at a speed > 40 km'h. however. befare
the cruise control can be activated. Once the
veh1cle is traveling at the desired speed, it is
sufficient to touch the switch in the direction
"Accelerate Set" or "Decelerate.Set" to main-
tain this speed until a new speed is tixed by the
driver or the cruise control is switched off. This
set speed can be varied. e.g. to adapt speed to
traffic tlow, by holding the switch in the direction
"Accelerate Set" or "Decelerate:Set" until the
desired speed is reached. To perform minar
changes in speed, it suffices to touch the
switch in the direction "Accelerate Set" or
"Decelerate Set" to increase or reduce the
speed by 1 kmh.
The speed memory can only " count up"
provided the throttle valve is not at full throttle
and can then only "count down" prov•ded the
throttle valve is not at idle speed (i.e. in decel
mode) . The vehicle is acceterated in this case
at a controlled speed of o. 7 m·s2 . Alter the
switch is released, the new speed is held. The
cruise control is switched off by briefly moving
the switch to the "Off" posillon or by touching
the brake pedal, the accelerator control then
adopts the accelerator position input by the
driver. When the cruise control is switched off,
the actuator motor is activated and moves the
accelerator control to the idle position.
30 .07 14 . 350· 18
The system remains operational alter being
switched off until the ignition is switched off. lf,
alter depressing the brake or switching off the
system, the switch is moved to the position
"Resume" ata vehicle speed above approx.
40 km,h, the vehicle automatically accelerates
with 1 m1s2 to the speed last fixed with the
"Set" position. The speed last fixed is erased
when the ignition is switched off. lf the set
speed is exceeded by depressing the acceler-
ator, e.g. for overtaking, the vehicle automati -
cally returns to the previously set speed when
the accelerator pedal is again released .
lf. when traveling uphill, engine power is not
adequate, the driving speed drops below the set
speed. The set speed is resumed again as soon
as the incline levels off and provided the speed
has not in the meantime dropped below 40 km/h
or the vehicle has not been braked. lf, when
traveling downhill, the engine braking action is
not sufficient, the set speed is exceeded and it
may be necessary to brake the vehicle. lf the
vehicle has not been braked, the set speed is
automatically resumed as soon as the downhill
slope levels off.
~
When driving with the cruise control do not
engage selector lever position "N" of the auto-
matic transmission otherwise the engine will
overrev.
The speed last stored in the control unit is
erased when the ignition is switched off. When
the ignition is switched on again the value "O
km/h" is input to the speed memory. This
ensures that, when starting off again, e.g. after
changing drivers, no unknown speed is stored.
The speed is constantly monitored by the elec-
tronic accelerator control unit. Any change of
speed is registered and analyzed by a computar.

lf the speed of the vehicle is changed with the

cruise control switch. the computar in the
electronic accelerator control unit ensures that
the specified values for the switch positions
"Accelerate/Set" of O. 7 m/s2 or for " Resume" of
1 m/s2 are maintained. When the cruise control
is switched off. the safety circuit in the electronic
accelerator control unit monitors that the elec-
tronic accelerator actuator drops back to the set
value of the accelerator. lf, for example, the
vehicle is decelerated > 1.5 m/s2 with a faulty
stop light switch. the deceleration is registered
by the computar and the electronic accelerator
actuator closes the throttle valve with the
maximum possible speed.

30.0714 . 350/19
G. Electronic accelerator control unit (N4/1)

The electronic accelerator control unit is located

below the instrument panel, above the pedals. lt
contains two printed circuit boards with elec-
tronic components. The housing is an aluminum
alloy with a 35-pin plug connector. The control
unit is linked to the wiring harness by a 35-pin
connector which is fixed in place by a spring clip
(arrow).

Voltage is supplied to the potentiometer for the

electronic accelerator actuator and electronic N4/1

~
accelerator reference potentiometer by the
electronic accelerator control unit when the 1 1
ignition starter switch is in "position 2". In 11111111111111111111111111111111111
P30 - 0059 · 11
addition, the signals input by the components are
processed accordingly. The electronic control
unit is split up functionally into the following
components:

• Position controller with input amplifier (signal

processing part)
• Output stage
• Monitoring device (safety circuit)
• Cruise control device
• ASA signal processing

The electronic accelerator control unit is

configurad in analog technology with the
exception of the cruise control computer.

30.0714 . 350120
 Positlon controller
The input signals to the position controller are
converted, liltered and amplified in the upstream
signal processing parts. Following this. these
signals are appropriately processed in the
position controller and a delined output signal
generated lor the output stage.
Output stage
The output signal ol the position controller is
passed to the output stage where it is amplilied.
In addition, this signal determines the positioning
direction (idle speed direction or full throttle
direction) ol the D.C. motor in the electronic
accelerator actuator. In this case, the D.C.
motor is actuated with a frequency ol 140-160
Hz. 11 the D.C. motor is blocked, a continuous
current is output briefly. lf the blockage persists.
the output stage is shut off by the monitoring
device. The output stage is short circuit proof to
ground.
Cruise control device
The cruise control function is integrated in the
electronic accelerator control unit. As with the
previous electrical cruise control, it is activated
and switched off with the cruise control switch.
lf the cruise control switch is constantly
operated < 40 kmih and the vehicle accelerated
with the accelerator pedal beyond the safety
threshold. the cruise control does not switch on.
The cruise control cannot be activated if the
switch is operated during a brake application.
When the cruise control is set, a corresponding
input signal is supplied to the position controller.
30.071 4. 350í21
As a result, the position ol the throttle valva is
fixed. 11 the driver demands a higher speed by
depressing the accelerator pedal, the cruise
control device is not active. lf the ASR detects
drive slip during the cruise control moda, the
reduction in engine power (lower speed) has
priority over the cruise control mode. Once the
drive slip has been eliminated, the cruise control
resumes the previously stored speed provided
the driver does not demand any other function.
Monitoring device
The monitoring device performs salety
functions. The lollowing functions are checked:
• The operating ranges of the electronic
accelerator relerence potentiometer and
electronic accelerator actuator.
• The cables to the eiectronic accelerator
reference potentiometer and electronic
accelerator actuator for short circuit or
interruption.
• The lunction ol the safety switches in the
electronic accelerator relerence potentio-
meter and electronic accelerator actuator.
• The positioning accuracy of the electronic
accelerator actuator. related to the set
position, which is fixed either by the acceler-
ator pedal (reference potentiometer}, cruise
control or by the ABS/ASR control unit.
• Short circuit of output stage of O.C. motor.
• Battery voltage at electronic accelerator
control unit. Below a battery voltage of 6 V,
the electronic accelerator control unit
switches off, and switches on again when
the voltage rises.
The function of the safety switch is independent
of the electrical 1 electronic control function of
the driving torque control loop. The current
through the safety switches ot electronic
accelerator reference potentiometer and
electronic accelerator actuator is looped through
the control unit. Consequently, in the driving
mode or at idling speed the fue! pump relay
(terminal 15) is energizad. The safety switch in
the electronic accelerator reference potentio-
meter closes when the accelerator is depressed
befare the safety switch in the electronic
accelerator actuator opens.
300714 . 350122
The situation is reversed when the accelerator
pedal is released. Oepending on the position of
the accelerator pedal, the contact in the
electronic accelerator reference potentiometer
or in the electronic accelerator actuator is
closed. To avoid any interruption in the voltage
supply occurring when a rapid adjustment
movement is made to idle speed, a switching
transistor is connected additionally to the output
of the electronic accelerator control unit.
When the safety switch in the electronic
accelerator reference potentiometer opens, this
transistor assumes the voltage supply to the fuel
pump relay for max. 150 ms. In the cruise
control mode, the safety switch in the electronic
accelerator reference potentiometer is open , as
is the safety switch in the electronic accelerator
actuator. The switching transistor (as already
indicated} assumes the task of the safety switch
of the electronic acceler ator reference potentio-
meter to ensure that the fue! pump relay is able
to maintain the voltage supply of the fuel pump
(terminals 30 and 87 jumped by relay contact).
The safety switches including switching
transistor are likewise covered by the monitoring
device.
Pin assignment ot electronic accelerator control
unit
1 Vottage suppty, term1nal 15 unprotected
2 Voltage supply, term1nal 15 unprotected
3 Electron1c accelerator actuator (motor)
4 ElectroniC accelerator actuator (motor)
5 Relerence potent1ometer, grovno
7 Do not create contact!
8 Not ass1gned
9 Reference potent1ometer. voltage supply ( + ¡
10 N ot assrgned
11 Banery grovnd (W10 ) only on Model 126.036/037/044
12 Etectron1c speedometer speed s.gnal
13 Safety sw1tch, reference potent1ometer
14 Stop hght swnch
15 Relerence potenuometer (w1per signat)
16 CrUise control sw1tch (Oecelerate, Set)
17 Not ass1gned
18 Cru1se control sw1tch (Resume¡
19 Do not create contact!
20 Electron1c accelerator actuator (motor)
21 Electron1c acceterator actuator (motor)
22 Battery ground (W10 )
23 Battery ground (W1 0 )
24 Not ass1gned
25 N ot ass1gned
26 Electron1c accelerator actuator. potent1ometer voltage
suppty ( + l
27 N ol ass1gned
28 Electroncc accererator actuator. potenttometer (wiper
srgnal)
29 Electronrc acceterator actuator (safety switCh) 18

30 Fue! pump retay, termrnal 15. contact 9

3 1 To ABSIASR con1r01 uOII (thronte valva aclual value)
32 Crurse control swrlch (A cceferate, Set)
33 Staner lockout and backup hght swrtch, dnve stage " R"
34 From ABSIASR control unrt (throttte valve set value)
35 Crurse control swuch (O ff)

Speed signal
The speed signa! from the electronic speedo-
meter is input to the electronic accelerator
control unit for the cruise control function. lt is
used by the electronic accelerator control unit
only for the cruise controL lf there is no speed
signar, this does not impair acceleration nor the
driving torque control.

30.0714 . 350123
Stop light switch signal
When the brake is applied, the cruise control
device is supplied with a signal change through
the stop light switch . This means that the ground
connection is interrupted. The cruise control
function is immediately canceled. At the position
controller, the input signal of the cruise control
device is cancelad. As a result. the electronic
accelerator actuator is controlled so that the
throttle valve is moved back to the set point by
the accelerator pedal. The position of the
accelerator pedal has priority. lf there is no
ground signal from the brake switch, the cruise
control is switched off. This does not impair
acceleration nor the driving torque control.

Selector lever position signal

When the driving position "R" is engaged by the
selector lever, the position controller is supplied
with an input signal from the starter lockout and
backup light switch. As a result, a characteristic
curve switchover is performed in the position
controller. When reversing, the throttle valve is
opened less rapidly up to approximately half
pedal travel. This achieves enhanced comfort for
reversing. 2) ;¡;-
1 Throttle valve angle
P30 · 0011·13A
2 Accelerator pedal travel

30.0714 . 350í24
ABS/ASR control unlt slgnal
An exchange of information occurs (200 times
per second) between the ABS,ASR control unit
and the electronic accelerator control unit. The
electronic accelerator control unit detects from
the shape of the signar from the ABStASR
control unit whether drive slip exists and what
maximum throttle valve opening is permissible.
Oepending on the slip conditions at the driven
wheels, the throttle valve can also be fully closed
by an appropriate ASR control signal.

This is also possible even if the driver or the

cruise control inputs full throttle. The electronic
accelerator control unit constantly informs the
ABStASR control unit by means of a similar
feedback signal (throttle valve actual value) of
the momentary position of the electronic
accelerator actuator and thus of the throttle
valve. The ABStASR control unit can thus check
during an ASR control cycle whether the elec-
tronic accelerator follows the control commands
of the ASR device. lf a fault exists in the elec-
tronic accelerator range (without cruise control
function) (actuator does not have voltage
supply). the feedback signa! disappears and the
ASR device shifts to fault. The ASR indicator
lamp (A 1e22) lights up.

30.0714 . 350125
H. Electronlc accelerator reference potentlometer (R25)

The electronic accelerator reference potentio-

meter is attached to the intake manifold at the
level of engine cylinder No. 4. lt consists of a
variable electrical resistor (potentiometer) and a
safety switch. The safety switch is designed as a
double-contact switch . Both components are
operated by the potentiometer shaft to which the
accelerator control lever is attached. The fulcrum
lever is mounted on the pin next to the potentio-
meter shaft. In ignition starter switch "position 2"
or when the engine is running, the potentiometer
is activated with a constant voltage by the elec-
tronic accelerator control unit. The potentiometer
position is altered by the adjusting movement at
R25 Reference potentJometer
the accelerator pedal through the accelerator
control linkage, fulcrum and accelerator control 13 Accererator control rever
levers. The potentiometer feeds back a defined 16 Fulcrum rever

variable voltage to the electronic accelerator

control unit as a function of the accelerator pedal
position. This signa! is further processed in the
position controller of tihe electronic accelerator
control unit. lf the accelerator pedal is not
depressed (idle position), the safety switch of the
electronic accelerator reference potentiometer is
open. Voltage is supplied to the input side of the
safety switch when the ignition is switched on or
when the engine is running. The switch point of
the safety switch is 4-6° adjustment angle above
the idle stop.

1 Adjustment shaft
2 Reference potentiometer relay lever
3 Housmg
4 PotenliOmeter
5 Safety switch
6 Pin for fulcrum lever

30.0 714 - 350/26

lf the safety switch is closed. terminal 15 at the
fuel pump relay is energizad. lf the accelerator
pedal is moved from full throttle toward idle
speed, the safety switch opens at approx . 6-4°
before idle speed stop. In the idle position. the
closed safety switch in the electronic accelerator
actuator (M16/ 1) adopts this voltage supply. The
maximum current flow must not exceed 1 A. The
switch is not short circuit proof to ground.

--·- - -· - - --
P3o-ooe•
_ _ __ __ __
-•3
___.J

l. Electronlc accelerator actuator (M 16/1)

The electronic accelerator actuator is attached to

the tace end of engine cylinder 1 by a mounting
bracket. lt consists of a D.C. motor with multi-
stage gear to which the output lever for the
accelerator control linkage is attached. In
addition, the wiper for the potentiometer and the
safety switch are coupled to the output shaft.
Here, too, the safety switch is designad as a
double-contact switch. When the ignition starter
switch is in "position 2" or when the engine is
running, the potentiometer is controlled with a
constant voltage from the electronic accelerator
control unit. The output signa! of the potentio-
meter to the electronic accelerator control unit
acts as a position feedback of the momentary M 1611 Electronic accelerator actuator
throttle valve position. This signal is further
21 Connecting rod
processed in the position c ontroller of the elec- 24 Output lever
tronic accelerator control unit. lf deviating signal
tones are received, the electronic accelerator
control unit alters the position of the throttle
valve.

30.0 714 . 35012 7

The adjustment range of the electronic accel-
erator actuator is 88-92°. This enables the
throttle valve to be moved by the accelerator
control linkage from idle speed through to full
throttle stop and vice versa.

The D.C. motor features a high positioning rate.

The total adjustment angle is covered in approx.
120 ms. At the same time, this ensures a high
positioning accuracy.

2 3 4

P30·00&&·55

, Output shatt 4 Armature

2 Reducllon gear 5 Potenttometer
3 Houstng 6 Safety swttch

30.0714 - 350/28
 The power consumption at maximum positioning
rate is 8 A. lf the accelerator pedal is not
depressed, the safety switch is closed. lt is
energizad when the ignition starter switch is in
"position 2" or when the engine is running, and
at the same time terminal 15 at the fuel pump
relay is also energizad. When the accelerator
M 16/1
pedal is depressed, the safety switch opens. The
switching point is approx. 8-12° above the idle
position. The safety switch of the electronic
speedometer reference potentiometer (R25) now
P30·0067·13
assumes the voltage supply for the fuel pump
relay. To avoid any switching lag when the
accelerator pedal is moved rapidly, a switching
transistor assumes the voltage supply for the
fuel pump relay for a defined period (see moni·
toring device. electronic accelerator control unit).
The maximum current flow must not exceed 1 A.
The switch is not short circuit- proof to ground.

30.0714 . 350/29
J. Accelerator control

~~~,., .~
= - t<a'':::¡n• : . :: ~
\

: r~ , .
~
P J0-0081-$7

M echanical parts 19 Connecting red

1 Accetera1or pedal 20 lclle 1ravel rocl (redundancy rocl)
3 Accelerator pedal lever 21 Connectlng rOd
4 Long1tud1na1control shaft ad¡usllng screw 22 Roturn spnng
S Long1tud1nal control shaft 23 Throttle valve relay lever
8 Connecllng rod 24 Output lever
9 Return spnng 25 LOCk1ng element
10 Relay lever 26 Connecllng rod
11 Connecllng rod 30 Con trol pressure cable
12 Reference potent1ometer relay lever
13 Fulcrum lever Elec tric aVEiectroni c parts
14 Lock1ng element M 16/ 1 Electron1c accelerator actuator
15 Roller $3012 KICkdown SWitCh
16 A ccelerator control levar
17 Rollcr

30.0714 . 350 '30

 The position ot the accelerator pedal is input to
the electronic accelerator reterence potentio-
meter through the accelerator pedal, accelerator
pedal lever, accelerator control linkage, fulcrum
and control levers. The throttle valve is then
always adjusted by means ot the electrical 1
electronic components - electronic accelerator
reference potentiometer . electronic accelerator
control unit and actuator .

The throttle valve is operated by the output lever

of the electronic accelerator control unit and
actuator by means of the accelerator control
linkage and relay lever. The adjustment travel
ranges from idle speed stop to tull throttle stop.
lf a fault occurs in the electrical 1 electronic
components, the throttle valve can be adjusted
by means of the idle travel rod (redundancy rod).
This enables the vehicle to be operated at
approx. 213 engine output.

Block dlagram accelerator control

,---------,
Electron1c : Electronic : Electronic
1 1
Accelerator
accelerator ____..1 accelerator 1• ...., accelerator - - - , . control linkage
reference : control unit : actuator
1 1
potentiometer 1 1
'-------- --~
1

+
Accelerator
pedal
... Accelerator pedal
lever
Fulcrum and
control lever
- - .... ldle travel roo
(redundancy
Relay lever

rod)

1 1
1

•
1

•
1

Accelerator
+1
1 Throttle valve
Accelerator
control hnkage --------..J control l1nkage

electric cables mechan1ca1 connect1ons

30.07 14 . 350131
ldle travel rod (redundancy rod)
The idle travel rod (20) is a spring-tensioned
accelerator control rod. lt connects the acceler-
ator control lever at the electronic accelerator
reference potentiometer with the relay levar on
the throttle valve side. When the throtlle valve is
adjusted electrically 1 electronically, the idle
travel rod is also moved. lt performs the
tollowing tasks:

• lf excessive driving torque exists at the

driven wheels, the idle travel rod enables the
throttle valve to be moved against the
accelerator pedal position. This adjustment
movement is assisted by the return springs
on the throttle valve relay lever and on the
throttle valva. A tixed accelerator control
linkage in place of the idle travel rod is
impractical as this would not permit an ASR
control mode.

• In the cruise control mode, the control

pressure cable ot the automatic transmission
is operated from the electronic accelerator
actuator. This enables the transmission to
shift down at high engine load.

• lt there is any fault or failure in the electrical

l electronic components. the idle travel rod
performs the adjustment ot the throttle valve.
This ensures that the vehicle can still be
driven and permits approx. 2/3 ot available
engine output to be utilizad. The emergency
driving facility is activated. The driver can
detect this from the higher accelerator pedal
torces and by the ASR indicator lamp lighting
u p.

30.0714 . 350132
K. Matchlng engine - electronlc accelerator reference potentiometer -
electronlc accelerator actuator - electronlc accelerator control unit

Engine Model Electron ic accelerator Electronic accelerator Electronic accelerator

reference potentiometer actuator control unit
Part No. Part No. Part No.

116, 117 126 006 548 85 17 003 545 50 32 126 545 00 32 up to 10!88
126 545 07 32 11188 - 07189
126 545 08 32 as of 08i89

30.0714 . 350t33
30-355 lnstructions for test and repalr work

• The plug connections of reference

potentiometer and actuator are water-tight.
They may be opened only for the test
work speclfled in the test routine.

• Cleaning agents or contact spray must not

be used on the plug connections of
reference potentiom eter and actuator.

• The electronic accelerator control unit is not

fuse- protected.

• Do not create a contact between connector

pins 7 and 19 of the electronic accelerator
control unit.

• Before adjusting or checking the accelerator

control with the ignition switched on,
depress accelerator pedal as far as full
throttle stop (approx . 5 seconds) to ensure
that the throt11e valve setpoint signal from
the ABS/ASR control unit enables the full
throttle position.

• Ground cables from the ABS/ASR control

unit and from the electronic accelerator
control unit are connected dlrectly to the
battery ground (W1 0).

• When performing welding work with an

electrical welding torch, pay attention to the
tollowing points:
- Disconnect negativa terminal of battery.
- Connect ground terminal of welding
equipment dlrectly to the part to be
welded.

30.0714 - 35511
 30-360 ABS/ASR and eleetronle aeeelerator input test

004

032
P30-0018 - 55A

Connection diagram of function generator and multimeter at contact box

01 Vehicle cable harness (ABSIASR control unit)
02 Test cable 645 589 02 63 oo
003 Mul~meter
004 Contact box 124 589 00 21 00
032 Function generator

30.0 71 4 . 360/ 1
Explanation of symbols
Multimeter ~
~- Function generator, square-wave
Contact box signal
Function generator ~ Multimeter, D.C. voltage mode

Test stepl Tester/ Operation/ Specification Possible causeíRemedy

Test scope Test connection Requirement

1 - lgnition: OFF - -
Detach
Connect
ABStASR
testers
control unit
connector

N30/ 1 Frequency Actuator must Test cables between control

2
Throttle 0 generator: only move unit (N30/ 1 and N4/ 1) for
20 -=-(ID!- 16 Connect approx. 50% open/short circuit.
valva signal
f=200 Hz from idle
fromi to
U= 10 V lf specification not reached,
electronic
perform ABSIASR test routine
accelerator
(42-720).
control unit
N30i 1 lgnition: On 4-7 V lf specification not reached.
~ Full throttle test electronic accelerator
20 -=<Yr- 13 Full throttle
position
(30-365).

1-

Special tools

124 589 00 21 00 201 589 00 99 00 645 589 00 63 00

Commerclal tools
Multimeter e.g. Sun, DMM-5
Function generator e.g. Sun

30 .0714 . 36012
30-365 Testing electronlc accelerator

PJO· 00118 ·57

M16/1 ElectroniC accelerator actuator A25 Accelerator pedal pos1tion sensor

N4/ 1 Electron'c accelera1or control unit
N16/4 Fuel pump relay with kickdown cut-out 20 ldle travel red (redundancy roo)

30.0 7 14 . 36511
 516/1
¡J
59/1 A1p8 540
P30-0099-57

A1p8 Electron1c s¡peedometer 516/ 1 Starter lock-out/backup lamp sw1tch

5911 Stop lamp sw1tch (4MATICIASD¡ 540 Cruise control switCh
v Deceleratelset
B Acceleratel set
SP Resume
A Off

Special tools

{;
-- -- - ~-:: -
- - - --
:"'
1
~~

124 589 00 21 00 645 589 00 63 00 645 589 01 63 00 645 589 02 63 00 201 589 00 99 00

Commerclal tool
Multimeter e.g. Sun, DMM-5

30.0714 - 36512
Explanatlon of symbols

Multimeter -=@!- Multimeter, resistance mode

Contact box -=<Xr- Multimeter, D.C. voltage mode
Battery
-< Contact

-
-<->-
Plug
Jumper
_1_ Ground

...==:J

~·
.....=:::::J

The stud {arrow) on the test cable

645 589 02 63 00 must be sawn off.

30.07 14 . 36513
Pin assignment on electronic accelerator N4/1
control unit
, Voltage supply, termtnal 15 unprotected
2 VoJtage supply, termmal 15 unprotected
3 Electrontc accelerator actuator (motor)
4 Electronoe accelerator actuator (motor)
5 Reterence potenbometer (ground)
6 Electronoc accelerator actuator potentiOmeter (ground)
7 Do not create contact!
8 Eng1ne 116, 117. 119: not ass1gned
Engtne 103. 104: odie speed swttCh1ng s1gnaltO
CIS-E control un1t
9 Refercnce potentlometer, voltage supply ( + )
10 Not ass1gned
1\ Battery ground {W 1Ol
12 Electromc speedometer speed sognal
13 Salety sw1tch. reterence potenttometer
14 Stoo ltgtlt sw1tch
15 Reterence potent1ometer (woper sognal)
16 Cru1se con trol swotch (Decelerate, Set)
17 Not ass1gned
18 Crutse control sw1tch (Resume)
19 Do not create contact!
20 Electron1c accelerator actuator (motor)
21 Electromc accelerator actuator (motor)
22 Battery ground (W 10)
23 Battery ground (W10)
24 Not ass•gned
25 Not assogned
26 Electrontc accelerator actuator. potentiometer
(voltage supplyl
18
27 Not assogned
28 Etectronte acceterator actuator, potenttometer (woper
sognal)
29 Electronoc accelerator actuator (safery swrtch)
30 Fuel pump rclay. termmal 15. contact 9 or engme
systems control u mt. term1nal 1 su. contact 1o
31 To ABSIASR control umt (throttle vatve actual value)
32 CrUtse control swotch (Accelerate, Set)
33 Starter lockout and backup toght swttch, dnvtng stage "R"
34 From ABSíASR control un1t (throttle valve set vaJue)
35 Cruose control swotch (Off)

30 .0714 • 365!4
Connection diagram with multlmeter for electronic:: accelerator test routlne

N4/1

02.~
09~ 004
P30 - 001~-53A

02 Test cable 645 589 02 63 00 003 Multimeter

03 Test cable 645 589 03 63 00 004 Contact box 124 589 00 21 00
09 Vehícle wiring harness (electron1c accelerator 048 Test cable 645 589 00 63 00
control unit) N4/ l Electron1c accelerator control unlt

30.0714 . 365/5
Connection dlagram with 2 multlmeters for electronic accelerator test routine

N4/1

03~ t

09
004 PJ0-0016 -57 A

02 Test cable 645 589 02 63 00 003 MultJmeter

03 Test cable 645 589 03 63 00 004 Contact box 124 589 00 21 00
09 Veh1c1e w1nng harness (electron'c accelerator 048 Test cable 645 589 00 63 00
control un1t) N411 Electron'c accelerator control unlt

Test requirement
Accelerator control linkage correctly set and
checked for ease of movement {30-305).
Battery voltage at least 11 Volts.

30.0714 . 365/6
 Test Test scope Testert Operationt Specifi- Possible causetRemedy
step Test connection Requirement cation

1.0 Ground ~ E3 - 11-14 V Battery ground

point at 22 ~ + connection (G1) loose,
electronic open circuit
accelerator
control unit r·,¡¡¡;;;;;;j E3 11-14 V Battery ground
(N4i 1) 23 ~ + connection (G1) loose,
open circuit

2.0 Power ~: lgnition: ON 11 - 14 V Wiring connection

supply of 22 -=&- 1 (N411) - (F1)
electronic Fuse No. 6
accelerator
control unit
(N4í 1) __
G~
... .. ~·
11 -14 V Wiring connection
(N4/ 1) - (F1)
22 ..::.&- 2 Fuse No. 6

3.0 Power .=:.:::.:.; lgnition: ON 6.8-7,6 V Check open circuit, see

supply of 5 ..::.&- 9 Note voltage
reading lnitial
test step 7.0
Reference potentiometer
reference
potentio- value (R25)
meter (R25) "A" for Control unít (N4/ 1)
table of
"Refer-
enee
potentio
meter
(R25)
voltage
levels"

3.1 Sígnal of ~ lgnition: ON Voltage Test wiring for open

reference 5 -=&- 15 Id le posí tion levels, circuit.íshort-circuit. see test
potentio- .. a" see table step 7.0 .
meter (R25) Opera te "Retar- lf specification not reached.
accelerator ene e see test step 3.3
Full throttle potentio-
position "b" meter
Kickdown "e" (R25)
voltage
levels"
column
a, b, e

30.0714 . 36517
Test Test scope Tester/ Operationl Specifi· Possible cause1Remedy
step Test connection Requirement cation

-
mg:.::::.
3.2 Reference lgnition: ON <1V Test wiring for open
- -
potentio· 22 ~ 13 ldle speed c ~rcuit
short-circuit, see test
meter (R25) pos1t10n step 7.0
switch point
safety Slowly deflect 11-14 V -
SWitCh accelerator
pedal until sh1ft
po1 nt occurs

Note voltage
reading at shift Voltage
::¡¡g::;; ¡
point levels, Reference potentiometer
5 ~ 15 see tabla faulty
"Refer·
Second multimeter enee
to contact box poten ti o-
meter
(R25)
voltage
levels"
column
lldtl

- ·
3.3 Reference -:::;;··-··· lgnition: OFF Voltage Reference potentiometer
potentlo· Detach must rise faulty
meter (R25) 1 9 electron1c to >9 V
-<--->-
accelerator
5 -<->- 22 control unit
connector.
5 ~ 15 lgn ition: ON
Deflect
accelerator
pedal as lar as
full throttle
stop

4.0 Actuator 1¡¡¡¡¡:!'" lgnition: ON 6.8-7.6 V Test wiring for open

(M16i 1) 6 ~ 26 Note voltage lnitial circuit/short-circuit, see test
power reading value step 8.0.
supply "8" for Electronic accelerator
potentio· table control unit faulty
meter "Actuator
(M16 1)
voltage
levels"

30 07 14 . 365t8
- ··-
Test Test scope Tester/ Operation/ Specifi· Possible cause/Remedy
step Test connection Requirement cation

4.1 Actuator "~'~::':: 1

1 lgnition: ON Voltage Test wiring for open
(M16/ 1) 6 --=&- 28 ldle position levels. circuit!short-circuit. see test
potentio- .. e .. see table step 8.0 .
meter signal Depress "Actuator lf specification is not
accelerator (M16/ 1) reached, see test step 4.4
Full throttle voltage
position "f" levels"
column
"e, f"

- -
4.2 Actuator ~ lgnition: ON 11-14 V Test wiring for open
(M16/ 1) 22 --=&- 29 ldle position circuit/short-circuit, see test
switch point step 8.0
safety Slowly deflect
switch accelerator <1V
pedal until
switch point
occurs

1~ Note voltage Voltage Actuator taulty

6 ~ 28 reading at levels,
switch point see table
"Actuator
Second multimeter
(M16í 1)
to contact box voltage
levels"
column
"g"

4.3 Actuator N4/1 lgnition: ON Voltage Test wiri•ng for open circuit,
(M16/ 1) HL;::::t Press acceler- must rise see test step 4.5.
D.C. 21 ~ 3 ator control ( + value) lf specifications are not
linkage, reached, see test step 4.4
connecting rod
(21, engine
116, 11 7 ill.
page 119)
toward idle
speed position

30.0714 . 365i9
Test Test scope Tester/ Operation/ Specifi- Possible causetRemedy
step Test connection Requirement cation

4.4 Actuator ill lgnition: OFF Voltage Actuator faulty

(M16 1)
, -<--->-- 26
Detach
electronic
must
drop to
accelerator <7V
6 -<~->- 22 control unit
connector.
6 ~ 28 lgni tion: O N
Deflect
accelerator
pedal as lar as
full throttle
stop

4.5 Actuator ~
. lgnition: OFF < 10 Q Actuator taulty
(M161) 21 ..:@!-- 3 Detach Electronic accelerator
electronic control unit faulty
accelerator
control unit
connector.
lgnition: ON
Deflect
accelerator
pedal

5.0 Backup light lili2J lgnition: ON <1V

switch 22 ~ 33 Sel actor levar
(81611) position "P"

Selector lever 11-14 V Test wiring for open

position "R" circuit/short-circuit

Part throttle Electronic accelerator

and shift control unit faulty
selector lever
from "P" lo
"R" and "R"
to "P"

6.0 Fuel pump ~ Start engine 11-14 V Test wiring for open
relay 22 ~ 30 ldle speed circuiUshort-circuit
(N16,4)
Detach test Engine ~
cable must cut Contact 30 is not short
645 589 02 63 out circuit proof to ground.
00 upstream ot Electronic accelerator
Y connector control unit faulty .
Test wiring for correct
assignment.

30.0714 . 365110
Test Test scope Tester! Operation/ Specifi- Possible cause/Remedy
step Test connection Requirement cation

7.0 Test wiring R25x1 lgnition: OFF > 500 kQ at < 500 kQ renew wiring
between - ( )- Detach harness
reference 1 -=@!- 2 connector at
potentio- 1 -=@!- 3 electronic
meter 1 ~ 6 accelera tor
connector 1 ~ 7 control unit.
(R25x1) and 2 -=@!- 3 Separate plug
control unit 2 -=@!- 6 connections at
connector 2 -=@!- 7 reference
{N4/ 1) 3 ..:.@!· 6 potentiometer
3 -=@!- 7 and actuator
6 -=@!- 7

8.0 Test wiring M 16/1x lgnition: OFF >500 kQ at < 500 kQ renew wiring
between -< )- Detach harness

~
actuator 1 2 connector at
+
connector 1 3 electronic
{M16i 1) and 1 -=@)-!- 4 accelera tor
control unit 1 ~ 5 control unit.
connector 1 -=@)-!- 6 Separata plug
{N4/ 1) 1 ~ 7 connections at
2 -=@!- 3 reference
2 -=@)-!- 4 potentiometer
2 -=@)-!- 5 and actuator
2 ~ 6
2 ~ 7
3 ~ 4
3 ~ 5
3 ..:.@!-- 6
3 -=-@!- 7
4 -=@)-!- 5
4 ~ 6
4 -=-@.!.. >

7
5 .
-=@)-!- 6
5 ~ 7
6 -=@)-!- 7

30.07 14 . 36511 1
Voltage levels electronic accelerator reference potentlometer (R25)
''A" '' a" "b" "e'· "d~

Potentiometer voltage Voltage in idle Voltage in full Voltage at Voltage at safety switch
supply speed position throttle posítion kickdown switch poínt
V V V V V

6.8 0.50-0.56 5.86-6.22 5.86-6.37 0.86-1.13

6.9 0.51-0.57 5.95-6.32 5.95-6.46 0.87-1.14
7.0 0.52-0.58 6.04-6.41 6.04-6.55 0.89-1 .16
7.1 0.53-0.58 6.13-6.50 6.13-6.64 0.90-1.17
7.2 0.53-0.59 6.21-6.59 6.21-6.74 0.91-1.19
7.3 0.54-0.60 6.30-6.68 6.30-6.83 0.92-1.21
7.4 0.55-0.61 6.39-6.77 6.37-6.92 0.94-1.22
7.5 0.56-0.62 6.48-6.86 6.48-7.01 0.95-1 .24
7.6 0.56-0.63 6.56-6.95 6.56-7.11 0.96-1 .26

Voltage levels electronic accelerator actuator (M16/1)

"8" "' e" "f" "g"
Potentíometer voltage Voltage in Voltage in full throttle Voltage at safety switch
supply idle posítion position switch point
V V V V

6.8 6.05-6.19 0.61-0.75 5.35-5.69

6.9 6.14-6.28 0.62-0.76 5.43-5.76
7. 0 6.23-6.37 0.63-0.77 5.51-5.89
7.1 6.32-0.46 0.64-0.78 5.59-5.93
7.2 6.4 1-6.55 0.65-0.79 5.67-6.01
7.3 6.50-6.64 0.66-0.80 5.75-6.10
7.4 6.59-6.73 0.67-0.81 5.82-6.18
7.5 6.68-6.83 0.68-0.83 5.90-6.26
7.6 6.76-6.92 0.69-0.84 5.98-6.35

30.071 4 . 365/ 12
 Wlrlng diagram

N 30M
ll
l ~ ~:
11 q'IS
sw
rt
Wl

X X X
89 89/3
89/1 r 12
rt~ lt~ ~-L .t :_f~·~~S
1

!l¡·~~.u fí5 40
~~· ~~\1Jf~~~
gn S:W
'?;
SW
q75 q75
!f1 rt
(l75
bt
X
0,75 (!75

sw rt
0,75
,._'JI
gt
(!75 (!75 0,75
J1 gt!f'br
75

r~J
OJS \S

~
[I1S 0,75 0,75
9f rs bl 'JI ge
sw

e f g
Wt Wt

T
D,75
T
0,75
br br

r - l {/
~ :
r:-:¡
[ i- 1 J::C:.' ,. . -1- 1

~ ~ lL:::v't-j:t1'
~ ~~ ;>v
IS
1
~~ 6S 1
L._ ._ _ :J L .... SP=.J ::::.J
L':: ~ l!_
M16 /1 F1 540 59/1 Y4 R25
f' 30• OOtJ· st

Fl Fuse and relay box X89/ 1 Connector, electronoc accelerator control

G! Banery uniVASR (2·pole)
M16xl Connector, cruose control actuator X89/ 2 Connector, etectronoc accelerator control
M16/l Electromc accelerator actuator umVengone hamess (2·pole)
N4/1 Electronic accelerator control umt X89/3 Connector, electronoc accelerator control
N30/1 ABS/ASR control unot vnoVautomatoc transmosston (2·pole)
R25 Accelerator pedal posotoon sensor Y4 Sw•tchover valve (transmtsston mode)
R25x1 Connector, accelerator pedal posotoon sensor z Connector sleeve (SOider 1o•nt on harness)
$9/1 Stop lamp swotch (4MA TIC/ASO)
$ 40 Cruise control swotch e Fuel pump relay, contact 9, termonal 15
V Deceleratetset f Economy mode swotch, contact 2
B Acceleratetset g Starter lockout and backup llght swotch, contact 4
SP Resume
A Off
S40xt Connector. cruose control SWitCh
WlO Ground, battery
X21 /2 Termonal block. stop lamp swotchlelectronoc
speedometer

30.0714 . 365113
Arrangement
The electronic acceler ator control unit (N4i 1) is
located below the instrument panel, above the
pedals.

The cruise control actuator connector (M 16x 1) is

located ahead ot the expansion tank (cover
removed).

The electronic accelerator reference potentio-

meter connector (R25x 1) is located next to the
expansion tank (cover removed).

30.0714 • 365114
 30-370 Testlng crulse control (vehlcles wlth ASA)

r-------------------- -----------------------~

P30 - 0098 - 57

M16/ 1 Electron1c accelerator actuator R25 Accelerator pedal poSition sensor

N4/ 1 Electronic acceterator control uM
N16f4 Fuel pump relay w1th k1ckdown cut-out 20 ldle travel roo (redundancy rod)

30.07 14 . 3 70/1
 516/1
¡J
59/1 A1p8
~
540
P30- 0099- 57

A1p8 Electronoc speedometer S1611 Starter lockovt andl backvp light swotch
S9/ 1 Electron•c accelerator control unit S40 Cru1se control swotch

Special tools

124 589 00 21 00 645 589 00 63 00

/
645 589 01 63 00 645 589 02 63 00 201 589 00 99 00

Commercial tools
Multimeter e.g. Sun, DMM-5
Function generator e.g. Sun, DTR-8416

30 .0714 . 37 012
Explanation of symbols

1- :: : ol
l•...:..!-!..!-J Multimeter -=@r-
Multimeter. resistance mode
1,, ,, ;·;;; 1
~ Contact box -=<Yr-
Multimeter, D.C. voltage mode
Function generator ~ Function generator, square-wave
Battery signa!
Contact
Connector
-<--->-- Jumper
-.L. Ground

c.. .. .-....... ..............,. .... .

~-

The stud (arrow) on the test cable

645 589 02 63 00 must be sawn off.

30.0 714 . 37013

Pin assignment on electronic accelerator
control unit
1 Voltage supply, term onal 15 unprotected
2 Voltage supply, termmal 15 unprotected
3 Etectronoc accelerator actuator (motor) N4 / 1
4 Etectron•c acceterator actuator (motor)
5 Aeference potentiometer (ground)
6 Electronic accelerator actuator potentoometer (ground)
7 Do not create contact!
8 Engone 116, 117. 11 9: not assigned
Engone 103. 104: odie speed swotch ong sognal to CtS-E
control umt
9 Aeterence potenuometer, voltage supply ( +)
10 Not asstgned
11 Battery ground (WlO)
12 Electron oc speedometer speed sognal
13 Salety swotch, reference potentoometer
14 Stop hght switch
15 Aeference potent1ometer (woper sognal)
16 Cruose control switch (Decelerate, Set)
17 Not ass1gned
18 Cruose control swotch (Resume)
19 Do not create contact1
20 Electron•c accelerator actuator (motor)
21 Elec tronoc accelerator actuator (motor)
22 Battery ground (W10)
23 Battery ground (W10)
24 Not assogned
25 Not ass1gned
26 Electronoc accelerator actuator. potentiometer
(vottage supply)
27 Not assogned
28 Etectronic accelerator actuator. potent•ometer
(woper sognal)
29 Electron •c accererator actua(or (safety sw•tchJ
30 Fuel pump relay, term•nal 15, contact 9 or eng1ne 18
systems control unot, terminal 15u, contact 10
31 Te ABSJASR control un1t (thronle valve actual vatue)
32 Cru1se control sw1tch (Accelerate. Set)
33 Staner lockout and backup fight switch, dnvong stage "R"
34 From ABS/ASR control un.t (throttle valve set value)
35 Cru1se control swotch (OH)

30.0714 - 370i4
 Connection dlagram wlth multlmeter for crulse control test routlne

N4/1

03 ~ ).

02 ~
09~
P30-0019- 53 A
'-- - - -- - - - - - - - - -- - --- ---- --- - -------- - - - --'
02 Test cable 645 589 02 63 00 004 Contact box 124 589 00 21 00
03 Test cable 645 589 01 63 00 003 Multimeter
09 Veh1cle cable harness (electron'c accelerator
control un1t) N4/1 Electronic accelerator control un1t
048 Test cable 645 589 00 63 00

Connection diagram with function generator for cruise control test routlne

N411

03 ~ ~

02 ~
09 ~ 004
P30 -0020-53A

02 Test cable 645 589 02 63 00 004 Contact oox 124 589 00 21 00

03 Test cable 645 589 01 63 00 003 Multimeter
09 Vehicle cable ham ess (electron'c accelerator
control umt) N411 Electronic accelerator control unit
048 Test cable 645 589 00 63 00

30.0714 . 37015
Test requlrement
Accelerator control adjusted and checked for ease of movement.
Battery voltage at least 11 Volts.

Test Test scope Testen Operation/ Specifi- Possible cause1Remedy

step Test connection Requirement cation

1.0 Cruise N4/1 lgnition: ON <1V Test wiring for open1short

control g¡ ¡~:; ::: Sw1tch not circuit.
SWitCh 22 -=®!.. 16 operated Cruise control switch (S40)
(S40) faulty
Decelerate 11-14 V
position

N4/1 Switch not <1V

0 operated
22 -=@!- 18
Resume 11-14 V
position

N4/1 Switch not <1 V

¡g:¡::::: operated
22 -=@!- 32
Accelerate 11-14 V
position

N4/1 Switch not 11-14 V

gg¡::;:: operated
--
22 -=®!.. 35
Off position <1V

2.0 Stop light N4/1 lgnit1on: ON < 10 Q Test wiring for open short
switch ~ Brake pedal circuit
(S9. 1) 22 .:.@!- 14 not operated Stop light switch faulty

Brake pedal >500 kQ

operated

3.0 Speed N4/1 lgnition: ON >1V Test wiring for open;short

signal ~ Driv e vehicle CirCUit
22 -=@!- 12 onto brake Electromc speedometer
dynamometer faulty
or onto
performance
dynamometer
( > 20 km/h)

4.0 Distance- N411 lgnition: ON 11-14 V Test wiring for opentshort

related 1~ circuit
~

pulse 11 -=®!.. 1 Test wiring for correct

number assignment

30.0714 . 370 '6

 Test Test scope Tester/ Operationi Specifi- Possible cause,Remedy
step Test connect10n Requirement cation

5.0 Actuator N4/1 Withdraw Actuator Electronic accelerator

function of ~ instrument moves control unit (N4~ 1)
cruise 22 ~ 12 cluster (A 1). toward
control detach fullload
connector "1"
Connect
frequency
generator.
Set f > 150 Hz
U=SV
lgnition: ON
Accelerate
position

Decelerate Actuator
position moves
toward
id le
speed

Off position Actuator

must
move
into idle
speed
position

Resume Actuator
position must
move
into
specified
position

Operate brake Actuator

pedal must
move
into idle
position

30.07 14 . 37017
47-010 Function of tuel tank with steadying bowl

~\.
\

P47-00 21-1J

P47-0022 -53

67 Steady1ng bowl 70 Return line

6711 Separatlng chamber 71 Riser line

The purpose of the steadying bowl (67) is to The vapor bubbles contained in the fuel flowing
ensure a constant fue! supply for the engine back are separated in the separating chamber
when the fuel level is low and during prolongad (67/ 1) and led up the way along the riser líne
cornering. (71 ). This avoids any splashing noises.

When the fuel pump is running, the fue! ftows at Standard implementation (vapor bubble
high speed out of the return nozzle (70a) into separation)
the steadying bowl. As a result, it also draws Model 107 = 05187, eH. Vehicle ldent End No.
the fuel around the re tu rn nozzle along with it A 069 655
into the steadying bowl. The return nozzle is Model 126 = 03187, eff. Vehicle ldent End No.
located on the underside of the steadying bowl. A 327 880.
The fuel leve! (h) is retained in the steadying
bowl even if the fuel leve! in the tank drops
below the height (h).

47 0714 . 010/1
47-020 Function of fuel gauge sendlng unit
1 W1per contact
2 Float
3 Contact plate
As the fuel level drops, the variable resistance
is increased by the float (2) as it moves down,
which causes the current to drop and the
needle in the fuel gauge drops back.
11 the fu el level drops to the reserve quantity,
the reserve warning contact (5) closes and
switches ground to the reserve warning lamp
which causes it to light up when the engine is
running.
47.07 14 . 020/ 1
P•U-0040- $5
4 Guide and contact rod
5 ResetVe fuel warmng contact
Note
The reserve warning lamp illuminates with a
weak light as a check function , and with a
stronger light to indicate reserve quantity.
Check immersion tube sending unit (54-256)
or fuel gauge (54-257).
 47-030 Functlon of fuel tank ventlng

A. Filler Cap Model 107, 126

~====~2
~~¡p=~~-3
~~~~~-l!-- 4
5

P47·0041·S3

1 Filler cap 4 Compression spnng

2 Se al 5 Filler neck
3 Lockmg clamp

An pressure of up to 50 mbar may occur in the Note

fuel tank in a system which is operating
properly. lf the passage in the vent line from the
fuel tank is restricted as a result of crimping or
improper routing, the fuel evaporation gases
may escape through the filler cap at an
pressure of 100-300 mbar.
The filler cap has been fitted with a ptastic seal
as a phased-in modification to facilitate oper-
ation. The locking bar (3) slides on this ring with
reduced friction and engages in the two end
positions.

47.0714 . 030/1
B. Model107

Function diagram of fuel tank venting

- - - 55
---~- 50

52 51

53

t~====:::....
u52/1
m

P 4 7 -0035- 57

A separata fuel expansion tank (55) is located Note

above the fuel tank which is connected by five Function of fuel evaporation control system
lines (64} to the fuel tank. Depending on the (47-200}.
tuel level and temperatura in the fuel tank. Checking fuel evaporation control system
these lines act as overflow, discharge or vent (47-300).
lines.
The vent line (64i 1) runs from the fuel
expansion tank (55) through the rear flow to the
vent valve (51). Air is admitted to, and released
from the fuel tank through the vent cap (52/ 1) of
the charcoal canister (52).

47.0714 . 030i2
C. Models 126

Functlon ot tuel tank venting

The ventilation system consists ot a central pipe

(54) with interrupter vessels (54f1). The inter-
rupter vessels (5411) preven! fuel escaping
along the vent line (64). The vent line (64) runs
from the central pipe to the vent valve (51).
Air is admitted to, and released from the fuel
tank (50) through the charcoal canister (52) and
the boot (52/ 1).

47.0714 . 03013
47-100 Removing and installing fuel tank

Preceding work:
MOdel107: Removing fuel expans1on tank (47-110).

84

~50 / 3
~/2
S~

P4 7 - 0043-59

Model 107
 tWe2
@62/1

@60/1
60 84

06s

74

., \~~0/3
~ 5~1
., 50/2

Model 126

~ . ...... ......... . .......... . . . .. . Observe safety instructions. Risk of accident!

Battery ground cable . . . . . . . . . . . . . . . . . . . .. disconnect. connect.
Filler cap (62) .... ... .. . . ........... .. . . remove. clase. Check seal (62 '1). renew if
necessary.
Fuel tank (50) drain, pump out fuel completely.
Capac•ty Model 107 approx. 85 liters.
Capac1ty Model 126 approx. 90 liters.
Cup seal (60 1) release. push in.
Trunk fuel tank partition wall remove and install (68-0700).
Connector at fuel gauge sending unit (84) detach. plug in.
 Feed line (69), return line (70)
4 nuts (50/3) or bolts (5013)
Fuer strainer (68)
Fuel tank (50) . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine
.... ... . ...... disconnect, connect.
Model126
additionally detach vent valve (51). Use
shortened open-end wrench for return line.
lnstallation
Model 107 feed line (69). 28 Nm.
Model 126 ensure cup seals (71 , 72) are
correctly fitted. Renew seal (7011).
Feed line (69) . 28 Nm.
Return line (70), 35 Nm.
unscrew, screw on. 21 Nm. Pay attention to
washers (5012).
remove and instan. if necessary, 39 Nm.
Model 107
Screw in M 18 x 1.5 bolt with locking nut in
place of screw connection. Tighten locking nut
and unscrew fuel strainer, clean. Renew sea!
(68í1).
remove.
lnstallation
Stick on packings (71, 71 .. 1) and soundproofing
strips (74).
Use universal adhesive 000 989 92 71 .
Model 107
lnstall bracing plates (50! 1) with strengthened
side between bracket and fuer tank .
start. Check connections for leaks.

Shop-made tool

Shorten commercial. deep-offset box wrench as

shown in drawing.

-140---lj

4 7 07 14 . 100'3
Note
The filler restrictor for the smaller pump nozzle
(unleaded fuel) must be reinstalled when
renewing the fuel tank.

P47·0042·53

Filler restrictor ( 1) . . . . . .. ... . . . . . . . . . .. .
remove and install. Withdraw the rivets (arrows)
w1th special tool 123 589 05 33 OO.
&
Rivets must not drop into the fuel tank. They
prevent proper operation of the steadying bowl
(reserve fuel quantity cannot be used).
lnstallation
Knock in rivets with mandrel.

Special toor

/
123 589053300

47.071 4 . 100;4
 47- 110 Removlng and lnstalling fu el expanslon tan k (Model 107)

Hardtop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . detach, lit on.

Soft top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rai se, lower.
Screws (56a) .. ....•. . .... ... ...... .. .. unscrew, screw in (trunk side).
Partition panel (57) .... . .. .. ... ....... .. . remove and install (68-0700).

Note
Detach lining. stick on
(M B Universal Adhes1ve 000 989 82 71 ).
Battery liner and battery . .... .. ... ..... ... remove and 1nstall.
Vent lines (64. 64 1) .... . ..... ...... ... .. detach at fuel tank (50). fuer expans1on tank
(55) and below rear floor. attach.
Vent line (64· 1) .. . . . .. . • , . ... .. . . . .. . . . . withóraw through truok floor, insert.

lnstallatlon instruction
Check whether vent lines (64, 64. 1) and fixing
clips can be re-used (use only hose quality
compatible with replacement parts).
Screws (56b) . .. .. . ..... . ... . . . . .. . . . unscrew from soft top compartment side. screw
in.
Fuel expansion tank (55) remove. insert.

~ ¡ O i l~ · '1 0.2
47-120 Removing and installing fuel gauge sending unlt

A. Model 107

Battery ground cable . . . .... .. .... . . ..... . disconnect, connect.

Hardtop .. . ..... . ........ . .... . .. . . . . . detach, attach .
Soft top ... ... . . . . . . . .. .. ... .. . ... .. . . raise, lower.
Cover .. .. .... . ........ . .. ..... . .. .. . unclip, clip in.
Connector at fuel gauge sending unit (84) detach, protect against slipping oH. plug in.
Fuel gauge sensor (84) .. . . .. . . .......... . remo ve and instan. run to empty if necessary.

Note
lf fuel tank full, pump off approx. 8 liters
beforehand.
Renew seal.
Remove locking pin below adhesiva sheet
(new part).
Tightening torque 39 Nm.

4 7.07 14 . 120. 1
B. Model126

Battery ground cable . . . . . . . . . . . . . . . . . . . . . disconnect, connect.

Backrest. rear bench seat . .. ...... ... .... . remove and install (91-170).
Cover . ........ . ... ... ... ... ... ... .. . unclip, clip in.
Connector on fuel gauge sensor (84) ... ... .. . disconnect, protect against slipping off, plug in .
Fuel gauge sensor (84) . . . . . . . . . . . . . . . . . . . remove and install, run to empty if necessary.

Note
lf fuel tank full, pump off approx. 8 liters
beforehand.
Renew seal.
Remove locking pin below adhesiva sheet (new
part only).
Tightening torque 39 Nm.

Special tool

/
001 589 72 21 00

47.0714 . 12012
47-200 Functlon of fuel evaporatlon control system

51

P47 -0031- 53

Model 107

52/1

P4 7-0032- 53

Model 126 and vehicles with ASR 11

36 Thermovatve (50 ~e red - starting 09/87 70 •e 52 eharcoal canister

blacklwhite) 5211 Boot
50 Fuel tank 53 Purge valva
51 Vent vatve

47.0714 . 200/1
General
A fuel evaporation control system is installed to
minimiza the fuel vapors which escape to
atmosphere. The fuel vapors from the fuel tank
(50) are passed to the charcoal canister (52)
where they are stored. Depending on the
operating conditions of the engine. the fuel
vapors are drawn by means of the intake
manifold vacuum through the purge valve (53)
and the throttle valve assembly (2) and burned in
the engine. The thermovalve (36) prevents any
fuel vapors being drawn oH if the coolant
ternperature is below approx. 50 oc or 70 oc .
respectively, and·or if the throttle valve is at tdle
stop.

Function diagram
Model 107 ws/sw

53

- sw

~
52/3
(ñ)
t
2 Throttle valve assembly
36 Thermovalve (50 oc red -
siarllng 09/87 70 oc
blackiwhlle)
50 Fuel tank
51 Vent valve
52 Charcoal canister
5213 Vent cap
P47-0034-37
53 Purge vatve

4 7.071 4 . 20012
Functlon diagram
Model 126
ws / s w

53

-
sw

!
52/ 3
(ñ)
t
2 Throttle valve assembly
36 Thermovalve (50 •e red -
starMg 09187 70 • e
black!whlte)
50 Fuel tank
51 Vent valve
52 Charcoal cantster
52/1 Boot
53 Purge valve

Function
lf an pressure of 30-50 mbar is reached in the
B
fuel tank , the vent valve (4) opens and the fuel
vapors flow to the charcoal canister.
Vent valve (51, see Function diagrams) to
l
7 -- --!1
charcoal canister open.
==J6~~~

P47· 0001 - 13

1 eompression spnng
2 Valve houstng
3 Spring plata
4 Vent valve
5 Valve plate
6 A11 admission valve
7 eonnect,on fitttng

A Charcoal camster connection

B Fuel tank connection

47.0714 . 200/3
lf a vacuum of 1-16 mbar is produced in the fuei
tank, the air admission valve (6) opens. As a a
result. air or fuel vapors are drawn in through the
charcoal canister.
t
Vent valve (51, see Function diagrams) to fuel
tank open.

When the engine is running and the coolant

temperatura is more than 50 oc
or 70 oc.
respectively, the intake manifold vacuum when
the throttle valve is just slightly open, flows
through the thermovalve to purge valve
(connection C).

Thermovalve 50 •e red. 70 • e black!whote

1 8ometal plate
2 0-rong
A T o purge valve
8 T o thronte valve assembly

The diaphragm (4) is pulled up against the spring e

force if the vacuum is 20-35 mbar or more. The
passage from connection A to connection 8 is
opened.
Purge valve (53, see Function diagrams) open.

1 eornpressoon sprong
4 Ooaphragm
A
A To charcoal canoster
8 To throt11e valve assembly
e Vacuum connectoon
B ... 7 •00)0•,)

47.0714 . 200:4
lf the throttle valve is closed further. the suction
port (e) in the throttle valve assembly is acti·
vated. As a result, the fuel vapors stored in the
charcoal canister are drawn off. The activated
charcoal is purged.

a To EGR thermovalve
b To fuel evaporation control system thermovalve
e To purge valve
d To EGR vacuum control valve
p 01' 2275 ll

Note
To prevent any enrichment of the mixture from
the charcoal canister, disconnect the purge line
to the throttle valve assembly at the purge valve
(78) and seal it when performing work such as
"Adjusting idle speed" or "Checking, tuning
engine".

47.0714 . 200.5
 47-300 Checking fuel evaporatlon control system

P47•0052·G1

36 Thermovalve 50 •e red, 70 •e blacklwh ite 53 Purga valve Modal 107, 126

52 Charcoar can1ster Model 107 53/ 1 not used
5211 Charcoar camster Model 126

Thermovalve (36) ... .. ... .... .... ... .. .. check that passage is clear.
Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . check that correctly connected, in good
condition and clear (remove bulkhead in front
left wheelhouse. if necessary).

47.0714 . 300/ 1
Engine oil temperatura approx. 80 oc.
Purge valve (53, 53i 1) detach line at right angled connection fitting in
left side of engine compartment. Slowly
increase engine speed to 3000 rpm.
No suction action at idle speed . Suction action
commences as engine speed increases.

P47·00S3•S7

51 Vent valve M odel 107 52/ 2 not used

51 /1 Vent valve Model 126

Vent valve (51, 51/ 1) . . . . . . . . . . . . . . . . . . . . . check for proper operation.

Note
Connect tester 201 589 13 21 00 to connection
fitting to fuel tank (pressure 3Q-50 mbar.
vacuum 1-16 mbar).

47.0714 . 300/2
 Charcoal canister (52, 52/ 1. 52! 2) . . . . . . . . . . . . check. The passages between the connections
must be clear.
Tester 201 589 13 21 OO.
Start engine and slowly accelerate to approx.
3000 rpm. No vacuum must be indicated on
tester. lf necessary, renew charcoal canister.

Special tools

201 589 13 21 00 124 589 07 21 00

Note

Model 126
The casing of the charcoal canister has been
manufacturad of plastic since 09/87 (previously
sheet metal).
When replacing part. always replace like with
like.

47.07 14 . 300:3
 47- 400 Functlon of fuel cooler

1 Fuel leed
2 Fuel return
3, 4 Aetngerant return
6 Outer tube
7 lnner tube
8 tnsulating hose
75 Fuel cooter P47-0054·17

To reduce the formation of vapor bubbles in the

fue! system at high outside temperaturas, a fue!
cooler is fitted. ft is located in the refrigeran!
return fine between evaporator and air
conditioning compressor. The fuel cooler is
attached at the vehicfe side.

When the engine is running, the excess fue! in

the tuel distributor flows back through the fuel
cooler into the fuel tank .

So long as the air conditioning compressor is

switched on, heat is withdrawn from the fue! by
the gaseous refrigeran! which is ffowing through
the inner tube of the fuel cooler.

4 7.0714 . 400/1
 49-100 Removing and installlng exhaust system

A. Model107

49.07 14. 10011

0 2 sensor heating coil connector (G312x 1) and
0 2 sensor sígnal connector (G312x2) detach in passenger compartment, plug
together.
Heat baffle plate (2c) remove, fit on. Pay attention to installed
position.
0 2 sensor (G3/2) .. . ... .. ... .. .. ... .. . . . unscrew. install.

lnstallation instruction
Coat thread with paste 000 989 88 51.
Ensure line is correctly laid.
Screws (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . unscrew, screw in. Renew screws (4) .
Tightening torque 25 Nm.
Rear muffler (9) .. . .. . .... .. ..... . ..... . detach from rubber ring ( 18) and take off, fit on
and attach.

lnstallation instruction
Check rear muffler (9), rubber ring ( 18) and
rubber stop (13) for signs of wear, replace if
necessary.
Rubber rings (18, 25) detach, attach.
Examine for signs of damage and wear.
Exhaust system take off, ínstall.
Riveted nuts (1) remove at exhaust manifold, instan.
Knock out riveted nuts with suitable tool
(e.g.: bolt).

lnstallation instructlon
lnstall riveted nuts with special tool
103 589 01 39 OO. Tightening torqu e of
special tool 30 Nm .
Exhaust system .. . .. .. ... ... .... .... .. . check for leaks with engine running.

Special tools

49.0714 . 10012
Note 7
1
lf necessary, clean any combustion or corrosion
residues off the tapered connection pieces of the
pipes (2. 7) and sintered seal (5) with emery
cloth.

Ensure parts are correctly installed.

Always renew self-locking nuts and asbestos or

graphite gasket after being used once.

2 Front exhaust pipe

3 Sell-locking nut
5 S1ntered seal
5a Flange
5b Graphlte seal
7 Center exhaust p1pe
8 M8 bolt

To renew the rear muffler, place new muffler

with socket fitting exactly over removed system
and mark pipe length of new muffler at the
removed system .

Cut through the pipe at a point 80 minus 1 O mm

from the marking in the directton of the rear
muffler in order to obtain an insertion depth of
70-80 mm.

P49-2058-13

Do not tighten the flanged joint to the exhaust

manifold until the complete system is attached in
the rubber rings. Ensure that the front exhaust 1
pipe is correctly located. Tightening torque of 1a
hex. bolts 20-25 Nm. 4
2d

P49-0002-13

49.07 14 . 100:3
B. Model126

0 2 sensor heating coil connector (G3í2x 1) and

0 2 sensor signal connector (G312x2) .. ..... . separate in passenger compartment, plug
together.
Heat baffle plate (2c) pull off, lit on. Pay attention to installed position.
0 2 sensor (G3/2) . ... .... .... .......... . unscrew, install.

lnstallatlon instructlon
Coat thread with paste 000 989 88 51.
Ensure line is correctly laid.

49 .0714 . 100i4
 Retaining bracket (6) with Belleville spring washers
(17) and self-locking nuts {16) ...... ..... ... remove, install. Tightening torque 7 Nm.

tnstallatlon instruction
Check parts and renew if necessary.
Bolts (4} unscrew, screw in. Renew bolts (4). Tightening
torque 25 Nm.
Rear muffler (9) ... . ........... ... ..... . detach from rubber rings (18) and take off; fit on
and attach.

Center muffler (7) . . . . . . . . . . . . . . . . . . . . . . .
lnstallatlon lnstructlon
Check rear muffler (9) and wbber ring ( 18) for
signs of wear. replace if necessary.
detach from rubber ring (18) and take off: fit on
and attach.

Side support (1 0) with bolts (11 ), washers (1 2).
rubber washers (14) and nuts (23) . . . . . . . . . . .
lnstallatlon instruction
Check center muffler (7) and rubber ring (18)
for signs of wear, replace if necessary.
remove. lit on. Tightening torque 20 Nm.

lnstallation instructlon
Check parts and renew if necessary.
Exhaust system . . • .. . . • . . . . . .. . .. . . .... take off. instan.
Rivet nuts ( 1) . . . . . . . . . . . . . . . . . . . . . . . • . . remove at exhaust manifold . install.
Knock out rivet nuts with suitable tool (e.g.:
bolt).

lnstallatlon instructlon
lnstall rivet nuts with special tool
103 589 01 39 OO. Tightening torque of
special tool 30 Nm.
Rubber stop ( 13) check for signs ot wear, replace it necessary.
Exhaust system check tor leaks with engine running.

49.07 14 . 100:5
Special tools

""1
l
1
/
pt·

001 589 66 21 00

Note
lf necessary. clean off any combustion or
corrosion residues on the tapered connection
pieces of the pipes (2. 7) and sintered seal (5)
with emery cloth.

Ensure parts are correctly installed.

Always renew selt-locking nuts and asbestos or

graphite gasket after using once.

2 Fron1 exhaust pope

3 Self·locking nut
5 Sintered seal
Sa Flange
Sb Graphite seal
7 Center exhaust pope
8 M8 bolt

Before inserting the rear exhaust pipe, first of all

support the front exhaust pipes with the
clamping bracket and side support, but do not
yet tighten at this stage.

lnstall tour Belleville spring washers on each side

)
of the retaining bracket so that the curved faces
point away from each other.

P 4 9 • 00U•13

49 071 4 . 10016
To renew the rear muffler, place rear muffler with
socket joint exactly over removed system and
mark pipe length of new muHier at the removed
system .

Cut through the pipe 80 minus 1O mm from the

marking in the direction of rear muffler to obtain
an insertion depth of 70-80 mm.

P4~ -20~1 :l

Do not tighten the flange joint to the exhaust

manifold untit the complete system ís attached in
the rubber rings. Ensure that the front exhaust 1
pipe is correctly located. Tightening torque of 1a
bolts 20-25 Nm. 4
2d

P49-0002-13

49.07 14 . 100/7