Mercedes Benz

Senice

ModelYear1992@ Modefs124,129,201
Inlroduction intoservice

Mercedes-Benz of North America, Inc.

Preface

Th s nlroducton ttanua s nlended to farnlarze yolr w th the techncal chanqes for Mode Year 1992 Th s manua coversmociels 124 129 an.:201,afd Sporlrremodels300 E. 300 CE and 190 E 2.6 Coverage of modes .100 E ar)d500 E s contalled n the ntroductton l,4anual Mode Year t9S2 @ N,4ode s 124.03,1 036 (400E 500 E) Coverage oi mode 140 s conlarned In the nlroduct on fManuai ModelY-oar 1ss2 '!D Mode 140 Untr the atestrepar nstruct Onsare avalable of m crolche th s nlrodLrct on lvlarual can be Lrsed by i\rlercedes-Benz scrlice p{]rsofnelo rarn ar le thertsevos w th rnporlant tecfrfrcal dela s 10periormrnanlenarrce and repafs orl lhe abovelvlodeYear 1992vehc es A I otherrepar fslructoos adluslmentva!es ano marntefance lolrs,rot rstedherecan be lound n ex st ng techncal teralure. Mercedes Eefz Akt engesetschalt Vertreb Personenwagen Febr!ary1992

Tableof contents
Vehicleand component idenrification 1 Drivetrain

Technical highlights Engines 102,103,104,119CIS-E

07.3 CIS-Egasoline injection system l,4odil catrons compared to Fulpump packaqe
enqlf e 10 2 .9 8 5

27

Automatic transmission Deet on of secofdary pump f1deay . . Upsh Rearaxle G e n e ran l t o rma t o n
Gpar sel and reara. e shall

.19 5t

35

..

..51
. . a4

46

Ealleryvo taqe-dependeft de enqne 119 n nrode 129 Transm ss on upshft delay 102 103.104 119 enqrnes Funclon I agrarn. transrn ss on ... upshftdeay lransmssronLrpsh ft de ay test 14 Emissioncontrol system
a<on <., ,- . r .a,n., L, ' .- i.r

Steering Stcorngwhee (140desqnl Eleciricalsystem - equipmentand

55

54

10
l0 12

instruments nstrument c uster

Sportilne(models124.030/051,201.029)

55

General lnlormation 32 Suspension

f,'lodlcatons Testand adlLrstmenl data 40 Wheels.wheel alignmenl whae s Whee a gfrnni Steefing Cfoss relrence, mode steerng eear Sreerng,,!hee 11,10desgn) S1 Seats Sporl4-pace seatrng ..

56

lCa rforf a o.|,r' )

56 57

Engine 602.962 07.1 Diesel intectionsystem on Genera niormal Fuel nlecton systemcomponenls Testand adlustmert !a Lres Eleclron c dese system(EDSI Funclondagrarn EDS Component ocatorrs E ectron rdle c speedconlro (ELR) gas rec rc! atron(EGR) Exhaust pressLrre Boost conlro (P2.contro ) Syslemdraqnosl cs Component operal on Vacuum ne layout Eectrc wrfq dagram (EDS)lesl Eleclrofo d ese systern

59

6r

r6
16 17 17 19 2A 22 23 24 25 25 30 31 32 46

62 62

63

'.,!n -

r..n

!!,

!:t,..:i

!.::r

,? 1,

Vehicle and component identification

Vehicle identificarion 1992 @
124.026 124.030 124.0 124.034 124.036 124.051 124.090 124.128 124.230 124.290

300E 2.6 300E 400 E 500 E 3OO CE TE 3OO 3OO D 2.5IURBO 300 E 4tvtATrc 3OO TE 4IV1ATIC

129.06 1 129 129.066

3OO SL

5OO SL

140.032

3OO SE 4OO SE 500sEL 600SEL

140.0

140.042 140.051 140.057

140

140.1

140. 134

3OO SD TURBO

201.028 201 201.029

190 E 2.3

190 E 2.6

Models Indrcaledn bold typo are covered in separatelntroduction l\,4anua s.

&

Mode Yearrggz @

M o d e ls 1 2 4 1 zs 2 a 1

Vehicle and component identification

Component identification 1992 Qsr) Salesdesignation Model 190 E 2.3 190 E 2.6 201.028 201.029 Eng ine 102.985 103.942 602.962 103.940 103.983 119.975
1 1 9 .9 7 4

Manual Automatic Power transmission transmrssron sleenng

717.413 717.432 722.408 722.409 722.418 722.409 722.358 722.354 722.365 722.359 722.358 722.342 722.342 722.367 722.502 722.366 722.370 722.362 722.500 722.353 765.903 765.903 765.904 765.904 765.904 765.921 765.921 765.908 765.904 765.906 765.906 765.940 765.940 765.940 765.940 765.940 765.907 765.925

3OO D 2.5TURBO 124.128

300 E 2.6 300 E 400 E 124.Q26 124.030 124.034 124.036 124.051 124.090 124.230 124.290 140.134 140.A32 140.042 140.051 140.057 129.0 61 129.0 66

500 E

300cE
TE 3OO
E 4N1ATIC 3OO 3OO TE 4IV1ATIC

104.980 103.983 103.985 103.985 603.971 104.990

1 1 9 .9 71

3OO SD TT]RBO
3OO SE 4OO SE 5OO SEL

119.970 120.980 104.981 119.960

600SEL
3OO SL 5OO SL

v . r F , " " , s s r @ r o o " ',

124 2s /al

Vehicleidentification
Vehicle identiflcation number (VlN) The following information is encodedinto the VIN: Manufacturer, model,restraint system,modelyear, manufacturing plantand chassisend number

Exam pl e, mo d e l3 0 0E : W DB E A 30DX L B t 2 3 4 S 6 WDB

123456

Manufacturer
I/odel D = 201, E = 124,F = 129,c = 140

Engine type
A= Gasoline, B= Diesel, D =4MAT|C N,4odel deslgnation 124.030 Restraint system D = Seat belts + SRS with driverairbag E = Seat belts r SRS with driverand front passenger airbag

Checkdigit [/odel year

M = 1991, N = 1992 Manufacturing plant') A - E=Sindelfingen F- H=Br eme n Chassis endnumber

1) plant ettermustbe specrfied Manulacturng withthe end nurnber produclron because sirnultaneous at both oJanls rnavrrean the sarneend number drgilsare assignedto two cars.

Moder Y e a r ,SSZ@

Uo O" t. 1 2 4 . 1 2 g .zO1

Vehicleidentif ication
Enginefamily designations The emission plateattachedto the radiator controlsysteminformation crossmember also shows the enginefamilydesignation. The enginefamilydesignation identifies modelyear, pistondisplacement, version, etc. (see example on next page).

Designations
Engine tamrly NMB 2.3 V 6 F A 19 NN4B 3.0 V 6 F A 1X 2) N[,48 3.0 V 6 F A 1X 2) NIVB3.OV6FA IX NN/B3.OV6FA20 Nl\,48 3.0 V6 F A lX NIV1B 2.5 D 9 J F 11 NMB 3.0 V 6 F A lX NIV1B3.OV6FAIX Nl\ilB3.0VOFA31 NMB 5.0 V 6 F A 14
1) 2)

Version ' A A A A A A F A A A A

L4odel 201 .028 2A1 .029 124.026 124.030 124.051 124.090 124.128 124.230 124.290 129.061 '129.066

Vehiclesalesdesronatron 190 E 2.3 190 E 2.6 300 E 2.6 300 E 300 cE 300 TE 300 D 2.5 TURBO 300 E 4lvlATlC 300 TE 4MAT|C 300 SL 500 sL

A=Al1 50 states(nclLrdLng Caifornra) F = Federal only (not rncluding Ca rlorn a) Forcertrfrcaton reasons, all 103.94engnesfall ntothe3.0 lterengrnelamrly, even I the dispacement equals only (190 E 2.6 and 300 E 2.6). 2.6 liters

ff

ModelYea' ,ega @,'l o,l ".

124 12g 2a1

Vehicle identif ication

Example:NN/B3.0 V 6 F A 1X

rvB 3.0
year: N4odel M = 1991,N=1992,etc. l\4anufacturer code: N4ercedes-Benz Piston drsplacement: i.e.: 3.0 liter Vehicle class: V = Passenger car withgasoline engine D = Passenger car with dieselengine Typelf fuel delivery: 5 = electronic injection (LH) 6 = mechanical injectron 9 = mechanrcal injection with turbocharger

Type of catalyst: F = 3-waycatalyst with lambdacontrol J = no cataiyst(diesel) For manufacturer's use: A = AII 50 states F = Federal Used by manufacturer for certitication purposes Checkdigit

i5

Model Year , nn, @

l,lo,tot. 124 12g. zO1

highlights Technical
102,103,104,119 Engines
07.3 cls-E gasoline injection system . o Dualfuel pump package(engine102 985). idle speed Batteryvoltage-dependent increase. upshift transmission operated Pneumatically oeray. rndicatol replacement O2-sensor (California only). Maintenancenote: lampcomeson (60,000 Whenwarning rePlace O2-sensor. miles),

14

control system Emission

Enoine602.962 07.1 Dieselinjectionsystem

to modelyear as compared lvlodifications I990i91: I o . . . o pump(camshape). lnjection Vacuumline layout. map). EDS controlunit (reference EDS test program. micloswitch. EGR shut-off wiring daagrams Eleckic Manual) (see Electrical Troubleshooting volume. with increased Prechamber valves: EGR, boost Electric switchover pressure controlflap. pressure control, for boost Singlevacuumtransducer controlflap pressure controland pressure

o .

6.*

ModelYear ,nna @

Q4 12g 2A 1 "oa".

Technical highlights
07.1 Dleselinjectionsystem(conrinued)
The following was deleted: . Boostpressure controlvacuumtransducer. . . Engineoverload protection. Vacuumamplifier and vacuumamplifier swrtchover valve.

Drivetrain AutOmatic transmission

o a

pumpdeleted. Secondary Transmission upshift delaymodif ied. Rearaxle ratiochangedin models124.026, 2U .A28029.

35

Rearaxle

46

Steering Electrical system- equipmentand instruments

. .

New design steering wheel. CHECKENGINE warning tampetiminated in Federal versionvehicles.

(models124.030/051, Sportline 201.029) 32 Susoension

o Suspension components modified, ride heightlowered. Newlydesigned 8-hole light-alloy wheels for models124.030,051 . Newlydesigned steering wheel, 390 mm in orameter. Sport4-placesealingstandard equipment in all Sport/rnemodels.

40

Wheels, wheelalignment

46

Steering

91

Seats

Mode year t9g2 @

M o d e ts1 2 4 .1 zg zA1

07.3 CIS-Egasolineinjectionsystem

102,103,104,119CIS-E Engines

to modelyear 1991 as compared Modifications

a a

(engine 102.985). Fuelpumppackage idle speed Batteryvoltage-dependent 129). (engine in model 119 increase delaY upshift Transmission Controlof upshiftdelayvta switchover valve (Y3i3). valve Relay(K29)as well as solenoid (Y3,'2) for upshiftdelaydeletedlrom transmtsston.

Fuelpump package
Engine 102.985 as rn model Two f uel pumpsare installed, 201.029.

i r

Mode Y ear i 992 @

Model s124. 1 29.201

Engines 102,103,104,119CIS-E
Batteryvoltage-dependent idle speed increase
Engine 119 in model 129 Effective serialnumber: As of chassisend no. F 032599 Depending on batteryvoltage,the engineidle speedis increased by approx. 100 rpm with the transmission in gear,therebyincreasing the chargingcapacityof the alternator. The CIS-Econtrolunit receiveda new part numberto differentiate the controlunit from the prevrous version.

07.3

Partno. @ rederat @ Catjfornia

012 545 22 32 012 545 23 32

Operation The idle speedIncrease is activated underthe toilowing conditions: . Enginecoolanttemperature between 60 - 110 "c, . Selectorleverin gear, . Batteryvoltage< 12.5 V for at least 20 seconds, . Eng,ne speedexceeded 900 rpm once.

The idle speedincrease is switchedoff if: . Selectorleverpositions"N" or "P" are engaged, o Enginecoolanttemperature exceeds'l 10 "C, o lgnitionis switchedOFF.

Once the conditions for activation are met, they remainstoredin the CIS-Econtrolunit untilthe ignitionis switchedoff, even if the battery voltagehas since risenabove 12.5 V.

M o d e lY e a . , n n , @

Vo ,t"," i2 4 . 1 2 g .2 O1

07.3
Transmission upshiftdelay
Engines 102,103,104,119 by The transmission upshiftdelay is controlled valve (Y3i3). the upshiftdelayswitchover for The condrtrons upshiftdelayremain ( Operation, see group27). unchanged

102,103,104,119C IS-E Engines

transmission upshiftdelay Function diagram,

3/1

P27-507 3-59

a^nrr^r

.f6<."ro

.rh

2 3 8 I

Checkva ve Intakemanlo d Upshft delayvacLrum elemenl Vacuum reservor

unit) N3/1 LH control lnrt (N3 - CIS-Econtrol vaive Y3/3 Upshrft delayswrtchover 0 acK grey green

gr gn

10

Mo(i e Year 1992@

Model s 124. 1 2g 201

Engines 102,103,104,1'19 CIS-E

Component locations Model 124

07.3

Y3i3 Upshrll de ay swrtchover va ve

Model129

Y3 J Upshft delaysw tchover vatve

lvtodel 201

Y3/3 Upshrfl delayswrtchover vave

nr*

Model Year ,nn, @

l,ro,t". 124 12s 2a1

11

07.3
issionupshiftdelaytest Transm
Soecialtools

102,103,104,119CIS-E Engines

11 6 58 9 27 21 00

201 589 13 21 0 0

124 589 09 63 00

201 589 00 99 00

Equipment r) Multimeter
r) EqupmentProgram Avarlable through the MBNA Standard

pickup Flukemodel23 with 80i - 410 inductive

Test conditions 80 'C. . Engine approx. oil temperature off. . AIIelectrical switched consumers '14 V. . Battery 11 voltage

Test step

Testscope Test connection vacuum of Disconnect Operation Figures upshiftdelay line(arrow, swrlcnover 1 - 3) on Y3i3, valve (Y3i3) vacuum Connect withYJitttng tester 3. to Y3i

Test condition Coolant temperature sensor(811i2) conneclor unplugged. Using resistance substitution units,simulate a 2.5 kO

Nominal value

Possible cause/remedy

> 400 Y3i3 activation, mbar circuit, up Open/short to max. Y3/3 defective. switching Vacuumelementfor time (see upshift Grp. transmission
27 fol pdescn ton or ton ). 0eray. line. Vacuum

( + 20"c)
resistance at sockets 1 + 3,2 + 4. Start 1) Engine:

1) Vehce musthave rearwheelsdftven sqnal dependent) value(speed nominal to rrieasure

12

Mode Year 1992@Modes

124 12s 2o1

Engines 102,103,104,119CIS-E
Test step
Test scope Test connection Test condition Nominal valuo 11 - 14 V

07.3
Possrble cause remedy protection Overvoltage relay, Open/short circuit.

Activation of W11 upshiftdelay ! -_{yF swrtchover valve(Y3i3)

Y3r3 lgnition: On ) 2 Connector on Y3i3 unplugged.

Y3/3 1<{-ts

E! temperature

1'1 - 14 V Openr'short circuit, up to CIS-Econtrolunit sensor(81112) max. defective. connector swrtching unprugged. trme Using (see Grp. resistance 27 tor substitution unrts, srmulate tion of a 2.5 kQ (+ 20 "c) tion). resistance at sockets 1 + 3,2 + 4.

Coolant

Engine:Start

Coil Y3/3 resrstance r of upshift oeray swrtcnover valve(Y3"3)

Y3r3 Connector on

25-40Q

Y3/3 defective.

-!

z Y3,'3 unplugged. lgnition: OFF

M o d e Y e a r 1 9 9 2@

M o d e ts 1 2 4 1 2 s 2 A1

13

14 Emission controlsystem
replacement indicator (California O2-sensor only)
The warning lamp(A1e33) for the O2-sensor replacement indicator is installed in the Instrument cluster. Uponreachi ng 60,000 every t 250 miles(r.e. illumination l amp 60,000miles), of the warning indicates that the O2-sensor must be replaced. For instructions on how to turn off the warning lampafterO2-sensor replacement, see ''lvlaintenance note".

Engine102.985

Activation lampoccursvia the of the warnrng replacement indicator O2-sensor controlunit (N44'1). is located in the unrt ,fhe control passenger-side footwell.

The Hall-etfect sensoroutputon the provides information speedometer on miles per milei s driven. The number of impulses determined by multiplying a fixednumberby the numberof impulses from the Hall-effect sensor. The resultrng is rn distance stored the control unit. The warninglampcomes on with the iqn,tion in posrtion "2 and goes stanerswrtch (circuit running out againwiththe engine 61 recognrton).

\to,-

o e . , ( D r t o , l '" ' d,

'/ a

2s 2al

Engine 102.985
jf the button(arrow)is A test mode is initiated pressedfor longerthan 5 secondswith the ignition/'starter switchin position"2". The test ;s mode start ,ndicated by the O2-sensor warning lamp switching off. o Aftera pauseof 5 seconds,the recorded mileage is indicated by a blink impulse. The warnrng lampblinks oncefor every10,000 milesrecorded. . Aftera 2 secondpause,the lampblinks once for every additional 1,000miles recor0e0. . Aftera further2 secondpause,the lamp blinksonce for every additional i 00 miles recoroe0. lf the mileage recorded is "0", thisrs indicated by the lampnot btinkjng. Aftera further5 secondpause,the operation of the Hall-eftect sensoris tested.Afterthe required 5 secondpause,the O2-sensor warning lampwill blinkcontinuously if the vehicleis drivenon the road or dynamometer. The test mode may only be interrupted by swrtchrng the ignition off. Maintenancenote: The O2-sensor must be replaced when the warnrng lampilluminates at 60,0001 250 miles. After replacing the sensor,the warninglamp may be switched off via the button(arrow)on the controlunit (N44i1). The buttonmust be pressedfor longefthan 2 secondsto turn off the lamp. In ignition, position starter "2', the lamp remainslit evenafter resetting the controlunit. Tne lampwillonlygo out alterthe engrne is started(ctrcuit 61 recognition)The previously recordedmrleage remainsstored. The warning lampwill illuminate agatn at 120,000 miles.

14

M o ( r ey e a r 1 99 2@

M o d e ts 1 2 4 1 zs 2 a 1

tc

07.1 Dieselinjectionsystem
Generalinformatlon
as comparedto modelyear lvlodifications : 1990i 1991
a a a a a o

602.962 Engine

was deleted: The following

a o

pump (cam shape), Injection layout, line Vacuum map), EDS controlunit (reference program, test EDS EGR shut-offmicroswitch, wiringdiagrams Electric N4anual), Troubleshooting (see Electrical volume, increased with Prechamber valves:EGR, boost Electricswitchover pressure controlflap, pressure control, lor boost Singlevacuumtransducer pressure controlflap. and pressulecontrol

o . o

controlvacuumtransducer, Boostpressure protection, Engineoverload and vacuumampftfier Vacuumamplifier valve. switchover

systemcomPonents Fuelinlectlon
ine Eng pump modeldesignation Injection 602.962 PES 5 M 55 C 320 RS 177 0 400 075 944 FPTKG 24 M 150 DN O SD 265 001 017 49 12

Boschnumber (fortestsheet) pump Fuel (Bosch designation)

nozzle Injection (Boschdesignation) nozzlePartno. Injection Nozzleholder (Boschdesignation) nozzleand holdercomplete Injection (Partno.)

KCA27 S 55 00201740 21

to

65

Y ear ,nsz @ Mo(l el

too"'"

12 4 12g.2Q1

Engine602.962
Test and adjustment values
Engines ldle speedat 60-80 "C coolanttemperature lnjectjon pump timing(reference impulse) adlustment value pump timing (reference Injection irnpulse) nominalvalue Boost pressureat 4,000 rpm, underload lnjectron nozzleopening pressure wrth new injection nozzles Inlection pressure nozzleopening with used injectton nozzles
r) One -tmead lus lm c nl al 15, 000m ies ,adt us o 14 + 0 . 5 " a t l e r T D C

07.1

602.962

rpm 680120
' 14+ 0.5o after TD C 1)

15 1 1' afterTDC bar 0.75- 0.85 bar 135- 145 bar 120

Electronic dieselsystem(EDS)
The EDS controlunit processes the following function s: . Electronic idlespeedcontrol(ELR), . Exhaust gas recirculation (EGR), o Boostpressurecontrol(P2-control), . Systemdiagnostics. The EDS control unrtprocesses the incoming srgnals and delivers a milliamp current to the vacuumtransducer(s) and to the electromagnetic actuator on the injection pump.The entrresystemcan be testedwith an impulse counteri.e. the malfunction memorycan be read by meansof an outputsignalto the test connection {X11,4).

&

Mode ,nn, @ ""u,

VoO". 124 1zs 2a1

17

07.1
Block diagram,EDS

602.962 Engine

Enginespeed sensor(L3)

Accelerator peoal

rmpurse readout, diagnostic test srgnal (socket4)

Pressurebeforethe Intakevalves 10' before fullload mlcroswrtch valvers actvatedby the conlro inkage The swtchover

18

65

V i i e' Yedr

'oC , @

tooo,

124 ' ?9 ?al

Engine602.962
Function diagram, EDS
72 103

07.1

62 67 62a

1 2 60 61 a 61 b 61 c 62a

72 99 100 103 110 137 137 a 138 224 8211 8211a B5/1 811/4 L7

pump Inleclion Governor EGR valve Or lice Ofrfce 0.5 Orifice 0.7 F lter Fllter Vacuum controlvalve vacuump!mp Vacuumdarnper Pressure conlrol llapand houstng Pressurecontrolflap vacuumactuator Anerod compensator (ALDA) Exhaustmanfold Turbocharger Boosl pressurecontrolvave vacuum acluaror lnlake man fold Acceleratorpeda Air fiowsensor Intakearr temperalure sefsor Pressure (EDS) sensor Coolant tempefature (EDS) sensor Stader ring gear speedsensor Fuelrackpostt on sensor

N39 Y22 Y27 Y27t4 Y31/1 Y31/5

EDS control unrt Electromagnetic actuator,e ecvonrctdle speeo contro(ELR) EGR swrlchover valve Boost pressurecontrolswrtchover valve Pressureconvol ilap switchovervalve EGR vacuumkansducer Boost pressureconlrol/pressure controlflap vacuum lransoucer lntakearr Exhaustgas venl line to passenger cornpanment Rernarnrng vacuumconsumets Pressureand vacuum connections at vacuum lransducers Vacuumfrom vacitumpump Vent Ine to passenger compartment Fromvacuum (y3t/1) to EGR lransducer sv,ilcnover valve(Y27) Fromvacuurn transducer (Y3t/5) to swltcnover valves lY27t4) aod lY27tS)

B a c

VAC OUT OUT

{h

Model Year,Sn, @

Voa"t. 124 12s 2o1

'19

07.1
locations Component

Engine 602.962

ffi w
F t|nl
LIll

rr

II Y27

Y27t4w Y27t5

^4, g
F811/4
LJ

20

Mode ""u,

,nO, @

toao'. i za. i 2g.2A 1

Engine602.962

07.1

B2t1 B5/1 81 1 /4 K1r1 L3 L3x1 L7 N39 x1 11 4 Y2 2

Arr ilow sensor and a r ntaketemperature sensor Pressure (EDS) sensor Coolant lerfperature sensor (EDS) Overvo/tageprotecltof relay, B7E Staner lng gear speed sensor Conneclor,starter nng gear speed sensor Fuel rack posrtion sensor EDS contro un1 EGR m cfoswitch Tesl conneclton for dragnosrs (impulse readoul, I'polel fleclo'-lagaelc d( rJalor. erecro.tc.de speed (ELR) control

Y27 Y27t4 Y27i5 Y 3 1 i1 Y 3 1 i5

EGR swrtchover va ve Eoost pfessurecontrolsw tchovervalve Pressurecontrolilap swltchovervalve EGR vacuum transducer Boost pressurecontrol/pressufe controlflap vacuumtransducer EGR va ve Pressure conlrol flapand housrng Pressurecontroli ap vacuurnactuator Booslpressure coflrol vaivevacuum acluaror

60 99 100 137 a

M o d e lY e a r , S n a @

Uo .t" ," 1 2 4 1 zs ? A1

21

07.1
idle speed control(ELR) Electronic
The starterring gear speed sensor(L3) picks per up the enginospeed(144impulses revolution) and sends it in the form of an AC voltagesignalto the EDS controlunit.The EDS the rpm stgnaland controlunit processes performsan nominal actualvaluecomparison.

Engine602.962

As a result,the idle speedis held constantby of actuatorregardless the electromagnetic below engineload. At coolanttemperatures 60 "C. the idle soeednominalvaluels map. to a presetreference increased according

Blockdiagram, idle speedcontrol

22

ffi

Moi l e Year 1992@

Modes 124 12g 2a1

Engine602.962
gas recirculation Exhaust (EGR)
Exhaustgas recirculation occurs as soon as the following conditions are met: . . r o Coolanttemperature between60 "C and 110 "c Batteryvoltage11-14 Volt Fuel rack travel < 9 mm Enginespeed up to approx.3500 rpm

07.1

Controlcurrentis appliedto the vacuum transducer which deliversa respective amount ot vacuumto the EGR valve. The EGR volumeis reducedas enginespeed and load increase. This means: Increasrng controlcurrent= jncreasing EGR voiume Decreasing controlcurrent= decreasing EGR volume. h addition:.EGRshut-ofI at 10" before futl load via controllinkagemicroswitch and swrtchover valvein vacuumline.As a result, smokeemission rs reduced duringloadchanges towardsfull load.

According to the input signalsfrom sensorse.g. fuel rack travel,enginespeed,etc., the EDS controlunit calculates the corresponding volume ol exhaustgas recrrculation for the respecttve operating conditions.

Blockdiagram, EGB

The EGRsystem withvacuum transducer, EGR switchover valve, EGRvalve, air flowsensor and EDScontrol unitoperates as a closed loop.

ir

Modet Year,nn, @

uolut" 124 1zs 2o1

23

07.1
Boost pressurecontrol(PZ-control)
is storedin A "reference map" (for P2-control) values the EDS controlunit. The pressure to injection receivedby the controlunit relative optimal volumeand enginespeed generate with respectto engineperformance NOx, HC and particulate consumption, emissron. By reducing the pressure(P2) aheadof the atis intakevalvesduringpartialloadoperation, particulate in possible a reduction to achieve emrssron. The EDS controlunit containsa closedloop circuitwhich comparespressures"P2 actual" (seeblockdiagram). with "P2 nominal"

Engine 602.962

values Anydifference between thetwo pressure pressure control is equalized by the boost either flap. valve or by the pressure control pressure valve is activated Theboost control by vacuum fromthe adlustable electronically vacuum andelectric switchover transducer valve. on: Boostpressure controlis dependent . Intake air pressure, . Engine. speed, . Fuelrackposition (travel).

control(P2-control) Block diagram, boost pressure EDScontrolunit

pressure Boost pressure controli flap control vacuum transducer

24

V dF't",'

'ooa @

"no-.

124 ?9 2al

Engine602.962
System diagnostlcs
The self-check programintegrated into the EDS controlunit tests the electronic dieselsystem r.o.detectsand storessystemmalfunctions. Intermittent malfunctions, which occur for longer than 4 seconds,are also stored. For example,sensormalfunctions, with the exceptionof enginespeed sensor,are stored into memory,as well as short circuitsin the actuatorsand their inputwiring. Throughthe use of an impulsecounterat socket4 of test connection (X11i4), the individual malfunctions can be recalled for evaluation.The properdiagnosis can be determined according to the indicated malfunction.

07.1

Component operation
EDS control unit (N39) The controlunit processes the incomingsignals and deliversa milliamp currentto the two vacuumtransducers, to the electromagnetic actuatoron the injection pump,and the boost pressurec0ntroland pressurecontrolflap switchovet valves. Th6 entiresystemcan be tested with an impulsecounteri.e. the malfunction memorycan be read by meansof the test connection (X11i4, socket4).

Atmospheric pressure sensor (integrated into control unit) Depending pressure, on altitudeor atmospheric pressuresensorinfluences the atmospheric EGR volumeand boost pressure. The armospneflc pressure sensorsendsthe control unit a decreasing voltagesignalat decreasing air pressures(increasing altitudes).The EGR and P2 reference map valuesare adapted according to a pressuredependent characteflstic.

ie

M o d e lY e a r , S S, @

r o d ".

1 2 4 1 2 s zO1

25

07.1
Test connectionfor diagnosis(Xt 1/4) readout for diagnosis canbe picked The impulse up at thistestconnection.

Engine602.962

Air flow sensor(Bz1) sensor(BZl a) Intakeair temperature the airfilterand in the air flowbetween Located the turbocharger.

A irom ar irlter B lo tu'boc"algel

Actingagainsta returnspnng,IntakearI opens the air flow sensorplateto a specificangle. The position by a of the plateis measured into a potentiometer whichconvertsthe position voltagesignal. is read by the The intakeair temperature in the air flow sensor(82,''la) temperature sensor.

,ll
l -\\

r.L1 I o)-

Y31/5) Vacuum transducers (Y31/1, the vacuum conditions, Respective to operating receivea controlcurrentfrom the transducers then controlunit. The vacuumtransducers amountof vacuumfor delivera correspondtng valves. the electricswitchover

Y31/1 EGR vave vacuurflransducer Y31/5 Boost pressurecontrol/pressure controlvalve vacuumtransducer(not v slble, located underair liller)

26

r5

ModeiYear 1992Q!,

Modets124. 1z g.2A l

Engine 602.962
EGRswitchover vatve(y27),EGR microswitch (S27/3) The EGRswitchover valve (y27)is actjvated by the control linkage microswitch (S27r3) 10" before full load, thereby closing the EGRvalve.

07.1

[l-.
9 N -/@

t\)
s27i3 EGRm croswrtch

yz7/S) Electric switchover valves (y2714, Depending on operating conditions, the electric swrtchover valvesreceivea controlcurrentfrom the controlunit and vacuumfrom rne vacuum transducer (Y3115).They conveythe controlunit commandas a pneumatic signalto the boost pressure controlvalveand pressure controlflap.

Y27 Y27/4 Y27t5

EGR swrlchover valve Eoostpfessure control swtlchover vave Pressurecontroli ap swrtchover valve

Starter ring gear speed sensor (L3) Determines enginespeedvia the starterring gear ('144impulses per revolution) and sends it in the form of a AC voltagesignalto the control unit.

,rL3 /./

1 \d'o.-,,) W,

ie

year,eeZ Mo.iel @

Voa"t" 124 12s zaj

27

07.1
(85/l) Pressure sensor the Located on the right, behind thefirewall, pressure pressule (P2) reads and sensor the it intoa voltage whichis usedby converts signal unitas an input signal. the EDScontrol

Engine602.962

4.7 5V

in mbar, relerence Pabs Abso utepresslre a t5 v s u p p y v o l ta g e

EGR valve (60) with the mixture tube, The EGR valve,together is boltedlaterally to the cylinderhead. lt is to the exhaustmanifold, the intake connected pipe and to a corrugated manifold crossover vacuumfrom the switchover tube. Controlled (Y31i1) is ualvelY27)and vacuum transducer applied to the EGR valveto open the valve.

B a 0 c
d

Exhaustto lhe nlake manrlo d Exhaust fromthe exhaust manrfold Vacuum connectron Spnng D aphragm
VAIVE

28

6*

',,to,-

o, .nr@u,

,p\ I2d

-o -0'

Engine 602.962
Coolant temperature sensor (81 1/4) Coolant temperature is determined by the coolant temperature sensor(811/4) whichis controlled by t he EDS control unit. The temperature sensorresistance changes accordrng to coolanttemperature.

07.1

Housing (94a)with pressure control flap (99) and vacuum actuator (100) A pneumatically operated pressurecontrolflap, locatedIn a housingon the intakemanifold. aolustsboostpressurein the intakemanjiold. The pressure controlflap closesthe fresh air intake duringEGR operation. A rninimal opening (arrows) betweenthe pressure controlflap and the housing remains. The vacuumactuator (100) s actrvated by the pressurecontrolflap switchover valve (Y27,'5) and vacuumtransducer (Y31,,5) (seef unctionat diagram).

60 100

:--,1t
EGR vaive Vaclum actuator

6q

M o d e lY e a ' , n n , @

Vo ,t" t. 1 2 4 1 2 s zo 1

29

07.1
Vacuumline layout

Engine602.962

D ,C

/o

lili

"rllll

'l

2 6 60 61 b 6 1d 62 62a 67 72 99 10 0 10 3 13 7 137a 13 8 14 0 8 5/1 Y22 Y27 Y27/4 Y27/5 Y3 1i1 Y3 1/5

Injecl on pump Governor Vacuumshul-oft un t EGR vaive Or fice prece(wrthout Conneclion ofiiice) Fr t er F ler Vacu!m conlrol valve vacuumpump Darfper Pressure flap control Pressurecontfolllap vacuum actuator Aneroid compensator iALDA) Turbocharger Boostpressure control vave vacLrum actuator Intake manlold Brake boostercheck va ve Prcss!resensor(EDS) E ectromagnet c actuator, elecvonrc dle speed contro (ELR) ttiH sw cnoverva ve Boostpressufe valve control swrtchover Pressureconlro f ap swrtchover valve EGR vacuurn lransducer 8oosl pressure I ap control/pressure control vacuumtransdLrcer

a o c e

Firewa I vent rneto passenger comparlmeft Key shLrtoif Rernain ng vacuumconsumers Erakebooster Pressure and vacuum cohnections at vacuum lransducels Vacuumffom vacuumpump Vent rneto passenger compartmeft (Y31i Fromvacuumlransducer 1) to EGR valve(Y27) swrtchover (Y31/5) Fromvacuumtransducer to swrtchover valves(Y2714) and (Y27,5) 0 acK whte grey brown blue lransparenl

VAC ATM OUT OUT

sw wof ws qr br bl t

30

de

Model Year tSO, @

124 12g 2A1 "o,1","

Engine602.962
Electricwiring diagram

07.1

x26

x4l 1

s2t2

xl114

8211 85/1 81 1 i4 F1 K',t /1 L3 L3xl L7 N39

s2/2 s27i3 w10 x4/1 x 4/ 10 x 11/ 4 x26 Y22 Y27

Arr llow sensorwrth inlake a|l temperature sensor(EDS) Pressure (EDS) sensor Coolantternperature sensor Fuse and relay box Battery Overvotage proteclron relay, 87E (7-pote) Starler ring gear speed sensor connector, slarler ring gear speed sensor Fuel rack posrton sensor EDS control unrt Glow/siarter sw lch Mrcrosw lch (ECR) Ground, battery Terminai block,termtnal (2 pote) 30/interior Termrnal block, termrnal 30/61,battery (3 pore) Test connectron ior dtagnosis (rmpu se readout, B-pole) Connectof, rntenor/eng ne (t 2-pole) E ectromagnettc actuator, eleckonicdle speed control lELR) EGR swrtchover va ve

Y274 Y27t5 Y31/1 Y31i5 z6i2 z7 t2

Boosl pressurecontrolswrtchover valve PressLrre controlilap swrtchover valve EGR valvevacuuan kansducef Boost pressurecontro/pressLrre controi flap vacuurf transducer groLtnd Connector sleeve, supply(soder joinl n connector) Connector sleeve, lerminal B7 (soder lorntIn narness) To A/C compressor controt unrt(N6),p n 4 To A,/Ccompfessor coftrolun t (N6),prn4 black whrle grey yerow green blue re0 prrk

a 0

gr gn
b

or n
TS

de

M o d e lY e a f , SSa @

Vo tu

"

1 e 4 1 zs 2 o 1

JI

07.1
test dieselsystem(EDS) Electronic
The test is dividedinto the following: . Diagnosis, o Electrical test program, o Functaon idle speedcontrol, test, electronic EGR, P2-control.

Engine 602.962

Diagnosis Test conditions: . 60 - 80 "C, Coolanttemperature o Automatic climatecontrolofJ, o Selector "P'. levertn position . protection fuse OK, Overvoltage o Batleryvoltageapprox.12 volts at protection relaybetween overvoltage sockets 1 and 5.

32

65

ModelYear ,SS t @

to,l "

"

12 4 12g.2A 1

Engine602.962
Special tools

07.1

<\

tl

F
201s8900 99 00
201 589 13 21 00

,, att a. ,, -

60358900 21 00

,ry
) { rt- tat aara * Flukemodels23, 83, 85, 87 Sun DM[/-s Bear DACE (Model40-960) Sun EIVIT101g/N/aster 3 Sun MCM-21 10 Sun MEA-1500M8 Y-distributor 117 078 01 45

1) Available throughthe MBNA StandardEqujpmentprogram

ig.r

M o d e lY e a r ,n n a @

L o O" l. 1 2 4 . 1 2 g ,2 O1

33

07.1

Engine502.962

diagram Connection

013

counter 013 lmpulse Battery Gl for X11/4 Teslconnection 0ragnosrs

sw ge rt otacK yellow red

Layout(X1'l/4)
1 2 4 Ground TD srqna unrtrnpulse EDScontro readoul

Note regarding impulse readout: a lf the impulsereadoutdoes not indicate perform in a malfunction spiteof complaint, function test. The number" 1" indicates that thereare no malfunctions in the electronic recognized reler to a particular All further numbers system. source. or malfunction component ranging from 1 to 15 may be displayed Numbers counter. on the impulse the It the LED "U-Batt"lightsafterconnecting then the impulsecounterand impulse counter, counterare ok. voltagesupplyfor the impulse

34

iS

Mode Y ear 1992@

Model s 124 12s 201

Engine 602.962
Testing with impulse counter 1 Connectimpulsecounteraccording to connection diagram. Note: LED "U-Batt"in displaymust tightup, olnerwrse: a) Check impulsecounterfuse, b) Checksocket 1 of test connection (X11i4) againstthe positivepoteof the battery (11-14 V), c) Check socket4 of test connection (Xl 1i4) againstsocket 1 (6-12 V). 2 3 Engineat idle. Pressstartbuttonfot 2 Io 4 seconds. Readand note impulsereadout displayed. = no malfunction Display" 1" stored, Greater than "1' = malfunction In system. Pressstart buttonagainfor 2 to 4 seconds. lf thereare no furthermalfunctions in the system,the previously displayed numberwill reappear.lf additional malfunctions exist, then the respective malfunction code will be drsplayed. Repeatstep 5 untilthe first number displayed is repeated. Eliminate notedmallunctions (impulse readout) according to troubleshooting chart. Performtests of individual components.

07.1
Erasing malfunction memory: After eliminating a malfunction, the respective impulsereadoutmust be clearedas follows: 9 Pressstart buttonand read out the eliminated malfunction.Then press the start buttonfor 6 to 8 seconds. Note: Each malfunction displayed must be erased individually. lf the malfunction has been eliminated and its respectrve readouterased,then the malfunction code will n0 longerbe displayed when perlorming the impulsereadout. lf the numberdisplayed is greaterthan 1, then there are furthermalfunctions in the system.

M o d e lY e a r , S SZ@

to C"t. 1 2 4 1 zg 2 O1

35

07.1
Malfunction table The respective numberin the displayof the impulsecounterindicates whethera component is defective, which one it is, or whether or not in the controlcircuitare delective, components EDS control unit lmpulsereadout Component/'malf unctioncircuit All functions ok. no malfunction stored Fuelrack position sensor(L7) Air flow sensor(82i 1)

Engine602.962

pressuresensor EDS controlunit (N39),atmospheric (Y31r EGR valvevacuumtransducer 1) or malfunction in EGR control circuit EDS controlunit (N39),internal voltagesupply Starterring gear speedsensor(L3) Coolant temperature sensor(811i4) lntake air temperature sensor(82 1a)

10
1121

Voltagesupply Electronic idle speedcontrolactuator or EGR valvevacuum (Y31i transducer 1)

12
/.t

Notused
EDS controlunit (N39)defective(internal memory) EDS pressutesensor(85/1)detective Boostpressure (Y31/5) control/pressure controlflap vacuumtransducer or defectin boosl pressure controlcircuit.

14

r) lf thereare complaints perform nonelheless, function EGR and P2-control. lestsfor eleclron c dle speedconlrol, 2) D sp ayed only il ther a shortc rcuit.

36

fF

Model Y ear,SS t @

toa"'.

124. 12g 201

Engine 602.962
Electrical test program Connection diagram, socketbox

07.1

002 003 004 005 N39

25-po1e lest cabte124 589 33 63 00 Multmetef 3s-pole socketbox 124 589 00 2i 0O Test cable124 589 34 63 0O EDS conlrol un t

9999e9999 @OOeOO@@o
oooo@ooo@ o@oo

004

Equipmenvtest symbols
Socketbox Nlultimeter Socket Pin -t-=@lVoltagemeasurement (DC volts) Resistancemeasurement(Ohms)

Note: lf nominal valuescannotbe met when performing pneumatjc tests,ensurethat all vacuumlines and connections are in orderby comparing routingand connections to applicable EDS vacuumschematrc. Test program

rmpurse Teststep/ readouttestscope 1

1.0

Test connection

Test condition Nominal Possible causelremedy value No malfunctionstored. lgnition: OFF EDS control unit unprugged. Replaceinjectionpump, Wiring. 50 14 0 25 !2 Q
co0 coO

2.0 N39 t:t::ir ii Fuelrack posrn0n 4 < (L7) a -< -=@! sensor -:@l-

a -< -! 4 <* !r

> s >- o >-s r

Mo d lYea r ez @ ,s

"oa"t .

124. 129. 201

37

>

07.1
Teststep/ tmpurse readouttestscope
Test connection L7

Engine602.962
cause/remedy Test condition Nominal Possrble value lgnition: OFF on Connector fuel rack posrtron sensor(L7) unplugged. Connector on fuel rack position sensor(L7) unpruggeo. 50!4 0

pump. Replace injection

zFuelrack posrtron (L7) sensor

--@ - * 3

t7

25 !2 Q

pump. Replaceinlection

e'.

--@!

.-r

2.2 Wiring

N39
,,! l: -J()}-+ <--{ o tj+ a a

Connector on fuelrack (L7) sensor unpruggeo.

lgnition:ON EDS control unit(N39) connected.

<10

3.0 Air flow sensor \82t1)

N39 ffit

510.5V

EDS control unit (N39).

3 ,< -:O!>
N39 FI

2a

< 0 . 5v

Opencircuit.

3 < -:@L>N39
*l ltlu l

to
Engine: at ldle 1.7 ! 0.2 V 1) EDS control unit (N39).

31

*@!r

ro

1) Voltagencreases rpm. wth Increastng

38

,SS, @ Model Year

Uoa". n4 ng 201

Engine602.962
lmpurse Teststep/ lTest connection readout testscope I

07.1
Test condition Nominal Possible cause/remedy value

tsl

Air flow sensor (B2i1)

I |

N39 ::::::i:::

tll I
|

lt I -

*-@t,

24lunit.(N3s). I lunpruggeo. I

_ lt q n it io nO : FF 1500 I EDScontrol I 12000

Air f low sensor(82/'t).

ls
| I
I'

--<*@1-> r0lposition. I
_\i!9. E

N39 1,,,,,,,.|l

| Air flowsensor I 50 rest 0 lptate, 1200

Air flow sensor(82/1).

rrl

3.2 Wiring

tttl
I

lt'<

-@-r-

r o ld e tte cte o |

IAirflowsensor |560futly I t rooo lplate,

Air flow sensor(82/1).

]
I |

Iro -<-'@t > sl{ezrr) tltt llCq

l r+

l !9 9 I iir*l

lConnector on lcto 82,'r sensor I airftow |

| l.ro

lunPrussed l
eztl

I
|

lro-.--@t , ol
tttl
4
4.0

I Opencircuit.

I
Atmospheric pressure sensor, replace EDS control unlt(N39).

5,r

5.0 EGRvalve
VACUUM

N39

Engine: at 700 ! 50 rpm

>3 V',)

transducer ( Y31 /1) EGRvalve

ig < -1-

>- r

Vacuum tester with Y-distributor at EGR valve.

approx. 250 mbar ')

Supplyline (blackiwhite) leaking, Vent line (black)clogged, Ventfilter(62a)clogged. Supplyline (black/white) or r'acuum line (blackrubber) llosed or jnterrupted. :GR valvevacuum :ransducer (Y31/1), rViring, :DS control unit (N39), \ir flow sensor(82/1), :GR valve, ,'oolant temperature ;ensor,

Brielly apply full throtUe. Vacuumand vo tage fall. The test va ues are aoproxmate.

M o d e lY e a r 1 9 9 2@

M o d e ts1 2 4 i2 9 2 0 1

39

07.1
Teststep/ rmpurse readouttestscope
c. I

Engine 602.962
Test connection cause/remedy Tesl condition Nominal Possible valus <,1 o

Wiring (Y31/1 )

N39 ll'*l 18 <-*_

on Connector Y31i1 vacuum r_ r transducer (Y31/1 ) unplugged.

Opencircuit.

N39

1 -< nsi,ts
5.2 EGR microswitch r

Y3111 >2

<1

Open circuit. (327/3). EGR microswitch

s27i3
-:/6Y-

(s27/3)

lgnition: OFF lvlicroswitch a connectot unpruggeo -Accel.pedal not in full load <1 0 posrtron. -Accel.pedal in Iull load posrtron.

coO

s27i3 5.3 3_< *@, Wire between EGR microswitch (S27l3)and EGR switchover valve (Y27)
5.4 EGR switchover valve (Y27)

Y27 lgnition:OFF on 1 i Connector

EGR switchover valve (Y271and on connector EGR microswitch(S27i3) unpruggeo.

<1

Vacuumtesterwith at Y-distributor valve switchover (sideoutlet).

Engine: at ldle > 250 mbar Full throttle < 10 mbar

EGR switchover

6.0

voltagesupply, Internal replaceEDS control unit (N39).

40

r5

Mo.le Year 1992 @

Models 124 12g 2o1

Engine 602.962
lmpulse Test stepi readout resr scope Test connection

07.1
Test condition Nominal Possible causeiremedy value

7.0 I Starterring | gear speed sensor(L3) lc

Hrss

. *!>

:"'::::

I rnoin.' rot"Ttz v "t I EDS control |

ttl
7.1 TD-signal
N39 :::i:r::ii ^ t.. >

zolunit I lunprusseo. I
| E noi ne: at l dl e I EDS control

Speedsensor,gap, dirt, " Wiring.

> 3.5V2)

3 -< --(!F

25 lunrr lconnected.

Shortcircuitin wire from N39 to (X1 114) or EDS controlunit (N39).

B;,; ;
527 Q 110 0/o

Starter ringgearspeed (L3), sensor Wiring.

VDO'' 1900 Q 110"./"

Connector (L3x 1) unplugged. Seru'' 527 Q ! 10 % VDO 3) 19000 110 % <1c) Starterring gear speed sensor(L3).

<l

)pen circurt.

I ) Vo tage ncreases wtlh ncreas ng rpm 2) Voitagedecreasesw'th ncreastn'g rpm. 3) Measured at 20 "C ambrent (forevery 1O 'C diiierence temperature in ambrent terfperature, the resstance changes by 4 %)

M o d e Y e a r r9 9 2 @

M o d e r si? 4 , 1 zg ,2 A1

A1

07.1
rmpurse readouttest scope
Test connection

Engine 602.962
remedy Test condition Nominal Possible causei value

N39 8.0 ;t,tl,tt:,1 Coolant IemperalUre 3 < r-9 -:@! r senso (B11ta) 8.1 Coolant Iemperalure sensor (811/4) N39

lgnition: ON EDScontrol unit connecleo.

Coolant temperature sensor, Wiring, EDS controlunit.

r:r

1a { -ior*

)- I

lgnition:OFF EDS control unit unprugge0.

temperature Coolant sensor, Wiring.

r ) 11

,1

Connector (811,4) unplugged.

1)

Coolant temperature sensor.

8.2 Wiring

N39

--*t < --(4+ 9 9

lgnition: OFF 811,4 EDScontrol unrt eo. unprugg

< 1Q

N39 lgnition:ON 9.0 :iti::::::] EDS control Intake arr *! unrt temperature 3 < >- 22 connected. sensor (82/1a) 9.1 N39 lntakeair r.iJ Iemperature 3 < -:@!> sensor (B2r 1a)
B2t1 --tt*

r)

Air flow sensorwrthintake air temperature sensor(82,1), Witing, EDS control unit (N39). Wirinqto intakeair sensor, temperalure Intakeair temperature sensor(82,,1a).

lqnition:OFF EDS control 22 unrt unplugged.

*2

on r) Connector air flow sensor(82,'1) unplugged.

Intakeair temperature sensor(B2i1a).

1) See tablefor coolant sensors. and rntake ar lemperature

ModelYear ,SS r @'Vo,l u'.

124 12s ,2A 1

Engine602.962
lmpulse Teststep/ readout reslscope
IOt

07.1
Test condition Nominal Possible causei remedy value lgnitjon: OFF EDS control 1 unit unplugg6d, connector0n air flow sensor(82/1) unplugged. <1 0

Test connection

9.2 Wiring

N39
ili:::iiiji]

Opencircuit.

B 2i 1

22 -<-@!

N39
::t:i::::i Fl t I

3 -< *agF 10
10.0 Voltage suppry
N39

)- 2
Engine: at approx. rpm l '1500

<1

Open circuit. Voltage> 18 V, voltage regulator.

14-<@ r

'!jli:r:rl

11')

11.0 I Electro- , m asn e trc l s actuator. I erectronrc I idle speed I control I (Y22) |

.N39 a.,,,, (*@:-r

I''r*ll

l l t -Npe. I
ruis

at (Y22), | Engine: I 11-14V lActuator wring. lapprox. I I zllboor pm I controt I IEDS lunit I lconnected. I I I | I

|
'?) EDS control unit (N39), performtest steps 5 and
tc,

ttl
,t.t 1
I

attote r . c ! z -< -=e- >- r Enoine: I I 0.5 v oril lr.",tion:

IEDS control I

t lt
t

411Q

nltr","r. fvizl,

""''"" lr . -=@- r e lunit

I
Open circuit.

lunPrussed l
--19+

11.2 Wiring

lgnition: OFF Y22 Connector on (Y22) >-2 actuator

unplugged.

*t 2 < -=@!

N39

Y22 Opencrrcutt.

Drspayed only f there rs a short circuit. Reference va ue only,voltage decreases wtlhlncreasrng engtne speed.

y e a . ]9 9 2 [.4ode @

M o d e ts1 2 4 1 2 s za 1

43

07.1
rmpulse Teststep/ reaooutresrscope
Test connection Test condition Nomrnal value

Engine502.962
Possible cause,remedy ReplaceEDS control unit (N39). N39 lgnition:ON EDS control 12 unit connected. > 4_9 V Pressulesensor, Wiring.

13

13.0

14

1 4 .0

Pressure sensor (85/1)

'14.1

3 <

E *@->
l;-t

N39

Pressure sensor (85/1 )

Engine: at ldle >'1.5V 0 mbar

3 <.@ r

tz

Pressure sensor, Pressure lines, Wiring.

Vacuum with tester Y-distributor at pressure sensor.

Brief ly apply fullthrottle.

Voltage increases as pressure rncreases > 500 mbar

14.2 Pressure sensor (Bsi 1) 1 4 .3 Wiring

N39 :t 3 < -!> t2

lgnition: OFF 310.2 kQ Pressure sensor, EDScontrol Wiring. unit unprug9eo.

lgnition: OFF
< 1Q

N39 L.::::::1 3 < -:@!

N39 i ;:::rr::1

Opencircuit.

8 5 1 EDS control r 2 unit

unpruggeo.

14.4

Wiring

12 <*:o!
' 1 4 .5 Wiring

lgnition: OFF EDScontrol > 3 unit unpruggeo.

85 1 lgnition: OFF EDS control unit unpruggeo.

<10

<1f2

Open circuit.

85 1

17 <-@1-r

44

i -r

V odo ,"ar 'oez @

l i o r. s 1) 4

29 201

Engine602.962
rmputse readout
15.0 Vacuum transducer (Y3115) Boost pressure controll pressure controlflap
l:::_t lrl"l

07.1
Possible cause/remedy N39 Engine: at ldle >4 V r) EDS control unit connected. Supplyline (blackiwhite) reaK, Vent line (black)clogged, Vent filter(62a)dlrty. Supplyline (black/white) or vacuumline (black rubber)cloggedor leaks, Vacuumtransducet (Y31i5), Open circuit, EDS control unit (N39).

*=@!

(our).

Vacuum tester with Y-distributor at vacuum transducer (Y31i5) outlet

> 300 mbar ')

1;. i
Wiring
+ lo!j+

Opencircuit.
Y3115
L r

N39
:ji:::::::]

--(!-F 15.2 Boost / control swrtcnover

VAIVE IY'7 A\

unplugged, connectorat Y3 1r5 Y31,'5 ) 2 unprugge0.

<1 Q

N39 ==] Lrn:l *!Y_r

1 connected.

pressure Boost control switchover valv e (Y 27|4), EDScontrol unit(N39), Opencircuit.

Vacuumtesterwith Y-distributor at switchover valve (Y2714) (side connection).

Enginei at ldle 12V > 300 mbar

Engine speeo:

<10 > 1000rpm '?) mbar

tc.J

N39

Pressure controlflap swrlcnover valve

*t

7 < -=o!

>

connected.

""",r"r swatchover valve(Y27,/5), EDScontrol unit(N39), Open circuit.

pt".lrr"

ii";

Vacuum tester with Y-distributor at swrtchover valve (Y2715) (side connection).

Engine: at ldle 12V > 300 mbar

> 1000rPm2)
r) 2) Voltage and vacuLrm decrease withtncreaslng rpm SlowlyIncrease eng ne speedto tOOO rpm (lrom idle)

> 200 mbar

f,

VodFl,ea

S9 2 @ vo o e ,s

)a

1 2 s lo l

45

07.1
rmpurse Teststep/ readoutresrscope
Test conneclion N39
iiii:ri::i

Engine602.962
Testcondition Nominal
value <1 Possible cause/remedy

151

15.4 Wiring \Y27t4)

7 --< N39

nsry

L :l:::i:iiil

'I --{

---ts

lgnition: OFF Y27/4 EDScontrol )-1 unit unplugged, conneclor aI Y27t4 Y27t4 >- 2 unplugged.
Y27t5 lgnition:OFF >-r connectorat Y27i4, Y27t5 unpruggeo. Y27t5 )_ 2

Opencircuit.

<1
<1

o
0

15.5 Wiring (Y27/5)

Y27t4

r _< *L

Y27i4

2 --< --(!-F

<1

Coolantand intakeair temoerature sensors Temperature in "C 20 30 40

50 (! 10 %) Resistance Voltage( 1 10 o/o ) 3.85V 3.47V

2.5ko
1 .7 kQ 1 .18 kQ

3.05V 2.63V
2.22 V 1.85V 1.5 V 1.22V

833 0 6000
440 Q 327 Q 2$A 185 Q

60
70

80 90 100

0.99 V

40

i t

[,l odel Y ear ,nS, @

toC "'" 124 , 1z g z l l

Engine 602.962
Function test, electronic idle speed control (ELR),EGR, pz-control Note: This test shouldbe performed if, in spiteof a complaant, the impulsereadoutdoes not indicate a malf unction.

07.1

Engine602.96 Teststepi resrscope

Test connection/ equipment Test condition Nominal value

Possible cause/ remedy

Actuator, Injection pump, Starterring gear speedsensor(L3), EDS controlunit (N39),see test steps 7 and 11 (EDStest). Adjustenginespeed at Inlection pump, InJection pump.

1.0 Connecttachometer Engine: at ldle 680! 20 ldle speedcontrol to test connection Coolant temperaturerpm (x11i4). approx. 80 "C.

Connector on 6 1 01 2 0 actuatorunplugged. rpm

2.0 EGRcontrol circuit

Connectvacuum testerwith Ydistributor to EGR valve.

Engine at 900150 rpm and approx. 300 mbar, brieflyapplyfull throttle.

Vacuum Vacuum transducer decreases (Y 3111),

Vacuumswitchover value(Y27), Nlechanically check air llow sensor(82/1), EDS control unit (N39), EGR valve, Pneumatic connectrons.
tuH vatve

3.0 EGRvalve

Connectvacuum Engine: OFF testerdirectly to EGR Apply 300 mbar valve, vacuum to EGR

ReplaceEGR valve.

closes aud ibly

valve. Pulloff vacuum ltne.

l
ie M o d e lY e a r tSOa@ Vo ,l"l. 1 2 4 . 1 2 g ,2 o 1

'

47

07.1
eSI SreP/

Engine602.962
Test connection/ equipment Test condition Engine:at ldle Nominal value

test )st scope

Possible cause/ remedy

4.0 pressure Boost control

vacuum Connect (20)withYtester to outlet distributor (OUT) vacuum of (Y31i3). transducer

> 300mbar Vacuum supply, Vacuum line, Vacuum transducer (Y31/3), EDScontrol unit(N39). Vacuum decreases

pressure Boost valve control vacuum actuator

4. 1

Slowlyincrease enginespeedto approx.2000 rpm

Engine:at ldle vacuum Connect Pressure control tester(20)withYto pressure distributor flapvacuum flapvacuum (100) control actuator (100). actuator Slowlyincrease speeoro engrne approx.2000 rpm

< 100mbar Vacuum supply, Vacuum line.

Vacuum increases

Vacuum transducer
(Y3112), line at Pressure pressure 1), sensor(B5i EDS control unit (N39).

I
48
i . ModelY ear ,ner @ 124 12g.2a1 "oa","

Models124,129,201 Automatictransm ission Deletion pump of secondary

27

Transmission 722.3
17 Cover 1 8 Gasket 4 3 Axralbracket Nut, axlal bracket 46 Governorcover Snap nng 50 Governor

The secondary pump was deleted. As a rssult, it is no longerpossible to tow-start the engine. Towingof the vehicleis still possibte as previously, i.e. selectorleverin position"N", maximumtowingspeedof 50 km/h (31 mph) and a maximumdistanceof 50 km (31 miles).

A cover (17)and gasket('18) are used to close oft the existing boresfor the secondary pump in the transmission housing.

M o d e l Ye a .1 SSZ @

Vo O"i. 1 2 4 .1 2 g ,2 o 1

49

27
with this change,the bores for the ln conjunction plate secondarypump in the largeintermediate valves The check deleted. (14) have also been pump (a9) and (67) as well as the secondary as well. (66) have been eliminated shift valve This does not applyto s-speedautomatic in model129 061' 722.5installed transmission (66),but only as a valve which still uses the shift closureplug.

Models124,129,201

Transm ssronhousng Lower cover p ate LargeIntermedlale 19 Gasket 4g Check valve 66 Shrft valve - secondary p ump Check valve
l

t3

u*^67
66

50

i gb

Mooe ,par'oq:@voo"s

2a

!9 2A 1

Modefs124,129,201
Upshift delay

27

3/1

P27-5073-59

1 2 3 B I

Controlpressure cable Checkvave lntakemanfold Upshtt delayvacuumeiemenl Vaculm reservorr

N3/1 LH control unit(N3 - CIS-Econlrol unrt) Y3/3 Upshiftdelay swrtchover valve gr gn

black grey qreen

f,

ModelYear ,Sn, @

VoO"t.124 12s zo1

ci

27
Modified upshift delay for rapid heating of catalyst by a controlled The upshiftdelaypreviously (Y3i2) in the relay(K29)and a solenoid pressurg governor ctrcuithas been eltminated The upshiftdelayis now actuatedpneumatlcally valve (Y3/3)and a by meansof a switchover vacuumelement(8) on the controlpressure the bowden bowdencable. This modifies on the controlvalve (46) in the cable'sinfluence valvebody.

Models124,129,201

Operation vehicle on the coolanttemperature, Depending delay the upshift and running time, speed groundvia the valve (Y3i3)receives switchover (N3). vacuum element The unit CIS-Econtrol the swltchover (8) then receivesvacuumvaa following conditions: valveunderthe aPProx. temperature Coolant 0 "C to 50 "C max., Vehiclespeedbetween6 mph (10 km/h) and 30 mph (48 kmih). Upshiftdelayremainsactivefor a maximumof 80 seconds. Underlightthrottlethe approx. shift pointfor the 2 - 3 upshiftis raised,thereby increasing the enginerpm and heatlngthe values quicker. The abovementioned catalyst on valuesand can vary depending are nominal version. engine

52

ModelYear ,nn, @

"oo" "

12 4 129 2a1

Models124,129.201
Vacuumelement(8)

27

P27-O200-59A

1 2

pressure Control cable Sh ft vatve

Lever

Lever

;i;J;"n.

vacuum pulls the diaphragm (6) to the reft agarnst the force of the sp/ing (5). By meansof a lever (4), the shift valve (2) is then moved upwards,independent of the controlpressure bowdencable(1).

rhis causesthe shift varve(2) to move the controlpressure varvevra a connectrnq rod and lever (3).

65

M o d e lY e a f r S e , @

1 2 4 1 2 s.zo 1 " o ,t"t.

53

35 Rearaxle
information General
Therearaxleratiowaschanged in models '1 / 029. 24.026, 201.028

.028lO29 Models'l 24.026,201

Gearset and rear axleshaft

Model 124.026 automatic Ringgeardia. (mm) 185 Ratio No. of teeth Gear,irotor on drive pinionfor ABS/ASD joint velocity Constant flange dia. (mm) Rearaxle shaft wrtnconstant vetoctw i^,^+ Balldia. inner (mm) No. of teeth 2.87 43:15 201.928 automatic 185
z,6a

201.029 automatic 185 2.85') 37:13

Transmission version
Rearaxlecenterpiece

37:13

33 90
22.225

34 90
19.05 19.05 86 25 100 100

90 22.225
22.225 94 25 120 120

ua dta.outer(mm) 22.225 Innerboltcircle diameter(mm) Shaftdia. (mm) Greasef ill quantity(g) Greasefill quantity(g) 94 25

inner 120 outer 120

l) matched Cearset

54

i r*

l l ode Year 1992@

Model s 124 . i z s ,2a1

Models124,129.201 Steering
Steering wheel(140-design)
All modelsare equipped with a newlydesigned steering wheelwhich is 400 mm in diameter (Sportline models390 mm). The steering wheel, alongwith the transmission shiftiselector lever knob,are coveredin leather. The steering wheelin model 129 is colorcoordinated to the interior. lnstallation note: Correctpositioning of the steering wheelduring installation is assuredby two groovesin the hub (arrows) and by a mark on the steeringshaft spin dle.

46,54

Electrical system- equipment and instruments

Instrument cluster
CHECK ENGINEwafning tamp (Ate26) Federal versionmodelsare no longerequipped with a cHEcK ENGINE warning lamp. As a result,the O2-sensor signalis no longerbeing monrtored in these models. California versionmodelsremainequipped with a CHECKENGINEwarninglampto jndicate an emissions-related component failure.

{eh

M o d e lY e a f ,e n a @

Uo ,ln l" 1 2 4 1 2 g .2 O1

55

32
Generalinformation

(models124.030/051, 201.029) Sportline

for A sportspackage(i.e. Spor/lne)is available and 201.029. Sporfline models 124.030/051 to provideenhanced modelswere developed drivors. for performance oriented characteristics by two badgeson modelsare identitied Sportline quarter panels and a leather front vehicle ths coveredshift knob with a Sport ne emblem. as are detailed modifications equipment Sportline follows:

Suspension

ications Modif
have components suspension The following performance: handling to increase been modified . . . . . Frontand rear spnngs, Frontdamperstruts, Rearshock absorbers, Controlarm bushings, Torsionbars.

The sporttuned springsand shocksare 20ok lime( than the standald approximately installed. components The overallvehicleheightis ioweredapprox. 23 mm 21 mm for model20'l.029 and approx. for modelsl24.0301051.

56

ModelY eaf ,ss, @

toa"'.

124 12g.2o1

Sportline(models124.030/051, 201.029)
Test and adjustmentdata

32

Crossreference Front spring

struts/shock absorbers Front damper strut Rear spring partno.

124 320 56 30 124 324 23 04 124 324 28 04

Rearshock aosoroer pan no.

124 320 17 31 124 320 17 31 201 320 12 31

124.030 124.051 201.029

124 321 29 04 124 321 29 04 201 321 37 04 201 321 38 04

12432056 30 201 320 44 30

'124 32428 04
201 324 39 04

Frontaxle - numberof points

L4od el Base points Slidingilifting roof Automatictransmission Automaticlockingdifferential (ASD) Headlamp cleaningsystem

124.030
57

124.051

201.029 49

3
Standard Not available Standard

3
Standard Not available Standard

2
4
'1 1

Crossreference - front springs/rubber mounts

N4odel Totalpoints Frontspringpart no. Heightof rubbermounts (mm) according to springcolor code blue 124.030i 051 53-59 60-66 124 321 29 04 201 321 37 04 2Q1321 38 04
t\)

red '18 23

18 '18 8

201.029

up to 49 5 0 -57

23

if,.

Model Year ,SSt @

Uo,lu

"

124 12g 2O1

57

32
Rearaxle - numberot Points
Model

(models124.030/051, 201.029) Sportline

124.030
29

124.051 41

201.029 19

Basepoints
roof Sliding/litting

3
Standard Not available

3
Standard Not available Standard

Automatic transmission (ASD) locking differential Automatic Rearheadrestraints

Standard

mounts Crossreference - rearsplings/rubber

Model Total points

partno. Rearspring

(mm) mounts Height of rubber colorcode according to spring

DIUE

reo 18 13 18

124.030
051 124.030i 201.029 201.Q29

21 -31 32-41 42-50

124324 23 Q4 124324 28 Q4 201 324 39 04 201 324 39 Q4

IJ

8
t!t

up to 25
26-34

8
IJ

18

58

f,

vodel "ear rssu @

V ooes t?a ' z e 2ol

Sportline(models124.030/051, 201.029) Wheels,chassismeasurement, wheel alignment

40

Wheels
Cross reference tire brands - wheels^ires/recommended
Model Rim designation Summer tires, tubeless part no. Tire size Brand

Winter tires, tubeless

Tire size Brand

124.030 Lightalloy 124.051 7 Jx 15 N 2 ET 41 1) 124 401 13 02 201.029 Lightalloy 7 Jx15H2 Ef 441t2) 201 400 13 02

205i60 ZR

tc

GOODYEAR EAGLE NCT I\,4ICHELIN [4XV

205i60R 15 91 H lvl+S

DUNLOP SP WINTER SPORT

205i55ZR 15

PIRELLI P6

205i55R 15 87TM+S

IVICHELIN I\,1XV

PIRELLI MS WINTER190 or CONTINENTAL SUPER CONIACT TS 740 DUNLOP SP WINTER SPORT

205/55R 15 +S 87H t!1

use balancrng wergnts w lh separate spring retanrnqclp. 2) Only use adhes ve baianctng werghts on ns de of rim.

M o d e lY e a f , S n , @

Uo C". 1 2 4 1 2 s zo 1

59

40

201.029) (models124.030/051, Sporttine

wheel rims Light-alloy 124.030/051 Models with wheel light-alloy 8-hole designed A newly is installed: designation the following 7J x15H2ET41.

K-%B 's-bg
r3 P40.5003
/-\ !

Model 201.029 wheel knownfrom model light-alloy The '1s-hole and has the following is installed 201.034 41. 7 Jt15H2Ef designation:

c. ",.--\/

('|Uf)' "0 "'

^ , l\ ))""

Wheel bolts for light-alloy wheel rims 201.029 Models 124.030/051, for all Sport/lne The wheel boltsare identical mooets. Partno.20'1400 00 70 of head "K" = Height Bolt shanklength "L" = cap. light-alloy 10 Nm. torque: '1 Tightening
1404- t3173 4

22.5 mm 40 mm The screw head is hollowand is coveredwilh a

60

,ss, @ l,lodelYear

ttoa",, 124 12g 2o1

Sportli n e (modets 124.030 t051,201 .0291

Wheelalignment
Test and adiustment data

40

Vehiclelevel lvlodels
124.030i051 Frontaxle (vehtcle at curb werght) mm +2 201.029
+ 10
t,l

Rearaxle (vehicleat curb weight) mm

+ t0

+2

+ 10

+ t0

Frontaxle wheelalignmentat specifiedvehiclelevel (curbweight)

Model Wheelsin straightaheadposition(toe 0.) -0 " 50' Permissible difterence betweenrioht and left 124.030i 051

[201.02e]
+ t0

_20,

(-0.85"

+ 0.15" 0.35'

Caster ')

Wheelsin straightaheadpositjon(toe 0") Measuredagainstwheelstop Permissrble diflerencebetweenriqhtand left

'10'40'+ 30' [10.40'- 30' 10"25',130'

(0.35 ") (10.65 " + 0.50") (10.65.- 0.s0.)l (10,40 " t 0.50.) (0.50 ") (0.35"t 0.15")

(Frontwheelsspreadwith g0 - 110 N force) Toe-outwith innerwheel turned20" 2) I/aximumpermissible steeringangleat innerwheel 3) 4) Balljoint position Permissible ballloint heightdifference betweenpitmanand idlerarms
r) 2) 3) a)

0"20' I 10'

-0 " 5 5 '1 3 0 ' r 30' [-.0.40,

43. 27.5!2 mm [30 t 2 mml

(-0 . 9 0 1 " 0.50") (-0.60.r 0.50.)l

(43.00. )

3 mm

Tolerance rs for checktng only ll ouisde of lolerance, adjustto specriied vaue. Vaue givendoesnol ncludeloe. Wheelange on oulstde wheelwtll be 7, to I j . lessthanon lnsrde wheel. Correctionts made on dler arm n upwardor downwarddirecttonby addtton or removat ol washer.

Note: Values In bold texl and in brackets [ ] are for modet201.029. values n parenlheses ( ) are decimai degrees.

65

Modei Year ,nS, @

Uoa"t. 124 1zs zo1

ol

46 Steering

(models124.030/051, 201.029) Sportline

gear model/steering Crossreference,

Model gear Steering ratioin parentheses) Ratio(standard

124.030
765.928 13.28(13.91)

124.051 765.904 13.91(14.61)

201.029 765.927 13.91(14.61)

wheel(14o-design) Steering

with a newly modelsare equipped Sport/lne whrch is 390 mm in wheel designed steering models400 mm). The diameter(standard is wheel coveredin leather. steering

il

I I
I IT

lI
ll

xi
62
n* ModelYear ,nn, @ 124.12g,2o1 "o0",.

Sportline(modets124.030/0S't, 201.029) Seats

91

Sport 4-placeseating
Model 201.029 Sport4-placeseatingknownfrom model 201.034is installed and is available only in leatherin the following interior colors: creme beige,black,blue,dark brownand grey. Modet 124.030 Sport4-placeleatherseatingis installed and is available only in the following interior colors: creme beige,black,blue,dark brownand grey. Model 124.051 Sport4-placeleatherseatingcontinues to be standard in this modeland is available in all eight interior colors.

n5

M o d e l Y e a .,n n , @

Uo O" ," j2 4 . 1 2 s,2 a 1

o,,