Electrical System PDF

1998-2004 ENGINE
Electrical System - Engine - 170 Chassis

GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE - AH15.00-Z-9999AZ
MODEL all

General notes on
contactless high voltage
distribution
ENGINE 112, 113... AH15.10-P-1002-
01WA

General notes on
distribution
ENGINE 104, 111... AH15.10-P-1002-
01WD

General notes on
distribution
ENGINE 119, 120... AH15.10-P-1002-01WE

General notes on testing
distribution
ENGINE 104, 111, 112, 113,
119, 120...
AH15.10-P-1003-01W

Notes on ignition coil
characteristics of ignition
systems
ENGINE 104, 111, 112, 113,
119, 120...
AH15.10-P-1001-01A

Notes on avoiding damage
to ignition system
ENGINE
266.920 /940 /960 /980 in
MODEL 169.0/3,245.2
AH15.10-P-0002-01AK

to the ignition system
ENGINE 111 with Gasoline-
inject-and Ignition system
PMS
AH15.10-P-0002-01B

ENGINE 104, 111 with
Gasoline-inject-and Ignition
system HFM
AH15.10-P-0002-01C

ENGINE 103, 104, 119 with
Gasoline fuel injection system
KE
AH15.10-P-0002-01E

ENGINE 104, 119, 120 with
Gasoline fuel injection system
LH
AH15.10-P-0002-01F

ENGINE 166 with Gasoline-
Inject- and Ignition system
MSM
AH15.10-P-0002-01G

Information on avoiding
damage to ignition system
ENGINE 137, 275, 285 AH15.10-P-0002-01L

2003 Mercedes-Benz SLK320
1998-2004 ENGINE Electrical System - Engine - 170 Chassis

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Friday, October 30, 2009 7:24:04 AM Page 1 2005 Mitchell Repair Information Company, LLC.
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NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002-01D
Engine 104, 111, 112, 113, 119, 120, 156, 271
To avoid damage to control unit connect and disconnect the two connectors on control unit only when
ignition is switched off.
Terminal 1 of ignition coils must not be short-circuited to GND, e.g. as anti-theft protection.
Install only original ignition system components.
Do not operate ignition system at starting speed unless all of the ignition cables are connected.
No tests such as holding ignition cable 4 at a distance to GND, unplugging a spark plug connector or
pulling cable 4 out of the ignition coils, may be performed at starting speed or when the engine is
running.
Every high voltage circuit must be loaded with at least 2 kohms (spark plug connector).
If it is necessary to test the ignition spark when providing roadside assistance, this must only be done with
a spark plug at a cylinder ignition cable. Ensure that the spark plug has good contact to ground.
Before working at cranking speed, e.g. checking compression pressure, switch off ignition and disconnect
connector "2" from control unit.
Engine 120 has two fuel injection and ignition systems.
Use of testers
Only connect and disconnect secondary measuring sensor to corresponding ignition cables when vertical
engine and ignition are switched off.
If the shot-circuit protection is operated (cylinder comparison) and the engine stays upright, it is not
possible to conduct the test with this test instrument.
Do not connect test lamp to ignition coil terminals 1 and 15.
NOTES ON IGNITION COIL CHARACTERISTICS OF IGNITION SYSTEMS - AH15.10-P-1001-01A
Engine 104, 111, 112, 113, 119, 120

In the case of the twin-spark ignition coil with kV pickup in ignition systems ME-SFI 2.1 and HFM-SFI, no

to ignition system
ENGINE 272, 273 AH15.10-P-0002-01V

to ignition system
ENGINE 104, 111, 112, 113,
119, 120, 156, 271, 112 with
Gasoline-Inject- and Ignition
system ME
AH15.10-P-0002-01D

Notes for ceramic glow
plugs
ENGINE 646.8, 642 AH15.20-P-0001-01A

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measurement facility exists at the ignition coil using the kV pickup although a kV pickup is fitted. It is only
possible to test the primary ignition circuit with adapter cable A.
Ignition coil characteristics of ignition systems
Engine Model HFM-SFI ME-SFI PEC Twin-spark
ignition coil
without kV
pickup
Twin-spark
ignition coil
with kV
pickup
Single-
spark
ignition coil
with kV
pickup
104 129 up to
05/96
X X
104 129 as of 06/96 2.1 X
104 140 up to
05/96
X X
104 140 as of 06/96 2.1 X
104 202 up to
07/96
X X
104 202 as of 08/96 2.1 X
104 210 X X
104
210 up
to 05/96
X X
104
210 as
of 06/96
2.1 X
111 163 X X
111 170.435 X X
111 170.445 2.1 X
111 170.447 2.1 X
111 202.018/020
up to 07/96
X X
111 202.018/020 as
of 08/96
X X
111 202.025 up to
07/96
X X
111 202.025 as of
08/96
2.1 X
111 202.022 up to
07/96
X X
111 202.023 as of
08/96
X X
111 202.023 as of
08/96
2.1 X
111 202.024 up to
07/96
X X

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GENERAL NOTES ON CONTACTLESS HIGH VOLTAGE DISTRIBUTION - AH15.10-P-1002
General notes on contactless high voltage distribution - AH15.10-P-1002-01WA
Engine 112, 113 with ME-SFI fuel injection and ignition system
The ignition system can be tested at the primary side and secondary side. It is only possible to test ignition
circuit a and ignition circuit b one after the other.
The ignition coils are fitted as standard with cast mounts for the secondary adapters (kV pickup C). The primary
ignition voltage curve can be plotted with a primary adapter cable (D).
111 202.024 as of
08/96
2.1 X
111 210 up to
05/96
X X
111 210 as of 06/96 X X
112 163 2.0 X
112 202 2.0 X
112 208 2.0 X
112 210 2.0 X
112 220 2.0 X
113 163 2.0 X
113 202 2.0 X
113 208 2.0 X
113 210 2.0 X
113 220 2.0 X
119.982 129 1.0 X
119.980 140 1.0 X
119.981 140 1.0 X
119 210 1.0 X
120.983 129 1.0 X
120.982 140 1.0 X

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Fig. 1: Identifying Connection Cables Of Double Ignition Coil
Diagnosis with engine tester:
Connect green connector (terminal 1) of engine tester alternatively to the yellow socket or green socket for
assessing an ignition circuit with the primary adapter cable.
Connect yellow connector (terminal 15) of engine tester to positive (tml. 30 /tml. 15).
General notes on contactless high voltage distribution - AH15.10-P-1002-01WD
Engine 104, 111 with ME-SFI fuel injection and ignition system
The ignition system can be tested only at the primary side.
No test facility by means of kV pickup at the ignition coil although kV pickup is present.
It is only possible to test the primary ignition circuit with adapter cable A.
Connection cables of optimized ignition coil

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Fig. 2: Identifying General Notes On Contactless High Voltage Distribution
Diagnosis with engine tester:
The ignition system can be tested only at the primary side.
BASIC KNOWLEDGE
SPARK PLUGS, LOCATION/TASK/DESIGN/FUNCTION - GF15.10-P-3101F
2
ENGINE 104, 111, 112, 113 /, 119, 120, 137, 166 (except, 112.96, 113.98 /99)
Fig. 3: Identifying Spark Plugs

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IGNITION COILS, LOCATION/TASK/DESIGN/FUNCTION - GF15.10-P-3102
Ignition coils, location/task/design/function - GF15.10-P-3102A
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
Shown on ENGINE 112
Spark plugs, location One or two spark plugs are
located in the cylinder head
per cylinder.

Spark plugs, task The spark plugs ignite the
suctioned and compressed
fuel-air mixture due to arcing
between the electrodes.

Spark plugs, design In the manufacturer's specific
type symbols, all the spark
plug features are assigned (e.
g. heat rating, shape of
seating, thread, width across
flats, electrode material,
spark position).

Spark plugs, function The ignition voltage travels
to the spark plugs from
directly connected ignition
coils or over the ignition
lines from the ignition coils
causing arcing in the air gap
between the center and
ground electrodes.

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Fig. 4: Identifying Spark Plug Connector And Ignition Coils Cylinder 4 - Shown On Engine 112
Ignition coils, location - GF15.10-P-3102-01A
Location on Engine 112
Fig. 5: Identifying Cylinder 1 To 6 Ignition Coils - Location On Engine 112
Location Engine 113
Ignition coils, location GF15.10-P-3102-01A
Ignition coils, task Supplying adequate
ignition energy in all
operating conditions for
the particular ignition
circuit.

Ignition coils, design One double ignition coil
for each cylinder. Attached
to cylinder head cover.

Ignition coils, function GF15.10-P-3102-02A

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Fig. 6: Identifying Cylinder 1 To 8 Ignition Coils - Location On Engine 113
Ignition coils, function - GF15.10-P-3102-02A
Each spark plug is actuated separately via its own ignition coil by the ME control unit. Both ignition coils of a
cylinder are combined to form a dual ignition coil.
The ME control unit actuates the primary wirings (L1) of the double ignition coils at circuits 1a or 1b with
ground.
The primary current flow is interrupted at the moment of ignition timing point. As a result of the sudden
collapse of the magnetic field the ignition voltage is generated in the secondary windings (L2). The ignition
voltage flows through the high voltage connection (4a and 4b) and through the spark plug connector to the
respective spark plug (R4).
The voltage supply of the double ignition coils is protected at circuit 15 (a).
Diodes are built-in to suppress additional ignition sparks when the primary current is switched on.
Because of the diodes, it is not possible to measure the resistance in the secondary windings.

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Fig. 7: Ignition Coils Circuit Diagram
Ignition coils, location/task/design/function - GF15.10-P-3102F
ENGINE 111.951 /952 /955 /956 /957 /958 /982 /983
ENGINE 119.980 /981 /982 /985
ENGINE 120.982 /983
Shown on engine 120

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Fig. 8: Identifying Ignition Coils, Location/Task/Design/Function (Engine - 120)
Ignition coils, location - GF15.10-P-3102-01GS
Engine 111 EVO EURO3/4
Ignition coils, location Engine 119, 120 GF15.10-P-3102-01F
Engine 111 EVO GF15.10-P-3102-01GS
Ignition coils, task Providing adequate
ignition energy in all
operating conditions

Ignition coils, design An ignition coil is installed
above the spark plug for
each cylinder.
Ignition coils are attached
to the intake manifold by
spring clips (engine 119,
120) or bolted to cylinder
head cover (engine 111).

Ignition coils, function GF15.10-P-3102-02F

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Fig. 9: Identifying Cylinder 1 To 4 Ignition Coils - Engine 111 EVO EURO3/4
Ignition coils, function - GF15.10-P-3102-02F
Engine 111 EVO
Engine 119, 120
Fig. 10: Identifying Ignition Coils, Function (Engine 119, 120)
Each spark plug is actuated separately by the ME-SFI control module through its own ignition coil.
The ME control module (N3/10) actuates the primary windings (L1) of the ignition coils (T1/1 to T1/12) at
circuit 1 with ground.
The primary current flow is interrupted at the moment of the ignition timing point. As a result of the sudden
collapse of the magnetic field the ignition voltage is generated in the secondary windings (L2). The ignition
voltage flows through the high voltage connection and through spark plug connector to the spark plug (R4).
The voltage supply of the ignition coils is protected at circuit 15.
Model 129, 210 as of 9/95
Model 140 as of 6/96
Diodes are integrated to suppress additional ignition sparks when the primary current is switched on. Because of
the diodes, it is not possible to measure the resistance in the secondary winding.
Ignition coils position/task/design/function - GF15.10-P-3102G

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ENGINE 104
ENGINE 166
ENGINES 111.921 /942 as of 1.9.98, 111.943, 111.944 as of 1.8.96, 111.946 as of 1.6.98, 111.947/973,
111.975 as of 1.8.96
ENGINE 111.945 in MODELS 208.335 /435 as of 1.6.98, 202.020/080 as of 1.9.98
ENGINE 111.974 with CODE (494a) USA version with CODE (807) Model year 1997 with CODE (808)
Model year 1998
Engine 104, 111
Fig. 11: Identifying Ignition Coils Position/Task/Design/Function (Engine - 104, 111)
Engine 166
Fig. 12: Identifying Ignition Coils Position/Task/Design/Function (Engine - 166)
Ignition coils, location GF15.10-P-3102-01G
Ignition coils, task Providing adequate ignition
energy for the respective
ignition circuit in all
operating conditions

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Ignition coils, location - GF15.10-P-3102-01G
Engine 104, 111, 166
Engine 104
Fig. 13: Identifying Ignition Coils, Location (Engine 104)
Engine 111 1st version
Ignition coils, design Engines 104, 111
The twin spark ignition coils
(T1/1, T1/2, T1/3) are
mounted directly onto a
spark plug together with a
spark plug connector via the
secondary output (4a). The
secondary output (4b) leads
via an ignition cable to the
other cylinder. The guide
sleeve (W) is at the same
time the ground connection
for the ignition coil. The
voltage is supplied fuse-
protected by the
ignition/starter switch
Engine 166
Two twin spark ignition
coils are used, which are
combined in a housing, the
ignition coil module (T2)

Ignition coils, function GF15.10-P-3102-02G

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Fig. 14: Identifying Ignition Coils, Location (Engine 111 - 1st Version)
Engine 111 2nd version
Fig. 15: Identifying Ignition Coils, Location (Engine 111 - 2nd Version)
Engine 166
Fig. 16: Identifying Ignition Coils, Location (Engine 166)
ME-SFI IGNITION SYSTEM FUNCTION - GF15.12-P-0001
ME-SFI ignition system function - GF15.12-P-0001F

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ENGINE 104.941 /943 /944 /991 /994 as of 1.8.96
Model year 1998 with CODE (498) as of Model Year 97 Japanese version
ENGINE 111.921 /942 as of 1.9.98, 111.943, 111.944 as of 1.8.96, 111.946 as of 1.6.98, 111.947 /973,
111.975 as of 1.8.96
ENGINE 111.945 in MODEL 208.335 /435 as of 1.6.98, 202.020 /080 as of 1.9.98
Model year 1998
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 120.982/ 983
ENGINE 137.970
Example of ME-SFI ignition system

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Fig. 17: ME-SFI Ignition System Function Diagram
Signal assignment Shown on engine 119
Fig. 18: ME-SFI Ignition Signal Assignment - Shown On Engine 119
Function

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When the crankshaft is rotating, an alternating voltage is generated in the crankshaft position sensor by the teeth
of the driven plate. In this case, each tooth generates an alternating voltage signal. No voltage is generated
through the gap of 2 missing teeth. The ME-SFI control unit detects the TDC position of the crankshaft with the
2nd negative slope after the gap.
If the signal from the camshaft Hall sensor is at 0 V ("low") at this moment, the ME control unit processes this
in order to detect ignition TDC. This is used for actuating the ignition coils and the fuel injectors.
The high voltage is distributed rotorlessly. Advantages of the rotorless high voltage distribution are:
significantly reduced electromagnetic interference level (no naked sparks)
no rotating parts
reduction in noise
reduced high voltage connections.
1. Determine ignition angle according to input signals, actuate ignition coils and release ignition
spark.
The ME-SFI control unit essentially analyzes the following signals for determining the ignition angle:
Engine load
Crankshaft position sensor
Camshaft Hall sensor
Coolant temperature sensor
Intake air temperature sensor/charge air.
Coil ignition: The ME control unit interrupts at the point of ignition timing at the ground end the ignition
coil primary circuit of the ignition coil.
ECI ignition system (engine 137): The ME control unit actuates the output stages in the ECI ignition
modules.
The ignition angle can only be checked with the HHT/STAR DIAGNOSIS.
2. Ignition angle adaptation
1. Catalytic converter heating-up (warming-up)
Engine Recognition of TDC position of
cylinder
Ignition TDC
111 1 and 4 Cylinder 1
104, 112, 113, 119 1 and 6 Cylinder 1
120, 137 Right hand cylinder bank: 1 and 6 Cylinder 1
Left cylinder bank: 7 and 12 Cylinder 7

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The ignition angle is continuously retarded for about 20 seconds in order to more rapidly warm up
the catalytic converter to its operating temperature if:
coolant temperature at start >15C and <40C
Selector lever position P or N
At the same time idle speed is increased by the idle speed control.
2. Idle speed
To assist the idle speed control, the ignition angle can be retarded by as much as 36 crank angle or
advanced by as much as 20 crank angle.
Altering the ignition angle provides a more rapid control than altering the position of the throttle
valve (idle speed control).
3. Deceleration fuel shutoff
The ignition angle is briefly retarded when combustion is resumed (fuel injectors actuated) in order
to prevent a sudden increase in torque.
4. Intake air temperature/coolant temperature
The ignition angle is retarded under load, as a function of the intake air temperature and coolant
temperature, in order to prevent any knocking tendency at high intake air and coolant temperatures.
The ignition angle is "Retarded" if:
Intake air temperature >35C
Coolant temperature >105C
In supercharged engines the charge air temperature is used as information for the ignition timing
adjustment in place of the intake air temperature.
The values of the retardation of the ignition angle of intake air temperature and coolant
temperature are added together.
5. Transmission overload protection
In order to protect the shift elements of the automatic transmission during power shifts (1-2-1, 2-3-
2) from excessive thermal stresses, the ignition angle is briefly retarded during the gearshift and the
engine torque reduced as a result. The ME-SFI control units are supplied with a signal for this
purpose from the ETC control unit (N15/3) over the CAN databus.
6. ESP/ASR control mode
In order to reduce the engine torque as rapidly as possible in the ESP/ ASR control mode, the

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ignition angle is retarded by the throttle valve actuator (opening angle reduced) prior to the control
mode being activated. The information from the ESP/ASR control unit is supplied over the CAN
databus to the ME-SFI control unit.
7. Anti-knock control (AKC)
If uncontrolled combustion (knocking) occurs at one or several cylinders, the ignition angle at the
relevant cylinder or cylinders is "Retarded".
8. Smooth engine running analysis
To restrain the three way catalytic converter from thermal overload through combustion misfiring
and in order to keep the exhaust emission values, the smooth operation of the engine is
continuously monitored.
If combustion misfiring is identified at one or several cylinders, the corresponding fuel injection
valves are no longer actuated after a certain number of misfires.
Engine 104, 111, 112, 113, 119, 120: Smooth operation evaluation is performed through the signals
of the crankshaft position sensor. Engine 137: Identification of combustion misfiring by means of
ionic current signal, see ECI ignition system function.
9. Double ignition engine 112, 113, 137
Two spark plugs for each cylinder are beneficial because of the arrangement of the valves for
achieving optimal emission levels and smooth engine running.
Each spark plug is actuated separately by the ME-SFI control unit through its own ignition coil. On
engine 112, 113 both ignition coils of a cylinder are combined to form a dual ignition coil.
In the lower part load range up to approx. 2000 rpm both ignition sparks of a cylinder are triggered
simultaneously. At moderate and high engine loads, the ignition sparks are triggered offset by as
much as 10 crank angle. In this case,
The sequence of actuation is constantly varied in order to achieve a uniform wear of both spark
plugs and to avoid deposits on only one side of the combustion chamber.
For troubleshooting in the dual ignition system, it is possible to switch off one ignition circuit each
with HHT or STAR DIAGNOSIS.
ME-SFI ignition system function
diagram
Engine 104 GF15.12-P-0001-01D
Engine 111 GF15.12-P-0001-01G
Engine 112 GF15.12-P-0001-01A
Engine 113 GF15.12-P-0001-01B
Engine 119 GF15.12-P-0001-01E

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Engine 120 GF15.12-P-0001-01F
ME-SFI control unit
position/task/design/function
GF07.61-P-5000F
ECI ignition system function Engine 137 GF15.15-P-3000L
Ignition coils,
location/task/design/function
Engine 119, 120 GF15.10-P-3102F
Engine 104, 111 GF15.10-P-3102G
Engine 112, 113 GF15.10-P-3102A
Crankshaft position sensor,
GF07.04-P-4116F
Camshaft Hall sensor,
GF07.04-P-4117F
Spark plugs,
GF15.10-P-3101F
Intake air temperature sensor,
GF07.04-P-2100F
Hot film mass air flow sensor,
Engine 119, 120 (round
connector)
GF07.07-P-4118E
Engine 104, 111, 112,
113, 137
GF07.07-P-4118G
Coolant temperature sensor,
Engine 104, 111 GF07.04-P-5026G
Engine 112, 113, 137 GF07.04-P-5026A
Engine 119, 120 GF07.04-P-5026F
Electronic accelerator,
location/design/function
Engine 104, 111, 112,
113, 119, 137
GF30.20-P-3010E
Engine 120 GF30.20-P-3010F
Anti-knock control function GF15.12-P-4024F
Transmission overload protection
function
with automatic
transmission
GF07.61-P-4026F
Overheating/pinging protection
function
GF07.61-P-4027F
Intake air temperature correction
function
GF07.61-P-4028F
ME-SFI synchronizing fuel
injection and firing order function
GF07.61-P-4009F
ME-SFI ignition system signal
assignment
Engine 104 GF15.12-P-0001-02D
Engine 111 GF15.12-P-0001-02G
Engine 112 GF15.12-P-0001-02A
Engine 113 GF15.12-P-0001-02B
Engine 119 GF15.12-P-0001-02E
Engine 120 GF15.12-P-0001-02F

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ME-SFI ignition system function diagram - GF15.12-P-0001-01A
Engine 137 GF15.12-P-0001-02L
ME engine speed signal function GF07.61-P-3017F
ASR V control unit
with code 471a
Model 129, 140, 202 as
of 6/94, 170, 208, 210
GF42.40-P-4500A
ESP control unit location / task /
function
with code 472a
Model 129 with engines
104, 119, 120
Model 140
Model 210 with engine
119
GF42.45-P-4500A
with code 472a
112, 113
Model 163 up to 8/02,
168, 215
Model 220 (except
220.08/18)
Model 202, 208 with
engine 112, 113
111, 112, 113
GF42.45-P-4500B
with code 472a
Model 170 with engines
111, 112
Model 202, 208 with
Engine 111
Model 203
GF42.45-P-4500C
Model 211, 230 GF42.45-P-4500SL
ETC control unit, location/task Transmission 722.6 GF27.19-P-4012G

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Fig. 19: Basic Diagram Of Ignition System With Rotorless High Voltage Distribution - Engine 112
Basic diagram of ignition system with rotorless high voltage distribution, engine 112
ME-SFI ignition system function diagram - GF15.12-P-0001-01G
Engine 111
Basic diagram of ignition system with rotorless high voltage distribution, engine 111

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Fig. 20: Basic Diagram Of Ignition System With Rotorless High Voltage Distribution - Engine 111
ME-SFI ignition system signal assignment - GF15.12-P-0001-02A
Signal assignment engine 112
Fig. 21: ME-SFI Ignition Signal Assignment Diagram - Engine 112
ME-SFI ignition system signal assignment - GF15.12-P-0001-02G
Engine 111

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Fig. 22: ME-SFI Ignition Signal Assignment - Engine 111
ME-SFI ignition system function - GF15.12-P-0001GS
ENGINE 111.951 /952 /955 /956 /957 /958 /982 /983
Fig. 23: ME-SFI Ignition System Function Diagram - Engine 111.951 /952 /955 /956 /957
When the crankshaft is rotating, an alternating voltage is generated in the crankshaft position sensor (L5) by the
teeth of the driven plate. In this case, each tooth generates an alternating voltage signal. No voltage is generated
as a result of the gap caused by 2 missing teeth. The ME-SFI control module detects the TDC position of the

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crankshaft with the 2nd negative slope after the gap.
If the signal of the camshaft Hall sensor (B6/1) is at U Batt ("high") at this moment, the ME control module
processes this for detecting ignition TDC of cylinder 1. This is used for actuating the ignition coils and the fuel
injectors.
The high voltage is distributed rotorlessly. Advantages of the rotorless high voltage distribution are:
significantly reduced electromagnetic interference level (no naked sparks)
no rotating parts
reduction in noise
reduced high voltage connections.
1. Determining the ignition angle in line with the input signals, actuating ignition coils and triggering
ignition sparks.
For determining the ignition angle, the ME control module essentially analyzes the following signals
from:
Hot film mass air flow sensor
Coolant temperature sensor
and interrupts the primary circuit of the ignition coil at the ground side at the moment of the ignition
timing point.
The ignition angle can only be tested with the STAR DIAGNOSIS.
2. Adaptation of ignition angle
1. Catalytic converter heating-up (warming-up)
The ignition angle is continuously retarded for about 20 seconds in order to more rapidly warm up
the catalytic converter to its operating temperature if:
coolant temperature at start >15C and <40C
selector lever position P or N
At the same time idle speed is increased by the idle speed control.
2. Idle speed
To assist the idle speed control, the ignition angle can be retarded by as much as 36 crank angle or
advanced by as much as 20 crank angle.

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The control by altering the ignition angle reacts more rapidly than by altering the position of the
throttle valve (idle speed control).
3. Inertia fuel shutoff
The ignition angle is briefly retarded in order to prevent a sudden increase in torque when
combustion is resumed (actuation of fuel injectors).
4. Intake air temperature/coolant temperature
In order to prevent the knocking tendency at high inlet and coolant temperatures, the ignition angle
under load is retarded in line with the intake air temperature and coolant temperature. The ignition
angle is retarded if:
intake air temperature >35C
coolant temperature >105C
The values of the retardation of the ignition angle of intake air temperature and coolant
temperature are added together.
5. Transmission overload protection
In order to protect the shift elements of the automatic transmission from excessive thermal stresses
during powershifts (1-2-1, 2-3-2), the ignition angle is briefly retarded during the gearshift and the
engine torque is thus reduced. The ME-SFI control modules are supplied with a signal for this
purpose from the ETC control module (N15/3) over the CAN databus.
6. ESP/ASR control mode
In order to reduce the engine torque as rapidly as possible in the ESP/ASR control mode, the
ignition angle is retarded by the throttle valve actuator (opening angle reduced) before the
commencement of the control cycle. The information flows from the ESP/ASR control module
over the CAN databus to the ME control module.
7. Knock sensor system (KSS)
If uncontrolled combustion (knocking) occurs at one or several cylinders, the ignition angle is
retarded at the relevant cylinder or cylinders.
8. Smooth engine running analysis
Smooth engine running is constantly monitored in order to protect the catalytic converter from
excessive thermal stresses if combustion misfiring exists.
If the smooth engine running analysis detects combustion misfiring, the appropriate fuel injector or
injectors are no longer operated after a certain number of misfirings.

Microsoft
ME-SFI ignition system function diagram - GF15.12-P-0001-01GS
ME ignition system, function diagram GF15.12-P-0001-
01GS
ME-SFI ignition system signal
assignment
GF15.12-P-0001-
02GS
ME-SFI control module position /
task / design /function
GF07.61-P-5000GS
Ignition coils,
GF15.10-P-3102F
GF07.04-P-4116F
GF07.04-P-4117F
Spark plugs,
GF15.10-P-3101F
GF07.04-P-5026G
Throttle valve actuator,
GF30.22-P-4101GS
Electronic accelerator function GF30.20-P-3010E
Hot film mass air flow sensor
location/Function/Design/Operation
GF07.07-P-4118GS
Knock sensor system function GF15.12-P-4024F
Transmission overload protection,
function
GF07.61-P-4026F
Overheating or pinging protection
function
GF07.61-P-4027F
Intake air temperature correction,
function
GF07.61-P-4028F
Synchronizing fuel injection and
firing order function
GF07.61-P-4009GS
Correction programming, function GF07.61-P-3031F
Engine speed signal function GF07.61-P-3017GS
ESP control module
Model 210 GF42.45-P-4500B
Model 170, 202, 203,
208
GF42.45-P-4500C
ETC control module, location/task Selector lever position
information P/N and
driving position
engaged.
Transmission 722.6
GF27.19-P-4012G

Microsoft
Basic diagram of ignition system with rotorless high voltage distribution engine 111 EURO 3
Fig. 24: Basic Diagram Of Ignition System With Rotorless High Voltage Distribution - Engine 111 EURO
3
ME-SFI ignition system signal assignment - GF15.12-P-0001-02GS
Fig. 25: ME-SFI Ignition System Signal Assignment - Engine 111
ANTI-KNOCK CONTROL FUNCTION - GF15.12-P-4024F
ENGINE 104.941 /943 /944 /991 /994 as of 1.8.96
Model year 1998 with CODE (498) as of Model Year 97 Japanese version

Microsoft
ENGINE 111.921 /942 as of 1.9.98, 111.943, 111.944 as of 1.8.96, 111.946 as of 1.6.98, 111.947 /973,
111.975 as of 1.8.96
Model year 1998
ENGINE 111.951 /952 /955 /956 /957 /958 /982 /983
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /969
ENGINE 119.980 /981 /982 /985
ENGINE 120.982/ 983
ENGINE 137.970
Shown on Engine 119
Fig. 26: Anti-Knock Control Function Diagram - Shown On Engine 119
Task
Ensuring knock-free operation of the engine with different fuels in all operating conditions from idling speed up
to maximum speed of engine, from an engine load of more than approx. 40%. For this purpose, if uncontrolled
combustion (knocking) occurs, the ignition angle at the relevant cylinder or cylinders is retarded.

Microsoft
Design/function
The anti-knock control (AKC) function is integrated in the ME-SFI control unit. The range of functions has
been enlarged compared to previous versions.
Input signals:
Engine speed (crankshaft position sensor)
Camshaft position (camshaft Hall sensor)
Knock identification:
Engine 104, 111, 112, 113, 119, 120 by means of knock sensors Engine 137 by ionic current
measurement
Engine temperature (coolant temperature sensor)
Engine load (hot film air flow sensor or pressure sensor on supercharged engines)
Accelerator pedal position (accelerator pedal sensor)
Precontrol by means of automatic RON switch (internal)
Output signals:
Cylinder specific ignition angle correction on the calculated map value of the ME control unit.
Ignition angle emergency mode if fault identified.
Basic function
The anti-knock control is active from a coolant temperature of 70C. If knocking is detected at a cylinder above
an engine load of approx. 40%, its ignition angle is retarded from the next ignition by about 2.3 crank angle
(e.g. M119) or by about 3.0 crank angle (e.g. M120). If knocking continues to be detected, the ignition angle is
continuously retarded in steps of 2.3 crank angle (e.g. M119) until the maximum retardation is reached
(approx. 10 to 15 crank angle, depending on engine speed). In addition, the automatic RON switch influences
the maximum retarding of the ignition timing - the higher the selected RON stage, the less is the maximum
retarding of the ignition timing.
If knocking-free combustion exists, the retardation is reduced in steps of approx. 0.75 crank angle after a few
ignitions (depending on engine speed) until the map value (a) is achieved, or knocking once again occurs.
Adaptation of anti-knock control
The adaptation of the anti-knock control is active from a coolant temperature of approx. 75C. Any corrections
required to the ignition angle because of knocking combustion are constantly detected for the specific cylinder
and stored together with the relevant operating state of the engine (engine load/speed range).
The stored adaptation value is taken into account in the output of the individual cylinder angle so that each
cylinder is immediately operated with the optimal ignition angle.

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During abrupt acceleration, no values are stored for about 2 seconds in order to avoid any incorrect adaptation
values.
Faults in the case of knocking detection
If no signals are received from the knock sensors or from the ionic
current measurement, the ignition angle of all the cylinders is retarded, for safety reasons, by as much as
approx. 11 crank angle depending on engine speed and temperature. The anti-knock control and the adaptation
are deactivated and a fault is stored.
Automatic RON switch
In addition to the RON correction using the HHT, the anti-knock control features an automatic RON switch.
This detects a persistent high knocking tendency of the engine and assists the anti-knock control by means of an
appropriate pre-control.
This is done by analyzing the stored adaptation values, the ignition angles of all the cylinders and the number of
control interventions in certain engine load and speed ranges. Depending on the threshold which has been
exceeded, the RON value is adjusted by one or several stages. The value is retained until the engine is switched
off. After engine start, only the RON correction which is carried out by means of the HHT/STAR DIAGNOSIS
is at first active.
GF07.04-P-4116F
Camshaft Hall sensor,
GF07.04-P-4117F
Knock sensors,
GF15.12-P-4101F
Engine 119, 120 GF07.04-P-5026F
Engine 104, 111 GF07.04-P-5026G
Engine 112, 113, 137 GF07.04-P-5026A
Hot film mass air flow sensor,
Engine 119, 120 (round
connector)
GF07.07-P-4118E
Engine 104, 111, 112,
113, 137
GF07.07-P-4118G
Engine 111 EVO GF07.07-P-4118GS
Pedal value sensor,
GF30.20-P-4011L
ME-SFI control unit
GF07.61-P-5000F
ME-SFI synchronizing fuel
injection and firing order function
GF07.61-P-4009F

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KNOCK SENSORS, LOCATION/TASK/DESIGN/FUNCTION - GF15.12-P-4101F
ENGINE 104.941 /942 /943 /944 /945 /991 /992 /994 /995
ENGINE 111.921 /943 /944 /945 /946 /947 /960 /961 /970 /973 /974 /975 /977
ENGINE 111.942 as of 1.6.96
ENGINE 111.951 /952 /955 /956 /957 /958 /982 /983
ENGINE 119.980 /981 /982 /985
ENGINE 120.982/ 983
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 166.940 /960 /990 /995
Fig. 27: Identifying Knock Sensors - Engine 120
Knock sensors, location Engine 104 GF15.12-P-4101-01D
Engine 111 GF15.12-P-4101-01G
Engine 112 GF15.12-P-4101-01A
Engine 113 GF15.12-P-4101-01B
Engine 119 GF15.12-P-4101-01E
Engine 120 GF15.12-P-4101-01F
Engine 166 GF15.12-P-4101-01GC
Knock sensors, task The knock sensor detects
vibrations at the crankcase.

Knock sensors, design The knock sensor is a self-
contained system. Inside

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Knock sensors, location - GF15.12-P-4101-01A
Fig. 28: Identifying Knock Sensors
Knock sensors, location - GF15.12-P-4101-01G
Engine 111
1. Knock sensor on left side of crankcase
Fig. 29: Identifying Knock Sensors - Engine 111
Knock sensors, function - GF15.12-P-4101-02KE
the sensor are piezo
crystals. The screened
cable is fitted directly onto
the knock sensor.
Knock sensors, function GF15.12-P-4101-02KE

Microsoft
Fig. 30: Identifying Knock Sensors Signal Pattern
Any vibrations which occur are converted with the aid of the piezo ceramic into electrical signals.
Piezo-electric effect: If a mechanical force acts on a crystal, electrical voltages are produced.
Knock sensor signals may also indicate engine damage, e.g. increased engine noise resulting from a widened
piston groove.
STARTER CONTROL, FUNCTION - GF15.30-P-3000
Starter control, function - GF15.30-P-3000G
ENGINE 111.921 /942 /943 /944 /946 /947 /973 /977 #0
ENGINE 111.974 #0 with CODE (494a) USA version with CODE (807) Model year 1997 with CODE
(808) Model year 1998
ENGINE 111.975 #0 as of 1.8.96
ENGINE 112.910 /911 /912 /913 /914 /916 /917 /920 /921 /923 #0
Shown on engine 111, 112

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Fig. 31: Starter Control Function Diagram - Shown On Engine 111
Task
Interrupting the circuit (circuit 50) to the starter solenoid switch after engine start speed is reached (switching
off starter).
Design
The starter solenoid switch is actuated not through the ignition/starter switch, but through the starter relay by the
engine control unit. The voltage for the starter relay (coil) is supplied through circuit 87. The starter relay is
actuated by the engine control unit through GND.
Function
When the ignition/start switch is turned from position 2 into the start position, start recognition is activated by
the engine control unit through circuit 50. As soon as an engine start speed of 400 to 700 rpm is reached, the
engine control unit interrupts the ground actuation to the starter relay and thus the start operation.
with manual transmission
The starter control is only enabled when the clutch pedal is operated. When the clutch pedal is depressed, the
clutch pedal switch is operated for start enable (S40/5).
HFM-SFI control unit,
GF07.51-P-4103D
Motor electronics control unit,
GF07.61-P-5000F
Crankshaft position sensor, GF07.04-P-4116F

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Starter control, function - GF15.30-P-3000GA
ENGINE 111.921 /942 as of 1.9.98, 111.943 /944 /946 /947 /973 with CODE (423a) 5-speed automatic
transmission (new-generation)
ENGINE 111.945 in MODEL 208.335 /435 as of 1.6.98, 202.020 /080 as of 1.9.98 with CODE (423a) 5-
speed automatic transmission (new generation)
ENGINE 111.974 with CODE (423a) 5-speed automatic transmission (new-generation) with CODE
(494a) USA version with CODE (807) Model year 1997 with CODE (808) Model year 1998
ENGINE 111.975 as of 1.8.96 with CODE (423a) 5-speed automatic transmission (new-generation)
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
with CODE (423a) 5-speed automatic transmission (new-generation)
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969 with CODE (423a) 5-speed
automatic transmission (new-generation)
ENGINE 120.983 as of 1.6.98
ENGINE 137.970
Shown on Engine 111
Fig. 32: Starter Control Function Diagram - Shown On Engine 111, 112
Start recognition function Engine 111 ME, 112 GF07.13-P-3014G

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Task
After engine start speed is reached, interrupt the circuit (circuit 50) M1 to the solenoid switch of the starter.
Design
The solenoid switch of the starter is operated not through the ignition/start switch S2/1, but in drive position P
or N through the starter relay, by the engine control unit.
The voltage for the starter relay (coil) is supplied through circuit 87.
The starter relay is actuated by the engine control unit through GND.
Function
When the ignition/start switch is operated in the start position, the engine control unit activates an automatic
start control. Once the engine start speed of 400 to 700 rpm is reached, the engine control unit interrupts the
ground actuation to the starter relay and thus the engine start operation.
Once the engine start operation is initiated, shutting off circuit 50 at the ignition/start switch has no effect. The
starter rotates until the specified start speed is reached, or for about 5 seconds at an engine temperature of +80
C, for a maximum of 10 seconds if the engine is cold.
Starter control function - GF15.30-P-3000GC
ENGINE 111.983 #0 in MODEL 170.449 with CODE (494a) USA version
Motor electronics control unit,
GF07.61-P-5000F
HFM-SFI control unit,
GF07.51-P-4103D
GF07.04-P-4116F
Start recognition function Engine 104,, 111, 112,
113, 137 (via terminal 50)
GF07.13-P-3014G
Engine 119, 120 (via
engine speed signal)
GF07.13-P-3014F
ETC control unit, location/task Selector lever position
information P/N and
driving position engaged.
Transmission 722.6
GF27.19-P-4012G
Electronic ignition switch control
unit, location/task/design/function
Model 202 as of 6/97,
208, 210 as of 3/97
GF80.57-P-4102A
Model 215, 220 GF80.57-P-4102S
Model 203, 209 GF80.57-P-4102PP

Microsoft
Fig. 33: Starter Control Function Diagram - Engine 111.983
After engine start speed is reached, the start control interrupts the power flow (circuit 50) to the solenoid switch
of the starter (starter shutoff).
The solenoid switch of the starter is actuated not through the ignition/starter switch, but through the starter relay
by the engine control module.
The voltage for the starter relay (coil) is supplied through circuit 87. The starter relay is actuated by the engine
control module through ground.
Start recognition by the engine control module is effected through circuit 50 by simultaneously operating the
clutch pedal and the ignition/starter switch from position 2 into start position. When an engine speed of 400 -
700 rpm is reached, the engine control module interrupts the ground actuation to the starter relay and thus the
start operation.
ME-SFI control module
GF07.61-P-5000GS
GF07.04-P-4116F
Start recognition function through circuit 50 GF07.13-P-3014G
Starter relay Model 170: in cycle
module (N65k2)
Model 202, 208, 210: in
fuse and relay module
(K40/4k2)

Starter
Ignition/starter switch
Electronic ignition switch (EIS) (models with DAS 3) GF80.57-P-4102A

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Starter control function - GF15.30-P-3000GS
ENGINE 111.951 /952 /955 /956 /957 /958 /982 /983 #2
Models 202, 203, 208, 210
Fig. 34: Starter Control Function Diagram - Models 202, 203, 208, 210
MODEL 170
control module
Clutch pedal switch
position/task/function

GF29.10-P-2100F

Microsoft
Fig. 35: Starter Control Function Diagram - Models 170
Position of cycle module model 170
Fig. 36: Identifying Fuse, Relay Box And Cycle Module - Model 170
The start control interrupts the circuit (circuit 50) to the solenoid switch of the starter after engine start speed is
reached.
The solenoid switch of the starter is actuated not through the ignition/start switch but in drive position P or N
through the starter relay by the engine control module.
The voltage for the starter relay (coil) is supplied through circuit 87. The starter relay is actuated by the engine
control module through ground.
When the ignition/start switch is operated in the start position, the engine control module activates an automatic
start control. Once the engine start speed of 400 to 700 rpm is reached, the engine control module interrupts the
ground actuation to the starter relay and thus the start process.
When the engine start operation is initiated, switching off circuit 50 at the ignition/start switch does not have
any effect. The starter rotates until the specified start speed is reached, or for about 5 seconds at an engine

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temperature of +80C, for a maximum of 10 seconds if the engine is cold.
CRASH SHUT-OFF RELAY, LOCATION/PURPOSE/FUNCTION - GF15.40-P-5011A
ENGINE 111.943 /958 /973 /983, 112.947 in MODEL 170
Location
Fig. 37: Identifying Crash Shut-Off Relay
Do not open crash shut-off relay
Purpose
The purpose of the crash shut-off relay is to disconnect the power supply from the generator/battery (c. 30) in
the event of an accident and thereby prevent a fire resulting from a short circuit.
ME-SFI control module position /
task / design / function
GF07.61-P-5000GS
GF07.04-P-4116F
ETC control module,
location/task
Selector lever position
information P/N and
driving position engaged.
Transmission 722.6
GF27.19-P-4012G
Start recognition, function through circuit 50 GF07.13-P-3014G
Front SAM control module with
fuse and relay module,
location/task/design
Model 203 GF54.21-P-4108PP
Electronic ignition switch (EIS)
control module
GF80.57-P-4102A

Microsoft
It serves as a type of battery isolation switch.
Function
In the event of an accident the crash shut-off relay is actuated by the airbag triggering unit when the airbag is
actuated. This destroys one of two fuses in the crash shut-off relay thereby interrupting the connection between
the generator and battery.
This circuit is also interrupted when the ignition is switched OFF or the vehicle shut off.
In normal operation the crash shut-off relay is actuated via the ignition lock (c. 15) ignition ON and connected
ground (c. 31).
This actuation connects the generator with the battery. If a malfunction occurs in the leads from c. 15 or c. 31
(e.g. discontinuity), the battery is not charged when the engine is running. The final result is complete failure of
the vehicle electrical system due to the continuously decreasing electrical system voltage resulting from the
battery not being charged.
A defect in the crash shut-off relay and therefore an interruption in the battery charging operation is not
indicated to the driver by the charge indicator lamp.
SAFETY PRECAUTIONS
SAFETY INFORMATION: ELECTRICAL SYSTEM - ENGINE - AS15.00-Z-9999ZZ
MODEL all
RISK OF DEATH CAUSED BY CONTACT WITH PARTS CONDUCTING HIGH VOLTAGES. -
AS15.10-Z-0001-01A
Do not touch parts which conduct high voltages. Persons who wear electronic implants (e.g. heart
pacemakers) must not carry out work on the ignition system

Risk of death caused by
coming into contact with
high-voltage parts
although ignition is turned
off.
ENGINE 137 ENGINE
275 ENGINE 285
AS15.15-Z-0001-01A

contact with parts
conducting high voltages.
ENGINE 103, 104, 111,
112, 113, 119, 120, 122,
132, 134, 135, 137, 155,
156, 160, 166, 266, 271,
272, 273, 275, 285, 613,
628, 629, 642, 646, 648,
902, 906...
AS15.10-Z-0001-01A

Microsoft
Risk of death caused by high voltages in the ignition system
Electronic ignition systems operate within a hazardous power range both on the low voltage side (primary
circuit) as well as on the high voltage side (secondary circuit). Contacts with such parts can result in burns,
heart flutter or cardiac arrest.
Fig. 38: Risk Of Death Caused By High Voltages In Ignition System
Safety instructions/precautions
Persons with heart pacemakers must not perform any work on the ignition system.
Switch ignition off before commencing any work on the ignition system.
Do not touch or dismantle components of ignition system when working on running or rotating engine
with cranking speed.
Wear safety shoes (with rubber soles).
Detach the crankshaft position sensor connection either at the control unit or at the position sensor.
Do not install any electrically conducting, uninsulated adapters or installation sensors into the ignition
cable.
TROUBLE DIAGNOSIS
STARTER OCCASIONALLY DOES NOT START - AF15.30-P-6405A
ENGINE 112 in MODEL 129, 163, 170, 202, 208, 210, 220
ENGINE 113 in MODEL 129, 163, 202, 208, 210, 215, 220
ENGINE 119 in MODEL 129, 210
ENGINE 120 in MODEL 129
Modification notes
24.7.00 Supersedes STIP 07.60-
022 dated 28.2.00
Reference link updated.

Microsoft
Parts ordering notes
TESTING & REPAIR
REMOVE, INSTALL CAMSHAFT HALL SENSOR - AR15.10-P-2000A
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
Damage code Cause Remedy
15 001 41
Starting operation is
terminated before engine
can start.
When starting tachometer
jumps momentarily in
direction >2000 rpm.
DTC in ME-SFI
control unit:
No DTC stored.
1 Remove starter.

ENGINE 112, 113 in
MODEL 129
AR15.30-P-7100CS
ENGINE 119, 120 in
MODEL 129
AR15.30-P-7100EC
ENGINE 112, 113 in
MODEL 210
AR15.30-P-7100FF
ENGINE 119.985 129 AR15.30-P-7100FAF
ENGINE 112 in MODEL
202
AR15.30-P-7100ED
ENGINE 112.940 in
MODEL 208

ENGINE 112.947 170 AR15.30-P-7100GA
ENGINE 112.942,
113.942 in MODEL 163
AR15.30-P-7100GH
ENGINE 113.960 in
MODEL 215,
AR15.30-P-7100I
ENGINE 112, 113 in
MODEL 220

2 Coat teeth on starter
ring gear lightly with
paste
Use only paste
specified in parts note
Ensure that excessive
quantity of paste is not
applied because this can
interfere with the signal
pickup of position sensor
L5

3 Install starter.
Part no. Designation Quantity
000 989 76 51 Paste (1 kg) 1

Microsoft
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209.361 /365/461 /465, 210,
211.061 /261 /065 /265 /080 /082 /280 /282, 220, 230.467
ENGINE 113 (except 113.990/991) in MODEL 129, 163, 202, 208, 209.375/475/376/476, 210,
211.070 /270 /083 /283, 215, 220, 230.472 /474 /475
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
Fig. 39: Identifying Camshaft Hall Sensor - Shown On Engine 112 In Model 220
Position sensor
Fig. item etc. Work instructions

Camshaft Hall sensor to
cylinder head
*BA15.10-P-1002-03A
B6/1 Camshaft Hall sensor
Replace O-ring.

Number Designation Engines
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976
Engines
113.940/941/
942/943/944/
948/960/961/
962/963/964/
965/966/967/
968/969/971/
980/981/982/
984/986/992/
993/995
Engine
113.987/
988/990/
991
BA15.10-P-
1002-03A
Camshaft Hall
sensor to
Nm8 8 8

Microsoft
TEST ROTORLESS HIGH VOLTAGE DISTRIBUTION - AR15.10-P-3000WD
ENGINE 104.943 /991 as of 1.6.96 in MODEL 129 ME-SFI fuel injection and ignition system with engine
diagnostic tester Datascope D 980
ENGINE 104.944 /994 as of 1.6.96 in MODEL 140 ME-SFI fuel injection and ignition system with engine
ENGINE 111.943, 111.946 as of 1.6.98, 111.973 in MODEL 170 ME-SFI fuel injection and ignition system
with engine diagnostic tester Datascope D 980
ENGINE 104.941, 111.944 as of 1.8.96 in MODEL 202 ME-SFI fuel injection and ignition system with
engine diagnostic tester Datascope D 980
ENGINE 111.974 in MODEL 202 with CODE (491) U.S. version ME-SFI fuel injection and ignition
system with engine diagnostic Datascope D 980
ENGINE 111.975 as of 1.8.96 in MODEL 202.024 ME-SFI fuel injection and ignition system with engine
ENGINE 111.975 in MODEL 202.085 ME-SFI fuel injection and ignition system with engine diagnostic
tester Datascope D 980
ENGINE 111.944 /975 in MODEL 208 ME-SFI fuel injection and ignition system with engine diagnostic
ENGINE 111.945 as of 1.6.98 in MODEL 208.335 ME-SFI fuel injection and ignition system with engine
ENGINE 104.995 as of 1.6.96 in MODEL 210 with CODE (491) U.S. version with CODE (498) Japanese
version ME-SFI fuel injection and ignition system with engine diagnostic tester Datascope D 980
cylinder head

Risk of accident.
Accidents may result if the
vehicle starts off
unintentionally with the
engine running. Risk of
injury as working around
Secure vehicle to prevent
it from moving. Wear
closed and snug-fitting
work clothes.
Do not grasp hot or
rotating parts.
AS00.00-Z-0005-01A

Microsoft
COMMERCIALLY AVAILABLE TOOLS
REPLACING IGNITION CABLES WITH M3 CABLE SCREW - AR15.12-P-0512G
ENGINE 104.94/99, 111, 119.97 (except 104.990)
Left-hand illustration
Attach sleeve of cable screw to insulation.
Right-hand illustration
Attach sleeve of cable screw to ignition cable core.
the engine during start-up
or while running may result
in contusions and burns

Risk of death. Death may
result if contact is made
with parts carrying high
voltages.
Do not touch parts
carrying high voltages.
Persons who wear
electronic implants (e.g.
heart pacemakers) must
not carry out work on the
ignition system.
AS15.10-Z-0001-01A
1 Remove intake connection
line at hot film mass air
flow sensor

2 Remove trim panel of
cylinder head cover

3 Test primary ignition
circuit
Datascope engine
diagnostic tester
*WH58.30-Z-1003-13A

General information on
rotorless high voltage
distribution
AH15.10-P-1002-01WD

General information on
testing rotorless high
voltage distribution
AH15.10-P-1003-01W
Number Designation
WH58.30-Z-1003-13A Engine tester

Microsoft
Fig. 40: Identifying Ignition Cables With M3 Cable Screw
Fig. 41: Identifying Cable Pliers (000 589 55 37 00)
REMOVE/INSTALL IGNITION COILS - AR15.12-P-2003
Remove/install ignition coils - AR15.12-P-2003A
Making up
1 Make up ignition cables to
correspond to the cables
removed
Ignition cables are still
only available on the parts
market in cut length. For
this reason, fit the
connecting parts on using
cable pliers before
installing the ignition
cables.

2 Strip the insulation off the
ends of the new ignition
cables over 6 mm

3 Fit on sleeve of cable screwFirst of all attach to the
insulation, then to the core
of the ignition cable

Fig. 41
4 Fit on markings for the
individual cylinders

5 Screw on spark plug
connectors

Microsoft
ENGINE 112.910 in MODELS 202.026 /086
ENGINE 112.920 in MODELS 202.029 /089
ENGINE 112.921 in MODELS 210.063 /081 /263 /281
ENGINE 112.922 in MODELS 220.063 /163
ENGINE 112.923 in MODEL 129.059
ENGINE 112.940 in MODELS 208.365 /465
ENGINE 112.941 in MODELS 210.065 /082 /265 /282
ENGINE 112.944 in MODELS 220.065 /165
ENGINE 112.945 in MODEL 463
ENGINE 113.940 in MODELS 210.070 /270
ENGINE 113.941 in MODELS 220.070 /170
ENGINE 113.960 in MODEL 215.375, 220.075 /175 /875
ENGINE 113.962 /982 in MODEL 463
ENGINE 113.980 in MODELS 210.074 /274
ENGINE 113.944 in MODELS 202.033 /093
ENGINE 113.943 in MODELS 208.370 /470
ENGINE 113.984 in MODELS 208.374
ENGINE 112.912 in MODELS 203.061 /261, 209.361 /461

Microsoft
ENGINE 112.946 in MODELS 203.064 /264
ENGINE 113.986 in MODEL 215.373, 220.073 /173
ENGINE 112.961 in MODELS 203.065 /265
ENGINE 113.968 in MODEL 209.375 /475
ENGINE 112.913 in MODELS 211.061 /261
ENGINE 112.949 in MODELS 211.065 /265
ENGINE 113.967 in MODELS 211.070 /270
ENGINE 113.987 in MODELS 209.376 /476
ENGINE 112.955 in MODELS 209.365 /465
ENGINE 113.990 in MODELS 211.076 /276
ENGINE 113.991 in MODELS 215.374, 220.074 /174
ENGINE 112.916 in MODELS 203.081 /281
ENGINE 112.953 in MODELS 203.084 /284
ENGINE 112.972 in MODELS 220.067 /167
ENGINE 112.975 in MODELS 220.087 /187
ENGINE 113.948 in MODELS 220.083 /183

Microsoft
ENGINE 113.966 in MODELS 220.084 /184
ENGINE 112.917 in MODELS 211.080 /280
ENGINE 112.954 in MODELS 211.082 /282
ENGINE 113.969 in MODELS 211.083 /283
ENGINE 113.988 in MODEL 203.076/276
ENGINE 113.993 in MODELS 463.270 /271
Fig. 42: Identifying Ignition Coil Remove/Install Components - Shown On Engine 112
Modification notes
16.5.06 "Disconnect/connect ground
line on battery" removed
Model 203, 209,
Remove/install

touching parts which
conduct high voltages
Do not touch parts which conduct
high voltages. Persons who wear
electronic implants (e.g. heart
pacemakers) should never perform
any work on the ignition system.
AS15.10-Z-0001-01A

Notes on avoiding
damage to ignition
system
AH15.10-P-0002-01D
1.1 Deactivate service mode
in TELE AID emergency
Only on model 463.270 with
code: Tele-Aid car phone
AR82.95-P-0005-
03GR

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call system emergency call system ET2.

Notes on TELE AID
emergency call system
Model
463.243/244/245/247/248/250/
254/270/309/322/323/332/333
TELE AID car telephone
emergency call system ET2
AH82.95-P-0001-
01GA
2 Disconnect ground line
from battery
Model 463 except model
463.241/248 with code 979
special protection version
AR54.10-P-0003G
Model 463.241 with: special
protection version code 979, -
special protection version FB4
with code ZS4, -special protection
version FB6 with code ZS6, -
special protection version FB7
with code ZS7, additional battery
100 Ah incl. cutoff relay code
E26.
AR54.10-P-0003PV
Model 463.248 with: special
protection version, code 979, -
special protection version FB6,
code ZS6, -special protection
version FB7, code ZS7, -
additional battery 100 Ah
including cutoff relay, code E26.
AR54.10-P-0003PM
3.1 Unclip cover on front
side of engine
Model 211, 215, 220, 230.475/476
4.1 Remove engine cover
with integrated air filter
Except model 170.466,
203.065/076/265/276,
209.376/476 from 24.4.04,
211.076/276, 215.374,
220.074/174, 230.474,
463.270/271
The air filter is integrated in the
engine cover. Remove the engine
cover or the air filter housing by
pulling it from the cylinder head
covers vertically in the upward
direction.

4.2 Remove air filter housingModel 170.466, 203.065/265,
211.076/276, 215.374,
220.074/174, 230.474
AR09.10-P-1150SVK
Model 203.076 /276, 209.376 /476
from 24.4.04, 171.473
AR09.10-P-1150AC
Model 463.270/271 AR09.10-P-1150GX
5 Unscrew screw (5/3)

*BA15.10-P-1001-

Microsoft
Ignition coil
04A
6 Detach spark plug
connector (5/1) from the
spark plugs
Pry off spark plug connector
(5/1) using open-end wrench,
double over the cylinder head
cover of the spark plugs.
Installation: Observe the
identification of the connector
(arrow) on the cylinder head cover
and the ignition coil of cylinders 1
to 6 or 1 to 8 for the
corresponding spark plug
connector (5/1).

Double open-ended
wrench Fig. 43
7 Separate electrical
connector of ignition coil
of cylinder 1 to 6 (T1/1
to T1/6) or 1 to 8 (T1/1
to T1/8)
Installation: Install new cable
ties.

8 Remove ignition coil of
cylinder 1 to 6 (T1/1 to
T1/6)or 1 to 8(T1/1 to
T1/8)

9 Install in the reverse
order

10.1 Activate Service mode in
Tele-Aid emergency call
system
Only on model 463.270 with
code: Tele-Aid car phone
emergency call system ET2.
AR82.95-P-0005-
03GR

Notes on TELE AID
emergency call system
Model
463.243/244/245/247/248/250/
254/270/309/322/323/332/333
TELE AID car telephone
emergency call system ET2
AH82.95-P-0001-
01GA
Number Designation Engines 112,113
BA15.10-P-1001-04A Bolt for ignition coil on
cylinder head cover
Nm8

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Fig. 43: Identifying Double Open-End Wrench (110 589 01 01 00)
Removing and installing ignition coils - AR15.12-P-2003GA
ENGINE 111.921 /942 /943 /945 /946 /947 /970 /973 /974 /975 /977
Fig. 44: Identifying Ignition Coils Remove/Install Components
Fig. item, etc. Work instructions

Hazard from touching
parts conducting high
voltages
Do not touch parts
Persons who are provided
with electronic implants
(heart pacemakers) must
not carry out any work on
the ignition system.
AS15.10-Z-0001-01A

Notes re avoiding damage
to ignition system
Engine 111
with PEC fuel injection
and ignition system
AH15.10-P-0002-01B
Engine 104, 111 AH15.10-P-0002-01C

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REMOVE/INSTALL CRANKSHAFT POSITION SENSOR - AR15.12-P-2133
Remove/install crankshaft position sensor - AR15.12-P-2133A
ENGINE 112.910 in MODEL 202.026 /086
ENGINE 112.920 in MODEL 202.029 /089
ENGINE 112.921 in MODEL 210.063 /081 /263 /281
ENGINE 112.940 in MODEL 208.365 /465
ENGINE 112.941 in MODEL 210.065/082/265/282
ENGINE 112.944 in MODEL 220.065/165
ENGINE 113.940 in MODEL 210.070 /270
ENGINE 113.941 in MODEL 220.070/170
ENGINE 113.960 in MODEL 215.375,220.075/175
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.944 in MODEL 202.033 /093
ENGINE 113.980 in MODEL 210.074/274
with HFM-SFI fuel
injection and ignition
system
Engine 104, 111, 112, 113,
119, 120
with ME-SFI fuel
injection and ignition
system
AH15.10-P-0002-01D

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ENGINE 113.943 in MODEL 208.370 /470
ENGINE 112.912 in MODEL 203.061/261,209.361 /461
ENGINE 112.946 in MODEL 203.064 /264
ENGINE 112.961 in MODEL 203.065 /265
ENGINE 112.913 in MODEL 211.061 /261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243 /246
ENGINE 112.955 in MODEL 209.365 /465
ENGINE 112.916 in MODEL 203.081 /281
ENGINE 112.953 in MODEL 203.084 /284
ENGINE 112.972 in MODEL 220.067/167
ENGINE 112.975 in MODEL 220.087/187

Microsoft
ENGINE 113.948 in MODEL 220.083/183
ENGINE 113.966 in MODEL 220.084/184
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
Fig. 45: Identifying Crankshaft Position Sensor - Shown On Engine 113 In Model 220
Remove/install
1.1 Remove engine cover with
integrated air filter
All except Engine 112.960
in Model 170.466, Engine
112.961 in Model
203.065 /265
Remove air filter
housing by lifting
vertically up and off the
cylinder head covers.
Installation: Slightly
moisten rubber retainers
on cylinder head covers
and sealing ring of hot film
mass air flow sensor in the
air filter housing with
lubricating paste

Lubricating paste *BR00.45-Z-1002-06A
1.2 Remove air filter housing Engine 112.960 in model
170.466
AR09.10-P-1150SVK
Engine 112.961 in model
203.065/ 265

Microsoft
Position sensor
Repair materials
Remove, install crankshaft position sensor - AR15.12-P-2133GA
ENGINE 111.943/946/973 in MODEL 170
ENGINE 111.921 /945 /974 in MODEL 202
ENGINE 104.945 /995, 111.942 /947 /970 in MODEL 210
2 Remove crankshaft position
sensor (L5)

*BA15.10-P-1001-03A
3 Install in the reverse order
4 Reinitialize crankshaft
position sensor (L5) using
STAR DIAGNOSIS
If crankshaft position
sensor (L5)was replaced, a
re-initialization must be
carried out with STAR-
DIAGNOSIS in the menu
item control unit
adaptations.

Number Designation Engine
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976
Engine
113.940/941/
942/943/944/
948/960/961/
962/963/964/
965/966/967/
968/969/971/
980/981/982/
984/986/992/
993/995
BA15.10-P-1001-
03A
Crankshaft position
sensor to engine
block
Nm8 8
Number Designation Order number
BR00.45-Z-1002-06A lubricating paste A 000 989 01 60

Microsoft
Fig. 46: Identifying Crankshaft Position Sensor (Engine 104 And 111)
Engine 111 in model 163, 170, 202, 208
Fig. 47: Identifying Crankshaft Position Sensor (Engine 111 In Model 163, 170, 202, 208)
Remove, install crankshaft position sensor - AR15.12-P-2133GS
ENGINE 111.951

Remove starter.
Engine 111 in model 163 AR15.30-P-7100GI
Engine 111 in model 170 AR15.30-P-7100G
Engine 111 in model 202,
208
AR15.30-P-7100EA
Engine 104, 111 in model
210
AR15.30-P-7100F
L5 Crankshaft position sensor

Perform re-initializing
of ME control module Re-
initializing must only be
performed with Star
Diagnosis in the menu
point "Control module
adaptation" if the
crankshaft position sensor
has been replaced.

Microsoft
ENGINE 111.955
ENGINE 111.958
ENGINE 111.983
Fig. 48: Identifying Crankshaft Position Sensor
POSITION SENSOR

Removing, installing
1 Remove engine
compartment paneling
Only model 203 with
engine 111.951/955
AR61.20-P-1105P
2 Unplug connector (arrow)
from crankshaft position
sensor (L5)

3 Unscrew crankshaft
position sensor retaining
bolt (L5)

*BA15.10-P-1001-03A
4 Remove crankshaft
position sensor (L5)
Installation :
Replace seal of crankshaft
position sensor.

6 Carry out re-initializing of
ME control module
Re-initializing must
only be performed with
Star Diagnosis in the menu
point "Control module
adaptation" if the
crankshaft position sensor
has been replaced.

Number Designation Engine 111.951/

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REMOVING AND INSTALLING, ADJUSTABLE CAMSHAFT POSITION SENSOR - AR15.12-P-2143
Removing and installing, adjustable camshaft position sensor - AR15.12-P-2143G
ENGINE 104.941 /942 /943 /944 /991 /992 /994,
111.920 /921 /940 /941 /943 /944 /945 /946 /947 /960 /961 /973 /974 /975 /977
Fig. 49: Identifying Crankshaft Position Sensor Remove/Install Components (Engine 119.92)
Fig. 50: Identifying Crankshaft Position Sensor Remove/Install Components (Engine 111.977)
955/958/ 983
BA15.10-P-1001-03A Crankshaft position sensor
to engine block
Nm8

1.1 Remove cylinder head
cover
Only engine 104
ra0100104c500x
2 Remove engine
compartment panel
Model 170/ 202/ 208 AR61.20-P-1105A
Model
210.03/04/05/07/23/24/27
AR61.20-P-1105AB
3 Remove camshaft
position sensor (L5/1)
Installation : Replace seal
(11/1)

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TEST DATA POSITION SENSOR
Removing, installing and adjusting camshaft position sensor - AR15.12-P-2143GS
ENGINE 111.951
ENGINE 111.955
ENGINE 111.958
ENGINE 111.983
If camshaft position sensor
is replaced, it is necessary to set
the clearance to the camshaft

Length of bolt for
attaching camshaft
position sensor
modified
Engine 111.961 BT07.51-P-0002-01A
4 Set camshaft position
sensor (L5/1)
Rotate crankshaft until the
camshaft sprocket segment is
opposite the camshaft position
sensor (L5/1). Measure size of
gap with feeler gage between
camshaft sprocket segment and
camshaft position sensor (L5/1)
Shims (11/2) are available
as replacement parts in 1/10
graduations from 0.1-1.0 mm
*BE15.10-P-1001-04A
5 Install in the reverse
order

Number Designation Engine 104 Engine 111
BE15.10-P-1001-
04A
Size of gap between
camshaft sprocket
segment and
camshaft position
sensor
mm0.5 0.5

Microsoft
Fig. 51: Identifying Crankshaft Position Sensor
POSITION SENSOR
REPLACING KNOCK SENSOR - AR15.12-P-2183

1 Unplug connector (arrow)
from camshaft position
sensor (L5)

2 Unscrew camshaft
position sensor retaining
bolt (L5)

*BA15.10-P-1003-03A
3 Remove camshaft
position sensor (L5/1)
Installation:
Replace camshaft position
sensor sealing ring.


Risk of accident from
vehicle starting off by
itself when engine is
running. Risk of injury
from bruises and burns if
you hold your hand into
engine when it is started
or when it is running.
MODEL all AS00.00-Z-0005-01A
5 Check for leaks with
engine running

Number Designation Engine 111.951/ 955/958/
983
BA15.10-P-1003-03A Camshaft position sensor
to cylinder head cover
Nm8

Microsoft
Replacing knock sensor - AR15.12-P-2183GA
ENGINE 111.960 as of 1.12.94 in MODEL 124
ENGINE 111.943 /946 /973 in MODEL 170
ENGINE 111.921 /945, 111.961 as of 1.12.94, 111.974 in MODEL 202
Fig. 52: Identifying Knock Sensor And Connector
Replacing knock sensor - AR15.12-P-2183GS
ENGINE 111.958 /983
A16/1 Knock sensor
Arrow Knock sensor connector Unplug. Compress
retaining clip for this step

Microsoft
Fig. 53: Identifying Knock Sensor
KNOCK SENSORS
REMOVE/INSTALL KNOCK SENSORS - AR15.12-P-2184A
ENGINE 112.910 in MODEL 202.026 /086
ENGINE 112.920 in MODEL 202.029 /089
ENGINE 112.921 in MODEL 210.063 /081 /263 /281
ENGINE 112.922 in MODEL 220.063 /163
ENGINE 112.940 in MODEL 208.365 /465
ENGINE 112.941 in MODEL 210.065/082/265/282
A16/1 Knock sensor Unbolt *BA15.10-P-1001-02A
Arrow Pull off knock sensor plug by pushing together the
clamp to release.

Number Designation Engine 111.951/ 955/958/
983
BA15.10-P-1001-02A Bolt, knock sensor to
engine block
Nm20

Microsoft
ENGINE 112.944 in MODEL 220.065/165
ENGINE 113.940 in MODEL 210.070 /270
ENGINE 113.941 in MODEL 220.070 /170
ENGINE 113.960 in MODEL 215.375, 220.075/175
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.944 in MODEL 202.033 /093
ENGINE 113.980 in MODEL 210.074/274
ENGINE 113.943 in MODEL 208.370 /470
ENGINE 112.912 in MODEL 203.061 /261, 209.361 /461
ENGINE 112.946 in MODEL 203.064 /264
ENGINE 112.961 in MODEL 203.065 /265
ENGINE 113.968 in MODEL 209.375 /475
ENGINE 112.913 in MODEL 211.061 /261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070 /270

Microsoft
ENGINE 113.987 in MODEL 209.376 /476
ENGINE 112.955 in MODEL 209.365 /465
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243 /246
ENGINE 112.953 in MODEL 203.084 /284
ENGINE 112.916 in MODEL 203.081 /281
ENGINE 112.972 in MODEL 220.067 /167
ENGINE 112.975 in MODEL 220.087 /187
ENGINE 113.948 in MODEL 220.083 /183
ENGINE 113.966 in MODEL 220.084/184
ENGINE 112.917 in MODEL 211.080 /280
ENGINE 112.954 in MODEL 211.082 /282
ENGINE 113.969 in MODEL 211.083 /283
ENGINE 113.990 in MODEL 211.076 /276
ENGINE 113.988 in MODEL 203.076 /276
ENGINE 113.993 in MODEL 463.270 /271

Microsoft
Fig. 54: Identifying Left Knock Sensor 2 - Shown On Engine 112 In Model 220
Knock sensors
Remove/install
1.1 Remove intake manifold All except model, 463 with
engine 113.962/982/993
112.945
Model 170.466 with engine
112.960
Model 203.065/265 with
engine 112.961
engine 113.990
AR09.20-P-1310A
Model 463 with Engine
112.945, 113.962/982
AR09.20-P-1310AG
1.2 Remove compressor Model 170.466 with engine,
112.960 model 203.065/265
with engine, 112.961 model
211.076/276 with engine
113.990
AR09.50-P-4705SVK
engine 113.993
AR09.50-P-4705GX
2 Detach knock sensor 1,
right and knock sensor 2,
left (A16/2) from cylinder
block

*BA15.10-P-1001-02A
112.910/911/
912/913/914/
Engine
113.940/941/
942/943/944/
Engine
113.989

Microsoft
SERVICING WIRING HARNESS - AR15.18-P-0500A
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 208, 210, 215, 220
Fig. 55: Identifying Cable Connection Of Mass Air Flow Sensor And Terminal Block
If a cable break or similar damage exists in the area of the plug connection of the mass air flow sensor (B2)
or temperature sensor (B11), it is possible to repair the wiring harness in order to avoid costly replacement of a
wiring harness.
Modification notes
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995
BA15.10-P-
1001-02A
Bolt securing
knock sensor to
cylinder block
Nm20 20 20
27.9.99 Supersedes SI 54/76 dated
23.1.96
Remove SI 54/76 from
your file.

Removing and installing
1 Remove air cleaner, install.
Only on engine 119

2 Expose wiring harness to
mass air flow sensor or
temperature sensor.
Ignition switched off

Microsoft
Parts ordering notes
REMOVING AND INSTALLING STARTER - AR15.30-P-7100
Removing and installing starter - AR15.30-P-7100G
3 Unplug socket from mass
air flow sensor or
temperature sensor.

4 Plug in repair socket
together with cables at
mass air flow sensor or
temperature sensor and
insert into cable duct.

5 Repair wiring harness
using end soldering sleeves
(Z).
Turn together cable of
engine wiring harness and
cable repair socket of the
same color and insert into
end soldered sleeves (Z).
Use end soldered
sleeves (Z)only in cross
section area 0.7 - 4.0 mm
2

AR54.18-P-0100-02A
6 Insert cables into the cable
duct.

7 Connect HHT, read faults
and erase
see Diagnosis Manual
Engine Volume 2 Index 0:
Connecting and using test
equipment

Part no. Designation Quantity
140 540 00 36 Repair kit socket (B2)1
1) Consisting of repair socket (B2)
and 5 cable connectors
acc. to condition
140 540 00 81 Repair socket (B2) acc. to condition
202 540 01 81 Repair socket (B11) 3-pin acc. to condition
126 540 30 81 Repair socket (B11) 4-pin acc. to condition
001 546 99 41 Cable connector acc. to condition
006 989 84 85 Fabric tape acc. to condition

Microsoft
Fig. 56: Identifying Starter Remove/Install Components (Engine 111.946 In Model 170.435)

Risk of explosion from
explosive gas. Risk of
poisoning and caustic
burns from swallowing
battery electrolyte. Risk of
injury from caustic burns
to eyes and skin from
battery electrolyte or from
handling damaged lead
acid batteries.
No fire, sparks, naked
flames or smoking. Wear
acid-protective gloves,
clothing and eye
protection. Pour battery
electrolyte only into
suitable and appropriately
marked containers.
AS54.10-Z-0001-01A
1 Disconnect ground cable
of battery
AR54.10-P-0003A

Notes on battery All models AH54.10-P-0001-01A
2 Remove bottom engine
compartment panel
AR61.20-P-1105A
3 Disconnect electric cables
(1, 2)
Nut of connection
circuit 30
*BA15.30-P-1001-01A

Nut of connection
circuit 50
*BA15.30-P-1002-01A
4 Remove bracket (4)
5 Unscrew screws (3)
Bolt of starter
*BA15.30-P-1003-01A

Microsoft
STARTER
Remove starter, install - AR15.30-P-7100GA
Fig. 57: Identifying Starter Remove/Install Components (Engine 112.947 /960 In Model 170)
MODIFICATION NOTES
6 Take starter (M1) down
and out

8 Carry out operational
check

9 Render electrical system
operational
Perform basic
programming.
AR00.19-P-0200B
Number Designation Engine 103, 104, 111,
120
BA15.30-P-1001-01A Nut of connection of
circuit 30
Nm14
circuit 50
Nm6
BA15.30-P-1003-01A Bolt of starter Nm42
6.7.00 Value modified from 16
Nm to 14 Nm
Value BA15.30-P-1001-
01A for Engine 112, 113
modified
*BA15.30-P-1001-01A
6.7.00 Value modified from 10 Value in BA15.30-P- *BA15.30-P-1002-01A

Microsoft
STARTER
Fig. 58: Identifying External Torx Set (001 589 76 09 00)
Nm to 6 Nm 1002-01A modified on
Engine 112, 113
6.7.00 Value modified from 58
Nm to 42 Nm
Value in BA15.30-P-
1003-01A for Engine 112,
113 modified
*BA15.30-P-1003-01A
Remove/Install
1 Disconnect ground line of
battery
AR54.10-P-0003A
2 Detach lower engine
AR61.20-P-1105A
3 Pull off protecton against
accidental contact (2)

4 Disconnect electrical lines
(1, 3)

*BA15.30-P-1001-01A

*BA15.30-P-1002-01A
5 Remove bearing bracket (5)
together with engine mount

6 Remove screws (4).

Fig. 58

*BA15.30-P-1003-01A
7 Take starter (M1) down and
out

Number Designation Engine 112 except
112.951, 113.94/ 96/98
circuit 30
Nm14
BA15.30-P-1002-01A Nut of connection circuit
50
Nm6
BA15.30-P-1003-01A Bolt of starter to crankcase Nm42

Microsoft
PREREQUISITES FOR TESTING THE ALTERNATOR - AR15.40-P-5009G
ENGINE 111.943 /946 /958 /973, 112.947 /960 in MODEL 170
Connection diagram
Fig. 59: Connection Diagram - Alternator

Check
1 Open engine hood AR88.40-P-1000G
2 Check electrical line
terminal 30 for firm
seating and a flawless
condition
Check at following
positions:
Battery (G1)
Terminal block (circuit
30)
Crash shutoff relay
(only for engine
111.943/973 up to
05.98)
Starter (M1) (only for
engine 112)
Fuse 1 in the interior
fuse box (from 06.98)
Alternator (G2)

3 Check electrical line
terminal 31 for firm
seating and a flawless
condition
Check at following
positions:

Microsoft
TEST VALUES FOR ALTERNATOR CHARGE INDICATOR LAMP
CHECK REGULATION VOLTAGE OF ALTERNATOR - AR15.40-P-5010G
ENGINES 111.943 /946 /958 /973, 112.947 /960 in MODEL 170
Connection diagram
Fig. 60: Connection Diagram - Regulation Voltage Of Alternator
Battery (G1)
Major assemblies
compartment ground
(W16)
Ground strap between
engine and body
4 Check tension of poly-
V-belt

Check poly-V-belt in
visible area for wear
AP13.22-P-1352Z
5 Check function of the
charge indicator lamp in
the instrument cluster
*BE54.30-P-1001-01A
6 Close engine hood AR88.40-P-1000G
Number Designation Model 129, 163, 168,
170, 202, 203, 208, 210
BE54.30-P-1001-01A Position of ignition / glow
start switch
Charge indicator lamp
Off
0/1
Charge indicator light On2

Microsoft

Check

Risk of explosion caused
by oxyhydrogen gas. Risk
of poisoning and caustic
burns caused by
swallowing battery acid.
Risk of injury caused by
burns to skin and eyes
from battery acid or when
handling damaged
leadacid batteries
No fire, sparks, open flames
or smoking. Wear acid-
resistant gloves, clothing
and safety glasses. Only
pour battery acid into
marked containers.
AS54.10-Z-0001-01A

Notes on battery AH54.10-P-0001-01A
1 Check condition of
battery (G1)
AR54.10-P-1129Z
2 Check whether
preconditions for
alternator testing have
been fulfilled
AR15.40-P-5009G
3 Attach volt ampere tester
(079) according to
connection plan
Volt ampere tester with
load resistance
*WH58.30-Z-1002-09A

Volt ampere tester ETT
011.00
*WH58.30-Z-1003-09A

Risk of accident caused
by vehicle starting off by
caused by contusions and
burns during starting
procedure or when
working near the running
engine
Secure vehicle to prevent it
from moving by itself.
Wear closed and snug-fitting
work clothes.
Do not grasp hot or rotating
parts.
AS00.00-Z-0005-01A
4 Start engine
5 Check function of charge
indicator lamp when
engine is idling and with
increasing engine speed
(up to 3000 rpm)
Charge indicator lamp
must extinguish.

6 Load battery (G1) using a
permanent consumer and
check regulation voltage
of alternator (G2)
*BE15.40-P-1001-02A

load resistance
*WH58.30-Z-1002-09A

*WH58.30-Z-1003-09A

Microsoft
CHECK VALUES FOR REGULATOR
011.00
Regulation voltage >
15.0 V:?

Replace regulator
Regulation voltage
<13.0 V:?
Check electrical
connections for
charging system for
transition resistances;
repair if necessary.
Electrical connections
OK: ?
AR15.40-P-5760G
Check crash relay for
engines 111.943/ 973 to
31.5.98.
AR15.40-P-5011-01A

Check alternator (G2)
diodes
AR15.40-P-9301-02EA
Engine tester with
oscilloscope
If diodes are faulty: ?
*WH58.30-Z-1046-13A

Replace alternator
(G2)
AR15.40-P-5032G
7 Turn off engine
8 Disconnect volt ampere
tester (079)
load resistance
*WH58.30-Z-1002-09A

011.00
*WH58.30-Z-1003-09A
Number Designation Engines 103, 104,
111, 112, 113, 119,
120, 137, 155, 166,
275
BE15.40-P-1001-
02A
Regulating voltage
(at battery)
Loading: only on
permanent consumer
V 13 to 15
Engine speed rpm3000
measured after minapprox. 2
Number Designation

Microsoft
CHECKING CHARGING CURRENT OF ALTERNATOR - AR15.40-P-5011G
ENGINE 111.943 /946 /958 /973, 112.947 /960 in MODEL 170
Connection diagram
Fig. 61: Wiring Diagram - Charging Current Of Alternator
MODIFICATION NOTES
WH58.30-Z-1002-09A Volt-amp(s) tester with load resistance (no longer
available)
WH58.30-Z-1003-09A Volt ampere tester
WH58.30-Z-1046-13A Engine tester with oscilloscope
18.10.05 Charging current of
alternator
Engine 111 *BE15.40-P-1001-01A

Checking

Risk of explosion caused
by oxyhydrogen gas. Risk
of poisoning and caustic
burns caused by
swallowing battery acid.
Risk of injury caused by
burns to skin and eyes
from battery acid or when
handling damaged
leadacid batteries
No fire, sparks, open
flames or smoking. Wear
acid-resistant gloves,
clothing and goggles. Only
pour battery acid into
marked containers.
AS54.10-Z-0001-01A

Notes on battery AH54.10-P-0001-01A

Microsoft
1 Check regulation voltage
of alternator
AR15.40-P-5010G
2 Connect volt ampere tester
(079) with DC clip-on
probe (065) according to
connection diagram
load resistance
*WH58.30-Z-1002-09A

011.00
*WH58.30-Z-1003-09A

Risk of accident caused
by vehicle starting off by
caused by contusions and
burns during starting
procedure or when
working near the running
engine
Secure vehicle to prevent
it from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or
rotating parts.
AS00.00-Z-0005-01A
3 Start engine
4 Load battery (G1) with
volt ampere tester (079)
and check charging
current of alternator (G2)
with increased engine
speed
Vary load resistance
long enough until the
maximum load current is
achieved; when this is
done, the regulating
voltage must not drop
below 12.7 V.

Engine 111 *BE15.40-P-1001-01A
Engine 112 *BE15.40-P-1001-01K

load resistance
*WH58.30-Z-1002-09A

011.00
Charging current below
desired value: ?
*WH58.30-Z-1003-09A
Check crash relay for
engines 111.943/ 973 up
to 05.98.
AR15.40-P-5011-01A
Check diodes for
alternator (G2).
AR15.40-P-9301-02EA
Engine tester with
oscilloscope
If diodes are faulty: ?
*WH58.30-Z-1046-13A
Replace alternator (G2) AR15.40-P-5032G
5 Turn off engine
6 Connect volt ampere tester
(079) with DC clip-on
load resistance
*WH58.30-Z-1002-09A

Microsoft
CHECK VALUES FOR ALTERNATOR
Checking crash relay - AR15.40-P-5011-01A
1. Disconnect coupling at crash relay.
2. Switch on ignition
3. Test step 1
Connect multimeter between terminal 15 (3) of disconnected crash relay coupling and ground
(component compartment) (W16).
Specified value: 11-14 V
probe (065)

011.00
*WH58.30-Z-1003-09A
Number Designation Engine 111 in
models 170, 202,
208, 210 Bosch
BE15.40-P-1001-
01A
Charging current of
alternator
max. A 90
min. A70
Ratio I=2.93
Number Designation Engine 112 in models
163, 170, 202, 203,
208, 209, in model
210 without code 978,
in model 211 without
code 910,
Bosch/Valeo
BE15.40-P-1001-
01K
Charging current of
alternator
max. A 120
min A90
Ratio I=2.93
Number Designation
WH58.30-Z-1002-09A Volt-amp(s) tester with load resistance (no longer
available)
WH58.30-Z-1003-09A Volt ampere tester

Microsoft
Specified value not achieved:
Eliminate fault in supply lead term. 15.
Specified value achieved:
Perform test step 2.
4. Test step 2.
Connect multimeter between terminal 31 (2) of crash relay coupling and positive terminal of the battery.
Specified value: 11-14V
Specified value not achieved:
Eliminate fault in supply lead term term. 31.
Specified value achieved:
Replace crash relay.
End of test.
Fig. 62: Identifying Air Bag Triggering Unit Control And Crash Relay
REMOVE AND INSTALL GENERATOR - AR15.40-P-5032G
ENGINE 111.943 /946 /958 /973, 112.947 /960 in MODEL 170
Shown on ENGINE 112

Microsoft
Fig. 63: Identifying Generator Remove/Install Components (Engine 112)
GENERATOR
Remove/Install
1 Disconnect ground cable of
battery
AR54.10-P-0003A
2 Slacken poly V-belt and
take it off at generator
Engine 111 AR13.22-P-1202A
Engine 112 AR13.22-P-1202SV
3 Detach lower engine
AR61.20-P-1105A
4 Remove protection against
accidental contact (4)

5 Disconnect electric cables
(1, 2)
With engine 112, the
electric cable (2) and
generator (G2) are
connected via a plug
connection.

Nut at cable (1)
*BA15.40-P-1001-01A

Nut to cable (2)
*BA15.40-P-1002-01A
6 Unscrew bolts (3)
With engine 112,
remove bracket (5).

*BA15.40-P-1003-01A
7 Remove alternator (G2)
downwards


Microsoft
REMOVE/INSTALL GENERATOR BELT PULLEY - AR15.40-P-5710EA
ENGINE 111.943 /946 /958 /973, 112.947 in MODEL 170
ENGINE 104.941,111.920 /921 /941 /944 /945 /961 /974/975,112.910 /920, 113.944, 601.913, 604.910 /915,
605.910/960 up to 31.5.97 in MODEL 202
ENGINE 111.944 /945 /975, 112.940, 113.943 in MODEL 208
ENGINE 104.945 /995,111.942 /970,112.911 /921 /941,113.940,119.985, 602.982 up to 30.11.95,
604.912 /917, 605.912, 606.912 up to 31.5.97 in MODEL 210
Fig. 64: Identifying Generator Belt Pulley Components
Number Designation Engine 111 Engine 112.91/92/94/
953/954/955/ 96/97,
113.94/96/98
BA15.40-P-1001-
01A
Nut of circuit B+to
generator
Nm15 15
BA15.40-P-1002-
01A
Nut of circuit D+to
generator
Nm4 4
BA15.40-P-1003-
01A
Screw, alternator Nm42 42

Remove/Install
1 Remove alternator Engine 111, 112 in model
170.
AR15.40-P-5032G
Engine 104, 111, 601, AR15.40-P-5032EA

Microsoft
Generator
Generator
Generator
604, 605 in model 202,
engine 111 in model 208,
Engine 104,111, 602,
604, 605, 606 in model
210.
AR15.40-P-5032F
Engine 112 in model 202,
engine 112, 113 model
208,
AR15.40-P-5032EB
Engine 112, 113, 119 in
model 210.
AR15.40-P-5032ED
2 Unscrew collar nut (1)
In order to retain the
alternator shaft (2),
multipoint head cap nut
or Allen nut with a
reversible ratchet.

Engine 104, 111,
112, 113, 119.
*BA15.40-P-1004-01A

Engine 601, 602,
604, 605, 606.
*BA15.40-P-1004-01E
3 Remove ribbed V-belt
pulley (3)
When replacing
generators after mileages
in excess of 100 000 km
(60,000 ml), replace the
poly V-belt pulley at the
same time.

Number Designation Engine 104 Engine 111 Engine 112.91/92/94/
953/954/955/96/97,
113.94/96/98
BA15.40-P-
1004-01A
Collar nut to
poly V-belt
pulley
Nm80 80 80
BA15.40-P-1004-
01A
Collar nut to poly
V-belt pulley
Nm80 80
Number Designation Engine 601 Engine 602 Engine 602
BA15.40-P-1004-
01E
Collar nut to
poly V-belt
Nm80 80 80

Microsoft
Generator
REMOVE, INSTALL REGULATOR OF GENERATOR - AR15.40-P-5760G
ENGINE 111.943 /946 /973, 112.947, 111.958, 112.960 in MODEL 170
Fig. 65: Identifying Regulator Of Generator Remove/Install Components
pulley
BA15.40-P-1004-
01E
Collar nut to poly
V-belt pulley
Nm80 80

1 Remove generator Engines 111, 112 AR15.40-P-5032G
2 Unscrew bolts (1)
Not with engine 112

3 Unclip cover (2) and
remove
Push apart retaining
lugs (3). (Not with engine
112).

4 Unscrew bolts (4)
5 Take out regulator (5) to
the side
Installation: When
inserting the regulator (5),
ensure that the ground lug
(6) is touching the
regulator.


Microsoft
TEST DIODES OF GENERATOR - AR15.40-P-9301-02EA
Fig. 66: Generator Connection Diagram - Model 129
Model 129 with engine 119 up to vehicle ident end no. 1F 032 589: Problems with power supply system -
test battery voltage-dependent idle speed increase (refer to Diagnosis Manual Engine Volume 2 Group 07.3).
Number Designation

Microsoft

Microsoft

Microsoft
Model 210: as of 1.6.99 a fuse for protection of generator is located in the terminal block circuit 30 (X12/3).
1. Connect DC clip-on probe (065) from engine tester with oscilloscope (030) to positive pole of battery
(G1)
2. Start engine.
3. Switch on low beam.
4. Assess diode harmonics at 3000 rpm (engine speed).
In this test it is not possible to assess the exciter diodes.

Microsoft
Fig. 74: Identifying Harmonics - Negative Diode Defective
Fig. 75: Identifying Harmonics - Positive Diode Defective
Fig. 76: Identifying Diode Harmonics OK
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE -
BE15.00-Z-9999AZ

Microsoft
MODEL all
SPARK PLUGS AND POSITION SENSOR - BE15.10-P-1000
Spark plugs - BE15.10-P-1000-01A
Spark plugs ENGINE all BE15.10-P-1000-01A
Position sensor ENGINE 104/, 111 BE15.10-P-1000-04A
Ignition angle ENGINE 103.985 in MODEL 124 BE15.12-P-1000-01A
Ignition angle ENGINE 104.990, 119.97, 120 BE15.12-P-1000-01B
Check values for
alternator
ENGINE 104, 111, 113, 119, 137,
155, 601, 602, 604, 605, 606, 611,
612, 613...
BE15.40-P-1000-01A
Test values for generator ENGINE 103, 104, 119, 120 in
MODEL 129
BE15.40-P-1000-01B
Test values for generator ENGINE 104, 119, 120, 603 in
MODEL 140
BE15.40-P-1000-01C
Test values for generator ENGINES
166.940/960/961 /990/991 /995
BE15.40-P-1000-01D
Test values for generator ENGINES 668.914/940/941/942 BE15.40-P-1000-01E
Check values for
alternator
ENGINE 642 in MODEL 164, 203,
209, 211, 219, 221, 251 ENGINE
642 in MODEL 463
BE15.40-P-1000-01H
Check values for
alternator
ENGINE 156, 266, 271, 272, 273,
275, 285...
BE15.40-P-1000-01I
Check values for
alternator
ENGINE 628, 629, 640, 646, 647,
648...
BE15.40-P-1000-01J
Test values for alternator ENGINE 112, 113 BE15.40-P-1000-01K
Check values for
alternator
ENGINE 271, 272, 642, 646 in
MODEL 204
BE15.40-P-1000-01L
Governor ENGINE 103, 104, 111, 112, 113,
119, 120, 137, 155, 166/,275
BE15.40-P-1000-02A
Governor ENGINE 601, 602, 603, 604, 605,
606, 611, 612 /, 613, 628 /, 642,
646, 647, 668 /
BE15.40-P-1000-02C
Coolant temperature
sensor
ENGINE 103/, 104/, 119, 120 BE15.60-P-1000-01A
Coolant temperature
sensor
ENGINE 111, 271 BE15.60-P-1000-01B
Intake air temperature
sensor
ENGINE 103, 104, 119, 120 BE15.60-P-1000-02A
Intake air temperature
sensor
ENGINE 111, 271 BE15.60-P-1000-02B

Microsoft
TEST VALUES OF SPARK PLUGS
Position sensor - BE15.10-P-1000-04A
Engine 104, 111
TEST DATA OF POSITION SENSOR
CHECK VALUES FOR ALTERNATOR AND GOVERNOR - BE15.40-P-1000
Check values for alternator - BE15.40-P-1000-01A
Engines 104, 111, 113, 119, 137, 155, 601, 602, 604, 605, 606, 611, 612, 613
MODIFICATION NOTES
Number Designation All engines
BE15.10-P-1001-01A Electrode gap mm0.8
BE15.10-P-1001-
04A
Gap between
camshaft sprocket
segment and
camshaft position
sensor
mm 0.50.5
18.10.05 Charging current of alternator Engine 111
104.941/
995
KC14V
45/90 A
Engine
104.941
NC 14 V
60/120 A
Engine
104.941/
995
NC14V
70/115 A
Engine
104.941/
NC14V
75/115 A
Engine
111 in
models
163,203
Engine
111 in
models
202, 208
with code
910
Bosch/
Valeo
BE15.40-P-
1001-01A
Charging
current of
alternator
max. A 90 120 115 115 120
min. A70 90 90 90 90
Engine
speed
rpm2200 2200 2300 2500 2500
Ratio I=2.93 2.93 2.82 2.9 2.93

Microsoft
Number Designation Engine 111
in models
170,202,
208,210
Bosch
Engine
113.940/
941/942/
960/961
NC 14V
90/150 A
Engine
119.985
NC 14 V
70/115 A
Engine
137.970
NF 14 V
90/150 A
Engine
155 NC
14 V
90/150 A
BE15.40-P-
1001-01A
Charging
current of
alternator
max. A 90 150 115 150 150
min. A70 120 90 120 120
Engine
speed
rpm2500 2200 2100 2500 2200
Ratio I=2.93 2,92 3.1 2.9 0.34
NC 14 V
40/70 A
Engine 601
NC 14 V
45/90A
Engine 602
in models
210 Valeo
Engine 602
in models
210 Bosch
BE15.40-P-
1001-01A
Charging
current of
alternator
max. A 70 90 90 90
min. A50 70 70 70
Engine
speed
rpm2500 2500 2500 2500
Ratio I=2.53 2.53 2.53 2.93
in models
210 with
code 450 or
910 Valeo
Engine 602
in models
210 with
code 450 or
910 Bosch
Engine 604
in model
202 Valeo
Engine 604
in model
202 Bosch
BE15.40-P-
1001-01A
Charging
current of
alternator
max. A 120 115 90 90
min. A90 90 70 70
Engine
speed
rpm2500 2000 2500 2500
Ratio I=2.93 2.93 2.53 2.93
604 in
models
210 with
code 450
or 910
Valeo
Engine
604 in
models
210
without
code 450
or 910
Valeo
Engine
604 in
models
210 with
code 450
or 910
Valeo
Engine
604 in
models
210 with
code 450
or 910
Bosch
Engine
605 in
models
124,202
Valeo
BE15.40-P- Charging max. A 90 90 120 115 90

Microsoft
1001-01A current of
alternator
min. A70 70 90 90 70
Engine
speed
rpm2500 2500 2500 2000 2500
Ratio I=2.53 2.93 2.93 2.93 2.53
605 in
models
124, 202
Bosch
Engine
605 in
models
210 with
code 210
or 910
Valeo
Engine
605 in
models
210
without
code 210
or 910
Valeo
Engine
605 in
models
210 with
code 210
or 910
Valeo
Engine
605 in
models
210 with
code 210
or 910
Bosch
BE15.40-P-
1001-01A
Charging
current of
alternator
max. A 90 90 90 120 115
min. A70 70 70 90 90
Engine
speed
rpm2500 2500 2500 2500 2000
Ratio I=2.93 2.53 2.93 2.93 2.93
in models
124, 140
Valeo
Engine 606
in models
124, 140
Bosch
Engine 606
in model
210 Valeo
Engine 606
in model
210 Bosch
BE15.40-P-
1001-01A
Charging
current of
alternator
max. A 90 90 120 115
min. A70 70 90 90
Engine
speed
rpm2500 2500 2500 2000
Ratio I=2.53 2.93 2.93 2.93
in models
202 Bosch
NCB1 14V
70/120 A
Engine 611
in model
202 NC 14
V 70/115 A
Engine 611
in models
203, 210
Delphi
Engine 612
in models
163, 203,
209, 210,
463 Delphi
BE15.40-P-
1001-01A
Charging
current of
alternator
max. A 120 115 190 190
min. A90 90 150 150
Engine
speed
rpm2500 2500 2500 2500
Ratio I=2.93 2.93 2.53 2.53

Microsoft
Governor - BE15.40-P-1000-02A
Engines 103, 104, 111, 112, 113, 119, 120, 137, 155, 166, 275
CHECK VALUES FOR REGULATOR
COOLANT/INTAKE AIR TEMPERATURE SENSOR - BE15.60-P-1000
Coolant temperature sensor - BE15.60-P-1000-01B
Engine 111, 271
TEST VALUES OF COOLANT TEMPERATURE SENSOR
Number Designation Engine 612 in
model
203.018/218/718
Bosch
Engine 612
in model 461
12V
alternator
Engine 612
in model 461
24V
alternator
Engine
613 in
models
210, 220
Delphi
BE15.40-P-
1001-01A
Charging
current of
alternator
max. A 150 150 80 190
min. A120 120 60 150
Engine
speed
rpm2500 2500 2500 2500
Ratio I=2.93 2.53 2.53 2.53
Number Designation Engines 103, 104,
111, 112, 113, 119,
120, 137, 155, 166,
275
BE15.40-P-1001-
02A
Regulating voltage
(at battery)
Loading: only on
permanent consumer
V 13 to 15
measured after minapprox. 2
BE15.60-P-1001-
01B
Coolant
temperature sensor
(B11/3)
10C ohms3700 (5%) 4925,4 (5%)
10C V3,9 (5%) 3.85 (0.06V)
20C ohms2500 (5%) 3086,6 (5%)
20C V 3,5 (5%) 3.39 (0.07V)
30C ohms1700 (5%) 1998,1 (5%)
30C V 3,1 (5%) 2.88 (0.07V)
40C ohms1170 (5%) 1327,1 (4%)
40C V 2,7 (5%) 2.37 (0.07V)
50C ohms830 (5%) 902,3 (4%)
50C V 2,3 (5%) 1.9 (0.06V)
60C ohms600 (5%) 626,7 (4%)

Microsoft
Intake air temperature sensor - BE15.60-P-1000-02B
Engine 111, 271
TEST VALUES OF INTAKE AIR TEMPERATURE SENSOR
MAINTENANCE
CHECK SPARK PLUGS AND REPLACE IF NECESSARY - AP15.00-P-1550Z
ENGINE 103, 104, 111, 119 with CODE (491) USA version
ENGINE 120 as of 1.10.93 with CODE (491) USA version
60C V 1,9 (5%) 1.49 (0.05V)
70C ohms435 (5%) 443,8 (3%)
70C V 1,5 (5%) 1.16 (0.04V)
80C ohms325 (5%) 319,9 (3%)
80C V 1,2 (5%) 0.894 (0.031V)
90C ohms245 (5%) 234,4 (3%)
90C V 1,0 (5%) 0.688 (0.024V)
BE15.60-P-1001-
02B
Intake air
temperature sensor
(B17)
10C ohms9670 (5%) 9470,2 (4,5%)
10C V3,2 (5%) 4.209 (0.036V)
20C ohms6060 (5%) 5869,2 (4,5%)
20C V 2,6 (5%) 3.836 (0.045V)
30C ohms3900 (5%) 3750,2 (4,5%)
30C V 2,1 (5%) 3.391 (0.053V)
40C ohms2600 (5%) 2469,6 (4%)
40C V 1,6 (5%) 2.906 (0.052V)
50C ohms1760 (5%) 1674 (3,5%)
50C V 1,2 (5%) 2.423 (0.046V)
60C ohms1220 (5%) 1164 (3,5%)
60C V 0,9 (5%) 1.977 (0.043V)
70C ohms860 (5%) 827,1 (3,5%)
70C V 0,7 (5%) 1.586 (0.041V)
80C ohms620 (5%) 599,2 (3,5%)
80C V 0,5 (5%) 1.259 (0.035V)
90C ohms245 (5%) 441,2 (3,5%)
90C V 0,2 (5%) 0.993 (0.029V)

Microsoft
Fig. 77: Identifying Spark Plugs - Shown On Engine 120 With ME 1.0
Fig. 78: Identifying Spark Plugs - Shown On Engine 104 With LH-SFI
CHECK VALUES FOR SPARK PLUGS
1 Blow out spark plug
pockets in cylinder head

Checking
2.1 Check spark plug
connectors, ignition coil
connectors and ignition
lines for damage,
deformation and crack
formation
Only for engine 111
Replace, if necessary.

3 Check spark plugs for
deposits
Visual inspection
If there are deposits on the
electrodes
?

Replace spark plugs
Engine 103, 104, 111, 120
AP15.10-P-1580CA
Engine 119.97/981/
982/985
AP15.10-P-1580EA
4 Check electrode gap and
adjust if necessary
*BE15.10-P-1001-01A

Microsoft
REPLACE SPARK PLUGS - AP15.10-P-1580
Replace spark plugs - AP15.10-P-1580A
ENGINE 112.910 in MODELS 202.086 /026
ENGINE 112.920 in MODELS 202.089 /029
ENGINE 113.944 in MODELS 202.093 /033
ENGINE 112.912 in MODELS 209.461 /361, 203.261 /061
ENGINE 112.946 in MODEL 203.764 /064 /264
ENGINE 112.940 in MODELS 208.465 /365
ENGINE 113.984 in MODELS 208.374
ENGINE 113.943 in MODELS 208.470 /370
ENGINE 112.911 in MODELS 210.261 /061
ENGINE 112.914 in MODELS 210.262 /062
ENGINE 112.921 in MODEL 210.663 /281 /063 /263 /081
ENGINE 112.941 in MODELS 210.282 /082 /265 /065
ENGINE 113.940 in MODELS 210.283 /083 /270 /070
ENGINE 113.980 in MODELS 210.274 /074
ENGINE 112.961 in MODELS 203.265 /065
ENGINE 113.968 in MODELS 209.475 /375
ENGINE 113.987 in MODELS 209.376 /476
ENGINE 112.955 in MODELS 209.365 /465
Number Designation All engines
BE15.10-P-1001-01A Electrode gap mm0.8

Microsoft
ENGINE 112.953 in MODELS 203.084 /284
ENGINE 112.916 in MODELS 203.081 /281
ENGINE 113.988 in MODELS 203.076 /276
Shown on model 210 with engine 112
Fig. 79: Identifying Spark Plugs - 210 With Engine 112

Remove/install

contact with parts
Do not touch parts which
conduct high voltages. Persons
with electronic implants (such as
pacemakers) must not work on
the ignition system.
AS15.10-Z-0001-01A

Notes on avoiding
damage to ignition
system
Engine 104, 111, 112, 113, 119,
120, 271
AH15.10-P-0002-01D
1.1 Remove top part of air
filter housing
Only on engines with air filter
fitted at vehicle side.

2.1 Remove hot film mass air
flow sensor with air
intake pipe
Only on engines with air filter
fitted at vehicle side.

Remove hot film mass air
flow sensor with air
intake pipe
202.026/ 086
202.029/ 089
AR07.07-P-1454A

Microsoft
208.365/ 465
210.061/ 261
210.063 /081 /263 /663 /281
210.065 /082 /265 /282
210.070/ 270
170.465
203.061/ 261, 209.361/ 461
203.064 / 264 / 764
209.375/ 475
209.376/ 476
209.365/ 465
203.084/ 284
Engine 112.916 in Model
203.081 /281
ENGINE 113.988 in model
203.076/ 276
AR07.07-P-1454SV
3 Remove engine cover
with integrated air filter
Pull engine cover with
integrated air filter vertically
upwards off the cylinder head
covers.

4 Remove the ignition coil
(1)

202.086/ 026
202.029/ 089
210.063 /081 /263/281
208.465/ 365
210.265 /065 /082/282
210.070/ 270
215.375, 220.175/075 /875
AR15.12-P-2003A

Microsoft
210.074/ 274
Engine 113.944 in models
202.033 /093
208.470/ 370
208.374
203.261 /061,209.361
203.264/ 064
170.465
170.466
203.265/ 065
209.375
209.376/ 476
209.365
203.081 /281
203.084/ 284
Except engine 112.946 in model
203.764
210.061/ 261
209.461
210.663
209.465
209.475
ENGINE 113.988 in model
203.076/ 276
5 Disconnect spark plug
connectors
Use double open-end wrench
to pry off spark plug connector
via the cylinder head cover.

Double open-ended
wrench
Fig. 43

Microsoft
Spark plugs
Fig. 80: Identifying Spark Plug Wrench (112 589 01 09 00)
Fig. 81: Identifying Open-End Wrench, Double (110 589 01 01 00)
Replace spark plugs - AP15.10-P-1580CA
ENGINE 103, 104 from 1.10.93,
111.920 /921 /940 /941 /942 /943 /944 /945 /946 /947 /952 /956 /957 /958 /960 /961 /970 /973 /974 /975 /977 /98

Checking
6 Check spark plug
connectors, ignition coil
connectors and ignition
lines for damage,
deformation and crack
formation

7 Remove the spark plug
(2)

*BA15.10-P-1001-
01A

Spark plug wrench
Fig. 80
Number Designation Engine 104, 110, 111,
113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/981/
115, 117, 119, 120
BA15.10-
P-1001-
01A
Spark
plugs
Nm28

Microsoft
120 from 1.10.93
Shown on engine 104 HFM-SFI
Fig. 82: Identifying Guide Rail, Cable Recess And Spark Plug
Shown on engine 104 HFM-SFI
Fig. 83: Identifying Ignition Coil
Shown on engine 120.982/983
Fig. 84: Identifying Ignition Coil (Engine 120.982/983)

Microsoft
Shown on engine 120.980/981
Fig. 85: Identifying DIS Cover And Wiring Harness
Removal

Risk of death caused
by contact with parts
conducting high
voltages.
Do not touch parts which conduct
high voltages. Persons who have
electronic implants (e.g.
pacemakers) must not perform any
work on the ignition system.
AS15.10-Z-0001-01A

Notes on avoiding
damage to ignition
system
Engine 111
with PEC fuel injection and ignition
system
AH15.10-P-0002-01B

Notes on avoiding
damage to ignition
system
Engine 104, 111
with HFM-SFI fuel injection and
ignition system
AH15.10-P-0002-01C

Notes on avoiding
damage to ignition
system
Engines 104, 111, 112, 113, 119,
120
with ME-SFI fuel injection and
ignition system
AH15.10-P-0002-01D

Notes on avoiding
damage to ignition
system
Engines 103, 104, 119
with CFI fuel injection system
AH15.10-P-0002-01E

Notes on avoiding
damage to ignition
system
Engine 104, 119, 120
with LH sequential multiport fuel
injection system
AH15.10-P-0002-01F
1 Ignition: OFF
2.1 Loosen the cable duct
partially
Engine 120.980/981 ra15001201031x

The cable duct must be loosened
partially in order to replace the spark
plug at cylinder 12.

Detach partial rubber seal, remove
the cover for the DI switching unit

Microsoft
(A) and cable harness (B).
Remove the mounting screws
(arrows) for the cable duct.
Detach the cable duct and press it
towards the front.
3.1 Remove ignition coils

Remove/install ignition
coils
Engine 111.921/942/
943/945/946/947/ 970/973/974/975/
977
AR15.12-P-2003GA

Remove ignition coils (T1/1,
T1/2) with connected control lines
and ignition lines.

Engine 104,
111.920/940/941/944/960/961
Remove ignition coils (T1/1,
T1/2, T1/3) with connected control
lines and ignition lines.
AR15.12-P-2003G
Engine 120.982/983 AR15.12-P-2003FA
4 Release and unplug
spark plug connector
through slight rotation
Use pliers for straight spark plug
connectors.

Fig. 89
5.1 Check the spark plug
connectors on the
inside for any
secondary spark gaps
(discoloration) and the
sealing for any
damage.
Engines 104, 111
The catalytic converter can get
damaged with spark plug connectors
having secondary spark gaps.

Checking
5.2 Check spark plug
connectors, ignition
coil connectors and
ignition lines for
damage, deformation
and crack formation
Only for engine 111


Installation
6 Blow out spark plug
stems and recesses with
compressed air

7 Replace spark plugs
Install only approved spark plugs.

*BA15.10-P-1001-01A

Engine 103 with tapered
Fig. 86

Microsoft
SPARK PLUGS
seat (B)

Engine 104, 111 with flat
seat (C)
Fig. 87

Engine 120 with flat seat
(C), cylinder 1 to 5 and 7 to 12
Fig. 88

Engine 120 with flat seat
(C), cylinder 6
Fig. 87
8 Connect spark plug
connector
Ensure that the ignition cables are
installed correctly.

9.1 Install ignition coils

Remove/install ignition
coils
Engine 111.921/942/
943/945/946/947/970/973/974/975/
977
AR15.12-P-2003GA
Engine 104,
111.920/940/941/944/960/961
AR15.12-P-2003G
Engine 120.982/983 AR15.12-P-2003FA
10.1 Assemble and fasten
cable duct
Engine 120.980/981 ra15001201031x
Number Designation Engine 103 Engine 104, 110, 111,
113.940/941/942/943/
944/948/960/961/962/
963/964/965/966/967/
968/969/971/980/981/
982/984/986/992/993/
995, 115, 117, 119, 120
Engines
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976
BA15.10-P-
1001-01A
Spark plugs Nm20 28 28

Microsoft
Fig. 89: Identifying Pliers (103 589 00 37 00)
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE - BA15.00-Z-
9999AZ
MODEL all
Ignition system ENGINE 102, 103, 104, 110, 111,
112, 113, 115, 117, 119, 120, 137,
155, 166...
BA15.10-P-1000-01A
Ignition system ENGINE 271, 272, 273, 275, 285 BA15.10-P-1000-01C
Ignition system ENGINE 266 BA15.10-P-1000-01E
Ignition system ENGINE 266.920 /940 /960 /980 BA15.10-P-1000-01F

Microsoft
Ignition system ENGINE 113.971 in MODEL 251 BA15.10-P-1000-01G
Ignition system ENGINE 156 BA15.10-P-1000-01H
Knock sensors ENGINE 111, 112, 113, 119, 120,
271...
BA15.10-P-1000-02A
Knock sensors ENGINE 272, 273, 275, 285 BA15.10-P-1000-02B
Knock sensors ENGINE 156 BA15.10-P-1000-02C
Knock sensors ENGINE 646.8 BA15.10-P-1000-02D
Position sensor ENGINE 111, 112, 113, 155... BA15.10-P-1000-03A
Position sensor ENGINE 137 BA15.10-P-1000-03B
Position sensor ENGINE
612.962 /963 /965 /966 /967 /990,
628, 629, 646, 647.961 /981, 648
BA15.10-P-1000-03C
Position sensor ENGINE 271, 275, 285 BA15.10-P-1000-03D
Position sensor ENGINE 272, 273 BA15.10-P-1000-03E
Position sensor ENGINE 640 BA15.10-P-1000-03F
Position sensor ENGINE 642 / BA15.10-P-1000-03G
Ignition coil ENGINE 112 / /, 113 /, 155, 272,
273
BA15.10-P-1000-04A
Ignition coil ENGINE 156 BA15.10-P-1000-04B
Ground strap MODEL 163 with ENGINE 111,
112, 113, 612, 628
BA15.10-P-1000-05A
Ground strap ENGINE 266.920 /940 /960 /980 BA15.10-P-1000-05B
Distributor ignition (DI
[EZL]) system
ENGINE
166.940 /960 /961 /990 /991 /995
BA15.12-P-1000-01A
ECI ignition system ENGINE 668.914 /940 /941 /942 BA15.12-P-1000-01B
DI ignition system ENGINE 120 BA15.12-P-1000-01C
[EZL]) system
ENGINE 137, 275, 285 BA15.12-P-1000-01D
[EZL]) system
ENGINE 111.951 /955 /981 BA15.12-P-1000-01E
[EZL]) system
ENGINE 271 BA15.12-P-1000-01F
[EZL]) system
ENGINE 266.920 /940 /960 /980 BA15.12-P-1000-01J
[EZL]) system
ENGINE 156 BA15.12-P-1000-01K
ECI ignition system ENGINE 275, 285 BA15.15-P-1000-01A
Engine wiring harness ENGINE 628.960 /961, 629 BA15.18-P-1000-01A
Engine wiring harness ENGINE 272, 273 BA15.18-P-1000-01B
Engine wiring harness ENGINE 646.8 BA15.18-P-1000-01C
Preglow system ENGINE 601, 602, 603, 604, 605,
606, 611, 612, 613, 628, 629, 646,
BA15.20-P-1000-01A

Microsoft
647, 648...
Preglow system ENGINE 668.914 /940 /941 /942 BA15.20-P-1000-01B
Preglow system ENGINE 640 BA15.20-P-1000-01E
Preglow system ENGINE 642 / BA15.20-P-1000-01F
Starter ENGINE 611, 612, 613, 642, 646,
647, 648...
BA15.30-N-1000-01G
Starter ENGINE 103, 104, 111, 112, 113,
119, 120, 271...
BA15.30-P-1000-01A
Starter ENGINE
166.940 /960 /961 /990 /995 /991
BA15.30-P-1000-01B
Starter ENGINE 601, 602, 604, 605, 606,
611, 628, 629...
BA15.30-P-1000-01C
Starter ENGINE 668.914 /940 /941 /942 BA15.30-P-1000-01
Starter ENGINE 137, 275, 285.950 BA15.30-P-1000-01G
Starter ENGINE 155.980 BA15.30-P-1000-01H
Starter ENGINE 272, 273 BA15.30-P-1000-01J
Starter ENGINE 640 BA15.30-P-1000-01K
Starter ENGINE 266.920 /940 /960 /980 BA15.30-P-1000-01L
Starter ENGINE 113 in MODEL 219 BA15.30-P-1000-01M
Starter ENGINE 642 ENGINE 642 in
MODEL 463
BA15.30-P-1000-01N
Starter ENGINE 156 BA15.30-P-1000-01O
Generator ENGINE 601.942 /943 /970,
602.980 /982 /984 /985
BA15.40-N-1000-01I
Alternator ENGINE 103, 104, 111, 112, 113,
119, 120, 137, 155...
BA15.40-P-1000-01A
Generator ENGINE
166.940 /960 /961 /990 /991 /995
BA15.40-P-1000-01B
Generator ENGINE 668.914 /940 /941 /942 BA15.40-P-1000-01C
Alternator ENGINE 611, 612, 613, 628, 629,
642, 646, 647, 648...
BA15.40-P-1000-01D
Generator ENGINE 601, 602, 603, 604, 605,
606, 612.966
BA15.40-P-1000-01E
Generator ENGINE 271, 272, 273 BA15.40-P-1000-01F
Alternator ENGINE 275, 285... BA15.40-P-1000-01I
Alternator ENGINE 266.920 /940 /960 /980,
640
BA15.40-P-1000-01K
Alternator ENGINE 113.967 /990 in MODEL
219
BA15.40-P-1000-01M
Alternator ENGINE 113.964 in MODEL 164.1
ENGINE 113.971 in MODEL
251.075 /175
BA15.40-P-1000-01N
Alternator ENGINE 156 BA15.40-P-1000-01P

Microsoft
IGNITION SYSTEM/COIL, KNOCK/POSITION SENSORS - BA15.10-P-1000
Ignition system - BA15.10-P-1000-01A
Engines 102, 103, 104, 110, 111, 112, 113, 115, 117, 119, 120, 137, 155, 166
SPARK PLUGS
SPARK PLUGS
Knock sensors - BA15.10-P-1000-02A
Engines 111, 112, 113, 119, 120, 271
KNOCK SENSORS
KNOCK SENSORS
Temperature sensor ENGINE 272, 273 BA15.60-P-1000-01A
Temperature sensor ENGINE 156 BA15.60-P-1000-01C
102
Engine
103
Engines 104, 110, 111,
113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/96
115, 117, 119, 120
BA15.10-
P-1001-
01A
Spark
plugs
Nm20 20 28
113.987/988/990/991
Engine
113.989
Engine
137
Engine
155
Engine
166.940/960/990/995
Engine
166.961/991
BA15.10-
P-1001-
01A
Spark
plugs
Nm25 25 28 25 25 25
111.951/955/958/983
Engines
112.910/911/912/913/914/915/916/917/920/921/922/923/940/941/
BA15.10-
P-1001-
02A
Bolt
securing
knock
sensor
to
cylinder
block
Nm20 20
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/968/969/971/
BA15.10-
P-1001-
Bolt
securing
Nm20

Microsoft
Position sensor - BA15.10-P-1000-03A
Engines 111, 112, 113, 155
POSITION SENSOR
POSITION SENSOR
02A knock
sensor
to
cylinder
block
111.951/955/958/983
Engines
112.910/911/912/913/914/915/916/917/920/921/922/923/940/94
BA15.10-
P-1001-
03A
Crankshaft
position
sensor on
engine
block
Nm8 8
BA15.10-
P-1002-
03A
Camshaft
Hall
sensor on
cylinder
head
Nm- 8
BA15.10-
P-1003-
03A
Camshaft
position
sensor on
cylinder
head cover
Nm8 -
BA15.10-
P-1004-
03A
Camshaft
position
sensor on
cylinder
head
Nm- -
Number Designation Engine 113.989 Engine 155
BA15.10-P-1001-
03A
Crankshaft position
sensor on engine
block
Nm7 8
BA15.10-P-1002-
03A
on cylinder head
Nm8 -
BA15.10-P-1003-
03A
Camshaft position
sensor on cylinder
head cover
Nm8 -
BA15.10-P-1004- Camshaft position Nm- 8

Microsoft
Ignition coil - BA15.10-P-1000-04A
Engines 112, 113, 155, 272, 273
IGNITION COIL
IGNITION COIL
STARTER - BA15.30-P-1000-01A
Engines 103, 104, 111, 112, 113, 119, 120, 271
STARTER
STARTER
03A sensor on cylinder
head
Number Designation Engines 112,
113
Engine 155 Engine 272
BA15.10-P-1001-
04A
Bolt, ignition
coil to cylinder
head cover
Nm8 8 9
BA15.10-P-1001-04A Bolt, ignition coil to
cylinder head cover
Nm9
103, 104,
111, 120
Engine 112
except
112.951,
113.94/96/98
Engines
112.951/976
Engine
113.964 in
model 164
Engine
113.971 in
model
251.075/175
BA15.30-P-
1001-01A
Nut for
connection
of circuit 30
Nm14 14 14 14 14
BA15.30-P-
1002-01A
Nut for
connection
of circuit 50
Nm6 6 6 6 6
BA15.30-P-
1003-01A
Bolt, starter
to crankcase
Nm42 42 40 40 40
113.987 in
model 209
Engine
113.988 in
model 203
Engine
113.989 in
model 171
Engine
113.990/991/993
BA15.30-P-
1001-01A
Nut for
connection of
circuit 30
Nm14 14 14 14

Microsoft
STARTER
ALTERNATOR - BA15.40-P-1000-01A
Engines 103, 104, 111, 112, 113, 119, 120, 137, 155
ALTERNATOR
BA15.30-P-
1002-01A
Nut for
connection of
circuit 50
Nm6 6 6 6
BA15.30-P-
1003-01A
Bolt, starter to
crankcase
Nm40 40 40 40
113.963 in
model 230
Engines
113.992/995 in
model 230
Engine 119 Engine 271
BA15.30-P-
1001-01A
Nut for
connection of
circuit 30
Nm14 14 14 14
BA15.30-P-
1002-01A
Nut for
connection of
circuit 50
Nm6 6 6 6
BA15.30-P-
1003-01A
Bolt, starter to
crankcase
Nm40 40 58 40
103
Engine
104
Engine
111
Engine
112.91/92/94/953/954/955/96/97,113.94/96/98
except 112.976
BA15.40-
P-1001-
01A
Nut, circuit B+to
alternator
Nm15 15 15 18
BA15.40-
P-1002-
01A
Nut, circuit D+to
alternator
Nm4 4 4 5
BA15.40-
P-1003-
01A
Bolt for alternator Nm42 42 42 42
BA15.40-
P-1004-
01A
Collar nut on
poly-V-pulley
Nm80 80 80 80
BA15.40-
P-1005-
01A
Self-
grooving
screw,
alternator
to timing
case
Thread
not
pre-
tapped
Nm- - - 57
Thread
pre-
Nm- - - 45

Microsoft
ALTERNATOR
ALTERNATOR
tapped
BA15.40-
P-1006-
01A
Bolt for
alternator to
cooling housing
Nm- - - -
BA15.40-
P-1007-
01A
Bolt,
cooler
housing
for
alternator
to
crankcase
M7 Nm- - - -
M8 Nm- - - -
112.951/976
Engine
113.963 in
model 230
Engine
113.987 in
model 209
Engine
113.988 in
model 203
BA15.40-P-
1001-01A
Nut, circuit B+to
alternator
Nm14 14 18 18
BA15.40-P-
1002-01A
Nut, circuit D+to
alternator
Nm- - 5 5
BA15.40-P-
1003-01A
Bolt for alternator Nm- - - -
BA15.40-P-
1004-01A
Collar nut on poly-V-
pulley
Nm80 - 80 80
BA15.40-P-
1005-01A
Self-
grooving
screw,
alternator to
timing case
Thread not
pre-tapped
Nm57 57 57 57
Thread pre-
tapped
Nm45 45 45 45
BA15.40-P-
1006-01A
Bolt, alternator to cooling
housing
Nm- - - -
BA15.40-P-
1007-01A
Bolt, cooler
housing of
alternator to
crankcase
M7 Nm- - - -
M8 Nm- - - -
Number Designation Engine 113.989
in model 171
Engine 113.990
in model 211
BA15.40-P-1001-
01A
Nut, circuit B+to alternator Nm18 14
BA15.40-P-1002-
01A
Nut, circuit D+to alternator Nm5 -
BA15.40-P-1003- Bolt for alternator Nm- -

Microsoft
ALTERNATOR
ALTERNATOR
01A
BA15.40-P-1004-
01A
Collar nut on poly-V-pulley Nm80 80
BA15.40-P-1005-
01A
Self-grooving
screw, alternator
to timing case
Thread not pre-
tapped
Nm57 57
Thread pre-
tapped
Nm45 45
BA15.40-P-1006-
01A
Bolt, alternator to cooling housing Nm- -
BA15.40-P-1007-
01A
Bolt, cooler
housing of
alternator to
crankcase
M7 Nm- -
M8 Nm- -
113.991 in
models 215,
220
Engine
113.992/995
in model 230
Engine
113.993
AMG in
model 463
Engine 119
BA15.40-P-
1001-01A
Nut, circuit B+to
alternator
Nm14 18 18 15
BA15.40-P-
1002-01A
Nut, circuit D+to
alternator
Nm- - - 4
BA15.40-P-
1003-01A
Bolt for alternator Nm- 42 42 42
BA15.40-P-
1004-01A
Collar nut to poly-V-pulley Nm80 - - 80
BA15.40-P-
1005-01A
Self-
grooving
screw,
alternator to
timing case
Thread not
pretapped
Nm57 57 57 -
Thread pre-
tapped
Nm45 45 45 -
BA15.40-P-
1006-01A
Bolt, alternator on cooling
housing
Nm- - - -
BA15.40-P-
1007-01A
Bolt, cooler
housing of
alternator to
crankcase
M7 Nm- - - -
M8 Nm- - - -
Number Designation Engine 120 Engine 137 Engine 155
BA15.40-P-
1001-01A
Nut, circuit B+to alternator Nm15 15 15
BA15.40-P- Nut, circuit D+to alternator Nm4 - -

Microsoft
1002-01A
BA15.40-P-
1003-01A
Bolt for alternator Nm42 - 30
BA15.40-P-
1004-01A
Collar nut on poly-V-pulley Nm80 80 -
BA15.40-P-
1005-01A
Self-grooving
screw,
alternator to
timing case
Thread not
pre-tapped
Nm- - -
Thread pre-
tapped
Nm- - -
BA15.40-P-
1006-01A
Bolt, alternator to cooling
housing
Nm- 8 -
BA15.40-P-
1007-01A
Bolt, cooler
housing of
alternator to
crankcase
M7 Nm- 14 -
M8 Nm- 20 -

Microsoft

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Electrical System PDF

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1998-2004 ENGINE

Electrical System - Engine - 170 Chassis

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