Mercedes S-Class W221 Workshop Manual 2007-2013
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sanderMercedes S-Class W221 Workshop Manual 2007-2013
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sanderGENERAL INFORMATION
Emission Control Abbreviations
"A"
A/C
Air Conditioning
A/C-ISUS
A/C Idle Speed-Up Solenoid
AAI
Air Assist Injector
ACL
Air Cleaner (Thermostatic Air Cleaner)
ACL-AD
ACL Air Diverter
ACL-BMS
ACL Bimetallic Sensor
ACL-CKV
ACL Check Valve
ACL-DV
ACL Delay Valve
ACL-PVS
ACL Ported Vacuum Switch
ACL-RDV
ACL Reverse Delay Valve
ACL-RDVS
ACL Reverse Delay Valve (Single)
ACL-TCV
ACL Thermal Control Valve
ACL-TS
ACL Temperature Sensor
ACL-TSOV
ACL Temperature Sensor Override Valve
ACL-TVS
ACL Thermal Vacuum Switch
ACL-TVV
ACL Thermal Vacuum Valve
ACL-VCDV
ACL Vacuum Control Delay Valve
ACL-VCV
ACL Vacuum Control Valve
ACL-VM
ACL Vacuum Motor
ACL-WP
ACL Wax Pellet Type Motor
ADS
Anti-Dieseling Solenoid
AFS
Air/Fuel Ratio Sensor
AIH
Air Intake Heaters
AIH-TS
AIH Temperature Sensor
AIS
Air Injection System
AIS-ACV
AIS Air Control Valve
AIS-AMV
AIS Air Management Valve
AIS-ASS
AIS Air Switching Solenoid
AIS-ASV
AIS Air Switching Valve
AIS-BPV
AIS By-Pass Valve
AIS-CKV
AIS Check Valve
AIS-CV
AIS Combination Valve
AIS-DV
AIS Diverter Valve
AIS-PAF
AIS Pulse Air Feeder
AIS-PM
AIS Pump Motor
AIS-PV
AIS Pneumatic Valve
AIS-RV
AIS Relief Valve
AIS-SOL
AIS Solenoid
AIS-SV
AIS Solenoid Valve
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AIS-VT
AIS Vacuum Tank
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
ALVW
Adjusted Loaded Vehicle Weight
AP
Air Pump Injection System
AP-ACV
AP Air Control Valve
AP-AMV
AP Air Management Valve
AP-ASRV
AP Air Switching Relief Valve
AP-ASS
AP Air Switching Solenoid
AP-ASV
AP Air Switching Valve
AP-BPV
AP By-Pass Valve
AP-CKV
AP Check Valve
AP-CS
AP Control Solenoid
AP-DCTO
AP Dual Coolant Temperature Override
AP-DLY
AP Delay Valve
AP-DV
AP Diverter Valve
AP-EADV
AP Electric Air Control Diverter Valve
AP-EAMR
AP Electric Air Management Relay
AP-EAMS
AP Electric Air Management Solenoid
AP-EAP
AP Electric Air Pump
AP-EC
AP Electromagnetic Clutch
AP-ERLY
AP Electric Air Pump Relay
AP-RDV
AP Reed Valve
AP-RV
AP Relief Valve
AP-SOV
AP Shut-Off Valve
AP-SV
AP Solenoid Valve
AP-SWV
AP Switchover Valve
AP-TV
AP Transmitting Valve
AP-VCS
AP Vacuum Control Solenoid
AP-VCV
AP Vacuum Control Valve
AP-VSV
AP Vacuum Switching Valve
A/T
Automatic Transmission
ATCV
Air Temperature Control Valve
"B"
BP/EGR
Backpressure EGR System
BP/EGR-BPS
BP/EGR Backpressure Sensor
BP/EGR-BPT
BP/EGR Backpressure Transducer
BP/EGR-BPV
BP/EGR Backpressure Valve
BP/EGR-BS
BP/EGR Bleed Solenoid
BP/EGR-BVSV
BP/EGR Bimetallic Vacuum Switching Valve
BP/EGR-C
BP/EGR Controller
BP/EGR-CLR
BP/EGR Cooler
BP/EGR-CS
BP/EGR Control Solenoid
BP/EGR-CTO
BP/EGR Coolant Temperature Override
BP/EGR-CV
BP/EGR Control Valve
BP/EGR-DCTO
BP/EGR Dual Coolant Temperature Override
BP/EGR-DS
BP/EGR Diagnostic Solenoid
BP/EGR-DSOL
BP/EGR Duty Solenoid
BP/EGR-DTVSW
BP/EGR Distributor Thermal Vacuum Switch
BP/EGR-DV
BP/EGR Delay Valve
BP/EGR-EET
BP/EGR Electric Transducer
BP/EGR-EPV
BP/EGR External Pressure Valve
BP/EGR-FDV
BP/EGR Forward Delay Valve
BP/EGR-LC
BP/EGR Load Control Valve
BP/EGR-PS
BP/EGR Position Sensor
BP/EGR-PVS
BP/EGR Ported Vacuum Switch
BP/EGR-RES
BP/EGR Reservoir
BP/EGR-RST
BP/EGR Restrictor
BP/EGR-SOL
BP/EGR Solenoid
BP/EGR-TCTVS
BP/EGR Torque Converter Thermal Vacuum Switch
BP/EGR-TCV
BP/EGR Thermal Control Valve
BP/EGR-TCVLV
BP/EGR Temperature Control Valve
BP/EGR-TS
BP/EGR Temperature Sensor
BP/EGR-TVS
BP/EGR Thermal Vacuum Switch
BP/EGR-TVV
BP/EGR Thermal Vacuum Valve
BP/EGR-VCV
BP/EGR Vacuum Control Valve
BP/EGR-VM
BP/EGR Vacuum Modulator
BP/EGR-VRV
BP/EGR Vacuum Regulator Valve
BP/EGR-VS
BP/EGR Vacuum Switch
BP/EGR-VSOL
BP/EGR Vent Solenoid
BP/EGR-VSV
BP/EGR Vacuum Switching Valve
"C"
C-4
Computer Controlled Catalytic Converter
CAC
Charge Air Cooler
CAS
Clean Air System
CB
Crankcase Breather
CBPS
Coasting By-Pass System
CBVC
Crankcase Breather Vapor Canister
CCIEV
Coolant Controlled Idle Enrichment Valve
CCS
Controlled Combustion System
CCV
Closed Crankcase Ventilation
CD-REGVLV
Crankcase Depression Regulator Valve
CDRV
Crankcase Depression Relief Valve
CEAB
Cold Engine Air Bleed
CEAB-TVS
CEAB Thermal Vacuum Switch
CEAB-TVV
CEAB Thermal Vacuum Valve
CEC
Computerized Engine Controls
CESS
Cold Engine Sensor Switch
CETS
Cold Engine Temperature Switch
CFI
Continuous Fuel Injection
CMH
Cold Mixture Heater
CNG
Compressed Natural Gas
CO
Carbon Monoxide
CO2
Carbon Dioxide
CPI
Central Port Injection
CRV
Coasting Richer Valve
CSI
Central Sequential Injection
CTAVS
Cold Temperature Activated Vacuum System
CTOX
Continous Trap Oxidizer
"D"
DCLV
Deceleration Valve
DCS
Deceleration Control System
DDI
Direct Diesel Injection
DFI
Direct Diesel Injection
DI
Direct Injection
DKV
Deceleration Kick Valve
DMCV
Deceleration Mixture Control Valve
DMS
Dual Manifold System
DOHC
Dual Overhead Cam
DPF
Diesel Particulate Filter
DPFE
Differential Pressure Feedback EGR Valve
DPFEGR
Differential Pressure Feedback EGR Valve
DTM
Deceleration Throttle Modulator
"E"
EAIR
Electric Air Injection System
EAIR-DV
EAIR Diverter Valve
ECM
Electronic Control Module
ECU
Electronic Control Unit
EDC
Electronic Diesel Control
EDS
Electronic Diesel System
EEC
Electronic Engine Control
EFE
Early Fuel Evaporation
EFE-CKV
EFE Check Valve
EFE-CV
EFE Control Valve
EFE-DTVS
EFE Delay Thermal Vacuum Switch
EFE-HTR
EFE Heater
EFE-HCV
EFE Heat Control Valve
EFE-OTS
EFE Oil Temperature Switch
EFE-PTC
EFE Positive Temperature Coefficient (Intake Heater Grid)
EFE-PVS
EFE Ported Vacuum Switch
EFE-SOL
EFE Solenoid
EFE-TVS
EFE Thermal Vacuum Switch
EFE-TVV
EFE Thermal Vacuum Valve
EFE-VSV
EFE Vacuum Switching Valve
EFI
Electronic Fuel Injection
EFI-MA
EFI Mass Airflow Sensor
EFI-MAF
EFI Mass Airflow Sensor
EGR
Exhaust Gas Recirculation System
EGR-BCS
EGR Boost Check Solenoid
EGR-BPBV
EGR By-Pass Backpressure Valve
EGR-BPT
EGR Backpressure Transducer
EGR-BPV
EGR By-Pass Valve
EGR-BS
EGR Bleed Solenoid
EGR-BSSV
EGR Boost Sensor Solenoid Valve
EGR-BVSV
EGR Bimetallic Vacuum Switching Valve
EGR-C
EGR Controller
EGR-CC
EGR Coolant Controlled
EGR-CLR
EGR Cooler
EGR-VSOL
EGR Vacuum Solenoid
EGR-CKV
EGR Check Valve
EGR-CS
EGR Control Solenoid
EGR-CSOL
EGR Cut-Off Solenoid
EGR-CSV
EGR Control Solenoid
EGR-CTO
EGR Coolant Temperature Override
EGR-CTS
EGR Charge Temperature Sensor
EGR-CTSW
EGR Charge Temperature Switch
EGR-CTTS
EGR Coolant Temperature Thermoswitch
EGR-CV
EGR Control Valve
EGR-CVCV
EGR Constant Vacuum Control Valve
EGR-CVS
EGR Control Vent Solenoid
EGR-DC
EGR Digital Control
EGR-DCTO
EGR Dual Coolant Temperature Override
EGR-DPFE
Differential Pressure Feedback EGR Sensor
EGR-DPFS
EGR Differential Pressure Feedback Sensor
EGR-DS
EGR Diagnostic Solenoid
EGR-DSOL
EGR Duty Solenoid
EGR-DTVS
EGR Delay Thermal Vacuum Switch
EGR-DTVSW
EGR Distributor Thermal Vacuum Switch
EGR-DV
EGR Delay Valve
EGR-EPRS
EGR Exhaust Pressure Regulator Solenoid
EGR-EPRV
EGR Exhaust Pressure Regulator Valve
EGR-EPV
EGR External Pressure Valve
EGR/EVAP-CSV
EGR/EVAP Control Solenoid Valve
EGR-EVR
EGR Vacuum Regulator
EGR-EVRV
EGR Electronic Vacuum Regulator Valve
EGR-FDV
EGR Forward Delay Valve
EGR-FJS
EGR Floor Jet System
EGR-FPS
EGR Feedback Pressure Sensor
EGR-LCV
EGR Load Control Valve
EGR-MAP
EGR Manifold Absolute Pressure Sensor
EGR-PFE
EGR-PFE Sensor
EGR-PS
EGR Position Sensor
EGR-PSW
EGR Pulse Switch
EGR-PVS
EGR Ported Vacuum Switch
EGR-REG
EGR Regulator
EGR-RES
EGR Reservoir
EGR-RST
EGR Restrictor
EGR-SC
EGR Signal Converter
EGR-SEC
EGR, Secondary
EGR-SEN
EGR Sensor
EGR-SOL
EGR Solenoid
EGR-SU
EGR Switchover Valve
EGR-SUB
Sub-EGR Valve
EGR-T
EGR Temperature Sensor
EGR-TC
EGR Transmission Controlled
EGR-TCTVS
EGR Torque Converter Thermal Vacuum Switch
EGR-TCV
EGR Thermal Control Valve
EGR-TCVLV
EGR Temperature Control Valve
EGR-TRANS
EGR Transducer
EGR-TS
EGR Temperature Sensor
EGR-TSW
EGR Temperature Switch
EGR-TVD
EGR Throttle Valve Diaphragm
EGR-TVS
EGR Thermal Vacuum Switch
EGR-TVSOL
EGR Throttle Valve Solenoid
EGR-TVV
EGR Thermal Vacuum Valve
EGR-VA
EGR Vacuum Amplifier
EGR-VCV
EGR Vacuum Control Valve
EGR-VM
EGR Vacuum Modulator
EGR-VR
EGR Vacuum Regulator
EGR-VRS
EGR Vacuum Regulator Solenoid
EGR-VRSV
EGR Vacuum Regulator Solenoid Valve
EGR-VRV
EGR Vacuum Regulator Valve
EGR-VS
EGR Vacuum Switch
EGR-VSDV
EGR Vacuum Switch Dump Valve
EGR-VSEN
EGR Vacuum Sensor
EGR-VSOL
EGR Vent Solenoid
EGR-VSS
EGR Vacuum Switching Solenoid
EGR-VSV
EGR Vacuum Switching Valve
EGR-VVCS
EGR Venturi Vacuum Control System
EGRC
EGR Control Solenoid
EGRC-BPT
EGR Control Backpressure Transducer
EGRC-SV
EGR Control Solenoid Valve
EHOC
Electronically Heated Oxidation Catalyst
EHTWC
Electronically Heated Three-Way Catalyst
EI
Electronic Ignition System
EIS
Electronic Ignition System
ELB
Electronic Lean Burn
EPR
Exhaust Pressure Regulator
EPR-SOL
EPR Solenoid
ESA
Electronic Spark Advance
EVAP
Fuel Evaporative System
EVAP-AAC
EVAP Auxiliary Air Control
EVAP-BPSV
EVAP By-Pass Solenoid Valve
EVAP-BVSV
EVAP Bimetallic Vacuum Switching Valve
EVAP-CAV
EVAP Canister Air Valve
EVAP-CCV
EVAP Control Canister Close Valve
EVAP-CCVSV
EVAP Control Canister Vent Shut Valve
EVAP-CCVVSV
EVAP Closed Canister Valve Vacuum Switching Valve
EVAP-CDCV
EVAP Canister Drain Cut Valve
EVAP-CKV
EVAP Check Valve
EVAP-CPCS
EVAP Canister Purge Control Solenoid
EVAP-CPCV
EVAP Canister Purge Control Valve
EVAP-CPRV
EVAP Canister Purge Regulator Valve
EVAP-CPSV
EVAP Canister Vent Shut Valve
EVAP-CPT
EVAP Canister Purge Timer
EVAP-CPTVS
EVAP Canister Purge Thermal Vacuum Switch
EVAP-CPV
EVAP Canister Vent Valve
EVAP-CPVCSV
EVAP Canister Purge Volume Control
EVAP-CPVDV
EVAP Canister Purge Vacuum Delay Valve
EVAP-CS
EVAP Control Solenoid
EVAP-CSPS
EVAP Control System Pressure Sensor
EVAP-CST
EVAP Canister Surge Tank
EVAP-CVCS
EVAP Canister Vent Control Solenoid
EVAP-CVCV
EVAP Canister Vent Control Valve
EVAP-CVS
EVAP Canister Vent Solenoid
EVAP-CVSV
EVAP Carburetor Vent Switching Valve
EVAP-CVV
EVAP Canister Vent Valve
EVAP-DCTO
EVAP Dual Coolant Temperature Override
EVAP-DPS
EVAP Differential Pressure Sensor
EVAP-EV
EVAP Emission Valve
EVAP-FBVV
EVAP Fuel Bowl Vent Valve
EVAP-FBVS
EVAP Fuel Bowl Vent Solenoid
EVAP-FLS
EVAP Fuel Level Sensor
EVAP-FOLV
EVAP Fuel Overflow Limiter Valve
EVAP-FS
EVAP Flow Switch
EVAP-FSV
EVAP Flow Switchover Valve<
EVAP-FTPCSV
EVAP Fuel Tank Pressure Control Solenoid Valve
EVAP-FTPS
EVAP Fuel Tank Pressure Sensor
EVAP-FTS
EVAP Fuel Temperature Sensor
EVAP-FVCV
EVAP Fuel Vapor Control Valve
EVAP-FVS
EVAP Fuel Vapor Separator
EVAP-FVV
EVAP Fuel Vent Valve
EVAP-IVS
EVAP Inner Vent Solenoid
EVAP-LDP
EVAP Leak Detection Pump
EVAP-LDPAF
EVAP Leak Detection Pump Air Filter
EVAP-LDPF
EVAP Leak Detection Pump Filter
EVAP-LDPVV
EVAP Leak Detection Pump Vent Valve
EVAP-LSEP
EVAP Liquid Separator
EVAP-NVLD
EVAP Natural Vacuum Leak Detection
EVAP-ORVR
Evaporative On-Board Refueling Vapor Recovery System
EVAP-ORVRFTVRV
EVAP-ORVR Fuel Tank Vapor Recirculation
EVAP-OVCV
EVAP Outer Vent Control Valve
EVAP-OWV
EVAP One-Way Valve
EVAP-PCSV
EVAP Purge Cut-Off Solenoid Valve
EVAP-PFS
EVAP Purge Flow Sensor
EVAP-PFSVVSV
EVAP Purge Flow Switching Valve Vacuum Switching Valve
EVAP-PRRV
EVAP Pressure Relief Rollover Valve
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PSOL
EVAP Purge Solenoid
EVAP-PSSV
EVAP Pressure Switching Solenoid
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PV
EVAP Purge (Frequency) Valve
EVAP-PVS
EVAP Ported Vacuum Switch
EVAP-RV
EVAP Rollover Valve
EVAP-RV/FTPS
EVAP Rollover Valve/Fuel Tank
EVAP-RVSV
EVAP Rollover Vapor Separator Valve
EVAP-SNR
EVAP Canister Sensor
EVAP-SOV
EVAP Shutoff Valve
EVAP-SSV
EVAP Shut-Off Solenoid Valve
EVAP-SV
EVAP Solenoid Valve
EVAP-TS
EVAP Temperature Switch
EVAP-TPBPV
EVAP Tank Pressure By-Pass Valve
EVAP-TPCS
EVAP Tank Pressure Control Solenoid
EVAP-TPCV
EVAP Tank Pressure Control Valve
EVAP-TRWV
EVAP Tree-Way Valve
EVAP-TV
EVAP Thermal Valve
EVAP-TVS
EVAP Thermal Vacuum Switch
EVAP-TWV
EVAP Two-Way Valve
EVAP-VC
EVAP Vapor Canister
EVAP-VCAT
EVAP Vapor Canister Air Tank
EVAP-VCF
EVAP Vapor Canister Filter
EVAP-VCTV
EVAP Vacuum Control Valve
EVAP-VCV
EVAP Vacuum Canister Valve
EVAP-VCVS
EVAP Vapor Canister Vent Solenoid
EVAP-VM
EVAP Vacuum Motor
EVAP-VPS
EVAP Vapor Pressure Sensor
EVAP-VPSVSV
EVAP Vapor Pressure Sensor Vacuum Switching Valve
EVAP-VS
EVAP Vacuum Sensor
EVAP-VSOL
EVAP Ventilation Solenoid
EVAP-VSOL/LDP
EVAP Ventilation Solenoid/Leak Detection Pump
EVAP-VST
EVAP Vacuum Surge Tank
EVAP-VSV
EVAP Vacuum Switching Valve
EVAP-VV
EVAP Ventilation Valve
EVRS
EGR Vacuum Regulator Solenoid
"F"
FBC
Feedback Carburetor
FCOV
Fuel Change Over Valve
FF
Flex Fuel
FF-CKV
Fuel Fill Check Valve
FF-FCV
Fuel Tank Fuel Cut-Off Valve
FF-FLVV
Fuel Tank Fill Limit Vent Valve
FGOV
Fuel Gravity/Overflow Valve
FGVV
Fuel Gravity Vent Valve
FI
Fuel Injected
FICD
Fast Idle Control Device
FISR
Fast Idle Solenoid Relay
FLV
Fill Limit Valve
FLVV
Fill Limiting Vent Valve
FP-CKV
Fill Pipe Check Valve
FP-RV
Fill Pipe Rollover Valve
FR
Fill Pipe Restrictor
FT-FLVV
Fuel Tank Fill Limit Vent Valve
FT-GVV
Fuel Tank Grade Vent Valve
FT-OPRV
Fuel Tank Over Pressure Vent Valve
FT-PCV
Fuel Tank Pressure Control Valve
FT-VCV
Fuel Tank Vapor Control Valve
FT-VRV
Fuel Tank Vapor Recirculation Valve
FTCV
Fuel Tank Check Valve
FTDPS
Fuel Tank Differential Pressure Sensor
FTEV
Fuel Tank EVAP Valve
FTPS
Fuel Tank Pressure Sensor
FTT
Fuel Tank Temperature Sensor
FTTS
Fuel Tank Temperature Sensor
FTVPRV
Fuel Tank Ventilation Pressure Retention Valve
FTVV
Fuel Tank Vent Valve
FVV
Fuel Vapor Valve
"G"
GVWR
Gross Vehicle Weight Rating
"H"
HAC
High Altitude Compensator
HAFS
Heated Air Fuel Ratio Sensor
HAI
Hot Air Intake
HAS
High Altitude System
HC
Hydrocarbons
HCAC-VSV
Hydrocarbon Absorber Catalyst Vacuum Switching Valve
HDC
Heavy Duty Cooling
HDC-CTO
HDC Coolant Temperature Override
HFM-SFI
Hot Film Engine Management SFI
HIC
Hot Idle Compensator
HIM
Heated Intake Manifold
HO
High Output
HO2S
Heated Oxygen Sensor
HP
High Performance
HP
Horsepower
HPCA
Housing Pressure Cold Advance
HSC
High Swirl Combustion
"I"
IAC
Idle Air Control Valve
IACV-SW
IACV Switch
ICOM
Idle Compensator
IDI
Indirect Diesel Injection
IES
Idle Enrichment System
IMCO
Improved Combustion System
"K"
KS
Knock Sensor
"L"
LH-SFI
Hot Wire Sequential Multiport Fuel Injection
LVFD
Liquid/Vapor Fuel Discriminator
LVW
Loaded Vehicle Weight
"M"
MD-TICS
Timing & Injection rate Control System
ME-SFI
Motor Electronics Sequential Fuel Injection
MFI
Multiport Fuel Injection
MFI-MAF
MFI Mass Airflow Sensor
MFLS
Main Fuel Level Sensor
MI
Mechanical Fuel Injection
MIL
Malfunction Indicator Light
M/T
Manual Transmission
"N"
NAC
Nitrogen Oxides (NOx) Adsorbing Catalyst
NLV
Non-Linear Valve
NOS
NOx Sensor
NOx
NOx Emission Control
NOxC
Nitrogen Oxide Catalyst
NOxS
Nitrogen Oxide Sensor
NSC
Nitrogen Oxides (NOx) Storage Catalyst
"O"
OBD
On-Board Diagnostic System
PBD (F)/(P)
Full/Partial On-Board Diagnostic
OC
Oxidation Catalytic Converter
OHC
Overhead Cam
ORVR
On-Board Refueling Vapor Recovery
ORVR-COV
ORVR Cut-Off Valve
ORVR-CV
ORVR Control Valve
ORVR-FMV
ORVR Flow Management Valve
ORVR-FTVCV
ORVR Fuel Tank Vapor Control Valve
ORVR-FTVRV
ORVR Fuel Tank Vapor Recirculation Valve
ORVR-LV
ORVR Leveling Valve
ORVR-OCKV
ORVR Overfill Check Valve
ORVR-RCV
ORVR Refueling Control Valve
ORVR-VCV
ORVR Vapor Cut Valve
ORVR-VRV
ORVR Vapor Recirculating Valve
ORVR-VSV
ORVR Vent Shut Valve
ORVR-VV
ORVR Vent Valve
OVCV
Outer Vent Control Valve
O2S
Oxygen Sensor
"P"
PAIR
Pulsed Secondary Air Injection
PAIR-ABV
PAIR Anti-Backfire Valve
PAIR-ACOV
PAIR Air Cut-Off Valve
PAIR-ACS
PAIR Air Control Solenoid
PAIR-ACV
PAIR Air Control Valve
PAIR-AIV
PAIR Air Injection Valve
PAIR-ASCS
PAIR Air Suction Control Solenoid
PAIR-ASOV
PAIR Air Shutoff Valve
PAIR-ASS
PAIR Air Switching Solenoid
PAIR-ASV
PAIR Air Switching Valve
PAIR-ASVL
PAIR Air Suction Valve
PAIR-AVCS
PAIR Air Valve Control Solenoid
PAIR-CSV
PAIR Control Solenoid Valve
PAIR-CKV
PAIR Check Valve
PAIR-DV
PAIR Diverter Valve
PAIR-PAF
PAIR Pulse Air Feeder
PAIR-PAV
PAIR Pulse Air Valve
PAIR-RES
PAIR Resonator
PAIR-RV
PAIR Reed Valve
PAIR-SCSV
PAIR Swirl Control Solenoid Valve
PAIR-SCV
PAIR Swirl Control Valve
PAIR-SOL
PAIR Solenoid
PAIR-VSV
PAIR Vacuum Switching Valve
PCM
Powertrain Control Module
PCV
Positive Crankcase Ventilation
PCV-DOV
PCV Dual Orifice Valve
PCV-HCB
PCV Heated Crankcase Breather
PCV-HE
PCV Heating Element
PCV-PRV
PCV Pressure Regulator Valve
PCV-SOL
PCV Solenoid
PEVR
Power Enrichment Vacuum Regulator
PPM
Parts Per Million
PTOX
Periodic Trap Oxidizer
PURCV
Purge Crankcase Ventilation
PVCS
Ported Valve Control System
PVCS-A
PVCS Actuator
PVCS-CS
PVCS Control Solenoid
PVLCS
Power Valve Control System
"R"
ROV
Rollover Valve
"S"
SAI-SV
Secondary Air Injection Shutoff Valve
SC
Supercharged or Super Charger
SC MFI
Supercharged Multiport Fuel Injection
SCR
Selective Catalytic Reduction
SCSV
Swirl Control Solenoid Valve
SCV
Swirl Control Valve
SCV-A
SCV Actuator
SFI
Sequential Multiport Fuel Injection
SFI-MAF
SFI Mass Airflow Sensor
SFLS
Sub-Fuel Level Sensor
SOHC
Single Overhead Cam
SPK
Spark Controls
SPK-AVM
SPK Advance Vacuum Modulator
SPK-BVSV
SPK Bimetal Vacuum Switching Valve
SPK-CC
SPK Computer Controlled
SPK-CKV
SPK Check Valve
SPK-CSSA
SPK Cold Start Spark Advance System
SPK-CSSH
SPK Cold Start Spark Hold System
SPK-CTO
SPK Coolant Temperature Override
SPK-DAVS
SPK Distributor Vacuum Advance Solenoid
SPK-DCKV
SPK Distributor Check Valve
SPK-DCTO
SPK Dual Coolant Temperature Override
SPK-DDD
SPK Dual Diaphragm Distributor
SPK-DMV
SPK Distributor Modulator Valve
SPK-DPD
SPK Dual Point Distributor
SPK-DPVS
SPK Distributor Ported Vacuum Switch
SPK-DRCV
SPK Distributor Retard Control Valve
SPK-DRS
SPK Distributor Retard Solenoid
SPK-DSVMV
SPK Distributor Spark Vacuum Modulator Valve
SPK-DTVS
SPK Distributor Thermal Vacuum Switch
SPK-DTVV
SPK Distributor Thermal Vacuum Valve
SPK-DV
SPK Delay Valve
SPK-DVA
SPK Distributor Vacuum Advance
SPK-DVAS
SPK Distributor Vacuum Advance Solenoid
SPK-DVCS
SPK Distributor Vacuum Control Solenoid
SPK-DVCSW
SPK Distributor Vacuum Controlled Switch
SPK-DVCV
SPK Distributor Vacuum Control Valve
SPK-DVDV
SPK Distributor Vacuum Delay Valve
SPK-DVRS
SPK Distributor Vacuum Retard Switch
SPK-DVRV
SPK Distributor Vacuum Regulating Valve
SPK-DVVV
SPK Distributor Vacuum Vent Valve
SPK-EAVS
SPK Electronically Actuated Vacuum Switch
SPK-EDM
SPK Electronic Distributor Modulator
SPK-EI
SPK Electronic Ignition
SPK-ESA
SPK Electronic Spark Advance
SPK-ESC
SPK Electronic Spark Control (Retard)
SPK-ESS
SPK Electronic Spark Selection
SPK-EST
SPK Electronic Spark Timing
SPK-FDV
SPK Forward Delay Valve
SPK-HPCA
SPK Housing Pressure Cold Advance
SPK-ITCS
SPK Ignition Timing Control System
SPK-ITVS
SPK Ignition Timing Vacuum Switch
SPK-NLVR
SPK Non-Linear Vacuum Regulator
SPK-OSAC
SPK Orifice Spark Advance Control
SPK-PVA
SPK Ported Vacuum Advance
SPK-PVS
SPK Ported Vacuum Switch
SPK-RDO
SPK Retard Delay Orifice
SPK-RDV
SPK Reverse Delay Valve
SPK-RDVD
SPK Reverse Delay Valve (Dual)
SPK-RDVLV
SPK Retard Delay Valve
SPK-RDVS
SPK Reverse Delay Valve (Single)
SPK-RETS
SPK Retard Switch
SPK-SC
SPK Speed Controlled
SPK-SOL
SPK Solenoid
SPK-SRRV
SPK Spark Relay Regulator Valve
SPK-TAVIA
SPK Temperature Activated Vacuum Ignition Advance
SPK-TCS
SPK Transmission Controlled Spark
SPK-TCSYS
SPK Timing Control System
SPK-TIDC
SPK Thermostatic Ignition Distributor Control
SPK-TV
SPK Thermal Valve
SPK-TVS
SPK Thermal Vacuum Switch
SPK-VACTO
SPK Vacuum Advance Coolant Temperature Override
SPK-VAS
SPK Vacuum Advance Solenoid
SPK-VAV
SPK Vacuum Advance Valve
SPK-VR
SPK Vacuum Retard
SPK-VRSW
SPK Vacuum Retard Switch
SPK-VSV
SPK Vacuum Switching Valve
SPK-VTCS
SPK Vacuum Timing Control System
SPL
Smoke Puff Limiter
SRI
Service Reminder Indicator
SSCA
Stepped Speed Control Actuator
SSCS
Stepped Speed Control Solenoid
STS
Service Throttle Soon Light
STVS
Secondary Throttle Valve System
SUB-O2S
Sub-Oxygen Sensor
SUB-TWC
Sub Three-Way Catalytic Converter
"T"
TAA
Turbo Air-To-Air
TAA
Throttle Actuator Assembly
TAB
Thermactor Air By-Pass
TAD
Thermactor Air Diverter
TBI
Throttle Body Injection
TBPCS
Throttle By-Pass Control System
TC
Turbo Charger
TCC
Torque Converter Clutch
TCCL
Torque Converter Control
TCD
Throttle Closing Dashpot
TC-DV
TC Delay Valve
TC-TVC
TC Thermal Vacuum Switch
TC-VS
TC Vacuum Switch
TD
Thermactor Diverter
TFT
Tank Fuel Temperature Sensor
TICV
Thermal Ignition Control Valve
TIV
Thermal Idle Valve
TK
Throttle Kicker
TLUC
Transmission Lock-Up Converter
TLUC-TVS
TLUC Thermal Vacuum Switch
TLUC-VS
TLUC Vacuum Switch
TM
Throttle Modulator
TOS
Throttle Opener System
TP
Throttle Positioner
TPI
Tuned Port Fuel Injection
TPV
Throttle Poppet Valve
TR
Thermal Reactor
TRC
Throttle Return Control
TRCS
Throttle Return Control Solenoid
TRCTL
Throttle Return Control Throttle Lever Actuator
TRSCV
Throttle Return Solenoid Control Valve
TRTVV
Temperature Regulator Thermal Vacuum Valve
TRVV
Transmission Vacuum Valve
TSOL
Throttle Solenoid
TVISD
Throttle Vacuum Idle Speed Diaphragm
TVM
Transmission Vacuum Modulator
TWC
Three-Way Catalytic Converter
TWC+OC
Three-Way + Oxidation Catalytic Converter
"V"
VA
Vacuum Advance Unit
VAC-AMP
Vacuum Amplifier
VA-CTO
VA Coolant Temperature Override
VCV
Vacuum Cut Valve
VCV-BV
VCV By-Pass Valve
VLFR
Vent Line Flow Restrictor/Anti-Trickle Fill Valve
"W"
WU
Warm-Up Catalyst
WU-OC
Warm-Up Oxidation Converter
WU-TWC
Warm-Up Three-Way Catalytic Converter
HVAC
Air Compressor, Belt Drives - S-Class (221)
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES -
AR13.00-Z-9156AB
ENGINE 156
Remove/install belt drive AR13.20-P-
ENGINES 156 in MODEL 204, 212
components 0001CMG
Remove/install belt drive AR13.20-P-
ENGINE 156 in MODEL 230
components 0001RMG
AR13.22-P-
Remove/install poly V-belt ENGINE 156 in MODEL 164, 251
1202GZS
ENGINE 156.982 in MODELS 209.377 /477 ENGINE AR13.22-P-
Remove/install poly V-belt
156.983 in MODELS 211.077 /277, 219.377 1202TMG
AR13.22-P-
Remove/install poly-V belt ENGINE 156 in MODEL 216, 221
1202SMG
Remove/install poly-V belt AR13.25-P-
ENGINE 156 in MODEL 164, 251
tensioning device 3200GZS
Remove/install poly-V belt AR13.25-P-
ENGINE 156 in MODEL 216, 221
tensioning device 3200SMG
Remove/install poly-V belt ENGINE 156.982 in MODEL 209.377 /477 ENGINE AR13.25-P-
tensioning device 156.983 in MODEL 211.077 /277, 219.377 3200TMG
TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES -
AR13.00-Z-9273AB
ENGINE 273
AR13.22-P-
Remove, install poly V-belt ENGINE 272, 273 in MODEL 230
1202RX
Remove/install belt drive ENGINES 272 in MODEL 204 ENGINES 272, 273 AR13.20-P-
components in MODEL 207 0001CV
Remove/install belt drive AR13.20-P-
ENGINES 272, 273 in MODEL 212
components 0001EWS
Remove/install belt drive AR13.20-P-
ENGINES 272, 273 in MODEL 164, 251
components 0001GZA
Remove/install belt drive ENGINES 272, 273 (except 272.974) in MODEL AR13.20-P-
components 221 ENGINES 273 in MODEL 216 0001SX
ENGINES 272, 273 in MODEL 211, 219
components 0001TS
AR13.22-P-
Remove/install poly V-belt ENGINE 272, 273...
1202QB
Remove/install poly V-belt AR13.25-P-
ENGINE 272, 273 in MODEL 230
tensioning device 3200RX
Remove/install poly-V belt AR13.21-P-
ENGINE 272, 273...
guide pulley 3350QB
Remove/install poly-V belt AR13.21-P-
ENGINES 272, 273 in MODEL 230
guide pulley 3350RX
Remove/install poly-V-belt AR13.25-P-
ENGINE 272, 273...
tensioning device 3200QB
TESTING AND REPAIR WORK: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES -
AR13.00-Z-9275AB
ENGINE 275
Remove/install components for AR13.20-P-
ENGINE 275 in MODEL 216, 221
belt drive 0001SZ
Remove/install poly V-belt AR13.25-P-
ENGINE 137, 275...
tensioning device 3200L
ENGINE 137 in MODEL 215, 220 ENGINE 275 in AR13.22-P-
Remove/install poly-V belt
MODEL 215, 220, 230 1202L
Remove/install poly-V belt AR13.25-P-
ENGINE 275 in MODEL 230
tensioning device 3200RR
REMOVE/INSTALL BELT DRIVE COMPONENTS - AR13.20-P-0001SX
ENGINES 272, 273 (except 272.974) in MODEL 221
ENGINES 273 in MODEL 216
Fig. 1: Identifying Belt Drive Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 2: Identifying Belt Drive Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury caused by moving No parts of the body or limbs should be
AS00.00-Z-
parts that can pinch, crush or, in within the operating range of the mechanism
0009-01A
when moving components.
extremities
Pull out front engine cover (1) from
1
mounts
Detach pressure line (6) from Vehicles with Active Body Control (Code
2
bracket (7) 487) only.
To do this swivel clamping device (3) on
3 Loosen poly-V belt (2) and remove hexagon (4) counterclockwise (arrow),
remove poly-V-belt (2) and slacken clamping
device (3).
Checking
Inspect belt pulley sections,
Check for damage, wear and dirt; replace if
4 tensioning device (3) and guide
necessary.
pulleys (5)
Check poly-V belt (2) and replace if
5
required
Check visible area of poly-V belt AP13.22-P-
for wear 1352SX
Remove/install clamping device Only perform steps 6 through 9 for
(3) remove/install of clamping device (3).
Swivel clamping device (3) at hexagon (4)
6 Lock tensioning device (3) in an anti-clockwise direction and lock in
place using drift (8).
Remove bolts (3b) and remove *BA13.25-P-
7
clamping device (3) 1001-01P
When replacing the clamping device (3)
Clamp tensioning device (3) in a vise,
swivel at hexagon (4) in an anti-clockwise
8 Slacken tensioning device (3) direction, pull out drift (8) and slacken
tensioning device (3).
Installation: The tensioning device (3) can
only be installed when locked.
9 Install in the reverse order
Only perform steps 10 through 12 for
Remove/install guide pulleys (5)
remove/install of guide pulleys (5).
10 Pry off covers (5b)
Remove bolts (5a) and remove *BA20.10-P-
11
guide pulleys (5) 1004-01U
12 Install in the reverse order
Install
To do this swivel clamping device (3) on
Fit on and tension (2) as per routing AR13.22-P-
13 hexagon (4) counterclockwise (arrow), fit on
diagram 3902-02SX
poly-V-belt (2) and slacken clamping device
Do not use wax or similar products, as this
may cause poly-V belt (2) to slip.
Install pressure line (6) to bracket Vehicles with Active Body Control (Code
14
(7) 487) only.
15 Install front engine cover (1)
BELT TENSIONING DEVICE
Engine Engine
Number Designation
272 273
BA13.25-P-1001- Bolt from poly-V belt tensioning device to timing case
Nm 35 35
01P cover
COOLANT PUMP, COOLANT THERMOSTAT
Engine Engine
Number Designation
272 273
Initial installation Nm 35 35
BA20.10-P-1004- Bolt, guide pulley between water pump
01U and belt tensioner Follow-up
Nm 25 25
operations
REMOVE/INSTALL BELT DRIVE COMPONENTS - AR13.20-P-0001MMB
ENGINES 157, 278 in MODEL 216, 221
Fig. 3: Identifying Belt Drive Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Remove/Install
Risk of injury caused by Keep body parts and limbs AS00.00-Z-0011-01A
fingers being pinched or well clear of moving parts.
crushed when removing,
installing or aligning hoods,
doors, trunk lids, liftgates ot
sliding roof.
1 Remove engine covers
2 Slacken poly-V belt and To do so, swivel clamping
remove device (1) at hexagon (4)
counterclockwise, remove
poly-V belt and detension
clamping device (1).
Installation: Do not use
wax or similar products,
as this may cause the
poly-V belt to slip.
Installation: Observe
routing plan for poly-V AR13.22-P-3902-
belt. 02MM
Checking
3 Inspect belt pulley sections, Check for damage, wear
tensioning device (1) and guide and dirt;
pulleys (3) replace if necessary.
4 Check poly-V belt Check for damage, wear AP13.22-P-1352SX
and dirt; replace if
necessary
Only perform steps 5 through 9 for
remove/install of clamping device (1)
5 Remove front section of lower AR61.20-P-1105SX
engine compartment paneling
6 Lock clamping device (1) Swivel clamping device
(1) at hexagon (4)
counterclockwise and lock
in place using drift (8).
7 Remove bolts on clamping *BA13.25-P-1001-01Y
device (1)
8 Remove clamping device (1)
downwards
9 Slacken clamping device (1) When replacing the
clamping device (1)
Clamp tensioning device
(1) in a vise, swivel at
hexagon (4) in an anti-
clockwise direction, pull
out drift (8) and slacken
tensioning device (1).
Installation: The
clamping device (1) can
be mounted in both a
locked and an unlocked
condition.
Only perform steps 10
through 12 for
removal/installation of guide
pulleys (3)
10 Remove left charge air ducts When removing guide AR09.41-P-
pulley (3) on the left 8620MMB
engine side
11 Remove bolts or guide pulleys *BA13.25-P-1002-
(3) 01Y
*BA13.25-P-1005-01Y
12 Remove guide pulleys (3)
Only carry out steps 13 and 14 for
removing/installing the upper guide pulley
13 Removing bolts for upper Vehicle with AIRmatic *BA13.25-P-1003-
guide pulley carrier 01Y
14 Remove upper guide pulley Vehicle with AIRmatic *BA13.25-P-1005-
and carrier from timing case 01Y
cover
15 Install in the reverse order
BELT TENSIONING DEVICE
Number Designation Engine 157 Engine 278
BA13.25-P- Bolt, poly-V belt tensioning Nm 20 20
1001-01Y device to timing case cover
BA13.25-P- Bolt, guide pulley to carrier Nm 70 70
1002-01Y
BA13.25-P- Bolt, guide pulley Nm 20 20
1003-01Y carrier/ABC pump to timing
case cover/coolant pump
BA13.25-P- Bolt, guide M8 Nm 35 35
1005-01Y pulley to
coolant
pump/oil
filter/ timing
case cover
M10 Nm 35 35
REMOVE/INSTALL COMPONENTS FOR BELT DRIVE - AR13.20-P-0001SZ
ENGINE 275 in MODEL 216, 221
Fig. 4: Identifying Belt Drive Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury caused by Keep all body parts and AS00.00-Z-0009-01A
moving parts that can limbs away from moving
pinch, crush or, in extreme mechanical components.
cases, even sever
extremities.
1 Remove fan shroud (1) Model 216, 221 except AR20.40-P-6800SZ
216.379, 221.179
Model 216.379, 221.179 AR20.40-P-6800SXM
2 Attach guard plate for
radiator / condenser
Radiator guard plate/ WF58.50-P-0110-01A
condenser
3 Loosen poly-V belt (2) and To do this turn hexagon
remove (3) of poly-V belt
tensioning device (8) in an
anti-clockwise direction
(arrow) until the tensioner
pulley (4) can be locked
with the drift (6)
Drift (6) with a
diameter of 5 mm.
Checking
4 Check profile of belt pulley
and poly-V belt tensioning
device (8) for damage and
soiling
5 Check poly-V belt (2) for
wear and damage and
replace if necessary
Check visible area of poly-V AP13.22-P-1352SZ
belt for wear
Remove/install poly-V belt Only perform steps 6
tensioning device (8) through 9 for
remove/install of poly-V
belt tensioning device (8).
6 Remove bolts (5) and poly- *BA13.25-P-1005-01D
V belt tensioning device (8)
Checking
7 Inspect tensioner pulley (4)
for damage and dirt; replace
if necessary
8 Unclamp poly-V belt When replacing poly-V
tensioning device (8) belt tensioning device (8)
Clamp poly-V belt
tensioning device (8) into
vise, swivel at hexagon (3)
in an anti-clockwise
direction (arrow), pull out
drift (6) and release
tension at poly-V belt
tensioning device (8).
The poly-V
belt tensioning device (8)
can only be installed when
locked.
9 Install in the reverse order
Install
10 Fit on and tension (2) as per To do this poly-V belt AR13.22-P-3902-02L
routing diagram tensioning device (8) at
hexagon (3)
counterclockwise (arrow),
fit on poly-V belt (2) and
slacken poly-V belt
tensioning device (8).
Do not use wax or
similar products, as this
may cause poly-V belt (2)
to slip.
11 Remove guard plate for
radiator/condenser
12 Install fan shroud (1) Model 216, 221 except AR20.40-P-6800SZ
216.379, 221.179
Model 216.379, 221.179 AR20.40-P-6800SXM
Risk of accident caused by Secure vehicle to prevent AS00.00-Z-0005-01A
vehicle starting off by itself it from moving by itself.
when engine is running. Wear closed and snug-
Risk of injury caused by fitting work clothes.
contusions and burns during Do not touch hot or
starting procedure or when rotating parts.
working near the engine as it
is running
13 Perform engine test run and
check for correct seating of
poly-V belt (2)
BELT TENSIONING DEVICE
Number Designation Engine 275
BA13.25-P-1005-01D Bolt, belt tensioner to timing case cover M7x25 Nm 14
REMOVE/INSTALL POLY-V BELT - AR13.22-P-1202SMG
ENGINE 156 in MODEL 216, 221
Symbolic representation
Fig. 5: Identifying Poly-V Belt Remove/Install Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value modified: Guide pulley on coolant pump housing (between power *BA13.25-P-
7.8.09
steering pump and guide pulley with grooved channel profile) 1003-01U
Removing
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or columns of vehicle lift
toppling off of the liftingand position four support
platform. plates at vehicle lift
support points specified
by vehicle manufacturer.
Risk of injury caused by Keep body parts and AS00.00-Z-0011-01A
fingers being pinched or limbs well clear of
crushed when removing, moving parts.
installing or aligning
hoods, doors, trunk lids,
tailgates or sliding roof.
1 Open engine hood
2 Remove left and right
intake air duct
3 Remove front engine Do not tilt front
cover engine cover, but lift
upwards vertically
otherwise the retaining
lugs can break off.
4 Raise vehicle with lifting AR00.60-P-1000SX
platform
5 Remove lower engine AR61.20-P-1105SX
compartment paneling
6 Loosen poly-V belt (1) The tensioner pulley
and remove (2) is more accessible
from below.
To do this, turn
hexagon (3) at tensioner
pulley (2) in an anti-
clockwise direction and
lock the tensioning pulley
(2) with a pin or drift (4)
(Ø 5 mm).
Checking
7 Inspect belt pulley Check for damage,
sections and tensioning wear and dirt; replace if
device necessary.
8 Check guide pulley Replace if necessary.
*BA13.25-P-1003-01U
*BA13.25-P-1004-01U
*BA13.25-P-1005-01U
9 Check poly-V belt (1)
Check poly-V belt (1) in AP13.22-P-1352SX
visible range for wear
Install
10 Install poly-V belt (1) and Do not use belt wax or
tighten it. any similar products.
Start in numerical
order of the relevant
running diagram at
tensioner pulley (2), refer
to: ?
Layout diagram of poly- AR13.22-P-3902-
V belt 02AMG
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes. Do
caused by contusions and not touch hot or rotating
burns during starting parts.
procedure or when
working near the engine
as it is running
11 Carry out engine test run
12 Close engine hood
BELT TENSIONING DEVICE
Engine 156,
Number Designation
159
BA13.25-P- Guide pulley on coolant pump housing (between power steering pump
Nm 30
1003-01U and guide pulley with grooved channel profile)
BA13.25-P- Guide pulley on coolant pump housing (between alternator and smooth
Nm 20
1004-01U guide pulley)
BA13.25-P- Guide pulley (between poly-V belt tensioning device and coolant
Nm 20
1005-01U pump)
ROUTING DIAGRAM OF POLY V-BELT - AR13.22-P-3902-02AMG
ENGINE 156
Fig. 6: Identifying Poly V-Belt Routing Diagram
Courtesy of MERCEDES-BENZ USA
ROUTING DIAGRAM OF POLY V-BELT - AR13.22-P-3902-02MM
ENGINE 157, 276, 278
Engine 276 in Model 212.095/195
Fig. 7: Identifying Poly V-belt Routing Diagram
Courtesy of MERCEDES-BENZ USA
Fig. 8: Identifying Poly V-belt Routing Diagram
Courtesy of MERCEDES-BENZ USA
Engine 276 with hydraulic power steering pump
Fig. 9: Identifying Poly V-belt Routing Diagram
Courtesy of MERCEDES-BENZ USA
Engine 157, 278 with Code 487 (Active Body Control (ABC))
Fig. 10: Identifying Poly V-belt Routing Diagram
Courtesy of MERCEDES-BENZ USA
Engine 157, 278 without Code 487 (Active Body Control (ABC))
Fig. 11: Identifying Poly V-belt Routing Diagram
Courtesy of MERCEDES-BENZ USA
ROUTING DIAGRAM OF POLY V-BELT - AR13.22-P-3902-02L
ENGINE 137, 275
1. Install poly-V-belt according to routing diagram.
Shown on engine 137.970
Fig. 12: Identifying Poly V-Belt Routing Diagram
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL POLY-V BELT TENSIONING DEVICE - AR13.25-P-3200SMG
ENGINE 156 in MODEL 216, 221
Fig. 13: Identifying Poly-V Belt Tensioning Device Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by Keep body parts and AS00.00-Z-0011-01A
fingers being pinched or limbs well clear of
crushed when removing, moving parts.
installing or aligning
hoods, doors, trunk lids,
tailgates or sliding roof.
1 Open engine hood and
raise to vertical position
2 Remove the left and right
intake air duct
3 Remove front engine Do not tilt front
cover engine cover, but lift
upwards vertically
otherwise the retaining
lugs can break off.
4 Partially remove poly-V Only remove poly-V AR13.22-P-1202SMG
belt (2) belt (2) from belt
pulley/guide pulleys until
tensioning device (3) is
accessible.
5 Rotate tensioning device Lock tensioning
at hexagon (3) in an anti- device using a pin or a 5
clockwise direction and mm Ø drift.
lock
6 Remove bolts (1) *BA13.25-P-1001-01U
7 Remove tensioning device Only model 221:
(3) Move clamping device
and take out upwards on
the right side (in direction
of travel).
8 Install in the reverse order
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
9 Carry out engine test run
BELT TENSIONING DEVICE
Number Designation Engine 156, 159
BA13.25-P-1001-01U Bolt, poly-V belt tensioning device to timing case cover M8 Nm 20
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES -
BE13.00-Z-9999AZ
MODEL all
Multi-belt drive ENGINE 111... BE13.21-P-1000-01A
Single-belt drive ENGINES 166.940 /960 /961 /990 /991 /995 BE13.22-P-1000-01G
Single-belt drive ENGINE 668.914 /940 /941 /942 BE13.22-P-1000-01H
Single-belt drive ENGINE 601, 602, 603... BE13.22-P-1000-01F
Single-belt drive ENGINE 104 BE13.22-P-1000-01D
Single-belt drive ENGINE 111.943 /944 /947 /973 /975 BE13.22-P-1000-01B
Single-belt drive ENGINE 103 BE13.22-P-1000-01C
Single-belt drive ENGINE 119, 120 BE13.22-P-1000-01E
Single-belt drive ENGINE 604, 605, 606, 611, 612, 613, 628, 629, 642, 651... BE13.22-P-1000-01A
MAINTENANCE
CHECK VISIBLE AREA OF POLY-V BELT FOR WEAR - AP13.22-P-1352SX
ENGINE 156, 157, 273, 278 in MODEL 216
ENGINE 156, 157, 272, 273, 276, 278 in MODEL 221
Fig. 14: Identifying Poly V Belt
Courtesy of MERCEDES-BENZ USA
Damage diagram
Fig. 15: Identifying Poly V Belt Damage Diagram
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or columns of vehicle lift
toppling off of the lifting and position four support
platform. plates at vehicle lift
support points specified
by vehicle manufacturer.
Checking
1 Check poly-V belt (1) at Replace poly-V belt
the visible points for wear (1) if worn: ?
and compare with damage Remove/install belt drive
patterns components:
Engine 272, 273 except AR13.20-P-0001SX
272.974,
Engine 276 AR13.20-P-0001MMA
Engines 157, 278 AR13.20-P-0001MMB
Remove/install poly V-
belt:
Engine 156 AR13.22-P-1202SMG
Engine 272.974 AR13.22-P-1202SXH
2 Raise vehicle with vehicle AR00.60-P-1000SX
lift
3 Remove bottom engine AR61.20-P-1105SX
compartment paneling Installation: Install
engine compartment
paneling only after
completing all
maintenance jobs.
Checking
4 Check poly-V belt (1) at Replace poly-V belt
the points which are (1) if worn: ?
visible when the vehicle is Remove/install belt drive
raised and compare with components:
damage patterns
Engine 272 except AR13.20-P-0001SX
272.974, except 273
Engine 276 AR13.20-P-0001MMA
Engines 157, 278 AR13.20-P-0001MMB
Remove/install poly V-
belt:
Engine 156 AR13.22-P-1202SMG
Engine 272.974 AR13.22-P-1202SXH
5 Install in the reverse order
CHECK POLY-V BELT IN VISIBLE RANGE FOR WEAR - AP13.22-P-1352SZ
ENGINE 275 in MODEL 216, 221
Fig. 16: Identifying Poly-V-Belt
Courtesy of MERCEDES-BENZ USA
Damage diagram
Fig. 17: Identifying Poly-V Belt Damage Pattern
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or columns of vehicle lift
toppling off of the lifting and position four support
platform. plates at vehicle lift
support points specified
by vehicle manufacturer.
Checking
1 Check poly-V-belt (1) for Replace the poly-V-
wear at visible points and belt (1) if worn: ?
compare with damage
profiles
Remove / install poly-V- AR13.20-P-0001SZ
belt.
2 Raise vehicle with lifting
platform
Lift/jack up vehicle AR00.60-P-1000SX
3 Remove bottom engine Install
compartment paneling engine compartment
paneling only after
completing all
maintenance jobs.
Detach/attach lower Vehicles without code AR61.20-P-1105SX
engine compartment (Z07) Top protection
paneling Vehicles with code (Z07) AR61.20-P-1105SXS
Top protection
Checking
4 Check poly-V-belt (1) for Replace the poly-V-
wear at points visible belt (1) if worn: ?
when vehicle is raised,
and compare with damage
profiles
Remove / install poly-V- AR13.20-P-0001SZ
belt.
5 Install in the reverse order
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES - BA13.00-Z-
9999AZ
MODEL all
Belt tensioning BA13.25-P-1000-
ENGINE 276
device 01X
Belt tensioning BA13.25-P-1000-
ENGINE 156, 159
device 01U
Belt tensioning BA13.25-P-1000-
ENGINE 119
device 01C
Belt tensioning BA13.25-P-1000-
ENGINE 112...
device 01M
Belt tensioning BA13.25-P-1000-
ENGINE 640
device 01R
Belt tensioning BA13.25-P-1000-
ENGINE 611, 612, 613, 646, 647, 648...
device 01G
Belt tensioning BA13.25-P-1000-
ENGINE 113, 137, 275, 285...
device 01D
Belt tensioning
ENGINE 271 BA13.25-P-1000-01I
device
Belt tensioning BA13.25-P-1000-
ENGINE 642 /
device 01T
Belt tensioning BA13.25-P-1000-
ENGINE 166.940 /960 /961 /990 /991 /995
device 01E
Belt tensioning BA13.25-P-1000-
ENGINE 668.914 /940 /941 /942
device 01F
Belt tensioning BA13.25-P-1000-
ENGINE 102, 103 /, 104 /, 111, 120
device 01B
Belt tensioning BA13.25-N-1000-
ENGINE 601.942 /943 /970, 602.980 /982 /983 /984 /985
device 01B
Belt tensioning BA13.25-P-1000-
ENGINE 155
device 01L
Belt tensioning BA13.25-P-1000-
ENGINE 157, 278
device 01Y
Belt tensioning BA13.25-P-1000-
ENGINE 628.960 /961 /962 /963, 629
device 01H
Belt tensioning BA13.25-P-1000-
ENGINE 651
device 01W
Belt tensioning BA13.25-P-1000-
ENGINE 266
device 01Q
Belt tensioning BA13.25-P-1000-
ENGINE 272, 273 /
device 01P
Belt tensioning ENGINE 601, 602 /, 603 /, 604, 605, 606 / (except, BA13.25-P-1000-
device 602.98 /98) 01A
BA13.21-P-1000-
Multi-belt drive ENGINE 111.943 /944 /947 /955 /958 /973 /975 /983, 155
01A
BA13.22-P-1000-
Single-belt drive ENGINE 112
01A
BELT TENSIONING DEVICE - BA13.25-P-1000-01D
Engine 113, 137, 275, 285
BELT TENSIONING DEVICE
Engine
Number Designation
113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/
Self- Thread
tapping not pre- Nm 35
BA13.25-
bolt, belt tapped
P-1001-
tensioner Thread
01D
to timing pre- Nm
case cover tapped
Bolt, guide
BA13.25-
pulley to
P-1002- M8x40 Nm 20
coolant
01D
pump
Shock
absorber,
belt
BA13.25-
tensioning
P-1003- Nm 25
device to
01D
belt
tensioning
device
absorber,
belt
BA13.25- tensioning
P-1004- device to Nm 35
01D coolant
pump
housing
Bolt, belt
BA13.25-
tensioner
P-1005- M7x25 Nm 35
to timing
01D
case cover
Self-
tapping Thread
bolt, not Nm -
BA13.25-
compressor pretapped
P-1006-
belt
01D
tensioner Thread
to timing pretapped Nm
case cover
Bracket for
BA13.25-
charge air
P-1007- Nm 7
cooler
01D
water pipes
Bolt, guide
pulley for
compressor
BA13.25-
and major
P-1008- M8x78 Nm -
assembly
01D
belts to
timing case
cover
BELT TENSIONING DEVICE
Engine Engine Engine
Number Designation
137 275 285.950
Thread not
Nm - - -
BA13.25-P- Self-tapping bolt, belt tensioner to pre-tapped
1001-01D timing case cover Thread pre-
Nm -- -
tapped
BA13.25-P-
Bolt, guide pulley to coolant pump M8x40 Nm - - -
1002-01D
BA13.25-P- Shock absorber, belt tensioning device
Nm - - -
1003-01D to belt tensioning device
BA13.25-P- Shock absorber, belt tensioning device
Nm - - -
1004-01D to coolant pump housing
BA13.25-P- Bolt, belt tensioner to timing case
M7x25 Nm 14 14 14
1005-01D cover
Thread not
Nm - - -
BA13.25-P- Self-tapping bolt, compressor belt pretapped
1006-01D tensioner to timing case cover Thread
Nm -- -
pretapped
BA13.25-P- Bracket for charge air cooler water
Nm - - -
1007-01D pipes
Bolt, guide pulley for compressor and
BA13.25-P-
major assembly belts to timing case M8x78 Nm - - -
1008-01D
cover
BELT TENSIONING DEVICE - BA13.25-P-1000-01P
Engine 272, 273
BELT TENSIONING DEVICE
Number Designation Engine 272 Engine 273
BA13.25-P-1001- Bolt from poly-V Nm 35 35
01P belt tensioning
device to timing
case cover
BA13.25-P-1002- Bolt from vibration Nm 35 35
01P damper to coolant
pump
BA13.25-P-1003- Bolt from vibration Nm 25 25
01P damper to timing
case cover
BA13.25-P-1004- Bolt from guide Nm 30 30
01P pulley to timing
case cover
BELT TENSIONING DEVICE - BA13.25-P-1000-01U
Engine 156, 159
MODIFICATION NOTES
Value modified: Guide pulley on coolant pump housing (between power steering pump and
7.8.09
guide pulley with grooved channel profile)
BELT TENSIONING DEVICE
Engine 156,
Number Designation
159
Bolt for poly-V-belt tensioning device on timing case cover M8 Nm 20
1001-01U
BA13.25-P-
Bolt for pulley on coolant pump M6 Nm 8.5
1002-01U
BA13.25-P- Guide pulley on coolant pump housing (between power steering pump
Nm 30
1003-01U and guide pulley with grooved channel profile)
BA13.25-P- Guide pulley on coolant pump housing (between alternator and smooth
Nm 20
1004-01U guide pulley)
BA13.25-P- Guide pulley (between poly-V-belt tensioning device and coolant
Nm 20
1005-01U pump)
BELT TENSIONING DEVICE - BA13.25-P-1000-01Y
ENGINE 152, 157, 278
BELT TENSIONING DEVICE
Number Designation Engine 152 Engine 157
BA13.25-P- Bolt for poly-V-belt tensioning Nm 20 20
1001-01Y device to timing case cover
BA13.25-P- Bolt, pulley to carrier Nm - 70
1002-01Y
BA13.25-P- Bolt, guide pulley carrier/ABC Nm - 20
1003-01Y pump to timing case cover/coolant
pump
BA13.25-P- Bolt, engine cover holder to guide Nm 9
1004-01Y pulley carrier
BA13.25-P- Bolt, guide pulley M8 Nm 35 35
1005-01Y to coolant pump/oil
filter/timing case M10 Nm - 35
cover
BELT TENSIONING DEVICE
Number Designation Engine 278
BA13.25-P-1001- Bolt for poly-V-belt tensioning device to Nm 20
01Y timing case cover
BA13.25-P-1002- Bolt, pulley to carrier Nm 70
01Y
BA13.25-P-1003- Bolt, guide pulley carrier/ABC pump to Nm 20
01Y timing case cover/coolant pump
BA13.25-P-1004- Bolt, engine cover holder to guide pulley Nm 9
01Y carrier
BA13.25-P-1005- Bolt, guide pulley to M8 Nm 35
01Y coolant pump/oil
filter/timing case M10 Nm 35
cover
SPECIAL TOOLS
SPECIAL TOOLS: PASSENGER CARS: AIR COMPRESSOR, BELT DRIVES - WS13.00-Z-9999AZ
MODEL all
000 589 29 33 00 Internal WS00.00-N-
FG 00 FG 05/13/26/27/28/ 33/42/set C
extractor 3027Z
FG 00/01/07/08/13/ WS00.00-P-
000 589 54 37 00 Clamp
14/18/20/22/28/33/46/47/54/82/83/Set B 0006Z
001 589 69 21 00 Measuring WS13.00-P-
FG 13/Set A
device 0001A
001 589 76 21 00 WS01.00-P-
FG 01/13/Set A
Compression tester 0004A
WS13.00-P-
102 589 01 07 00 Screwdriver FG 13/Set B
0002B
110 589 03 59 00 Mounting FG 00/01/05/13/18/ WS00.00-P-
wedge 26/42/54/67/68/72/77/80/82/83/88/91/ Set K 0274K
WS13.00-P-
117 589 05 07 00 Screwdriver FG 13/Set A
0003A
WS13.00-P-
117 589 05 07 04 Hexagon pin FG 13/Set A
0003-01A
166 589 00 03 00 Assembly WS13.00-P-
FG 13/Set B
lever 0004B
220 589 00 99 00 Electrical WS54.00-P-
FG 00 FG 01/13/15/ 20/25/42/43/47/54/72/ Set B
connection kit 0050B
220 589 05 99 00 Electrical WS00.00-P-
FG 00/01/09/13/15/ 20/25/42/43/47/54/ 72/ Set B
connection kit 0279Z
270 589 00 07 00 Assembly WS13.00-P-
FG 13/Set B
lever 0008B
272 589 01 61 00 Assembly WS13.00-P-
FG 13/Set B
tool 0014B
ENGINE
Air Intake, Turbo Charging - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - AH09.00-Z-9999AZ
MODEL all
Notes on installing air intake hose on ENGINE 612, 646, 647, 648, AH09.40-P-0001-
turbocharger 651... 02OM
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - AR09.00-
Z-9156AB
ENGINE 156
AR09.10-P-
Remove/install air filter housing ENGINE 156 in MODEL 204, 212
1150CMG
AR09.10-P-
Remove/install air filter housing ENGINE 156 in MODEL 164, 251
1150GZS
AR09.10-P-
Remove/install air filter housing ENGINES 156 in MODEL 230
1150RMG
AR09.10-P-
Remove/install air filter housing ENGINE 156 in MODEL 216, 221
1150SMG
ENGINE 156.982 in MODEL 209.377 /477
AR09.10-P-
Remove/install air filter housing ENGINE 156.983 in MODEL 211.077 /277,
1150TMG
219.377
Remove/install resonance intake AR09.20-P-
ENGINES 156 in MODEL 204, 212
manifold 1961CMG
Remove/install resonance intake AR09.20-P-
ENGINES 156 in MODEL 164, 251
manifold 1961GZS
Remove/install resonance intake AR09.20-P-
ENGINES 156 in MODEL 230.470
manifold 1961RMG
Remove/install resonance intake AR09.20-P-
ENGINE 156 in MODEL 216, 221
manifold 1961SMG
ENGINE 156.982 in MODEL 209.377 /477
Remove/install resonance intake AR09.20-P-
ENGINE 156.983 in MODEL 211.077 /277,
manifold 1961TMG
219.377
TESTING AND REPAIR WORK: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - AR09.00-
Z-9273AB
ENGINE 273
Remove, install the tumble flap and
ENGINE 272, 273 (except 272.985) in AR09.20-P-
resonance flap switchover valve at the intake
MODEL 211, 219 1990TS
manifold
ENGINE 272 (except 272.982) in MODEL
Remove, install tumble flap and resonance AR09.20-P-
204 ENGINE 272, 273 (except 272.984) in
flap switchover valve to intake manifold 1990CV
MODEL 207
Remove, install tumble flap and resonance ENGINE 272, 273 in MODEL 221 AR09.20-P-
flap switchover valve to intake manifold ENGINE 273 in MODEL 216 1990SX
Remove, install tumble flap position sensor at AR09.20-P-
ENGINE 272, 273...
intake manifold 1995QB
Remove, install tumble flap position sensor ENGINE 272, 273 in MODEL 221 AR09.20-P-
to intake manifold ENGINE 273 in MODEL 216 1995SX
ENGINE 272 in MODEL 204 ENGINE AR09.20-P-
Remove/install air duct housing
272, 273 in MODEL 207 0080CV
AR09.20-P-
Remove/install air duct housing ENGINES 272, 273 in MODEL 212
0080EW
ENGINES 272, 273 in MODEL 164, 251 AR09.20-P-
Remove/install air duct housing
ENGINES 273 in MODEL 463 0080GZA
ENGINE 272 in MODEL 204 ENGINE AR09.10-P-
Remove/install air filter housing
272, 273 in MODEL 207 1150CV
AR09.10-P-
Remove/install air filter housing ENGINES 272, 273 in MODEL 212
1150EWS
ENGINES 272, 273 (except 272.973) in AR09.10-P-
Remove/install air filter housing
MODEL 164, 251 1150GZA
AR09.10-P-
Remove/install air filter housing ENGINE 272, 273...
1150QB
AR09.10-P-
Remove/install air filter housing ENGINE 272, 273 in MODEL 230
1150RX
ENGINE 272, 273 in MODEL 221 AR09.10-P-
Remove/install air filter housing
ENGINE 273 in MODEL 216 1150SX
AR09.10-P-
Remove/install air filter housing ENGINE 272, 273 in MODEL 211, 219
1150TS
ENGINE 272 (except 272.982) in MODEL
AR09.20-P-
Remove/install resonance intake manifold 204 ENGINE 272, 273 (except 272.984) in
1961CV
MODEL 207
ENGINE 272, 273 (except 272.983) in AR09.20-P-
Remove/install resonance intake manifold
MODEL 212 1961EW
ENGINE 272, 273 in MODEL 164, 251 AR09.20-P-
Remove/install resonance intake manifold
ENGINE 273 in MODEL 463 1961GZA
Remove/install resonance intake manifold ENGINE 272, 273...
1961QB
AR09.20-P-
Remove/install resonance intake manifold ENGINE 272, 273 in MODEL 230
1961RX
ENGINE 272, 273 in MODEL 221 AR09.20-P-
Remove/install resonance intake manifold
ENGINE 273 in MODEL 216 1961SX
ENGINE 272, 273 (except 272.985) in AR09.20-P-
Remove/install resonance intake manifold
MODEL 211, 219 1961TS
AR09.20-P-
Remove/install the air duct housing ENGINE 272, 273...
0080QB
AR09.20-P-
Remove/install the air duct housing ENGINE 272, 273 in MODEL 230
0080RX
AR09.20-P-
Remove/install the air duct housing ENGINE 272, 273 in MODELS 211, 219
0080TS
Remove/install the tumble flap and resonance ENGINES 272, 273 (except 272.983) in AR09.20-P-
flap switchover valve at the intake manifold MODEL 212 1990EW
Remove/install the tumble flap and resonance AR09.20-P-
ENGINE 272, 273 in MODEL 164, 251
flap switchover valve at the intake manifold 1990GZD
Remove/install the tumble flap and resonance ENGINE 272.966 in MODEL 230.456 AR09.20-P-
flap switchover valve at the intake manifold ENGINE 273.965 in MODEL 230.471 1990RX
ENGINE 272 (except 272.982) in MODEL
Remove/install the tumble flap position AR09.20-P-
204 ENGINE 272, 273 (except 272.984) in
sensor at intake manifold 1995CV
MODEL 207
Remove/install the tumble flap position ENGINES 272, 273 (except 272.983) in AR09.20-P-
sensor at intake manifold MODEL 212 1995EW
Remove/install the tumble flap position AR09.20-P-
ENGINE 272, 273 in MODEL 164, 251
sensor at intake manifold 1995GZA
Remove/install the tumble flap position ENGINE 272, 273 (except 272.985) in AR09.20-P-
sensor at intake manifold MODEL 211, 219 1995TS
Remove/install tumble flap position sensor at ENGINE 272.966 in MODEL 230.456 AR09.20-P-
intake manifold ENGINE 273.965 in MODEL 230.471 1995RX
Removing/installing the resonance flap AR09.20-P-
ENGINE 272, 273...
switchover valve on the intake manifold 1993QB
Removing/installing the tumble flap AR09.20-P-
ENGINE 272, 273...
switchover valve at the intake manifold 1994QB
TESTING AND REPAIR WORK: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - AR09.00-
Z-9275AB
ENGINE 275
AR09.10-P-
Remove/install air filter ENGINE 275...
1050LA
AR09.10-P-
Remove/install air filter housing ENGINE 275...
1150LA
ENGINE 275 in MODEL 230 with CODE AR09.10-P-
Remove/install air filter housing
(P99) "AMG Black Series" special model 1150RBS
ENGINE 275 in MODEL 215, 216, 220, 221, AR09.41-P-
Remove/install charge air cooler
230 ENGINE 285 in MODEL 240 6817HH
Remove/install charge air duct ENGINES 275 in MODEL 215, 216, 220, 221, AR09.50-P-
downstream of charge air cooler 230 ENGINES 285 in MODEL 240 8680H
ENGINES 275 in MODEL 215, 216, 220, 221, AR09.41-P-
Remove/install charge air manifold
230 ENGINES 285 in MODEL 240 1310HH
Remove/install circulation pump for AR09.41-P-
ENGINE 275 in MODEL 215, 216, 220, 221
low-temperature water circuit 6925LA
Remove/install circulation pump for ENGINES 275 in MODEL 230 except CODE AR09.41-P-
low-temperature water circuit (P99) Special model "AMG Black Series" 6925R
Remove/install circulation pump for ENGINE 275 in MODEL 230 with CODE AR09.41-P-
low-temperature water circuit (P99) "AMG Black Series" special model 6925RBS
AR09.40-P-
Remove/install deceleration air valve ENGINE 275 in MODEL 216, 221
3001SZ
Remove/install divert air switchover ENGINE 275 in MODEL 215, 216, 220, 221, AR09.40-P-
valve 230 ENGINE 285 in MODEL 240 3000M
Remove/install engine charge air duct ENGINES 275 in MODEL 215, 216, 220, 221, AR09.41-P-
upstream of charge air cooler 230 ENGINES 285 in MODEL 240 8623H
Remove/install low temperature water ENGINE 275.980 in MODELS 215.379, AR09.41-P-
circuit radiator 220.179 6935IM
Remove/install low temperature water AR09.41-P-
ENGINE 275.950 in MODEL 220.176
circuit radiator 6935MC
ENGINE 275 in MODEL 230.476 /477
Remove/install low temperature water AR09.41-P-
ENGINE 275 in MODEL 230.479 up to Model
circuit radiator 6935R
Year 2007
Remove/install low temperature water ENGINE 275 in MODEL 230 with CODE AR09.41-P-
circuit radiator (P99) "AMG Black Series" special model 6935RBS
Remove/install low temperature water AR09.41-P-
ENGINE 275...
circuit radiator 6935RMB
Remove/install low temperature water AR09.41-P-
ENGINE 275.982 in MODEL 216.379, 221.179
circuit radiator 6935SXM
Remove/install low temperature water ENGINE 275 (except 275.982) in MODEL 216, AR09.41-P-
circuit radiator 221 6935SZ
ENGINE 275 in MODEL 215, 216, 220, 221, AR09.40-P-
Remove/install turbocharger
230 6020MC
Removing/installing the deceleration AR09.40-P-
ENGINE 275 in MODELS 215, 220
air valve 3001M
Removing/installing the deceleration AR09.40-P-
ENGINE 275 in MODEL 230
air valve 3001R
REMOVE/INSTALL AIR FILTER HOUSING - AR09.10-P-1150LA
ENGINES 275 in MODEL 215, 216, 220, 221
ENGINES 275 in MODEL 230 except CODE (P99) Special model "AMG Black Series"
Illustrated on model 220.176
Fig. 1: Identifying Air Filter Housing Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR01.10-P-
Engine 275.95
2405LA
1 Remove engine cover.
AR01.10-P-
Engine 275.98
2405IM
Disconnect electrical connector at pressure sensor
downstream of air filter, left cylinder bank
2
(B28/4) and at pressure sensor downstream of air
filter, right cylinder bank (B28/5)
*BA09.10-P-
3 Remove screws (5) and screws (6)
1001-01E
Lift air filter housing, right side (3) and pull back
4
and out of air intake pipe, right side (2)
Unclip pneumatic line (8) on left air filter housing
5
(4)
6 Disconnect pneumatic line (8)
Observe crankcase
Installation: Ensure that
Lift air filter housing, left side (4) and pull back crankcase ventilation system
7
and out of air intake pipe, left side (1) (7) hose is put on intake
manifold (4/1).
8 Install in the reverse order
AIR FILTER
Number Designation Engines 275, 285.950
BA09.10-P-1001-01E Bolt, air filter housing to bracket Nm 8
REMOVE/INSTALL AIR FILTER HOUSING - AR09.10-P-1150SMG
ENGINE 156 in MODEL 216, 221
Fig. 2: Identifying Air Filter Housing Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing,
installing or aligning hoods, doors, trunk lids, Keep body parts and limbs well AS00.00-Z-
tailgates or sliding roof. clear of moving parts. 0011-01A
1 Open engine hood
Do not tilt front engine cover
(1) but instead lift it off vertically,
2 Remove front engine cover (1)
otherwise the retaining lugs can
break off.
3 Remove the intake air ducts (2)
4 Unclip covers
Disconnect electrical connectors (4) at hot
5
film mass air flow sensor
6 Loosen clamps at air filter housing (5)
7 Unclip retaining clips (6) at intake port Check sealing ring on intake
port; replace if necessary.
Cover intake opening
Installation: Coat rubber
mounts on valve covers with
8 Remove both air filter housings (5).
antifriction agent.
*BR00.45-Z-
Liquid lubricant (Naphtolen H)
1003-06A
9 Install in the reverse order
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-06A Brake pad paste replaced by: A 001 989 94 51 000 989 01 60
REMOVE/INSTALL AIR FILTER HOUSING - AR09.10-P-1150SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
25.7.08 Installation instructions for the air filter housing - added Step 5
Remove/install
Installation: Check for correct seating of the
Pull off the front engine cover
1 front engine cover (1) on the air filter housing
(1) from above.
(4).
Remove left and right engine air
Check left and right engine air intake duct (2)
2 intake duct (2) upstream of air
fort damage and replace if necessary.
filter
If necessary
Detach hose (3) for air pump at Installation: The arrows on hose (3) and the
3
air filter housing (4) air filter housing (4) must point towards each
other.
Lever off clamp (5) from the air
4 If necessary
filter housing (4)
In order to avoid scratches and damage, the
air filter housing (4) must be put down on a
padded base.
Apply lubricant to support (4a) on the left and
Detach air filter housing (4) right cylinder head cover and the seal (6) on the
upwards from mounts (4a) on air filter housing (4) using a suitable tool.
5
left and right cylinder head Press air filter housing (4) evenly into the
cover supports (4a) and ensure correct seating of the
seal (6) in the air filter housing (4) and on the hot
film mass air flow sensor (B2/5).
The gap between air filter housing (4) and seal
(6) must be even and closed.
*BR00.45-Z-
Antifriction agent
1010-06A
6 Install in the reverse order
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
TORQUE DIAGRAM FOR INTAKE MANIFOLD FASTENING SYSTEM - AR09.20-P-1310-03AMG
MODIFICATION NOTES
6.8.09 Value changed: bolt, intake manifold to cylinder head *BA09.20-P-1002-01R
Value changed: bolt, intake manifold to cylinder head *BA09.20-P-1002-01R
Value changed: bolt, intake manifold to cylinder head *BA09.20-P-1002-01R
INTAKE MANIFOLD
Number Designation Engine 156
Stage 1 Nm 10
BA09.20-P-1002-01R Bolt, intake manifold to cylinder head Stage 2 Angle° 90
Stage 3 Angle° 10
1. Tighten bolts on the intake manifold in numerical sequence.
Fig. 4: Tightening Sequence Of Intake Manifold Bolts
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL RESONANCE INTAKE MANIFOLD - AR09.20-P-1961SMG
ENGINE 156 in MODEL 216, 221
Fig. 5: Identifying Resonance Intake Manifold Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
6.8.09 Value changed: Bolt, intake manifold to cylinder head *BA09.20-P-1002-01R
Value changed: Bolt, intake manifold to cylinder head *BA09.20-P-1002-01R
Value changed: Bolt, intake manifold to cylinder head *BA09.20-P-1002-01R
Remove/install
No fire, sparks, open flames
Risk of explosion caused by fuel igniting, risk of or smoking. Only pour fuels
poisoning caused by inhaling and swallowing fuel into suitable and appropriately AS47.00-Z-
and risk of injury to eyes and skin caused by marked containers. 0001-01A
contact with fuel Wear protective clothing when
handling fuel.
Risk of injury caused by fingers being pinched
Keep body parts and limbs AS00.00-Z-
or crushed when removing, installing or aligning
well clear of moving parts. 0011-01A
hoods, doors, trunk lids, liftgates or sliding roof
Switch ignition off, remove ignition key
1
(transmitter key).
2 Open engine hood
Remove both engine suction fan ducts in front of
3
air filter
cover, but lift upwards
4 Remove front engine cover vertically otherwise the
retaining lugs can break off.
AR09.10-P-
5 Remove air filter housing
1150SMG
AR07.03-P-
Release fuel pressure with pressure hose via 1460-
6 01TMG
service valve
Fig. 6
Install new sealing rings.
7 Detach fuel line from fuel distributor (4) *BA07.03-P-
1001-01C
Disconnect connectors (2) at intake pipe (1) at
8
front
9 Detach vacuum line (3)
Detach brake booster vacuum line at connection
10
(11)
11 Remove insulating cover
12 Disconnect connectors for injection valves Place wiring hardness to
side.
*BA07.03-P-
13 Remove bolt (6) and purge line (5)
1002-01C
Detach vacuum hose (9) from intake manifold (1) Detach hose to vacuum
14
or from vacuum unit (13) reservoir.
15 Remove vacuum line (10).
16 Disconnect connector (12)
Close off intake ports in
doing so Injection valves is
not damaged.
Installation: Clean sealing
surfaces; replace intake
Remove bolts (8) from intake pipe (1) then manifold seals and bolts.
17
remove intake pipe (1) upwards
Installation: Observe AR09.20-P-
tightening pattern for 1310-
fastening the intake manifold. 03AMG
*BA09.20-P-
1002-01R
BT09.20-P-
Seals and bolts on the intake manifold 0005-
01AMG
18 Install in the reverse order
Risk of accident caused by vehicle starting off by
itself when engine is running. Risk of injury Secure vehicle to prevent it
procedure or when working near the engine as it is Wear closed and snug-fitting
running work clothes. AS00.00-Z-
Carry out engine test run and check intake Do not touch hot or rotating 0005-01A
19 parts.
manifold (1) for leaks
INJECTORS, INJECTION VALVES, LINES
Number Designation Engine 156
BA07.03-P-1001-01C Union nut, fuel line to fuel distributor Nm 20
BA07.03-P-1002-01C Bolt, fuel distributor to resonance intake manifold Nm 9
INTAKE MANIFOLD
Number Designation Engine 156
Stage 1 Nm 10
BA09.20-P-1002-01R Bolt, intake manifold to cylinder head Stage 2 Angle° 90
Stage 3 Angle° 10
Fig. 6: Identifying Pressure Hose (119 589 04 63 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL RESONANCE INTAKE MANIFOLD - AR09.20-P-1961SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 7: Identifying Resonance Intake Manifold Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.071 with Active Body Control (ABC) Code 487
Fig. 8: Identifying Resonance Intake Manifold Components - Engine 273.961
Courtesy of MERCEDES-BENZ USA
Shown on engine 273.961
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to
0001-01A
electrostatic discharge
Vehicles with Keyless Go, code 889:
Press Keyless Go start/stop button
repeatedly until ignition is switched off.
1 Turn key in ignition lock to position "0"
Remove Keyless Go transmitter card or
transmitter key from the vehicle and store
beyond transmitter range (min. 2 m).
AR09.10-P-
2 Remove air filter housing
1150SX
Disconnect right connector (R) at ME-
3
SFI [ME] control unit (N3/10)
Disconnect electrical connectors (1a,
4
1b)
Remove jack for electrical connector
5 Install new cable ties.
(1b) on fuel distributor (2)
Remove electrical feed line (1c) from
6 Install new cable ties.
left control unit bracket (3l)
Pull ME-SFI [ME] control unit (N3/10)
Do not disconnected left connector (L)
7 out of control unit brackets (3l, 3r) and
at ME-SFI [ME] control unit (N3/10).
place down to one side
Remove hot film mass air flow sensor AR07.07-P-
8
(B2/5) 1453SX
9 Remove air duct housing (4)
Disconnect hoses (5a, 5b) from
10
crankcase ventilation system
*BA07.08-
11 Remove right control unit bracket (3r)
P-1002-01A
Remove feed duct (6a) from cylinder
*BA15.18-
12 head cover and resonance intake
P-1001-01B
manifold (7)
*BA15.18-
P-1002-01B
Remove feed duct (6b) from resonance *BA15.18-
13
intake manifold (7) P-1001-01B
*BA01.30-
14 Remove left rear engine lifting eye (8)
P-1005-01O
*BA15.18-
P-1003-01B
Remove feed duct (6c) from cylinder *BA15.18-
15
head cover P-1002-01B
Disconnect electrical connectors at fuel
16
injection valves (Y62)
Disconnect electrical connectors at
17
position sensors (B28/9, B28/10)
18 Disconnect electrical connector (9)
Disconnect electrical connector at the
19
throttle valve actuator (M16/6)
Disconnect electrical connector from
20
electrical air pump (M33)
Release fuel pressure over service valve AR07.03-P-
21
(10) 1460-01VA
*BA07.03-
P-1004-01B
Fig. 6
Disconnect fuel line (11) from fuel
22 Seal connections immediately.
distributor (2)
Fig. 9
*BA07.03-
P-1001-01B
23 Remove bolts (7a)
front and detach pneumatic lines (12)
24 from connection fittings at resonance
intake manifold (7)
25 Take out resonance intake manifold (7) Installation: Replace seals (7b).
Installation: Objects that have entered
the intake tract must always be removed
26 Cover openings in cylinder heads before fitting resonance intake manifold
(7) otherwise there may be engine
damage.
Only perform steps 27 to 30 when
replacing resonance intake manifold
(7)
Detach left control unit bracket (3l) *BA07.08-
27
from resonance intake manifold (7) P-1002-01A
Detach fuel distributor (2) with fuel
*BA07.03-
28 injection valves (Y62) from resonance
P-1002-01B
intake manifold (7)
Detach throttle valve actuator (M16/6) *BA07.61-
29
from resonance intake manifold (7) P-1001-01D
Detach position sensors (B28/9, B28/10) *BA09.20-
30
from resonance intake manifold (7) P-1002-01N
31 Install in the reverse order
Checking
Risk of accident caused by vehicle
Secure vehicle to prevent it from moving
starting off by itself when engine is
by itself.
running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-fitting work
contusions and burns during starting 0005-01A
clothes.
procedure or when working near the
Do not touch hot or rotating parts.
engine as it is running
Carry out an engine test run and check
32
intake tract and fuel system for leaks
INTAKE MANIFOLD
Engine Engine
Number Designation
272 273
BA09.20-P-1001-
Bolt, resonance intake manifold to cylinder head Nm 9 9
01N
BA09.20-P-1002- Bolt, tumble flap position sensor to resonance intake
Nm 6 6
01N manifold
CONTROL UNIT
Engine Engine
Number Designation
272 273
01A manifold Nm 8 8
ENGINE WIRING HARNESS
Number Designation Engine 272 Engine 273
BA15.18-P-1001-01B Bolt, feed duct to resonance intake manifold Nm 8 8
BA15.18-P-1002-01B Bolt, feed duct to cylinder head cover Nm 8 8
BA15.18-P-1003-01B Bolt, feed duct to engine lifting eye Nm 8 8
CYLINDER HEAD
Number Designation Engine 272 Engine 273
BA01.30-P-1005-01O Bolt, lifting eye to cylinder head M8 Nm 20 20
INJECTORS, INJECTION VALVES, LINES
Engine Engine
Number Designation
272 273
BA07.03-P-1001-
Union nut, fuel line to fuel distributor Nm 20 20
01B
BA07.03-P-1002- Bolt, fuel distributor to resonance intake
Nm 9 9
01B manifold
BA07.03-P-1004- Plastic Nm 2 -
Protective cap on service valve
01B Metal Nm 15 -
ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM
Engine Engine
Number Designation
272 273
BA07.61-P-1001- Bolt, throttle valve actuator to resonance intake
Nm 9 9
01D manifold
Fig. 9: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 10: Identifying Pressure Hose (119 589 04 63 00)
Courtesy of MERCEDES-BENZ USA
REMOVE, INSTALL TUMBLE FLAP AND RESONANCE FLAP SWITCHOVER VALVE TO
INTAKE MANIFOLD - AR09.20-P-1990SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 11: Identifying Tumble Flap & Resonance Flap Switchover Valve Components
Courtesy of MERCEDES-BENZ USA
Remove/install
On vehicles with code 889 Keyless-Go:
Press Keyless-Go start/stop button
Switch ignition off, remove ignition key repeatedly until the ignition is switched off.
1
(transmitter key) Remove Keyless Go transmitter card or
transmitter key from the vehicle and store
AR09.10-
2 Remove air filter housing
P-1150SX
AR09.20-
3 Remove resonance intake manifold (5)
P-1961SX
Never use pointed or sharp tools to
remove pneumatic line otherwise this may
Pull pneumatic line (1 or 2) out of
4 be damaged.
switchover valve (Y22/6 or Y22/9)
Installation: Check pneumatic line for
damage and replace if necessary.
5 Remove lock washer (3 or 4) Installation: Replace lock washer.
Disconnect electrical connector (X205)
6
at switchover valve (Y22/6 or Y22/9)
Remove switchover valve (Y22/6 or
7 Y22/9) from resonance intake manifold
(5)
8 Install in the reverse order
Checking
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving
AS00.00-
running. Risk of injury caused by by itself.
Z-0005-
contusions and burns during starting Wear closed and snug-fitting work clothes.
01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
Carry out an engine test run and check
9
intake tract and fuel system for leaks
REMOVE, INSTALL TUMBLE FLAP POSITION SENSOR TO INTAKE MANIFOLD - AR09.20-P-
1995SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 12: Identifying Tumble Flap Position Sensor Components
Courtesy of MERCEDES-BENZ USA
Shown on Model 221.071 with Active
Body Control (ABC) Code 487
Remove/install
Vehicles with Keyless Go, code 889: Press
Keyless Go start/stop button repeatedly until ignition
Turn key in ignition switch
1 is switched off. Remove Keyless Go transmitter card
to position "0".
or transmitter key from the vehicle and store beyond
transmitter range (min. 2 m).
2 Remove air filter housing AR09.10-P-1150SX
Disconnect electrical
connector (1) at left and
3
right position sensor (B28/9
or B28/10)
*BA09.20-P-
4 Remove bolt (2)
1002-01N
Pull left and right position
sensor (B28/9 or B28/10)
5 Installation: Replace the gaskets.
out of resonance intake
manifold (3)
6 Install in the reverse order
Read out fault memory with
7
STAR DIAGNOSIS
INTAKE MANIFOLD
Engine Engine
Number Designation
272 273
BA09.20-P-1002- Bolt connecting tumble flap position sensor to resonance
Nm 6 6
01N intake manifold
REMOVE/INSTALL DIVERT AIR SWITCHOVER VALVE - AR09.40-P-3000M
ENGINE 275 in MODEL 215, 216, 220, 221, 230
ENGINE 285 in MODEL 240
Fig. 13: Identifying Divert Air Switchover Valve Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR01.10-P-
Engine 275.98
2405IM
1 Remove engine trim panel
AR01.10-P-
Engine 275.95, 285
2405LA
Model 215, 216, 220, 221, 230 without
AR09.10-P-
code (P99) Special model "AMG
1150LA
2 Remove right air filter housing Black Series"
AR09.10-P-
Model 240
1150H
Detach right charge air cooler from engine
Do not open low temperature AR09.41-P-
3 and connect with connected coolant hoses
circuit. 6817HH
to engine hood
Installation: Check pneumatic lines
Remove pneumatic line (1) on divert air
4 (1) and hose clamps for wear and
switchover valve (Y101)
Disconnect electrical connector (2) at
5
divert air switchover valve (Y101)
Lift locking detent (4) and detach divert
6 air switchover valve (Y101) in direction of
travel from bracket (3)
7 Install in the reverse order
REMOVE/INSTALL DECELERATION AIR VALVE - AR09.40-P-3001SZ
ENGINE 275 in MODEL 216, 221
Fig. 14: Identifying Deceleration Air Valve Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 15: Identifying Deceleration Air Valve Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 16: Identifying Deceleration Air Valve Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Remove/install
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
Vehicles without code (Z07) Top AR61.20-P-
Remove bottom engine compartment protection 1105SX
1
paneling Vehicles with code (Z07) Top AR61.20-P-
protection 1105SXS
Left deceleration air valve
Remove bolts (5) on deceleration air valve *BA09.40-P-
2
(110/4) and deceleration air valve (110/4) 1014-01H
Check left pneumatic line (4b)
Remove left pneumatic line (4b) on
3 and hose clamp for damage, replace
deceleration air valve (110/4)
if necessary.
Right deceleration air valve
AR14.30-P-
4 Remove air pump
7251SZ
Unscrew bolts (1) and remove air pump *BA14.30-P-
5
holder (2) 1003-01B
Detach expansion reservoir for coolant and AR20.30-P-
6
lay to the side with attached coolant lines 4950SX
Remove bolts (3) on deceleration air valve *BA09.40-P-
7
(110/4) and deceleration air valve (110/4) 1014-01H
Check right pneumatic line (4a)
Remove right pneumatic line (4a) on
8 and hose clamp for damage, replace
deceleration air valve (110/4)
if necessary.
9 Install in the reverse order
Checking
Remove pneumatic lines (4a, 4b) from T- Inspect hose clamps for damage,
10
piece (7) replace if necessary.
If vacuum drops within 1 minute
Attach manual vacuum pump to by no more than 50 mbar then
11 pneumatic lines (4a, 4b) and apply 700 mbar deceleration air valve (110/4) is
vacuum to deceleration air valve (110/4) OK.
Fig. 17
TURBOCHARGER
Number Designation Engine 275
BA09.40-P-1014-01H Bolt, deceleration air valve to turbocharger Nm 7
AIR PUMP
Number Designation Engines 275
BA14.30-P-1003-01B Bolt, air pump holder to cylinder head Nm 8
Fig. 17: Identifying Hand Vacuum Pump (001 589 73 21 00)
Courtesy of MERCEDES-BENZ USA
TORQUE DIAGRAM FOR EXHAUST MANIFOLD - AR09.40-P-6020-11MC
TURBOCHARGER
Number Designation Engine 275
BA09.40-P-1011-01H Exhaust manifold on cylinder head Nm 15
Fig. 18: Identifying Assembly Arm (285 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
Do not use any assembly paste or similar product!
1. Tighten all the nuts (1 to 12) to the specified tightening sequence with the specified torque.
2. Dismount assembly tool (01, 02).
3. Tighten all the nuts (1 to 12) once again to the specified tightening sequence with the specified torque.
Fig. 19: Torque Diagram For Exhaust Manifold
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TURBOCHARGER - AR09.40-P-6020MC
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Fig. 20: Identifying Turbocharger Components
Courtesy of MERCEDES-BENZ USA
Illustrated on right turbocharger
Fig. 21: Identifying Support Brace And Turbocharger
Courtesy of MERCEDES-BENZ USA
Fig. 22: Identifying Turbocharger, Engine Support, Coolant Feed Line And Oil Return Line
Courtesy of MERCEDES-BENZ USA
Fig. 23: Identifying Turbocharger, Assembly Arm And Nut
Courtesy of MERCEDES-BENZ USA
Remove/install
Model 220 with code (979) Special
protection version, code (Z04) Light
armoring or code (Z07) Highest protection
1.1 Remove engine
Model 215. 220 without code (979) Special
AR01.10-P-
protection version, code (Z04) Light
2400MC
armoring or code (Z07) Highest protection
AR01.10-P-
Model 216, 221
2500SZ
Remove engine with front axle Model 230 without code (P99) Special AR01.10-P-
1.2
carrier model "AMG Black Series" 2500RC
Model 230 with code (P99) Special model AR01.10-P-
"AMG Black Series" 2500RBS
2 Mount engine onto assembly stand Model 215, 220
Model 215, 216, 220, 221, 230 without code AR09.10-P-
3 Remove right air filter housing
(P99) Special model "AMG Black Series" 1150LA
AR09.41-P-
4 Remove charge air cooler
6817HH
Remove engine charge air channel AR09.41-P-
5
upstream of charge air cooler 8623H
AR15.12-P-
6 Remove ignition coil module
1100LA
*BA09.40-P-
Remove support (1) from 1009-01H
7
turbocharger (2) *BA09.40-P-
1010-01H
*BA22.10-P-
8 Remove engine supports (3)
1001-02A
Installation: Install new sealing rings.
*BA09.40-P-
Remove coolant feed line (4) from
9 1005-01H
crankcase to turbocharger (2)
*BA09.40-P-
1007-01H
Installation: Replace gasket and sealing
ring.
Remove oil return line (5) from *BA09.40-P-
10
turbocharger (2) 1004-01H
*BA09.40-P-
1006-01H
Detach pneumatic lines (6) from Installation: Check condition of
11 deceleration air valve (7) and from pneumatic lines (6) and hose clamps;
vacuum cell (8) replace if necessary.
Installation: Replace gaskets and sealing
rings.
Remove bolts (9) of oil feed line
*BA09.40-P-
12 (10) and of coolant return line (11)
1002-01H
at turbocharger (2)
*BA09.40-P-
1003-01H
Remove shields (12) at *BA09.40-P-
13
turbocharger (2) 1012-01H
Remove bolts (13) of coolant line *BA09.40-P-
14
(14) at cylinder head (15) 1001-01H
Turbocharger and exhaust manifold are
one unit and must not be disassembled, as
Mount assembly tool (16) with 4 this can lead to leakage.
15 bolts (bolt M8 20) onto
Assembly tools (16) serve to fix the
turbocharger (2)
flexible exhaust manifold parts in place.
Fig. 18
AR09.40-P-
Installation: Observe torque diagram. 6020-11MC
Fig. 25
Unscrew nuts (17) at exhaust Fig. 26
16
manifold *BA09.40-P-
1011-01H
Remove turbocharger (2) with
17 exhaust manifold from cylinder Installation: Install new seal
head (15)
18 Install in the reverse order
TURBOCHARGER
Number Designation Engine 275
BA09.40-P-1001-01H Coolant line to cylinder head Nm 9
BA09.40-P-1002-01H Bolt, oil feed line to turbocharger Nm 8
BA09.40-P-1003-01H Bolt, coolant return flow line to turbocharger Nm 8
BA09.40-P-1004-01H Bolt, oil return flow line to turbocharger Nm 8
BA09.40-P-1005-01H Bolt connecting coolant feed line to turbocharger Nm 8
BA09.40-P-1006-01H Bolt, oil return flow line to crankcase Nm 8
BA09.40-P-1007-01H Banjo bolt, coolant feed line to crankcase Nm 25
BA09.40-P-1009-01H Bolt, support to turbocharger Nm 30
BA09.40-P-1010-01H Bolt, turbocharger support to crankcase Nm 20
BA09.40-P-1011-01H Exhaust manifold to cylinder head Nm 15
BA09.40-P-1012-01H Shield to turbocharger Nm 9
ENGINE SUPPORT (ENGINE SIDE)
Number Designation Engine 275
Stage 1 Nm 20
BA22.10-P-1001-02A Bolt, engine support to cylinder crankcase
Stage 2 Angle° 90
Fig. 24: Identifying Assembly Arm (285 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
Fig. 25: Identifying Box Wrench Bit (285 589 00 03 00)
Courtesy of MERCEDES-BENZ USA
Fig. 26: Identifying Torque Wrench (001 589 87 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CHARGE AIR MANIFOLD - AR09.41-P-1310HH
ENGINES 275 in MODEL 215, 216, 220, 221, 230
ENGINES 285 in MODEL 240
Fig. 27: Identifying Charge Air Manifold Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR07.03-P-
1 Remove fuel distributor rail (1)
1451H
Remove hose (3) of crankcase Check hose (3) and hose clamp for
2
ventilation system damage, replace if required.
Detach hose (2) at charge air manifold Check hose (2) and hose clamp for
3
(4) damage, replace if required.
Engine 275
Detach rear vacuum supply hose of Check vacuum supply hose and
4
brake system at charge air manifold (4) hose clamp for damage, replace if
required.
Remove bolts (5) of charge air *BA09.20-P-
5
manifold (4) 1001-01L
6 Take out charge air manifold (4) Installation: Replace seals (6)..
7 Install in the reverse order
INTAKE MANIFOLD
Number Designation Engine 275, 285
BA09.20-P-1001-01L Bolt, intake manifold to cylinder head M6 Nm 8
OPEN AND CLOSE COUPLING - AR09.41-P-1311-01AL
Open coupling
1. Slide nose (2) of catch spring (3) to position (B).
Do not pull on the eyelet (1) as the catch spring (3) will lose pretension.
2. Detach hose on component.
3. Replace seal.
Close coupling
4. Slide nose (2) of catch spring (3) to position (A).
5. Slide hose onto component until the catch spring (3) latches.
6. Check connection by pulling a little at the hose.
Fig. 28: Identifying Catch Spring And Catch Spring Positions
Courtesy of MERCEDES-BENZ USA
CHECK CHARGE AIR COOLER - AR09.41-P-6800-01H
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Testing internal leakage via the air inlet trim
If necessary after test:?
Replace charge air cooler. AR09.41-P-6817HH
1. Check left and right charge air cooler (5/1, 5/2) through visual inspection in the air intake support (1) for
traces of fluid and residues of coolant.
For this Use inspection mirror (01) and hand lamp (02) or cylinder inspection light with flexible
endoscope.
Shown on right charge air cooler in Model 240
Fig. 29: Checking Charge Air Cooler
Courtesy of MERCEDES-BENZ USA
CHECK CHARGE AIR COOLER - AR09.41-P-6800-01HH
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Testing internal leakage via the air inlet trim
If necessary after test:?
Replace charge air cooler. AR09.41-P-6817HH
1. Carefully tilt left and right charge air cooler (5/1, 5/2) and check, if coolant is flowing out of air intake
support (1).
Do not put connection fitting (5a) of coolant lines under tension when tilting left and right charge air
cooler, otherwise leaks may occur.
2. Check left and right charge air cooler through visual inspection in the air intake support (1) for traces of
fluid and residues of coolant.
Shown on right charge air cooler in Model 240
Fig. 30: Checking Charge Air Cooler
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CHARGE AIR COOLER - AR09.41-P-6817HH
ENGINE 275 in MODEL 215, 216, 220, 221, 230
ENGINE 285 in MODEL 240
Fig. 31: Identifying Charge Air Cooler Components
Courtesy of MERCEDES-BENZ USA
Shown on engine 285
Remove/install
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant AS20.00-Z-
pressure. Do not pour coolant into
spray. Risk of poisoning caused by 0001-01A
beverage containers.
swallowing coolant.
Wear protective gloves, protective
clothing and safety glasses.
AR01.10-P-
Engine 275.98
2405IM
1 Remove engine trim panel
AR01.10-P-
Engine 275.95, 285
2405LA
Model 215, 216, 220, 221, 230
AR09.10-P-
without code (P99) Special Model
1150LA
2 Remove air filter housing "AMG Black Series"
AR09.10-P-
Model 240
1150H
Model 215, 216, 220, 221, 230
1142HM
3 Drain coolant from low temperature circuit AR20.00-P-
Model 240
1142HN
Installation: check charge air hose
(1) and hose clamp for damage bad
replace if required.
Clean and degrease inside of charge
Disconnect charge air hose (1) at charge air air hose (1) as well as its connection
4 fitting at charge air cooler (2).
cooler (2).
*BA09.41-
P-1002-02B
*BR00.45-
Cleaner from package
Z-1028-04A
Installation: Check charge air
duct (3) and hose clamp for damage
Disconnect charge air duct (3) at charge air
5 and replace if required.
cooler (2).
*BA09.41-
P-1003-02B
Only when removing from right
charge air cooler (2).
Remove pneumatic line (4a) at charge air
6 Installation: Check pneumatic
cooler (2).
line (4a) and hose clamp for damage;
replace if necessary.
Only when removing from right
charge air cooler (2).
Disconnect electrical connector at pressure The pneumatic line (4b) is bonded
sensor upstream of throttle valve actuator with the support to charge air cooler
7 (B28/6) and detach pressure sensor (2). This combination must not be
upstream of throttle valve actuator (B28/6) separated, otherwise leakage may
from bracket (5) occur.
*BA09.41-
P-1002-03A
Only when removing from right
Remove pneumatic line (4c) from charge air
8 charge air cooler (2).
cooler (2).
Installation: Install new cable ties.
*BA09.41-
9 Remove bolts (6)
P-1001-03A
For better accessibility lift charge
air cooler (2) slightly forward.
Remove coolant hoses on fitting (2a) for
10 Installation: Check coolant hoses
charge air cooler (2)
at fitting (2a) and hose clamp for
damage; replace if necessary.
Unclip plug connection for O2
11 Take out charge air cooler (2) sensor from retaining spring at rear of
charge air cooler (2).
12 Install in the reverse order
AR20.00-P-
13 Bleed low temperature circuit
1145H
AR20.00-P-
14 Inspect cooling system for leaks
1010HN
CHARGE AIR DUCT
Engine 275,
Number Designation
285
BA09.41-P- Hose clamp, charge air hose to engine charge air channel and to charge
Nm 3
1002-02B air cooler
BA09.41-P- Hose clamp, charge air channel as required charge air cooler to charge
Nm 3
1003-02B air cooler and to electronic accelerator actuator
CHARGE AIR COOLER
Engine 275,
Number Designation
285
BA09.41-P-1001-
Bolt, charge air cooler to cylinder head cover Nm 8
03A
BA09.41-P-1002- Bolt, pressure sensor in front of throttle valve actuator to
Nm 6
03A bracket
REPAIR MATERIALS
Number Designation Order number
Adolf Wurth GmbH & Co. KG
Reinhold-Wurth-Str. 12-17
74653 Kunzelsau-Gaisbach
BR00.45-Z-1028-04A Cleaner from package Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
REMOVE/INSTALL CIRCULATION PUMP FOR LOW-TEMPERATURE WATER CIRCUIT -
AR09.41-P-6925LA
ENGINE 275 in MODEL 215, 216, 220, 221
Shown on model 220
Fig. 32: Identifying Charge Air Cooler Circulation Pump Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not open cooling system unless
coolant temperature is below 90°C. Open
Risk of injury to skin and eyes caused
cap slowly and release the pressure. Do
by scalding from contact with hot AS20.00-Z-
not pour coolant into beverage
coolant spray. Risk of poisoning caused 0001-01A
containers.
by swallowing coolant.
Wear protective gloves, protective
clothing and safety glasses.
AR61.20-P-
Model 215, 220
1105M
AR61.20-P-
Model 216
Remove lower engine compartment 1105SX
1
paneling Model 221 without code (Z07) Top
protection
Model 221 with code (Z07) Top AR61.20-P-
protection 1105SXS
Drain coolant out of low temperature AR20.00-P-
2
water circuit 1142HM
3 Pull off pneumatic hose (1)
Pull off electrical plug connector (2) on
4 circulation pump for the charge air
cooler (M44)
*BA09.41-P-
5 Unscrew bolt (3) and remove clamp (4)
1003-01G
Remove hoses (5, 6) on circulation
6
pump for charge air cooler (M44)
Remove circulation pump for charge air *BA09.41-P-
7
cooler (M44) 1004-01G
8 Install in the reverse order
Venting air from low temperature AR20.00-P-
9
circuit 1145H
AR20.00-P-
10 Inspect cooling system for leaks
1010HN
CHARGE AIR PIPE/CHARGE AIR COOLING
Number Designation Engine 275, 285
BA09.41-P-1003-01G Bolt, pump for low-temperature water circuit to bracket Nm 5
BA09.41-P-1004-01G Hose clamps to pump for low-temperature water circuit Nm 3
REMOVE/INSTALL LOW TEMPERATURE WATER CIRCUIT RADIATOR - AR09.41-P-6935SXM
ENGINE 275.982 in MODEL 216.379, 221.179
Fig. 33: Identifying Low Temperature Water Circuit Radiator Components
Courtesy of MERCEDES-BENZ USA
Remove/install
the power steering are integrated into one
component
AR18.30-
1 Remove engine oil cooler (3)
P-1000SX
AR20.00-
2 Drain coolant from low temperature circuit
P-1142HM
Installation: Check
Detach coolant hoses (6) at the low-temperature condition of coolant hoses (6)
3 and replace if necessary. Ensure
cooler (1)
coolant hoses are fitted
correctly.
Extract oil from power steering expansion
4 Fig. 34
reservoir
Remove oil pressure lines (4) from power steering Plug openings
5
cooler (7) Fig. 9
Remove nuts (5) and low-temperature cooler (1)
6
from condenser (2)
Unhook low-temperature cooler (1) from
7
condenser (2) and remove
8 Install in the reverse order
AR20.00-
9 Bleed low temperature circuit
P-1145H
AR20.00-
10 Inspect cooling system for leaks
P-1010HN
AR46.30-
11 Fill power steering pump and bleed
P-0010SX
Checking
Risk of accident caused by vehicle starting off by Secure vehicle to prevent it from
itself when engine is running. Risk of injury moving by itself.
AS00.00-Z-
caused by contusions and burns during starting Wear closed and snug-fitting
0005-01A
procedure or when working near the engine as it is work clothes. Do not touch hot
running or rotating parts.
Carry out visual inspection for leaks when engine
12
is running
Fig. 34: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
Fig. 35: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL LOW TEMPERATURE WATER CIRCUIT RADIATOR - AR09.41-P-6935SZ
ENGINE 275 (except 275.982) in MODEL 216, 221
Fig. 36: Identifying Low Temperature Water Circuit Radiator Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove right engine intake air duct upstream of
1
left air filter
2 Remove expansion clip (7) from engine radiator
Model 216
3 Remove radiator grille from bumper Installation: First install
radiator paneling in bumper.
4 Remove right air ducting (6)
Vehicles without top AR61.20-P-
Remove front section of lower engine protection 1105SX
5
compartment paneling Vehicles with code Z07 Top AR61.20-P-
protection 1105SXS
Remove front section of fender liner in right front
6
fender
AR18.30-P-
7 Loosen oil cooler and secure with cable tie Model 221.176, 216.376
1000SZ
8 Remove lower air ducting (5)
AR20.00-P-
9 Drain coolant from low temperature circuit
1142HM
Remove coolant hoses (9r, 9z) on low-
10 temperature cooler (9) with hose clamp pliers
with Bowden cable
Press bracket (9h) upwards and unclip low
11
temperature cooler (9) from engine radiator
Unhook low temperature cooler (9) from engine
12 radiator and raise low temperature cooler (9)
somewhat
13 Take low temperature cooler (9) down and out
14 Install in the reverse order
AR20.00-P-
15 Bleed low temperature circuit
1145H
AR20.00-P-
16 Inspect cooling system for leaks
1010HN
REMOVE/INSTALL ENGINE CHARGE AIR DUCT UPSTREAM OF CHARGE AIR COOLER -
AR09.41-P-8623H
ENGINES 275 in MODEL 215, 216, 220, 221, 230
ENGINES 285 in MODEL 240
Fig. 37: Identifying Engine Charge Air Duct Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR01.10-P-
Engine 275.98
2405IM
1 Remove engine trim panel
Engine 275.95, 285
2405LA
Model 215, 216, 220, 221, 230 without code AR09.10-P-
(P99) Special Model "AMG Black Series" 1150LA
2 Remove air filter housing
AR09.10-P-
Model 240
1150H
Tighten hose clamps (1) using the prescribed
torque so that charge air cooler (6) can separate
Release hose clamps (1) on from charge air ducts (7) in the event of an
3
charge air hoses (2) accident.
*BA09.41-P-
1002-02B
Tighten hose clamps (3) using the prescribed
torque so that charge air cooler (6) can separate
Loosen hose clamps (3) at
from charge air ducts (4) in the event of an
4 charge air duct (4) downstream
accident.
of charge air cooler (6)
*BA09.41-P-
1003-02B
Do not open the low temperature water
circuit.
5 Remove bolts (5)
*BA09.41-P-
1001-01G
Pull charge air cooler (6) and
Do not damage coolant hoses running to
6 charge air hoses (2) out of
charge air ducts (7) charge air coolers (6).
*BA09.41-P-
7 Remove fork (8)
1001-02B
Remove charge air ducts (7)
8 upstream of charge air coolers
(6)
9 Install in the reverse order
CHARGE AIR DUCT
Engine 275,
Number Designation
285
BA09.41-P-
Bolt, charge air channel before charge air cooler to turbocharger Nm 8
1001-02B
BA09.41-P- Hose clamp, charge air hose to engine charge air channel and to charge
Nm 3
1002-02B air cooler
BA09.41-P- Hose clamp, charge air channel as required charge air cooler to charge
Nm 3
1003-02B air cooler and to electronic accelerator actuator
CHARGE AIR PIPE/CHARGE AIR COOLING
Number Designation Engine 275, 285
BA09.41-P-1001-01G Bolt, charge air cooler to cylinder head cover Nm 8
REMOVE/INSTALL CHARGE AIR DUCTS- AR09.41-P-8620MMB
ENGINE 157, 278 in MODEL 216, 221
Fig. 38: Identifying Charge Air Ducts Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being keep body parts and AS00.00-Z-0011-01A
pinched or crushed when removing, limbs well clear of
installing or aligning hoods, doors, trunk moving parts.
lids, liftgates or sliding roof.
1 Remove engine covers
2 Loosen clamp between The boot between upper
upper charge air duct charge air duct (1l, 1r) and
(1l, 1r) and air filter air filter housing remains on
housing (4) the air filter housing (4)
3 Loosen clamp between The boot between
upper charge air duct turbocharger and upper
(1l, 1r) and charge air duct (1l, 1r)
turbocharger remains on the upper air
duct (1l, 1r)
4 Remove bolt for upper *BA09.40-P-1008-01R
charge air duct (1l, 1r)
on cylinder head cover
5 Remove upper charge plug openings Fig. 40
air duct (1l, 1r)
6 Remove air filter
housing (4)
7 Remove engine oil Engine 157
cooling oil lines from Seal openings using stop
oil filter housing and plugs.
lay to the side outside Installation: replace
the working area sealing rings and clean
connection area of the oil
lines. Fig. 39
8 Loosen clamp between The boot between lower
lower charge air duct charge air duct (2l, 2r) and
(2l, 2r) and charge air charge air cooler (6)
cooler (6) remains on the charge air
cooler (6)
9 Loosen clamp between The boot between lower
lower charge air duct charge air duct (2l, 2r) and
(2l, 2r) and turbocharger remains on the
turbocharger turbocharger.
10.1 Remove bolts for right When removing the right *BA09.40-P-1008-01R
lower charge air duct lower charge air duct (2r)
(2r) from cylinder head
10.2 Remove bolts for left When removing the left *BA09.40-P-1008-01R
lower charge air duct lower charge air duct (2r)
(2l) from cylinder head
and oil filter housing
11 Remove lower charge Plug openings, Fig. 40
air duct (2l, 2r)
Checking
12 Check boot and rubber
seal for cracks or
damage and replace if
necessary
13 Check clamps for
damage and replace as
necessary.
14 Install in the reverse
order
Risk of accident caused by vehicle starting Secure vehicle to AS00.00-Z-0005-01A
off by itself when engine is running. Risk of prevent it from moving
injury caused by contusions and burns by itself. Wear closed
during starting procedure or when working and snug-fitting work
near the engine as it is running clothes. Do not touch hot
or rotating parts.
15 Carry out engine test
run, checking the
engine for proper
operation and leaks.
TURBOCHARGER
Number Designation Engine 157 Engine 278
BA09.40-P-1008- Bolt, charge air Nm 9 9
01R manifold to front
cover/oil filter
housing/ cylinder
head/ cylinder head
cover
Fig. 39: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 40: Identifying Set Of Protective Caps (001 589 02 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CHARGE AIR DUCT DOWNSTREAM OF CHARGE AIR COOLER - AR09.50-
P-8680H
ENGINES 275 in MODEL 215, 216, 220, 221, 230
ENGINES 285 in MODEL 240
Illustrated on model 240
Fig. 41: Identifying Charge Air Duct Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR01.10-P-
Engine 275.98
2405IM
1 Remove engine trim panel
AR01.10-P-
Engine 275.95, 285
2405LA
Model 215, 216, 220, 221, 230 without code AR09.10-P-
(P99) Special Model "AMG Black Series" 1150LA
2 Remove air filter housing
AR09.10-P-
Model 240
1150H
Tighten hose clamps (1) using the prescribed
torque so that charge air cooler (6) can separate
Release hose clamps (1) on from charge air ducts in the event of an
3
charge air hoses (2) accident.
*BA09.41-P-
1002-02B
Tighten hose clamps (3) using the prescribed
torque so that charge air cooler (6) can separate
Release hose clamps (3) on from charge air ducts (4) in the event of an
4
charge air duct (4) accident.
*BA09.41-P-
1003-02B
circuit.
5 Remove bolts (5) *BA09.41-P-
1001-01G
Lever charge air cooler (6) out Do not damage coolant hoses running to
6
of charge air hoses (2) charge air coolers (6).
Take charge air cooler (6) out of
7
charge air duct (4)
Remove charge air duct (4)
8 from throttle valve actuator
(M16/6) and take it out
9 Install in the reverse order
CHARGE AIR DUCT
Engine 275,
Number Designation
285
BA09.41-P- Hose clamp, charge air hose to engine charge air channel and to charge
Nm 3
1002-02B air cooler
BA09.41-P- Hose clamp, charge air channel as required charge air cooler to charge
Nm 3
1003-02B air cooler and to electronic accelerator actuator
CHARGE AIR PIPE/CHARGE AIR COOLING
Number Designation Engine 275, 285
BA09.41-P-1001-01G Bolt, charge air cooler to cylinder head cover Nm 8
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - BA09.00-Z-
9999AZ
MODEL all
BA09.10-P-1000-
Air cleaner ENGINE 611.960 /961 /962 /980
01B
BA09.10-P-1000-
Air filter ENGINE 642, 629, 642
01H
BA09.10-P-1000-
Air filter ENGINE 668.914 /940 /941 /942
01A
BA09.10-P-1000-
Air filter ENGINE 651
01K
BA09.10-P-1000-
Air filter ENGINE 646.8
01I
BA09.10-P-1000-
Air filter ENGINE 155.980, 275, 285.950
01E
BA09.10-P-1000-
Air filter ENGINE 640
01F
BA09.10-P-1000-
Air filter ENGINE 271
01C
BA09.10-P-1000-
Air filter ENGINE 157, 276, 278
01M
BA09.41-P-1000-
Boost pressure sensor ENGINE 646.8
04B
BA09.41-P-1000-
Charge air cooler ENGINE 275, 285
03A
BA09.41-P-1000-
Charge air duct ENGINE 271
02A
BA09.41-P-1000-
Charge air duct ENGINE 275, 285
02B
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 111.943 /944 /947 /973 /975
cooler 01B
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 112, 113.990 /991 /992 /993 /995, 155
cooling 01C
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 271
cooling 01D
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 628.960 /961 /962 /963
cooling 01H
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 642 /
cooling 01J
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 275, 285
cooling 01G
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 629
cooling 01M
Charge air pipe/charge air ENGINE 602, 605, 606, 611, 612, 613, 646, 647, BA09.41-P-1000-
cooling 648... 01A
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 651
cooling 01N
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 157, 278
cooling 01O
Charge air pipe/charge air BA09.41-P-1000-
ENGINE 640
cooling 01I
BA09.50-P-1000-
Compressor ENGINE 112, 113.990 /991 /992 /993 /995, 155
01B
BA09.50-P-1000-
Compressor ENGINE 271
01C
BA09.50-P-1000-
Compressor ENGINE 111
01A
BA09.20-P-1000-
Intake manifold ENGINE 629, 642 /
01Q
BA09.20-P-1000-
Intake manifold ENGINE 112 / /, 113 /
01D
BA09.20-P-1000-
Intake manifold ENGINE 159
01S
BA09.20-P-1000-
Intake manifold ENGINE 137
01G
BA09.20-P-1000-
Intake manifold ENGINE 266
01O
BA09.20-P-1000-
Intake manifold ENGINE 275, 285
01L
BA09.20-P-1000-
Intake manifold ENGINE 604, 605, 606 /, 611.960 /961 /980
01A
BA09.20-P-1000-
Intake manifold ENGINE 119, 120
01C
BA09.20-P-1000-
Intake manifold ENGINE 668.914 /940 /941 /942
01F
BA09.20-P-1000-
Intake manifold ENGINE 166.940 /960 /961 /990 /991 /995
01E
BA09.20-P-1000-
Intake manifold ENGINE 156
01R
BA09.20-P-1000-
Intake manifold ENGINE 272, 273 /
01N
BA09.20-P-1000-
Intake manifold ENGINE 640
01P
BA09.20-P-1000-
Intake manifold ENGINE 104 /, 111
01B
BA09.20-P-1000-
Intake manifold ENGINE 271
01I
BA09.20-P-1000-
Intake manifold ENGINE 276
01T
BA09.40-P-1000-
Turbocharger ENGINE 271.8
01Q
BA09.40-P-1000-
Turbocharger ENGINE 646.951 /961 /962 /963 /966, 647, 648
01E
BA09.40-P-1000-
Turbocharger ENGINE 157, 278
01R
BA09.40-P-1000-
Turbocharger ENGINE 628.960 /961 /962 /963, 629
01D
BA09.40-P-1000-
Turbocharger ENGINE 646.8
01N
BA09.40-P-1000-
Turbocharger ENGINE 275, 285
01H
BA09.40-P-1000-
Turbocharger ENGINE 602.982 /983, 605.960 /962, 606.961 /964
01A
BA09.40-P-1000-
Turbocharger ENGINE 642 /
01K
BA09.40-P-1000-
Turbocharger ENGINE 611, 612, 613, 647...
01C
BA09.40-P-1000-
Turbocharger ENGINE 668.914 /940 /941 /942
01B
BA09.40-P-1000-
Turbocharger ENGINE 640
01J
BA09.40-P-1000-
Turbocharger ENGINE 651
01P
AIR FILTER - BA09.10-P-1000-01E
Engine 155, 275, 285
AIR FILTER
Engine Engine 275,
Number Designation
155.980 285.950
BA09.10-P-1001-
Bolt air filter housing to bracket Nm - 8
01E
BA09.10-P-1002- Bolt of air filter housing top section to air filter
Nm 6 -
01E housing bottom section
INTAKE MANIFOLD - BA09.20-P-1000-01L
Engines 275, 285
INTAKE MANIFOLD
Number Designation Engine 275, 285
BA09.20-P-1001-01L Bolt, intake manifold to cylinder head M6 Nm 8
Stage 1 M6 Nm 8
BA09.20-P-1002-01L Bolt of throttle valve actuator to intake manifold
Stage 2 M6 Nm 8
INTAKE MANIFOLD - BA09.20-P-1000-01N
Engine 272, 273
INTAKE MANIFOLD
Engine Engine
Number Designation
272 273
BA09.20-P-1001-
Bolt of resonance intake manifold to cylinder head Nm 9 9
01N
BA09.20-P-1002- Bolt for tumble flap position sensor to resonance intake
Nm 6 6
01N manifold
INTAKE MANIFOLD - BA09.20-P-1000-01R
Engine 156
MODIFICATION NOTES
6.8.09 Value changed: Bolt, intake manifold to cylinder head
Value changed: Bolt, intake manifold to cylinder head
Value changed: Bolt, intake manifold to cylinder head
6.8.09 Value changed: Bolt, intake manifold to cylinder head
Value changed: Bolt, intake manifold to cylinder head
Value changed: Bolt, intake manifold to cylinder head
6.8.09 Value changed: Bolt, intake manifold to cylinder head
Value changed: Bolt, intake manifold to cylinder head
Value changed: Bolt, intake manifold to cylinder head
6.8.09 Value changed: Bolt, intake manifold to cylinder head
Value changed: Bolt, intake manifold to cylinder head
Value changed: Bolt, intake manifold to cylinder head
INTAKE MANIFOLD
Number Designation Engine 156
BA09.20-P-1001-01R Bolt, pressure sensor/fuel to fuel distributor Nm 5
Stage 1 Nm 10
BA09.20-P-1002-01R Bolt, intake manifold to cylinder head Stage 2 Angle° 90
Stage 3 Angle° 10
M6 Nm 6.5
BA09.20-P-1003-01R Bolt, reservoir to crankcase
M8 Nm 20
Initial installation Nm 9
BA09.20-P-1004-01R Bolt, collector to intake manifold
Follow-up operations Nm 7
TURBOCHARGER - BA09.40-P-1000-01H
Engine 275, 285
TURBOCHARGER
Engine Engine
Number Designation
275 285
BA09.40-P-1001-
Coolant line to cylinder head Nm 9 -
01H
Bolt, oil feed line to turbocharger Nm 8 8
01H
BA09.40-P-1003-
Bolt, coolant return flow line to turbocharger Nm 8 8
01H
BA09.40-P-1004-
Bolt, oil return flow line to turbocharger Nm 8 8
01H
BA09.40-P-1005-
Bolt connecting coolant feed line to turbocharger Nm 8 8
01H
BA09.40-P-1006-
Bolt, oil return flow line to crankcase Nm 8 8
01H
BA09.40-P-1007-
Banjo bolt, coolant feed line to crankcase Nm 25 -
01H
BA09.40-P-1008- Connection of turbocharger to front catalytic
Nm 7 -
01H converter
BA09.40-P-1009-
Bolt, support to turbocharger Nm 30 30
01H
BA09.40-P-1010-
Bolt, turbocharger support to crankcase Nm 20 20
01H
BA09.40-P-1011-
Exhaust manifold to cylinder head Nm 15 -
01H
BA09.40-P-1012-
Shield to turbocharger Nm 9 -
01H
BA09.40-P-1013-
Banjo bolt of coolant feed line to crankcase Nm - 25
01H
BA09.40-P-1014-
Bolt of deceleration air valve to turbocharger Nm 7 -
01H
BA09.40-P-1015-
Bolt, oil feed line to cylinder head Nm 8 -
01H
CHARGE AIR PIPE/CHARGE AIR COOLING - BA09.41-P-1000-01G
Engines 275, 285
CHARGE AIR PIPE/CHARGE AIR COOLING
Engine 275,
Number Designation
285
BA09.41-P-
Bolt, charge air cooler to cylinder head cover Nm 8
1001-01G
BA09.41-P-
Bolt, filler neck for low temperature water circuit to bracket Nm 8
1002-01G
BA09.41-P-
Bolt, pump for low temperature water circuit to bracket Nm 5
1003-01G
BA09.41-P-
Hose clamps at pump for low temperature water circuit Nm 3
1004-01G
1005-01G Bolt, cable duct to charge air distribution pipe Nm 8
BA09.41-P-
Bolt, ground line to charge air distribution pipe Nm 8
1006-01G
BA09.41-P- Bolt, connecting pipe bracket for low temperature water circuit to
Nm 8
1007-01G cylinder head cover
BA09.41-P- Bolt, connecting pipe bracket for low temperature water circuit to
Nm 8
1008-01G connecting pipe for low temperature water circuit
CHARGE AIR DUCT - BA09.41-P-1000-02B
Engines 275, 285
CHARGE AIR DUCT
Engine 275,
Number Designation
285
BA09.41-P-
Bolt, charge air channel before charge air cooler to turbocharger Nm 8
1001-02B
BA09.41-P- Hose clamp, charge air hose to engine charge air channel and to charge
Nm 3
1002-02B air cooler
BA09.41-P- Hose clamp, charge air channel as required charge air cooler to charge
Nm 3
1003-02B air cooler and to electronic accelerator actuator
BA09.41-P- Bolt connecting charge air duct downstream of charge air cooler to
Nm -
1004-02B pressure damper
CHARGE AIR COOLER - BA09.41-P-1000-03A
Engines 275, 285
CHARGE AIR COOLER
Engine 275,
Number Designation
285
BA09.41-P-1001-
Bolt charge air cooler to cylinder head cover Nm 8
03A
BA09.41-P-1002- Bolt of pressure sensor in front of throttle valve actuator at
Nm 6
03A bracket
BA09.41-P-1003-
Bolt of radiator of low temperature circuit to condenser Nm 5
03A
BA09.41-P-1004-
Bolt cooler for low temperature cooling circuit to radiator Nm 5
03A
BA09.41-P-1005-
Nut of condenser to radiator low temperature circuit Nm 5
03A
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: AIR INTAKE, SUPERCHARGING -
BE09.00-Z-9999AZ
MODEL all
Electromagnetic clutch ENGINE 111, 112.960 /961, 113.990 /991 /992 /995 BE09.50-P-1000-01A
Turbocharger ENGINE 603 / BE09.40-P-1000-01A
BASIC KNOWLEDGE
TURBOCHARGING, FUNCTION - GF09.00-P-2000M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 42: Turbocharging Function Diagram
Courtesy of MERCEDES-BENZ USA
For exhaust-gas turbocharging the flow kinetic energy of the exhaust gases coming out of each cylinder bank is
used to drive the turbocharger (110a, 110b). The turbochargers take in clean air downstream of the air filters.
The compressed air (E) is cooled in the charge air cooler (5/1, 5/2).
Downstream of the charge air coolers, the combined charge air (E) from the right and left turbochargers flows
to the intake manifold (12) via the throttle valve actuator (M16/6).
There is a coolant cooled turbocharger (biturbo) installed in every cylinder bank. An optimal response
characteristic and a resulting high boost pressure are achieved even at low RPM speeds by installing the
turbochargers immediately on the exhaust manifolds. Short exhaust gas paths guarantee fast warm up and thus a
high efficiency of the three way catalytic converters.
The turbochargers start to produce boost pressure at approx. 1500 RPM. The maximum boost pressure is
reached at approx. 2000 RPM. Injection quantity and ignition timing are controlled by the ME-SFI [ME] control
unit (N3/10) as needed for the present load condition.
The boost pressure is measured through the signal of the pressure sensor upstream of the throttle valve actuator
(B28/6), the load is measured through the signal of the pressure sensor downstream of the throttle valve actuator
(B28/7).
Boost pressure control of both turbochargers is performed by means of the boost pressure control pressure
transducer (Y31/5) and the pressure regulator valves (wastgate valves) operated by the vacuum cells in the
turbine housings.
Additionally, fast control operations and load adjustments below the basic charge pressure are performed via the
throttle valve actuator.
The maximum boost pressure at sea level is:
For engine 275.950/951/953/954 approx. 0.9 bar
For engine 285.950 about 1.3 bar
For engine 275.980/981/982, 285.980 (AMG) about 1.5 bar.
The cooled air downstream of the charge air coolers has a higher density. Through this, the cylinder charge and
hence the engine output are increased. Furthermore the tendency to knock is reduced. The maximum boost
pressure is released only when the charge air temperature is less than 70°C. The charge air temperature sensor
(B17/8) is mounted at the intake manifold.
If the charge air temperature becomes too high, the reason for this could be air bubbles in the low temperature
cooling circuit.
During a load change, e.g. when changing into deceleration mode, a deceleration air valve opens at each
compressor housing.
Through this the boost pressure is quickly reduced and charger noises are prevented.
A pressure sensor downstream of air filter for the left or right cylinder bank (B28/4, B28/5) is located in the air
filter housing after every air filter in order to recognize the pressure drop over the air filter.
In order to limit the maximum charger RPM the pressure conditions downstream and upstream of the
turbocharger is calculated (based on pressure values for the pressure sensor downstream of air filter and
pressure sensor upstream of throttle valve actuator (B28/6)) and regulated dependent on the performance map
by the boost pressure control.
In higher altitudes the maximum boost pressure is limited.
Boost pressure control, function GF09.40-P-3000M
Divert air actuation, function GF09.40-P-3002M
Charge air cooling system, function GF09.41-P-3104M
ME-SFI pneumatic diagrams PP07.61-P-5000M
COMPONENT DESCRIPTION FOR THE VARIABLE INTAKE MANIFOLD SWITCHOVER
VALVE - GF09.20-P-6001AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211, 219
ENGINE 156.984 in MODEL 216, 221 up to Model Year 8
Location
The switchover valve is mounted at the front of variable intake manifold.
Fig. 43: Locating Variable Intake Manifold Switchover Valve
Courtesy of MERCEDES-BENZ USA
Task
The switchover valve applies vacuum to variable intake manifold vacuum unit to intake manifold switchover
(long intake routes) or ventilates it again (short intake routes).
Design
The switchover valve is an electromagnetic switchover valve which is cast in a plastic housing.
The coil resistance about 30 ohms at 20°C.
Function
Fig. 44: Switchover Valve Function Diagram
Courtesy of MERCEDES-BENZ USA
The switchover valve is actuated by the ME-SFI control unit (N3/10) from the ground side via its own output
stage. The voltage supply takes place from "circuit 87 M2e".
In an activate condition a valve plate is pulled by solenoids and a rubber seal closes the connection (3). The
connection between the connection (2) and connection (1) is released in this way and the vacuum from the
vacuum reservoir is built up to the vacuum unit.
In the deenergized state the link again exists between connection 2 and 3 through which Connection 1 is
supplied with air again.
COMPONENT DESCRIPTION FOR THE VARIABLE INTAKE MANIFOLD SWITCHOVER
VALVE - GF09.20-P-6001V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.942 in MODEL 171 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.960 in MODEL 203 up to Model Year 8
ENGINE 272.963 in MODEL 171 up to Model Year 8
ENGINE 272.964 in MODEL 211, 219
ENGINE 272.965 in MODEL 221 up to Model Year 8
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.972 in MODEL 211
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 272.985 in MODEL 211, 219
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.923 in MODEL 164 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Shown on engine 272.963
Fig. 45: Locating Variable Intake Manifold Switchover Valve
Courtesy of MERCEDES-BENZ USA
Location
The variable intake manifold switchover valve is mounted at the front of the variable intake manifold.
Task
Pressurize intake manifold switchover aneroid capsules with vacuum or admitting air.
Design
Electromagnetic switchover valve in the plastic housing, coil resistance approx. 30. Ventilation via cap.
Shown on engine 272.963
Fig. 46: Variable Intake Manifold Switchover Valve Function Diagram
Courtesy of MERCEDES-BENZ USA
Function
The variable intake manifold switchover valve is actuated on the earth side by the engine control unit through
its own output stage. The voltage is supplied through circuit 87.
A valve plate operated by a coil armature shifts between atmosphere and vacuum storage.
COMPONENT DESCRIPTION FOR THE VARIABLE INTAKE MANIFOLD - GF09.20-P-6002AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211, 219
ENGINE 156.984 in MODEL 216, 221 up to Model Year 8
Location
The variable intake manifold is located in the middle between the cylinder heads.
Fig. 47: Locating Variable Intake Manifold
Courtesy of MERCEDES-BENZ USA
Task
Switching between long and short intake routes can occur with the variable intake manifold. The vibration
response of the intake air for different operating conditions is used in a specific way to achieve internal
charging.
The variable intake pipe lengths also allows better distribution of the mixture which leads to better combustion
and thus to a higher engine torque.
External structure
Fig. 48: Variable Intake Manifold External Structure
Courtesy of MERCEDES-BENZ USA
Internal structure
Fig. 49: Identifying Throttle Valves, Variable Flaps And Air Guide Duct
Courtesy of MERCEDES-BENZ USA
The variable intake manifold consists of a number of magnesium pressure castings. When fitted together, they
produce the individual intake manifolds and the air collecting volume. The parts are sealed off to each other by
plastic.
The variable intake manifold must not be disassembled down to the housing bottom section and the throttle
valve actuator.
Function
Short intake routes (Switch flaps opened)
Fig. 50: Variable Intake Manifold Routes Diagram (Switch Flaps Opened)
Courtesy of MERCEDES-BENZ USA
Short intake routes improve the engine torque at low rotational speeds and low loads. Short intake routes also
achievement of high motor speeds.
The variable intake manifold switchover valve is de-energized and the aneroid capsule is ventilated. The switch
flaps are or will be opened through the spring force of the vacuum unit via the gearshift linkage and releases the
short intake routes.
The switch flap shafts of the right and left cylinder head are connected at the rear in the variable intake manifold
via a further gearshift linkage.
Long intake routes (Switch flaps closed)
Fig. 51: Variable Intake Manifold Routes Diagram (Switch Flaps Closed)
Courtesy of MERCEDES-BENZ USA
Long intake routes improve the engine torque at low rotational speeds and high loads.
The variable intake manifold switchover valve is actuated at the ground end from the ME-SFI [ME] control unit
(N3/10) and switches off the vacuum from the vacuum reservoir through to the vacuum unit. The aneroid
capsule actuates the gearshift linkage of the switch flap shafts and the switch flaps close the short intake routes.
INTAKE MANIFOLD COMPONENT DESCRIPTION - GF09.20-P-6010V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.942 in MODEL 171 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.963 in MODEL 171 up to Model Year 8
ENGINE 272.964 in MODEL 211, 219
ENGINE 272.965 in MODEL 221 up to Model Year 8
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.970 in MODEL 203 up to Model Year 8
ENGINE 272.972 in MODEL 211
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.923 in MODEL 164 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Shown on ENGINE 272
Fig. 52: Identifying Intake Manifold Components
Courtesy of MERCEDES-BENZ USA
Location
The intake manifold is located between the cylinder banks.
Task
Optimizes engine torque curve by means of two different intake manifold lengths
Improves flow via swing-out tumble flaps in the intake port.
Design
The intake manifold is assembled out of several magnesium pressure castings. During assembly, the individual
intake manifolds for each cylinder and the air manifold collecting sections are in the center. The intake manifold
cannot be disassembled. A total of four shafts are stored in the intake manifold.
The vacuum pressure for the aneroid capsules is supplied by a vacuum reservoir in the intake manifold when the
switchover valves are actuated. The reservoir volume is designed for several operations without renewed
evacuation.
Shown on ENGINE 272
Fig. 53: Identifying Intake Manifold Components (Engine 272)
Courtesy of MERCEDES-BENZ USA
Shown on ENGINE 273
Fig. 54: Identifying Intake Manifold Components (Engine 273)
Courtesy of MERCEDES-BENZ USA
Intake manifold switchover, function
The individual intake manifolds each approx. 800 mm long, are arranged in a spiral shape around the air
collecting volume. Each single intake manifold has a further opening to the air collecting volume somewhere in
the middle. These can be opened or closed by rotating longitudinal switch flap shafts. The switch flaps of a
cylinder bank are interconnected by a shaft and each of the flap is actuated by an aneroid capsule in case of
engine 272 BOTH aneroid capsules for the intake manifold switchover are connected to the variable intake
manifold switchover valve via hose pipes. Engine 273 has only one aneroid capsule. The flap shafts are
connected in the intake manifold. The switch flaps open by spring force without actuation and enable the short
suction way.
Cut at intake manifold at cylinder level, short intake route
Fig. 55: Identifying Intake Air Short Intake Route
Courtesy of MERCEDES-BENZ USA
At higher speeds (from approx. 3500/min) the intake manifold switchover aneroid capsules are ventilated and
the switch flaps opened by the spring force. The intake air takes the short intake route.
Cut at intake manifold at cylinder level, long intake route
At lower speed (up to approx. 3500/min) the intake manifold aneroid capsules are pressurized with vacuum
pressure and the longitudinal switch flaps closed. The intake air takes the long intake route. The result is
improved cylinder charge and thus an increase in torque.
Fig. 56: Identifying Intake Air Long Intake Route
Courtesy of MERCEDES-BENZ USA
Tumble flap switchover function
At partial load, tumble flaps can be fully swung out in each cylinder intake port in the intake manifold. This
closes the intake manifold by around 50 %.
The flow speed of the intake air is increased and allows for improved distribution of the fuel/air mixture in the
combustion chamber. The tumble flaps are actuated via an aneroid capsule and linkage.
BOOST PRESSURE CONTROL, FUNCTION - GF09.40-P-3000M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 57: Boost Pressure Control Function Diagram
Courtesy of MERCEDES-BENZ USA
The ME-SFI [ME] control unit actuates the boost pressure control pressure transducer for the boost pressure
control by means of pulse width modulation with a duty cycle of 5 to 95% and with a frequency of 30 Hz.
According to the duty cycle, the boost pressure operates fully or partially in the vacuum cells of the
turbocharger.
The boost pressure control valves (wastegate valves) are actuated via vacuum cells and control rods. For
limitation of the boost pressure, the boost pressure control valves open and part of the exhaust is guided past the
turbine wheel.
The boost pressure is calculated based on the pressure conditions downstream and upstream of the
turbochargers (based on the pressure values of the pressure sensor downstream of air filter and pressure sensor
upstream of throttle valve actuator).
The boost pressure control is performed in line with the performance map.
Identification of the load (dependent on throttle valve angle) is performed through the signal of the pressure
sensor downstream of throttle valve actuator.
Boost pressure control shown on a turbocharger Duty cycle (t i) on boost pressure control pressure
Fig. 58: Duty Cycle Of Boost Pressure Control Pressure Transducer <5%
Courtesy of MERCEDES-BENZ USA
Without actuation, the entire boost pressure in the vacuum cell is used. The boost pressure control valve opens
at approx. 300 mbar boost pressure (mechanical basic boost pressure). The boost pressure does not increase
further and power shortage is the consequence.
Boost pressure control shown on a turbocharger Duty cycle (t i) on boost pressure control pressure
transducer >5%
Fig. 59: Duty Cycle Of Boost Pressure Control Pressure Transducer >5%
Courtesy of MERCEDES-BENZ USA
The vacuum cell is vented to the atmosphere so that no boost pressure can act anymore in the vacuum cell. In
unpressurized condition, a spring holds the boost pressure control valve closed in the vacuum cell. The whole
exhaust gas drives the turbine wheel and the maximum boost pressure is generated.
If the hose lines between the vacuum cells, pressure transducer and charge air cooler on the right cylinder
bank are leaky the fault "Boost pressure too high" is stored in the ME-SFI [ME] control unit.
The input parameters for the boost pressure control are:
Pressure values of pressure sensor downstream of air filter
Pressure values from pressure sensor upstream of throttle valve actuator
Charge air temperature, signal from charge air temperature sensor
Load recognition from pressure sensor downstream of throttle valve actuator
Ambient pressure (altitude correction), signal from pressure sensor in ME-SFI [ME] control unit
Engine speed
Coolant temperature
Engaged drive mode
Engine oil temperature
Pressure drop in air filter, detection by pressure sensor downstream of air filter
Exhaust gas temperature (from model calculation/performance map)
Knock control active (maximum boost pressure only possible with RON 98)
Catalytic converter damaging misfire recognized/not recognized
The maximum boost pressure is only released via the signal from the charge air temperature sensor, if the
charge air temperature is less than < 70°C.
If the charge air temperature becomes too high, the reason for this could be air bubbles in the low
temperature cooling circuit.
In order to protect the exhaust gas turbochargers from overspeed when in altitude mode and in case of soiled air
filters, the maximum boost pressure is limited pressure conditions upstream/downstream of the turbochargers.
Further to the boost pressure control it is possible under certain conditions (e.g. for an excessively high boost
pressure due to leaky lines to the vacuum cell) for load limiting to take place through closing of the throttle
valve.
The function of the boost pressure control can only be evaluated if the message "Boost pressure control
adapted" is read out using the DAS. After replacing the ME-SFI [ME] control unit or a turbocharger is a long
drive under certain operating conditions is required to perform the adaptation.
GF07.61-P-
ME-SFI control unit, location/task/design/function
5000M
GF07.17-P-
Boost pressure control pressure transducer, location/task/design/function
3160M
GF07.04-P-
Pressure sensor upstream of throttle valve actuator, location/task/function
5048M
Pressure sensor downstream of throttle valve actuator, GF07.04-P-
location/task/function 5049M
GF07.04-P-
Charge air temperature sensor, location/task/function
5038M
GF09.40-P-
Turbocharger, location/task/function
3100M
GF07.04-P-
Pressure sensor downstream of air filter, location/task/function
5041M
ME-SFI pneumatic diagrams PP07.61-P-5000M
BOOST PRESSURE CONTROL, FUNCTION - GF09.40-P-3000MOS
ENGINE 275.953 in MODEL 216.376, 221.176 as of Model Year 09 /AEJ 08
ENGINE 275.982 in MODEL 216.379, 221.179 as of Model Year 09 /AEJ 08
Boost pressure control function requirements - general
Circuit 87M ON (engine control ON)
Engine running
Boost pressure control - general
Cylinder filling efficiency is improved by forced induction. This raises the engine torque and engine power.
One turbocharger is installed for each cylinder bank (Biturbo). An optimal response characteristic and a
resulting high boost pressure are achieved even at low RPM speeds by installing the turbochargers immediately
on the exhaust manifolds.
With forced induction, the flow energy of the exhaust gases is used to drive the turbocharger.
The turbochargers draw fresh air through the air filters into the compressor inlets, from where it passes through
the compressor outlets to the charge air pipes upstream of the charge air coolers. Due to the high rotational
speed of the compressor impellers and the resulting high volume flow rate, the intake air becomes compressed
in the charge air pipes.
As the charge air is compressed, it heats up, and flows through the charge air pipes to the charge air coolers.
These cool the charge air down and guide it through the Y-connection pipe and the throttle valve actuator
(M16/6) to the intake manifold.
The turbochargers start to produce boost pressure at approx. 1500 RPM. The maximum boost pressure is
reached at approx. 2000 RPM.
The maximum boost pressure is about 0.9 on engine 275.953 and about 1.5 bar on engine 275.982 (AMG).
View of charge air path
Fig. 60: View Of Charge Air Path
Courtesy of MERCEDES-BENZ USA
For the boost pressure control, the ME-SFI control unit (N3/10) reads the following sensors and signals:
Coolant temperature sensor (B11/4)
Charge air temperature sensor (B17/8)
Pressure sensor downstream of air filter, LH and RH cylinder bank (B28/4, B28/5), intake air pressure
Pressure sensor upstream of throttle valve actuator (B28/6), boost pressure
Pressure sensor downstream of throttle valve actuator (B28/7), engine load
Accelerator pedal sensor (B37), load request by driver
Oil sensor (oil level, temperature and grade) (B40), engine oil temperature
Crankshaft position sensor (L5), motor speed
ETC control unit (N15/3), gear range over the drive train CAN (CAN C)
Atmospheric air pressure sensor in the ME-SFI control unit, altitude adaptation (maximum boost pressure
is limited at high altitudes)
Exhaust gas temperature (from model calculation/performance map)
Fuel grade (maximum boost pressure only for RON 98 (R esearch - O ctane N umber))
The boost pressure control also depends on the safety functions of the engine control (for example, knock
control and overheating/knock protection).
Boost pressure control function sequence
The boost pressure is controlled electropneumatically by the boost pressure control pressure transducer (Y31/5),
which is actuated by the ME-SFI control unit.
Depending on the performance map and load, the ME-SFI control unit actuates the pressure transducer with a
PWM (pulse width modulated) signal with a duty cycle of 5 to 95 %. Depending on the duty cycle, the boost
pressure from the charge air cooler of the RH cylinder bank acts totally or partially on the vacuum cells (boost
pressure control flaps). Through a linkage, these open the boost pressure control flaps, which close off the
bypasses. The boost pressure control flaps thus allow the exhaust flow to bypass the turbine wheels, and in this
way control the boost pressure and limit the turbine speed.
To monitor the current boost pressure, the pressure sensor upstream of the throttle valve actuator sends the
corresponding voltage signal to the ME-SFI control unit.
Die pressure sensors downstream of the air filter of the LH and RH cylinder banks, which are located in the
intake lines upstream of the turbocharger, are used by the ME-SFI control unit to monitor the charging process
(pressure drop through the air filter).
The charge air temperature is detected in the intake manifold by the charge air temperature sensor and sent to
the ME-SFI control unit as a voltage signal. The maximum boost pressure is enabled only at charge air
temperatures less than 70°C.
Engine load is detected (according to the throttle valve angle) using the voltage signal from the pressure sensor
downstream of the throttle valve actuator.
Diagnosis
The boost pressure control function can only be assessed when the "boost pressure control adapted" message is
displayed with the Diagnosis Assistance System (DAS). If the ME-SFI control unit or one of the turbochargers
is replaced, a longer driving distance is required in certain operating conditions, in order to allow the ME-SFI
control unit to perform the adaptation.
Diagnosis
If the hose lines are leaky between the vacuum cells, boost pressure control pressure transducer and charge air
cooler of the RH cylinder bank, a "boost pressure too high" fault is stored in the ME-SFI control unit.
Fast load requests below the basic boost pressure are controlled by the throttle valve actuator.
Boost pressure control shown with a duty cycle of (t i ) <5 %
Without actuation, the entire boost pressure in the vacuum cell is used. The vacuum cell opens boost pressure
control flap at about 300 mbar boost pressure (mechanical basic boost pressure). The boost pressure no longer
rises, and a condition restriction results.
Fig. 61: Duty Cycle Of Boost Pressure Control <5%
Courtesy of MERCEDES-BENZ USA
Boost pressure control shown with a duty cycle of (t i ) >5 %
Fig. 62: Duty Cycle Of Boost Pressure Control >5%
Courtesy of MERCEDES-BENZ USA
The vacuum cell is ventilated to atmospheric pressure, so that no boost pressure is then acting on the vacuum
cell. In the unpressurized state, the spring in the vacuum cell holds the boost pressure control flap closed. All of
the exhaust gas drives the turbine wheel, thus generating the maximum boost pressure.
Model 216 PE09.40-P-2050-97CAA
Electrical function schematic for boost pressure control
Model 221 PE09.40-P-2050-97SAA
ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MOS
ACTUATION DIVERT AIR, FUNCTION - GF09.40-P-3002
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 63: Actuation Divert Air Function Diagram
Courtesy of MERCEDES-BENZ USA
Fig. 64: Identifying Vacuum Reservoir
Courtesy of MERCEDES-BENZ USA
Fig. 65: Identifying Charge Air Cooler, Right Cylinder Bank And Test Connection For Divert Air
Courtesy of MERCEDES-BENZ USA
Function
If the engine control unit identifies the transition from load to deceleration operation, the switchover valve
deceleration switchover (Y101) is actuated. Through this both deceleration air valves at the turbochargers are
discharged with vacuum from the vacuum tank (22). The deceleration air valves open a bypass around the
individual compressor turbine wheel, through which the boost pressure is immediately removed. Charger noises
(brief howling) during transition into the deceleration mode cannot result from pressure points in the charger.
The turbochargers rotate a little, by means of the inertia of masses of shaft, the compressor and the turbine
wheel after start of deceleration and create against the closed throttle valve briefly further boost pressure. This
pressure is quickly released through the deceleration air valves.
Without actuation at the switchover valve deceleration switchover the diaphragm chambers of the deceleration
air valves are connected with the intake manifold. The deceleration air valves close in load operation through
the boost pressure and the spring load. If a deceleration air valve does not close, less boost pressure is released.
In the vacuum tank vacuum is gathered in the suction operation of the engine and in the deceleration. The check
valve opens only at vacuum.
ME-SFI control unit, location/task/design/function GF07.61-P-5000M
Accelerator pedal sensor, location/task/design/function GF30.20-P-4010M
Divert air switchover valve location/task/structure/function GF07.05-P-3104M
Turbocharger, location/task/function GF09.40-P-3100M
ME-SFI pneumatic diagrams PP07.61-P-5000M
ACTUATION DIVERT AIR, FUNCTION - GF09.40-P-3002M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 66: Actuation Divert Air Function Diagram
Courtesy of MERCEDES-BENZ USA
Fig. 67: Identifying Vacuum Reservoir
Courtesy of MERCEDES-BENZ USA
Fig. 68: Identifying Charge Air Cooler, Right Cylinder Bank And Test Connection For Divert Air
Courtesy of MERCEDES-BENZ USA
Function
If the engine control unit identifies the transition from load to deceleration operation, the switchover valve
deceleration switchover (Y101) is actuated. Through this both deceleration air valves at the turbochargers are
discharged with vacuum from the vacuum tank (22). The deceleration air valves open a bypass around the
individual compressor turbine wheel, through which the boost pressure is immediately removed. Charger noises
(brief howling) during transition into the deceleration mode cannot result from pressure points in the charger.
The turbochargers rotate a little, by means of the inertia of masses of shaft, the compressor and the turbine
wheel after start of deceleration and create against the closed throttle valve briefly further boost pressure. This
pressure is quickly released through the deceleration air valves.
Without actuation at the switchover valve deceleration switchover the diaphragm chambers of the deceleration
air valves are connected with the intake manifold. The deceleration air valves close in load operation through
the boost pressure and the spring load. If a deceleration air valve does not close, less boost pressure is released.
In the vacuum tank vacuum is gathered in the suction operation of the engine and in the deceleration. The check
valve opens only at vacuum.
ME-SFI control unit, location/task/design/function GF07.61-P-5000M
Accelerator pedal sensor, location/task/design/function GF30.20-P-4010M
Divert air switchover valve location/task/structure/function GF07.05-P-3104M
Turbocharger, location/task/function GF09.40-P-3100M
ME-SFI pneumatic diagrams PP07.61-P-5000M
ENGINE 275.953 in MODEL 216.376, 221.176 as of Model Year 09 /AEJ 08
ENGINE 275.982 in MODEL 216.379, 221.179 as of Model Year 09 /AEJ 08
Acceleration air function requirements - general
Circuit 87M ON (engine control ON)
Engine running
Deceleration air - general
At the start of deceleration, the turbochargers continue to turn for a little time due to the mass inertia of the
shafts, compressor and turbine wheels, and generate more boost pressure against the closed throttle valve.
Pressure peaks (brief howling) in the turbochargers are prevented by the deceleration air switchover valve
(Y101).
Deceleration air function sequence
If the ME-SFI control unit (N3/10) detects the transition from load to deceleration mode on the signals from the
accelerator pedal sensor (B37), the deceleration mode switchover valve is actuated with a ground signal.
This causes the two deceleration air valves at the turbochargers to be charged with vacuum from the vacuum
reservoir. The deceleration air valves open a bypass (around the related compressor impeller), causing the boost
pressure to drop immediately.
When the deceleration air switchover valve is not actuated (in charging mode), the diaphragm chambers of the
deceleration air valves are connected to the intake manifold. The deceleration air valves are closed by the
integrated springs and by the boost pressure in the intake manifold.
If a deceleration air valve does not close, less boost pressure is generated.
Vacuum is built up in the vacuum reservoir during the engine intake phase and in deceleration mode.
To do this, the check valve (under vacuum) opens the line between the intake manifold and vacuum reservoir.
Fig. 69: Deceleration Air Function Diagram
Courtesy of MERCEDES-BENZ USA
ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MOS
TURBOCHARGER, FUNCTION - GF09.40-P-3100-01M
ENGINE 275.950 in MODEL 215, 220 ENGINE 275.951 in MODEL 230 ENGINE 275.953 in MODEL
216, 221 ENGINE 275.954 in MODEL 230 ENGINE 275.980 in MODEL 215, 220 ENGINE 275.981 in
MODEL 230 ENGINE 275.982 in MODEL 216, 221 ENGINE 285.950 i
Cut-away model left turbocharger
Fig. 70: Cut-Away Model Of Left Turbocharger
Courtesy of MERCEDES-BENZ USA
Fig. 71: Identifying Turbocharger Components
Courtesy of MERCEDES-BENZ USA
Function
The exhaust gases of each cylinder bank are directed through the exhaust manifold into the turbine housing onto
the turbine wheel (110c). The flow energy of the exhaust gases (B) set the turbine wheel in rotation.
As a result, the compressor turbine wheel (110d), which is connected to the turbine wheel by the shaft (110e), is
also driven at the same speed. The clean air suctioned by the compressor turbine wheel (D) is compressed (E)
and allocated to the engine.
The boost pressure control is performed by opening and closing the boost pressure control valve (110/3a),
which releases a bypass around the turbine wheel. The boost pressure control valve (110/3a) is operated via the
vacuum cell (110/3) with the control rod (110/3b). The controlled range on the control rod is approx. 8 up to 13
mm.
The vacuum cells (110/3) of both turbochargers are discharged together with the pressure of the boost pressure
control pressure transducer (Y31/5).
Each turbocharger has a deceleration air valve, which on transition from load to deceleration operation releases
a bypass around the compressor turbine wheel. Through the quick boost pressure removal charger noises are
prevented.
The shaft housing of both turbochargers are cooled with coolant and connected to the engine lubrication.
The compressor turbine wheel at the left turbocharger can be slightly smeared with oil due to the vapors of
the crankcase ventilation.
Observe installation notes for exhaust manifold/turbocharger with assembly tool!
For troubleshooting when boost pressure is missing, continue as follows:
1. Check leaktightness of boost pressure pipes (check gaskets and hose clamps between compressor housing
and intake manifold)
2. Check function of boost pressure control with boost pressure control pressure transducer (Y31/5).
3. Check leaktightness and actuation of deceleration air valves.
4. Check rotation of both turbochargers (exhaust system removed).
Fig. 72: Checking Turbocharger Rotation
Courtesy of MERCEDES-BENZ USA
TURBOCHARGER, LOCATION/TASK/FUNCTION - GF09.40-P-3100M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.953 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 275.954 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.982 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 73: Identifying Turbocharger Components
Courtesy of MERCEDES-BENZ USA
Turbocharger In each cylinder bank a turbocharger out of steel casting (Biturbo) is
location built-in. The turbine housing is integrated in the exhaust manifold.
Turbocharger
Build up boost pressure for each engine operating condition.
task
Turbocharger GF09.40-P-
function 3100-01M
CHARGE AIR COOLER, FUNCTION - GF09.41-P-3100-01M
ENGINE 275.950 in MODEL 215, 220 ENGINE 275.951 in MODEL 230 ENGINE 275.953 in MODEL
216, 221 ENGINE 275.954 in MODEL 230 ENGINE 275.980 in MODEL 215, 220 ENGINE 275.981 in
MODEL 230 ENGINE 275.982 in MODEL 216, 221 ENGINE 285.950 i
Low temperature circuit
Shown: Model 240
Fig. 74: Identifying Charge Air Cooler Components
Courtesy of MERCEDES-BENZ USA
The charge air coolers are connected to a separate coolant circuit with a low temperature cooler (110/11) and an
electrical charge air cooler circulation pump (M44). The air that is heated during the charging process dissipates
the heat to the coolant flowing through the charge air cooler.
The coolant is subsequently cooled in the low temperature cooler and then pumped back to the charge air
coolers from the charge air cooler circulation pump.
The function of the charge air cooler is dependent crucially from the air bubble free filling of the low
temperature cooling circuit. A special tool (vacuum pump) is required for filling and work instructions must be
followed carefully.
Open the cap at the low temperature coolant circuit only when the charge air temperature is increased (power
shortage) and when the engine is cold. The coolant must reach up to the cap.
CHARGE PRESSURE COOLER, LOCATION/TASK/DESIGN/FUNCTION - GF09.41-P-3100M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.953 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 275.954 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.982 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 75: Identifying Charge Pressure Cooler Components
Courtesy of MERCEDES-BENZ USA
Charge air For each cylinder bank, a charge air cooler is mounted behind the air
cooler position filter.
Charge air Cool off charge air which is compressed and heated by the
cooler task turbochargers.
The compact charge air coolers out of aluminum are designed as a
Charge air
water/air cooler. Its own low temperature cooling circuit dissipates the
cooler design
heat.
Charge air GF09.41-P-
cooler function 3100-01M
CHARGE AIR COOLING CIRCULATION PUMP, ARRANGEMENT - GF09.41-P-3102-01MS
ENGINE 275.953 in MODEL 216, 221 up to Model Year 08 /AEJ 07 ENGINE 275.982 in MODEL 216,
221 up to Model Year 08 /AEJ 07
Fig. 76: Identifying Charge Air Cooler Circulation Pump
Courtesy of MERCEDES-BENZ USA
CHARGE AIR COOLING CIRCULATION PUMP, LOCATION/TASK/FUNCTION - GF09.41-P-
3102M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.953 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 275.954 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.982 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 77: Identifying Charge Air Cooler Circulation Pump, Coolant Hose Connections & Electrical
Connection
Courtesy of MERCEDES-BENZ USA
Charge air cooling Model 215, 220 GF09.41-P-3102-01K
circulation pump, Model 216, 221 GF09.41-P-3102-01MS
arrangement Model 230 GF09.41-P-3102-01RA
Model 240 GF09.41-P-3102-01M
Charge air cooling Keep the charge air
circulation pump task temperature below 70°C
by means of coolant
circulation.
Charge air cooling The circulation pump is
circulation pump function actuated via a relay by the
engine control unit.
Switch on:
Charge air temperature
above approx.
47°C
Switch off:
Charge air temperature
below approx. 35°C.
LOW TEMPERATURE COOLER, LOCATION/TASK/DESIGN/FUNCTION - GF09.41-P-3103M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.953 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 275.954 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.982 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Shown: model 240
Fig. 78: Identifying Low Temperature Cooler Components
Courtesy of MERCEDES-BENZ USA
Located in the cooler module at vehicle front behind the cooler of the
Position of the low
engine cooling system.
temperature cooler
Engine 275.98, 285.98: In front of the cooler of the engine cooling system.
Task of the low The coolant which is heated in the charge air cooler is cooled off in the low
temperature cooler temperature coolant circuit.
The low temperature cooler is designed as an air/fluid heat exchanger.
Design of the low
Engine 275.98, 285.98: Increased cooling due to larger low temperature
temperature cooler
coolers.
Function of the low The airstream flows through the numerous cooling fins and thus cools the
temperature cooler coolant flowing through the low temperature cooler.
CHARGE AIR COOLING SYSTEM, FUNCTION - GF09.41-P-3104M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Shown is model 240
Fig. 79: Charge Air Cooling System Function Diagram
Courtesy of MERCEDES-BENZ USA
The cooled air downstream of the charge air coolers has a higher density. This increases the cylinder charge and
thus the engine output. In addition, the tendency to knock and NO X formation is reduced by the low exhaust
gas temperatures The maximum boost pressure becomes available only when the charge air temperature is
lower than 70°C. The charge air temperature sensor detects the temperature (B17/8) at the intake manifold.
A water/charge air cooler is built into each cylinder bank. Both water/charge air coolers are connected to the
low temperature cooling circuit with low temperature cooler and electric circulation pump (M44). The
circulation pump (M44) is actuated via the charge air cooler circulation pump relay by the engine control unit in
the following manner:
Switching on at a charge air temperature above approx. 47°C
Switching off at a charge air temperature below approx. 35°C
The function of the charge air cooler is fully dependent on the air bubble free filling of the low temperature
cooling circuit. A special tool (vacuum pump) is required for filling and the work instructions must be followed
carefully.
Open the cap at the low temperature coolant circuit only when the charge air temperature is increased (power
shortage) and the engine is cold. The coolant must reach up to the cap.
ME-SFI control unit, location/task/design/function GF07.61-P-5000M
Charge air temperature sensor, location/task/function GF07.04-P-5038M
Charge pressure cooler, location/task/design/function GF09.41-P-3100M
Charge air cooling circulation pump, location/task/function GF09.41-P-3102M
Low temperature cooler, location/task/design/function GF09.41-P-3103M
Charge air cooler circulation pump relay, location/task/design/function GF09.41-P-3106M
CHARGE AIR COOLING SYSTEM, FUNCTION - GF09.41-P-3104MOS
ENGINE 275.953 in MODEL 216.376, 221.176 as of Model Year 09 /AEJ 08
ENGINE 275.982 in MODEL 216.379, 221.179 as of Model Year 09 /AEJ 08
Charge air cooling function requirements - general
Circuit 87M ON (engine control ON)
Engine running
Charge air cooling - general
The charge air cooling holds the charge air temperature below 70°C.
The cooled air downstream of the charge air coolers has higher density. This increases the cylinder charge, and
therefore engine performance. It also reduces the tendency to knock, and the lower exhaust temperatures reduce
the formation of nitrogen oxides (NO X ).
One water/charge air cooler is installed for each cylinder bank. Both water/charge air coolers are connected to
the low-temperature cooling circuit with low-temperature cooler and circulation pump charge air cooler (M44).
Charge air cooling function sequence
If the charge air temperature is above 47°C, the ME-SFI control unit (N3/10) actuates the charge air cooler
circulation pump through the circulation pump relay (N10/2kQ).
If the charge air temperature falls below 35°C, the charge air cooler circulation pump is switched off again.
The charge air temperature in the intake manifold is detected by the charge air temperature sensor (B17/8) and
sent to the ME-SFI control unit (N3/10) in the form of a voltage signal.
The charge air cooling function crucial depends on bubble-free filling of the low-temperature cooling circuit.
A special tool (vacuum pump) is required for filling this circuit.
Only open the cap on the low-temperature coolant circuit when the charge air temperature is increased (lack
of power) and the engine is cold. The coolant must reach up to the cap.
Shown on charge air cooling model 240
Fig. 80: Charge Air Cooling System Function Diagram
Courtesy of MERCEDES-BENZ USA
ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MOS
RELAY FOR CHARGE AIR COOLER RECIRCULATION PUMP - LOCATION - GF09.41-P-3106-
01MS
ENGINE 275.953 in MODEL 216, 221 up to Model Year 08 /AEJ 07 ENGINE 275.982 in MODEL 216,
221 up to Model Year 08 /AEJ 07
Fig. 81: Identifying Rear SAM Control Unit With Fuse And Relay Module And Charge Air Cooler
Circulation Pump Relay
Courtesy of MERCEDES-BENZ USA
The power supply to the charge air cooler circulation pump relay is fused
CHARGE AIR COOLER CIRCULATION PUMP RELAY, LOCATION/TASK/DESIGN/FUNCTION -
GF09.41-P-3106M
ENGINE 275.951 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.953 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 275.954 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 08 /AEJ 07
ENGINE 275.982 in MODEL 216, 221 up to Model Year 08 /AEJ 07
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Shown on engine 275.950/951/980, 285
Fig. 82: Identifying Charge Air Cooler Circulation Pump Relay
Courtesy of MERCEDES-BENZ USA
GF09.41-P-
Model 215, 220
3106-01MA
GF09.41-P-
Model 216, 221 with engine 275.953/982
3106-01MS
Relay for charge air
GF09.41-P-
cooler recirculation Model 230 with engine 275.951/954
3106-01RA
pump - location
GF09.41-P-
Model 230 with engine 275.981
3106-01RB
GF09.41-P-
Model 240
3106-01MM
Relay for charge air
cooler recirculation Actuates the charge air cooler recirculation pump.
pump - task
Relay for charge air
Relay for charge air cooler recirculation pump is a 4-pin plug-in
cooler recirculation
relay.
pump - design
Upon actuation of the ME control unit by a ground signal, the
Relay for charge air
power supply contact closes and thus supplies the charge air
cooler recirculation
cooler recirculation pump (M44) fused with a voltage (circuit
pump, function
87).
WIRING DIAGRAMS
ELECTRIC WIRING DIAGRAMS: PASSENGER CARS: AIR INTAKE, SUPERCHARGING -
PE09.00-Z-9999AZ
MODEL all
Electrical function ENGINE 275... PE09.40-P-2050-97SAA
schematic for boost
pressure control
ELECTRICAL FUNCTION SCHEMATIC FOR BOOST PRESSURE CONTROL - PE09.40-P-2050-
97SAA
MODEL 221 with ENGINE 275 as of model year 09/ YoM 08
Code: Designation: Position:
1 Gear range, status 7E
B11/4 Coolant temperature sensor 5A
B17/8 Charge air temperature sensor 1D
B28/4 Pressure sensor downstream of air 2H
filter, left cylinder bank
B28/5 Pressure sensor downstream of air 2H
filter
B28/6 Pressure sensor upstream of 3J
throttle valve actuator
B28/7 Pressure sensor downstream of 5J
throttle valve actuator
B37 Accelerator pedal sensor 7H
B40 Oil sensor (oil level, temperature 1F
and quality)
CAN C Drive train CAN 8F
L5 Crankshaft position sensor 3C
N15/3 ETC [EGS] control unit 11E
N3/10 ME-SFI [ME] control unit 4E
Y31/5 Boost pressure control pressure 6C
transducer
Fig. 83: Boost Pressure Control - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS
285 589 01 03 00 BOX WRENCH BIT - WS09.00-P-0002B
FG 09/Set B
ENGINE 275, 285, 640
Use:
Box wrench bit E 10, Hazet with square socket 12x9 mm.
Fig. 84: Identifying Box Wrench Bit (285 589 01 03 00)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 00 ENGINE MOUNT WRENCH SET - WS09.00-P-0010B
FG 09/Set B
MODEL all
Further use 001 589 01 16 00 Engine mount wrench set WS22.00-P-0008B
Further use 001 589 01 16 00 Engine mount wrench set WS28.00-P-0088B
Separate part FG22/Set B 001 589 01 16 01 Plug-in adapter WS22.00-P-0008-01B
Separate part FG22/Set B 001 589 01 16 02 Box wrench bit WS22.00-P-0008-02B
Separate part FG22/Set B 001 589 01 16 03 box wrench WS22.00-P-0008-03B
Separate part FG22/Set B 001 589 01 16 04 Wrench socket WS22.00-P-0008-04B
Separate part FG22/Set B 001 589 01 16 05 Wrench socket WS22.00-P-0008-05B
Separate part FG22/Set B 001 589 01 16 06 Wrench socket WS22.00-P-0008-06B
Separate part FG22/Set B 001 589 01 16 07 Angled piece WS22.00-P-0008-07B
Separate part FG22/Set B 001 589 01 16 09 Box wrench bit WS22.00-P-0008-09B
Separate part FG22/Set B 001 589 01 16 08 Plug-in joint adapter WS22.00-P-0008-10B
Use:
Engine mount wrench set to remove the temperature sensor at the turbocharger and to loosen the bolts of the
turbocharger at the exhaust manifold.
Fig. 85: Identifying Engine Mount Wrench Set (001 589 01 16 00)
Courtesy of MERCEDES-BENZ USA
273 589 00 91 00 ADAPTER - WS09.00-P-0014
FG 09/Set B
ENGINE 272, 273
Use:
Adapter for leaktightness testing of the charge air system.
NOTE: Use only in combination with leak tester 611 589 02 21 00 and gasket A 272 094
00 80 of intake manifold. Application is documented in the DAS.
Fig. 86: Identifying Adapter (273 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
273 589 00 91 00 ADAPTER - WS09.00-P-0014B
FG 09/Set B
ENGINE 272, 273
Use:
Adapter for leaktightness testing of the charge air system.
NOTE: Use only in combination with leak tester 611 589 02 21 00 and gasket A 272 094
00 80 of intake manifold. Application is documented in the DAS.
Fig. 87: Identifying Adapter (273 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS: PASSENGER CARS: AIR INTAKE, SUPERCHARGING - WS09.00-Z-9999AZ
MODEL all
000 589 68 03 00 Box WS07.00-N-
FG 01/07/09/14/set A
wrench bit 0004A
000 589 68 03 00 Box WS07.00-P-
FG 07/09/Set B
wrench bit 0004B
000 589 69 03 00 Ring WS07.00-P-
FG 01/05/07/09/Set B
wrench bit 0088B
001 589 01 16 00 Engine WS09.00-P-
FG 09/Set B
mount wrench set 0010B
001 589 01 16 00 Engine WS22.00-P-
FG 01/22/07/09/28/61/ Set B
mount wrench set 0008B
001 589 01 16 01 Plug-in WS22.00-P-
FG22/07/09/28/Set B
adapter 0008-01B
001 589 01 16 02 Box WS22.00-P-
FG22/09/28/Set B
001 589 01 16 03 box WS22.00-P-
FG22/09/28/Set B
wrench 0008-03B
001 589 01 16 04 Wrench WS22.00-P-
FG22/09/28/Set B
socket 0008-04B
001 589 01 16 05 Wrench WS22.00-P-
FG22/07/09/28/Set B
socket 0008-05B
001 589 01 16 06 Wrench WS22.00-P-
FG22/09/28/Set B
socket 0008-06B
001 589 01 16 07 Angled WS22.00-P-
FG22/09/28/91/Set B
piece 0008-07B
001 589 01 16 08 Plug-in WS22.00-P-
FG22/09/28/Set B
joint adapter 0008-10B
001 589 01 16 09 Box WS22.00-P-
FG22/09/28/Set B
wrench bit 0008-09B
001 589 01 91 00 Set of WS01.00-P-
FG 01/08/09/14/15/ 54/83/ Set B
protective covers 0111B
001 589 02 91 00 Set of WS01.00-P-
FG 01/09/46/54 / Set B
protective covers 0112B
001 589 73 21 00 Hand WS00.00-P-
FG 00/01/07/09/14/15/ 20/30
vacuum pump 0018Z
001 589 77 09 00 Socket WS07.00-P-
FG 07/09/Set B
wrench 0084B
001 589 81 09 00 Set of WS00.00-P-
FG 00/01/07/09/14/15/ 20/Set B
flexible head wrenches 0251B
003 589 03 37 00 Hose WS01.00-P-
FG 01/07/09/18/20/ 46/54/ set B
clamp pliers 0113B
WS01.00-P-
112 589 00 62 00 Bracket FG 01/09/22/Set B
0062B
112 589 02 62 00 Set of WS09.00-P-
FG 09/Set C
dowel bolts 0007C
WS09.00-P-
113 589 00 33 00 Puller FG 09/Set B
0011B
119 589 04 63 00 WS07.00-P-
FG 01/09/07/47/ Set B
Pressure hose 0024B
120 589 07 21 00 WS18.00-P-
FG 18/01/05/09/Set B
Measuring rod 0024B
124 589 09 63 00 Ohm WS15.00-N-
FG 09/15/20/Set C
decade 0009C
124 589 24 21 02 WS20.00-P-
FG 09/20/Set B
Pressure hose 0016-01B
129 589 00 91 00 Record FG 00/Set Z FG 01/05/06/07/09/14/15/18/20/22/25/26/ WS00.00-P-
plug 27/29/32/33/35/42/46/47/68/82/83/88/ 91/Set B 0255Z
WS47.00-P-
163 589 00 37 00 Pliers FG 09/47 Set B
0009B
201 589 13 21 00 WS25.00-P-
FG 25/09/Set B
Vacuum tester 0012B
201 589 13 21 00 WS42.00-P-
FG 42/43/09/14/Set B
Vacuum tester 0036B
210 589 00 71 00 Hand WS00.00-P-
FG 00/01/07/09/20/25/ 27/32/33/43/46/88
pump 0280Z
220 589 00 99 11 Adapter WS54.00-P-
FG 00/09/15/42/43/54/ Set B
line 0050-11B
220 589 00 99 35 Adapter WS54.00-P-
FG 00/09/20/42/43/54/Set B
cable 0050-24B
220 589 05 99 00 WS00.00-P-
FG 00/01/09/13/15/ 20/25/42/43/47/54/ 72/ Set B
Electrical connection kit 0279Z
266 589 00 91 00 WS09.00-P-
FG 09/Set B
Connector 0012B
270 589 00 91 00 WS09.00-P-
FG 09/Set B
Connection adapter 0003B
271 589 00 91 00 WS09.00-P-
FG 09/Set B
Connecting piece 0008B
271 589 01 91 00 WS09.00-P-
FG 09/Set B
Connection adapter 0016B
WS09.00-P-
273 589 00 91 00 Adapter FG 09/Set B
0014B
WS09.00-P-
278 589 00 91 00 Adapter FG 09/Set B
0018B
285 589 01 03 00 Box WS09.00-P-
FG 09/Set B
wrench bit 0002B
WS09.00-P-
603 589 03 21 00 Tester FG 09/Set B
0001B
611 589 02 21 00 WS09.00-P-
FG 09/Set B
Leaktightness tester 0006B
WS09.00-P-
640 589 00 91 00 Adapter FG 09/Set B
0009B
WS09.00-P-
642 589 01 91 00 Adapter FG 09/Set B
0013B
651 589 00 07 00 Plug-in WS09.00-N-
FG 09/Set B
adapter 3010B
WS09.00-P-
651 589 02 91 00 Adapter FG 09/Set B
0015B
ACCESSORIES & BODY, CAB
Central Locking System - Basic Knowledge - S-Class (221)
BASIC KNOWLEDGE
REMOTE TRUNK CLOSING, LOCATION OF COMPONENTS - GF80.20-P-0002-01LE
Fig. 1: Locating Remote Trunk Closing Components
Courtesy of MERCEDES-BENZ USA
REMOTE TRUNK CLOSING, BLOCK DIAGRAM - GF80.20-P-0002-02LE
Fig. 2: Remote Trunk Closing Block Diagram
Courtesy of MERCEDES-BENZ USA
REMOTE TRUNK CLOSING, FUNCTION - GF80.20-P-0002LE
MODEL 216.3 as of model year 09 /YoM 08
MODEL 221.0 /1 as of model year 09 /YoM 08 with CODE (881) Remote trunk closing (RTC [HDFS])
Function requirements for remote trunk closing, general
Circuit 30
No overvoltage or undervoltage
System synchronized
Vehicle speed v = 0 km/h
Normalization of the remote trunk closing should only be performed after replacing a component or after
adjustment work on the trunk lid.
Remote trunk closing function, general
The trunk lid can be opened or closed automatically with the remote trunk closing function.
Manual operation of the trunk lid is possible, but requires increased force, since the hydraulic system also has to
be moved.
Information on vehicle speed is transmitted to the TLC control unit (N121) by the instrument cluster (A1) over
the interior CAN. The TLC control unit actuates the TLC hydraulic pump (M51) according to the request. The
trunk lid then can be opened or closed with the hydraulic cylinder or multiple-joint hinge.
If various requests are present at the same time, the opening/closing procedure is interrupted immediately and
continued only after a new request is continued.
The trunk lid remote closing function comprises the following partial functions:
Function sequence for closing trunk lid
Function sequence for opening trunk lid
Function sequence for opening angle limitation
Function sequence for lockup recognition
Additional function requirements for closing trunk lid
Trunk lid opened
Function sequence for closing trunk lid
Closing the trunk lid comprises the following subfunctions:
Function sequence for closing trunk lid via TLC button (S62/26)
Function sequence for closing trunk lid via trunk lid open/close switch (S20/1s6)
Function sequence for closing trunk lid via TLC button
Closing the trunk lid is requested by actuating the TLC button. The TLC control unit reads in the status of the
TLC button and actuates the TLC hydraulic pump. The trunk lid is then closed by the hydraulic cylinder and the
multiple-joint hinge. As soon as the trunk lid reaches the trunk lid rotary tumbler microswitch (M14/7s3), the
rear SAM control unit with fuse and relay module (N10/2) transmits a corresponding signal via the interior
CAN to the TLC control unit, which then switches off the TLC hydraulic pump. Simultaneously the rear SAM
control unit actuates the trunk lid CL motor (M14/7), whereby the trunk lid is closed completely by the power
locking feature.
On vehicles with code (889) Keyless Go the central locking (CL) can be locked additionally according to the
actuation of the TLC button.
Function sequence for closing trunk lid via trunk lid switch
Closing the trunk lid can be requested by actuating the trunk lid switch. The status of the trunk lid switch is read
in by the left front door control unit (N69/1) (model 221) or left door control unit (N69/1) (model 216) via the
the TLC hydraulic pump. The trunk lid is then closed by the hydraulic cylinder and the multiple-joint hinge. As
soon as the trunk lid reaches the trunk lid rotary tumbler microswitch, the rear SAM control unit transmits a
corresponding signal via the interior CAN to the TLC control, which then switches off the TLC hydraulic
pump. Simultaneously the rear SAM control unit actuates the trunk lid CL motor, whereby the trunk lid is
closed completely by the power locking feature.
Additional function requirements for opening trunk lid
Trunk lid closed
Function sequence for opening trunk lid
Opening the trunk lid comprises the following partial functions:
Function sequence for opening trunk lid via trunk lid external operation switch (S88/8)
Function sequence for opening trunk lid via trunk lid switch
Function sequence for opening trunk lid via transmitter key (A8/1)
Function sequence for opening trunk lid via trunk lid external operation switch
Opening the trunk lid is requested by actuating the trunk lid external operation switch. The rear SAM control
unit directly reads in the status of the trunk lid external operation switch and actuates the trunk lid CL motor to
unlock the trunk lid.
Then the rear SAM control unit transmits the status "Trunk lid unlocked" via the interior CAN to the TLC
control unit, which then actuates the TLC hydraulic pump. The hydraulic cylinder is charged with oil and opens
the trunk lid with the multiple-joint hinge.
The TLC control unit monitors the hydraulic motion over the trunk lid position sensor (B24/16). As soon as the
trunk lid position sensor recognizes the determined end switch-off angle, the TLC control unit switches off the
TLC hydraulic pump.
Function sequence for opening trunk lid via trunk lid switch
Opening the trunk lid can be requested by actuating the trunk lid switch. The left door control unit or left front
door control unit reads in the status of the trunk lid switch via the front door LIN and transmits it via the interior
CAN to the rear SAM control unit, when then actuates the trunk lid CL motor to unlock the trunk lid.
Then the rear SAM control unit transmits the status "Trunk lid unlocked" via the interior CAN to the TLC
control unit, which then actuates the TLC hydraulic pump. The hydraulic cylinder is charged with oil and opens
the trunk lid with the multiple-joint hinge. The TLC control unit monitors the hydraulic motion via the trunk lid
position sensor. As soon as the trunk lid position sensor recognizes the determined end switch-off angle, the
TLC control unit switches off the TLC hydraulic pump.
Function sequence for opening trunk lid via transmitter key
Opening the trunk lid is requested by actuating the trunk lid button on the transmitter key for longer than t = 0, 5
s. The request is transmitted by the transmitter key via radio to the rear antenna amplifier module (A2/12) and
relayed to the rear SAM control unit. The rear SAM control unit transmits them to the interior CAN. The EIS
control unit (N73) reads in the request and checks the authorization of the transmitter key.
When the transmitter key is valid, the EIS control unit transmits a corresponding signal to the interior CAN.
The rear SAM control unit receives this signal, actuates the trunk lid CL motor to unlock the trunk lid and
transmits the status "Trunk lid unlocked" via the interior CAN to the TLC control unit.
The TLC control unit then actuates the TLC hydraulic pump. The hydraulic cylinder is charged with oil and
opens the trunk lid with the multiple-joint hinge. The TLC control unit monitors the hydraulic motion via the
trunk lid position sensor. As soon as the trunk lid position sensor recognizes the determined end switch-off
angle, the TLC control unit switches off the TLC hydraulic pump.
By actuating the trunk lid emergency opening switch (S88/10) (with code (494) USA version) the trunk lid is
opened regardless of the vehicle speed and the locking status.
Function sequence for opening angle limitation
The limitation function of the opening angle serves to determine a new end position of the trunk lid (garage
position or maximum opening) to prevent damaging the rear-end door by hitting against extending
transportation goods (ski box, surfboard, etc.).
The "Garage position" can be switched on/off in the menu in the COMAND control unit (A40/3) or defined as
new end position. Operation is accomplished over the front central control unit (A40/9) and displayed by the
COMAND display (A40/8).
Function sequence for lockup recognition
The TLC control unit senses the current status and any change of the vehicle speed during opening/closing by
the signals from the trunk lid position sensor.
If blockage is detected during closing the trunk lid, the TLC hydraulic pump is reversed and the trunk lid is
moved to the initial position.
If blockage is detected during closing, the TLC hydraulic pump switches off and the trunk lid remains in the
momentary position.
GF80.20-P-
Model 216
Remote trunk closing, 0002-01LA
location of components GF80.20-P-
Model 221
0002-01LE
Electrical function schematic Model 216 PE80.20-P-
for trunk lid remote closing 2051-97CAB
(HDFS) Model 221
2051-97SAB
Remote trunk closing, block GF80.20-P-
diagram 0002-02LE
Instrument cluster, component GF54.30-P-
A1
description 6000LE
A40/3
with code (526) COMAND with single DVD
GF82.85-P-
drive (without navigation) or code (527)
3136LE
COMAND APS with single DVD drive (with
COMAND controller unit, navigation)
component description
GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
COMAND display, GF54.30-P-
A40/8
component description 6110LE
Front central operating unit, GF54.21-P-
A40/9
component description 4500LE
Rear SAM control unit with
GF54.21-P-
fuse and relay module, N10/2
6030LE
component description
Left door control unit, N69/1 GF72.29-P-
component description Model 216 4124LA
Left front door control unit, N69/1 GF72.29-P-
component description Model 221 4141LE
Component description for the GF80.57-P-
N73
EZS control unit 6003LE
Central gateway control unit, GF54.21-P-
N93
component description 4170LE
TLC control unit, component GF80.20-P-
N121
description 6000LE
CENTRAL LOCKING (CL [ZV]), LOCATION OF COMPONENTS - GF80.20-P-0005-01LE
Fig. 3: Locating Central Locking Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
CENTRAL LOCKING (CL), LOCATION OF COMPONENTS - GF80.20-P-0005-01SX
Fig. 4: Locating Central Locking Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
CENTRAL LOCKING (CL [ZV]), BLOCK DIAGRAM - GF80.20-P-0005-10LE
Fig. 5: Central Locking (ZV) Block Diagram
Courtesy of MERCEDES-BENZ USA
CENTRAL LOCKING (CL), BLOCK DIAGRAM - GF80.20-P-0005-10SX
Fig. 6: Central Locking Block Diagram
Courtesy of MERCEDES-BENZ USA
CENTRAL LOCKING (CL), FUNCTION - GF80.20-P-0005LE
MODEL 221.0 /1, 216.3 as of model year 2009 /YoM 08
Central locking (CL), general
The CL electrically locks and unlocks the vehicle doors, the trunk lid and the fuel filler flap.
The following controls are available:
Transmitter key (A8/1)
Left interior CL [ZV] switch (S85/5)
Right interior CL switch (S85/6)
Trunk lid open/close switch (S20/1s6) (open trunk lid only, remaining CL remains locked)
On vehicles with code (881) Remote trunk closing (RTC), the trunk lid can be opened and closed
hydraulically.
Additional information is given in the separate function description Remote trunk closing.
The CL function comprises the following partial functions:
Function sequence for unlocking by opening a door from inside
Function sequence for child safety lock on rear door doors (on model 221 up to 31.5.09 without
code (494) USA version and Code (460) Canada version or on model 221 as of 1.6.09)
Function sequence for emergency opening in event of crash
Function sequence for additional door lock (with code (833) Great Britain version)
Further subfunctions are described in separate documents:
Central locking operation with transmitter key, function
Locking/unlocking vehicle with inside switch, function
Automatic locking, function
Additional function requirements for unlocking by opening a door from inside
Vehicle locked by:
Left interior actuation CL switch or right interior actuation CL switch
Automatic locking
Function sequence for unlocking by opening a door from inside
The doors can always be opened from the inside regardless of the status of the CL. The corresponding door lock
is then unlocked.
Special case:
Globally locked vehicle locked with interior actuation CL switch or automatic function.
In this case, the vehicle is unlocked globally when the driver or passenger door is opened from inside.
Vehicles with code (833) Great Britain version:
If the CL is locked or relocked from the outside, the doors can only be opened from the inside, if the additional
door lock was previously deactivated via the menu point "Vehicle" in the COMAND control unit (A40/3).
Function sequence for child safety lock on rear doors (on model 221 up to 31.5.09 without code (494) USA
version and Code (460) Canada version or on model 221 as of 1.6.09)
When the mechanical child safety lock in the rear doors is actuated, they cannot be opened from the inside.
This mechanical lockout can be overridden with the safety lever on the rear doors.
On vehicles without code (833) Great Britain version, without code (460) Canada version and without code
(494) USA version disabling can be eliminated for t = 5 s by pressing the interior CL actuation switch.
while actuating the left rear child safety lock motor (A85/3m5) and right rear child safety lock motor
(A85/4m5).
The left interior actuation CL switch is read in by the left front door control unit (N69/1) and the right interior
actuation CL switch by the right front door control unit (N69/2)
From there the signal is transmitted via the interior CAN (CAN B) to the EIS [EZS] control unit (N73), which
then transmits the command to actuate the rear child safety lock motors to the left rear door control unit (N69/3)
and right rear door control unit (N69/4).
Function sequence for emergency opening in event of crash
The emergency opening function unlocks the doors of the vehicle after an accident. The restraint system control
unit (N2/7) transmits the corresponding message to the EIS control unit.
Parallel to this, the crash signal is transmitted to the central gateway control unit (N93), which relays the signal
to the following control unit via the interior CAN:
Model 221:
Door control module front left
Door control module front right
Door control module rear left
Door control module rear right
Model 216:
Left door control unit (N69/1)
Right door control unit (N69/2)
After a waiting time of t = 8 to 11 s, the doors are unlocked.
The emergency opening function overrides all other central locking functions. When the vehicle has been
locked from the outside, the emergency opening function is not active.
Interior protection activated (on vehicles with code (882) Interior monitoring (only with ATA))
Function sequence for additional door lock (with code (833) Great Britain version)
When the vehicle is locked with the transmitter key, the mechanical interior actuation is decoupled from all
doors, so that it is no longer possible to open the doors from the inside.
The interior protection and the additional door lock are deactivated via the menu point "Vehicle" in the
COMAND control unit.
If the vehicle is unlocked from the outside with the transmitter key, the additional door lock is deactivated
simultaneously by a command from the EIS control unit to the door control units via the interior CAN. The
doors can now be opened again from the inside.
Central locking (CL), location of components GF80.20-P-0005-01LE
Central locking (CL), block diagram GF80.20-P-0005-10LE
Operating central locking with transmitter key, function GF80.20-P-2002LE
Locking/unlocking vehicle with inside switch, function GF80.20-P-3009LE
Automatic locking, function GF80.20-P-4009LE
CENTRAL LOCKING (CL), FUNCTION - GF80.20-P-0005SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Function
The central locking (CL) controls electric locking and unlocking of the vehicle doors, the trunk lid and the fuel
filler flap.
Automatic functions
Speed-dependent locking:
Trunk lid locking (speed above 3 km/h)
Door locking (speed above 15 km/h)
Relocking
Emergency opening after an accident
Operation
The following controls are available:
Transmitter key (A8/1)
Left interior CL [ZV] switch (S85/5)
Right interior CL switch (S85/6)
Trunk lid open/close switch (S20/1s6) (open trunk lid only, remaining CL remains locked)
On vehicles with code (881) Remote trunk closing (RTC), the trunk lid can be opened and closed
hydraulically. For this purpose, see separate function description "Remote trunk closing (RTC) function".
Opening a vehicle door from inside
The vehicle doors can always be opened from the inside regardless of the status of the central locking (CL). The
corresponding door lock is then unlocked.
Special case
Globally unlocked vehicle locked with interior actuation CL switch or automatic function
In this case, the vehicle is unlocked globally when the driver or passenger door is opened from inside.
National version :
If the CL is locked or relocked from the outside, the doors can only be opened from the inside, if the additional
door lock was previously deactivated via the menu point "Vehicle" in the COMAND control unit (A40/3).
Child safety lock on rear doors (model 221)
When the mechanical child safety lock in the rear doors is actuated, they cannot be opened from the inside.
This mechanical lockout can be overridden with the safety lever on the rear doors.
National version except , and :
As an alternative, the lockout can be released for 5 s by pressing the interior actuation CL switch while
actuating the left rear child safety lock motor (A85/3m5) and right rear child safety lock motor (A85/4m5).
Auxiliary door lock (only )
Function requirement
Interior protection activated (on vehicles with code (882) Interior monitoring (only with ATA))
Function
When the vehicle is locked with the transmitter key, the mechanical interior actuation is decoupled from all
doors, so that it is no longer possible to open the doors from the inside.
The interior protection and the additional door lock are deactivated via the menu point "Vehicle" in the
COMAND control unit.
If the vehicle is unlocked from the outside with the transmitter key, the additional door lock is deactivated
simultaneously by a command from the EIS control unit (N73). The doors can now be opened again from the
inside.
Emergency opening
The emergency opening function unlocks the doors of the vehicle after an accident. The restraint systems
control unit (N2/7) transmits the corresponding message to the EIS control unit and the central gateway control
unit (N93). After a waiting time of 8 to 11 s, the doors are unlocked.
The emergency opening function overrides all other central locking functions. When the vehicle has been
locked from the outside, the emergency opening function is not active.
Trunk lid emergency release (only )
The trunk lid emergency release switch (S88/10) is located on the inside of the trunk lid and is read in by the
rear SAM control unit with fuse and relay module (N10/2). When actuated, the rear SAM control unit actuates
the trunk lid CL motor (M14/7) to unlock the trunk lid lock. This function is accomplished regardless of the
vehicle speed.
Central locking (CL), location of components GF80.20-P-0005-01SX
Central locking (CL), block diagram GF80.20-P-0005-10SX
Operating central locking with transmitter key, function GF80.20-P-2002SX
Locking/unlocking vehicle with inside switch, function GF80.20-P-3009SX
Automatic locking, function GF80.20-P-4009SX
REMOTE TRUNK CLOSING (RTC), LOCATION OF COMPONENTS - GF80.20-P-0007-02SX
Fig. 7: Locating Remote Trunk Closing Components
Courtesy of MERCEDES-BENZ USA
REMOTE TRUNK CLOSING (RTC) BLOCK DIAGRAM - GF80.20-P-0007-04SX
Fig. 8: Remote Trunk Closing Block Diagram
Courtesy of MERCEDES-BENZ USA
REMOTE TRUNK LID CLOSING, FUNCTION - GF80.20-P-0007SX
MODEL 221.0 /1, 216.3 with CODE (881) Remote trunk closing (RTC [HDFS]) up to Model Year 8
Description
The remote trunk closing (RTC) makes it possible to open and close the trunk lid hydraulically. The RTC is
controlled by the TLC control unit (N121). The trunk lid is driven via a hydraulic cylinder, which is integrated
into the trunk lid mechanism. The hydraulic volume flow required for operation is generated by the TLC
hydraulic pump (M51). The trunk lid position sensor (B24/16) is integrated into the hydraulic cylinder. The
trunk lid is completely closed by the power closing (SVS).
Opening trunk lid
The trunk lid can be opened with the following controls:
Transmitter key (A8/1)
Remote trunk lid open/close switch (S20/1s6)
Trunk lid external operation switch (S88/8)
Trunk lid emergency release switch (S88/10) (only )
The trunk lid can be opened to the limit stop or the stored garage position. The opening motion can be stopped
at any time by reactuating the controls mentioned above.
Closing trunk lid
The trunk lid can be closed with the following controls:
Trunk lid open/close switch
TLC [HDS] button (S62/26)
The trunk lid open/close switch must be actuated during the entire closing procedure.
When closing via the TLC button, closing can be stopped by actuating the TLC button again.
Limitation of opening position of trunk lid (garage position)
The limitation of the opening position is intended to prevent the trunk lid from being damaged by extending
transportation goods (e.g. ski box) or when the space available is insufficient (e.g. underground garage).
The garage position can be adjusted with the front central operating unit (A40/9) in the menu COMAND
control unit (A40/3). The menu is shown in the COMAND display (A40/8).
Synchronizing
Normalization is performed via STAR DIAGNOSIS in the TLC control unit and must be performed during
initial start-up. It is necessary to learn in the closed and completely open position of the trunk lid. Before
normalization of the upper end position, it is not possible to close the trunk lid hydraulically.
Since the end points of the trunk lid are not yet known during normalization, the trunk lid approaches the end
points with increased speed.
Synchronizing upper end position, function prerequisites:
Trunk lid lock opened and
no synchronization present
When the trunk lid external operation switch is actuated, the trunk lid is opened automatically. If the TLC
control unit recognizes that the end position is reached within the normalization range adjusted via STAR
DIAGNOSIS, the TLC hydraulic unit is actuated another 8 s and this position is stored as 0 position (trunk lid
open). Then the TLC hydraulic pump switches off regardless of whether the request is still present.
Normalization of lower end position
Function prerequisites:
Trunk lid lock open,
upper normalization present and
lower normalization not present
An automatic run is started in the closing direction to normalize the lower end position after the TLC button is
actuated. The trunk lid is completely closed.
If the trunk lid is within the normalization limits for the closed position at that time and the trunk lid position
sensor indicates a plausible value, normalization is completed.
Lockup recognition
The TLC control unit recognizes the position and the speed of the trunk lid with the aid of the trunk lid position
sensor.
Closing procedure
If trunk lid lock-up is recognized while closing, the trunk lid is moved to the default position, preceding lock-
up.
Opening procedure
If trunk lid lock-up is recognized while opening, the drive is switched off and the trunk lid remains in the
momentary position.
Remote trunk closing (RTC), location of components GF80.20-P-0007-02SX
Remote trunk closing (RTC) block diagram GF80.20-P-0007-04SX
Closing trunk lid, function GF80.20-P-2006SX
Opening remote trunk closing (RTC), function GF80.20-P-2010SX
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF REMOTE TRUNK CLOSING -
GF80.20-P-0992LE
MODEL 216.3 as of model year 09 /YoM 08
MODEL 221.0 /1 as of model year 09 /YoM 08 with CODE (881) Remote trunk closing (RTC [HDFS])
Remote trunk closing, function GF80.20-P-0002LE
Model 216 GF80.20-P-0002-01LA
Remote trunk closing, location of components
Model 221 GF80.20-P-0002-01LE
Remote trunk closing, block diagram GF80.20-P-0002-02LE
Overview of system components for remote trunk closing GF80.20-P-9990LE
TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR REMOTE TRUNK LID CLOSING -
GF80.20-P-0994SX
MODEL 221.0 /1, 216.3 with CODE (881) Remote trunk closing (RTC [HDFS]) up to Model Year 8
Remote trunk lid closing, function GF80.20-P-0007SX
Remote trunk closing (RTC), location of components GF80.20-P-0007-02SX
Remote trunk closing (RTC) block diagram GF80.20-P-0007-04SX
Closing trunk lid, function GF80.20-P-2006SX
Opening remote trunk closing (RTC), function GF80.20-P-2010SX
Overview of system components, remote trunk closing, component description GF80.20-P-9999SX
CONTENTS, FUNCTION DESCRIPTION OF CENTRAL LOCKING (CL) - GF80.20-P-0996LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08
Central locking (CL), function GF80.20-P-0005LE
GF80.20-P-0005-
Central locking (CL), location of components
01LE
GF80.20-P-0005-
Central locking (CL), block diagram
10LE
Operating central locking with transmitter key, function GF80.20-P-2002LE
Locking/unlocking vehicle with inside switch, function GF80.20-P-3009LE
Automatic locking, function GF80.20-P-4009LE
Overview of system components for central locking (CL), component
GF80.20-P-9993LE
description
CONTENTS, FUNCTION DESCRIPTION OF CENTRAL LOCKING (CL) - GF80.20-P-0996SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Central locking (CL), function GF80.20-P-0005SX
GF80.20-P-0005-
Central locking (CL), location of components
01SX
GF80.20-P-0005-
Central locking (CL), block diagram
10SX
Operating central locking with transmitter key, function GF80.20-P-2002SX
Locking/unlocking vehicle with inside switch, function GF80.20-P-3009SX
Automatic locking, function GF80.20-P-4009SX
Overview of system components for central locking (CL), component
GF80.20-P-9993SX
description
OPERATING CENTRAL LOCKING WITH TRANSMITTER KEY, FUNCTION - GF80.20-P-2002LE
MODEL 221.0 /1, 216.3 as of model year 2009 /YoM 08
Function requirements, general
Terminal 15C OFF
Central locking (CL), operation with transmitter key (A8/1) function, general
The CL can be operated with the transmitter key.
The operation of the transmitter key comprises the following partial functions:
Function sequence for presetting global and selective unlocking
Function sequence for locking or unlocking
Function sequence for visual feedback (without code (494) USA version)
Function sequence for acoustic feedback (1.9.10)
Function sequence for trunk lid remote opening
Function sequence for mechanical trunk lid locking (With code (887) Valet Parking)
Function sequence for presetting global and selective unlocking
If the unlock and lock buttons on the transmitter key are pressed simultaneously for t = 5 seconds, a change
between the "global" and "selective" settings takes place. The indicator lamp on the transmitter key comes on
for confirmation.
Global unlocking
The entire vehicle is unlocked by pressing the "Unlock" button on the transmitter key (doors, trunk lid
and fuel filler flap).
Selective unlocking
Only the driver door and the fuel filler flap are unlocked when the "Unlock" button on the transmitter key is
pressed. Only the next actuation of the "Unlock" transmit button unlocks the entire vehicle.
Function sequence for locking or unlocking
When the "Lock or unlock" button the transmitter key is actuated, it transmits a radio signal via the rear window
antenna amplifier module (A2/12) to the rear SAM control unit with fuse and relay module (N10/2). The EIS
control unit (N73) receives the signal from the SAM control unit via the interior CAN. Parallel to the radio
signal, an infrared signal is transmitted driver door infrared sensor (B58) (precise aiming required). This signal
is read in by the left door control unit (N69/1) (on model 216) or left front door control unit (N69/1) (on model
221) and transmitted to the EIS control unit via the interior CAN (CAN B).
The infrared and radio signals contain the same information (redundant). The first signal received always has
priority.
In both cases, the EIS control unit checks the access authorization of the transmitter key.
If the access authorization is valid, the EIS control unit transmits the command "Lock or unlock" via the interior
CAN to the following control units:
Model 221:
Left front door control unit
Left front door lock unit actuation (A85)
Right front door control unit (N69/2)
Right front door lock unit actuation (A85/1)
left rear door control unit (N69/3)
Left rear door lock unit actuation (A85/3)
Right rear door control unit (N69/4)
Right rear front door lock unit actuation (A85/4)
Rear SAM control unit
Trunk lid CL motor actuation (M14/7)
Fuel filler flap CL motor actuation (M14/10)
Model 216:
Left door control unit
Left door lock unit actuation (A85)
Right door control unit (N69/2)
Right door lock unit actuation (A85/1)
Rear SAM control unit
Trunk lid CL motor actuation
Fuel filler flap CL motor actuation
Moreover, the rear SAM control unit enables or disables the opening request from the trunk lid external switch
(S88/8).
If the driver door is opened during locking, the driver door is not locked An open passenger door is locked
When the vehicle is unlocked, the interior illumination (IBL) is switched on with the soft-on feature by the
overhead control panel control unit (N70).
Function sequence for visual feedback (without code (494) USA version)
After successful locking or unlocking, the turn signal lamps flash as visual feedback.
The function is controlled by the rear SAM control unit, transmitting the turn signal as blinkmaster with the
interior CAN:
Locking: flashes three times
Unlocking: flashes once
For further information on visual feedback see separate function description on exterior lights.
If a door is still open when locking, there is no visual feedback.
Function sequence for acoustic feedback (as of 1.9.10)
Select and activate acoustic feedback in instrument cluster (A1) via left multifunction steering wheel button
group (S110) and right multifunction steering wheel button group (S111).
The status of the acoustic feedback is transmitted by the instrument cluster via the central CAN (CAN F) to the
central gateway control unit (N93) and from there to the front fuse and relay module control unit (N10/1) via
the interior CAN. If the acoustic feedback function is activated and the successful locking and unlocking, an
acoustic feedback is output by momentarily actuating the left horn (H2) and right horn (H2/1).
If the transmitter key is valid and the acoustic feedback activated, the EIS control unit transmits the command
"Lock or unlock" via the interior CAN to the front SAM control unit, which momentarily actuates the horns via
the horn relay (N10/1kF).
Locking: three times
Unlocking: once
If a door is still open when locking, there is no acoustic feedback.
Function sequence for trunk lid remote opening
When the "Remote trunk release" is actuated, the transmitter key transmits the corresponding signal. The data
flow is the same as described previously for "Locking or unlocking".
However, only the trunk lid CL motor is actuated by the rear SAM control unit to unlock the trunk lid. The
remaining CL remains deactivated.
After closing, the trunk lid it is relocked.
Function sequence for mechanical trunk lid locking (with code (887) Valet Parking)
The trunk lid can be secured mechanically by locking with the emergency key. The position of the trunk lid is
relayed to the rear SAM control unit by the trunk lid contact switch (S88/6). The opening request from the rear
SAM control unit is enabled or disabled according to the position.
Model 216 97CAA
Electrical function schematic for central
locking, operation with transmitter key PE80.20-P-2052-
Model 221
97SAA
A1
GF54.30-P-
Model 216.3, model 221
6000LE
Component description for instrument cluster (except 221.095/195)
GF54.30-P-
Model 221.095/195
6000LEH
Component description for front SAM control GF54.21-P-
N10/1
unit with fuse and relay module 6070LE
Component description for rear SAM control GF54.21-P-
N10/2
unit with fuse and relay module 6030LE
Component description for left door control N69/1 GF72.29-P-
unit Model 216 4124LA
Component description for left front door N69/1 GF72.29-P-
control unit Model 221 4141LE
Component description for right door control N69/2 GF72.29-P-
unit Model 216 4128LA
Component description for right front door N69/2 GF72.29-P-
control unit Model 221 4142LE
N69/3, N69/4 GF72.29-P-
Rear door control unit, component description
Model 221 6020LE
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for steering column GF54.21-P-
N80
tube module 6050LE
Component description for central gateway GF54.21-P-
N93
control unit 4170LE
OPERATING CENTRAL LOCKING WITH TRANSMITTER KEY, FUNCTION - GF80.20-P-2002SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 9: Operating Central Locking With Transmitter Key Function Diagram
Courtesy of MERCEDES-BENZ USA
Shown on global locking and unlocking on model 221.0
Changing functions "global" and "selective" unlocking
If the unlock and lock buttons on the transmitter key are pressed simultaneously for 5 seconds, the "global" and
"selective" functions change. The indicator lamp on the transmitter key comes on to confirm this change.
Global unlocking
The entire vehicle is unlocked by pressing the "Unlock" button on the transmitter key (doors, trunk lid
and fuel filler flap).
Selective unlocking
Only the driver door and the fuel filler flap are unlocked when the "Unlock" button on the transmitter key is
pressed. Only the next actuation of the "Unlock" transmit button unlocks the entire vehicle.
Function sequence for locking or unlocking
When the "Lock/unlock button" on the transmitter key is actuated, it transmits a radio signal to the rear SAM
control unit via the antenna amplifier module and relays it to the EIS control unit. An infrared signal is
transmitted parallel to the radio signal to the driver door infrared sensor (precise aiming required). This signal is
read in by the corresponding door control unit and transmitted to the EIS control unit.
The infrared and radio signals include the same information (redundant); the first signal received is accepted.
In both cases, the EIS control unit checks the access authorization of the transmitter key. If the access
authorization is valid, the EIS control unit transmits the "Locking or unlocking" command to the control units
and the rear SAM control unit. They then actuate the corresponding door lock units and the fuel filler flap CL
motor.
Moreover, the rear SAM control unit enables or disables the opening request from the trunk lid external switch
(S88/8).
If the driver door is opened during locking, the driver door is not locked An open passenger door is locked
When the vehicle is unlocked, the interior illumination (IBL) is switched on with the soft-on feature by the
overhead control panel control unit (N70).
Visual feedback
After successful locking or unlocking, the turn signal lamps flash as visual feedback.
The function is controlled by the rear SAM control unit, which acts as master flasher forwarding the signal to
flash to the door control unit and front SAM control unit with fuse and relay module (N10/1).
Locking: flashing 3 times
Unlocking: flashing once
If a door is still open when locking, there is no visual feedback.
Function sequence for remote trunk lid release (RTR)
When the "Remote trunk release" is actuated, the transmitter key transmits the corresponding signal. The data
flow is the same as described previously for "Locking or unlocking".
However, only the trunk lid CL motor (M14/7) is actuated by the rear SAM control unit to unlock the trunk lid.
The remaining CL remains deactivated.
After closing, the trunk lid it is relocked.
Mechanical trunk lid locking (only )
The trunk lid can be secured mechanically by locking. The position of the trunk lid is relayed to the rear SAM
control unit by the trunk lid contact switch (S88/6). The opening request from the rear SAM control unit is
enabled or disabled according to the position.
A2/12
Vehicles without code (494) USA GF82.62-P-
version or without code (498) Japan 3131SX
Rear window antenna module component version
description GF82.62-P-
Vehicles with code (498) Japan version
3131SXJ
GF82.62-P-
Vehicles with code (494) USA version
3131SXU
GF80.57-P-
Transmitter key, component description A8/1
6010SX
Infrared remote control receiver, component GF80.30-P-
B58
description 6000SX
Driver-side SAM control unit with fuse and GF54.21-P-
N10/1
relay module, component description 6010SX
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
N69/1 GF72.29-P-
Driver-side front door control unit, Model 221 6000SX
component description GF72.29-P-
Model 216
6000SC
N69/2 GF72.29-P-
Passenger-side front door control unit, Model 221 6010SX
component description GF72.29-P-
Model 216
6010SC
N69/3, N69/4 GF72.29-P-
Rear door control unit component description
Model 221 6020SX
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS) component description 6000SX
CLOSING TRUNK LID, FUNCTION - GF80.20-P-2006SX
MODEL 221.0 /1, 216.3 with CODE (881) Remote trunk closing (RTC [HDFS]) up to Model Year 8
Fig. 10: Closing Trunk Lid Function Diagram
Courtesy of MERCEDES-BENZ USA
The trunk lid can also be closed by hand. In this case, it is necessary to overcome the resistance of the
hydraulic drive.
Function requirements
Normalize trunk lid
No overvoltage/undervoltage
Vehicle stationary
Function
The trunk lid can be closed using the following 2 controls.
Actuation differs only up to the time the request is present at the TLC control unit.
1.1 Trunk lid open/close switch
When the trunk lid open/close switch is actuated and held down, the "Open" signal is read in by the
corresponding door control unit via front door LIN.
The door control unit relays it to the TLC control unit via interior CAN.
When the trunk open/close switch is released, the closing procedure is stopped.
1.2 TCL button
The TCL button is read in directly by the TLC control unit. Momentary actuation is sufficient.
Vehicles with code (889) Keyless Go:
The TCL button is designed as two-piece version. When the left button is actuated, the trunk lid is closed,
when the right button is actuated, the vehicle is locked.
The Keyless Go control unit initiates a check of the transmitter key (A8/1) (N69/5); validity of the
transmitter key is checked by the EIS control unit. Locking is only accomplished, if a valid transmitter
key is recognized outside of the vehicle.
2 Close trunk lid
The TLC control unit actuates the TLC hydraulic pump as long as the trunk lid rotary tumbler microswitch
(M14/7s3) signals "Trunk lid closed" to the SAM control unit.
The closing procedure of the trunk lid is monitored via the trunk lid position sensor by the TLC control unit.
Then the trunk lid is completely closed with power closing via the trunk lid CL motor.
GF54.30-P-
Instrument cluster, component description A1
6000SX
GF80.57-P-
Transmitter key, component description A8/1
6010SX
GF80.20-P-
Trunk lid drive unit, component description B24/16 and M51
6010SX
Rear SAM control unit with fuse and relay module, GF54.21-P-
N10/2
component description 6030SX
N69/1 GF72.29-P-
Model 216 6000SC
Driver-side front door control unit, component description
GF72.29-P-
Model 221
6000SX
N69/5
GF80.61-P-
Keyless Go control unit, component description Vehicles with Keyless-Go
4200SX
code 889:
Electronic ignition/starter switch control unit (EIS) GF80.57-P-
N73
component description 6000SX
GF54.21-P-
Central gateway control unit, component description N93
4170SX
GF80.20-P-
TLC control unit, component description N121
6000SX
Driver power window, outside mirror and trunk lid switch GF54.25-P-
S20/1
group, component description 4230SX
OPENING REMOTE TRUNK CLOSING (RTC), FUNCTION - GF80.20-P-2010SX
MODEL 221.0 /1, 216.3 with CODE (881) Remote trunk closing (RTC [HDFS]) up to Model Year 8
Fig. 11: Opening Remote Trunk Closing (RTC) Function Diagram
Courtesy of MERCEDES-BENZ USA
Function requirements
Normalize trunk lid
No overvoltage/undervoltage
Vehicle standing still (not with emergency opening ( )
Central locking (CL) unlocked (with trunk lid external actuation switch control and trunk lid open/close
switch)
Function
The trunk lid can be opened via the following 4 controls. Actuation differs only up to the time the request is
present at the rear SAM control unit
1.1 Transmitter key
When the "Trunk lid opening" transmit button is actuated for longer than 0.5 s, the transmitter key
transmits a radio signal to the rear window antenna amplifier module. This signal is relayed to the EIS
control unit via the rear SAM control unit. The EIS control unit checks the access authorization of the
transmitter key.
If the access authorization is valid, the EZS control unit sends the command "Open trunk lid" to the rear
SAM control unit.
1.2 Trunk lid external operation switch
When the trunk lid external operation switch is actuated, the command to open the rear SAM control unit
is read in.
1.3 Trunk lid open/close switch
When the trunk lid open/close switch is actuated, the "Open" signal is read in by the corresponding door
control unit via front door LIN. The door control unit relays the signal to the TLC control unit and rear
SAM control unit via the interior CAN.
1.4 Trunk lid emergency release switch
When the trunk lid emergency release switch is actuated, the command to open the rear SAM control unit
is read in.
2 Actuating open trunk lid (independent from controls)
The rear SAM control unit actuates the trunk lid CL motor to unlock the trunk lid. If the trunk lid is unlocked,
the rear SAM control unit transmits this signal via the interior CAN to the TLC control unit, which actuates the
TLC hydraulic pump. When the trunk lid has reached its end position, the TLC hydraulic pump is stopped by
the TLC control unit and the trunk lid remains in the open position.
The opening procedure is monitored by the trunk lid position sensor.
If an opening is requested during the opening procedure, the automatic drive is stopped.
Regardless of how the trunk lid is opened, the rear SAM control unit transmits a feedback signal to the left door
control unit via the open trunk lid via the interior CAN, which then actuates the function LED in the trunk lid
GF54.30-P-
Instrument cluster, component description A1
6000SX
GF80.57-P-
Transmitter key, component description A8/1
6010SX
A40/3
Vehicles without code (494) USA GF82.85-P-
version and without code (498) Japan 3136SX
COMAND controller unit, component version
description GF82.85-P-
Vehicles with code (498) Japan version
3136SXJ
GF82.85-P-
Vehicles with code (494) USA version
3136SXU
GF54.30-P-
Cockpit central display, component description A40/8
6100SX
Front central operating unit, component GF54.21-P-
A40/9
description 4500SX
GF80.20-P-
Trunk lid drive unit, component description B24/16 and M51
6010SX
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
N69/1 GF72.29-P-
Driver-side front door control unit, component Model 216 6000SC
description GF72.29-P-
Model 221
6000SX
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS) component description 6000SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
GF80.20-P-
TLC control unit, component description N121
6000SX
Driver power window, outside mirror and trunk GF54.25-P-
S20/1
lid switch group, component description 4230SX
LOCKING/UNLOCKING VEHICLE WITH INSIDE SWITCH, FUNCTION - GF80.20-P-3009LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08
General function requirements
Vehicle must not be locked from outside with transmitter key (A8/1)
Locking/unlocking vehicle with inside switch, general
The vehicle can locked/unlocked with the left interior actuation CL switch (S85/5), right interior actuation CL
switch (S85/6) and trunk lid open/close switch (S20/1s6).
The function locking/unlocking vehicle with interior switch comprises the following partial functions:
Function sequence for locking/unlocking CL
Function sequence for unlocking trunk lid (opening)
Function sequence for trunk lid emergency opening (with code (494) USA version)
Additional function requirements for locking/unlocking CL
Vehicle unlocked globally or selectively
Function sequence for locking/unlocking
The vehicle can be locked and unlocked by actuation the interior CL actuation switch (except fuel filler flap).
The left interior actuation CL switch is read in by the left front seat operation switch group (S22). The seat
operation switch group transmits the request to the left front door control unit (N69/1) (model 221) or left door
control unit (N69/1) (model 216) via the front door LIN.
The right interior actuation CL switch is read in by the right front seat operation switch group (S23). The seat
operation switch group transmits the request to the right front door control unit (N69/2) (model 221) or right
door control unit (N69/2) (model 216) via the front door LIN.
The corresponding door control unit relays the signal to the EIS control unit (N73) via the interior CAN.
The EIS control unit transmits the "Lock or unlock" command to the following control units via the interior
CAN:
Model 221:
Left front door control unit
Left front door lock unit actuation (A85)
Right front door control unit
Right front door lock unit actuation (A85/1)
left rear door control unit (N69/3)
Left rear door lock unit actuation (A85/3)
Right rear door control unit (N69/4)
Right rear front door lock unit actuation (A85/4)
Rear SAM control unit with fuse and relay module (N10/2)
Trunk lid CL motor actuation (M14/7)
Model 216:
Left door control unit
Right door control unit
Right door lock unit actuation (A85/1)
Rear SAM control unit
Trunk lid CL motor actuation
The rear SAM control unit enables or disables the request from the trunk lid external operation switch (S88/8).
The unlocking and locking functions are enabled depending on the door status as follows:
Driver and passenger door closed:
Unlocking function activated
Locking function activated
Passenger door open:
Unlocking function activated
Locking function deactivated
Driver door open:
Unlocking function activated
Locking function activated (Drive's door not actuated)
The current door status of the front doors is relayed by the corresponding door lock unit to the corresponding
door control unit which relays the signals to the EIS control unit.
Additional function requirements for unlocking trunk lid (opening)
Vehicle unlocked globally (not with emergency opening (with code (494) USA version))
Function sequence for unlocking trunk lid(opening)
The trunk lid open/close switch is located in the driver side outside mirror and trunk lid power window switch
group (S20/1) and is read in by the corresponding door control unit via the front door LIN.
When the trunk lid open/close switch is actuated, the signal is transmitted from the door control unit via the
interior CAN to the EIS control unit and from there relayed to the rear SAM control unit. The latter actuates the
trunk lid CL motor to unlock.
Function sequence for trunk lid emergency opening
The trunk lid emergency opening switch (S88/10) is located on the inside of the trunk lid and is read in by the
rear SAM control unit. When the trunk lid emergency release switch is actuated, the rear SAM control unit
actuates the trunk lid CL motor to unlock.
The function is dependent of the vehicle speed and locking status of the CL.
PE80.20-P-2053-
Model 216
Function schematic for electric central locking with interior 97CAA
switch, locking and unlocking PE80.20-P-2053-
Model 221
97SAA
Rear SAM control unit with fuse and relay module, component GF54.21-P-
N10/2
description 6030LE
N69/1 GF72.29-P-
Left door control unit, component description
Model 216 4124LA
N69/1 GF72.29-P-
Left front door control unit, component description
Model 221 4141LE
N69/2 GF72.29-P-
Right door control unit, component description
Model 216 4128LA
N69/2 GF72.29-P-
Right front door control unit, component description
Model 221 4142LE
N69/3,
GF72.29-P-
Rear door control unit, component description N69/4
6020LE
Model 221
GF80.57-P-
Component description for the EZS control unit N73
6003LE
LOCKING/UNLOCKING VEHICLE WITH INSIDE SWITCH, FUNCTION - GF80.20-P-3009SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 12: Locking/Unlocking Vehicle With Inside Switch Function Diagram
Courtesy of MERCEDES-BENZ USA
The following functions can be actuated using the switch in the passenger compartment:
Locking or unlocking central locking (CL)
Open trunk lid
Trunk lid emergency opening (only )
Locking or unlocking CL
Function requirements:
Vehicle unlocked globally or selectively
Function
The vehicle (except fuel filler flap) can be locked or unlocked by actuating the CL switch. The signal from the
CL switch is transmitted via front door LIN to the corresponding door control unit which relays the signals to
the EIS control unit. The EIS control unit transmits the command "Lock or unlock" to the corresponding door
control units or rear SAM control unit. The door control units then actuate the door lock units correspondingly.
The rear SAM control unit enables or disables the request from the trunk lid external operation switch (S88/8).
Enabled function depending on door status
Driver and passenger door closed:
Unlocking function activated
Locking function activated
Passenger door open:
Unlocking function activated
Locking function deactivated
Driver door open:
Unlocking function activated
Locking function activated (Drive's door not actuated)
The current door status of the front doors is relayed by the corresponding door lock unit to the corresponding
door control unit which relays the signals to the EIS control unit.
Opening trunk lid
Function requirements:
Vehicle unlocked globally (not with emergency opening )
Trunk lid open/close switch
The trunk lid open/close switch is located in the driver power window, outside mirror and trunk lid switch
group (S20/1) and is read in by the door control unit via front door LIN. When the trunk lid open/close switch is
actuated, the signal from the door control unit is relayed via the EIS control unit to the rear SAM control unit,
which actuates the trunk lid CL motor to unlock.
Trunk lid emergency opening switch (only )
The trunk lid emergency release switch is located on the inside of the trunk lid and is read in by the rear SAM
control unit. When the trunk lid emergency release switch is actuated, the rear SAM control unit actuates the
trunk lid CL motor to unlock. This function is independent of the vehicle speed and locking status.
Rear SAM control unit with fuse and relay module, component GF54.21-P-
N10/2
description 6030SX
N69/1 GF72.29-P-
Model 221 6000SX
Driver-side front door control unit, component description
GF72.29-P-
Model 216
6000SC
N69/2 GF72.29-P-
Model 221 6010SX
Passenger-side front door control unit, component description
GF72.29-P-
Model 216
6010SC
N69/3,
GF72.29-P-
Rear door control unit component description N69/4
6020SX
Model 221
Electronic ignition/starter switch control unit (EIS) component GF80.57-P-
N73
description 6000SX
AUTOMATIC LOCKING, FUNCTION - GF80.20-P-4009LE
MODEL 221.0 /1, 216.3 as of model year 2009 /YoM 08
Function requirements, general
Central locking (CL) unlocked
Automatic locking function activated via COMAND control unit (A40/3)
Automatic locking, general
The vehicle is automatically locked under certain conditions.
The automatic locking function comprises the following partial functions:
Function sequence for locking, depending on vehicle speed
Function sequence for automatic relocking
Function sequence for locking, depending on vehicle speed
CL activated depending on vehicle speed:
Vehicles speed v > 3 km/h:
Trunk lid locked
Vehicle speed above v > 15 km/h:
Doors locked
The EIS control unit (N73) recognizes if the limit values are exceeded by evaluating the speed signals from the
instrument cluster (A1) and transmits the "Lock" command via the interior CAN (CAN B) to the:
Left door control unit (N69/1) (model 216)
Left front door control unit (N69/1) (model 221)
Right door control unit (N69/2) (model 216
Right front door control unit (N69/2) (model 221)
Left rear door control unit (N69/3) (model 221)
Right rear door control unit (N69/4) (model 221)
rear SAM control unit with fuse and relay module (N10/2)
The instrument cluster transmits the speed signal to the central gateway control unit (N93) via the central
CAN (CAN F).
The central gateway control unit transmits the signal to the EIS control unit via the interior CAN.
The door control units lock:
Left door lock unit (A85) (model 216)
Left front door lock unit (A85) (model 221)
Right door lock unit (A85/1) (model 216)
Right front door lock unit (A85/1) (model 221)
Left rear door lock unit (A85/3) (model 221)
Right rear door lock unit (A85/4) (model 221)
Moreover, opening of the trunk lid via the trunk lid external operation switch (S88/8) is suppressed by the rear
SAM control unit.
The fuel filler flap CL motor (M14/10) is not actuated.
If, after automatic locking, the vehicle is unlocked with the left interior actuation CL switch (S85/5) or right
interior actuation CL switch (S85/6) it remains unlocked even at speeds above the corresponding limit value.
The vehicle is returned to the initial state when one of the doors is opened or c. 15 is switched on and off again.
If a door is opened while driving and then closed again, and the vehicle speed is above the limit for automatic
locking, the door is locked again after it is closed.
Function sequence for automatic relocking
After the vehicle is unlocked with the transmitter key (A8/1), a waiting time of 40 s starts. After expiration of
this waiting time, the vehicle is locked again, if a door or the trunk lid was not opened previously.
Relock is confirmed by optical feedback
The anti-theft alarm (ATA) (on vehicles with code (551) Anti-theft alarm (ATA)) is also activated by the
relocking function.
Electrical function PE80.20-P-
Model 216
schematic for central 2055-97CAA
locking (CL), automatic PE80.20-P-
locking Model 221
2055-97SAA
A1 GF54.30-P-
Component description for Model 216.3, model 221 (except 221.095/195) 6000LE
instrument cluster GF54.30-P-
Model 221.095/195
6000LEH
A40/3
With code (526) COMAND with single DVD drive
GF82.85-P-
(without navigation system) or with code (527)
3136LE
COMAND APS with single DVD drive (with
Component description for navigation system)
COMAND controller unit
GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
Component description for
GF54.21-P-
rear SAM control unit with N10/2
6030LE
fuse and relay module
Component description for N69/1 GF72.29-P-
left door control unit Model 216 4124LA
Component description for N69/1 GF72.29-P-
left front door control unit Model 221 4141LE
Component description for N69/2 GF72.29-P-
right door control unit Model 216 4128LA
Component description for N69/2 GF72.29-P-
right front door control unit Model 221 4142LE
Rear door control unit, N69/3, N69/4 GF72.29-P-
component description Model 221 6020LE
EZS control unit, GF80.57-P-
N73
component description 6003LE
Component description for GF54.21-P-
N93
central gateway control unit 4170LE
AUTOMATIC LOCKING, FUNCTION - GF80.20-P-4009SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Speed-dependent locking
Function requirements
Central locking (CL) unlocked
Automatic locking function activated via COMAND control unit (A40/3)
Function
CL activated depending on vehicle speed:
Vehicle speed above 3 km/h
Trunk lid locked
Vehicle speed above 15 km/h
Doors locked
The EIS control unit (N73) recognizes if the limit values are exceeded by evaluating the speed signals from the
instrument cluster (A1) and transmits the command "Lock" to the:
Left door control unit (N69/1) on model 216 or Left front door control unit (N69/1) on model 221
Right door control unit (N69/2) on model 216 or Right front door control unit (N69/2) on model 221
Left rear door control unit (N69/3) on model 221
Right rear door control unit (N69/4) on model 221
Rear SAM control unit with fuse and relay module (N10/2)
They then cause the following to be locked:
Left door lock unit (A85) on model 216 or Left front door lock unit (A85) on model 221
Right door lock unit (A85/1) on model 216 or Right front door lock unit (A85/1) on model 221
Left rear door lock unit (A85/3) on model 221
Right rear door lock unit (A85/4) on model 221
Moreover, opening of the trunk lid via the trunk lid external operation switch (S88/8) is suppressed by the rear
SAM control unit.
The fuel filler flap CL motor (M14/10) is not actuated.
If, after automatic locking, the vehicle is unlocked with the left interior CL switch (S85/5) or right interior CL
switch (S85/6), it remains unlocked even at speed above the corresponding limit value.
The vehicle is returned to the initial state when one of the doors is opened or circuit 15 is switched on and off
again.
If a door is opened while driving and then closed again, and the vehicle speed is above the limit for automatic
locking, the door is locked again after it is closed.
Automatic relocking function
After the vehicle is unlocked with the transmitter key (A8/1), a waiting time of 40 s starts. After expiration of
this waiting time, the vehicle is locked again, if a door or the trunk lid was not opened previously.
Relock is confirmed by optical feedback
The anti-theft alarm (ATA) (on vehicles with code (551) Anti-theft alarm (ATA)) is also activated by the
relocking function.
Rear SAM control unit with fuse and relay module, component GF54.21-P-
N10/2
description 6030SX
N69/1 GF72.29-P-
Model 221 6000SX
Driver-side front door control unit, component description
GF72.29-P-
Model 216
6000SC
N69/2 GF72.29-P-
Model 221 6010SX
Passenger-side front door control unit, component description
GF72.29-P-
Model 216
6010SC
N69/3,
GF72.29-P-
Rear door control unit component description N69/4
6020SX
Model 221
Electronic ignition/starter switch control unit (EIS) component GF80.57-P-
N73
description 6000SX
TLC CONTROL UNIT, COMPONENT DESCRIPTION - GF80.20-P-6000LE
MODEL 216.3 as of model year 09 /YoM 08
MODEL 221.0 /1 as of model year 09 /YoM 08 with CODE (881) Remote trunk closing (RTC [HDFS])
Illustrated on model 221.0
Fig. 13: Locating TLC Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The TLC control unit is located in the trunk at the right rear.
Task
The TLC control unit has the following tasks:
Reading in of sensors and signals
Evaluation of input factors
Actuation of components
Reading in of sensors and signals
The input factors are read in with the following connections:
Direct line
Interior CAN
Direct line
The signals from the following components are read via a direct line:
Trunk lid position sensor (B24/16)
TLC [HDS] button (S62/26)
Interior CAN
The following information is read in via the interior CAN:
by the left door control unit (N69/1) (model 216) or left front door control unit (N69/1) (model 221):
Status trunk lid open/close switch (S20/1s6)
by the rear SAM control unit with fuse and relay module (N10/2):
Trunk lid CL motor status (M14/7)
Status of trunk lid emergency opening switch (S88/10) (with code (494) USA version)
Rear window antenna amplifier module (A2/12)
by the instrument cluster (A1):
Vehicle speed
by the COMAND control unit (A40/3) via the central gateway control unit (N93):
Garage position status
Evaluation of input factors
The input factors that have been read in are evaluated by the integrated microprocessor and the relevant
components are then actuated.
Actuation of components
The following components are actuated with a direct line:
TLC hydraulic pump (M51)
Model 216 PE72.30-P-2101-99CAB
Wiring diagram for remote trunk closing control unit
Model 221 PE72.30-P-2101-99SAB
TLC CONTROL UNIT, COMPONENT DESCRIPTION - GF80.20-P-6000SX
MODEL 221.0 /1, 216.3 with CODE (881) Remote trunk closing (RTC [HDFS]) up to Model Year 8
Shown on model 221
Fig. 14: Locating TLC Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The TLC control unit is located in the trunk on the right.
Tasks
Control of remote trunk closing (RTC)
Control of trunk lid in intermediate position (garage position)
Realization of overload protection when opening trunk lid
Realization of anti-pinch protection when closing trunk lid
Storing normalization of trunk lid
Discrete inputs
Circuit 30
Circuit 31
Trunk lid position sensor (B24/16)
Discrete outputs
TLC hydraulic pump (M51)
LED in TLC button
Inputs and outputs via interior CAN
The TLC control unit is connected with other control units via interior CAN to exchange information.
TRUNK LID DRIVE UNIT, COMPONENT DESCRIPTION - GF80.20-P-6010SX
MODEL 221.0 /1, 216.3 with CODE (881) Remote trunk closing (RTC [HDFS]) up to Model Year 8
Fig. 15: Locating Trunk Lid Drive Unit Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221
Location
The components are located in the trunk lid drive unit in the trunk on the right.
Design
The trunk lid drive unit consists of the following components:
Hydraulic cylinder
TLC [HDS] hydraulic pump
Trunk lid position sensor
Function
Opening and closing the trunk lid is controlled and monitored by the TLC control unit. When the TLC hydraulic
pump is activated, the trunk lid is opened or closed by the hydraulic cylinder. The motion of the hydraulic
cylinder is monitored by the trunk lid position sensor which transfers this information to the TLC control unit
for control of the TLC hydraulic pump.
OVERVIEW OF SYSTEM COMPONENTS FOR REMOTE TRUNK CLOSING - GF80.20-P-9990LE
MODEL 216.3 as of model year 09 /YoM 08
MODEL 221.0 /1 as of model year 09 /YoM 08 with CODE (881) Remote trunk closing (RTC [HDFS])
Instrument cluster, component GF54.30-P-
A1
description 6000LE
A40/3
With code (526) COMAND with single DVD drive GF82.85-P-
(without navigation) or code (527) COMAND APS with 3136LE
COMAND controller unit, single DVD drive (with navigation)
component description GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with navigation GF82.85-P-
system) 3136LEU
COMAND display, component GF54.30-P-
A40/8
description 6110LE
Front central operating unit, GF54.21-P-
A40/9
component description 4500LE
Rear SAM control unit with fuse
GF54.21-P-
and relay module, component N10/2
6030LE
description
Left door control unit, N69/1 GF72.29-P-
component description Model 216 4124LA
Left front door control unit, N69/1 GF72.29-P-
component description Model 221 4141LE
Component description for the GF80.57-P-
N73
EZS control unit 6003LE
Central gateway control unit, GF54.21-P-
N93
component description 4170LE
TLC control unit, component GF80.20-P-
N121
description 6000LE
Table of contents for function
GF80.20-P-
description of remote trunk
0992LE
closing
OVERVIEW OF SYSTEM COMPONENTS FOR CENTRAL LOCKING (CL), COMPONENT
DESCRIPTION - GF80.20-P-9993LE
MODEL 221.0 /1, 216.3 as of model year 2009 /YoM 08
A1 GF54.30-P-
Component description for Model 216.3, model 221 (except 221.095/195) 6000LE
instrument cluster GF54.30-P-
Model 221.095/195
6000LEH
A40/3
With code (526) COMAND with single DVD drive
GF82.85-P-
(without navigation system) or with code (527)
3136LE
COMAND APS with single DVD drive (with navigation
Component description for system)
COMAND controller unit
GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with navigation GF82.85-P-
system) 3136LEU
Component description for
GF54.21-P-
front SAM control unit with N10/1
6070LE
fuse and relay module
Component description for rear
GF54.21-P-
SAM control unit with fuse N10/2
6030LE
and relay module
Component description for left N69/1 GF72.29-P-
door control unit Model 216 4124LA
Component description for left N69/1 GF72.29-P-
front door control unit Model 221 4141LE
Component description for N69/2 GF72.29-P-
right door control unit Model 216 4128LA
Component description for N69/2 GF72.29-P-
right front door control unit Model 221 4142LE
Rear door control unit, N69/3, N69/4 GF72.29-P-
component description Model 221 6020LE
Component description for GF54.21-P-
N80
steering column tube module 6050LE
EZS control unit, component GF80.57-P-
N73
description 6003LE
Component description for GF54.21-P-
N93
central gateway control unit 4170LE
Contents, function description GF80.20-P-
of central locking (CL) 0996LE
OVERVIEW OF SYSTEM COMPONENTS FOR CENTRAL LOCKING (CL), COMPONENT
DESCRIPTION - GF80.20-P-9993SX
MODEL 221.0 /1, 216.3 up to Model Year 8
A2/12
version or without code (498) Japan 3131SX
version
Rear window antenna module component GF82.62-P-
Vehicles with code (498) Japan version
description 3131SXJ
GF82.62-P-
Vehicles with code (494) USA version
3131SXU
GF80.57-P-
Transmitter key, component description A8/1
6010SX
Infrared remote control receiver, component GF80.30-P-
B58
description 6000SX
Driver-side SAM control unit with fuse and GF54.21-P-
N10/1
relay module, component description 6010SX
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
N69/1 GF72.29-P-
Driver-side front door control unit, Model 221 6000SX
component description GF72.29-P-
Model 216
6000SC
N69/2 GF72.29-P-
Passenger-side front door control unit, Model 221 6010SX
component description GF72.29-P-
Model 216
6010SC
N69/3, N69/4 GF72.29-P-
Rear door control unit component description
Model 221 6020SX
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS) component description 6000SX
Contents, function description of central GF80.20-P-
locking (CL) 0996SX
OVERVIEW OF SYSTEM COMPONENTS, REMOTE TRUNK CLOSING, COMPONENT
DESCRIPTION - GF80.20-P-9999SX
MODEL 221.0 /1, 216.3 with CODE (881) Remote trunk closing (RTC [HDFS]) up to Model Year 8
GF54.30-P-
Instrument cluster, component description A1
6000SX
GF80.57-P-
Transmitter key, component description A8/1
6010SX
A40/3
Vehicles without code (494) USA GF82.85-P-
version and without code (498) Japan 3136SX
COMAND controller unit, component
version
description
GF82.85-P-
Vehicles with code (498) Japan version
3136SXJ
GF82.85-P-
Vehicles with code (494) USA version
3136SXU
GF54.30-P-
Cockpit central display, component description A40/8
6100SX
Front central operating unit, component GF54.21-P-
A40/9
description 4500SX
GF80.20-P-
Trunk lid drive unit, component description B24/16 andM51
6010SX
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
N69/1 GF72.29-P-
Driver-side front door control unit, component Model 216 6000SC
description GF72.29-P-
Model 221
6000SX
Keyless Go control unit, component N69/5 GF80.61-P-
description Vehicles with Keyless-Go code 889: 4200SX
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS) component description 6000SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
GF80.20-P-
TLC control unit, component description N121
6000SX
Driver power window, outside mirror and trunk GF54.25-P-
S20/1
lid switch group, component description 4230SX
Table of contents, function description for GF80.20-P-
remote trunk lid closing 0994SX
INFRARED REMOTE CONTROL RECEIVER, COMPONENT DESCRIPTION - GF80.30-P-6000SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 16: Locating Driver Door Infrared Sensor
Courtesy of MERCEDES-BENZ USA
Location
The infrared sensor is located in the door handle on the driver door.
Task
The infrared sensor receives the signals from the transmitter key (A8/1) and relays them to the
Left door control unit (N69/1) on model 216 or
Left front door control unit (N69/1) on model 221
The corresponding door control unit transfers the signals to the interior CAN.
Receiver signals
Global locking and unlocking central locking (ZV)
Selective unlocking
Remote trunk closing and opening
Convenience opening and closing
CONVENIENCE FEATURE (CF), LOCATION OF COMPONENTS - GF80.45-P-0003-01LE
Fig. 17: Locating Convenience Feature Components
Courtesy of MERCEDES-BENZ USA
CONVENIENCE FEATURE (CF), BLOCK DIAGRAM - GF80.45-P-0003-03LE
Fig. 18: Convenience Feature Block Diagram
Courtesy of MERCEDES-BENZ USA
CONVENIENCE FEATURE (CF), BLOCK DIAGRAM - GF80.45-P-0003-03SX
Fig. 19: Convenience Feature Block Diagram
Courtesy of MERCEDES-BENZ USA
CONVENIENCE FEATURE (CF), FUNCTION - GF80.45-P-0003LE
MODEL 221.0 /1 as of Model Year 09 /modification year 08
General function requirements
Tilting/sliding roof power window (with code (414) Electric glass tilting/sliding roof) or panoramic
sliding roof (with code (413) Panoramic glass sunroof with top sliding sunroof) normalized
Convenience feature (CF), general
The side windows, the tilting/sliding roof or the panoramic sliding roof and the rear roller sun blinds (with code
(297) Roller sun blind in rear doors) can be opened and closed centrally with the CF function.
On vehicles with code (401) Front comfort seats, including seat heating and seat ventilation, the seat ventilation
in the driver seat is switched to stage 3 during convenience opening.
The convenience feature comprises the following partial functions:
Function sequence for convenience feature via transmitter key (A8/1)
Function sequence for convenience feature via air recirculation function (without code (494) USA
version)
Function sequence for convenience feature via Keyless-Go (with code (889) Keyless-Go)
Additional function prerequisites for convenience feature via transmitter key
C. 15C OFF
Doors closed
Function sequence for convenience feature via transmitter key
When the "Lock" or "Unlock" button the transmitter key is actuated for a longer period of time, it transmits a
signal to the driver door infrared sensor (B58) via the interior CAN (precise aiming required). This signal is
read in by the left front door control unit (N69/1) and transmitted to the EIS control unit (N73) via the interior
CAN. The EIS control unit checks the access authorization of the transmitter key and enables the requested
function.
After enabling, the left front door control unit transmits the "open" or "close" signal to the following control
units via the interior CAN according to the request.
Right front door control unit (N69/2)
Left rear door control unit (N69/3)
Right rear door control unit (N69/4)
Overhead control panel control unit (N70)
Panoramic sliding roof control module (A98) (with code (413) Panoramic glass sunroof with top sliding
sunroof)
Left front seat control unit (N32/1) (with code (401) Front comfort seats incl. seat heating and seat
ventilation)
The left front door control unit actuates the left front power window motor (M10/3), the right front door control
unit actuates the right front power window motor (M10/4), the left rear door control unit actuates the left rear
power window motor (M10/5) and left rear side roller sun blind motor (M24/5) (with code (297) Roller sun
blind in rear doors) and right rear door control unit the right rear power window motor (M10/6) and right rear
side roller sun blind motor (M24/6) (with code (297) Roller sun blind in rear doors to open and close the side
windows and the rear roller side sun blinds according to the request.
On vehicles with code (414) Electric glass tilting/sliding roof the overhead control panel control unit actuates
the roof system drive unit (M12) to open or close the tilting/sliding roof according to the request.
On vehicles with code (413) Panoramic glass sunroof with top sliding roof, the panoramic sliding roof control
unit actuates the integrated panoramic sliding roof motor (A98m1), the front roller sun blind motor (M54) and
rear roller sun blind motor (M54/1) to close or open the panoramic sliding roof and the roller sun blind
according to the request.
On vehicles with code (401) Front comfort seats incl. seat heating and seat ventilation, the left front seat control
unit (N29/5) actuates the left front seat cushion ventilation motor group (M18/9) and the left front seat backrest
ventilation motor group (M18/10) via the left front seat ventilation blower regulator to switch on the seat
ventilation for the drive seat to stage 3.
On vehicles with panoramic sliding roof and rear side roller sun blinds on the rear doors, the roller sun blinds
and rear side roller sun blinds are opened first during comfort opening. The side and the panoramic sliding roof
are opened only after a new request. During comfort closing, the roller sun blinds and the rear side roller sun
blinds are actuated only the side windows, the panoramic sliding roof are completely closed and new request is
present.
Additional function requirements for convenience feature via air recirculation button
Circuit 15 On
Function sequence for convenience feature via air recirculation function
Comfort opening or closing is requested by the air recirculation switch (N72/1s37). he status of the air
recirculation switch is read in by the upper control panel control unit (N72/1) and transmitted to the AAC
control unit (N22/1) via the interior CAN. The AAC control unit then transmits the request to the following
control units via the interior CAN:
Door control module front left
Door control module front right
Door control module rear left
Door control module rear right
Overhead control panel control unit
Panoramic sliding roof control module
Left front seat control unit
The left front door control unit actuates the left front power window motor, the right front door control unit
actuates the right front power window motor, the left rear door control unit actuates the left rear power window
motor and left rear side roller sun blind and the right rear door control unit actuates the right rear power window
motor and right rear roller sun blind motor to open and close the side windows and the rear roller sun blinds
according to the request.
The overhead control panel control unit actuates the roof system drive unit to open or close the tilting/sliding
roof according to the request.
The panoramic sliding roof control unit actuates the integrated panoramic sliding roof motor, the front roller sun
blind motor and rear roller sun blind motor, to open or close the panoramic sliding roof and the roller sun blinds
according to the request.
The convenience feature is stopped when the air recirculation button is actuated again.
When closing with the air recirculation button, the current positions of the side windows, tilting/sliding roof
or panoramic roof are stored.
The next time the air recirculation button is pressed the windows are moved to the previously stored positions.
On vehicles with panoramic sliding roof and rear side roller sun blinds in the rear doors, the roller sun blinds
and rear side roller sun blinds are opened first during comfort opening. The side and the panoramic sliding roof
are opened only after a new request.
During comfort closing, the roller sun blinds and rear roller sun blinds are actuated only after the side windows,
the panoramic sliding roof are completely closed and a new request is present.
Additional function requirements for convenience feature via KEYLESS-GO
Circuit 15 Off
A transmitter key is located outside of the vehicle and an in the vicinity (s = 1 m) of the actuated left front
comfort sensor (B67/1b1), right front comfort sensor (B67/2b1), left rear comfort sensor (B67/3b1) or
right rear comfort sensor (B67/4b1)
Doors closed and vehicle locked
Touching comfort sensor on outside of door handle for t > 1, 5 s
A request to determine the position of the transmitter key is transmitted to the KEYLESS-GO trunk antenna
(A2/35), left rear door KEYLESS-GO antenna (A2/39) and right rear door KEYLESS-GO antenna (A2/41).
The transmitter key then transmits its position to the rear window antenna amplifier module (A2/12) which is
read in by the KEYLESS-GO control unit (N69/5).
Function sequence for convenience feature via Keyless-Go
When touching the comfort sensor, it transmits a signal to the KEYLESS-GO control unit. The KEYLESS-GO
control unit transmits the signal "Comfort closing" to the following control units via the interior CAN:
Door control module front left
Door control module front right
Door control module rear left
Door control module rear right
Overhead control panel control unit
Panoramic sliding roof control module
The left front door control unit actuates the left front power window motor, the right front door control unit
actuates the right front power window motor, the left rear door control unit actuates the left rear power window
motor and the left rear side window roller sun blind motor and the right rear door control unit actuates the right
rear power window motor and right rear roller sun blind motor to close the side windows and the rear side roller
sun blinds.
The overhead control panel control unit actuates the roof system drive unit to close the tilting/sliding roof.
The panoramic sliding roof control unit actuates the integrated panoramic sliding roof motor, the front roller sun
blind motor and rear roller sun blind motor to close the panoramic sliding roof and the roller sun blinds.
During comfort closing, the roller sun blinds and the rear roller sun blinds are actuated only after the side
windows, the panoramic sliding roof or the tilting/sliding roof are completely closed and a new request is
present.
Convenience closing is interrupted in the following cases:
when another comfort sensor is touched,
when the comfort sensor is no longer touched,
After max. t = 90 s
If another central locking command is present
The convenience function is a manual closing function, i.e. the comfort sensor must be touched during the
entire closing procedure; when the sensor is released, the procedure is stopped.
If during comfort closed or max. t = 2 s after the same KEYLESS-GO door handle is pulled, the emergency
opening function is activated. In this case, the side windows, the tilting/sliding roof or the panoramic sliding
roof are actuated in the opening direction. Actuation is performed for min. t = 2 s or as long as the KEYLESS-
GO door handle is pulled, max. t = 90 s.
Convenience feature (CF), location of GF80.45-P-
components 0003-01LE
Function schematic for electric convenience PE80.45-P-
opening/closing with transmitter key 2052-97SAA
Function schematic for electric convenience PE80.45-P-
opening/closing via recirculated air function 2053-97SAA
Function schematic for electric convenience PE80.45-P-
With CODE (889) Keyless-Go
closing via keyless go 2054-97SAA
GF80.45-P-
Convenience feature (CF), block diagram
0003-03LE
A98
Panoramic sliding roof control module, On model 221.1 with code (413) GF77.20-P-
component description Panoramic glass roof with top 4106LE
sliding roof
Automatic air conditioning control unit GF83.40-P-
N22/1
component description 3012LE
Left front seat control unit, component GF91.29-P-
N32/1
description 5230LE
description N69/1 4141LE
Right front door control unit, component GF72.29-P-
N69/2
description 4142LE
Rear door control unit, component GF72.29-P-
N69/3, N69/4
description 6020LE
Keyless-Go control unit, component N69/5 GF80.61-P-
description With CODE (889) Keyless-Go 4204LE
Overhead control panel control unit, GF82.20-P-
N70
component description 5216LE
Upper control panel control unit, GF54.21-P-
N72/1
component description 6040LE
Component description for the EZS control GF80.57-P-
N73
unit 6003LE
CONVENIENCE FEATURE (CF), FUNCTION - GF80.45-P-0003SX
MODEL 221.0 /1 up to Model Year 8
Fig. 20: Convenience Feature Function Diagram
Courtesy of MERCEDES-BENZ USA
General
The convenience feature (CF) includes the following functions
Convenience closing/opening with transmitter key
Convenience opening/closing via recirculated air
Convenience closing via Keyless Go (with code (889) Keyless Go)
The convenience opening/closing function opens and closes
the windows
the tilting/sliding roof (with code (414) Power glass tilting/sliding roof)
the panoramic glass roof with roller blinds in roof (on model 221.1 with code (413) Panoramic sliding
roof with top sliding roof)
the rear side roller blinds (with code (297) Roller sun blind in rear doors)
Activation sequence for convenience opening
Vehicles up to 31.5.07:
The front windows and the roller sun blinds are opened first. When reactuated, the rear windows and the
tilting/sliding roof or panoramic roof open.
Vehicles as of 1.6.07:
The roller sun blinds are opened first. When reactuated, the rear windows and the tilting/sliding roof open.
Activation sequence for convenience closing
The windows and the tilting/sliding roof or panoramic are closed first. When reactuated, the roller sun blinds
close.
The roller sun blinds are not actuated via recirculated air during convenience closing/opening.
Convenience feature via transmitter key
Function requirements
No transmitter key in EIS control unit
Driver door closed
Function
When the "Lock or unlock" button on the transmitter key is pressed and held down (t > 1 s), it transmits an
infrared command "Convenience feature" to the driver door infrared sensor. This signal is read in by the left
front door control unit and transmitted to the EIS control unit via interior CAN. The EIS control unit checks the
access authorization of the transmitter key. If the access authorization is valid, the EIS control unit transmits the
"Convenience feature" command via the interior CAN to the door control units, and overhead control panel
control unit which actuate the corresponding motors.
When the "Lock or unlock" button is released, the convenience feature is stopped.
Convenience opening/closing via recirculated air button
Function requirements
Circuit 15 On
Function
When the recirculated air button in the upper control panel control unit is actuated for longer than 1.5 s, the
"Convenience actuation" command is transmitted to the door control unit and overhead control panel control
unit via the interior CAN. The current positions are stored and convenience closing is performed. When the air
recirculation switch is actuated again for longer than 1.5 s, the corresponding windows and tilting/sliding roof
are automatically moved the position they were in before convenience closing was started.
A panoramic sliding roof must be moved manually to the desired position.
The convenience feature is immediately stopped when the air recirculation switch is actuated again.
Convenience closing via keyless go
Function requirements
No transmitter key in EIS control unit
All doors closed
Function
When a comfort sensor is touched (t > 1.5 s), it transmits a signal to the KEYLESS GO control unit. The
Keyless Go control unit then transmits the "Convenience actuation" command to the door control units and
overhead control panel control unit for the duration of the actuation via the interior CAN
Convenience closing is interrupted in the following cases:
another comfort sensor is actuated
when the comfort sensor is no longer touched,
after max. 90 s
If the same door handle is pulled during convenience closing, or max. 2 s thereafter, emergency opening is
activated. Actuation is performed for min. 2 s or as long as the door handle is pulled, max. 90 s.
GF80.45-P-
Convenience feature (CF), block diagram
0003-03SX
GF80.57-P-
Transmitter key, component description A8/1
6010SX
Infrared remote control receiver, GF80.30-P-
B58
component description 6000SX
Keyless Go sensor unit, component B67/1, B67/2, B67/3, B67/4 GF80.61-P-
description On vehicles with code (889) Keyless Go 4109SX
description M10/3, M10/4, M10/5, M10/6 6030SX
M12
Tilting/sliding roof system (SR) drive unit, GF77.20-P-
On vehicles with code (414) Power glass
component description 5214SX
tilting/sliding roof
M12
Panoramic sliding roof system drive unit, GF77.20-P-
on model 221.1 with code (413)
component description 5213SX
Panoramic glass roof with top sliding roof
M24/5, M24/6
Rear side roller sun blind motor, GF68.50-P-
On vehicles with code (297) Roller sun
component description 5000SX
blinds in rear doors
on model 221.1 with code (413)
Panoramic glass roof with top sliding roof
Panoramic sliding roof roller sun blind Front roller sun blind motor GF77.20-P-
motor, component description M54 5215SX
Rear roller sun blind motor GF77.20-P-
M54/1 5215SXA
Driver-side front door control unit, GF72.29-P-
N69/1
component description 6000SX
Passenger-side front door control unit, GF72.29-P-
N69/2
component description 6010SX
Rear door control unit, component GF72.29-P-
N69/3, N69/4
description 6020SX
Keyless Go control unit, component N69/5 GF80.61-P-
description On vehicles with code (889) Keyless Go 4200SX
Overhead control panel control unit, GF82.20-P-
N70
component description 5216SX
Upper control panel control unit, GF54.21-P-
N72/1
component description 6040SX
Electronic ignition/starter switch control GF80.57-P-
N73
unit (EIS), component description 6000SX
TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR CONVENIENCE FEATURE (CF) -
GF80.45-P-0999LE
MODEL 221.0 /1 as of Model Year 09 /modification year 08
Convenience feature (CF), function GF80.45-P-0003LE
Convenience feature (CF), location of components GF80.45-P-0003-01LE
Convenience feature (CF), block diagram GF80.45-P-0003-03LE
Overview of system components for convenience actuation (CF) GF80.45-P-9998LE
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF CONVENIENCE FEATURE (CF) -
GF80.45-P-0999SX
MODEL 221.0 /1 up to Model Year 8
Convenience feature (CF), function GF80.45-P-0003SX
Convenience feature (CF), block diagram GF80.45-P-0003-03SX
Overview of system components for convenience feature (CF) GF80.45-P-9998SX
OVERVIEW OF SYSTEM COMPONENTS FOR CONVENIENCE ACTUATION (CF) - GF80.45-P-
9998LE
MODEL 221.0 /1 as of Model Year 09 /modification year 08
A98
Panoramic sliding roof control module, GF77.20-P-
On model 221.1 with code (413) Panoramic
component description 4106LE
glass roof with top sliding roof
Automatic air conditioning control unit GF83.40-P-
N22/1
component description 3012LE
Left front seat control unit, component GF91.29-P-
N32/1
description 5230LE
Left front door control unit, component GF72.29-P-
N69/1
description 4141LE
Right front door control unit, component GF72.29-P-
N69/2
description 4142LE
Rear door control unit, component GF72.29-P-
N69/3, N69/4
description 6020LE
Keyless-Go control unit, component N69/5 GF80.61-P-
description With CODE (889) Keyless-Go 4204LE
Overhead control panel control unit, GF82.20-P-
N70
component description 5216LE
Upper control panel control unit, GF54.21-P-
N72/1
component description 6040LE
Component description for the EZS GF80.57-P-
N73
control unit 6003LE
Table of contents, function description for GF80.45-P-
convenience feature (CF) 0999LE
OVERVIEW OF SYSTEM COMPONENTS FOR CONVENIENCE FEATURE (CF) - GF80.45-P-
9998SX
MODEL 221.0 /1 up to Model Year 8
GF80.57-P-
Transmitter key, component description A8/1
6010SX
Infrared remote control receiver unit, GF80.30-P-
B58
component description 6000SX
Keyless Go sensor unit, component B67/1, B67/2, B67/3 and B67/4 GF80.61-P-
description On vehicles with code (889) Keyless Go 4109SX
Power window motor, component GF72.29-P-
M10/3, M10/4, M10/5 and M10/6
description 6030SX
M12
Tilting/sliding roof system (SR) drive unit, GF77.20-P-
On vehicles with code (414) Power glass
component description 5214SX
tilting/sliding roof
M12
Panoramic sliding roof system drive unit, GF77.20-P-
On vehicles with code (413) Panoramic
component description 5213SX
glass roof with top sliding roof
M24/5, M24/6
Rear side roller sun blind motor, GF68.50-P-
On vehicles with code (297) Roller sun
component description 5000SX
blinds in rear doors
On vehicles with code (413) Panoramic
glass roof with top sliding roof
Panoramic sliding roof roller sun blind GF77.20-P-
M54
motor, component description 5215SX
GF77.20-P-
M54/1
5215SXA
Driver front door control unit, component GF72.29-P-
N69/1
description 6000SX
Passenger front door control unit, GF72.29-P-
N69/2
component description 6010SX
Rear door control unit, component GF72.29-P-
N69/3, N69/4
description 6020SX
Keyless Go control unit, component N69/5 GF80.61-P-
description On vehicles with code (889) Keyless Go 4200SX
Overhead control panel control unit, GF82.20-P-
N70
component description 5216SX
Upper control panel control unit, GF54.21-P-
N72/1
component description 6040SX
Electronic ignition switch (EIS) control GF80.57-P-
N73
unit, component description 6000SX
Table of contents for function description GF80.45-P-
of convenience feature (CF) 0999SX
ANTI-THEFT ALARM SYSTEM (ATA [EDW]), BLOCK DIAGRAM - GF80.50-P-0001-01LE
Fig. 21: Anti-Theft Alarm System Block Diagram
Courtesy of MERCEDES-BENZ USA
ANTI-THEFT ALARM SYSTEM (ATA [EDW]), BLOCK DIAGRAM - GF80.50-P-0001-01SX
Fig. 22: Anti-Theft Alarm System Block Diagram
Courtesy of MERCEDES-BENZ USA
ANTI-THEFT ALARM SYSTEM (ATA), LOCATION OF COMPONENTS - GF80.50-P-0001-02LE
Fig. 23: Locating Anti-Theft Alarm System Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
ANTI-THEFT ALARM SYSTEM (ATA), LOCATION OF COMPONENTS - GF80.50-P-0001-02SX
Fig. 24: Locating Anti-Theft Alarm System Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
ANTI-THEFT ALARM SYSTEM (ATA [EDW]), FUNCTION - GF80.50-P-0001LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08 with CODE (551) Anti-theft alarm system (ATA
[EDW])
Antitheft alarm system (ATA), general
The anti-theft alarm system (ATA) monitors all relevant inputs for their non-actuated state If it detects a change
The acoustic signals are output by the alarm signal siren (H3/1). The visual signals are output country-specific
by means of the exterior lights. In addition, the interior illumination (front and rear) is switched on via the
overhead control panel control unit (N70).
When the panic alarm is activated (with code (763) Radio remote control with panic alarm), the interior
illumination is not activated in contrast to the ATA.
The rear SAM control unit with rear fuse and relay module (N10/2) has the master function for the ATA.
The ATA, when armed, monitors:
Doors
Trunk lid
Engine hood
Position change of vehicle (tow-away protection) (except on:
Code (494) USA version
Code (460) Canada version
Code (498) Japan version)
Voltage supply and data line for alarm signal horn
Motion in interior compartment (interior protection) (with code (882) Interior monitoring (only with
ATA))
The ATA comprises the following partial functions described in separate documents:
Activate anti-theft alarm system, function
Anti-theft alarm system trigger, function
Alarm actuation by panic switch, function (with code (763) Radio remote control with panic switch)
Anti-theft alarm system (ATA), location GF80.50-P-0001-
of components 02LE
Anti-theft alarm system (ATA [EDW]), GF80.50-P-0001-
block diagram 01LE
GF80.50-P-
Activate anti-theft alarm system, function
2002LE
GF80.50-P-
Anti-theft alarm system trigger, function
2004LE
Triggering alarm with panic switch, With code (763) Radio remote control GF80.50-P-
function with panic switch 3014LEU
ANTI-THEFT ALARM SYSTEM (ATA [EDW]), FUNCTION - GF80.50-P-0001SX
MODEL 221.0 /1, 216.3 with CODE (551) Anti-theft alarm system (ATA [EDW]) up to Model Year 8
The anti-theft alarm system (ATA) monitors all relevant inputs for their non-actuated state If it detects a change
of state in one of the monitored inputs, it triggers a country-specific acoustic and visual alarm.
The acoustic signals are output by the alarm signal horn with additional battery (H3/1). The visual signals are
output country-specific by means of the exterior lights. In addition, the interior illumination (front and rear) is
switched on via the overhead control panel control unit (N70). When the panic alarm is activated (only
with code (763) Radio remote control with panic alarm), the interior illumination is not activated in contrast to
the ATA. The rear SAM control unit with rear fuse and relay module (N10/2) has the master function for the
ATA.
The national functions and alarm outputs can be set with the vehicle programming.
The ATA, when armed, monitors:
Doors
Trunk lid
Engine hood
Position change of vehicle (tow-away protection)
Voltage supply and data line for alarm signal horn
Motions in interior compartment (with code (882) Interior monitoring (with ATA only))
ATA activated by:
Locking the vehicle with the transmitter key (A8/1)
Locking vehicle via Keyless Go (KG) (with code (889) Keyless Go)
Locking by automatic relocking:
Automatic activation (only )
If the driver door is opened and closed again after removing the transmitter key, the ATA activates
automatically 2 minutes after the last door is closed regardless whether the vehicle is locked.
Alarm inputs
The ATA evaluates the following alarm inputs:
Alarm signal siren
Left rotary tumbler switch (A85s1) (model 216) or left front rotary tumbler switch (A85s1) (model 221)
Right rotary tumbler switch (A85/1s1) (model 216) or Right front rotary tumbler switch (A85/1s1)
(model 221)
Left rear rotary tumbler switch (A85/3s1) (model 221)
Right rear rotary tumbler switch (A85/4s1) (model 221)
Engine hood ATA switch (S62)
Trunk lid rotary tumbler microswitch (M14/7s3)
Ultrasonic echo sounder sensor (A26/13) (with code (882) Interior monitoring (with ATA [EDW] only))
Function
After the central locking (CL) is closed, the EIS control unit (N73) transmits the message "Vehicle locked" to
the rear SAM control unit, which then activates the ATA. The outer right ATA function display (N72/1e2) in
the upper control panel control unit (N72/1) flashes. The status of the alarm inputs is checked cyclically (every
0.4 s). If the polls indicate that an input is at rest within 10 s, the corresponding input is then armed. Alarm
inputs set later to the non-actuated state (e.g. if the trunk lid is closed only after the vehicle has been locked), are
also armed 10 s after closing. The turn signal feedback flashes three times only after the last door and trunk lid
are closed.
Partial activation of ATA
Function requirement
ATA not activated
Function
The tow-away protection and the interior protection (with code (882) Interior monitoring (with ATA only)) can
be deactivated using the COMAND control unit (A40/3) or the free programming button (A40/9s10) in the
central front operating unit (A40/9). The interior protection and the tow-away sensor can be deactivated or
activated independently from the selected circuit status. This makes it possible, for example, to deactivate the
corresponding function while driving. Deactivation is only valid for the following activation. It is reset with
ignition "ON" (c. 15) or each time the ATA is deactivated. Exceptions are activations after
Trunk lid remote release
Remote trunk closing/opening
Relocking CL
The previous status is restored during these procedures.
Tow-away protection
The tow-away protection is activated 10 seconds after the closing command of the EIS control unit and only
after the last door and the trunk lid are locked. The inclination sensor is integrated into the alarm signal horn
and communicates with the rear SAM control unit. When the inclination sensor is defective or not connected,
the full function of all other ATA components is maintained.
Interior protection
(with code (882) Interior monitoring (with ATA only))
The ultrasonic echo sounder sensor is activated 10 s after the last door or the trunk lid is locked. The ultrasonic
echo sounder sensor is ready for an alarm after an additional 20 seconds; this time is required for it to measure
the interior compartment for reference purposes.
Automatic relocking
The automatic relocking function is actuated by the EIS control unit.
If the vehicle is unlocked and neither a door nor the trunk lid is opened within 40 s, the vehicle relocks
automatically. Relocking is not signaled by the turn signal lamps. The rear SAM control unit arms the ATA
when the EIS control unit is relocked. The interior protection and tow-away protection are set to the same status
as before the opening procedure
Special case: Driver door
If the driver door is still open when the ATA is activated, the left front door lock unit (A85) on model 221 or
left door lock unit (A85) on model 216 is not actuated and the door remains unlocked. After the driver door is
closed, the door status is transmitted to the rear SAM control unit and the alarm input is included in the poll
cycle leading to alarm actuation when the driver door is opened without previously deactivating the ATA.
Automatic activation (only )
Activation for the Belgium national version is supplemented so that the ATA is completely disarmed following
a delay time of 120 s after the transmitter key is removed and the driver door is opened/closed. This is
accomplished regardless of central locking.
Special case: Acoustic feedback following successful activation (only )
In addition to the visual feedback, the alarm signal horn with additional battery outputs an acoustic signal by
buzzing momentarily.
If one door is not properly closed during ATA [EDW] activation, no feedback will be given.
Deactivating ATA
The ATA can be deactivated by:
Unlocking CL with transmitter key or
Inserting transmitter key into EIS control unit (c. 15C ON) or
Unlocking via Keyless Go (KG) (with code (889) Keyless Go)
The corresponding signals from the EIS control unit are read in by the rear SAM control unit, which deactivates
the ATA.
Special case: Acoustic deactivation feedback (only )
The alarm signal horn with additional battery outputs an acoustic feedback by buzzing once.
Anti-theft alarm system (ATA GF80.50-P-
[EDW]), block diagram 0001-01SX
Anti-theft alarm system (ATA), GF80.50-P-
location of components 0001-02SX
Anti-theft alarm system trigger, GF80.50-P-
function 2004SX
Triggering alarm with panic On vehicles with code (494) USA version with GF80.50-P-
switch, function CODE (763) Radio remote control with panic switch 3014SXU
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION FOR ANTI-THEFT ALARM SYSTEM
(ATA) - GF80.50-P-0999LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08 with CODE (551) Anti-theft alarm system (ATA
[EDW])
Anti-theft alarm system (ATA [EDW]), GF80.50-P-
function 0001LE
Anti-theft alarm system (ATA), location of GF80.50-P-0001-
components 02LE
Anti-theft alarm system (ATA [EDW]), block GF80.50-P-0001-
diagram 01LE
GF80.50-P-
Activate anti-theft alarm system, function
2002LE
GF80.50-P-
Anti-theft alarm system trigger, function
2004LE
With code (763) Radio remote GF80.50-P-
Triggering alarm with panic switch, function
control with panic switch 3014LEU
Overview of system components for anti-theft GF80.50-P-
alarm system (ATA) 9998LE
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION FOR ANTI-THEFT ALARM SYSTEM
(ATA) - GF80.50-P-0999SX
MODEL 221.0 /1, 216.3 with CODE (551) Anti-theft alarm system (ATA [EDW]) up to Model Year 8
Anti-theft alarm system (ATA GF80.50-P-
[EDW]), function 0001SX
Anti-theft alarm system (ATA GF80.50-P-
[EDW]), block diagram 0001-01SX
Anti-theft alarm system (ATA), GF80.50-P-
location of components 0001-02SX
Anti-theft alarm system trigger, GF80.50-P-
function 2004SX
function CODE (763) Radio remote control with panic 3014SXU
switch
Overview of system components for GF80.50-P-
anti-theft alarm system (ATA) 9998SX
ACTIVATE ANTI-THEFT ALARM SYSTEM, FUNCTION - GF80.50-P-2002LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08 with CODE (551) Anti-theft alarm system (ATA
[EDW])
Function requirements, general
C. 15C OFF
Central locking operating properly
Activate antitheft alarm system (ATA), general
The antitheft alarm system (ATA) is activated automatically when the vehicle is locked with the central locking
(CL). Then the individual alarm inputs are monitored. The activated ATA is indicated by the ATA function
indicator (N72/1e2) flashing continuously.
On vehicles for Belgium, the ATA arms automatically without locking the vehicle with the CL.
It is possible, before locking the CL, to switch off the tow-away protection (except with code (494) USA
version, with code (460) Canada version and with code (498) Japan version) or the interior protection (on
vehicles with code (882)Interior monitoring (only with ATA)).
Activation of the ATA comprises several subfunctions:
Function sequence for activating ATA
Function sequence for switching off tow-away protection of ATA
Function sequence for switching off interior protection of ATA
Function sequence for activating alarm inputs
Function sequence for activating ATA
The partial function is comprised of the following partial functions:
Function sequence for locking with transmitter key (A8/1)
Function sequence for locking CL with automatic relocking feature
Function sequence for locking CL with Keyless-Go (with code (889) Keyless-Go)
Function sequence for automatic activation (only on vehicles for Belgium)
Special case: Driver door
If the driver door is still open when the CL is locked, it is not locked. When the driver door is closed, the door
status is indicated to the rear SAM control unit with fuse and relay module (N10/2) and the alarm input is
included in the checking cycle. This leads to actuation of an alarm when opening the driver door without
previous deactivation of the ATA.
Function sequence for locking CL with transmitter key
When the "Lock" button on the transmitter key (A8/1) is actuated, it transmits a radio signal via the rear
window antenna amplifier module (A2/12) to the rear SAM control unit. This relays the signal to the EIS
control unit (N73) via interior CAN. Parallel to the radio signal an infrared signal is transmitted by the
transmitter key to the driver door (B58) (precise aiming required).
This signal is read in by the left door control unit (N69/1) (model 216) or left front door control unit (N69/1)
(model 221) and is transmitted by the EIS control unit via the interior CAN.
In both cases, the EIS control unit checks the access authorization of the transmitter key.
If the access authorization is valid, the message "Vehicle locked" is transmitted with the interior CAN to the
SAM control unit, which then activates the ATA.
Function sequence for locking CL with automatic relocking feature
The automatic relocking function is actuated by the EIS control unit. If the vehicle is unlocked and neither a
door nor the trunk lid is opened within 40 s, the vehicle relocks automatically. The EIS control unit transmits
via interior CAN the message "Vehicle locked" to the rear SAM control unit, which then activates the ATA.
Function sequence for locking CL with Keyless-Go:
Detailed information on the function sequence for locking the CL via Keyless-Go is given in the separate
Keyless-Go function description.
After locking the CL, the EIS control unit transmits the message "Vehicle locked" via interior CAN to the rear
SAM control unit, which then activates the ATA.
Function sequence for self-activation
When the transmitter key is removed from the EIS control unit, the driver door or the trunk is opened and
closed again, the ATA is activated automatically 2 s after the last door or the trunk lid is closed, regardless of
the status of the vehicle central locking. The interior protection and the tow-away protection are set to the same
state as before the last unlocking procedure.
Additional function requirements for switching off tow-away protection of ATA
ATA not yet activated
Function sequence for switching off tow-away protection of ATA
The tow-way protection can be deactivated with the COMAND control unit (A40/3) or by the button for free
programming (A40/9s10), if not programmed previously, in the front central operating unit (A40/9). The tow-
way protection can be deactivated or activated independently from the selected circuit status. This makes it
possible, for example, to deactivate the tow-away protection while driving. Deactivation is only valid for the
following activation. It is reset with ignition "ON" (c. 15) or each time the ATA is deactivated.
Additional function requirements for switching off interior protection of ATA
ATA not yet activated
Function sequence for switching off interior protection of ATA
The interior protection (with code (882) Interior monitoring (only with ATA)) can be deactivated with the
COMAND control unit or the button free for programming, if not programmed previously in the central front
control unit. The interior protection can be deactivated or activated independently from the selected circuit
status. This makes it possible, for example, to deactivate the interior protection while driving. Deactivation is
only valid for the following activation. It is reset with ignition "ON" (c. 15) or each time the ATA is
deactivated.
Additional function requirements for activating alarm inputs
ATA activated
Function sequence for activating alarm inputs
The partial function is comprised of the following partial functions:
Function sequence for monitoring switch
Function sequence for activating tow-away protection
Function sequence for activating interior protection
Function sequence for activating alarm siren (H3/1)
Function sequence for monitoring switch
The status of the following switches is checked cyclically every t = 0, 4 ms. If the polls indicate that an input is
at rest within t = 10 s, the corresponding input is then armed. Alarm inputs set later to the non-actuated state,
e.g. if the trunk lid is closed only after the vehicle has been locked, are also armed t = 10 s after closing.
Monitored switches:
Left rotary tumbler switch (A85s1) (model 216) or left front rotary tumbler switch (A85s1) (model 221)
Right rotary tumbler switch (A85/1s1) (model 216) or Right front rotary tumbler switch (A85/1s1)
(model 221)
Left rear rotary tumbler switch (A85/3s1) (model 221)
Right rear rotary tumbler switch (A85/4s1) (model 221)
Engine hood ATA switch (S62)
Trunk lid rotary tumbler microswitch (M14/7s3)
Ultrasonic echo sounder sensor (A26/13) (with code (882) Interior monitoring (with ATA [EDW] only))
Alarm signal siren (H3/1)
Function sequence for activating tow-away protection
The tow-away protection is activated (if not previously deselected for the next locking operation) t = 10 s after
the locking command from the EIS control unit and after closing the last door and tailgate.
The inclination sensor in the alarm siren determines a reference position, with which the relative vehicle
inclination is compared during the activation. Determination of the reference position requires approx. t = 10 to
15 to s, for this reason an alarm can only be triggered t = 25 s at the earliest after arming.
The inclination sensor communicates with the rear SAM control unit with rear SAM-LIN.
When the maximum vehicle inclination is exceeded with regard to the reference position, an alarm is triggered.
If the vehicle inclination changes very slowly (e.g. leaky tire), the reference position adapts to the current
vehicle position to prevent inadvertent activation of the inclination sensor.
If the vehicle inclination sensor is faulty, all other components of the ATA continue to function properly and the
corresponding fault codes are entered in the fault memory in the rear SAM control unit.
Function sequence for activating interior protection
The interior protection is activated (if not previously deselected for the next closing) t = 10 s after the last door
or the trunk is closed. The interior protection is ready for alarm after another t = 20 s, because it is first
necessary to calibrate the ultrasonic echo sounder sensor to the vehicle interior.
The status of the ultrasonic echo sounder sensor is monitored by the rear SAM control unit. If a defect is
detected, the remaining ATA functions are still ensured regardless of this error. The corresponding fault codes
are stored in the fault memory in the rear SAM control unit.
Function sequence for activating alarm siren
The alarm siren is armed together with the ATA and checked cyclically approx. every t = 700 ms by the rear
SAM control unit with rear SAM-LIN.
Deactivating ATA:
The ATA is deactivated completely by opening the CL with transmitter key with infrared or radio or by
switching on circuit 15C (valid transmitter key in EIS control unit). The EIS control unit transmits the
corresponding signal via interior CAN to the rear control unit, which then activates the ATA.
PE80.50-P-
Function schematic for Model 216
2052-97CAA
electric anti-theft alarm
system, activation PE80.50-P-
Model 221
2052-97SAA
A40/3
With code (526) COMAND with single DVD drive GF82.85-P-
(without navigation) or with code (527) COMAND 3136LE
COMAND controller unit, APS with single DVD drive (with navigation)
component description GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
Front central operating unit, GF54.21-P-
A40/9
component description 4500LE
Rear SAM control unit with
GF54.21-P-
fuse and relay module, N10/2
6030LE
component description
Left door control unit, N69/1 GF72.29-P-
component description Model 216 4124LA
Left front door control unit, N69/1 GF72.29-P-
component description Model 221 4141LE
Upper control panel control GF54.21-P-
N72/1
unit, component description 6040LE
Component description for GF80.57-P-
N73
the EZS control unit 6003LE
ANTI-THEFT ALARM SYSTEM TRIGGER, FUNCTION - GF80.50-P-2004LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08 with CODE (551) Anti-theft alarm system (ATA
[EDW])
General function requirements
Anti-theft alarm system (ATA) activated
Anti-theft alarm system alarm triggering, general
If one of the alarm inputs of the activated ATA exits its non-actuated state, an alarm is triggered.
Alarm actuation in the event of undervoltage
The operating voltage range of the ATA is defined from U = 8 to 16 V. If the voltage drops below U < or =8 V,
it is no longer possible to trigger a visual alarm output. Only an acoustic alarm is triggered. The battery voltage
is stored in the ATA alarm memory in the rear SAM control unit with fuse and relay module (N10/2).
The ATA alarm triggering comprises the following partial functions:
Function sequence for alarm actuation by opening a door, trunk lid or engine hood
Function sequence for alarm actuation by changing vehicle position (without code (494) USA
version, without code (460) Canada version or without code (498) Japan version)
Function sequence for alarm triggering by motion in interior compartment (with code (882)
Interior monitoring (only with ATA))
Function sequence for alarm actuation from communication loss to alarm siren (H3/1)
Function sequence for emergency opening (with code (494) USA version)
Function sequence for alarm output
Function sequence for alarm interruption
Function sequence for alarm actuation by opening a door, trunk lid or engine hood
The rear SAM control unit actuates an alarm as soon as the non-actuated state of one of the following switches
is interrupted for t > 0.5 s:
Left rotary tumbler switch (A85s1) (model 216) or left front rotary tumbler switch (A85s1) (model 221)
Right rotary tumbler switch (A85/1s1) (model 216) or Right front rotary tumbler switch (A85/1s1)
(model 221)
Left rear rotary tumbler switch (A85/3s1) (model 221)
Right rear rotary tumbler switch (A85/4s1) (model 221)
Engine hood ATA switch (S62)
Trunk lid rotary tumbler microswitch (M14/7s3)
The status of the rotary tumbler is read in by the
Left door control unit (N69/1) (model 216) or left front door control unit (N69/1) (model 221),
Right door control unit (N69/2) (model 216) or right front door control unit (N69/2) (model 221),
Left rear door control unit (N69/3) (model 221) or right rear door control unit (N69/4) (model 221)
and transmitted to the rear SAM control unit via the interior CAN.
The ATA engine hood switch and the trunk lid rotary tumbler microswitch are read in directly by the rear SAM
control unit. To trigger a new alarm, the corresponding switch must first change to the non-actuated state.
After a non-actuated state of t = 10 s an alarm can be reactuated by the same switch, if an acoustic alarm is not
present.
If a locked vehicle is unlocked with the mechanical key and the door is opened, the ATA triggers an alarm.
Additional function requirements for alarm triggering by changing vehicle inclination
Tow-away protection not deactivated
Function sequence for alarm actuation due to change of vehicle inclination
If the inclination sensor integrated into the alarm siren recognizes an alarm-relevant inclination, an alarm is
output. The corresponding signal is relayed to the rear SAM control unit with the rear SAM-LIN.
Actuation criterion:
Change in vehicle inclination (horizontal axis) 1° to -1°, ±0.2°
Alarm is recognized before a wheel looses ground contact when lifting the vehicle.
Additional function requirements for alarm triggering by motion in interior compartment
Interior protection not deactivated
Function sequence for alarm actuation from motion in interior compartment
The signals from the ultrasonic echo sounder sensor (A26/13) (with code (882) Interior monitoring (only with
ATA)) are read in by the rear SAM control unit.
If a movement in the vehicle interior is recognized and considered to be alarm-relevant, an alarm is output.
On vehicles with tilting/sliding roof (SHD) (with code (414) Electric glass tilting/sliding roof) or panoramic
sliding roof (with code (413) Panoramic glass sunroof with top sliding sunroof) the interior compartment is not
monitored during activated rain closing.
Function sequence for alarm triggering from communication loss to alarm siren
The alarm siren is actuated cyclically by the rear SAM control unit via the rear SAM-LIN. If a reply to this
request is not received within t = 1 s by the alarm siren (no communication), the rear SAM control unit and
alarm siren trigger an alarm. If the alarm siren detects a loss in the supply voltage, it also outputs an acoustic
alarm automatically.
An alarm is only repeated if a new alarm event is registered after the active acoustic alarm was terminated.
Function sequence for emergency opening
The trunk lid emergency opening switch (S88/10) ensures that the trunk lid can also be opened from the inside
of the trunk lid when the vehicle is locked. The rear SAM control unit reads in and evaluates the trunk lid
emergency opening switch. The ATA triggers an alarm when the trunk lid emergency release switch is actuated.
Function sequence for alarm output
The following components for the exterior lights are actuated to output a visual alarm:
by the front SAM control unit with fuse and relay module (N10/1):
Left turn signal light (E1e5)
Right turn signal light (E2e5)
by the rear SAM control unit:
Left turn signal light (E3e1)
Right turn signal light (E4e1)
by the left door control unit (model 216) or left front door control unit (model 221):
Left outside mirror turn signal light (E6/5)
by the right door control unit (model 216) or right front door control unit (model 221):
Right outside mirror turn signal lamp (E6/6)
The acoustic alarm is output by the rear SAM control unit actuating the alarm siren via the rear SAM-LIN. The
interior illumination is switched on by the overhead control panel control unit (N70).
Function sequence for alarm interruption
An alarm is interrupted by opening the central locking (CL) of the vehicle with the transmitter key (A8/1) or by
switching on circuit 15C (valid transmitter key inserted into EIS control unit (N73)).
The EIS control unit transmits the corresponding signal via the interior CAN to the rear SAM control unit,
which then terminates the activated alarm.
PE80.50-P-2053-
Model 216
Function schematic for electric anti-theft alarm system, alarm 97CAA
actuation PE80.50-P-2053-
Model 221
97SAA
Front SAM control unit with fuse and relay module,
N10/1 GF54.21-P-6070LE
component description
Rear SAM control unit with fuse and relay module,
N10/2 GF54.21-P-6030LE
component description
N69/1
Left door control unit, component description GF72.29-P-4124LA
Model 216
N69/1
Left front door control unit, component description GF72.29-P-4141LE
Model 221
N69/2
Right door control unit, component description GF72.29-P-4128LA
Model 216
N69/2
Right front door control unit, component description GF72.29-P-4142LE
Model 221
N69/3,
Rear door control unit, component description N69/4 GF72.29-P-6020LE
Model 221
Overhead control panel control unit, component description N70 GF82.20-P-5216LE
Component description for the EZS control unit N73 GF80.57-P-6003LE
ANTI-THEFT ALARM SYSTEM TRIGGER, FUNCTION - GF80.50-P-2004SX
MODEL 221.0 /1, 216.3 with CODE (551) Anti-theft alarm system (ATA [EDW]) up to Model Year 8
Fig. 25: Anti-Theft Alarm System Trigger Function Diagram
Courtesy of MERCEDES-BENZ USA
Shown on model 221
Alarm actuation by opening a door, the trunk lid or the engine hood
Function requirements:
Anti-theft alarm system (ATA) is activated.
Function
If a switch changes from the non-actuated state, an alarm is triggered. The rear SAM control unit starts an
acoustic and visual alarm.
If a locked vehicle is unlocked with the mechanical key and the door is opened, the ATA triggers an alarm.
Alarm actuation due to change of vehicle inclination
Function requirements
ATA activated
Tow-away protection not previously deactivated
Function
The rear SAM control unit checks with the inclination sensor integrated into the alarm siren the vehicle
inclination a number of times each second.
If an inclination change is recognized, an acoustic and optic alarm is triggered.
Each time the ATA is activated, the inclination sensor determines a new reference position with which the
relative vehicle inclination is compared during the activated time period. If the maximum vehicle inclination in
relation to the reference position is exceeded, an alarm is triggered, at the earliest, 25 s after arming. If the
vehicle inclination changes very slowly (e.g. leaky tire), the reference position adapts to the current vehicle
position to prevent inadvertent activation.
Alarm actuation by motion in the interior compartment (with code (882) Interior monitoring (with ATA
only))
Function requirements
ATA activated
Interior protection not previously deactivated
Function
If motion is detected in the vehicle interior by the ultrasonic echo sounder sensor and is considered to be alarm-
relevant, an acoustic and visual alarm is triggered.
Rain closing feature (except )
(On model 216 and on model 221 with code (414) Power glass tilting/sliding roof)
If the SR rain closing and the interior protection features are activated and the sliding/tilting roof (SR) is open,
the signals from the ultrasonic echo sounder sensor are ignored by the rear SAM control unit and no alarm is
triggered. The remaining ATA sources remain armed and ready for operation.
After completing rain closing, the rear SAM control unit again allows the ultrasonic echo sounder sensor to
trigger an alarm. The ultrasonic echo sounder sensor is ignored only once for rain closing during each arming
phase.
Alarm actuation by communication breakdown to alarm signal horn
Function requirement
ATA activated
Function
The alarm signal horn is polled cyclically by the rear SAM control unit If no answer is received from the alarm
signal horn by the rear SAM control unit within approx. 1 s, an alarm is triggered. The alarm is only output
visually, as the alarm signal horn cannot be addressed
If the alarm signal horn detects a loss of the supply voltage or communication, it automatically outputs an
acoustic alarm.
Alarm actuation caused by power loss
Function requirement
ATA activated
Function
If the voltage supply is interrupted when the ATA is armed, an acoustic alarm is triggered.
The power is supplied by the additional battery of the alarm signal horn The rest of the ATA system is out of
operation.
Special case: Alarm actuation in the event of undervoltage
The operating voltage of the ATA is between 8.0 V and 16 V. It can drop below a value of 8.0 V when the
battery is continuously discharged If the operating voltage drops below 8.0 V, it is no longer possible to trigger
a visual alarm. Only an acoustic alarm is triggered. The power is supplied by the additional battery of the alarm
signal horn
Repeated alarm
An alarm is only repeated if a new alarm event is registered after the active acoustic alarm was terminated.
Triggering the alarm again results in an extension of the visual and/or acoustic alarm. In the case of repetition
the same activation times apply as for a new actuation.
Alarm memory
Triggered alarms (max. 5) are stored in the rear SAM control unit and can be read out with STAR
DIAGNOSIS.
A26/13
GF80.50-P-
Interior protection component description On vehicles with code (882) Interior
6000SX
monitoring (with ATA only)
GF80.50-P-
Alarm signal horn, component description H3/1
6020SX
Driver-side SAM control unit with fuse and GF54.21-P-
N10/1
relay module, component description 6010SX
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
N69/1 GF72.29-P-
Driver-side front door control unit, component Model 221 6000SX
description GF72.29-P-
Model 216
6000SC
N69/2 GF72.29-P-
Passenger-side front door control unit, Model 221 6010SX
component description GF72.29-P-
Model 216
6010SC
N69/3, N69/4 GF72.29-P-
Rear door control unit component description
Model 221 6020SX
Overhead control panel control unit, component GF82.20-P-
N70
description 5216SX
TRIGGERING ALARM WITH PANIC SWITCH, FUNCTION - GF80.50-P-3014LEU
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08 with CODE (551) Anti-theft alarm system (ATA
[EDW]) with CODE (763) Radio remote control with panic switch
General function requirements
C. 15C OFF
Alarm triggered by panic switch, general
With the panic alarm it is possible to trigger the visual and acoustic antitheft alarm (ATA) with the transmitter
key (A8/1) (e.g. in an emergency).
Function sequence when panic alarm and ATA alarm are triggered simultaneously:
The panic alarm has priority over the ATA alarm.
If both alarms are actuated the alarm with the higher priority is output and the ATA alarm is suppressed. This
alarm is still actuated in the background. If one of the two alarms is terminated or is interrupted, the other is still
actuated.
The alarm triggering with the panic switch comprises the following subfunctions:
Function sequence for actuating panic alarm
Function sequence for panic alarm output
Interrupting function sequence for panic alarm
Function sequence for actuating panic alarm
When the panic alarm button on the transmitter key is actuated fort < or = 2 s, it transmits a radio signal via the
rear window antenna amplifier module (A2/12) to the rear SAM control unit with fuse and relay module
(N10/2) and relays it to the EIS control unit (N73).
Parallel to the radio signal, an infrared signal is transmitted to the driver door infrared sensor (B58) (precise
aiming required).
This signal is read in by the Left door control unit (N69/1) (model 216) or left front door control unit (N69/1)
(model 221) and is transmitted to the EIS control unit.
In both cases, the EIS control unit checks the access authorization of the transmitter key.
If the access authorization is valid, the EIS control unit transmits the "Activate panic alarm" command to the
rear SAM control unit.
It then transmits the requests for visual and acoustic alarm via interior CAN.
Additional function requirements for panic alarm output
Panic alarm triggered
Function sequence for panic alarm output
The alarm is output by the exterior lights, interior illumination as well as the alarm siren (H3/1).
The acoustic alarm is output by the rear SAM control unit actuating the alarm siren via the rear SAM-LIN.
The interior illumination is switched on by the overhead control panel control unit (N70).
The following components of the exterior lights are actuated:
by the front SAM control unit with fuse and relay module (N10/1):
Left turn signal light (E1e5)
Right turn signal light (E2e5)
by the rear SAM control unit:
Left turn signal light (E3e1)
Right turn signal light (E4e1)
by the left door control unit (model 216) or left front door control unit (model 221):
Left outside mirror turn signal light (E6/5)
by the right door control unit (N69/2) (model 216) or right front door control unit (N69/2) (model 221):
Right outside mirror turn signal light (E6/6)
The duration of the visual and acoustic panic alarm is equal, however, stored separately in the alarm siren and
rear SAM control unit.
Interrupting function sequence for panic alarm
The panic alarm is interrupted when the panic alarm button on the transmitter key is actuated briefly.
The function sequence for interrupting the panic alarm is the same as for actuating the panic alarm.
Model PE80.50-P-2054-
Function schematic for electric anti-theft alarm system, alarm 216 97CAA
actuation by panic switch Model PE80.50-P-2054-
221 97SAA
Front SAM control unit with fuse and relay module, component
N10/1 GF54.21-P-6070LE
description
Rear SAM control unit with fuse and relay module, component
N10/2 GF54.21-P-6030LE
description
N69/1
Left door control unit, component description Model GF72.29-P-4124LA
216
N69/1
Left front door control unit, component description Model GF72.29-P-4141LE
221
N69/2
Right door control unit, component description Model GF72.29-P-4128LA
216
N69/2
Right front door control unit, component description Model GF72.29-P-4142LE
221
Overhead control panel control unit, component description N70 GF82.20-P-5216LE
Component description for the EZS control unit N73 GF80.57-P-6003LE
TRIGGERING ALARM WITH PANIC SWITCH, FUNCTION - GF80.50-P-3014SXU
MODEL 221.0 /1, 216.3 with CODE (494) USA version with CODE (551) Anti-theft alarm system (ATA
[EDW]) with CODE (763) Radio remote control with panic switch up to Model Year 8
Fig. 26: Triggering Alarm With Panic Switch Function Diagram
Courtesy of MERCEDES-BENZ USA
Shown on model 221
Activating panic alarm
Function requirements:
Circuit 15C OFF (no circuit switched)
Function
When the panic alarm button is actuated on the transmitter key for approx. 2 s, it transmits a signal to the rear
radio signal, an infrared signal is transmitted to the driver door infrared sensor (precise aiming required). This
signal is read in by the corresponding door control unit and transferred to the EIS control unit.
In both cases, the EIS control unit checks the access authorization of the transmitter key. If the access
authorization is valid, the EIS control unit transmits the command "Activate panic alarm" to the rear SAM
control unit, which then actuates a visual and acoustic alarm.
The duration of the visual and acoustic panic alarm is equal. On vehicles with panic alarm, the interior
illumination is not activated as it is the case with the ATA.
The panic alarm has priority over the ATA.
Deactivate panic alarm
Function
The panic alarm is interrupted when the panic alarm button on the transmitter key is actuated briefly. The
function sequence is identical to the panic alarm activation function.
The panic alarm function and the alarm duration are programmable.
Function sequence when panic alarm and ATA are actuated simultaneously
If both alarms are actuated, the panic alarm with the higher priority is activated and the ATA is suppressed. The
ATA remains activated in the background.
If the panic alarm is completed or interrupted, the ATA suppressed up to that time is activated. A coding variant
in the rear SAM control unit offers an exception, with which the ATA is interrupted as soon as the panic alarm
is terminated.
A2/12
Vehicles without code (494) USA GF82.62-P-
version or without code (498) Japan 3131SX
Rear window antenna module component version
description GF82.62-P-
Vehicles with code (498) Japan version
3131SXJ
GF82.62-P-
Vehicles with code (494) USA version
3131SXU
GF80.57-P-
Transmitter key, component description A8/1
6010SX
Infrared remote control receiver, component GF80.30-P-
B58
description 6000SX
GF80.50-P-
Alarm signal horn, component description H3/1
6020SX
Driver-side SAM control unit with fuse and GF54.21-P-
N10/1
relay module, component description 6010SX
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
N69/1 GF72.29-P-
Driver-side front door control unit, Model 221 6000SX
component description GF72.29-P-
Model 216
6000SC
N69/2 GF72.29-P-
Passenger-side front door control unit, Model 221 6010SX
component description GF72.29-P-
Model 216
6010SC
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS), component description 6000SX
INTERIOR PROTECTION, COMPONENT DESCRIPTION - GF80.50-P-6000SX
MODEL 221.0 /1, 216.3 with CODE (551) Anti-theft alarm system (ATA [EDW]) with CODE (882)
Interior monitoring (with ATA [EDW] only) up to Model Year 8
Illustrated on model 221
Fig. 27: Locating Ultrasonic Echo Sounder Sensor
Courtesy of MERCEDES-BENZ USA
Location
The ultrasonic echo sounder sensor is located in the center of the headliner.
Task
Monitors interior compartment for motions
The status of the ultrasonic echo sounder sensor is fed back for each interrogation signal sent to it by the rear
SAM control unit with fuse and relay module (N10/2). The following replies can occur for the status feedbacks:
Ultrasonic echo sounder sensor hardware defective
Ultrasonic echo sounder sensor armed/disarmed
Signal from ultrasonic echo sensor not plausible
Ultrasonic echo sounder sensor alarm or
No reply: Ultrasonic echo sounder sensor not connected or defective
ALARM SIGNAL HORN, COMPONENT DESCRIPTION - GF80.50-P-6020SX
MODEL 221.0 /1, 216.3 with CODE (551) Anti-theft alarm system (ATA [EDW]) up to Model Year 8
Shown on model 221.0
Fig. 28: Locating Alarm Signal Horn With Additional Battery
Courtesy of MERCEDES-BENZ USA
Location
The alarm signal horn is located in the front left wheelhouse.
Design
The alarm signal horn includes:
Rechargeable battery for ensuring power supply
Inclination sensor for analyzing vehicle inclination
Speaker for acoustic alarm output
Purposes of alarm signal horn
Acoustic alarm output for anti-theft alarm (ATA)
Automatic alarm output in the event of loss of supply voltage or communication
Monitoring vehicle inclination for realizing tow-away protection function
Inclination sensor, function
When the tow-away protection function is activated, the inclination sensor determines a new reference position
with which the relative vehicle inclination is compared during the activated time period. If the maximum
vehicle inclination in relation to the reference position is exceeded, an alarm is output, at the earliest, 25 s after
arming. If the vehicle inclination changes very slowly (e.g. leaky tire), the reference position adapts to the
current vehicle position to prevent inadvertent activation of the inclination sensor.
OVERVIEW OF SYSTEM COMPONENTS FOR ANTI-THEFT ALARM SYSTEM (ATA) - GF80.50-
P-9998LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08 with CODE (551) Anti-theft alarm system (ATA
[EDW])
A40/3
With code (526) COMAND with single DVD drive GF82.85-P-
(without navigation) or with code (527) COMAND APS 3136LE
COMAND controller unit, with single DVD drive (with navigation)
component description GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with navigation GF82.85-P-
system) 3136LEU
Front central operating unit, GF54.21-P-
A40/9
component description 4500LE
Front SAM control unit with
GF54.21-P-
fuse and relay module, N10/1
6070LE
component description
Rear SAM control unit with fuse
GF54.21-P-
and relay module, component N10/2
6030LE
description
Left door control unit, N69/1 GF72.29-P-
component description Model 216 4124LA
Left front door control unit, N69/1 GF72.29-P-
component description Model 221 4141LE
Right door control unit, N69/2 GF72.29-P-
component description Model 216 4128LA
Right front door control unit, N69/2 GF72.29-P-
component description Model 221 4142LE
Rear door control unit, N69/3, N69/4 GF72.29-P-
component description Model 221 6020LE
Overhead control panel control GF82.20-P-
N70
unit, component description 5216LE
Upper control panel control unit, GF54.21-P-
N72/1
component description 6040LE
Component description for the GF80.57-P-
N73
EZS control unit 6003LE
Table of contents for function
GF80.50-P-
description for anti-theft alarm
0999LE
system (ATA)
OVERVIEW OF SYSTEM COMPONENTS FOR ANTI-THEFT ALARM SYSTEM (ATA) - GF80.50-
P-9998SX
MODEL 221.0 /1, 216.3 with CODE (551) Anti-theft alarm system (ATA [EDW]) up to Model Year 8
A2/12
GF82.62-P-
Vehicles without code (494) USA version
3131SX
or without code (498) Japan version
Rear window antenna module component
GF82.62-P-
description Vehicles with code (498) Japan version
3131SXJ
GF82.62-P-
Vehicles with code (494) USA version
3131SXU
GF80.57-P-
Transmitter key, component description A8/1
6010SX
A26/13
GF80.50-P-
Interior protection component description On vehicles with code (882) Interior
6000SX
monitoring (with ATA only)
Infrared remote control receiver, component GF80.30-P-
B58
description 6000SX
GF80.50-P-
Alarm signal horn, component description H3/1
6020SX
Driver-side SAM control unit with fuse and GF54.21-P-
N10/1
relay module, component description 6010SX
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
N69/1 GF72.29-P-
Driver-side front door control unit, Model 221 6000SX
component description GF72.29-P-
Model 216
6000SC
N69/2 GF72.29-P-
Passenger-side front door control unit, Model 221 6010SX
component description GF72.29-P-
Model 216
6010SC
N69/3, N69/4 GF72.29-P-
Rear door control unit component description
Model 221 6020SX
Overhead control panel control unit, GF82.20-P-
N70
component description 5216SX
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS) component description 6000SX
Table of contents for function description for GF80.50-P-
anti-theft alarm system (ATA) 0999SX
DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS 3), LOCATION OF COMPONENTS - GF80.57-
P-0003-01LE
Illustrated on model 221.0
Fig. 29: Locating Drive Authorization System Components
Courtesy of MERCEDES-BENZ USA
DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS 3), LOCATION OF COMPONENTS - GF80.57-
P-0003-01SX
Shown on model 221.0
Fig. 30: Locating Drive Authorization System Components
Courtesy of MERCEDES-BENZ USA
DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS 3), BLOCK DIAGRAM - GF80.57-P-0003-02LE
Fig. 31: Drive Authorization System Block Diagram
Courtesy of MERCEDES-BENZ USA
DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS 3), BLOCK DIAGRAM - GF80.57-P-0003-02SX
Fig. 32: Drive Authorization System Block Diagram
Courtesy of MERCEDES-BENZ USA
DRIVE AUTHORIZATION SYSTEM LEVEL 3 (DAS [FBS] 3), FUNCTION - GF80.57-P-0003LE
Model 221.0 /1, 216.3 as of model year 09 /YoM 08
Positions of the transmitter key (A8/1) in the EZS control unit (N73):
Fig. 33: Identifying Positions Of Transmitter Key In EZS Control Unit
Courtesy of MERCEDES-BENZ USA
Function requirements, general
Circuit 30 ON
Valid transmitter key inserted into EZS control unit
Drive authorization system, stage 3 (DAS 3), general
The DAS 3 allows the ignition to be switched on and the engine to be started. DAS 3 is a compound system
consisting of control units, each of which calculate and compare the drive authorization code independently. If
the check in question is valid, each component is released automatically.
The following control units are integral parts of the DAS 3 system:
EZS control unit
ME-SFI control unit (N3/10) (with gasoline engine) or CDI control unit (N3/9) (with diesel engine)
EGS control unit (N15/3) (with transmission 722.6) or fully integrated transmission control unit (Y3/8n4)
(with transmission 722.9)
Intelligent servo module for DIRECT SELECT (A80)
The DAS 3 system comprises the following subfunctions:
Function sequence for switching circuit 15C (transmitter key in position "A")
Function sequence for switching circuit 15R (transmitter key in position "B")
Function sequence for switching circuit 15 (transmitter key in position "C")
Function sequence for switching circuit 50 (transmitter key in position "D")
Deactivating circuits
Keylock function
Function sequence for switching circuit 15C (transmitter key in position "A")
When the transmitter key is inserted into the EZS control unit, it switches on the inductive power transmission
for power supply to the transmitter key. Encrypted data is exchanged via infrared signals between the
transmitter key and the EZS control unit for identification of the transmitter key.
The identification code is computed in dialog between transmitter key and the EZS control unit using the so-
called Hash method.
The EZS control unit transmits the hash value of the transmitter key to all other control units involved.
Check, release and feedback is performed separately by each control unit.
Hash function:
The hash method is single-way encryption which prevents the vehicle from being started with an invalid
transmitter key. With this method a new number combination is calculated from the old number combination. It
is not possible to calculate vice versa. Number combinations already calculated cannot be calculated again.
The next Hash values are computed in the EZS control unit. After completion of the calculation, the energy
transmission is switched off. After positive identification the following is performed:
Key position recognition switched on
Waking up interior CAN
Output of circuit 15C
The vehicle can also be started when the batteries of the transmitter key are discharged.
The function keys of the transmitter key are not active as long as the EZS control unit is inserted
If an invalid transmitter key is used, the message "Key does not belong to vehicle" is indicated in the instrument
cluster (A1).
Function sequence for switching circuit 15R (transmitter key in position "B")
Circuit 15R is actuated by turning transmitter key to position "B". The status of circuit 15R is output to the
interior CAN.
The transmitter key can no longer be removed in position "B".
Function sequence for switching circuit 15 (transmitter key in position "C")
Circuit 15 is actuated by turning transmitter key to position "C". The status of circuit 15 is output to chassis
CAN and interior CAN. Power-intensive consumers are supplied by circuit 15X.
Parallel to this, an encrypted DAS 3 request is transmitted to the ME-SFI control unit or CDI control unit,
electronic transmission control unit or fully integrated transmission control unit and intelligent servo module for
DIRECT SELECT.
Function sequence for switching circuit 50 (transmitter key in position "D")
The starter (M1) is actuated via the ME control unit or CDI control unit by turning the transmitter key to
position "D". The status for circuit 50 is output to the interior CAN or chassis CAN.
Circuit 15X is removed from the interior CAN and the chassis CAN until circuit 50 is off again and the engine
is running (time control, if applicable).
When circuit 15X is switched off, all electrical consumers are switched off to facilitate starting the engine.
The transmitter key automatically returns to position "C" when released
Deactivating circuits
Turning transmitter key back to left switches off the engine. The following functions are implemented in the
EZS control unit:
Transmitter key in position "B"
Switch off signals circuit 15 and circuit 15X
Transmitter key in position "A"
Circuit 15R Off
Transmitter key can be removed when removing the transmitter key, the transmission is shifted to
position "P")
The EZS control unit can request a new check for identification of the transmitter key during restart without
removing the transmitter key.
Keylock function
The EZS control unit transmits the request to the intelligent servo module for DIRECT SELECT for the
transmission to automatically shift to the "Park position" when
The transmitter key is removed from the EZS control unit
The driver or front passenger door is opened (only with code (889) Keyless-Go)
Then the intelligent servo module for DIRECT SELECT shifts the transmission to the "Park position".
If the communication is interrupted or the EZS control unit or the intelligent servo module for DIRECT
SELECT is defective, actuation is accomplished over the emergency path. The EZS control unit on-board
power supply voltage is switched to the emergency path. A spring-loaded actuator is actuated in the intelligent
servo module for DIRECT SELECT and the transmission is shifted to the "Park position". The electrical and
mechanical system in the intelligent servo module for DIRECT SELECT are synchronized automatically after
reproducing the functionality.
location of components 01LE
PE80.57-P-2050-
Model 216
Electrical function schematic for drive authorization 97CAB
system (DAS) PE80.57-P-2050-
Model 221
97SAB
Drive authorization system, stage 3 (DAS 3), block GF80.57-P-0003-
diagram 02LE
A80 GF27.19-P-
Component description for intelligent servo module Transmission 722.6 4020ACS
for DIRECT SELECT GF27.19-P-
Transmission 722.9
4020AHS
N3/9
GF07.16-P-
Model 221 with engine
6000OA
Component description for CDI control unit 629.9
Model 221 with engine GF07.16-P-
642.9 6000OHL
N3/10 GF07.61-P-
Engine 156 6000MAS
GF07.61-P-
Engine 272
6000MIS
ME-SFI [ME] control unit, component description
GF07.61-P-
Engine 273
6000MLS
GF07.61-P-
Engine 275
6000MOS
Component description for electronic transmission N15/3 GF27.60-P-
control unit Transmission 722.6 5164ACS
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for fully integrated Y3/8n4 GF27.60-P-
transmission control unit Transmission 722.9 5165AHS
DRIVE AUTHORIZATION SYSTEM LEVEL 3 (DAS [FBS] 3), FUNCTION - GF80.57-P-0003SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 34: Drive Authorization System Function Diagram
Courtesy of MERCEDES-BENZ USA
Description
The drive authorization system stage 3 (DAS 3) is a system combination of control units consisting of:
EIS control unit (EZS),
ME-SFI control unit or CDI control unit
Fully integrated transmission control (VGS) control unit or electronic transmission control (EGS) control
unit
Intelligent servo module for DIRECT SELECT
Hash function
The encrypted base module of the drive authorization system, stage 3 (DAS 3) is a so-called "Hash" function.
The most important property of the "Hash" function is the one-way characteristic. This means that by using the
"Hash" function, a number can easily be calculated from another number. It is not possible to calculate vice
versa.
The encrypted data is exchanged between the transmitter key and the EIS control unit via infrared signal. The
code is computed in dialog between the transmitter key and the EIS control unit using the Hash method.
The corresponding Hash value of the transmitter key is transmitted to control units by the EIS control unit.
Check, release and feedback is performed separately by each control unit
Up to eight transmitter keys can be used simultaneously. A special memory cell is available for each
transmitter key in all relevant components.
Function
The transmitter key identifies itself to the EIS control unit when inserted into the EIS control unit. If identified
positively, the lift solenoid in the rotary lock is enabled in the EIS control unit. The transmitter key can now be
turned.
The function keys in the transmitter key are no longer active. When turned, the transmitter key is secured
against removal.
An encrypted request is sent to the drive authorization by the:
ME-SFI control unit or CDI control unit,
fully integrated transmission control (VGS) control unit or electronic transmission control (EGS) control
unit, and
intelligent servo module for DIRECT SELECT
to the EIS control unit. Each of these control units checks separately whether the data package is enabled and
provides the EIS control unit with a feedback. During this communication, the ME-SFI [ME] control unit serves
primarily as a gateway between the chassis CAN and drive train CAN.
Transmitter key in position "0"
The inductive energy transmission to the voltage supply of the transmitter key is switched on.
Encrypted data exchange between transmitter key and EIS control unit for identification.
Calculation of next hash value in transmitter key
After the calculation is completed, the transmitter key signals that the "power supply is switched off".
After positive identification the following is performed:
Release of rotary lock in EIS control unit for transmitter key
Key position recognition switched on.
Wake-up of chassis CAN and interior CAN
Signal output of circuit 15C
Transmitter key in position "I"
Actuation of circuit 15R
Status output of circuit 15R from EIS control unit to chassis CAN and interior CAN
Transmitter key in position "II"
Circuit 15 is actuated
Status output of circuit 15 and circuit 15X from EIS control unit to chassis CAN and interior CAN
Transmitter key in position "III"
Actuation of starter (M1) by relay circuit 50, starter (N10/1kH) via ME-SFI control unit and CDI control
unit
Output of status c. 50 to chassis CAN and interior CAN
Circuit 15X is actuated by chassis CAN and interior CAN until circuit 50 is off again and the engine is
running (circuit 61)
The transmitter key automatically returns to position "II" when released.
Take vehicle out of operation
When the transmitter key is turned back to the left, the engine is switched off and the circuit status is changed
correspondingly. If the transmitter key is in position "I", circuit 15R remains switched on. If the transmitter key
is in position "0", the transmitter key can be removed.
Keylock, function
Conditions of operation
Vehicle at rest
Function
The EIS control unit transmits the request to automatically shift the transmission to the "Park position" when
the transmitter key is removed from the EIS control unit, or
when the driver or front passenger door is opened (only with code (889) Keyless Go)
to the servo module for DIRECT SELECT. It shifts the transmission to the "Park position".
Emergency function
If the communication is interrupted or the EIS control unit or the servo module for DIRECT SELECT is
defective, the emergency path is actuated. The EIS control unit on-board power supply voltage is switched to
the emergency path. A spring accumulator is actuated in the servo module for DIRECT SELECT and the
transmission is moved to the "Park position". The electrical and mechanical system in the servo module for
DIRECT SELECT are synchronized automatically after reproducing the functionality.
Drive authorization system, stage 3 (DAS 3), location GF80.57-P-
of components 0003-01SX
diagram 0003-02SX
GF80.57-P-
Transmitter key, component description A8/1
6010SX
A80
GF27.19-P-
Model 221 with transmission
4015SX
Intelligent servo module (ISM) component description 722.9
Model 221 with transmission GF27.19-P-
722.6 4015SXA
N3/9 GF07.16-P-
CDI control unit component description
Model 221.0/1 with engine 642 6000SX
N3/10
GF07.61-P-
ME-SFI [ME] control unit, component description Model 221 with engines
6000V
272.965 and 273.961
N3/10
GF07.61-P-
ME-SFI control unit, location/task/design/function Model 221 with engine
5000M
275.953/982
N15/3
GF27.19-P-
ETC [EGS] control unit, component description Model 221 with transmission
4018G
722.6
Electronic ignition/starter switch control unit (EIS) GF80.57-P-
N73
component description 6000SX
Y3/8n4
GF27.19-P-
VGS control unit, component description Model 221 with transmission
4016SX
722.9
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF DRIVE AUTHORIZATION SYSTEM
STAGE 3 (DAS 3) - GF80.57-P-0999LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08
Drive authorization system level 3 (DAS [FBS] 3), function GF80.57-P-0003LE
Drive authorization system, stage 3 (DAS 3), location of components GF80.57-P-0003-01LE
Drive authorization system, stage 3 (DAS 3), block diagram GF80.57-P-0003-02LE
Survey, system components, drive authorization system, stage 3 (DAS 3) GF80.57-P-9998LE
CONTENTS, FUNCTION DESCRIPTION OF DRIVE AUTHORIZATION SYSTEM STAGE 3 (DAS
3) - GF80.57-P-0999SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Drive authorization system stage 3 (DAS 3), function GF80.57-P-0003SX
Drive authorization, stage 3 (DAS 3) location of components GF80.57-P-0003-01SX
Drive authorization system, stage 3 (DAS 3), block diagram GF80.57-P-0003-02SX
Survey, system components, drive authorization system, stage 3 (DAS 3), GF80.57-P-9998SX
ELECTRONIC IGNITION/STARTER SWITCH CONTROL UNIT (EIS) COMPONENT
DESCRIPTION - GF80.57-P-6000SX
MODEL 216.3, 221.0 /1 up to Model Year 8
Fig. 35: Locating EIS Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The EIS control unit is located on the right, next to the steering column.
Task
The EIS control unit is the master control unit for the following functions:
Drive authorization stage 3 (DAS 3)
Central locking (CL [ZV])
Auxiliary door lock (only )
Task
Communication with transmitter key when transmitter (A8/1) is inserted, via infrared signals and
inductive energy transmission.
Transmission of polling data to enable DAS 3 to:
CDI control unit (N3/9) (on diesel engines) or ME control unit (N3/10) (on gasoline engines)
Fully integrated transmission control (VGS) (Y3/8n4) control unit (with transmission 722.9) or
ETC control unit (N15/3) (with transmission 722.6)
Intelligent servo module for DIRECT SELECT (A80)
Rotation-angle-dependent activation of circuit 15R, 15, 50.
Output of circuit 15R, 15, 50 to interior CAN and chassis CAN.
Mechanically locking of transmitter key in turned position and mechanical return between start and
driving position.
Request for selector lever position "P" via servo module for DIRECT SELECT when transmitter key is
removed On vehicles with code (889) Keyless Go actuation is accomplished with driver door open.
Interface to Keyless go control unit (N69/5) via interior CAN for Keyless Go access and Keyless Go
operation (with code (889) Keyless Go).
Mechanical sensing and read-in of Keyless Go start/stop button (S2/3) (with code (889) Keyless Go).
The limit switch for circuit 15R and 15 are not installed in the EIS control unit. The rear SAM control unit
with fuse and relay module (N10/2) switches circuit 15R and the front SAM control unit with fuse and relay
module (N10/1) switches circuit 15.
Discrete inputs
Circuit 30
Circuit 31
Circuit 30 and circuit 31 (redundant supply)
with code (889) Keyless Go:
Right rotary tumbler switch (A85/1s1) on model 216 or Right front rotary tumbler switch (A85/1s1) on
model 221
Left rotary tumbler switch (A85s1) on model 216 or Left front rotary tumbler switch (A85s1) on model
221
Discrete outputs
Emergency path to servo module for DIRECT SELECT
Signal "Transmitter key removed" to vehicle power supply control unit (N82/1)
CAN signals
The EIS control unit is a subscriber on the interior CAN and chassis CAN. However, it is not a gateway.
COMPONENT DESCRIPTION FOR THE EZS CONTROL UNIT - GF80.57-P-6003LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08
Illustrated on model 221.0
Fig. 36: Locating EIS Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The EIS control unit is located on the right, next to the steering column.
Task
The EIS control unit has the following tasks:
Control of functions
Reading in of signals
Evaluation of input factors
Actuation of components
Power supply for transmitter key (A8/1)
Interface to KEYLESS-GO control unit (N69/5) (with code (889) Keyless-Go)
Control of functions
The EIS control unit is the master control unit for the following functions:
Central locking (CL [ZV])
Convenience feature (CF)
Drive authorization stage 3 (DAS 3)
Encrypted data exchange according to hash method for key identification
Activation of individual circuits (c. 15, c. 15R, c. 50, c. 15X and c. 15C) depending on rotation
angle
"Keylock function": When the transmitter key is removed, the EIS control unit requests the transmission
to shift to gear range "P"
"Auto N function": If the transmitter key is turned to position 0 (c. 15C) when the engine is running and
the transmission is shifted to gear range "D" or "R", the transmission is shifted automatically to gear
range "N". The EIS control unit requests the transmission to shift to gear range "N".
Supplemented auto P function: If the driver door and passenger door is opened following the "Auto N
function", the transmission automatically shifts to gear range "P". The EIS control unit requests the
transmission to shift to gear range "P".
Reading in of signals
The input factors are read in with the following connections:
Direct line
Interior CAN
Chassis CAN
Direct line
The following signals are read in via a direct line:
Circuit 30
Circuit 31 (ground)
C. 30b (backup battery supply)
C. 31 emergency supply
Status of left front door lock unit (A85) (model 221) or left door lock unit (A85) (model 216)
Interior CAN
The signals are read in by the EIS control unit via the interior CAN. The functions resulting therefrom are
described in the corresponding function descriptions (see block diagram or function schematic).
Chassis CAN
The signals are read in by the EIS control unit via the chassis CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Evaluation of input factors
The input factors that have been read in are evaluated by the integrated microprocessor and the relevant
components are then actuated.
Actuation of components
Components are actuated with the following lines:
Direct line
Interior CAN
Chassis CAN
Direct line
The intelligent servo module for DIRECT SELECT (A80) can be actuated directly by the emergency path in the
event of an error.
If the communication is interrupted or the EIS control unit or the intelligent servo module for DIRECT
supply voltage is switched to the emergency path. A spring-loaded actuator is actuated in the intelligent servo
module for DIRECT SELECT and the transmission is shifted to the "Park position". The electrical and
mechanical system in the intelligent servo module for DIRECT SELECT are synchronized automatically after
reproducing the functionality.
Interior CAN
The signals are transmitted by the EIS control unit via the interior CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Chassis CAN
The signals are transmitted by the EIS control unit via the chassis CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Power supply for transmitter key
When the transmitter key is inserted into the EIS control unit, it switches on the inductive power transmission
for power supply to the transmitter key.
If the key is not identified (invalid transmitter key), it is still possible to turn the key, however, the circuit is
not switched in the EIS control unit. The message "Key does not belong the vehicle" in the multifunction
display (A1p13) of the instrument cluster (A1).
Interface to KEYLESS-GO control unit
Interface to Keyless-Go control module via interior CAN for Keyless-Go access and Keyless-Go
operation
Mechanical sensing and read-in of KEYLESS-GO start/stop button (S2/3) for Keyless-Go operation
Model PE54.21-P-2104-
Wiring diagram for electronic ignition switch (EIS) control 216 99CAA
unit Model PE54.21-P-2104-
221 99SAA
TRANSMITTER KEY, COMPONENT DESCRIPTION - GF80.57-P-6010SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 37: Identifying Transmitter Key Buttons
Courtesy of MERCEDES-BENZ USA
Design
An "electronic key" is integrated in the transmitter key. This key includes an FM radio transmitter, an infrared
transmitter/receiver unit, a computer chip as well as two batteries (button cells). Moreover, the following
controls and control indicators are integrated:
Lock transmit button (1)
Unlock transmit button (2)
Remote trunk opening transmit button (3)
LED battery check (4)
Panic alarm (6) transmitter button (with code (763) Radio remote control with panic switch)
The mechanical key (7) can be unlocked and removed with the unlock slider (5).
Central locking (CL [ZV])
Actuate lock transmit button:
Press once (global locking)
press and hold down while aiming infrared sensor at driver door (B58) (additional convenience closing)
Actuate unlock transmit button:
Pressing once when set to "Selective" (driver door and fuel filler flap are unlocked)
Press once when set to "global" (unlocks all)
Pressing twice when set to "Selective" (unlocks all)
press and hold down while aiming infrared sensor at driver doors (additional convenience opening)
Switchover unlocking from "Selective" to "Global" or vice versa:
Press and hold "Lock" transmit button and "Unlock" transmit button simultaneously for approx. 5 seconds
until the "Battery check" LED flashes twice.
Panic alarm
with code (763) Radio remote control with panic switch
Actuate panic alarm transmit button:
Press approx. 2 s (trigger panic alarm)
Press approx. 0.5 s (terminate panic alarm)
When the transmitter key is inserted into the key opening on the EIS control unit (N73), the panic alarm is
terminated.
Remote trunk opening (RTO)
Actuate remote trunk opening transmit button:
press approx. 0.5 s (trunk lid opens)
Drive authorization stage 3 (DAS 3)
When the transmitter key is inserted into the EIS control unit, it is supplied with voltage. Data exchange takes
place to verify the drive authorization status.
Keyless Go (KG) (with code (889) Keyless Go)
Communication with the vehicle via inductive signals and radio signals. Determine request location in relation
to vehicle.
Battery check
When the transmit button (1, 2 or 3) is actuated, the battery control LED comes on momentarily and indicates
thereby the proper state of the batteries in the transmitter key.
SURVEY, SYSTEM COMPONENTS, DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS 3) -
GF80.57-P-9998LE
MODEL 221.0 /1, 216.3 as of model year 09 /YoM 08
A80 GF27.19-P-
Intelligent servo module for DIRECT SELECT, component Transmission 722.6 4020ACS
description GF27.19-P-
Transmission 722.9
4020AHS
N3/9
GF07.16-P-
Model 221 with engine
6000OA
Component description for CDI control unit 629.9
Model 221 with engine GF07.16-P-
642.9 6000OHL
N3/10 GF07.61-P-
Engine 156 6000MAS
GF07.61-P-
Engine 272
6000MIS
ME-SFI [ME] control unit, component description
GF07.61-P-
Engine 273
6000MLS
GF07.61-P-
Engine 275
6000MOS
Electronic transmission control control unit, component N15/3 GF27.60-P-
description Transmission 722.6 5164ACS
GF80.57-P-
Component description for the EZS control unit N73
6003LE
Fully integrated transmission control unit, component Y3/8n4 GF27.60-P-
description Transmission 722.9 5165AHS
Table of contents for function description of drive GF80.57-P-
authorization system stage 3 (DAS 3) 0999LE
SURVEY, SYSTEM COMPONENTS, DRIVE AUTHORIZATION SYSTEM, STAGE 3 (DAS 3) -
GF80.57-P-9998SX
MODEL 221.0 /1, 216.3 up to Model Year 8
GF80.57-P-
Transmitter key, component description A8/1
6010SX
A80
GF27.19-P-
Model 221 with transmission
4015SX
Intelligent servo module (ISM) component description 722.9
Model 221 with transmission GF27.19-P-
722.6 4015SXA
N3/9
GF07.16-P-
CDI control unit component description Model 221.0/1 with engine
6000SX
642
N3/10
GF07.61-P-
ME-SFI [ME] control unit, component description Model 221 with engines
6000V
272.965 and 273.961
N3/10
GF07.61-P-
ME-SFI control unit, location/task/design/function Model 221 with engine
5000M
275.953/982
ETC [EGS] control unit, component description N15/3
722.6 4018G
Electronic ignition/starter switch control unit (EIS) GF80.57-P-
N73
component description 6000SX
Y3/8n4
GF27.19-P-
VGS control unit, component description Model 221 with transmission
4016SX
722.9
Table of contents for function description of drive GF80.57-P-
authorization system stage 3 (DAS 3) 0999SX
KEYLESS-GO, LOCATION OF COMPONENTS - GF80.61-P-0005-01LE
Fig. 38: Locating Keyless-Go Components
Courtesy of MERCEDES-BENZ USA
KEYLESS GO, LOCATION OF COMPONENTS - GF80.61-P-0005-01SX
Fig. 39: Locating Keyless-Go Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
KEYLESS-GO, BLOCK DIAGRAM - GF80.61-P-0005-02LE
Fig. 40: Keyless-Go Block Diagram
Courtesy of MERCEDES-BENZ USA
KEYLESS GO, BLOCK DIAGRAM - GF80.61-P-0005-02SX
Fig. 41: Keyless-Go Block Diagram
Courtesy of MERCEDES-BENZ USA
KEYLESS-GO, FUNCTION - GF80.61-P-0005LE
MODEL 216.3, 221.0 /1 with CODE (889) KEYLESS-GO as of model year 2009 /YoM 08
KEYLESS-GO (KG), general
The KEYLESS-GO system allows access to the vehicle and starting the vehicle engine without using the
transmitter key (A8/1). It is sufficient to just carry the transmitter key
Operation of the central locking (CL) via the transmitter key remains possible parallel to the KEYLESS-GO
functions.
The anti-theft alarm system (ATA) (with code (551) Anti-theft alarm system (ATA)) functions in the same
manner as when locking/unlocking the CL with the transmitter key.
The KEYLESS-GO system comprises the following partial functions:
Function sequence for position definition of transmitter key
The following partial functions are described in separated documents:
Locking/unlocking, function
Engine start/stop, function
Function sequence for position determination of transmitter key (on model 216)
A position determination of the transmitter key is required for the individual functions. When the
Trunk KEYLESS-GO antenna (A2/35),
Left door KEYLESS-GO antenna (A2/39),
Right door KEYLESS-GO antenna (A2/41),
Center console KEYLESS-GO antenna (A2/60) and
Interior compartment KEYLESS-GO antenna (A2/61) (up to 31.8.10).
are activated by the KEYLESS-GO system, the transmitter key can determine the area (A, B, C, D or E) in
which it is located.
Fig. 42: Identifying Transmitter Key Function Positions
Courtesy of MERCEDES-BENZ USA
Function sequence for position determination of transmitter key (on model 221)
A position determination of the transmitter key is required for the individual functions. When the
Trunk KEYLESS-GO antenna (A2/35),
Left rear door KEYLESS-GO antenna (A2/39),
Right rear door KEYLESS-GO antenna (A2/41),
Center console KEYLESS-GO antenna (A2/60) and
Interior compartment KEYLESS-GO antenna (A2/61) (up to 31.8.10)
are activated by the KEYLESS-GO system, the transmitter key can determine the area (A, B, C, D or E) in
which it is located.
Fig. 43: Identifying Transmitter Key Function Positions
Courtesy of MERCEDES-BENZ USA
The determined position is transmitted by the transmitter key via radio signal. The rear window antenna
amplifier module (A2/12) edits the signal and relays it to the KEYLESS-GO control unit (N69/5).
Model 216 GF80.61-P-0005-01LA
KEYLESS-GO, location of components
Model 221 GF80.61-P-0005-01LE
KEYLESS-GO, block diagram GF80.61-P-0005-02LE
Locking/unlocking, function GF80.61-P-2008LE
Engine start/stop, function GF80.61-P-3012LE
KEYLESS GO, FUNCTION - GF80.61-P-0005SX
MODEL 221.0 /1, 216.3 with CODE (889) Keyless Go up to Model Year 8
The Keyless Go system (KG) allows access to the vehicle and starting the vehicle engine without using the
transmitter key (A8/1). It is sufficient to just carry the transmitter key
Unlock
The vehicle can be unlocked by:
Gripping any door handle (global or selective opening) or
Gripping and pulling any door handle (global or selective opening) or
Actuating trunk lid external operation switch (S88/8) (only unlocking trunk lid)
Lock
The vehicle can be locked by:
Touching capacitive sensor outside on
Left Keyless Go sensor unit (B67/1) (model 216) or Left front keyless sensor unit (B67/1) (model
221)
Right Keyless Go sensor unit (B67/2) (model 216) or Right front keyless sensor unit (B67/2)
(model 221)
Left rear Keyless Go sensor unit (B67/3) (model 221)
Right rear Keyless Go sensor unit (B67/4) (model 221)
on corresponding door handle.
Touching
Left comfort sensor (B67/1b1) (model 216) or Left front comfort sensor (B67/1b1) (model 221)
Right comfort sensor (B67/2b1) (model 216) or Right front comfort sensor (B67/2b1) (model 221)
Left rear comfort sensor (B67/3b1) (model 221)
Right rear comfort sensor (B67/4b1) (model 221)
on corresponding door handle during convenience closing
Actuate trunk lid KEYLESS-GO button (S62/21) outside on trunk lid (model 221 up to 30.11.06)
Actuating RTC button (S62/26) (on vehicles with code (881) Remote trunk closing (RTC))
Operation of the central locking (CL) via the transmitter key remains possible parallel to the Keyless Go
functions.
Start engine and switch off
The engine can be started or switched off by pressing the Keyless Go start/stop button (S2/3) on the EIS control
unit (N73)..
If required, the start/stop button can be removed from the EIS control unit and the engine can be started and
shut down "normally" with the transmitter key via the EIS control unit.
Detection areas
(Shown as an example on model 221.0) When the system is activated, the transmitter key receives a signal in
the areas (A, B, C, D, E) from the:
Trunk Keyless Go antenna (A2/35)
Left door Keyless Go antenna (A2/39) (model 216) or Left rear door Keyless Go antenna (A2/39) (model
221)
Right door Keyless Go antenna (A2/41) (model 216) or Right rear door Keyless Go antenna (A2/41)
(model 221)
Center console Keyless Go antenna (A2/60)
interior Keyless Go antenna (A2/61)
Fig. 44: Identifying Transmitter Key Detection Areas
Courtesy of MERCEDES-BENZ USA
Sequence of position determination
The position of the transmitter key can be determined by the signals from the various Keyless-Go antennas
transmitted to the Keyless-Go control unit (N69/5) via the rear window antenna amplifier module (A2/12).
Keyless Go, location of components GF80.61-P-0005-01SX
Keyless Go, block diagram GF80.61-P-0005-02SX
Locking/unlocking, function GF80.61-P-2008SX
Engine start/stop, function GF80.61-P-3012SX
CONTENTS, FUNCTION DESCRIPTION OF KEYLESS-GO - GF80.61-P-0996LE
MODEL 216.3, 221.0 /1 as of model year 09 /YoM 08 with CODE (889) Keyless-Go
Keyless-Go, function GF80.61-P-0005LE
Model 216 GF80.61-P-0005-01LA
Keyless-Go, location of components
Model 221 GF80.61-P-0005-01LE
Keyless-Go, block diagram GF80.61-P-0005-02LE
Locking/unlocking, function GF80.61-P-2008LE
Engine start/stop, function GF80.61-P-3012LE
Survey of Keyless-Go system components, component description GF80.61-P-9997LE
CONTENTS, FUNCTION DESCRIPTION OF KEYLESS GO - GF80.61-P-0996SX
MODEL 221.0 /1, 216.3 with CODE (889) Keyless Go up to Model Year 8
Keyless Go, function GF80.61-P-0005SX
Keyless Go, location of components GF80.61-P-0005-01SX
Keyless Go, block diagram GF80.61-P-0005-02SX
Locking/unlocking, function GF80.61-P-2008SX
Engine start/stop, function GF80.61-P-3012SX
Survey of Keyless Go system components, component description GF80.61-P-9997SX
LOCKING/UNLOCKING, FUNCTION - GF80.61-P-2008LE
MODEL 216.3, 221.0 /1 with CODE (889) KEYLESS-GO as of model year 2009 /YoM 08
Function requirements, general
Valid transmitter key (A8/1) outside of vehicle (maximum distance to one of the controls s = 1 m)
Terminal 15C OFF
Locking/unlocking, general
Locking/unlocking allows the vehicle to be opened and closed.
The following control elements are available:
To lock and unlock (integrated into door handles):
Left KEYLESS-GO sensor unit (B67/1) (model 216)
Left front KEYLESS-GO sensor unit (B67/1) (model 221)
Right KEYLESS-GO sensor unit (B67/2) (model 216)
Right front KEYLESS-GO sensor unit (B67/2) (model 221)
Left rear KEYLESS-GO sensor unit (B67/3) (model 221)
Right rear KEYLESS-GO sensor unit (B67/4) (model 221)
To open trunk:
Trunk lid external operation switch (S88/8)
To lock:
TLC button (S62/26) (model 221 with code (881) Remote trunk closing (RTC), model 216)
The locking/unlocking functions comprise the following subfunctions:
Function sequence for preadjustment of unlocking mode
Function sequence for unlocking
Function sequence for locking
Function sequence for visual feedback (without code (494) USA version)
Function sequence for acoustic feedback (as of 1.9.10)
Function sequence for unlocking and opening trunk lid
Function sequence for closing and locking trunk lid (model 221 with code (881) Remote trunk
closing (RTS), model 216)
The sensor units are switched off when c. 15 is switched on. Activation takes place when circuit 15 is
switched off and then a door is opened.
The inner capacitive sensor is switched off after t = 72 h to save the on-board electrical system battery (G1).
After switching off, the vehicle can no longer be unlocked by touching the sensor unit (recognized by the inner
capacitive sensor). The sensor unit must be pulled
Function sequence for preadjustment of unlocking mode
Basically the following types of unlocking are differentiated:
Global unlocking:
The entire vehicle is unlocked gripping and pulling a sensor unit.
Selective unlocking (only possible on driver door):
Only the driver door and the fuel filler flap are unlocked by gripping and pulling the sensor unit on the driver
door. If the transmitter key is set to selective unlocking and the triggering location for unlocking is not the
driver door sensor unit, the vehicle is unlocked globally.
Simultaneously pressing the lock/unlock buttons on the transmitter key for t = 5 s, switches the system between
two types of unlocking. The LED on the transmitter key comes on twice to confirm this change.
Unlocking possibilities:
Grip any sensor unit
Grip and pull any sensor unit
Locking possibilities:
Touching outside of sensor unit
Actuating comfort sensor on sensor unit
Function sequence for unlocking
(example global unlocking at left front door)
If the sensor unit on the driver door is gripped, this is recognized by the inner capacitive sensor. This signal is
read in by the KEYLESS-GO control unit (N69/5).
The KEYLESS-GO control then actuates the left door KEYLESS-GO antenna (A2/39) (model 216) or left rear
door KEYLESS-GO antenna (A2/39) (model 221), which transmits a wake-up signal to the transmitter key.
In addition the KEYLESS-GO control unit causes the following antennas to transmit a location finding signal:
trunk KEYLESS-GO antenna (A2/35)
Left front door KEYLESS-GO antenna (model 216)
Right door KEYLESS-GO antenna (A2/41) (model 216)
Right rear door KEYLESS-GO antenna (model 221)
Right rear door KEYLESS-GO antenna (model 221)
Center console KEYLESS-GO antenna (A2/60)
Interior compartment KEYLESS-GO antenna (A2/61) (up to 31.8.10)
The locating finding signals are always transmitted by all KEYLESS-GO antennas, regardless of the transmitter
key setting (selective/global). The transmitter key transmits its access authorization code and its position to the
rear window antenna amplifier module (A2/12), which relays the data to the KEYLESS-GO control unit.
The KEYLESS-GO control unit relays the access authorization code to the EIS control unit (N73) via the
interior CAN (CAN B). If the access authorization code is valid, the EIS control unit transmits the command
"Open central locking" to the:
Rear SAM control unit with fuse and relay module (N10/)N10/2
Left door control unit (N69/1) (model 216) Left front door control unit (N69/1) (model 221)
Right door control unit (N69/2) (model 216) Right front door control unit (N69/2) (model 221)
Left rear door control unit (N69/3) (model 221)
Right rear door control unit (N69/4) (model 221)
They then unlock the following components:
Left door lock unit (A85) (model 216) or Left front door lock unit (A85) (model 221)
Right door lock unit (A85/1) (model 216) or Right front door lock unit (A85/1) (model 221)
Left rear door lock unit (A85/3) (on model 221)
Right rear door lock unit (A85/4) (on model 221)
Fuel filler flap CL [ZV] motor (M14/10)
If the driver door sensor unit is pulled within t = 0.5 s after the central locking is unlocked, this is sensed by the
Hall sensor in the driver door sensor and transmitted to the KEYLESS-GO control unit. The latter then actuates
the left front opening assist motor (A85m2) (model 221) or left opening assist motor (A85m2) (model 216).
When the opening assist motor is actuated, the rotary tumbler "Opens" and the door pops open.
The external operation switch is enabled to unlock the trunk lid by the rear SAM control unit.
If the transmitter key is set to selective opening and the sensor unit in the driver door is gripped, only the
driver door and the tank flap are unlocked.
Function sequence for locking
The outer capacitive sensor in the sensor unit recognizes if a door handle is gripped from the outside.
The further function sequence is performed analog to global unlocking described previously. However, the
opening assist motor is not actuated.
Function sequence for visual feedback (without code (494) USA version)
After successful locking or unlocking, the turn signal lamps flash as visual feedback.
The function is controlled by the rear SAM control unit, transmitting the turn signal as blinkmaster with the
interior CAN:
Locking: flashes three times
Unlocking: flashes once
For further information on visual feedback see separate function description on exterior lights.
If a door is still open when locking, there is no visual feedback.
Function sequence for acoustic feedback (as of 1.9.10)
Select and activate the acoustic feedback in the instrument cluster (A1) via the left multifunction steering wheel
button group (S110) and right multifunction steering wheel button group (S111). The status of the acoustic
feedback is transmitted by the instrument cluster via the central CAN (CAN F) to the central gateway control
unit (N93) and from there to the front SAM control unit with fuse and relay module (N10/1) via the interior
CAN. If the acoustic feedback function is activated and the successful locking and unlocking, an acoustic
feedback is output by momentarily actuating the left horn (H2) and right horn (H2/1).
The left multifunction steering wheel button group and right multifunction steering wheel button group is
read via the steering LIN (LIN E1) by the steering column tube module (N80).
If the transmitter key is valid and the acoustic feedback is activated, the EIS control unit transmits the command
"Lock or unlock" via the interior CAN to front SAM control unit, which momentarily actuates the horns via the
horn relay (N10/1kF).
Locking: three times
Unlocking: once
If a door is still open when locking, there is no acoustic feedback.
Function sequence for unlocking and opening trunk lid
The rear SAM control unit recognizes when the trunk lid external operation switch is actuated and signals it to
the KEYLESS-GO control unit via interior CAN. The KEYLESS-GO control unit then actuates the trunk
KEYLESS-GO antenna, which transmits a wake up signal to the transmitter key.
The transmitter key transmits its access authorization code and position to the KEYLESS-GO control unit via
the rear window antenna amplifier module.
The access authorization code is transmitted by the KEYLESS-GO control unit to the EIS control unit via the
interior CAN. The access authorization code is valid, the EIS control unit transmits the command "Unlock" to
the rear SAM control unit. This signal enables the trunk lid external operation switch. The rear SAM control
unit actuates the trunk lid CL motor (M14/7) and opens the trunk lid. The doors remain still unlocked.
The trunk is locked automatically after closing.
Function sequence for closing and locking trunk lid (model 221 with code (881) Remote trunk closing
(RTS), model 216)
Actuation of the TLC button is recognized by the TLC control unit (N121) and relayed to the KEYLESS-GO
control unit via the interior CAN.
The further function sequence is performed analog to unlocking described previously. The trunk lid is closed
hydraulically by the TLC control unit only when the vehicle is locked.
The precise sequence is described in the function "Remote trunk closing (RTC)".
On vehicles with code (551) Anti-theft alarm (ATA), the anti-theft alarm (ATA) is activated or deactivated
with each Model e of locking or unlocking.
PE80.61-P-
Model 216
Electrical function schematic for 2051-97CAA
KEYLESS-GO locking and unlocking PE80.61-P-
Model 221
2051-97SAA
Component description for front SAM GF54.21-P-
N10/1
control unit with fuse and relay module 6070LE
Component description for rear SAM GF54.21-P-
N10/2
control unit with fuse and relay module 6030LE
Component description for left door N69/1 GF72.29-P-
control unit Model 216 4124LA
Component description for left front door N69/1 GF72.29-P-
control unit Model 221 4141LE
Component description for right door N69/2 GF72.29-P-
control unit Model 216 4128LA
Component description for right front door N69/2 GF72.29-P-
control unit Model 221 4142LE
Rear door control unit, component N69/3, N69/4 GF72.29-P-
description Model 221 6020LE
Component description for KEYLESS-GO GF80.61-P-
N69/5
control unit 4204LE
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for steering GF54.21-P-
N80
column tube module 6050LE
N121
Model 221 with code (881)
GF80.20-P-
TLC control unit, component description Remote trunk closing (RTC
6000LE
[HDFS])
Model 216
LOCKING/UNLOCKING, FUNCTION - GF80.61-P-2008SX
MODEL 221.0 /1, 216.3 with CODE (889) Keyless Go up to Model Year 8
Fig. 45: Keyless Go Locking/Unlocking Function Diagram
Courtesy of MERCEDES-BENZ USA
Shown on model 221
Unlocking/locking function via door handle
Function requirements
Valid transmitter key outside of vehicle (max. approx. distance to door handle 1 m)
Circuit 15C OFF
Unlocking possibilities:
Gripping and pulling any door handle (global or selective opening)
Locking possibilities:
Touching door handle outer side or
Actuating following sensors on door handles:
Left front comfort sensor (B67/1b1) (model 216) or Right front comfort sensor (B67/1b1) (model
221)
Right comfort sensor (B67/2b1) (model 216) or Right front comfort sensor (B67/2b1) (model 221)
Left rear comfort sensor (B67/3b1) (model 221)
Right rear comfort sensor (B67/4b1) (model 221)
Function sequence for unlocking
(Explained on left front door on model 221 as an example)
The inner capacitive sensor in the left front Keyless Go sensor unit recognizes if a door handle is gripped and
signals this to the Keyless Go control unit which transmits a wake-up signal to the transmitter key via the left
rear door Keyless Go antenna.
The transmitter key transmits its access authorization code and its position to the rear window antenna amplifier
module, which relays it to the Keyless Go control unit. The access authorization code is transmitted to the EIS
control unit via the interior CAN. If it is valid, the EIS control unit transmits the command "Unlock CL" to the
door control units and to the rear SAM control unit. They actuate the corresponding motors in the central
locking (CL) to unlock. If a door handle is pulled within 0.5 s after the CL is unlocked, the Hall sensor in the
door handle senses this and sends a corresponding signal to the Keyless Go control unit, which then actuates the
left front opening assist motor. When the left front opening assist motor is actuated, the rotary tumbler "Opens"
and the door pops open.
Function sequence for locking
(Explained on left front door on model 221 as an example)
The outer capacitive sensor in the left front Keyless Go sensor unit recognizes if a door handle is gripped from
the outside. Further sequence same as when unlocking, however, the CL motors are actuated to lock.
The convenience closing function via Keyless Go (KG) is described in the "Convenience feature function".
Switching over from "global" to "selective" unlocking.
If the unlock and lock buttons on the transmitter key are pressed simultaneously for 5 seconds, a change
between the "global" and "selective" functions takes place. The indicator lamp on the transmitter key comes on
to confirm this change.
Global unlocking
The entire vehicle can be unlocked by gripping and pulling a door handle.
Selective unlocking (only possible on driver door handle)
Only the driver door and the fuel filler flap can be unlocked by gripping and pulling the driver door handle. If,
however, the transmitter key is set to selective unlocking and the triggering location for unlocking is not the
driver door handle, the vehicle is unlocked globally.
Unlocking function via trunk lid external operation switch
Function sequence
The rear SAM control unit recognizes when the trunk lid external operation switch is actuated and signals it to
the KEYLESS-GO control unit via interior CAN.
It transmits a wake-up signal to the transmitter key via the left trunk Keyless Go antenna.
The transmitter key transmits its access authorization code and its position to the rear window antenna amplifier
module, which relays it to the Keyless Go control unit.
The access authorization code is transmitted to the EIS control unit via the interior CAN. If it is valid, the EIS
control unit sends the command "Unlock CL" to the rear SAM control unit, which actuates the trunk lid CL
motor and opens the rotary tumbler.
On vehicles with code (881) Remote trunk closing (RTC) the automatic mode is stopped when the trunk lid
external operation switch is actuated again; if actuated anew, the procedure is continued.
Locking function via trunk lid KG button
(Model 221 up to 30.11.06)
Function requirements
Valid transmitter key outside of vehicle (max. approx. distance to trunk lid 1 m)
Circuit 15C OFF
Doors closed
Function sequence
If the trunk lid Keyless Go button is pressed, this is recognized by the rear SAM control unit and relayed to the
Keyless Go control unit. It transmits a wake-up signal to the transmitter key via the left trunk Keyless Go
antenna.
The transmitter key transmits its access authorization code and its position to the rear window antenna amplifier
module, which relays it to the Keyless Go control unit. The access authorization code is transmitted to the EIS
control unit via the interior CAN.
If it is valid, the EIS control unit transmits the command "Lock CL" to the door control units and the rear SAM
control unit. They then actuate the corresponding CL motors to lock.
The function is accomplished regardless of whether the trunk lid is open or closed.
Locking function via RTC button (with code (881) Remote trunk closing (RTC))
If the TLC button is actuated when the trunk lid is open, a signal is transmitted from the TLC control unit to the
KEYLESS-GO control unit via the interior CAN.
It transmits a wake-up signal to the transmitter key via the left trunk Keyless Go antenna.
The transmitter key transmits its access authorization code and its position to the rear window antenna amplifier
module, which relays it to the Keyless Go control unit.
The access authorization code is transmitted to the EIS control unit via the interior CAN. If it is valid, the EIS
control unit sends the command to lock the vehicle and the command to release the trunk lid lock. The TLC
control unit closes the trunk lid.
A2/12
GF82.62-P-
Vehicles without code (494) USA version
3131SX
or without code (498) Japan version
Rear window antenna module, component
GF82.62-P-
description Vehicles with code (498) Japan version
3131SXJ
GF82.62-P-
Vehicles with code (494) USA version
3131SXU
Keyless Go antenna, component GF82.62-P-
A2/35, A2/39, A2/41, A2/60, A2/61
description 4099SX
GF80.57-P-
Transmitter key, component description A8/1
6010SX
Keyless Go sensor unit, component GF80.61-P-
B67/1, B67/2, B67/3, B67/4
description 4109SX
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
N69/1 GF72.29-P-
Driver-side front door control unit, Model 221 6000SX
component description GF72.29-P-
Model 216
6000SC
Model 221 6010SX
Passenger-side front door control unit,
component description GF72.29-P-
Model 216
6010SC
Rear door control unit, component N69/3, N69/4 GF72.29-P-
description Model 221 6020SX
Keyless Go control unit, component GF80.61-P-
N69/5
description 4200SX
Electronic ignition switch control unit GF80.57-P-
N73
(EIS), component description 6000SX
N121
GF80.20-P-
TLC control unit, component description Vehicles with code (881) Remote trunk
6000SX
closing (RTC)
Trunk lid Keyless Go button, component S62/21 GF80.61-P-
description Model 221 up to 30.11.06 4107SX
S62/26
Close TLC button and lock Keyless Go, GF80.61-P-
Vehicles with code (881) Remote trunk
component description 4108SX
closing (RTC)
ENGINE START/STOP, FUNCTION - GF80.61-P-3012LE
MODEL 216.3, 221.0 /1 with CODE (889) KEYLESS-GO as of model year 2009 /YoM 08
Function requirements, general
The transmitter key (A8/1) is located in the vehicle interior
Engine start/stop, general
The engine start/stop function allows to start and stop the engine.
The engine start/stop function comprises the following subfunctions.
Function sequence for starting engine
Function sequence for circuit activation
Function sequence for stopping engine
Additional function requirements for starting engine
DIRECT SELECT gear selector switch (S16/13) is in the "P" or "N" position.
Brake pedal actuated (Signal from ESP control unit (N47-5) (except model 221.095/195) or signal from
regenerative breaking system (N30/6) (on model 221.095/195))
Function sequence for starting engine
access authorization code and transmits the signal "Start engine" to the KEYLESS-GO control unit (N69/5) via
the interior CAN (CAN B). The KEYLESS-GO control unit causes the following antennas to transmit a wake-
up and location finding signal to the transmitter key:
trunk KEYLESS-GO antenna (A2/35)
Left door KEYLESS-GO antenna (A2/39) (model 216)
Left rear door KEYLESS-GO antenna (A2/39) (model 221)
Right door KEYLESS-GO antenna (A2/41) (model 216)
Right rear door KEYLESS-GO antenna (A2/41) (model 221)
Center console KEYLESS-GO antenna (A2/60)
Interior compartment KEYLESS-GO antenna (A2/61) (up to 31.8.10)
The transmitter key transmits its access authorization code and its position to the rear window antenna amplifier
module (A2/12), which relays it to the KEYLESS-GO control unit. The access authorization code is transmitted
to the EIS control unit via the interior CAN.
If the access authorization code is valid and the transmitter key is located in the vehicle interior, c. 15R and c.
15 are switched on and the motor for the ME-SFI control unit (N3/10) (on gasoline engine) or CDI control unit
(N3/9) (on diesel engine) is started.
Error messages in instrument cluster (A1):
If a transmitter key is not recognized in the interior compartment when starting, the instrument cluster indicates
"Key not recognized" and the start attempt is interrupted (circuit 15R and circuit 15 remain off).
If, during a start attempt, the gear selector switch DIRECT SELECT is not in position "P" or "N", a
corresponding note is indicated in the instrument cluster.
The display request in the instrument cluster is transmitted by the EIS control unit to the central gateway
control unit (N93) via the interior CAN. The central gateway control unit routes this request to the instrument
cluster via the central CAN (CAN F).
Each time the vehicle is started or if a door is opened with the engine running, the EIS control unit requests the
KEYLESS-GO control unit to check the transmitter key.
If then a transmitter key is not recognized in the passenger compartment, the instrument cluster displays the
message "Key not recognized" in red and a warning tone is output via the warning buzzer (A1h1).
Function sequence for circuit activation
If the foot brake is not depressed when the KEYLESS-GO start/stop button is actuated, only circuit 15R is
switched on. Repeated actuation activates circuit 15. Further repeated actuation switches circuit 15R and circuit
15 off. If the driver door is closed, circuit 15C remains active for t = 30 min.
Function sequence for stopping engine
When the KEYLESS-GO start/stop button is pressed, the signal "Stop engine" is transmitted to the EIS control
unit and then c. 15 is switched off and the motor is switched off by the ME-SFI control unit or CDI control unit.
If the driver door is closed, circuit 15R remains active for t = 30 min.
Switching off engine depending on vehicle speed:
Speed v < 3 km/h: Switch off immediately
Speed v > 3 km/h: Switch-off occurs only after pressing KEYLESS-GO start/stop button for longer than t
>3s
PE80.61-P-2052-
Model 216
Function schematic for electric KEYLESS- 97CAA
GO engine start/stop PE80.61-P-2052-
Model 221
97SAA
A1
GF54.30-P-
Model 216.3, model 221 (except
Component description for instrument 6000LE
221.095/195)
cluster
GF54.30-P-
Model 221.095/195
6000LEH
N3/9 GF07.16-P-
Model 221 with engine 629.9 6000OA
Component description for CDI control GF07.16-P-
Model 221 with engine 642.8
unit 6000OHS
GF07.16-P-
Model 221 with engine 642.9
6000OHL
N3/10 GF07.61-P-
With engine 156 6000MAS
On model 221 with engine 272 GF07.61-P-
(except 272.974) 6000MIS
GF07.61-P-
Model 221 with engine 272.974
6000MEH
Component description for ME-SFI [ME] GF07.61-P-
With engine 273
control unit 6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
Model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278.
6000MMC
Component description for regenerative N30/6 GF42.22-P-
braking system control unit On model 221.095/195 1100LEH
N47-5
Component description for ESP control GF42.45-P-
Model 216.3, 221 (except
unit 5118LE
221.095/195)
control unit N69/5 4204LE
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for central gateway GF54.21-P-
N93
control unit 4170LE
ENGINE START/STOP, FUNCTION - GF80.61-P-3012SX
MODEL 221.0 /1, 216.3 with CODE (889) Keyless Go up to Model Year 8
Fig. 46: Engine Start/Stop Function Diagram
Courtesy of MERCEDES-BENZ USA
Shown on model 221
Function
The engine or circuits 15C, 15R, 15 can be switched on or switched off by pressing the start/stop button on the
EIS control unit.
Start engine, function
Function requirements
The transmitter key is located in the vehicle interior
DIRECT SELECT gear selector switch (S16/13) is in the "P" or "N" position.
Foot brake actuated
Function
When the start/stop button in the EIS control unit is pressed, a request is transmitted to the Keyless Go control
unit. It then transmits locating signals via the center console Keyless Go antenna and the interior Keyless Go
antenna to allow the transmitter key to determine its position.
Simultaneously with this procedure, the Keyless Go control unit requests the transmitter key to transmits an
access authorization code.
The transmitter key transmits its access authorization code and its position to the rear window antenna amplifier
module, which relays it to the Keyless Go control unit; the access authorization code is sent to the EIS control
unit via the interior CAN. If valid, circuit 15R and circuit 15 are switched on and the engine is started.
Possible error messages in the instrument cluster if function prerequisites are not fulfilled
If a transmitter key is not recognized in the interior compartment when starting, the instrument cluster
indicates "Key not recognized" and the start attempt is interrupted (c. 15R and c. 15 remain off).
If the DIRECT SELECT gear selection switch is not in position "P" or "N" when attempting to start, the
instrument cluster indicates:
"To start. Select drive position P or N".
Activating c.15C, 15R or 15 without engine start
If the foot brake is not depressed when the start/stop button is actuated, only circuit 15R is switched on.
Repeated actuation activates circuit 15. Further repeated actuation switches circuit 15R and circuit 15 off. If the
driver door is closed, c. 15C remains active for approx. 30 minutes.
Shut off engine, function
The engine can be switched off any time via the start/stop button
Function
The signal "Switch off engine" is transmitted to the EIS control unit by pressing the start/stop button and then
the engine is switched off via circuit 15. With the driver door closed, circuit 15C remains active for approx. 30
minutes.
Switch-off function of engine depending on vehicle speed
Speed below 3 km/h: Switch off occurs immediately
Speed above 3 km/h: Switch off occurs only after pressing start/stop button for an extended period
(approx. 3 seconds).
Starting requests, function
Each time the vehicle is started or if a door is opened with the engine running, the EIS control unit requests the
Keyless Go control unit to check the transmitter key.
If a transmitter key is not recognized in the passenger compartment, the instrument cluster indicates: "Key not
recognized".
A2/12
Vehicles with/without code (494) USA GF82.62-P-
version or without code (498) Japan 3131SX
Rear window antenna module, component version
description GF82.62-P-
Vehicles with code (498) Japan version
3131SXJ
GF82.62-P-
Vehicles with code (494) USA version
3131SXU
GF82.62-P-
Keyless Go antenna, component description A2/35, A2/39, A2/41, A2/60, A2/61
4099SX
GF80.57-P-
Transmitter key, component description A8/1
6010SX
N3/9 GF07.16-P-
CDI control unit, component description
Model 221 with engine 642 6000SX
N3/10
ME-SFI [ME] control unit, component GF07.61-P-
Model 221 with engine 272.965, 273.961
description 6000V
Model 216 with engine 273.961
ME-SFI control unit, N3/10 GF07.61-P-
location/task/design/function Model 221 with engine 275.953/982 5000M
GF42.45-P-
ESP control unit, component description N47-5
5118SX
Keyless Go control unit, component GF80.61-P-
N69/5
description 4200SX
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS), component description 6000SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
TRUNK LID KEYLESS GO BUTTON, COMPONENT DESCRIPTION - GF80.61-P-4107SX
MODEL 221.0 /1 up to 30.11.06 with CODE (889) Keyless Go
Fig. 47: Locating Trunk Lid Keyless-Go Button
Courtesy of MERCEDES-BENZ USA
Location
The trunk lid Keyless Go button is located on the outside of the trunk lid on the right next to the trunk lid
external operation switch (S88/8).
Task
When the trunk lid Keyless Go button is actuated, the vehicle is locked. Actuation of the trunk lid KEYLESS-
GO button is recognized by the rear SAM control unit with fuse and relay module (N10/2).
CLOSE TLC BUTTON AND LOCK KEYLESS GO, COMPONENT DESCRIPTION - GF80.61-P-
4108SX
MODEL 221.0 /1, 216.3 with CODE (889) Keyless Go with CODE (881) Remote trunk closing (RTC
[HDFS]) up to Model Year 8
Shown on model 221.0
Fig. 48: Locating TLC Button
Courtesy of MERCEDES-BENZ USA
Location
The TLC button is located in the trunk lid, on the right next to the trunk lid CL motor (M14/7).
Task
The trunk lid can be closed using the left button (1).
The trunk lid and the CL can be locked using the right button (2).
Actuation of the TLC button is read in by the TLC control unit (N121).
KEYLESS GO SENSOR UNIT, COMPONENT DESCRIPTION - GF80.61-P-4109SX
MODEL 221.0 /1, 216.3 with CODE (889) Keyless Go up to Model Year 8
Shown on model 221.0
Fig. 49: Locating Keyless Go Sensor Units
Courtesy of MERCEDES-BENZ USA
Location
The Keyless Go sensor unit is located in the corresponding outer door handle.
Design
A total of four sensors is integrated into the Keyless Go sensor unit:
Comfort sensor (recessed area)
Outer capacitive sensor
Inner capacitive sensor
Hall sensor
Function
The inner capacitive sensors detect when the door handle is gripped to open the door and the vehicle is
unlocked.
The outer capacitive sensors detects when the door handle is touched to close the door and the vehicle is
locked.
The Hall sensors detect when the door handle is pulled by activating an opening assist (only if a door
handle is pulled within 0.5 s after unlocking the central locking (CL))
The convenience sensor actuates the sliding/tilting roof convenience closing function as long as the
sensor is touched (on model 216 or on model 221 with code (414) Power glass tilting/sliding roof) or top
sliding roof (on model 221 with code (413) Panoramic glass roof with top sliding roof) and all side
windows as well as roller sun blinds (with code (540) Electric roller blind for rear window or on model
221 with code (297) Roller sun blinds in rear doors).
KEYLESS GO CONTROL UNIT, COMPONENT DESCRIPTION - GF80.61-P-4200SX
MODEL 221.0 /1, 216.3 with CODE (889) Keyless Go up to Model Year 8
Shown on model 221.0
Fig. 50: Locating Keyless Go Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The control unit is located in the trunk on the right rear.
Function
The control unit is connected to the interior CAN for exchanging data, reads in the following sensors, switches
and consumers and actuates their voltage supply and function.
Controlling
Left opening assist motor (A85m2) (model 216) or Left front opening assist motor(A85m2) (model 221)
Right opening assist motor (A85/1m2) (model 216) or Right front opening assist motor (A85/1m2)
(model 221)
Left rear opening assist motor (A85/3m2) (model 221)
Right rear opening assist motor(A85/4m2) (model 221)
Trunk Keyless Go antenna (A2/35)
Left door Keyless Go antenna (A2/39) (model 216) or Left rear door Keyless Go antenna (A2/39) (model
221)
Right door Keyless Go antenna (A2/41) (model 216) or Right rear door Keyless Go antenna (A2/41)
(model 221)
Center console Keyless Go antenna (A2/60)
Interior Keyless Go antenna (A2/61)
Reading in of sensors
Left Keyless Go sensor unit (B67/1) (model 216) or Left front keyless sensor unit (B67/1) (model 221)
Right Keyless Go sensor unit (B67/2) (model 216) or Right front Keyless Go sensor unit (B67/2) (model
221)
Left rear Keyless Go sensor unit (B67/3) (model 221)
Right rear Keyless Go sensor unit (B67/4) (model 221)
Reading in rear window antenna amplifier module (A2/12) for detecting position of transmitter key
(A8/1) and access authorization code.
Discrete inputs
Circuit 30
Circuit 31
Keyless Go sensor units
Rear window antenna amplifier module
Discrete outputs
Opening assist motors
Keyless Go antennas
COMPONENT DESCRIPTION FOR KEYLESS-GO CONTROL UNIT - GF80.61-P-4204LE
MODEL 216.3, 221.0 /1 with CODE (889) KEYLESS-GO as of model year 2009 /YoM 08
Shown on model 221.0 up to 31.8.10
Fig. 51: Locating Keyless-Go Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The KEYLESS-GO control unit is located behind the right paneling in the trunk.
As of 1.9.10 the KEYLESS-GO control unit behind the left paneling in the trunk.
Task
The KEYLESS-GO control unit has the following purposes:
Reading in of sensors
Evaluation of input factors
Actuation of components
Reading in of sensors
The input factors are read in via the following connections:
Direct line
Interior CAN (CAN B)
Direct line
The following components are read in via a direct line:
Left KEYLESS-GO sensor unit (B67/1) (model 216)
Left front KEYLESS-GO sensor unit (B67/1) (model 221)
Right KEYLESS-GO sensor unit (B67/2) (model 216)
Right front KEYLESS-GO sensor unit (B67/2) (model 221)
Left rear KEYLESS-GO sensor unit (B67/3) (model 221)
Right rear KEYLESS-GO sensor unit (B67/4) (model 221)
Rear window antenna amplifier module (A2/)A2/12
Interior CAN
The following sensors are read in via the interior CAN:
From EIS control unit (N73) for KEYLESS-GO start/stop button (S2/3)
From Rear SAM control unit with fuse and relay module (N10/2) for trunk lid external operation switch
(S88/8)
From ESP control unit (N47-5) (except model 221.095/195) or regenerative brake system control unit
From instrument cluster (A1) via central gateway control unit for vehicle speed signal
From TLC control unit (N121) (model 221 with code (881) Remote trunk closing (RTS), model 216) for
TLC button (S62/26)
Evaluation of input factors
The input factors that have been read in are evaluated by the integrated microprocessor and the relevant
components are then actuated.
Actuation of components
Components are actuated with the following connection:
Direct line
Direct line
The following components are actuated via a direct line:
trunk KEYLESS-GO antenna (A2/35)
Left door KEYLESS-GO antenna (A2/39) (model 216)
Right door KEYLESS-GO antenna (A2/41) (model 216)
Left rear door KEYLESS-GO antenna (A2/39) (model 221)
Right rear door KEYLESS-GO antenna (A2/41) (model 221)
Center console KEYLESS-GO antenna (A2/60)
Interior compartment KEYLESS-GO antenna (A2/61) (up to 31.8.10)
Left door lock unit (A85) (model 216)
Left front door lock unit (A85) (model 221)
Right door lock unit (A85/1) (model 216)
Right front door lock unit (A85/1) (model 221)
Left rear door lock unit (A85/3) (model 221)
Right rear door lock unit (A85/4) (model 221)
Model 216 PE80.61-P-2101-97CAA
Wiring diagram for KEYLESS-GO control unit
Model 221 PE80.61-P-2101-97SAA
SURVEY OF KEYLESS-GO SYSTEM COMPONENTS, COMPONENT DESCRIPTION - GF80.61-P-
9997LE
MODEL 216.3, 221.0 /1 with CODE (889) KEYLESS-GO as of model year 2009 /YoM 08
Model 216.3, model 221 (except 6000LE
221.095/195)
Component description for instrument cluster
GF54.30-P-
Model 221.095/195
6000LEH
N3/9 GF07.16-P-
Model 221 with engine 629.9 6000OA
GF07.16-P-
Component description for CDI control unit Model 221 with engine 642.8
6000OHS
GF07.16-P-
Model 221 with engine 642.9
6000OHL
N3/10 GF07.61-P-
With engine 156 6000MAS
on model 221 with engine 272 (except GF07.61-P-
272.974) 6000MIS
GF07.61-P-
Model 221 with engine 272.974
6000MEH
Component description for ME-SFI [ME] GF07.61-P-
With engine 273
control unit 6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
Model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278.
6000MMC
Component description for front SAM control GF54.21-P-
N10/1
unit with fuse and relay module 6070LE
Component description for rear SAM control GF54.21-P-
N10/2
unit with fuse and relay module 6030LE
Component description for regenerative N30/6 GF42.22-P-
braking system control unit Model 221.095/195 1100LEH
N47-5
GF42.45-P-
Component description for ESP control unit Model 216.3, model 221 (except
5118LE
221.095/195)
Component description for left door control N69/1 GF72.29-P-
unit Model 216 4124LA
Component description for left front door N69/1 GF72.29-P-
control unit Model 221 4141LE
Component description for right door control N69/2 GF72.29-P-
unit Model 216 4128LA
Component description for right front door N69/2 GF72.29-P-
control unit Model 221 4142LE
Rear door control unit, component N69/3, N69/4 GF72.29-P-
description Model 221 6020LE
N69/5
control unit 4204LE
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for steering column GF54.21-P-
N80
tube module 6050LE
Component description for central gateway GF54.21-P-
N93
control unit 4170LE
N121
Model 221 with code (881) Remote GF80.20-P-
TLC control unit, component description
trunk closing (RTC [HDFS]) 6000LE
Model 216
Contents, function description of KEYLESS- GF80.61-P-
GO 0996LE
SURVEY OF KEYLESS GO SYSTEM COMPONENTS, COMPONENT DESCRIPTION - GF80.61-P-
9997SX
MODEL 221.0 /1, 216.3 with CODE (889) Keyless Go up to Model Year 8
A2/12
Vehicles without code (494) USA GF82.62-P-
version or without code (498) Japan 3131SX
Rear window antenna module, component version
description GF82.62-P-
Vehicles with code (498) Japan version
3131SXJ
GF82.62-P-
Vehicles with code (494) USA version
3131SXU
GF82.62-P-
Keyless Go antenna, component description A2/35, A2/39, A2/41, A2/60, A2/61
4099SX
GF80.57-P-
Transmitter key, component description A8/1
6010SX
GF80.61-P-
Keyless Go sensor unit, component description B67/1, B67/2, B67/3, B67/4
4109SX
N3/9 GF07.16-P-
Component description for CDI control unit
Model 221 with engine 642 6000SX
N3/10
ME-SFI [ME] control unit, component Model 221 with engine 272.946/965/975, GF07.61-P-
description 273.924/961/968 6000V
Model 216 with engine 273.961
N3/10
ME-SFI control unit, GF07.61-P-
Model 216 with engine 275.953/982
location/task/design/function 5000M
Model 221 with engine 275.953/982
Rear SAM control unit with fuse and relay GF54.21-P-
N10/2
module, component description 6030SX
GF42.45-P-
ESP control unit, component description N47-5
5118SX
N69/1 GF72.29-P-
Driver-side front door control unit, component Model 221 6000SX
description GF72.29-P-
Model 216
6000SC
N69/2 GF72.29-P-
Passenger-side front door control unit, Model 221 6010SX
component description GF72.29-P-
Model 216
6010SC
N69/3, N69/4 GF72.29-P-
Rear door control unit, component description
Model 221 6020SX
Keyless Go control unit, component GF80.61-P-
N69/5
description 4200SX
Electronic ignition switch control unit (EIS), GF80.57-P-
N73
component description 6000SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
N121
GF80.20-P-
TLC control unit, component description Vehicles with code (881) Remote trunk
6000SX
closing (RTC)
Trunk lid Keyless Go button, component S62/21 GF80.61-P-
description Model 221 up to 30.11.06 4107SX
S62/26
Close TLC button and lock Keyless Go, GF80.61-P-
Vehicles with code (881) Remote trunk
component description 4108SX
closing (RTC)
GF80.61-P-
Contents, function description of Keyless Go
0996SX
ACCESSORIES & BODY, CAB
Central Locking System - Testing & Repair - S-Class (221)
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: CENTRAL LOCKING, CONVENIENCE
FEATURE, DRIVE AUTHORIZATION SYSTEM - AR80.00-Z-9221AA
MODEL 221
Remove/install electronic ignition AR80.57-P-
MODEL 221.0 /1, 216
switch control unit 1000SX
Remove/install front door infrared AR80.30-P-
MODEL 221.0/ 1
remote control receiver 4305SX
Remove/install fuel filler flap CL AR80.20-P-
MODEL 216.3, 221.0 /1
element 2300SX
Remove/install interior protection MODEL 216.3, 221.0 /1 with CODE (882) AR80.50-P-
infrared sensors Interior monitoring (with ATA [EDW] only) 9831SX
Remove/install Keyless Go control AR80.35-P-
MODEL 221.0 /1 with CODE (889) Keyless Go
unit 0001SX
REMOVE/INSTALL FUEL FILLER FLAP CL ELEMENT - AR80.20-P-2300SX
MODEL 216.3, 221.0 /1
Fig. 1: Identifying Fuel Filler Flap CL Element Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221
MODIFICATION NOTES
12.6.06 Repair method completely modified
Remove/install
AR88.60-P-
1 Remove tank recess
2000SX
Remove fuel filler flap CL [ZV] motor Installation: Ensure that guides (2)
2 (M14/10) with mount (1) in direction of of bracket (1) are seated correctly in
arrow rear fender and spacer (4).
3 Disconnect electrical connector (3)
Unscrew bolts from rear of bracket (1) and
Only when replacing fuel filler flap CL
4.1 remove bracket (1) from fuel filler flap CL
[ZV] motor (M14/10).
[ZV] motor (M14/10)
5 Install in the reverse order
REMOVE/INSTALL FRONT DOOR INFRARED REMOTE CONTROL RECEIVER - AR80.30-P-
4305SX
MODEL 221.0/ 1
Shown on model 221.0
Fig. 2: Identifying Front Door Infrared Remote Control Receiver Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove cover (1) and loosen bolt *BA72.10-P-
1
below 1005-01Q
guide (2) until electrical connector Installation: Ensure that seal (4) is
2
(5) can be disconnected positioned correctly.
Disconnect electrical connector (5) When replacing driver door infrared
3 and remove guide (6) with driver sensor (B58) replace cap (3), because cap
door infrared sensor (B58) (3) is damaged when removing guide (6).
4 Install in the reverse order
FRONT DOOR
Number Designation Model 221
BA72.10-P-1005-01Q Bolt, guide of lock cylinder to front door Nm 3
REMOVE/INSTALL KEYLESS GO CONTROL UNIT - AR80.35-P-0001SX
MODEL 221.0 /1 with CODE (889) Keyless Go
Fig. 3: Identifying Keyless Go Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Switch off ignition and remove transmitter Keyless Go start/stop button only
1 key or Keyless Go start/stop button from EIS on vehicles with code (889) Keyless
control unit Go.
Do not bend hinge lever passage
frame (2), otherwise the plastic
Loosen side paneling in trunk (3) and pivot material can discolor
2 to side until Keyless Go control unit (N69/5)
See: ?
is accessible
AR68.30-P-
Remove/install panelings in trunk
4600SX
3 Unscrew nuts (4)
Keyless Go control unit (N69/5) and remove
4
Keyless Go control unit (N69/5)
5 Install in the reverse order
REMOVE/INSTALL INTERIOR PROTECTION INFRARED SENSORS - AR80.50-P-9831SX
MODEL 216.3, 221.0 /1 with CODE (882) Interior monitoring (with ATA [EDW] only)
Fig. 4: Identifying Ultrasonic Echo Sounder Sensor Components
Courtesy of MERCEDES-BENZ USA
Illustrated on model 221
Remove/install
Carefully unclip cover (1) with ultrasonic echo
Fig.
1 sounder sensor (A26/13) on pins (3) from
5
headliner (5).
Disconnect electrical connector (4) and remove
2 cover (1) with ultrasonic echo sounder sensor
(A26/13).
Carefully unclip ultrasonic echo
Unclip ultrasonic echo sounder sensor (A26/13)
3 sounder sensor (A26/13); catch hooks (6)
from covering (1).
can break off.
4 Install in the reverse order
Fig. 5: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ELECTRONIC IGNITION SWITCH CONTROL UNIT - AR80.57-P-1000SX
MODEL 221.0 /1, 216
Fig. 6: Identifying Electronic Ignition Switch Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
When replacing control unit
(N73)
1 Perform data transfer with STAR DIAGNOSIS Connect STAR
DIAGNOSIS and select EIS
menu point.
STAR DIAGNOSIS diagnosis *WH58.30-Z-
system 1048-13A
Fold left cover downward below instrument AR68.10-P-
2
cover 1500SX
Press clips (1) together and press control unit
3 (N73) out of bracket (2) from outside toward
inside
Remove control unit (N73) downward until
4
electrical connectors (3, 4) are accessible
Disconnect electrical connectors (3, 4) from
5
control unit (N73)
6 Install in the reverse order
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
TRANSMISSION
Automatic Transmission - Testing & Repair - S-Class (221)
TESTING & REPAIR
INSERT SELECTOR VALVE INTO DRIVER OF DETENT PLATE - AR27.19-P-0200-01A
TRANSMISSION 722.6 /9
1. When inserting electrohydraulic control unit into transmission housing, plastic part of selector valve (10)
must engage in driver of detent plate (11).
Fig. 1: Identifying Detent Plate With Plastic Part Of Selector Valve
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ELECTROHYDRAULIC CONTROLLER UNIT (TRANSMISSION
INSTALLED) - AR27.19-P-0200W
TRANSMISSION 722.9
Fig. 2: Identifying Electrohydraulic Controller Unit Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Shown on transmission of model 211
MODIFICATION NOTES
23.6.10 Work information on removing/installing the electrical controller unit, added
Remove/install
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or columns of vehicle lift
toppling off of the liftingand position four support
platform. plates at vehicle lift
support points specified
by vehicle manufacturer.
Notes on self-locking nuts AH00.00-N-0001-01A
and bolts
Information on preventing AH54.00-P-0001-01A
damage to electronic
components due to
electrostatic discharge
Installation: Shift
through the gears on the
transmission a few times
before initial startup to
flush out any air
inclusions from the
electric controller unit
(Y3/8).
1 Switch off ignition, On vehicles with code
remove ignition key or (889) Keyless-Go: Press
transmitter key the start and stop button
repeatedly until the
ignition is switched off.
Remove the Keyless Go
transmitter card or
transmitter key from the
vehicle and store beyond
the reach of the
transmitter (at least 2 m).
2 Remove heat shield above
the transmission Model 204, 207 AR27.40-P-0700-01CW
connector (4e) Model 172, 212, 218 AR27.40-P-0700-01EW
Model 164, 251 AR27.40-P-0700-01GZ
Model 216, 221 AR27.40-P-0700-01SX
Model 171, 203, 209, AR27.40-P-0700-01V
211, 219
Model 230 AR27.40-P-0700-01RX
3 Remove transmission oil AR27.10-P-7030W
pan (3)
4 Remove oil filter (34) Installation: Replace
oil filter (34).
5 Unplug 5-pin connector at Clean the transmission
transmission connector connector (4e) and
(4e) connector on electric
controller unit (Y3/8).
6 Remove bolts (4s) and If the electric
remove the electric controller unit (Y3/8) is
controller unit (Y3/8) seized, press it off
carefully with a suitable
tool while covering the
sealing surfaces of the
transmission housing to
prevent damage.
Installation: Replace
bolts (4s) and B3 oil
guide pipe (2).
Installation: Insert
B3 oil guide pipe (2) into
transmission housing (1)
before installation of the
electric controller unit
(Y3/8).
When inserting the
electric controller unit
(Y3/8), insert the selector
valve (4w) into the driver
of the detent plate (82): ?
Insert selector valve (4w) AR27.19-P-0200-01A
into driver of detent plate
(82).
*BA27.19-P-1001-01A
7 Install in the reverse order
8 Check transmission oil Transmission 722.9 AR27.00-P-0270W
level and correct if except 722.96
necessary Transmission 722.96 AR27.00-P-0270SYZ
9 Read out fault memory STAR DIAGNOSIS AD00.00-P-2000-04A
and erase Stored faults which can
result from cables being
disconnected or from
simulation during
removal and installation
or test work, have to be
processed and erased in
the fault memories after
completing the work.
10 Perform transmission After replacing or
adaptation repairing transmission,
perform transmission
adaptation.
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
11 Test run engine and check
transmission for
leaktightness and proper
operation
ELECTROHYDRAULIC CONTROLLER UNIT
Transmission
Number Designation
722.9
Stage
Nm 4
1
BA27.19-P-1001- Bolt, electrohydraulic controller unit to Stage
Angle° 90
01A transmission housing 2
Stage
Angle° -
3
REMOVE/INSTALL CONTROL SOLENOID VALVES OF ELECTRIC CONTROLLER UNIT -
AR27.19-P-0212A
TRANSMISSION 722.9
Fig. 3: Identifying Control Solenoid Valves Of Electric Controller Unit Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Electrohydraulic controller unit, model 221
Fig. 4: Identifying Control Solenoid Valve Conditions
Courtesy of MERCEDES-BENZ USA
Removing
Notes on self-locking nuts and AH00.00-N-0001-01A
bolts
Information on preventing damage AH54.00-P-0001-01A
to electronic components due to
electrostatic discharge
If more than 4
control solenoid valves
(Y3/8y1 to Y3/8y8)
are damaged or soiled,
then the Market
Performance Center
(MPC) or the general
distributor (GV) is to
be notified, and it will
then determine how to
proceed.
In order to avoid
damage to the
transmission, always
observe the
Specifications for
Operating Fluids !
1 Remove electrohydraulic AR27.19-P-0200W
controller unit
Disassemble/assemble
2 Unscrew bolts (1) and remove leaf *BA27.19-P-1002-
springs (2) 01A
3 Pull control solenoid valves Assembly: Each
(Y3/8y1 to Y3/8y8) out of the control solenoid valve
electric controller unit (Y3/8) (Y3/8y1 to Y3/8y8)
must be installed at its
original installation
location again.
Moisten O-rings with
transmission oil.
Transmissions up to BB00.40-P-0236-14A
production date
18.06.2010 and all
transmissions 722.9 in
combination with
engine 629
All transmissions BB00.40-P-0236-15A
722.9 as of production
date 21.06.2010 except
transmission 722.9 in
combination with
engine 629
Checking
4 Determine degree of soiling on If the control
control solenoid valves (Y3/8y1 to solenoid valves
Y3/8y8) (Y3/8y1 to Y3/8y8)
are soiled, they should
always be rinsed clean.
If the control
solenoid valves show
no traces of abrasion or
soiling (see picture C),
it is not necessary to
rinse them.
Clean
5 Clean sieves of control solenoid Use a magnet first
valves (Y3/8y1 to Y3/8y8) to clean the sieve of
the control solenoid
valves (Y3/8y1 to
Y3/8y8) and then clean
the sieve by swiveling
it in fresh gear oil until
the soiling is removed
To clean the control
solenoid valves
(Y3/8y1 to Y3/8y8)
aids such as rags,
compressed air, brake
cleanser etc. must
never be used. The
control solenoid valves
(Y3/8y1 to Y3/8y8)
may only be cleaned in
fresh gear oil.
Transmissions up to BB00.40-P-0236-14A
production date
18.06.2010 and all
transmissions 722.9 in
combination with
engine 629
All transmissions BB00.40-P-0236-15A
722.9 as of production
date 21.06.2010 except
transmission 722.9 in
combination with
engine 629
Checking
6 Check control solenoid valves If, after cleaning the
(Y3/8y1 to Y3/8y8) after cleaning control solenoid valves
for cleanliness and signs of (Y3/8y1 to Y3/8y8),
damage no soiling or damage is
recognizable (C), then
these control solenoid
valves (Y3/8y1 to
Y3/8y8) may be used
again.
If damage or soiling is
detected (B), then the
respective control
solenoid valves
(Y3/8y1 to Y3/8y8)
has to be renewed.
Clean
7 Clean seats of control solenoid By pulling the
valves (Y3/8y1 to Y3/8y8) and control solenoid valves
shifting channels in the valve (Y3/8y1 to Y3/8y8)
body assembly (7) out of the valve body
assembly (7) abrasion
or dirt particles drop
into the channel below.
This abrasion must be
removed from the
valve body assembly
(7) with the aid of
magnets and/or using a
pipette.
8 Pull magnet (6) of shift valve (6a) Use a lint-free rag
out slightly and clean to remove shavings
and abrasion from
magnet (6) of shift
valve (6a).
Assembly: Check
shift valve (6a) for
correct seating in valve
body assembly (7).
9 Assemble in the reverse order
Install
10 Install electrohydraulic controller Installation: Clean AR27.19-P-0200W
unit oil pan and magnet
thoroughly and replace
oil filter.
11 Conduct gear selection adaptation After replacing the AD00.00-P-2000-04A
of renewed control solenoid control solenoid valves
valves (Y3/8y1 to Y3/8y8) using (Y3/8y1 to Y3/8y8)
STAR DIAGNOSIS The adaptation
values of the electric
controller unit (VGS)
(Y3/8) must not be
reset.
After replacing the
following control
solenoid valves the
corresponding gears
are to be adapted:
?
Y3/8y2 Control
solenoid valve
coupling K1
(VGS) gear 6 to
5 and gear 2 to 3
Y3/8y3 Control
solenoid valve
coupling K2
(VGS) Gear 3 to
4
Y3/8y4 Control
solenoid valve
coupling K3
(VGS) Gear 4 to
3 and gear 4 to 5
Y3/8y5 Control
solenoid valve
brake B1 (VGS)
Gear 3 to 2 and
gear 1 to 2
Y3/8y6 Control
solenoid valve
brake B2 (VGS)
Gear 5 to 4 and
ESV to R and D
Y3/8y7 Control
solenoid valve
brake B3 (VGS)
Gear 2 to 1
Y3/8y8 Control
solenoid valve
(KUB) torque
converter lockup
clutch (VGS)
ELECTROHYDRAULIC CONTROLLER UNIT
Number Designation Transmission 722.9
BA27.19-P-1002-01A Bolt, solenoid valve to shift plate Nm 8
DISASSEMBLE AND ASSEMBLE ELECTROHYDRAULIC CONTROLLER UNIT - AR27.19-P-
0220A
TRANSMISSION 722.6 in MODEL
Shown on electrohydraulic controller unit in model 163
Fig. 5: Identifying Electricohydraulic Control Unit Disassemble/Assemble Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
24.9.97 Remove caps Operation step 1 added
24.9.97 Caps for solenoid valves Operation step 1 BT.27.19-P-0003-01A
added
Disassemble/Assemble
1 Take off caps of solenoid Valves Transmission 722.6 as
of 8/1/97 in model 461
(except 461.331)
Transmission 722.6 as
Caps for solenoid valve, new of 8/1/97 in Model 221 BT27.19-P-0003-01A
2 Unscrew bolts (17a, 17b) and Installation: Pay
remove leaf springs (17) attention to the
different length of the
bolts (17a, 17b)
Bolt, solenoid valve to
shift plate *BA27.19-P-1002-01A
3 Pull modulating pressure control Installation: Check O-
solenoid valve (y3/6y1) and shift rings on modulating
pressure control solenoid valve pressure control
(y3/6y2) out of valve body assembly solenoid valve (y3/6y1)
(16) using pliers and on shift pressure
control solenoid valve
(y3/6y2); replace valve
if necessary.
Pliers: Fig. 6
Installation:
solenoid valve (y3/6y3), shift rings on shift operation
operation 3-4 solenoid valve 1-2 and 4-5 solenoid
(y3/6y4) and shift operation 2-3 valve (y3/6y3), shift
solenoid valve (y3/6y5) out of valve operation 3-4 solenoid
body assembly (16) using pliers valve (y3/6y4) and
shift operation 2-3
solenoid valve
(y3/6y5); replace valve
if necessary.
Pliers: Fig. 6
5.1 Remove electric controller unit Transmission 722.6##
(y3/6) from valve body assembly ## up to 0026194 in
(16) Model 221
Installation: Make
sure that the two
centering pins of the
electric controller unit
(y3/6) engage in the
valve body assembly
(16)
5.2 Bend retaining lug on stiffening rib Transmission 722.6##
on Oil temperature sensor to one ## up to 0026195 in
side and remove electric controller Model 221
unit (y3/6) from valve body
assembly (16)
Retaining lug added to
electrohydaulic control module BT27.19-P-0001-01A
6 Disassemble shift plate (16) Dismantle and AR27.35-P-0350A
assemble shift plate
Only when the shift
plate (16) is dirty or
metal shavings are
present in the
transmission oil.
7 Assemble in the reverse order
ELECTROHYDRAULIC CONTROLLER UNIT
Number Designation Transmission 722.6
BA27.19-P-1002-01A Bolt, solenoid valve to Nm 8
shift plate
Fig. 6: Identifying Pliers (606 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE AND ASSEMBLE ELECTROHYDRAULIC CONTROLLER UNIT - AR27.19-P-
0220B
TRANSMISSION 722.9
Fig. 7: Identifying Electrohydraulic Controller Unit Disassemble And Assemble Components
Courtesy of MERCEDES-BENZ USA
Electrohydraulic controller unit, model 221
Fig. 8: Identifying Electrohydraulic Controller Unit
Courtesy of MERCEDES-BENZ USA
Electrohydraulic controller unit, model 221
MODIFICATION NOTES
23.6.10 Work information on removing/installing the electrical controller unit, added
Removing
Notes on self-locking nuts and AH00.00-N-0001-01A
bolts
Information on preventing damage AH54.00-P-0001-01A
to electronic components due to
electrostatic discharge
In order to avoid
damage to the
transmission, always
observe the
Specifications for
Operating Fluids !
Before removal of
the electric controller
unit (Y3/8), the guided
test must always be
performed with STAR
DIAGNOSIS and the
characteristics stored
in the control unit
transferred.
After installation of a
new electric controller
unit (Y3/8), the data
stored before removal
must be transferred to
the new electric
controller unit (Y3/8).
Make sure that the
STAR DIAGNOSIS
unit used before
removal is also used
for installation.
1 Remove electrohydraulic AR27.19-P-0200W
controller unit
Disassemble/assemble
2 Unscrew bolts (1) and remove leaf *BA27.19-P-1002-
springs (2) 01A
3 Pull control solenoid valves Assembly: Always
(Y3/8y1 to Y3/8y8) out of the mount each control
electric controller unit (Y3/8) solenoid valve in its
original installation
position again.
Moisten O-rings with
transmission oil.
Transmissions up to BB00.40-P-0236-14A
production date
18.06.2010 and all
transmissions 722.9 in
combination with
engine 629
All transmissions BB00.40-P-0236-15A
722.9 as of production
date 21.06.2010 except
transmission 722.9 in
combination with
engine 629
Clean
4 Clean strainers of control solenoid Check control AR27.19-P-0212A
valves solenoid valves and
replace if necessary.
Assembly: Before
installation, clean the
strainer of the valves
by swirling it around
not clean any other
parts of the electric
controller unit (Y3/8)
with rags or
compressed air!
Transmissions up to BB00.40-P-0236-14A
production date
18.06.2010 and all
transmissions 722.9 in
combination with
engine 629
All transmissions BB00.40-P-0236-15A
722.9 as of production
date 21.06.2010 except
transmission 722.9 in
combination with
engine 629
5 Remove bolt (3a). Assembly: Install
new bolt (3a).
*BA27.19-P-1007-
01A
6 Remove bolts (3b) and electric Assembly: Press in
controller unit (Y3/8) from valve spring pin (5) from
body assembly (7) repair kit up to the end
stop by hand and
moisten O-rings (4d)
on EHS connector (4e)
with transmission oil.
Assembly: Make
sure that the retaining
lug of the electric
controller unit (Y3/8),
which is located under
the output speed
sensor (Y3/8n3) (see
picture), is positioned
correctly on the valve
body assembly (7)
otherwise the electric
controller unit (Y3/8)
will be damaged.
Transmissions up to BB00.40-P-0236-14A
production date
18.06.2010 and all
transmissions 722.9 in
combination with
engine 629
All transmissions BB00.40-P-0236-15A
722.9 as of production
date 21.06.2010 except
transmission 722.9 in
combination with
engine 629
Clean
7 Clean magnet (6) of shift valve Use a lint-free rag
(6a) to remove shavings
from magnet (6) of
shift valve (6a).
Assembly: Check
shift valve (6a) for
correct seating in
valve body assembly
(7).
8 Assemble in the reverse order
Install
9 Install electrohydraulic controller After installation AR27.19-P-0200W
unit (Y3/8) of the new electric
controller unit (Y3/8),
the stored adaptation
values are transferred.
Transmission
adaptation is only
necessary after further
repair measures.
ELECTROHYDRAULIC CONTROLLER UNIT
Transmission
Number Designation
722.9
BA27.19-P-
Bolt, solenoid valve to shift plate Nm 8
1002-01A
BA27.19-P- Bolt, controller unit for fully integrated transmission control to
Nm 8
1007-01A electrohydraulic controller unit
REPLACE PILOT BUSHING IN ELECTROHYDRAULIC CONTROLLER UNIT - AR27.19-P-0230A
TRANSMISSION 722.6
Fig. 9: Identifying Electrohydraulic Controller Unit, Pilot Bushing, Screw, Heat Shield And Connectors
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value changed: Bolt securing pilot bushing to electrohydraulic controller *BA27.19-P-1003-
26.2.08
unit 01A
Remove/install
In order to prevent damage
to the electric controller
unit, the transmission oil
temperature must be < 50
°C when removing and
installing the pilot bushing
(21).
1.1 Switch off the ignition, Vehicles without Keyless
remove the ignition key Go
from the EIS control unit
1.2 Remove the Keyless Go Vehicles with Keyless
transmitter (ignition Go Code 889
key/card) from the vehicle Switch off engine.
and store beyond the reach
of the transmitter
2.1 Remove the rear section of Vehicles with gasoline
the engine compartment engine except model 461
paneling and 463
Model 129, 202, 208, AR61.20-P-1105AB
210
Model 140
Model 163 AR61.20-P-1105GH
Model 170 AR61.20-P-1105A
Model 171 AR61.20-P-1105V
Model 199 AR61.20-P-1105SLR
Model 203, 209 AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Model 215, 220 AR61.20-P-1105M
Model 216, 221 except AR61.20-P-1105SX
code (Z07) Top
protection
Model 221 with code AR61.20-P-1105SXS
(Z07) Top protection
Model 230 AR61.20-P-1105R
Model 240 AR61.20-P-1105H
2.2 Remove rear part of Vehicles with diesel
bottom sections of engine except model 461
soundproofing and 463
Model 163 AR94.30-P-5400GH
Model 202.1 AR94.30-P-5300A
Model 203, 209 AR94.30-P-5300P
Model 204
Model 210 AR94.30-P-5300AB
Model 211 AR94.30-P-5300T
Model 220 AR94.30-P-5300M
3.1 Disconnect plug connector Model 163
(26)
3.2 Detach heat shield (62) Except model 163, 230 AR27.10-P-0500-01A
and unplug connector (26) with transmission
722.649, 240 with
transmission 722.649
Model 230 with AR27.10-P-0500-01H
transmission 722.649,
240 with transmission
722.649
*BA27.40-P-1014-01A
*BA27.40-P-1003-01B
4 Remove bolt (22) and When removing pilot
remove pilot bushing (21) bushing (21) watch for
from the electrohydraulic transmission oil run off.
controller unit (19) *BA27.19-P-1003-01A
5 Install in the reverse order
6 Check oil level in AR27.00-P-0100AC
automatic transmission,
correct if necessary
ELECTROHYDRAULIC CONTROLLER UNIT
Number Designation Transmission 722.6
BA27.19-P-1003-01A Bolt, pilot bushing to electrohydraulic controller unit Nm 2.5
HOUSING
Transmission 722.6 except Transmission
Number Designation
722.660/661/662/663/666/673/674 722.660/661/662/663/666/673/674
Bolt, heat
BA27.40-
shield to
P-1014- Nm 6 6
transmission
01A
housing
HOUSING
Transmission 722.6 in Transmission 722.6 in
Number Designation
model 230 model 240
BA27.40-P- Bolt, heat shield to
Nm 12 11
1003-01B transmission housing
REMOVE/INSTALL INTELLIGENT SERVO MODULE - AR27.19-P-0550SX
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3
Fig. 10: Identifying Intelligent Servo Module Remove/Install Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Illustrated on model 221.171
Fig. 11: Identifying Intelligent Servo Module Remove/Install Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value modified: Self-locking nut of flex disk to transmission or front *BA41.10-P-1001-
29.6.10
propeller shaft, M12 01H
Remove/install
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or toppling columns of vehicle lift
off of the lifting platform. and position four
support plates at vehicle
lift support points
specified by vehicle
manufacturer.
Information on preventing AH54.00-P-0001-01A
damage to electronic
components due to
electrostatic discharge
Notes on self-locking nuts AH00.00-N-0001-01A
and bolts
1 Release parking brake
2 Disconnect ground lines Insulate terminals of AR54.10-P-0003SX
from batteries ground lines to prevent
accidental contact with
the ground points of the
batteries.
Notes on battery AH54.10-P-0001-01A
3 Remove bottom engine Vehicles without top AR61.20-P-1105SX
compartment paneling protection
Vehicles with code AR61.20-P-1105SXS
(Z07) Top protection
4 Support and secure Secure the
transmission (1) transmission (1) with a
tensioning strap to
prevent it from tilting or
slipping off.
5 Remove rear engine cross The engine mount (5)
member (2) must also be removed on
vehicles without 4-
MATIC.
Without 4-MATIC AR22.10-P-1180SX
With 4-MATIC AR22.10-P-1180SW
6 Mark position of front This is to ensure
flexible coupling relative to reinstallation at the ex-
output flange and propeller factory installation
shaft position, otherwise drive
line vibrations can be
produced.
7 Detach propeller shaft from If the fitted sleeves AR41.10-P-0050-02SX
transmission (1) are jammed: ?
Release the guide AR41.10-P-0050-09SX
sleeves on
Drift for loosening fitting WF58.50-P-4110-01A
sleeves in flex disks.
Installation: Attach AR41.10-P-0050-07SX
the propeller shaft.
*BA41.10-P-1001-01H
8 Detach front exhaust bracket Without 4-MATIC
(6) from transmission (1) Engine 156, 272, 273 *BA49.10-P-1008-01Z
Engine 629 *BA49.10-P-1004-
01AA
Engine 642 *BA49.10-P-1002-01V
9.1 Remove exhaust system without 4-MATIC
from flange connections Engine 156, 272, 273 AR49.10-P-7100SX
(center muffler to catalytic
converters) Engine 629, 642 AR49.10-P-7100SXI
9.2 Detach exhaust system from Engine 273 with 4- AR49.10-P-7100SX
exhaust manifolds MATIC
9.3 Detach exhaust system from Engine 642 with 4- AR49.10-P-7100SXI
diesel particulate filter MATIC
10 Detach front exhaust system
from rubber retainers
11 Disconnect electrical
connector from intelligent
servo module (A80)
12 Lower transmission (1) When the engine is
being lowered, it must
not rest on the front axle
carrier, otherwise the
engine oil pan will be
damaged.
13 Remove the bolts (10) on the Installation: Replace
intelligent servo module bolts (10).
(A80) *BA27.40-P-1021-01A
14 Remove intelligent servo When reusing the
module (A80) with bleed intelligent servo module
hose (A80) do not detach
bleed hose. Leaky
separation points result
in water entry.
15 Rotate the range selector When replacing the
shaft (3) of the transmission intelligent servo module
(1) counterclockwise up to (A80).
the end stop at position the new intelligent
"D" (arrow) servo module (A80) is
on position
"D" (arrow). (condition
as supplied)
When replacing
intelligent servo module
(A80) replace bleed
hose.
installation: The
positions of the range
selection shaft (3) and
intelligent servo module
(A80) must match up,
rotate range selection
shaft (3) if necessary.
Fig. 12
16 Install in the reverse order
17 Connect STAR
DIAGNOSIS, read out fault
memory and erase if
necessary
18 Using STAR DIAGNOSIS, After replacing
perform initial startup of intelligent servo module
intelligent servo module (A80)
(A80)
HOUSING
Transmission
Number Designation
722.9
Stage
Nm 4
BA27.40-P- Standard bolt/hexagon-spacer bolt, shift module 1
1021-01A (ISM) to transmission housing Stage
Angle° 90
2
PROPELLER SHAFT
Model Model
Number Designation
216 221
BA41.10-P-1001- Self-locking nut of flex disk to transmission or front
M12 Nm 68 68
01H propeller shaft
EXHAUST SYSTEM
Engine 642 in model
Number Designation
221
BA49.10-P-1002- Bolt connecting bracket of front exhaust system to
Nm 20
01V transmission
EXHAUST SYSTEM
Engine 273 in Engine 272 in Engine 273 in
Number Designation
model 216 model 221 model 221
BA49.10-P- Bolt, catalytic converter
Nm 20 20 20
1008-01Z bracket to transmission
EXHAUST SYSTEM
Engine 156 in Engine 156 in
Number Designation
model 216 model 221
BA49.10-P-1008- Bolt, catalytic converter bracket to
Nm 20 20
01Z transmission
EXHAUST SYSTEM
Number Designation Engine 629
BA49.10-P-1004-01AA Nut, catalytic converter to transmission bracket Nm 20
Fig. 12: Identifying Assembly Tool (722 589 03 09 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL INTELLIGENT SERVO MODULE - AR27.19-P-0550SZ
TRANSMISSION 722.6 in MODEL 221.1, 216.3
Fig. 13: Identifying Intelligent Servo Module Remove/Install Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 14: Identifying Intelligent Servo Module Remove/Install Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value modified: Self-locking nut of flex disk to transmission or front *BA41.10-P-1001-
29.6.10
propeller shaft, M12 01H
Remove/install
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or toppling columns of vehicle lift
off of the lifting platform. and position four
support plates at vehicle
lift support points
specified by vehicle
manufacturer.
Information on preventing AH54.00-P-0001-01A
damage to electronic
components due to
electrostatic discharge
Notes on self-locking nuts AH00.00-N-0001-01A
and bolts
1 Release parking brake
2 Disconnect ground lines Insulate terminals of AR54.10-P-0003SX
from batteries ground lines to prevent
accidental contact with
the ground points of the
batteries.
Notes on battery AH54.10-P-0001-01A
3 Remove bottom engine Vehicles without top AR61.20-P-1105SX
compartment paneling protection
Vehicles with code AR61.20-P-1105SXS
(Z07) Top protection
4 Remove catalytic converters See: Remove AR49.10-P-7100SX
(9) components of exhaust
system.
5 Support transmission (1) Secure the
transmission (1) with a
tensioning strap to
prevent it from tilting or
slipping off.
6 Remove rear engine AR22.10-P-1180SX
crossmember (2) and rear
engine mount
7 Mark position of front This is to ensure
flexible coupling (20V) reinstallation at the ex-
relative to output flange of factory installation
transmission (1) and to position, otherwise drive
propeller shaft (20) line vibrations can be
produced.
8 Detach flexible coupling If the fitted sleeves AR41.10-P-0050-02SX
(20V) from output flange of are jammed: ?
transmission (1) and from
the propeller shaft (20) and
remove
Loosen fitting sleeves of AR41.10-P-0050-09SX
flexible coupling (20V).
Drift for loosening fitting WF58.50-P-4110-01A
sleeves in flex disks.
Installation: Attach AR41.10-P-0050-07SX
the propeller shaft (20).
*BA41.10-P-1001-01H
9 Detach front exhaust bracket *BA49.10-P-1008-01Z
(6) from transmission (1)
10 Disconnect electrical
connector from intelligent
servo module (A80)
11 Lower transmission (1) When the engine is
slightly being lowered, it must
not rest against the
bulkhead, otherwise the
coolant hoses and
engine wiring harness
will be damaged.
12 Remove the bolts (10) on the Installation: Replace
intelligent servo module bolts (10).
(A80)
13 Remove intelligent servo When reusing the
module (A80) with bleed intelligent servo module
hose (A80) do not detach
bleed hose. Leaky
separation points result
in water entry.
14 Twist the range selector shaft When replacing the
(3) of the transmission intelligent servo module
counterclockwise up to the (A80).
end stop on position the new intelligent
"D" (arrow) servo module (A80) is
on position
"D" (arrow). (condition
as supplied)
When replacing
intelligent servo module
(A80) replace bleed
hose.
installation: The
positions of the range
selection shaft (3) and
intelligent servo module
(A80) must match up,
rotate range selection
shaft (3) if necessary.
Fig. 15
15 Install in the reverse order
16 Connect STAR
DIAGNOSIS, read out fault
memory and erase if
necessary
17 Using STAR DIAGNOSIS, After replacing
perform initial startup of intelligent servo module
intelligent servo module (A80)
(A80)
PROPELLER SHAFT
Model Model
Number Designation
216 221
BA41.10-P-1001- Self-locking nut of flex disk to transmission or front
M12 Nm 68 68
01H propeller shaft
EXHAUST SYSTEM
Engine 275 in Engine 275 in
Number Designation
model 216 model 221
BA49.10-P-1008- Bolt, catalytic converter bracket to
Nm 20 20
01Z transmission
Fig. 15: Identifying Assembly Tool (722 589 03 09 00)
Courtesy of MERCEDES-BENZ USA
DETACH/ATTACH TORQUE CONVERTER ON DRIVER - AR27.20-P-0100-01A
TRANSMISSION 722.9 (except 722.93) For special angle of the torque converter
TRANSMISSION 722.9 For special angle of the torque converter
TORQUE CONVERTER
Transmission
Number Designation
722.9
Straight threaded
M8 Nm 42
connection
Stage
Nm 4
BA27.20-P-1002- Bolt, torque converter to 1
01C drive plate Angled threaded Stage
Nm 30
connection 2
Stage
Angle° 90
3
Fig. 16: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 17: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Detaching
To unscrew or screw in do not use an impact wrench or compressed-air tool, otherwise the threaded unions
in the driven plate will be damaged.
1. Remove cover (8).
2. Remove bolts (1 to 4 or 1 to 6) of the torque converter from the driven plate.
Continue turning the engine in the direction of engine rotation using socket on the crankshaft
center bolt. If the center bolt is not accessible, continue turning the torque converter using a wide
screwdriver.
Fig. 18: Identifying Cover
Courtesy of MERCEDES-BENZ USA
Checking
3. Check driven plate (7) for damage.
The driven plate (7) must be replaced if the threaded unions (7a) are damaged or loose.
Attaching
4. Mount torque converter (9) on driven plate (7).
Replace bolts (1 to 4 or 1 to 6).
Observe tightening sequence, tightening torque and numerical sequence, otherwise the torque
converter (9) or the driven plate (7) will be damaged.
Fig. 19: Identifying Driven Plate
Courtesy of MERCEDES-BENZ USA
Fig. 20: Checking Driven Plate For Damage
Courtesy of MERCEDES-BENZ USA
Torque converter with 4-x angled threaded connection
Torque converter with 6-x angled threaded connection
TIGHTENING SEQUENCE
Tightening
Screw stage
sequence
Press the torque converter (9) against the driven plate
1
(7) using a long wedge
Torque converter with 6-x angled
2.1 Attach the bolts (1 to 6) and position by hand
threaded connection
Torque converter with 4-x angled
2.2 Partially screw in bolts (1 to 4) and position by hand
threaded connection
Tighten bolts (1, 2) and while tightening press the 1st stage with torque converter
3.1 torque converter (9) against the driven plate (7) with a with 6-x angled threaded
long wedge connection
Tighten bolts (1) and press the torque converter (9) 1st stage with torque converter
3.2 while tightening up against the driven plate (7) using a with 4-x angled threaded
long wedge connection
1st stage with torque converter
4.1 Tighten bolts (3 to 6) with 6-x angled threaded
connection
1st stage with torque converter
4.2 Tighten bolts (2 to 4) with 4-x angled threaded
connection
2nd stage with torque converter
5.1 Tighten bolts (1 to 6) with 6-x angled threaded
connection
2nd stage with torque converter
5.2 Tighten bolts (1 to 4) with 4-x angled threaded
connection
3rd stage with torque converter
6.1 Tighten bolts (1 to 6) with 6-x angled threaded
connection
3rd stage with torque converter
6.2 Tighten bolts (1 to 4) with 4-x angled threaded
connection
REMOVE/INSTALL TORQUE CONVERTER - AR27.20-P-0500-01P
TRANSMISSION 722.6 in MODEL 171, 203, 204, 207, 209, 216, 219, 221
TORQUE CONVERTER TEST VALUES
Transmission
Number Designation 722.600/601/602/603/604/605/608/611/614/615/616/619/626/629/634/637/
BE27.20- Installed Distance mm 7 (-2)
P-1001- height of from
01B torque transmission
converter housing
TORQUE CONVERTER TEST VALUES
Transmission Transmission
Number Designation 722.646 722.649
BE27.20-P- Installed Distance from mm 17.5 20 (-2)
1001-01B height of transmission
converter
Fig. 21: Identifying Grab Handle (168 589 00 62 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
Remove torque converter
1. Position transmission vertically.
2. Fit grab handles (065) to torque converter.
3. Remove torque converter from transmission housing.
4. 4.1 If there are metal shavings in the transmission oil pan:
Drain transmission oil from torque converter through a clean cloth.
If there are metal chips in the cloth, replace torque converter.
In case of doubt flush out the torque converter with transmission oil.
Remaining metal chips can cause transmission damage!
5. 4.2 If transmission oil is burnt or interspersed with abrasive particles: Flush oil cooler lines and oil cooler.
Fig. 22: Identifying Grab Handles On Torque Converter
Courtesy of MERCEDES-BENZ USA
Install torque converter
6. Grease the crankshaft journals with multipurpose paste and insert torque converter into transmission
housing.
Do not use force, otherwise the axial stop of the torque converter will be destroyed.
Move torque converter back and forth so that the teeth on the torque converter and the transmission
primary pump engage in one another.
Fig. 23: Installing Torque Converter
Courtesy of MERCEDES-BENZ USA
Measure installed height of torque converter in transmission housing
7. Measure dimension (A) between transmission housing and torque converter mount using depth gauge.
Torque converter and primary pump will be damaged if torque converter is seated incorrectly in transmission
housing.
Fig. 24: Measuring Installed Height Of Torque Converter In Transmission Housing
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TORQUE CONVERTER - AR27.20-P-0500-01W
TRANSMISSION 722.9 /9 (except 722.93)
MODIFICATION NOTES
7.6.06 Installed height of torque Transmission 722.9 *BE27.20-P-1001-01E
converter
22.5.06 Measurement for Step 6
determining installed
height of torque converter
changed
TEST VALUES FOR TORQUE CONVERTER
Transmission
Number Designation
722.9
helical screwed
mm 9.5
connection
BE27.20-P- Installed height of Distance, bolt flange to axial screwed
mm 19.5
1001-01E torque converter transmission housing flange connection
AR27.20-P-
See fig.
0500-01W
Fig. 25: Identifying Grab Handle (168 589 00 62 00)
Courtesy of MERCEDES-BENZ USA
Fig. 26: Identifying Parallel Support (126 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
Remove torque converter
1. Position transmission vertically.
2. Fit grab handles (065) to torque converter.
3. Remove torque converter without tilting.
4.1 If there are metal shavings in transmission oil pan, drain transmission oil from torque converter
through a clean cloth.
If there are metal shavings in the cloth: replace the torque converter as any remaining metal shavings
will damage the transmission.
4.2 If transmission oil is burnt or interspersed with abrasive particles: Rinse torque converter, oil cooling
lines and oil cooler.
Fig. 27: Identifying Torque Converter Removal
Courtesy of MERCEDES-BENZ USA
Install torque converter
5 Insert torque converter carefully without tilting.
Do not use force, otherwise the axial end stop of the torque converter will be irreparably damaged.
When doing so, move the torque converter back and forth until the drive spigots of the oil pump
engage in the disengagement shift tubes of the torque converter.
6 Apply a little multi-purpose paste to journal (96).
Fig. 28: Identifying Torque Converter Installation
Courtesy of MERCEDES-BENZ USA
Check that torque converter is seated correctly
An incorrectly inserted torque converter will be damaged when the transmission is installed, and will
cause damage to the oil pump.
Fig. 29: Checking Correct Installation Of Torque Converter
Courtesy of MERCEDES-BENZ USA
7 Place parallel gauge (01) on flange of transmission housing.
8 Using depth gauge, measure difference dimension (D1) between parallel gauge (01) and bolt
flange of torque converter.
9 Add measured difference dimension (D1) and specified distance dimension (D2) together.
If the torque converter is inserted correctly, the sum (D1+D2) corresponds to the thickness (D3) of the
parallel gauge (01): D1+ D2= D3.
If D1+ D2 D3: remove and insert the torque converter again and check whether it is seated correctly.
10 Detach grab handles (065) from torque converter.
Depth gauge
REMOVE/INSTALL AUXILIARY OIL PUMP FOR AUTOMATIC TRANSMISSION - AR27.30-P-
0651SXH
TRANSMISSION 722.9 in MODEL 216, 221
Fig. 30: Identifying Auxiliary Oil Pump For Automatic Transmission Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Before starting the
work the area
surrounding the
connecting points on the
transmission (5) must be
thoroughly cleaned. Even
the smallest dirt particles
in the hydraulic
components can lead to
malfunctions and a total
failure of the
transmission (5).
1 Remove engine Vehicles without code AR61.20-P-1105SX
compartment paneling (Z07) Top protection
Vehicles with code (Z07) AR61.20-P-1105SXS
Top protection
2 Remove drain screw from Collect escaping ATF
transmission oil pan with drain pan. Note
automatic transmission
oil quantity.
It is not necessary to
pry off the overflow pipe
from the base of the
transmission oil pan.
Drain pan
3 Detach electrical
connector (1a) on electric
transmission oil pump
(M42)
4 Detach electrical wiring
harness from transmission
(5) and set aside
5 Remove screws (2) and When installing the
detach electric electrical transmission oil
transmission oil pump pump (M42) again: ?
(M42) Installation: Check
sealing rings (3, 4) on
intake and pressure side
(A, B), and replace if
necessary.
*BA27.55-P-1009-01D
6 Install in the reverse order
7 Fill transmission (5) with Model 221, 216 except AR27.00-P-0270W
oil. 221.08/ 094/ 18/ 194,
216.38/ 39
Model 221.08/ 18, 216.38 AR27.00-P-0270SYZ
Model 221.094/ 194,
216.39
Checking
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
8 Perform engine test run
and check transmission
(5) for function and leaks
TRANSMISSION OIL COOLING
Transmission
Number Designation
722.9
BA27.55-P-1009- Bolt, transmission oil auxiliary pump to transmission
Nm 8
01D housing
DISMANTLE AND ASSEMBLE SHIFT PLATE - AR27.35-P-0350A
TRANSMISSION 722.6
Location of regulating valve
Fig. 31: Identifying Shift Plate Components (1 Of 5)
Courtesy of MERCEDES-BENZ USA
Fig. 32: Identifying Shift Plate Components (2 Of 5)
Courtesy of MERCEDES-BENZ USA
Fig. 33: Identifying Shift Plate Components (3 Of 5)
Courtesy of MERCEDES-BENZ USA
Fig. 34: Identifying Shift Plate Components (4 Of 5)
Courtesy of MERCEDES-BENZ USA
Fig. 35: Identifying Shift Plate Components (5 Of 5)
Courtesy of MERCEDES-BENZ USA
Disassemble/assemble
1 Detach leaf spring (82)
Assembly : Insert locating pin (59) into
valve housing (74) (arrow).
*BA27.35-P-
Detach valve housing (72) from
2 1001-03A
valve body housing (74)
Assembly: To be observed on
transmission 722.6 as of end number
0538312:
BT27.35-P-
Strainer for modulating pressure 0004-01A
and shift pressure control solenoid Assembly: To be observed on
valve, new transmission 722.6 as of end number
0485895:
Strainer in inlet to converter lock- BT27.35-P-
up control solenoid valve, new 0005-01A
Located in the valve housing (74) are four
3 Detach gasket (73) plastic valve balls (75) and eight steel valve
balls (76).
All the valves are only to be checked for
easy movement and swarf in case of
requirement
The sleeves and piston of components
regulating valve,
"2-3" overlap with sleeve and piston
(72.2),
regulating valve, overlap
"3-4" with sleeve and piston (72.8)
Detach side cover from valve body and regulating valve, overlap "1-2" and
4 housing (74) and from valve
housing (72)
"4-5" with sleeve and piston (74.18) must not
be interchanged as otherwise malfunctions
will occur.
The removal/installation of the shift valve
"multidisk brake B2" (74.27) is only possible
when the valve housing (72) is disassembled.
Assembly: To be observed on
transmission 722.6 as of end number
0027083:
*BA27.35-P-
1002-03A
Installation of a pressure feed BT27.35-P-
valve 0002-01A
Ensure that parts are not blown away.
Wash all parts and blow them
5 Only rags made of leather may be used to
clean using compressed air
clean the parts.
6 Assemble in the reverse order
TIGHTENING TORQUES OF VALVE HOUSING
Number Designation Transmission 722.6
BA27.35-P-1001- Bolt, valve body to M6x30 Nm 8
03A slide valve housing
BA27.35-P-1002- Bolt, side cover to M4x12 Nm 4
03A valve body and
valve housing
REMOVE/INSTALL RADIAL SHAFT SEALING RING AT OUTPUT FLANGE - AR27.40-P-0205SX
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 without 4MATIC
TRANSMISSION 722.6 in MODEL 221.1, 216.3
Fig. 36: Identifying Radial Shaft Sealing Ring Remove/Install Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value modified: Self-locking nut, flexible coupling to transmission and *BA41.10-P-1001-
25.6.10
front propeller shaft, M12 01H
Remove/install
Notes on self-locking nuts AH00.00-N-0001-01A
and bolts
1 Set DIRECT SELECT
gear selector switch to
position "N"
2 Release parking brake
3 Support and secure the
transmission using
transmission jack and
transmission platform
4 Remove rear engine Except engine 651 AR22.10-P-1180SX
crossmember (1) and rear
engine mount (2) Engine 651 AR22.10-P-1180CW
5 Mark position of flexible This is to ensure
coupling (3) relative to reinstallation at the ex-
output flange (4) and to factory installation
propeller shaft (6) position, otherwise
drivetrain vibrations can
be produced.
6 Detach flexible coupling If the fitted sleeves are AR41.10-P-0050-02SX
(3) from output flange (4) jammed: ?
and from propeller shaft
(6)
Loosen fitting sleeves of AR41.10-P-0050-09SX
flexible coupling (3)
from output flange (4).
Drift for loosening fitting WF58.50-P-4110-01A
sleeves in flex disks.
Installation: Attach AR41.10-P-0050-07SX
the flexible coupling (3)
to the output flange (4).
*BA41.10-P-1001-01H
7 Lower the transmission When the engine is
jack slightly being lowered, it must
not rest on the front axle
carrier, otherwise the oil
pan will be damaged.
8 Remove output flange (4) AR27.50-P-0620-02W
*BA27.50-P-1001-01A
Fig. 38
Fig. 39
Fig. 40
9 Pry radial shaft sealing Do not damage the
ring (5) out of seat of the radial shaft
transmission housing (7) sealing ring (5) in the
using a wide screwdriver transmission housing (7).
Installation: Press the
new radial shaft sealing
ring (5) into the
transmission housing (7)
using the drift
(01) until the drift
(01) touches the
transmission housing (7).
Fig. 37
10 Install in the reverse order
11 Check transmission oil Transmission 722.6 AR27.00-P-0100AC
level and correct if
necessary Transmission 722.9 AR27.00-P-0270W
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
12 Perform engine test run
and check transmission
for leaks with engine
running
GEAR ASSEMBLY
Number Designation Transmission 722.55/6/9
BA27.50-P-1001-01A Collar nut, output flange to output shaft Nm 200
PROPELLER SHAFT
Model Model
Number Designation
216 221
BA41.10-P-1001- Self-locking nut, flex disk to transmission or front
M12 Nm 68 68
01H propeller shaft
Fig. 37: Identifying Drift (140 589 12 15 00)
Courtesy of MERCEDES-BENZ USA
Fig. 38: Identifying Wrench Socket (126 589 02 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 39: Identifying Pin Wrench (129 589 01 07 00)
Courtesy of MERCEDES-BENZ USA
Fig. 40: Identifying Two-Armed Puller (000 589 88 33 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL SHIFT SHAFT RADIAL SHAFT SEALING RING - AR27.40-P-0220A
TRANSMISSION 722.9 /55 Transmission with intelligent servo module (ISM)
Fig. 41: Identifying Shift Shaft Radial Shaft Sealing Ring Components
Courtesy of MERCEDES-BENZ USA
Shown on transmission 722.9
Removing
Risk of death when Do not touch components AS54.00-Z-0001-01A
touching components on and open lines of the
vehicles with high- high-voltage on-board
voltage on-board electrical system. Persons
electrical system who are carriers of
electronic implants (e.g.
cardiac pacemakers),
must not carry out any
work on high-voltage on-
board electrical systems.
1 Remove intelligent servo Model 164 AR27.19-P-0550GZA
module (ISM) Model 221 AR27.19-P-0550SX
Model 251 AR27.19-P-0550RT
2 Remove heat shield (3) of
left catalytic converter
and bracket (2) of lower
engine compartment
paneling
Clean
3 Clean transmission Cleaner from package *BR00.45-Z-1028-04A
housing (1) around shift
shaft (40) and radial shaft
sealing ring (20)
4 Remove transmission oil Transmission 722.9 AR27.10-P-7030W
pan Transmission 722.55 AR27.10-P-7030GZH
5 Remove bolt (16a) and
detach spring element
(16)
6 Remove clamp bolt (82a)
and pull out shift shaft
(40)
7 Pry out radial shaft Make sure that the
sealing ring (20) using a contact surface in the
suitable tool transmission housing (1)
is not damaged, otherwise
leakage will occur.
Checking
8 Check shift shaft (40) for
install a new shift shaft if
necessary
Install
9 Drive radial shaft sealing Check that the radial
ring (20) all the way into shaft sealing ring (20) is
transmission housing (1) seated correctly in the
using drift (01) transmission housing (1),
otherwise leakage will
occur.
Fig. 42
10 Insert shift shaft (40) and Make sure that the
screw in clamp bolt (82a) shift shaft (40) is
positioned correctly in
the detent plate (82).
Transmission 722.9 *BA27.19-P-1004-01A
Transmission 722.55 *BA27.40-P-1006-01A
11 Mount spring element Transmission 722.9 *BA27.19-P-1005-01A
(16) and screw in bolt
(16a) Transmission 722.55 *BA27.40-P-1019-01A
12 Install transmission oil AR27.10-P-7030W
pan
13 Install intelligent servo Model 164 AR27.19-P-0550GZA
module (ISM) Model 221 AR27.19-P-0550SX
Model 251 AR27.19-P-0550RT
14 Fill transmission with Transmission 722.9 AR27.00-P-0270W
gear oil except 722.960/ 961/962/
963/ 964
Transmissions 722.960/ AR27.00-P-0270SYZ
961/ 962/ 963/ 964
Transmission 722.55 AR27.00-P-0100GZH
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
15 Perform engine test run;
check transmission
housing (1) at separation
points and at radial shaft
sealing ring (20) for leaks
and check that
transmission is
functioning correctly
ELECTROHYDRAULIC CONTROLLER UNIT
Transmission
Number Designation
722.9
BA27.19-P-1004-
Shift shaft clamp bolt to detent plate Nm 8
01A
BA27.19-P-1005- Detent plate spring element bolt to electrohydraulic
Nm 9
01A controller unit
HOUSING
Number Designation Transmission 722.55
BA27.40-P-1006-01A Bolt, detent plate to range selector lever Nm 8
BA27.40-P-1019-01A Bolt, leaf spring to transmission housing Nm 5
Fig. 42: Identifying Drift (722 589 02 15 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1028-04A Cleaner from package
REMOVE/INSTALL SHIFT SHAFT RADIAL SHAFT SEALING RING - AR27.40-P-0220B
TRANSMISSION 722.9 Transmission with range selector lever, with propeller shaft detached and rear
engine crossmember removed
Fig. 43: Identifying Radial Shaft Seal Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Removing
1 Detach safety clip and
pull shift rod out of the
range selector lever (2)
2 Remove heat shield of the
left catalytic converter
and left bracket of the
lower engine
compartment paneling
Clean
3 Clean transmission LU cleaner *BR00.45-Z-1028-04A
housing (1) in the area of
the range selector lever
(2) and the radial shaft
sealing ring (20)
4 Remove transmission oil AR27.10-P-7030W
pan
5 Unscrew bolt (16a) and
detach spring element
(16)
6 Unscrew clamp screw Pull out at the side
(82a) and remove range without using tools.
selector lever (2) Check rubber mount
(5) of shift rod at range
selector lever (2) and
replace if necessary.
sealing ring (20) using a Make sure that the
suitable tool contact surface in the
transmission housing (1)
is not damaged, otherwise
leakage will occur.
Checking
8 Check range selector
lever (2) for galling and
damage, replace if
necessary
Install
9 Drive radial shaft sealing Fig. 44
ring (20) all the way into
transmission housing (1)
using drift (01)
10 Insert range selector lever Pay attention to the
(2) and screw in clamp correct position of the
screw (82a) range selector lever (2) in
the detent plate (82).
*BA27.19-P-1004-01A
11 Mount spring element *BA27.19-P-1005-01A
(16) and screw in bolt
(16a)
12 Install transmission oil AR27.10-P-7030W
pan
13 Insert shift rod at range Replace safety clip of
selector lever (2) and shift rod at range selector
mount safety clip lever (2).
14 Fill transmission with AR27.00-P-0270W
gear oil
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
15 Perform engine test run;
check transmission
housing (1) at separation
points and at radial shaft
sealing ring (20) for leaks
and check that
transmission is
functioning correctly
ELECTROHYDRAULIC CONTROLLER UNIT
Transmission
Number Designation
722.9
BA27.19-P-1004-
Shift shaft clamp bolt to detent plate Nm 8
01A
BA27.19-P-1005- Detent plate spring element bolt to electrohydraulic
Nm 9
01A controller unit
Fig. 44: Identifying Drift (722 589 02 15 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1028-04A LU cleaner
REMOVE/INSTALL OIL PUMP RADIAL SHAFT SEALING RING - AR27.40-P-0300A
TRANSMISSION 722.6 /9 /9 Developed torque converter
Fig. 45: Identifying Oil Pump Radial Shaft Sealing Ring Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Remove
1 Lever radial shaft sealing Do not damage seat of
ring (1) out of oil pump radial shaft sealing ring
housing (2). (1) to prevent oil loss and
therefore damage to the
transmission (3).
Install
2 Install radial shaft sealing Install new radial shaft
ring (1) flush using sealing ring (1).
drift (01). Coat radial shaft
sealing ring (1) between
lips with multi-purpose
paste.
Drift Fig. 46
Multi-purpose paste *BR00.45-Z-1009-06A
Fig. 46: Identifying Drift (722 589 00 15 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1009-06A Multi-purpose paste A 000 989 80 51 10
TRANSMISSION
Automatic Transmission - Testing & Repair - S-Class (221)
TESTING & REPAIR
CHECK OIL LEVEL IN AUTOMATIC TRANSMISSION AND CORRECT IF NECESSARY. -
AR27.00-P-0100AC
TRANSMISSION 722.6
Fig. 1: Checking Oil Level Of Automatic Transmission
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value
changed:
Filling
6.8.08 capacity,
Specifications
for Operating
Fluids
Transmission
722.600/601/604/605/606/607/608/609/611/613/614/616/617/618/619/629/634/639/660/66
Transmission 722.602/603/615
Transmissions 722.610/638
Transmission 722.620/621 in model 129
Value Transmission 722.620/621 in model 140, transmission 722.622/623/624/625/626/627/628/6
Filling Transmission 722.637 in model 461.302/331/332/342/345
capacity, Transmission 722.637 in model 463.322/323
Transmission 722.640/644
Transmission 722.642
Transmission 722.648
Transmission 722.649
Transmission 722.667/668/672/676/690
Transmission 722.671/675/677
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
The vehicle must be
positioned horizontally
on its wheels, otherwise
measurement errors will
occur.
Check and pour in
transmission oil when
cold (approx. 25 °C)
1 Remove engine cover. Only if required
2 Remove locking pin To do so, break off the
(93a) and take plug (93) plate of the locking pin
off oil filler pipe (93a) using a suitable tool
and remove the pin
remaining in the cap (93)
by pressing downwards.
3 Fill with transmission oil After a complete refill
and after changing the
transmission oil, pour in
approx. 5 liters of
transmission oil before
starting the engine.
Insufficient and
excessive quantities of oil
can result in malfunctions
and transmission damage.
*BF27.00-P-1001-01C
Fig. 2
Fig. 4
4 Start engine and allow it
to idle briefly in gear
range "P"
5 Fill with remaining Only with complete refill
quantity of transmission
oil
*BF27.00-P-1001-01C
6 Actuate service brake and
briefly shift through gear
ranges several times with
vehicle stationary and
engine running at idle
speed, then reengage gear
range "P"
7 Insert oil dipstick all the When cold, the
way into oil filler pipe, transmission oil level
pull it out again and read must be between the
off transmission oil level "min" and "max" marking
in the range (A).
Fig. 3
8 Correct transmission oil If necessary
level Insufficient and
excessive quantities of oil
can result in malfunctions
and transmission damage.
Fig. 5
Fig. 4
Fig. 2
9 Check transmission oil After pouring in
level again transmission oil.
Only perform steps 10 Precise checking is
to 14 if shifting only possible at a
problems occur. transmission oil
temperature > 80 °C .
10 Connect Star Diagnosis Operate the service
and check transmission brake when doing so.
oil temperature in gear
range "R" or "D"
11 Start engine and allow it
to idle in gear range "P"
12 Insert oil dipstick all the The transmission oil
way into oil filler pipe, level must be between the
pull it out again and read "min" and "max" marking
off transmission oil level in the range (B).
Fig. 3
13 Correct transmission oil If necessary
level Insufficient and
excessive quantities of oil
can result in malfunctions
and transmission damage.
Fig. 5
Fig. 4
Fig. 2
14 Check transmission oil After pouring in
level again transmission oil.
15 Mount cap (93) on oil
filler pipe and press in
new locking pin (93a)
until it latches
16 Perform engine test run
and, with engine running,
check transmission for
leaks and that it is
functioning correctly
AUTOMATIC TRANSMISSION
Transmission
Number Designation 722.600/601/604/605/606/607/608/609/611/613/614/616/617/618/619/62
BF27.00- Filling Initial charge Liters 7.5 (+0.5)
P-1001- capacity during oil Liters -
01C change
Specifications Sheet BB00.40-P-0236-14A
for Operating
Fluids
Sheet -
AUTOMATIC TRANSMISSION
Transmission
722.620/621 Transmission 722.620/621 in model 140, transmission
Number Designation in model 129 722.622/623/624/625/626/627/628/630/631/632/633/635/
BF27.00- Filling Initial charge Liters 8.2 (+0.5) 8.6 (+0.5)
P-1001- capacity during oil Liters - -
01C change
Specifications Sheet BB00.40-P- BB00.40-P-0236-14A
for Operating 0236-14A
Fluids
Sheet - -
AUTOMATIC TRANSMISSION
Transmission
Transmission 722.637 in 722.637 in
model model
Number Designation 461.302/331/332/342/345 463.322/323
BF27.00-P- Filling Initial charge Liters 7.9 7.9
1001-01C capacity during oil Liters - -
change
Specifications Sheet BB00.40-P-0236-14A BB00.40-P-
for Operating 0236-14A
Fluids
Sheet - -
AUTOMATIC TRANSMISSION
Transmissions Transmission Transmission
Number Designation 722.640/644 722.642 722.643
BF27.00- Filling Initial charge Liters 7.5 7.3 (+0.5) 8, 7
P-1001- capacity during oil Liters - - -
01C change
Specifications Sheet BB00.40-P-0236- BB00.40-P- BB00.40-P-
for Operating 14A 0236-14A 0236-14A
Fluids
Sheet - - -
AUTOMATIC TRANSMISSION
Transmission Transmission Transmission
Number Designation 722.648 722.649 722.667/668/672/676/690
BF27.00- Filling Initial charge Liters 8 8, 0 9
P-1001- capacity during oil Liters 5 6.5 -
01C change
Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-0236-14A
for Operating 0236-14A 0236-14A
Fluids
Sheet - - -
AUTOMATIC TRANSMISSION
Transmission Transmission Transmission
722.673 in 722.674 in 722.641 in
Number Designation model 163 model 163 model 170
BF27.00- Filling Initial charge Liters 7.6 to 8.0 8.8 to 9.2 7.3 to 7.7
P-1001- capacity during oil Liters - - -
01C
change
Specifications Sheet BB00.40-P- BB00.40-P- BB00.40-P-
for Operating 0236-14A 0236-14A 0236-14A
Fluids
Sheet - - -
AUTOMATIC TRANSMISSION
Transmission Transmission Transmission
722.612/697/698 in 722.621 in 722.645 in
Number Designation model 202 model 202 model 463
BF27.00- Filling Initial charge Liters 7.3 to 7.7 8.5 to 8.9 8.8 to 9.2
P-1001- capacity during oil Liters - - -
01C change
Specifications Sheet BB00.40-P-0236- BB00.40-P- BB00.40-P-
for Operating 14A 0236-14A 0236-14A
Fluids
Sheet - - -
AUTOMATIC TRANSMISSION
Transmission Transmission Transmission
Number Designation 722.646 722.671/675/677 722.694
BF27.00- Filling Initial charge Liters 8.3 8.5 to 8.9 7.3
P-1001- capacity during oil Liters - - -
01C change
Specifications Sheet BB00.40-P- BB00.40-P-0236- BB00.40-P-
for Operating 0236-14A 14A 0236-14A
Fluids
Sheet - - -
Fig. 2: Identifying Funnel (126 589 12 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 3: Identifying Dipstick (140 589 15 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 4: Identifying Filling Pipe (140 589 49 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 5: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
FILLING AUTOMATIC TRANSMISSION WITH FLUID - AR27.00-P-0270SYZ
TRANSMISSION 722.96
Fig. 6: Identifying Overflow Pipe And Adapter
Courtesy of MERCEDES-BENZ USA
Fig. 7: Identifying Filling Automatic Transmission With Fluid
Courtesy of MERCEDES-BENZ USA
Adding transmission oil
Risk of death caused by Align vehicle between columns AS00.00-Z-0010-
vehicle slipping or toppling of vehicle lift and position four 01A
off of the lifting platform. support plates at vehicle lift
support points specified by
vehicle manufacturer.
Risk of accident caused by Secure vehicle to prevent it AS00.00-Z-0005-
vehicle starting off by itself from moving by itself. 01A
when engine is running. Wear closed and snug-fitting
Risk of injury caused by work clothes.
contusions and burns during Do not touch hot or rotating
starting procedure or when parts.
working near the engine as it
is running
In order to avoid damage to
the transmission, always
observe the Specifications for
Operating Fluids !
The transmission must be
filled with transmission oil
before starting the engine
1 Raise vehicle The vehicle must be AR00.60-P-1000SX
situated on the lifting platform
so that it is level in both the
longitudinal and transverse
axes.
Model 216, 221
Model 204, 212, 218
2 Check the transmission oil
pan for damage and
leaktightness
3 Remove rear engine Model 204, 212, 218 AR22.10-P-1180CW
crossmember Model 216, 221 AR22.10-P-1180SW
4 Lower transmission/transfer
case at rear
5 Prefill transfer case with Remove the oil filler screw
transmission oil from the transfer case, pour the
prefill quantity (700 ml) into
the transfer case and screw in a
new oil filler screw.
*BA28.10-P-1005-
01E
Fig. 8
6 Install rear engine Model 204, 212, 218 AR22.10-P-1180CW
crossmember
Model 216, 221 AR22.10-P-1180SW
Notes on bolted connections AH00.00-P-0007-
with self tapping screws 01SF
7 Remove oil drain screw (3) The adapter (2) and oil
on transmission, mount dispenser can be obtained from
adapter (2) and connect oil two manufacturers:
dispenser Adapter
Oil dispenser
8 Pump 6 liters of transmission In order to avoid damage to
oil into transmission the transmission, always
observe the Specifications for
Operating Fluids.
On transmissions which *BF27.00-P-1001-
have been repaired the quantity 01C
of transmission oil drained
+0.5 liters should be poured in.
Transmissions up to production BB00.40-P-0236-
date 18.06.2010 and all 14A
transmissions 722.9 in
combination with engine 629
All transmissions 722.9 as of BB00.40-P-0236-
production date 21.06.2010 15A
except transmission 722.9 in
combination with engine 629
9 Start engine
10 Call up the transmission AD00.00-P-2000-
fluid temperature using 04A
STAR DIAGNOSIS
11.1 Bring transmission oil Vehicles with additional
temperature to 90 °C/194 °F transmission oil cooler
Only with previous
removal/replacement of
additional transmission oil
cooler.
Thermostat opens at 90°
C/194°F.
Engine speed 2500 rpm,
selector lever in position "P".
11.2 Bring transmission oil Vehicles without additional
temperature to 45°C/113°F transmission oil cooler
12.1 Switch off engine and allow Vehicles with additional
transmission oil to cool transmission oil cooler
down Only with previous
removal/replacement of
additional transmission oil
cooler.
12.2 Turn off engine Vehicles without additional
transmission oil cooler
13 Call up the transmission Transmission oil
fluid temperature using temperature 45 °C/113 °F.
STAR DIAGNOSIS The transmission oil
temperature must not exceed
the specified value as the
overflow pipe (1) in the
transmission oil pan is
designed for the transmission
oil temperature.
14 Start engine and allow to run
in selector lever position "P"
15 Pump transmission oil using After replacing the
oil dispenser into transmission and torque
transmission converter :
Refill 4 liters of transmission
oil.
If the torque converter
has not been emptied:
Refill 2 liters of transmission
oil.
Correct transmission fluid
level
16 Shift through "P-R-N-D"
several times with the
vehicle stationary and the
engine idling
17 Allow engine to idle in
selector lever position "P"
18 Call up the transmission Transmission oil
fluid temperature using temperature 45 °C/113 °F.
STAR DIAGNOSIS The transmission oil
temperature must not exceed
the specified value as the
overflow pipe (1) in the
transmission oil pan is
designed for the transmission
oil temperature.
19 Remove the adapter (2)
20 Drain off constant oil flow Transmission oil
(arrow a) at specified temperature 45 °C/113 °F.
transmission oil temperature, The engine must run at idle
until only drops come out speed and the transmission oil
(refer to correct oil filling temperature must not be above
capacity (arrow b)) the specified transmission oil
temperature, too much
transmission oil is drained at a
higher transmission oil
temperature.
If the oil flow is not
constant after opening the drain
screw, the transmission oil
level has to be corrected (as of
operation step 15) and then
adjusted again.
21 Replace sealing ring and *BA27.10-P-1001-
screw in oil drain screw (3) 03D
22 Turn off engine
23 Lower vehicle
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation Transmission 722.9
BA27.10-P-1001-03D Drain plug on Nm 22
transmission oil pan
BA28.10-P-1005-01E Oil filler screw to Nm 20
intermediate housing
Fig. 8: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
FILLING AUTOMATIC TRANSMISSION WITH FLUID - AR27.00-P-0270W
TRANSMISSION 722.9 (except 722.96)
TRANSMISSION 722.9
Fig. 9: Identifying Overflow Pipe And Adapter
Courtesy of MERCEDES-BENZ USA
Fig. 10: Identifying Filling Automatic Transmission With Fluid
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
23.6.10 Reference to modified transmission oil pan, added BT27.10-P-0006-01A
Adding transmission
oil
Risk of death caused Align vehicle between columns AS00.00-Z-0010-01A
by vehicle slipping or of vehicle lift and position four
toppling off of the support plates at vehicle lift
lifting platform. support points specified by
vehicle manufacturer.
Risk of accident Secure vehicle to prevent it from AS00.00-Z-0005-01A
caused by vehicle moving by itself.
starting off by itself Wear closed and snug-fitting
when engine is work clothes.
running. Risk of Do not touch hot or rotating parts.
injury caused by
contusions and burns
during starting
procedure or when
working near the
engine as it is running
In order to avoid damage to
the transmission, always observe
the Specifications for Operating
Fluids !
The transmission must be
filled with transmission oil before
starting the engine
1 Raise vehicle The vehicle must be situated
on the lifting platform so that it is
level in both the longitudinal and
transverse axes.
2 Inspecting The transmission oil pan and
transmission oil pan the overflow pipe (1) have been
redesigned to optimize the oil
feed of the transmission. When
checking and correcting the fluid
level, always note the fluid
temperatures associated with the
specific individual oil pan noted.
Transmission oil pan Only category P with BT27.10-P-0006-01A
and overflow pipe (1) transmission 722.9 as of
modified production date 21.6.2010 with
engine 113, 156, 157, 271, 272,
273, 275, 276, 278, 642, 651
Transmission oil pan Only category P with BT27.10-P-0006-01W
and overflow pipe (1) transmission 722.901
modified
3 Remove oil drain The adapter (2) and oil
screw (3) and mount dispenser can be obtained from
adapter (2) and two manufacturers:
connect oil dispenser Adapter
Oil dispenser
4 Pump 6 liters of In order to avoid damage to *BF27.00-P-1001-01C
transmission oil into the transmission, always observe
transmission the Specifications for Operating
Fluids.
On transmissions which have
been repaired the quantity of
transmission oil drained +0.5
liters should be poured in.
Transmissions up to production BB00.40-P-0236-14A
date 18.06.2010 and all
transmissions 722.9 in
combination with engine 629
All transmissions 722.9 as of BB00.40-P-0236-15A
production date 21.06.2010
except transmission 722.9 in
combination with engine 629
5 Start engine
6 Call up the AD00.00-P-2000-04A
transmission fluid
temperature using
STAR DIAGNOSIS
7.1 Bring transmission oil Vehicles with additional
temperature to 90 ° transmission oil cooler
C/194 °F Only with previous
removal/replacement of
additional transmission oil cooler.
Thermostat opens at 90°
C/194°F.
Engine speed 2500 rpm,
selector lever in position "P".
7.2 Bring transmission oil Vehicles without additional
temperature to 45° transmission oil cooler
C/113°F On vehicles without additional
transmission oil cooler and with
chamfered transmission oil pan
and with white or green overflow
pipe (1) the transmission oil
temperature must be 45 °C/113 °
F.
7.3 Bring transmission oil Vehicles without additional
temperature to 35° transmission oil cooler
C/95°F On vehicles without additional
transmission oil cooler and
without chamfered transmission
oil pan and with black overflow
pipe (1) the transmission oil
temperature must be 35 °C/95 °F.
8.1 Switch off engine and Vehicles with additional
allow transmission oil transmission oil cooler
to cool down Only with previous
removal/replacement of
additional transmission oil cooler.
8.2 Turn off engine Vehicles without additional
transmission oil cooler
9 Call up the On transmissions with
transmission fluid chamfered transmission oil pan
temperature using and with white or green overflow
STAR DIAGNOSIS pipe (1) the transmission oil
temperature must be 45 °C/113 °
F.
On transmissions without
chamfered transmission oil pan
and with black overflow pipe (1)
the transmission oil temperature
must be 35 °C/95 °F.
10 Start engine and allow
to run in selector lever
position "P"
11 Pump transmission oil After replacing the *BF27.00-P-1001-01C
using oil dispenser into transmission and torque
transmission converter:
Pour in approx. 4 liters of
transmission oil.
If the torque converter has
not been emptied:
Pour in approx. 2 liters of
transmission oil.
Correct transmission
fluid level
12 Shift through "P-R-N-
D" several times with
the vehicle stationary
and the engine idling
13 Allow engine to idle in
selector lever position
"P"
14 Call up the Because the overflow tube (1)
transmission fluid within the oil pan is designed for
temperature using operation at the specified fluid
STAR DIAGNOSIS temperature, this temperature
should never exceed the level
indicated.
On transmissions with
chamfered transmission oil pan
and with white or green overflow
pipe (1) the transmission oil
temperature must be 45 °C/113 °
F.
On transmissions without
chamfered transmission oil pan
and with black overflow pipe (1)
the transmission oil temperature
must be 35 °C/95 °F.
15 Remove the adapter
(2)
16 Drain off constant oil It is essential that the engine
flow (arrow a) at be running at idle speed, and that
specified transmission the temperature of the
oil temperature, until transmission fluid not exceed the
(refer to correct oil carried out with the fluid at a
filling capacity (arrow higher temperature, too much
b)) fluid will be drained.
If the oil flow is not constant
after opening the drain screw, the
transmission oil level has to be
corrected (as of operation step
11) and then adjusted again.
On transmissions with
chamfered transmission oil pan
and white or green overflow pipe
(1) the transmission oil
temperature must be 45 °C/113 °
F.
On transmissions without
chamfered transmission oil pan
and black overflow pipe (1) the
transmission oil temperature must
be 35 °C/95 °F.
17 Replace sealing ring *BA27.10-P-1001-
and screw in oil drain 03D
screw (3)
18 Turn off engine
19 Lower vehicle
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation Transmission 722.9
BA27.10-P-1001-03D Drain plug on transmission oil pan Nm 22
AUTOMATIC TRANSMISSION
Transmission 722.9 Transmission
Number Designation
except 722.93/96 722.93
Initial charge Liters 9 7.1
during oil change Liters --
BF27.00-P- Filling BB00.40-P-0236-
1001-01C capacity Sheet BB00.40-P-0236-14A
Specifications for 14A
Operating Fluids BB00.40-P-0236-
Sheet BB00.40-P-0236-15A
15A
TESTING AND REPAIR WORK: PASSENGER CARS: AUTOMATIC TRANSMISSION - AR27.00-Z-
9722AC
TRANSMISSION 722
Check oil level in automatic TRANSMISSION 722.6 AR27.00-P-0100AC
transmission and correct if
necessary.
Detach/attach transmission TRANSMISSION 722.6 AR27.50-P-0601A
housing on torque converter
housing.
Detach/attach transmission TRANSMISSION 722.9 AR27.50-P-0601W
housing on torque converter
housing.
Disassemble and assemble TRANSMISSION 722.6 AR27.51-P-0830A
clutch K3.
Disassemble and assemble TRANSMISSION 722.6 AR27.19-P-0220A
electrohydraulic control unit
Disassemble and assemble TRANSMISSION 722.9 AR27.19-P-0220B
electrohydraulic controller unit
Disassemble/assemble clutch TRANSMISSIONS 722.6 AR27.51-P-0800B
K1
Disassemble/assemble clutch TRANSMISSION 722.9 AR27.51-P-0830W
K3
Disassemble/assemble K1 TRANSMISSION 722.9 AR27.51-P-0800W
clutch
Disassemble/assemble K2 TRANSMISSION 722.9 AR27.51-P-0820W
clutch
Disassemble/assemble multi- TRANSMISSION 722.9 AR27.50-P-0870W
disk brake B1
Disassemble/assemble multi- TRANSMISSION 722.6 AR27.50-P-0880A
disk brake B2
Disassemble/assemble multi- TRANSMISSION 722.9 AR27.50-P-0880W
disk brake B2
Disassemble/assemble multi- TRANSMISSION 722.9 AR27.50-P-0890W
disk brake B3
Disassemble/assemble output TRANSMISSION 722.6 AR27.50-P-0810A
shaft with center and rear gear
set
Disassembling and assembling TRANSMISSION 722.6 AR27.50-P-0850A
rear hollow shaft with rear
freewheel
Dismantle and assemble rear TRANSMISSION 722.9 AR27.50-P-0851W
tubular shaft
Dismantle and assemble shift TRANSMISSION 722.6 AR27.35-P-0350A
plate
Dismantling and assembling TRANSMISSION 722.6 AR27.51-P-0825A
drive shaft with clutch K2 and
front gear set
Dismantling and assembling TRANSMISSION 722.6 AR27.50-P-0870A
multi-disk brake B1
Filling automatic transmission TRANSMISSION 722.96 AR27.00-P-
with fluid 0270SYZ
Filling automatic transmission TRANSMISSION 722.9 AR27.00-P-0270W
with fluid (except 722.96)
TRANSMISSION 722.9
Flush out automatic TRANSMISSION 722.6 AR27.55-P-0100A
transmission and torque Without transmission
converter rinsing device
Flush out automatic TRANSMISSION 722.6 /9 AR27.55-P-0100B
transmission and torque With transmission rinsing
converter device
Flush out automatic TRANSMISSION 722.9 in AR27.55-P-0100SX
transmission and torque Model 221
converter
Flushing out oil cooler lines TRANSMISSION 722.6/ 7 AR27.55-P-0001A
and oil cooler
Flushing out oil cooler lines TRANSMISSION 722.9 in AR27.55-P-0001SX
and oil cooler MODEL 221.0 /1, 216.3
without 4MATIC
Flushing out oil cooler lines TRANSMISSION 722.9 in AR27.55-P-
and oil cooler MODEL 221.0 /1, 216.3, 0001SYZ
204 with 4MATIC
Measure and adjust clearance TRANSMISSION 722.9 AR27.51-P-7229W
Multidisk brake B1, B2, B3
and multidisk clutch K1,
K2, K3
Remove, install park pawl TRANSMISSION 722.9 AR27.60-P-0950W
mechanism Transmission removed
Remove/install automatic TRANSMISSION 722.9 AR27.10-P-7030W
transmission oil pan
Remove/install auxiliary oil TRANSMISSION 722.9 in AR27.30-P-
pump for automatic MODEL 216, 221 0651SXH
transmission
Remove/install clutch pack BR, TRANSMISSION 722.9 AR27.50-P-0782W
multidisk brake B2 and park
pawl gear
Remove/install control solenoid TRANSMISSION 722.9 AR27.19-P-0212A
valves of electric controller unit
Remove/install electrohydraulic TRANSMISSION 722.9 AR27.19-P-0200W
controller unit (transmission
installed)
Remove/install intelligent servo TRANSMISSION 722.9 in AR27.19-P-0550SX
module MODEL 221.0 /1, 216.3
Remove/install intelligent servo TRANSMISSION 722.6 in AR27.19-P-0550SZ
module MODEL 221.1, 216.3
Remove/install K3, rear hollow TRANSMISSION 722.9 AR27.50-P-0611W
shaft, rear planet carrier and
output shaft
Remove/install main TRANSMISSION 722.9 AR27.50-P-0610W
components of transmission
Remove/install multi-disk TRANSMISSION 722.6 AR27.50-P-0721A
brake B1 and oil pump
Remove/install multi-disk TRANSMISSION 722.9 /9 AR27.50-P-0721W
brake B1 and oil pump (except 722.93)
Remove/install multi-disk TRANSMISSION 722.93 AR27.50-P-
brake B1 and oil pump 0721WMG
Remove/install multi-disk TRANSMISSION 722.6 AR27.50-P-0781A
brake B2, disk pack B3 and
park pawl gear
Remove/install oil filler pipe TRANSMISSION 722.6 in AR27.10-P-7010SZ
for automatic transmission MODEL 216.3, 221.1
Remove/install oil lines of oil TRANSMISSION AR27.55-P-0600SX
cooling for automatic 722.9/722.6 in MODEL
transmission 216.3, 221.1
Remove/install oil lines of oil TRANSMISSION 722.9 in AR27.55-P-
cooling for automatic MODEL 221.0 /1, 216.3 0600SYZ
transmission with 4MATIC
Remove/install oil pump TRANSMISSION 722.6 AR27.10-P-0400A
Remove/install oil pump radial TRANSMISSION AR27.40-P-0300A
shaft sealing ring 722.6 /9 /9
Developed torque converter
Remove/install park pawl TRANSMISSION 722.6 AR27.60-P-0950A
mechanism
Remove/install radial shaft TRANSMISSION 722... AR27.40-P-0205SX
sealing ring at output flange
Remove/install selector lever TRANSMISSION 722.6 up AR27.60-P-0930A
to 1.5.96
Remove/install shift shaft radial TRANSMISSION AR27.40-P-0220A
shaft sealing ring 722.9 /55 Transmission
with intelligent servo
module (ISM)
Remove/install shift shaft radial TRANSMISSION 722... AR27.40-P-0220B
shaft sealing ring
Remove/install transmission TRANSMISSION 722.9 in AR27.10-P-0500SX
with torque converter MODEL 221.0 /1, 216.3
without 4MATIC
Remove/install transmission TRANSMISSION 722.9 in AR27.10-P-
with torque converter MODEL 221, 216 with 0500SYZ
4MATIC
Remove/install transmission TRANSMISSION 722.6 in AR27.10-P-0500SZ
with torque converter MODEL 221.1, 216.3
Removing and installing TRANSMISSION 722.6 AR27.50-P-0621A
multiple-disc clutches K1, K2
and K3
Removing/installing drive shaft TRANSMISSION 722.9 AR27.50-P-0612W
with K2, front planet carrier,
internal plate carrier with K1
and B3
Replace pilot bushing in TRANSMISSION 722.6 AR27.19-P-0230A
electrohydraulic controller unit
REMOVE/INSTALL OIL PUMP - AR27.10-P-0400A
TRANSMISSION 722.6
Fig. 11: Identifying Oil Pump Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Remove/Install
1 Remove transmission with Model 129, 140, 170, AR27.10-P-0500B
torque converter 202, 208, 210
Model 163 AR27.10-P-0500GH
Model 203 without AR27.10-P-0500P
4MATIC, 209
Model 203 with AR27.10-P-0500PW
4MATIC
Model 211 with AR27.10-P-0500TW
4MATIC
Model 215, 220 without AR27.10-P-0500I
4MATIC
Model 220 with AR27.10-P-0500IW
4MATIC
2 Put transmission down on
workbench
3 Take transmission housing Internal Torx drive
(1) off torque converter bolts (2a) 15 bolts and
housing (2) internal Torx drive bolts
(1a) 2 bolts.
Installation: The
intermediate panel (6) on
the torque converter
housing (2) can usually
be used several times.
The panel must not be
coated with sealant.
Bolt, transmission *BA27.40-P-1002-01A
housing to converter
housing
4 Pull torque converter Ensure that the multi-
housing (2) off disk clutch K1 (3) does
transmission housing (1) not fall out.
5 Unscrew internal Torx Bolt, oil pump with *BA27.40-P-1003-01A
drive bolts (4a) of oil multi-disk brake B1 to
pump (4) converter housing
6 Screw two opposed bolts
(a) into the oil pump
housing (4) and press the
oil pump (4) out of the
converter housing (2) by
applying light blows with
a plastic hammer.
Inspect
7 Check oil pump (4) According to AR27.50-P-0720-01A
condition: ?
Dismantle and assemble
oil pump
8 Check teflon rings (5a) of Installation: Insert
multi-disk brake B1 (5), both teflon rings (5a) into
replace if necessary groove with grease so
together.
9 Install in the reverse order
HOUSING
Transmission 722.6 except Transmission
Number Designation
722.660/661/662 /663/666/673/674 722.660/661/662 /663/666/673/674
Bolt,
transmission
BA27.40-
housing to
P-1002- Nm 20 20
torque
01A
converter
housing
Bolt, oil pump
with multi-disk
BA27.40-
brake B1 to
P-1003- Nm 20 20
torque
01A
converter
housing
DISCONNECTING AND CONNECTING PLUG CONNECTOR - AR27.10-P-0500-01A
TRANSMISSION 722.6 /610 /611 /630 /637 /638 /645 (except 722.660 /661 /662 /663 /666 /674)
HOUSING
Transmission 722.6 except
722.660/661/662/
Number Designation 663/666/673/674
BA27.40-P-1014-01A Bolt, heat shield to Nm 6
transmission housing
1. Unscrew bolt (62a) .
2. Undo bolt (62b)
3. Remove heat shield (62)
Heat shield (62) not installed on model 463.
Fig. 12: Identifying Heat Shield And Bolts
Courtesy of MERCEDES-BENZ USA
4. Turn bayonet fitting of pilot bushing (21) 90° to the left and detach electrical connector (26).
Replace O-ring of electrical connector (26).
5. Install in the reverse order.
Fig. 13: Turning Bayonet Fitting Of Pilot Bushing
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TRANSMISSION WITH TORQUE CONVERTER - AR27.10-P-0500SX
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 without 4MATIC
Fig. 14: Identifying Transmission With Torque Converter Remove/Install Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 15: Identifying Transmission With Torque Converter Remove/Install Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Shown on model 221.071
Fig. 16: Identifying Transmission With Torque Converter Remove/Install Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value modified: Self-locking nut, flexible coupling to transmission and *BA41.10-P-1001-
25.6.10
front propeller shaft, M12 01H
Remove/install
Before starting work,
the area around the oil
cooling lines (10L, 10R)
must be thoroughly
cleaned at the separation
points on the
transmission (5). Even
the smallest dirt particles
in the hydraulic
components can lead to
malfunctions and a total
failure of the
transmission (5).
Model 221.095/ 195:
Work on high-voltage
system or on hybrid
components may be
performed by skilled
workshop personnel
only.
1 Set DIRECT SELECT
gear selector switch to
position "N"
2 Release parking brake
3 Open engine hood
4.1 Detach ground line(s) Except model AR54.10-P-0003SX
from battery/batteries 221.095 /195
Notes on battery AH54.10-P-0001-01A
Risk of death when Do not touch components AS54.00-Z-0001-01A
touching components on and open lines of the
vehicles with high-voltage high-voltage on-board
on-board electrical system electrical system. Persons
who are carriers of
electronic implants (e.g.
cardiac pacemakers),
must not carry out any
work on high-voltage on-
board electrical systems.
4.2 Perform disable for the Model 221.095 / 195 AR54.10-P-1150SXH
high-voltage on-board with engine 272
electrical system After completing the
work, attach initial
startup event log together
with the disconnection
log to the vehicle file.
Note on high-voltage AH54.10-P-0006-01A
battery
Note on the voltage on- AH54.00-P-0010-01A
board electrical system
5 Detach electrical feed line Model 221.095 / 195
for right O2-sensor on
power electronics holder
6 Detach output distributor Model 221.095 / 195 AR08.10-P-0011SXH
from transmission (5) and
fasten to the air duct
housing free of stress with
cable tie
7 Secure vehicle on vehicle AR00.60-P-0100SX
lift
8 Remove engine Vehicles without code AR61.20-P-1105SX
compartment paneling (Z07) Top protection
Vehicles with code (Z07) AR61.20-P-1105SXS
Top protection
9.1 Disconnect the electrical Vehicles with gasoline AR07.52-P-5303SX
connectors (G3/3x1, engine except model
G3/4x1, G3/5x1, G3/6x1) 221.095/ 195
of O2 sensors
9.2 Remove right catalytic Model 221.095 / 195 AR49.10-P-7100SX
converter
9.3 Remove diesel particulate Vehicles with diesel
filter engine except
Engine 651
Engine 642 AR14.40-P-1000SXI
Engine 629 AR14.40-P-1000SXJ
9.4 Remove catalytic Engine 651 AR49.10-P-5501SXI
converter diesel
particulate filter unit
10 Unclip electrical feed lines Except model
from bracket (6) on 221.095 /195
transmission (5) and place
to one side
11.1 Detach bracket (6) from Except model
transmission (5) 221.095 /195
*BA27.40-P-1007-01E
11.2 Remove heat shield below Model 221.095 / 195 AR08.10-P-0011SXH
right catalytic converter engine 272
and heat shield between
the exhaust manifold and
power electronics
12 Remove shield (1) and AR27.40-P-0700-01SX
disconnect electrical *BA27.40-P-1003-01E
connector from electric *BA27.40-P-1019-01A
Only if transmission
controller unit
(5) is replaced.
13 Detach electrical
connector from intelligent
servo module (A80),
unclip retaining clips and
place electrical line to one
side
14 Detach electrical Model 221.095 / 195
connector on auxiliary oil
pump for automatic
transmission, unclip
retaining clips on
transmission oil pan and
place electrical line to one
side
15.1 Detach torque converter except transmission AR27.20-P-0100-01A
(9) from driven plate (7) 722.93
or flexible plate from Bolt, torque converter *BA27.20-P-1002-01C
integrated starter- to driver plate
alternator *BA27.20-P-1004-01C
Bolt, flexible plate to
integrated starter
alternator
Fig. 17
Fig. 18
15.2 Detach start-up clutch Transmission 722.93 AR27.51-P-0400-01W
from driven plate Bolt, start up clutch to *BA27.51-P-1001-01A
driver
Fig. 17
Fig. 18
16 Pry torque converter (9) or Fig. 18
start-up clutch uniformly
off driven plate (7) or
integrated starter-
alternator using long
wedge
17 Remove exhaust bracket Vehicles with gasoline
(17) from transmission (5) engine
Engine 156, 272, 273 *BA49.10-P-1008-01Z
Engine 157, 276, 278 *BA49.10-P-1011-01Z
Vehicles with diesel *BA49.10-P-1006-01AJ
engine
Engine 651
Engine 642 *BA49.10-P-1013-01V
18 Support transmission (5) Transmission plate for
and secure to prevent it passenger cars and
from falling down commercial vehicles
Workshop lifter, floor
travel
19 Remove rear engine Except engine 651 AR22.10-P-1180SX
crossmember (3) together
with rear engine mount (2)
Engine 651 AR22.10-P-1180CW
Notes on bolted AH00.00-P-0007-01SF
connections with self
tapping screws
20 Mark position of front This is to ensure
flexible coupling (20V) reinstallation at the ex-
relative to transmission (5) factory installation
and to propeller shaft (20) position, otherwise drive
line vibrations can be
produced.
21 Remove front flexible If the fitted sleeves AR41.10-P-0050-02SX
coupling (20V) are jammed: ?
Loosen fitted sleeves in AR41.10-P-0050-09SX
front flexible coupling
(20V).
Drift for loosening fitting WF58.50-P-4110-01A
sleeves in flex disks.
Installation: Attach AR41.10-P-0050-07SX
the front flexible
coupling (20V) to the
transmission (5).
*BA41.10-P-1001-01H
22.1 Detach oil cooling lines Except model AR27.55-P-0600SX
(10L, 10R) from 221.095 /195
transmission (5) and
engine oil pan and place to
one side
22.2 Detach left oil cooling line Model 221.095 / 195
(10L) and right oil cooling
line (10R) from
transmission (5), remove
engine oil pan and place to
one side
23 Detach starter from Except model
transmission (5) 221.095 /195
Place starter to the
side with lines connected
and secure to prevent it
falling down.
Engine 157, 278 AR15.30-P-7100MMB
Engine 276 AR15.30-P-7100MMA
Engine 272, 273 AR15.30-P-7100SX
Engine 156 AR15.30-P-7100SMG
Engine 642 AR15.30-P-7100SXI
Engine 629 AR15.30-P-7100SXD
Engine 651 AR15.30-P-7100CD
24 Remove bolts (8) Installation: Secure
bracket of electric feed
lines at transmission (5).
*BA27.40-P-1001-01E
*BA27.40-P-1002-01E
*BA27.40-P-1003-01E
25 Remove transmission (5) Secure torque
from below converter (9) to prevent it
from falling out.
Installation: Line up
bores of torque converter
(9) exactly with threaded
unions (7a) in driven
plate (7) or integrated
starter alternator.
26.1 Remove torque converter If necessary
(9) except transmission AR27.20-P-0500-01W
722.93
With angular bolted
on torque converter (9):
Attach grab handles to
torque converter (9) with
bolts and nuts.
Model 221.095/ 195:
Remove torque converter
(9) without grab handles
on flexible plate.
Model 221.095/ 195:
To measure the
installation height the
flexible plate has to be
dismantled from the
torque converter (9).
Installed height of torque *BE27.20-P-1001-01E
converter
*BA27.20-P-1003-01C
Fig. 19
Fig. 20
Multi-purpose paste *BR00.45-Z-1009-06A
26.2 Remove start-up clutch Transmission 722.93 AR27.51-P-0400-
02AMG
Installed height of start *BE27.51-P-1001-02A
up clutch
Fig. 19
Fig. 20
Checking
27.1 Check threaded unions Except model
(7a) of driven plate (7) 221.095 /195
For damaged and
loose threaded unions
(7a): ?
Replace driven plate (7):
Engine 157, 276, 278 AR03.30-P-8001MM
Engine 156 AR03.30-P-8001SMG
Engine 273, 272 except AR03.30-P-8001SX
272.974
Engine 629 AR03.30-P-8001SXD
Engine 642 AR03.30-P-8001SXI
Engine 651 AR03.30-P-8001CD
27.2 Check threaded union in Model 221.095 / 195 AR15.40-P-0003SXH
integrated starter For damaged threaded
alternator unions: ?
Replace integrated starter
alternator.
28 Check rear engine mount Except engine 651 AR22.10-P-1180SX
(2) for wear and damage,
replace if necessary Engine 651 AR22.10-P-1180CW
29 Check front flexible
coupling (20V) for wear
and damage
Check propeller shaft flex AP41.10-P-4152SX
disks for signs of damage
and deformation
30 Install in the reverse order
31 Fill transmission (5) with AR27.00-P-0270W
transmission oil or check
transmission oil level and
correct if necessary
32 Read out fault memory
with STAR DIAGNOSIS
and erase if necessary
Connect STAR AD00.00-P-2000-04A
DIAGNOSIS and read out
fault memory
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
33 Perform engine test run
and check transmission (5)
for leaks and that it is
functioning correctly
34 Perform transmission A transmission
adaptation adaptation must be
carried out after
exchanging or repairing
the transmission (5).
TEST VALUES FOR TORQUE CONVERTER
Transmission
Number Designation
722.9
helical screwed
mm 9.5
connection
BE27.20-P- Installed height of Distance, bolt flange to axial screwed
mm 19.5
1001-01E torque converter transmission housing flange connection
AR27.20-P-
See fig.
0500-01W
TEST VALUES FOR START UP CLUTCH
Transmission
Number Designation
722.93
mm 9.5
BE27.51-P- Installed height of start Distance, bolt flange to transmission
1001-02A up clutch housing flange See
-
fig.
HOUSING
Transmission 722.9 in Model 216,
Number Designation
221
BA27.40-P-1001-
Bolt, automatic transmission to crankcase Nm 39
01E
BA27.40-P-1002- Bolt, automatic transmission to engine oil
Nm 39
01E pan
BA27.40-P-1003-
Bolt, heat shield to transmission housing Nm 10
01E
BA27.40-P-1007- Bracket, wiring harness to automatic
Nm 10
01E transmission
HOUSING
Number Designation Transmission 722.9
BA27.40-P-1019-01A Bolt, leaf spring to transmission housing Nm 5
TORQUE CONVERTER
Transmission
Number Designation
722.9
Straight threaded
M8 Nm 42
connection
Stage
Nm 4
BA27.20-P- Bolt, torque converter to drive 1
1002-01C plate Angled threaded Stage
Nm 30
connection 2
Stage
Angle° 90
3
BA27.20-P- Bolt, torque converter to flexible
M10 Nm 58
1003-01C plate
BA27.20-P- Bolt, flexible plate to integrated
M10 Nm 58
1004-01C starter alternator
PROPELLER SHAFT
Model Model
Number Designation
216 221
BA41.10-P-1001- Self-locking nut, flex disk to transmission or front
M12 Nm 68 68
01H propeller shaft
EXHAUST SYSTEM
Engine 273 in Engine 272 in Engine 273 in
Number Designation
model 216 model 221 model 221
BA49.10-P- Bolt, catalytic converter
Nm 20 20 20
1008-01Z bracket to transmission
EXHAUST SYSTEM
Engine 276 in Engine 278 in Engine 278 in
Number Designation
model 221 model 221 model 216
BA49.10-P- Bolt, catalytic converter bracket to top
Nm 20 20 20
1011-01Z bracket/transmission housing
EXHAUST SYSTEM
Engine 157 in model
Number Designation
216/221
BA49.10-P-1011- Bolt, catalytic converter bracket to top
Nm 20
01Z bracket/transmission housing
EXHAUST SYSTEM
Engine 642 in model
Number Designation
221
BA49.10-P-1013- Bolt, SCR catalytic converter bracket to
Nm 27
01V transmission
START UP CLUTCH
Number Designation Transmission 722.93
Stage 1 Nm 4
BA27.51-P-1001-01A Bolt, start up clutch to driver Stage 2 Nm 30
Stage 3 Angle° 90
EXHAUST SYSTEM
Number Designation
221
BA49.10-P-1006- Nut, catalytic converter system bracket below to
Nm 27
01AJ transmission
EXHAUST SYSTEM
Engine 156 in Engine 156 in
Number Designation
model 216 model 221
BA49.10-P-1008- Bolt, catalytic converter bracket to
Nm 20 20
01Z transmission
Fig. 17: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 18: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 19: Identifying Parallel Support (126 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
Fig. 20: Identifying Grab Handle (168 589 00 62 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1009-06A Multi-purpose paste 000 989 80 51 10
REMOVE/INSTALL TRANSMISSION WITH TORQUE CONVERTER - AR27.10-P-0500SYZ
TRANSMISSION 722.9 in MODEL 221, 216 with 4MATIC
Fig. 21: Identifying Transmission With Torque Converter Remove/Install Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 22: Identifying Transmission With Torque Converter Remove/Install Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 23: Identifying Transmission With Torque Converter Remove/Install Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value modified: Self-locking nut, flexible coupling to transmission and *BA41.10-P-1001-
25.6.10
front propeller shaft, M12 01H
Remove/install
Before starting the
work the area
surrounding the oil
cooling lines (10L, 10R)
must be thoroughly
cleaned in the area of the
separation points on the
transmission (5) and
transfer case. Even the
smallest dirt particles in
the hydraulic components
can lead to malfunctions
and a total failure of the
transmission (5) and
transfer case.
1 Move DIRECT SELECT
gear selector switch to
position "N"
2 Release parking brake
3 Disconnect ground lines AR54.10-P-0003SX
from batteries
4 Secure vehicle on vehicle AR00.60-P-0100SX
lift
5 Remove front axle gear AR41.10-P-0070SYZ
propeller shaft
6 Unclip electrical feed Only vehicles with
lines from bracket (6) on gasoline engine
transmission (5) and place
to one side
7 Remove shield (1) and AR27.40-P-0700-01SX
disconnect electrical *BA27.40-P-1019-01A
connector from electric
controller unit *BA27.40-P-1003-01E
8 Drain transmission oil at Only drain the
oil pan automatic transmission
fluid when replacing the
transmission (5) or torque
converter (9).
Installation: Install
new seal in order to avoid
oil loss.
If the transmission oil AR27.55-P-0001SYZ
is burnt or contains
abrasive particles the oil
cooling lines (10L, 10R)
and the oil cooler must be
flushed in order to avoid
damage to the
transmission (5).
*BA27.10-P-1001-03D
9 Remove front exhaust Engine 272, 273 *BA49.10-P-1008-01Z
bracket (17) from Engine 276, 278 *BA49.10-P-1011-01Z
transmission (5)
Engine 642 *BA49.10-P-1002-01V
10 Detach bracket (6) of *BA27.40-P-1007-01E
wiring harness on
transmission (5)
11 Disconnect electrical
connector from intelligent
servo module (A80)
12 Support transmission (5)
with transmission jack
and transmission platform
and lash down securely
13 Remove rear engine cross AR22.10-P-1180SW
member (2)
14 Mark position of front This is to ensure
flexible coupling (20v) reinstallation at the ex-
relative to transmission factory installation
(5) and to propeller shaft position, otherwise drive
(20) line vibrations can be
produced.
15 Remove front flexible If the fitted sleeves are AR41.10-P-0050-02SX
coupling (20v) jammed: ?
Loosen fitting sleeves of AR41.10-P-0050-09SX
flexible coupling (20v).
Drift for loosening fitting WF58.50-P-4110-01A
sleeves in flex disks.
Installation: Mount AR41.10-P-0050-07SX
front flexible coupling
(20v) on transmission (5).
*BA41.10-P-1001-01H
16 Detach torque converter AR27.20-P-0100-01A
(9) from driven plate (7) *BA27.20-P-1001-01C
*BA27.20-P-1002-01C
Fig. 24
Fig. 25
17 Pry torque converter (9) Fig. 25
evenly off driven plate (7)
using long wedge
18 Detach oil cooling lines AR27.55-P-0600SYZ
(10L, 10R) from
transmission (5), transfer
case and engine oil pan
and place to one side
19 Detach starter from Place starter to the
transmission (5) side with lines connected
and secure to prevent it
falling down.
Engine 272, 273 AR15.30-P-7100SX
Engine 276 AR15.30-P-7100MMA
Engine 278 AR15.30-P-7100MMB
Engine 642 AR15.30-P-7100SYZ
20 Remove bolts (8) Installation: Secure
bracket of electric feed
lines at transmission (5).
*BA27.40-P-1001-01E
*BA27.40-P-1002-01E
*BA27.40-P-1007-01E
21 Remove transmission (5) Secure torque
from below converter (9) to prevent it
from falling out.
Installation: Align
the holes of the torque
converter (9) with the
threaded unions (7a) in
the driven plate (7).
22 Remove torque converter If necessary AR27.20-P-0500-01W
(9) *BE27.20-P-1001-01E
Fig. 26
Fig. 27
Multipurpose paste *BR00.45-Z-1009-06A
Checking
23 Check threaded unions A new driven plate (7)
(7a) of driven plate (7) must be installed if the
threaded unions (7a) are
damaged and loose.
24 Check rear engine mount
for wear and damage and
replace if necessary
25 Check front flexible
coupling (20v) for wear
and damage, replace if
necessary
Check propeller shaft flex AP41.10-P-4152SX
disks for signs of damage
and deformation
26 Install in the reverse order
27 Check transmission oil AR27.00-P-0270SYZ
level and correct if
necessary
28 Read out fault memory
with STAR DIAGNOSIS
and erase if necessary
29 Perform transmission A transmission
adaptation adaptation must be
carried out after
exchanging or repairing
the transmission (5).
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
30 Test run engine and check
transfer case and
transmission (5) for leaks
and function
TEST VALUES FOR TORQUE CONVERTER
Transmission
Number Designation
722.9
helical screwed
mm 9.5
connection
BE27.20-P- Installed height of Distance, bolt flange to axial screwed
mm 19.5
1001-01E torque converter transmission housing flange connection
AR27.20-P-
See fig.
0500-01W
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation Transmission 722.9
BA27.10-P-1001-03D Drain plug on transmission oil pan Nm 22
TORQUE CONVERTER
Transmission
Number Designation
722.9
BA27.20-P-1001- Oil drain bolt to torque M8 Nm 10
01C converter M10 Nm 15
Straight threaded
M8 Nm 42
connection
Stage
Nm 4
BA27.20-P-1002- Bolt, torque converter to 1
01C drive plate Angled threaded Stage
Nm 30
connection 2
Stage
Angle° 90
3
HOUSING
Transmission 722.9 in Model 216,
Number Designation
221
BA27.40-P-1001-
Bolt, automatic transmission to crankcase Nm 39
01E
BA27.40-P-1002- Bolt, automatic transmission to engine oil
Nm 39
01E pan
BA27.40-P-1003-
Bolt, heat shield to transmission housing Nm 10
01E
BA27.40-P-1007- Bracket, wiring harness to automatic
Nm 10
01E transmission
HOUSING
Number Designation Transmission 722.9
BA27.40-P-1019-01A Bolt, leaf spring to transmission housing Nm 5
PROPELLER SHAFT
Model Model
Number Designation
216 221
BA41.10-P-1001- Self-locking nut, flex disk to transmission or front
M12 Nm 68 68
01H propeller shaft
EXHAUST SYSTEM
Engine 642 in model
Number Designation
221
BA49.10-P-1002- Bolt connecting bracket for front exhaust system to
Nm 20
01V transmission
EXHAUST SYSTEM
Engine 273 in Engine 272 in Engine 273 in
Number Designation
model 216 model 221 model 221
Nm 20 20 20
1008-01Z bracket to transmission
EXHAUST SYSTEM
Engine 276 in Engine 278 in Engine 278 in
Number Designation
model 221 model 221 model 216
BA49.10-P- Bolt, catalytic converter bracket to top
Nm 20 20 20
1011-01Z bracket/transmission housing
Fig. 24: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 25: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 26: Identifying Parallel Support (126 589 04 31 00)
Fig. 27: Identifying Grab Handle (168 589 00 62 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1009-06A Multipurpose paste A 000 989 80 51 10
REMOVE/INSTALL TRANSMISSION WITH TORQUE CONVERTER - AR27.10-P-0500SZ
TRANSMISSION 722.6 in MODEL 221.1, 216.3
Fig. 28: Identifying Transmission With Torque Converter Remove/Install Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 29: Identifying Transmission With Torque Converter Remove/Install Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 30: Identifying Transmission With Torque Converter Remove/Install Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
6.8.08 Value changed: Filling capacity, Sheet *BF27.00-P-1001-01C
Value changed: Filling capacity, Sheet *BF27.00-P-1001-01C
Remove/install
and bolts
Before starting work, the
area around the oil
cooling lines (10L, 10R)
must be thoroughly
cleaned at the separation
points on the transmission
(5). Even the smallest dirt
particles in the hydraulic
components can lead to
malfunctions and a total
failure of the transmission
(5)
1 Move DIRECT SELECT
gear selector switch to
position "N"
2 Release parking brake
3 Open engine hood
4 Disconnect ground lines AR54.10-P-0003SX
from batteries
5 Secure vehicle on vehicle AR00.60-P-0100SX
lift
6 Remove lower engine Vehicles without code AR61.20-P-1105SX
compartment paneling (Z07) Top protection
Vehicles with code (Z07) AR61.20-P-1105SXS
Top protection
7 Remove front exhaust *BA49.10-P-1008-01Z
bracket (17) from
transmission (5)
8 Remove catalytic See: Remove components AR49.10-P-7100SX
converters of exhaust system.
9 Remove shield (1) and AR27.40-P-0700-01SX
disconnect electrical
connector from electric
controller unit
10 Unclip electrical feed
lines from bracket (6) on
transmission (5) and place
to one side
11 Remove bolts securing *BA27.40-P-1003-01B
bracket (6) to
transmission (5)
12 Disconnect electrical
connector (12) on
intelligent servo module
(A80)
13 Remove oil drain screws If necessary
from transmission oil pan If there are metal
and torque converter (7) shavings in the
and drain transmission oil transmission oil pan,
allow the transmission oil
to drain out of the torque
converter (7) through a
clean cloth If there are
metal shavings in the
cloth after draining the
transmission fluid, the
torque converter (7) must
be replaced.
If the transmission oil
is burnt or contains wear
debris, the oil cooling
lines (10L, 10R) and oil
cooler must be flushed
out, otherwise damage
could be caused inside
the transmission (5): ?
Flush out oil cooling AR27.55-P-0001A
lines (10L, 10R) and oil
cooler.
Only flush out the
torque converter (7) with
transmission oil.
*BA27.10-P-1001-03A
*BA27.20-P-1001-01C
*BF27.00-P-1001-01C
14 Detach heat shield and Place starter to the AR15.30-P-7100SZ
starter from transmission side with lines connected
(5) and secure to prevent it
falling down.
15 Detach left heat shield
from transmission (5)
16 Detach torque converter Crank the engine at
(7) from driven plate; to the center bolt of the
do so, unclip cover (13) crankshaft in the
from engine oil pan and direction of engine
remove bolts (7a) rotation until the bolts
(7a) are accessible
through the recess in the
engine oil pan.
*BA27.20-P-1002-01C
17 Pry torque converter (7) Fig. 31
evenly off driven plate
using long wedge
18 Detach oil cooling lines Installation: Replace
(10L, 10R) from sealing rings.
transmission (5); to do so,
remove banjo bolts (15) *BA27.55-P-1002-01B
19 Detach oil cooling lines Do not bend or kink AR27.55-P-0600SX
(10L, 10R) from brackets; the oil cooling lines (10L,
to do so, remove bolts 10R).
(11)
20 Detach bracket (6) of
electrical connectors from
transmission (5)
21 Support transmission (5) Secure the
with transmission jack transmission (5) with a
and platform tensioning strap to
prevent it from tilting and
slipping off.
Transmission platform,
transmission jack.
22 Remove rear engine AR22.10-P-1180SX
crossmember (3) and
detach rear engine mount
(2) from transmission (5);
to do this, unscrew bolts
(4, 9)
23 Mark position of front This is to ensure
flexible coupling (20V) reinstallation at the ex-
relative to transmission factory installation
(5) and to propeller shaftposition, otherwise drive
(20) line vibrations can be
produced.
24 Remove front flexible If the fitted sleeves are AR41.10-P-0050-02SX
coupling (20V) jammed: ?
Loosen fitted sleeves in AR41.10-P-0050-09SX
front flexible coupling
(20V).
Installation: Attach AR41.10-P-0050-07SX
the front flexible
coupling (20V) to the
transmission (5).
25 Remove oil filler pipe of AR27.10-P-7010SZ
transmission (5)
26 Remove bolts (8) Installation: Secure
the bracket of the
electrical feed lines and
the catalytic converter
bracket to the
transmission (5).
*BA49.10-P-1011-01Z
*BA27.40-P-1001-01B
*BA27.40-P-1002-01B
27 Remove transmission (5) Secure torque
from below converter (7) to prevent it
from falling out.
Installation: Align
the bolt holes on the
torque converter (7) with
the holes in the driven
plate.
28 Remove torque converter If necessary AR27.20-P-0500-01P
(7) with grab
handles
Checking
29 Check threaded unions in A new torque
torque converter (7) converter (7) must be
installed if the threaded
unions are damaged.
30 Check rear engine mount
(2) for wear and damage;
replace if necessary
31 Check front flexible
coupling (20V) for wear
and damage
Check propeller shaft flex AP41.10-P-4152SX
disks for signs of damage
and deformation
32 Install in the reverse order
33 Check oil level in AR27.00-P-0100AC
automatic transmission
(5); correct if necessary
34 Read out fault memory
with STAR DIAGNOSIS
and erase if necessary
35 Perform transmission A transmission
adaptation adaptation must be
carried out after
exchanging or repairing
the transmission (5).
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
36 Perform engine test run
and check transmission
(5) for function and leaks
TORQUE CONVERTER
Transmission 722.6
Number Designation
except 722.648
BA27.20-P- Oil drain bolt to torque M8 Nm 10
1001-01C converter M10 Nm 15
Straight threaded
M8 Nm 42
connection
Stage
Nm 4
BA27.20-P- Bolt, torque converter to 1
1002-01C drive plate Angled threaded Stage
Nm 30
connection 2
Stage
Angle° 90
3
HOUSING
Transmission 722.6 in Model 216,
Number Designation
221
BA27.40-P-1001-
Bolt, automatic transmission to crankcase Nm 39
01B
BA27.40-P-1002- Bolt, automatic transmission to engine oil
Nm 39
01B pan
BA27.40-P-1003-
Bolt, heat shield to transmission housing Nm 10
01B
EXHAUST SYSTEM
Engine 275 in Engine 275 in
Number Designation
model 216 model 221
BA49.10-P- Bolt, catalytic converter bracket to
Nm 20 20
1008-01Z transmission
BA49.10-P- Bolt, catalytic converter bracket to top
Nm 20 20
1011-01Z bracket/transmission housing
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation Transmission 722.649
BA27.10-P-1001-03A Oil drain screw to oil pan Nm 22
TRANSMISSION OIL COOLING
Transmission 722.6 in
Number Designation
model 204, 216, 221
Stage 1 Nm 5
Banjo bolt or union nut, oil cooler line to
BA27.55-P- Stage 2 Angle° 90
torque converter and transmission
1002-01B Hexalobular
housing Nm 12
bolt
AUTOMATIC TRANSMISSION
Number Designation Transmission 722.649
Initial charge Liters 8, 0
during oil change Liters 6.5
BF27.00-P-1001-01C Filling capacity
Sheet BB00.40-P-0236-14A
Specifications for Operating Fluids
Sheet -
Fig. 31: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
DISCONNECT/CONNECT TRANSMISSION OIL LINE - AR27.10-P-0501-03SX
TRANSMISSION 722.9 in MODEL 230, 216.3, 221.1 /0, 231
TRANSMISSION 722.6 in MODEL 230, 216.3, 221.1
Fig. 32: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Remove retaining clamp on connector
Before opening the hydraulic system the area surrounding the separation point should be cleaned thoroughly.
Even minute particles of dirt in the hydraulic components can result in malfunctions and total failure of the
hydraulic system.
1. Detach dust cap (3) and push back along the transmission oil line (1) until the connector (2) is accessible.
2. Position a suitable tool (e.g. hook) at one end of the retaining clamp (2a) and pull the retaining clamp (2a)
off the connector (2).
3. Pull transmission oil line (1) out of connector (2).
Seal off line connections using plugs.
4. Pull dust cap (3) off transmission oil line (1).
Fig. 33: Identifying Transmission Oil Line, Connector, Dust Cap And Retaining Clamp
Courtesy of MERCEDES-BENZ USA
Attach retaining clamp to connector
The safety clamp (2a) must be replaced after every disconnection of a transmission oil line (1).
5. Introduce one end of the safety clamp (2a) into a cutout (2b) on the connector (2).
6. Push retaining clamp (2a) in the direction of the arrow until the retaining clamp (2a) clicks into place in
the connector (2).
Fig. 34: Identifying Safety Clamp
Courtesy of MERCEDES-BENZ USA
Fig. 35: Pushing Retaining Clamp
Courtesy of MERCEDES-BENZ USA
The securing clamp (2a) must not be pushed straight (radially) over the connector (2) otherwise the
securing clamp (2a) will be overstretched and correct sealing of the line connection is no longer
guaranteed.
Fig. 36: Identifying Incorrect Securing Clamp Positioning
Courtesy of MERCEDES-BENZ USA
Attach transmission oil line to connector
The dust cap (3) must be replaced after every disconnection of a transmission oil line (1).
7. Push dust cap (3) onto the transmission oil line (1).
8. Introduce transmission oil line (1) straight into the connector (2) until it audibly and noticeable latches.
9. Push dust cap (3) onto the connector (2) until it latches and can turn freely.
If the dust cap (3) cannot be pushed over the connecting point then the transmission oil line (1) is not
fully latched in the connector (2) or the safety clamp (2a) is overstretched.
REMOVE/INSTALL LINES AT AUTOMATIC TRANSMISSION - AR27.10-P-0502-01SX
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 without 4MATIC
TRANSMISSION 722.6 in MODEL 216.3, 221.1
TRANSMISSION OIL COOLING
Transmission 722.6 in
Number Designation
model 204, 216, 221
Stage 1 Nm 5
torque converter and transmission Stage 2 Angle° 90
BA27.55-P- housing
1002-01B Hexalobular
Nm 12
bolt
BA27.55-P-
Bolt, oil cooling line double clamp to engine oil pan Nm 10
1009-01B
BA27.55-P-
Bolt, oil cooling line double clamp to bracket Nm 10
1010-01B
TRANSMISSION OIL COOLING SYSTEM
Transmission
Number Designation
722.9
Stage
Nm 5
Banjo 1
BA27.55-P-1002- Bolt, transmission oil line to bolt Stage
01D transmission housing Angle° 90
2
Hexalobular bolt Nm 12
BA27.55-P-1005-
Bolt, oil cooling line double clamp to bracket Nm 8
01D
BA27.55-P-1006-
Bolt, oil cooling line double clamp to engine oil pan Nm 8
01D
Fig. 37: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1028-04A Cleaner from package
Shown on transmission 722.906
Fig. 38: Identifying Left And Right Oil Cooling Line
Courtesy of MERCEDES-BENZ USA
Shown on transmission 722.906
Fig. 39: Identifying Left And Right Oil Cooling Line, Screw And Double Clamp
Courtesy of MERCEDES-BENZ USA
1. Thoroughly clean area around separation point at hydraulic system.
Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure
of the transmission.
2. Remove bolts (9, 11, 13).
3. Remove double clamps (10, 12, 14) and retaining clamps.
5. Pull right oil cooling line (7) out of transmission and seal line connection and oil hole in transmission
using stop plugs.
To prevent damage and leaks, do not kink or bend the right oil cooling line (7).
Installation: Install new gasket
6. Remove bolt (19).
7. Pull left oil cooling line (8) out of transmission and seal line connection and oil hole in transmission using
stop plugs.
To prevent damage and leaks, do not kink or bend the left oil cooling line (8).
Installation: Install new gasket
8. Install in the reverse order.
FASTEN TRANSMISSION TO ASSEMBLY STAND - AR27.10-P-0600-01B
TRANSMISSION 722.6
Support plate for mounting transmission Only for transmission 722.626 WF58.50-P-2750-04A
Fig. 40: Identifying Assembly Stand (116 589 06 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 41: Identifying Support Plate (140 589 34 63 00)
Courtesy of MERCEDES-BENZ USA
1. Bolt support plate (071) to assembly stand (070).
2. Insert transmission into support plate (071) and secure with three bolts (arrows).
Fig. 42: Identifying Bolt Support Plate To Assembly Stand
Courtesy of MERCEDES-BENZ USA
Fig. 43: Identifying Transmission On Support Plate
FASTEN TRANSMISSION ON ASSEMBLY STAND - AR27.10-P-0600-01W
Transmission 722.9
Fig. 44: Identifying Assembly Stand (116 589 06 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 45: Identifying Support Plate (140 589 34 63 00)
Courtesy of MERCEDES-BENZ USA
1. Bolt support plate (H) to assembly stand (B) at threaded holes (B1, B2, B3).
2. Align holes (G1, G2, G3) of torque converter housing (1w) with threaded holes (H1, H2, H3) of support
plate (H).
After positioning, secure the transmission to prevent it from tilting and slipping off.
3. Bolt torque converter housing (1w) to support plate (H) at threaded holes (H1, H2, H3).
Fig. 46: Bolting Support Plate To Assembly Stand At Threaded Holes
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL OIL FILLER PIPE FOR AUTOMATIC TRANSMISSION - AR27.10-P-7010SZ
TRANSMISSION 722.6 in MODEL 216.3, 221.1
Fig. 47: Identifying Oil Filler Pipe For Automatic Transmission Remove/Install Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
11.10.07 Bolt, automatic transmission to crankcase *BA27.40-P-1001-01B
15.10.07 Bolt, leaf spring to transmission housing *BA27.40-P-1019-01A
Remove/install
1 Remove bottom engine Vehicles without code AR61.20-P-1105SX
compartment paneling (Z07) Top protection
Vehicles with code (Z07) AR61.20-P-1105SXS
Top protection
2 Detach exhaust system See Remove/install AR49.10-P-7100SX
from flange connections exhaust system
(center muffler to components.
catalytic converters)
3 Support transmission (1) Secure the
with transmission jack transmission (1) with a
and platform tensioning strap to
prevent it from tilting or
slipping off.
Transmission platform,
transmission jack.
4 Remove rear engine AR22.10-P-1180SX
crossmember and detach
rear engine mount from
transmission (1)
5 Lower the transmission When the engine is
jack slightly being lowered, it must
not rest against the
bulkhead, otherwise the
coolant hoses and engine
wiring harness will be
damaged.
6 Loosen bolt (2) *BA27.40-P-1019-01A
7 Remove bolt (3) *BA27.40-P-1001-01B
8 Pull oil filler pipe (5) out Installation: Install a
of transmission (1) new sealing ring on the
oil filler pipe (5).
9 Install in the reverse order
10 Check oil level in AR27.00-P-0100AC
automatic transmission
(1); correct if necessary
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
11 Perform engine test run
and check transmission
(1) for function and leaks
HOUSING
Transmission 722.6 in model 216,
Number Designation
221
BA27.40-P-1001- Bolt, automatic transmission to
Nm 39
01B crankcase
HOUSING
Transmission 722.6 except
Number Designation
722.660/661/662/663/666/673/674
BA27.40-P- Bolt, leaf spring to
Nm 8
1019-01A transmission housing
REMOVE/INSTALL AUTOMATIC TRANSMISSION OIL PAN - AR27.10-P-7030W
TRANSMISSION 722.9
Fig. 48: Identifying Automatic Transmission Oil Pan Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Illustration shows transmission oil pan without sloped surface and with black overflow tube
MODIFICATION NOTES
23.6.10 Reference to modified transmission oil pan, added BT27.10-P-0006-01A
Remove/install
Risk of death Align vehicle between columns of vehicle AS00.00-Z-0010-
caused by vehicle lift and position four support plates at 01A
slipping or toppling vehicle lift support points specified by
off of the lifting vehicle manufacturer.
platform.
General notes
Pay attention to cleanliness during all
operations. No fluffy cleaning cloths may
be used. Chamois leathers are the most
suitable.
1 Check transmission The transmission oil pan (3) and
oil pan (3) overflow pipe (31) have been redesigned to
optimize the oil supply to the A/T. The
previous transmission oil pan (3) without
chamfers and with a black overflow pipe
(31) after removal is to be replaced by a
transmission oil pan (3) with chamfers and
with a white overflow pipe (31).
Redesigned oil pan Only category P with transmission 722.9 BT27.10-P-0006-
and overflow tube as of production date 21.6.2010 with 01A
engine 113, 156, 157, 271, 272, 273, 275,
276, 278, 642, 651
Redesigned oil pan Only category P with transmission 722.901 BT27.10-P-0006-
and overflow tube 01W
Clean
2 Clean transmission
oil pan (3) and
surrounding area
thoroughly
3 Drain the Remove drain plug and pry overflow
transmission oil and pipe (31) off base (arrow) using
collect for drift. The remaining transmission oil drains
determining the out immediately after prying off.
quantity of Installation: Replace sealing ring.
transmission
*BA27.10-P-1001-
03D
Fig. 49
4 Detach the Installation: The sprags (3a) are only
transmission oil pan permitted for transmission 722.9 and must
(3) from the not be mixed up with sprags from another
transmission transmission otherwise contact corrosion
housing (1) can occur. Replace bolts (3b).
*BA27.10-P-1002-
03D
5 Remove overflow Installation: Replace overflow pipe
pipe (31) from the (31) and press firmly onto the base
transmission oil pan (arrow).
(3) The distance from the upper edge of the
overflow pipe (31) to the base of the
transmission oil pan (3) determines the
filling capacity of the transmission.
6 Remove gasket (33) Installation: Always replace seal (33).
Installation: Do not apply any sealant
or sealing compound to the transmission
oil pan (3) and transmission housing (1)
Clean
7 Remove and clean Check the magnet (32) for damage and
the magnet (32) replace if necessary
from the
transmission oil pan
(3)
8 Clean the It is essential to clean and degrease
transmission oil pan sealing surfaces thoroughly. Allow
(3) cleaning spray used to flash off
completely, otherwise leakages can occur.
The sealing surfaces on the transmission
oil pan (3) and transmission housing (1)
must be free from oil and grease.
9 Check oil filter (34)
and replace if
necessary
10 Install in the reverse
order
11 Fill transmission To prevent damage to the transmission,
with transmission it is essential to adhere to the work
fluid procedure and to observe the
Specifications for Operating Fluids.
Transmission 722.9 except AR27.00-P-0270W
722.950 /960 /961 /962 /963 /964
Transmission AR27.00-P-
722.950 /960 /961 /962 /963 /964 0270SYZ
Risk of accident Secure vehicle to prevent it from moving AS00.00-Z-0005-
caused by vehicle by itself. 01A
starting off by itself Wear closed and snug-fitting work clothes.
when engine is Do not touch hot or rotating parts.
running. Risk of
injury caused by
contusions and
burns during
starting procedure
or when working
near the engine as it
is running
12 Test run engine and
check transmission
for leaktightness
and proper
operation
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation Transmission 722.9
BA27.10-P-1001-03D Drain plug on transmission oil pan Nm 22
Stage 1 Nm 4
BA27.10-P-1002-03D Bolt, oil pan to transmission housing
Stage 2 Angle° 180
Fig. 49: Identifying Drift (722 589 03 15 00)
Courtesy of MERCEDES-BENZ USA
TRANSMISSION
Automatic Transmission - Testing & Repair - S-Class (221)
TESTING & REPAIR
REMOVE/INSTALL SHIELD AT TRANSMISSION - AR27.40-P-0700-01SX
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3
TRANSMISSION 722.6 in MODEL 221.1, 216.3
HOUSING
Transmission 722.6 except Transmission
Number Designation
722.660/661/662/ 663/666/673/674 722.9
BA27.40-P- Bolt, leaf spring to
Nm 8 5
1019-01A transmission housing
HOUSING
Transmission 722.6 in model 216,
Number Designation
221
BA27.40-P-1003- Bolt, heat shield to transmission
Nm 10
01B housing
HOUSING
Transmission 722.9 in Model 216,
Number Designation
221
BA27.40-P-1003- Bolt, heat shield to transmission
Nm 10
01E housing
1. Remove bolt (1) and remove shield (2) downwards.
2. Press cable holder (4) out of shield (2) and remove shield (2).
Installation: The shield (2) must be positioned under the leaf spring (3).
The leaf spring (3) must be modified if a new transmission is installed.
Fig. 1: Identifying Shield, Bolt, Leaf Spring And Cable Holder
Courtesy of MERCEDES-BENZ USA
SCREW ON AND SECURE TWELVE-POINT COLLARED NUT AND SECURE - AR27.50-P-0600-
04B
TRANSMISSION 722.6
GEAR SET
Number Designation Transmission 722.55/6/9
BA27.50-P-1001-01A Collared nut, output Nm 200
flange to output shaft
Fig. 2: Identifying Wrench Socket (126 589 02 09 00)
Courtesy of MERCEDES-BENZ USA
1. Block transmission gear assembly by engaging park pawl.
2. Push output flange (48) onto the output shaft.
Transmission 722.611: On this model the output flange is not designed as a three-arm flange, the
attachment to the output shaft with the aid of a twelve-point collar nut corresponds to that on the three-
arm flange.
3. Fasten twelve-point collar nut (47) using the socket wrench bit 126 589 02 09 00.
Replace twelve-point collar nut (47).
4. Secure twelve-point collar nut (47) by hammering the collar into the recess in the output shaft. (Arrow)
Fig. 3: Securing Twelve-Point Collar Nut
Courtesy of MERCEDES-BENZ USA
INSTALL GROOVED BALL BEARING IN REAR TRANSMISSION HOUSING - AR27.50-P-0600-05A
TRANSMISSION 722.6/9, 724.2
1. Press grooved ball bearing (67) into transmission housing using a suitable drift.
Closed side of plastic cage must face towards park pawl gear.
2. Fit circlip (68) in groove.
3. Use feeler gage to determine play between grooved ball bearing (67) and circlip (68).
No play should exist between circlip (68) and grooved ball bearing (67). If circlip cannot be fitted, a
thinner one must be used. If play exists between circlip and grooved ball bearing, a thicker circlip must be
used.
Circlips (68) are available in thicknesses 2.0, 2.1 and 2.2 mm.
Fig. 4: Identifying Pressed Grooved Ball Bearing Into Transmission Housing Using Drift
Courtesy of MERCEDES-BENZ USA
MEASURE END PLAY BETWEEN PARK PAWL GEAR AND GROOVED BALL BEARING -
AR27.50-P-0600-06A
TRANSMISSION 722.6, 722.9 (except 722.96), 724.2
TEST VALUES FOR GEAR SET
Transmission Transmission
Number Designation
722.6 722.9
BE27.50-P-1004- End play between park pawl gear and
mm 0.3 to 0.5 0.20 to 0.40
01A grooved ball bearing
Fig. 5: Identifying Parallel Support (126 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
Determine dimension "a"
1. Place parallel support (029) on the transmission housing and measure with the depth gauge from the
parallel support (029) to the park pawl gear (15).
Fig. 6: Identifying Parallel Support On Transmission Housing
Courtesy of MERCEDES-BENZ USA
Determine dimension "b"
2. Using the depth gauge measure from the parallel support (029) to the contact surface of the grooved ball
bearing (67) in the transmission housing.
Fig. 7: Measuring Parallel Support To Contact Surface Of Grooved Ball Bearing
Courtesy of MERCEDES-BENZ USA
3. Adjust the axial play "E" by means of shim as per the calculation example.
Example calculation:
Dimension "a" 49, 9 mm
Dimension "b" 49, 0 mm
Difference 0, 9 mm
Axial play "E" -0, 4 MM
Shim 0, 5 mm
4. Install the corresponding shim.
Shims are available in thicknesses of 0.2 to 0.5 mm. The graduation is 0.1 mm.
MEASURE END PLAY BETWEEN PARK PAWL GEAR AND GROOVED BALL BEARING -
AR27.50-P-0600-06SYZ
TRANSMISSION 722.96 in MODEL 204, 212, 216, 218, 221
TEST SPECIFICATIONS FOR GEAR SET
Transmission
Number Designation
722.9
BE27.50-P-1004- End play between park pawl gear and grooved ball
mm 0.20...0.40
01A bearing
Fig. 8: Identifying Parallel Support (126 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1038-04A Loctite 7200
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
A digital-vernier caliper is required to determine the shim size.
Clean
1. Thoroughly clean the faces and contact surfaces on the transfer case drive pinion case, thrust plate on the
park pawl gear, transmission output shaft, guide sleeve and sealing surface on transmission housing.
Do not use any sharp-edged tools or abrasive paper as otherwise the sealing surface shall be damaged.
Pay attention to absolute cleanliness otherwise an incorrect measurement will occur which will result
in destruction of the automatic transmission.
Measure overall height (dimension a)
2. Measure and note down overall height (dimension a) using vernier caliper (01) as shown.
Overall height (dimension a): Measure from guide sleeve (3) through transfer case drive pinion (4) to
the parallel gauge (02).
Fig. 9: Measuring Drive Pinion Overall Height
Courtesy of MERCEDES-BENZ USA
Measure partial height 1 (dimension b)
3 Measure and note down partial height 1 (dimension b) using vernier caliper (01) as shown.
Partial height 1 (dimension b): Measure from face on transmission output shaft (7) to thrust plate on
park pawl gear (6).
When measuring partial height 1 (dimension b), neither the guide sleeve (3) nor the shim may be
installed.
Fig. 10: Measuring Transmission Output Shaft Partial Height 1
Courtesy of MERCEDES-BENZ USA
Measure partial height 2 (dimension c)
4 Mount transfer case drive pinion (4) onto transmission output shaft (7) and check it is correctly seated
in the transmission housing (5).
5 Measure and note down partial height 2 (dimension c) using vernier caliper (01) as shown.
Partial height 2 (dimension c): Measure from face on transfer case drive pinion (4) to face on
transmission output shaft (7).
When measuring partial height 2 (dimension c), neither the guide sleeve (3) nor the shim (27s) may be
installed.
When measuring partial height 2 (dimension c) make sure that the vernier caliper (01) is located on the
transmission output shaft's (7) face and that it is not measured on the threaded hole's chamfer.
Fig. 11: Measuring Drive Pinion Partial Height 2
6 Calculate shim (27s) size :
The following values must be added up first and then the overall height (dimension a) subtracted from
the result:
+ Partial height 1 (dimension b)
+ Partial height 2 (dimension c)
+ Specified play/axial play check values (dimension: 0.2 to 0.4 mm)
- Overall height (dimension a)
= Shim size (27s)
Fig. 12: Identifying Guide Sleeve, Transmission Housing And Shim
Courtesy of MERCEDES-BENZ USA
Calculation example for shim (27s) size:
+81.97 mm (partial height 1 (dimension b))
+85.73 mm (partial height 2 (dimension c))
+0.3 mm (specified play/axial play check values)
-166.47 mm (overall height (dimension a))
= 1.53 mm (shim size (27s))
7 Adjust axial play, to do so fit the determined shim (27s) over the transmission output shaft (7) onto the
thrust plate on the park pawl gear (6).
Shims (27s) are available in sizes ranging from 1.4 - 2.1 mm in steps of 0.1 mm. In the above-
mentioned calculation example a shim size of 1.5 mm is installed.
REMOVE GROOVED BALL BEARING IN REAR TRANSMISSION HOUSING - AR27.50-P-0601-
01A
TRANSMISSION 722.6/9, 724.2
MODIFICATION NOTES
13.2.08 Remove retaining ring with pliers, added Step 1
Fig. 13: Identifying Puller (001 589 50 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 14: Identifying Chuck (140 589 06 34 00)
Courtesy of MERCEDES-BENZ USA
1. Remove retaining ring of grooved ball bearing with pliers.
2. Screw collet into puller and tighten.
3. Attach puller over the bearing inner race.
4. The collet is tightened (picture A) by turning the puller upper part counterclockwise (arrow).
5. Using pulling device, pull grooved ball bearing out of transmission housing (picture B).
Fig. 15: Turning Puller Upper Part
Courtesy of MERCEDES-BENZ USA
Fig. 16: Pulling Grooved Ball Bearing Out Of Transmission Using Pulling Device
Courtesy of MERCEDES-BENZ USA
DETACH/ATTACH TRANSMISSION HOUSING ON TORQUE CONVERTER HOUSING. - AR27.50-
P-0601A
TRANSMISSION 722.6
Fig. 17: Identifying Disassembled View Of Transmission Housing
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
27.7.01 Magnet in oil pan, newly included Step 4 and 26 added BT27.40-P-0003-01A
Disassemble
AR27.10-P-
Fasten transmission on assembly 0600-01B
1
stand Assembly stand Fig. 18
Support plate Fig. 22
Support plate for transmission mount WF58.50-P-
(722.626) 2750-04A
Loosen guide bush (21) and remove
2
from the transmission housing
3 Detach oil pan (3)
4 Remove magnet (69) from oil pan Vehicles as of 04/2001.
BT27.40-P-
Magnet in oil pan, newly included
0003-01A
5 Remove oil filter (5)
Remove internal Torx bolt (19a) and According to condition:? AR27.19-P-
6 remove electrohydraulic controller Disassemble and assemble 0220A
unit (19) electrohydraulic controller unit
Socket
7 Detach output flange (48) Model 463: The output flange is not Fig. 20
designed as a three-arm flange but as a
cylindrical flange
8 Press out radial sealing ring (20)
9 Remove shim (67a) As of transmission no. 1658778.
10 Remove circlip (68)
AR27.50-P-
Remove deep-groove ball bearing 0601-01A
11
(67) from transmission housing Puller Fig. 21
Clamping pliers Fig. 23
12 Remove shim (18)
Unscrew internal Torx bolts (1a, 2a)
13 from converter housing and Torx insert for Torx bolts
transmission housing
Continued operations according to
findings:? AR27.50-P-
Take transmission housing (2) off Remove/install multi-disc clutch K1, K2 0621A
14 and K3
torque converter housing (1)
Remove/install multi-disk brake B2, disk AR27.50-P-
pack B3 and park pawl gear 0781A
Assemble
Insert both Teflon rings (12a) in the
15 groove with grease so that the joint
stays together
Mount transmission housing (2) on Align discs of multiple-disc brakes B2
16
converter housing (1) and B3
*BA27.40-P-
17 Screw in internal Torx bolts (1a, 2a)
1002-01A
Only necessary when installing new AR27.50-P-
parts, e.g. gear set, output shaft etc. 0600-06A
Measure end play between park pawl
18 Steel straightedge Fig. 24
gear and grooved ball bearing
*BE27.50-P-
1004-01A
19 Install shim (18)
Install grooved ball bearing in rear AR27.50-P-
20
transmission housing 0600-05A
21 Insert shim (67a) As of transmission no. 1658778.
Additional shim between grooved ball BT27.10-P-
Transmission 722.6
bearing and output flange 0005-01A
Drive radial seal (20) into
22 Drift Fig. 19
transmission housing
AR27.50-P-
0600-04B
23 Install output flange (48) Socket Fig. 20
*BA27.50-P-
1001-01A
Install and tighten electrohydraulic *BA27.19-P-
24
controller unit (19) 1001-01A
25 Install oil filter (5)
26 Insert magnet (69) in oil pan Vehicles as of 04/2001.
Clean abrasion particles from magnet. BT27.40-P-
Magnet in oil pan, newly included 0003-01A
*BA27.10-P-
27 Mount oil pan (3)
1002-03A
Insert guide bush (21) in transmission
28
housing and tighten
TEST VALUES FOR GEAR SET
Number Designation Transmission 722.6
BE27.50-P-1004-01A End play between park mm 0.3...0.5
pawl gear and grooved
ball bearing
HOUSING
Transmission 722.6 except
Number Designation 722.660/661/662/663/666/673/674
BA27.40-P-1002- Bolt, transmission Nm 20
01A housing to
converter housing
OIL PAN, AUTOMATIC TRANSMISSION
Transmission 722.6
Number Designation except 722.628/648/649
BA27.10-P-1002-03A Bolt, oil pan to Nm 8
transmission housing
GEAR ASSEMBLY
Number Designation Transmission 722.55/6/9
BA27.50-P-1001-01A Collar nut, output flange Nm 200
to output shaft
ELECTROHYDRAULIC CONTROLLER UNIT
Number Designation Transmission 722.6
BA27.19-P-1001- Bolt, electrohydraulic Stage 1 Nm 8
01A controller unit to Stage 2 Angle° -
transmission housing Stage 3 Angle° -
Fig. 18: Identifying Assembly Stand (116 589 06 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 19: Identifying Drift (140 589 12 15 00)
Courtesy of MERCEDES-BENZ USA
Fig. 20: Identifying Wrench Socket (126 589 02 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 21: Identifying Puller (001 589 50 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 22: Identifying Support Plate (140 589 34 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 23: Identifying Chuck (140 589 06 34 00)
Courtesy of MERCEDES-BENZ USA
Fig. 24: Identifying Parallel Support (126 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
DETACH/ATTACH TRANSMISSION HOUSING ON TORQUE CONVERTER HOUSING. - AR27.50-
P-0601W
TRANSMISSION 722.9
Fig. 25: Identifying Transmission Housing Detach/Attach Components
Courtesy of MERCEDES-BENZ USA
Disassemble/assemble
General
information:
Absolute cleanliness is
required at all times
when performing the
work. No fluffy
cleaning cloths may be
used. Chamois leathers
are the most suitable.
1 Fasten transmission on assembly AR27.10-P-0600-
stand 01W
Fig. 26
Fig. 27
2 Drain transmission oil and detach AR27.10-P-7030W
oil pan (3)
3 Remove oil filter (34) Installation: Install
new sealing ring.
4 Remove electrohydraulic AR27.19-P-0200W
controller unit (4)
5 Detach output flange (20) Installation: Replace AR27.50-P-0620-
the collar nut. 02W
Fig. 28
Fig. 29
Fig. 30
*BA27.50-P-1001-
01A
6 Remove radial sealing ring (1r) Do not damage seat
of radial sealing ring
(1r).
Installation: Using
drift hammer new
radial sealing ring (1r)
into the rear cover
until the drift abuts the
rear cover.
Fig. 33
7 Remove grooved ball bearing (1l) AR27.50-P-0601-01A
Fig. 32
Fig. 31
Installation: Check AR27.50-P-0600-05A
the play and insert the
retaining ring.
8 Remove shim between grooved Installation: Measure
ball bearing (1l) and park pawl and adjust the axial
gear play between the park
pawl gear and grooved
ball bearing (1l):
?
Measure axial play
between the park pawl
gear and grooved ball
bearing (1l):
Transmission 722.9 AR27.50-P-0600-06A
except 722.96
Transmission 722.96 AR27.50-P-0600-
Digital vernier caliper 06SYZ
Measuring tool / scales
Fig. 34
End play between park *BE27.50-P-1004-
pawl gear and grooved 01A
ball bearing
Cleaner from package *BR00.45-Z-1028-
04A
Loctite 7063 cleaning *BR00.45-Z-1046-
spray (150 ml) 04A
Loctite 7200 *BR00.45-Z-1038-
04A
9 Detach rear engine mount bearing Installation: Install
bracket (1h) new bolts.
*BA27.40-P-1018-
01A
10 Attach support plate (P1) and Fig. 35
valve lifter (H) to pry off
transmission housing (1) Fig. 36
11 Remove internal Torx bolts (11w, Position the
12w) transmission so that it
is vertical with the
torque converter
housing (1w) facing
downward. Otherwise
the transmission
housing (1) falls down
after removing the last
internal Torx bolt
(11w, 12w).
Installation: Replace
the internal Torx bolts
(11w, 12w).
*BA27.40-P-1015-
01A
12 Detach transmission housing (1) Installation:
from bell housing (1w) with the Carefully mount the
aid of the valve lifter (H) transmission housing
(1). The lamella of the
clutch pack BR (5) and
multidisk brake B2 (6)
break off easily.
Installation: The
transmission housing
(1) must lie
completely flush
(without gaps) against
the seal (1d) on the
torque converter
housing (1w) (arrow).
Never tighten the
transmission housing
(1) against the torque
converter housing
(1w) using the internal
Torx bolts (11w, 12w).
Otherwise the lamella
of the clutch pack BR
(5) and multidisk
brake B2 (6) break off
Installation: Align the
disks in the
transmission housing
(1). Push the output
flange (20) onto the
output shaft (24).
Quickly turn the
output shaft (24) and
simultaneously lift the
transmission housing
(1) so that the
transmission housing
(1) gradually slips at
the seal (1d) of the
torque converter
housing (1w).
13 Assemble in the reverse order
TEST SPECIFICATIONS FOR GEAR SET
Number Designation
722.9
BE27.50-P-1004- End play between park pawl gear and grooved ball
mm 0.20...0.40
01A bearing
GEAR ASSEMBLY
Number Designation Transmission 722.55/6/9
BA27.50-P-1001-01A Collar nut, output flange to output shaft Nm 200
HOUSING
Transmission
Number Designation
722.9
Stage
Nm 10
BA27.40-P-1015- 1
Bolt, transmission housing to converter housing
01A Stage
Angle° 90
2
Stage
Nm 10
BA27.40-P-1018- Bolt, bracket for rear engine mount to 1
01A transmission Stage
Angle° 90
2
Fig. 26: Identifying Assembly Stand (116 589 06 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 27: Identifying Support Plate (140 589 34 63 00)
Fig. 28: Identifying Wrench Socket (126 589 02 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 29: Identifying Pin Wrench (129 589 01 07 00)
Courtesy of MERCEDES-BENZ USA
Fig. 30: Identifying Two-Armed Puller (000 589 88 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 31: Identifying Chuck (140 589 06 34 00)
Courtesy of MERCEDES-BENZ USA
Fig. 32: Identifying Puller (001 589 50 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 33: Identifying Drift (140 589 12 15 00)
Courtesy of MERCEDES-BENZ USA
Fig. 34: Identifying Parallel Support (126 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
Fig. 35: Identifying Support Plate (722 589 00 31 00)
Courtesy of MERCEDES-BENZ USA
Fig. 36: Identifying Valve Lifter (442 589 00 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1028-04A Cleaner from package
BR00.45-Z-1038-04A Loctite 7200
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
REMOVE/INSTALL MAIN COMPONENTS OF TRANSMISSION - AR27.50-P-0610W
TRANSMISSION 722.9
Fig. 37: Identifying Transmission Remove/Install Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Reference changed from "Disassemble electrohydraulic controller unit" to "Remove Step
1.7.03
electrohydraulic controller unit". 1
Remove/install
Pay attention to cleanliness during all operations. No
General information fluffy cleaning cloths may be used. Chamois leathers
are the most suitable.
Remove electrohydraulic AR27.19-
1
controller unit (4) P-0200W
Detach transmission
AR27.50-
2 housing (1) from torque
P-0601W
converter housing (1w)
Remove housing The housing components (55) are the disk pack BR, AR27.50-
3
components (55) multidisk brake B2 and parking lock gear. P-0782W
The output unit (44) consists of the multidisk clutch AR27.50-
4 Remove output unit (44) K3, rear hollow shaft, rear planet carrier, output shaft P-0611W
The drive unit (33) consists of the drive shaft, AR27.50-
5 Remove drive unit (33) multidisk clutch K2, front planet carrier, internal plate P-0612W
carrier, multidisk clutch K1 and multidisk brake B3.
except transmission 722.93
Transmission 722.93: Do not detach the external
Remove multi-disk brake AR27.50-
6 plate carrier of multidisk brake B1 (16) from the torque
B1 (16) P-0721W
converter housing (1w). The components would
otherwise be damaged irreparably when assembled.
7 Remove oil pump
8 Install in the reverse order
REMOVE/INSTALL K3, REAR HOLLOW SHAFT, REAR PLANET CARRIER AND OUTPUT
SHAFT - AR27.50-P-0611W
TRANSMISSION 722.9
Fig. 38: Identifying Rear Hollow Shaft, Rear Planet Carrier And Output Shaft Remove/Install
Components
Courtesy of MERCEDES-BENZ USA
Fig. 39: Identifying Output Shaft And Multidisk Clutch
Courtesy of MERCEDES-BENZ USA
Remove/install
General information Apply oil to the transmission
components before installation in
order to prevent damage during
the starting phase.
1 Detach transmission AR27.50-P-0601W
housing from torque
converter housing (1w)
2 Detach Torlon rings Installation: Replace the
(2a) from output shaft Torlon rings (2a).
(24) Fig. 40
3 Remove circlip (2b), Installation: Check the axial
shim (2c), axial needleplay between the shim (2c) and
roller bearing (2d) andcirclip (2b): ?
thrust plate (2e) from Check/adjust axial play between AR27.50-P-0810-01A
output shaft (24) shim and circlip
4 Remove multidisk According to condition: ?
clutch K3 (21) Disassemble/assemble multidisk AR27.51-P-0830W
clutch K3 (21).
5 Remove rear hollow According to condition: ?
shaft (22) from output Disassemble/assemble rear AR27.50-P-0851W
shaft hollow shaft (22).
6 Remove output shaft
(24)
7 Detach remaining Installation: Replace the
Torlon rings from Torlon rings.
output shaft (24) Fig. 40
8 Remove circlip and
detach rear ring gear
(25)
9 Install in the reverse
order
Fig. 40: Identifying Sleeve (722 589 00 14 00)
Courtesy of MERCEDES-BENZ USA
REMOVING/INSTALLING DRIVE SHAFT WITH K2, FRONT PLANET CARRIER, INTERNAL
PLATE CARRIER WITH K1 AND B3 - AR27.50-P-0612W
TRANSMISSION 722.9
Fig. 41: Identifying Drive Shaft With K2, Front Planet Carrier, Internal Plate Carrier
Removing/Installing Components
Courtesy of MERCEDES-BENZ USA
Remove/Install
General note Lubricate transmission
components before
installing in order to
prevent damage during
starting phase.
1 Remove output unit Output unit consists of AR27.50-P-0611W
multi-disk clutch K3, rear
hollow shaft, rear planet
carrier, output shaft and
rear ring gear.
2 Remove drive shaft (11) According to findings ?
Disassemble and AR27.51-P-0820W
assemble multi-disk
clutch K2
3 Detach Torlon rings (1a) Installation: Install
from drive shaft (11) new Torlon rings (1a)
Fig. 42
4 Remove cylinder flange
together with front planet
carrier (12)
5 Remove internal plate
carrier (13)
6 Remove multi-disk brake Installation: Align
B3 (15) holes (arrows) of multi-
disk brake B3 (15)
precisely with multi-disk
brake B1 (16)
According to findings ?
B3 Disassemble and AR27.50-P-0890W
assemble multi-disk
brake (15)
7 Remove multi-disk clutch According to findings ?
K1 (14) Disassemble and AR27.51-P-0800W
assemble multi-disk
clutch K1 (14)
8 Install in the reverse order
Fig. 42: Identifying Sleeve (722 589 01 14 00)
Courtesy of MERCEDES-BENZ USA
OUTPUT FLANGE REMOVAL AND INSTALLATION - AR27.50-P-0620-02W
TRANSMISSION 722.6/9, 724.2
GEAR ASSEMBLY
Number Designation Transmission 722.55/6/9
BA27.50-P-1001-01A Collar nut, output flange to output shaft Nm 200
Fig. 43: Identifying Socket Wrench Bit (126 589 02 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 44: Identifying Pin Wrench (129 589 01 07 00)
Courtesy of MERCEDES-BENZ USA
Fig. 45: Identifying Two-Legged Puller (000 589 88 33 00)
Courtesy of MERCEDES-BENZ USA
Remove output flange
1. Counter-hold output flange (1) with pin wrench (07).
2. Unscrew twelve-point nut (2) from output shaft (3) using socket wrench bit (3).
Fig. 46: Identifying Twelve-Point Nut And Output Shaft
Courtesy of MERCEDES-BENZ USA
3. Remove output flange (1).
If output flange (1) is firmly attached use two-arm puller (08).
Install output flange
4. Push output flange (1) onto output shaft (3).
5. Counterhold output flange (1) using pin wrench (07) and tighten twelve-point nut (2) using
socket wrench bit.
Replace twelve-point nut (2).
Fig. 47: Installing Output Flange
Courtesy of MERCEDES-BENZ USA
6. Secure twelve-point nut (2) in duplicate; to do this, hammer collar into the two grooves (arrow) of the
output shaft (3) using a drift punch.
Fig. 48: Identifying Twelve-Point Nut And Output Shaft
Courtesy of MERCEDES-BENZ USA
REMOVING AND INSTALLING MULTIPLE-DISC CLUTCHES K1, K2 AND K3 - AR27.50-P-0621A
TRANSMISSION 722.6
Fig. 49: Identifying Multiple-Disc Clutches Remove/Install Components (K1, K2 And K3)
Courtesy of MERCEDES-BENZ USA
Dismantling
1 Remove transmission AR27.50-P-0601A
housing from converter
housing
2 Remove output shaft with According to
center and rear gear set findings ?
and clutch K3 (12) Dismantle and assemble AR27.50-P-0810A
output shaft with center
and rear gear set and K3
Dismantle and assemble AR27.51-P-0830A
clutch K3
3 Remove thrust needle
bearing (13) and thrust
washer (13a)
4 Remove drive shaft with According to
clutch K2 and front gear findings ?
set (58)
Dismantle and assemble AR27.51-P-0825A
drive shaft with clutch K2
and front gear set
5 Remove clutch K1 (83) According to
findings ?
Remove, install multiple- AR27.50-P-0721A
disc brake B1 and oil
pump
Dismantle and assemble AR27.51-P-0800B
clutch K1
Assembly
6 Using grease, insert *BR00.45-Z-1007-06A
Teflon rings in the
multiple-disc brake B1 in
the groove so that the
joint remains together
7 Mount clutch K1 (83)
8 Using grease, insert
Teflon rings (58a) in the
groove so that the joint
remains together
9 Install drive shaft with
clutch K2 and front gear
set (58)
10 Install front washer (13a)
and thrust needle bearing
(13)
11 Install output shaft with
center and rear gear set
and clutch K3 (12)
12 Install transmission AR27.50-P-0601A
housing on converter
housing
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1007-06A Anticorrosion grease/DB supply specification 6834.00 A 001 989 37 51
DISMANTLING AND ASSEMBLING OIL PUMP - AR27.50-P-0720-01A
TRANSMISSION 722.6
1. Remove pump gears (22 and 23) from pump housing
2. Check radial seal ring (24), replace if necessary
3. Replace O-ring (25)
4. Lubricate pump gears and place in the pump housing. Insert pump gear (22) so that the chamfer (arrow)
points towards the pump housing.
Use ATF oil
Fig. 50: Identifying Pump Gear From Pump Housing Removal
Courtesy of MERCEDES-BENZ USA
Fig. 51: Identifying Radial Seal Ring And O-Ring
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL MULTI-DISK BRAKE B1 AND OIL PUMP - AR27.50-P-0721A
TRANSMISSION 722.6
Fig. 52: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 53: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Figure modified from 8 Nm Value modified in BA27.40-P-1004-01A for *BA27.40-P-1004-
2.8.00
to 10 Nm transmission 722.6 01A
Dismantle
1 Remove multi-disk clutch AR27.50-P-0621A
K1, K2 and K3
2 Unscrew Torx socket Removal:
bolts (7a) and remove oil Screw two opposed bolts
pump (7) into the oil pump housing
and press the oil pump
out of the converter
housing by applying light
blows with a plastic
hammer.
According to
findings ?
Dismantle and assemble AR27.50-P-0720-01A
oil pump
3 Unscrew Torx socket Removal:
bolts (6a) and remove Screw two opposed bolts
multi-disk brake B1 (6) into the multi-disk brake
from converter housing B1 and separate from the
converter housing by
applying light blows with
a plastic hammer.
According to
findings ?
Dismantle and assemble AR27.50-P-0870A
multi-disk brake B1
4 Detach intermediate Use a suitable tool for
panel (8) from converter loosening
housing (1) Additional work ?
Remove/install multi-disk AR27.50-P-0781A
brake B2, multi-disk pack
B3 and park pawl gear
Assembling
5 Place intermediate panel The intermediate
(8) on converter housing panel can generally be
(1) and align used several times. The
panel must not be coated
with sealant
6 Securely tighten multi- Installed position of
disk brake B1 (6) on multi-disk brake B1 in
converter housing (1) relation to converter
housing is specified by a
plain dowel pin in the
multi-disk brake B1
(arrow).
*BA27.40-P-1004-01A
7 Install oil pump (7) and *BA27.40-P-1003-01A
securely tighten
8 Install multi-disk clutch AR27.50-P-0621A
K1, K2 and K3
HOUSING
Transmission 722.6 except
Number Designation
722.660/661/662/663/666/673/674
BA27.40-P- Bolt, oil pump with multi-disk brake
Nm 20
1003-01A B1 to torque converter housing
BA27.40-P- Bolt, multi-disk brake B1 to
Nm 10
1004-01A converter housing
REMOVE/INSTALL MULTI-DISK BRAKE B1 AND OIL PUMP - AR27.50-P-0721W
TRANSMISSION 722.9 /9 (except 722.93)
Fig. 54: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 55: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Removing
General information Apply oil to the transmission
components before installation in
order to prevent damage during
the starting phase.
1 Remove drive unit The drive unit consists of the AR27.50-P-0612W
drive shaft, multidisk clutch K2,
front planet carrier, internal plate
carrier, multidisk clutch K1 and
multidisk brake B3.
2 Unscrew bolts (17a) Screw two opposing bolts
and remove oil pump (17a) into the housing (17g) and
(17) loosen the oil pump (17) by
applying gentle blows using a
plastic mallet.
The impellers (17r, 17z) lie
loose in the housing (17g).
3 Unscrew bolts (16a) Loosen the multidisk brake
and remove multidisk (16) by applying gentle blows
brake (16) using a plastic mallet.
According to condition: ?
Disassemble/assemble multidisk AR27.50-P-0870W
brake (16).
4 Remove gasket (1d)
Install
5 Place gasket (1d) on The gasket (1d) can normally
torque converter be reused several times. The
housing (1w) and align gasket (1d) must not exhibit any
scratches and must not be coated
with sealant.
6 Attach multidisk brake The installation position is
(16) to torque predetermined by a dowel pin on
converter housing (1w) the multidisk brake (16).
*BA27.40-P-1004-
01A
7 Attach oil pump (17) Replace the radial sealing ring
and O-ring (17o).
Insert the impeller (17r) in
such a way that the chamfer
(arrow) points toward the housing
(17g).
*BA27.40-P-1003-
01A
8 Install drive unit AR27.50-P-0612W
HOUSING
Transmission
Number Designation
722.9
BA27.40-P-1003- Bolt, oil pump with multi-disk brake B1 to torque converter
Nm 20
01A housing
BA27.40-P-1004-
Bolt, multi-disk brake B1 to converter housing Nm 11
01A
REMOVE/INSTALL MULTI-DISK BRAKE B1 AND OIL PUMP - AR27.50-P-0721WMG
TRANSMISSION 722.93
Fig. 56: Identifying Multi-Disk Brake B1 And Oil Pump Remove/Install Components
Courtesy of MERCEDES-BENZ USA
Removing
General information Apply oil to the
transmission components
before installation in
order to prevent damage
during the starting phase.
1 Remove drive unit The drive unit consists AR27.50-P-0612W
of the drive shaft,
multidisk clutch K2, front
planet carrier, internal
plate carrier, multidisk
clutch K1 and multidisk
brake B3.
2 Unscrew bolts (17a) and Partially unscrew two
remove oil pump (17) opposing bolts (17a) and
remove the oil pump
from the torque converter
housing (1w) by applying
gentle blows using a
plastic mallet.
The impellers (17r,
17z) lie loose in the oil
pump housing.
3 Disassemble multidisk If necessary. AR27.50-P-0870W
brake B1 Do not detach the
external plate carrier
(16a) of multidisk brake
B1 from the torque
converter housing (1w).
The external plate carrier
(16a) and torque
converter housing (1w)
would otherwise be
damaged irreparably
when assembled.
The torque converter
housing (1w), external
plate carrier (16a) and
gasket (1d) form a single
unit and must always be
replaced together.
Checking
4 Check gasket (1d) If undamaged, the
gasket (1d) can be reused
several times.
The gasket (1d) must not
exhibit any scratches or
any other damage; do not
apply sealant to the
gasket.
The torque converter
housing (1w), external
plate carrier (16a) and
gasket (1d) form a single
unit and must always be
replaced together.
Install
5 Install oil pump (17) Replace the radial
sealing ring and O-ring
(17o).
Insert the impeller
(17r) in such a way that
the chamfer (arrow)
points toward the oil
pump (17).
*BA27.40-P-1003-01A
6 Install drive unit AR27.50-P-0612W
HOUSING
Transmission
Number Designation
722.9
BA27.40-P-1003- Bolt, oil pump with multi-disk brake B1 to torque converter
Nm 20
01A housing
INSERTING AND MEASURING MULTIPLE-DISC PACK B3 - AR27.50-P-0780-11A
TRANSMISSION 722.6
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Number Designation Transmission 722.6
BE27.50-P-1003- Play in multiple- - mm 1.0...1.4
02B discbrake B3
Fig. 57: Identifying Different Toothed Gear Thickness
Courtesy of MERCEDES-BENZ USA
Place new friction plates in ATF fluid 1 hour before installation.
1. Assemble lamella for the multi-disk brake B3 in the sequence shown in the picture and insert
individually.
2. Using a feeler gage, measure the clearance "L" at three points between the snap ring (133a) and externally
toothed plate (133c).
For the measuring procedure the snap ring (133a) must abut the upper contact surface of the groove in
the external plate carrier.
3. with snap ring (133a), adjust if necessary.
Snap rings are available in thicknesses of 3.2, 3.5, 3.8, 4.1, 4.4 and 4.7 mm
Fig. 58: Measuring Clearance L At Three Points Between Snap Ring And Externally Toothed Plate
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL MULTI-DISK BRAKE B2, DISK PACK B3 AND PARK PAWL GEAR - AR27.50-
P-0781A
TRANSMISSION 722.6
Fig. 59: Identifying Multi-Disk Brake B2, Disk Pack B3 And Park Pawl Gear Remove/Install
Components
Courtesy of MERCEDES-BENZ USA
Removing
housing (2) from torque
converter housing.
Transmission housing WF58.50-P-2750-03A
bracket
This bracket should
only be used if the torque
converter housing with
gear sets is detached from
the transmission housing
(2).
Disassemble
2 Take out disk pack B3 To facilitate removal
(133) and disk spring of the snap ring (133a),
(133b), to do so, remove squeeze the disk pack B3
snap ring (133a) in (133) together slightly.
transmission housing (2) Check multi-disks for
scorch marks and wear.
3 Unscrew internal Torx
bolts (11)
4 Take multidisk brake B2 The external plate
(14) out of transmission carrier for the multidisk
housing (2) brake B2 (14) also serves
as the piston for the disk
pack B3 (133). According
to condition: ?
Disassembling and AR27.50-P-0880A
assembling multi-disk
brake B2.
5 Remove park pawl gear
(15)
Assemble
6 Insert park pawl gear (15)
7 Insert multidisk brake B2
(14) into transmission
housing (2)
8 Screw in internal Torx *BA27.40-P-1005-01A
bolts (11)
9 Insert disk spring (133b) Pay attention to AR27.50-P-0780-11A
and disk pack B3 (133) sequence of disks.
and measure
Play in multiple-disc *BE27.50-P-1003-02B
brake B3
Survey of multi-disk GF27.51-P-5200A
components, production
10 Attach snap ring (133a)
Install
11 Install transmission AR27.50-P-0601A
housing (2) at torque
converter housing.
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Number Designation Transmission 722.6
BE27.50-P-1003-02B Play in multiple-disc brake B3 - mm 1.0...1.4
HOUSING
Transmission 722.6 except Transmission
Number Designation
722.660/661/662/663/666/673/674 722.660/661/662/663/666/673/674
Bolt, multi- Stage
BA27.40- disk brake 1 Nm 16 16
P-1005- B2 to
01A transmission Stage Angle° --
housing 2
REMOVE/INSTALL CLUTCH PACK BR, MULTIDISK BRAKE B2 AND PARK PAWL GEAR -
AR27.50-P-0782W
TRANSMISSION 722.9
Fig. 60: Identifying Clutch Pack BR, Multidisk Brake B2 And Park Pawl Gear Remove/Install
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
4.12.07 Reference to modified end disk inserted Step 3 BT27.50-P-0015-01W
Remove/install
1 Detach transmission AR27.50-P-0601W
housing (1) from torque
converter housing
2 Remove circlip (5s); to do The thickness of the
this, compress clutch pack circlip (5s) determines
BR (5) the clearance.
Installation: Measure AR27.51-P-7229-01W
and adjust clearance of
the multidisk brake BR.
Clearance of multi-disk *BE27.50-P-1004-02C
brake BR
3 Remove clutch pack BR Check disks for
(5) scorch marks and wear.
Installation: Observe
lamella sequence: ?
Survey of multi-disk GF27.51-P-5200W
components, production
details
End disk modified BT27.50-P-0015-01W
4 Remove disk spring (5t) Installation: Insert
disk spring (5t) so that
the curvature of the inner
circumference points in
the direction of the
multidisk brake B2 (6).
5 Remove multidisk brake Installation: The
B2 (6); to do this, remove external plate carrier of
bolts (6s) the multidisk brake B2
(6) is simultaneously the
piston of the clutch pack
BR (5) and must not tilt
over. Before tightening
the bolts (6s) press the
external plate carrier
from inside against the
park pawl gear (7).
Installation: Replace
bolts (6s).
*BA27.40-P-1005-01A
According to condition: ?
Disassembling and AR27.50-P-0880W
assembling multi-disk
brake B2.
6 Measure and adjust AR27.51-P-7229W
clearance of multi-disk
brake B2 (6).
7 Remove park pawl gear
(7)
8 Install in the reverse order
SET VALUES FOR MULTI-DISK BRAKE
Transmission 722.9 except Transmission
Number Designation
722.93 722.93
BE27.50-P-1004- Clearance of multi-disk
mm 1.00...1.40 1.00...1.40
02C brake BR
HOUSING
Transmission
Number Designation
722.9
Stage
Nm 10
BA27.40-P-1005- Bolt, multi-disk brake B2 to transmission 1
01A housing Stage
Angle° 90
2
CHECKING AND ADJUSTING END PLAY BETWEEN SHIM AND CIRCLIP - AR27.50-P-0810-01A
TRANSMISSION 722.6/9, 724.2
TEST VALUES FOR GEAR SET
Number Designation Transmission 722.6 Transmission 722.9
BE27.50-P-1005-01A Axial play between shim and circlip mm 0.15...0.6 0.15...0.60
1. Using a feeler gage, check axial play "S" between shim (42e) and circlip (42f).
Push multi-disk clutch K3 (44) hard by hand in direction of arrow.
2. Remove shim (42e) and measure thickness.
3. Adjust play with shim (42e).
Shims (42e) are available in thicknesses 3.1 to 3.7 mm. They are available in graduations of 0.3 mm.
Fig. 61: Checking Axial Play "S" Between Shim And Circlip
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE OUTPUT SHAFT WITH CENTER AND REAR GEAR SET - AR27.50-P-
0810A
TRANSMISSION 722.6
Fig. 62: Identifying Output Shaft With Center And Rear Gear Set Disassemble/Assemble Components
Courtesy of MERCEDES-BENZ USA
Disassemble
Remove transmission housing from torque AR27.50-P-
1
converter housing 0601A
AR27.50-P-
2 Remove multidisk clutch K1, K2 and K3
0621A
Remove top two visible teflon rings (42b) from
3
output shaft
Remove retaining ring (42f), shim (42e), axial
4 needle roller bearing (42d) and thrust plate
(42c) from output shaft
According to condition:?
5 Remove clutch K3 (44) AR27.51-P-
Disassemble/assemble K3 clutch
0830A
According to condition:?
Remove rear hollow shaft (45) from output
6 Disassemble/assemble rear AR27.50-P-
shaft
hollow shaft 0850A
Remove rear gear set (43) with integrated ring
7
gear of center gear set from output shaft
Changeover from 18° to 23° toothing in the BT27.50-P-
Transmission 722.6
front and rear planetary gear set 0012-01A
8 Remove thrust plate (43a)
Remove/install multi-disk brake B1 and oil AR27.50-P-
9
pump 0721A
Assemble
Put on thrust plate (43a) with the collar
10
pointing toward the planet carrier
Connect rear gear set (43) with integrated ring
11
gear of center gear set to output shaft
Insert bottom three teflon rings (42) in the
*BR00.45-Z-
12 groove with grease so that the joint remains
1007-06A
together
Check O-rings on hollow
13 Connect rear hollow shaft (45) to output shaft
shaft, replace if necessary.
14 Install clutch K3 (44)
Mount retaining ring, shim, axial needle roller
15
bearing and thrust plate (42c-42f)
Insert top two teflon rings (42) in the groove
16
with grease so that the joint remains together
AR27.50-P-
17 0810-01A
retaining ring (42f) *BE27.50-P-
1005-01A
AR27.50-P-
18 Install multidisk clutch K1, K2 and K3
0621A
TEST VALUES FOR GEAR SET
Number Designation Transmission 722.6
BE27.50-P-1005-01A Axial play between shim mm 0.15 to 0.6
and circlip
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1007-06A Anticorrosion grease/DB supply specification 6834.00 A 001 989 37 51
DISASSEMBLING AND ASSEMBLING REAR HOLLOW SHAFT WITH REAR FREEWHEEL -
AR27.50-P-0850A
TRANSMISSION 722.6
Fig. 63: Identifying Disassembled Rear Hollow Shaft With Rear Freewheel
Courtesy of MERCEDES-BENZ USA
Disassemble/assemble
Detach transmission housing from torque AR27.50-P-
1
converter housing 0601A
Remove multi-disk clutch K1, K2 and AR27.50-P-
2
K3 0621A
Installation: Check that circlip is
correctly seated.
Remove circlip (45h), shim (45g), axle Check O-rings (45b), replace if
3 needle roller bearing (45f) from hollow necessary.
shaft (45a). If using BT27.50-P-0011-01A,
axial needle roller bearing and shim
are no longer required.
Remove rear sun gear (45e) with Installation: Install hollow shaft
4 internally toothed disk carrier / K3 and (45a) on freewheel and press in while
rear freewheel (45d). turning counterclockwise
Friction bearing in sun gear of rear
BT27.50-P-
planetary gearset converted to anti- Transmission 722.6
0011-01A
friction bearing
5 Remove snap ring (45c) for freewheel
Installation: The thrust plate of the
6 Press freewheel out of sun gear. freewheel (45d) must face the snap
ring (45c).
7 Assemble in reverse order
DISMANTLE AND ASSEMBLE REAR TUBULAR SHAFT - AR27.50-P-0851W
TRANSMISSION 722.9
Fig. 64: Identifying Exploded View Of Rear Tubular Shaft
Courtesy of MERCEDES-BENZ USA
Disassemble/assemble
Installation: The needles of the axial needle roller
Remove circlip (22c), shim (22b) and
1 bearing (22a) must point towards the shim (22b).
axial needle roller bearing (22a)
Check circlip (22c) for correct seating.
Detach sun gear (22s) from hollow
2 Installation: Replace O-rings (22d).
shaft (22w)
3 Remove bearing (22l)
4 Assemble in reverse order
INSERTING AND MEASURING MULTI-DISK PACK B1 - AR27.50-P-0870-01A
TRANSMISSION 722.6## ## up to 3947339 up to 1.9.02
Thickness steel multi-disks B1, K1 and K2 changed BT27.51-P-0002-01A
MODIFICATION NOTES
25.8.98 New special tool for setting clearance Point 2 and 3 added
30.3.99 New values for clearance of multi-disk brake
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission 722.6
up to 01.09.02 with
double sided multi-
Number Designation disks
BE27.50-P- Play in multi- Number of 2 mm 2.30...2.70
1001-02B disk brake multi-disks B1 3 mm 2.70...3.10
4 mm 3.00...3.40
Fig. 65: Identifying Pressing Tool (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 66: Identifying Sequence Of Disks For Multi-Disk Brake B1
Courtesy of MERCEDES-BENZ USA
Soak new friction multi-disks in automatic transmission fluid for 1 hour before installation.
1. Assemble the disks for multi-disk brake B1 in the sequence shown in the diagram and insert one at a time.
2. Place pressing tool (078) on externally toothed plate (70c).
3. Press together multi-disk pack by pressing together pressing tool as far as stop using a lever press (the
marking ring can then still be seen, refer to small arrow).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (6h) and the
externally toothed plate (70c).
During the measuring procedure, the snap ring (6h) must touch the upper contact surface of the groove
in the external plate carrier.
5. Adjust clearance if necessary using appropriate snap ring (6h).
Snap rings are available in thicknesses of 2.6, 2.9, 3.2, 3.5, 3.8 and 4.1 mm.
Fig. 67: Identifying Pressing Tool And Multi-Disk Pack
Courtesy of MERCEDES-BENZ USA
INSERTING AND MEASURING MULTIPLE-DISC PACK B1 - AR27.50-P-0870-01AA
TRANSMISSION 722.6## ## as of 3947440 as of 2.9.02
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission 722.6
as of 02.09.02 with
single-sided
Number Designation multiple-discs
BE27.50-P- Play in Number of 2 mm 2.20...2.60
1001-02B multiple-disc multiple-discs 3 mm 2.40...2.80
brake B1 4 mm 2, 60...3, 00
Fig. 68: Identifying Thrust Device (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
1. Assemble the new disks for the multi-disk brake B1 in the sequence shown and dismantle individually.
Insert the new disks in ATF oil before installation for 1 h.
Fig. 69: Identifying Externally And Internally Toothed Plates, External Plate Carrier And End
Disk
Courtesy of MERCEDES-BENZ USA
2. Mount pressure device (078) onto end disk (70c).
3. Compress the disk pack, to do so press the pressure device (078) together using a lever press up to
stop.
The marking ring (smaller arrow) is then still visible.
4. Use a feeler gauge to measure the clearance (L) at three points between the snap ring (6h) and end disk
(70c).
During the measuring procedure, the snap ring (6h) must lie against the upper contact surface of the
groove in the external plate carrier (6b).
5. Use corresponding snap ring (6h) to adjust clearance (L) if necessary.
The snap rings (6h) are available at sizes 2.6 mm, 2.9 mm, 3.2 mm, 3.5 mm, 3.8 mm and 4.1 mm.
Fig. 70: Compressing Disk Pack
Courtesy of MERCEDES-BENZ USA
DISMANTLING AND ASSEMBLING MULTI-DISK BRAKE B1 - AR27.50-P-0870A
TRANSMISSION 722.6
Fig. 71: Identifying Disassembled View Of Multi-Disk Brake B1
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
New special tool for setting AR27.50-P-0870-
25.8.98
clearance 01A
Multi-disks for B1, K1 and K3 Transmission 722.6 as of 02.09.02, refer to BT27.50-P-0013-
16.9.02
changed step 10. 01A
Dismantling
1 Remove snap ring (6h)
2 Remove multi-disk pack Check multi-disks for
(6g) and spring washer scorch marks and wear.
(6f) from external plate
carrier
3 Place assembly device Assembly device Fig. 72
(073) on spring washer
(6d) and tension until the
snap ring (6e) is exposed
4 Remove snap ring (6e)
5 Remove piston (6c) from
the external plate carrier
by carefully blowing
compressed air into the
bore (A).
Assemble
6 Install piston (6c) in Inspect molded
external plate carrier gasket, replace if
necessary.
Press in the piston
with the assistance of the
spring washer (6d) and
the assembly device
(073).
7 Insert spring washer (6d) Insert spring washer
with the curvature
towards the multi-disk
pack.
8 Place assembly device Assembly device Fig. 72
(073) on spring washer
(6d) and tension until the
groove of the snap ring is
exposed
9 Insert snap ring (6e) The collar of the snap
ring must point towards
the multi-disk pack.
After installing, check
snap ring for correct seat
10 Insert spring washer (6f) Observe outer multi-
and multi-disk pack (6g) disk sequence Inserting
in the external plate and measuring multi-disk
carrier and measure pack B1:?
Transmission 722.6 up to AR27.50-P-0870-01A
01.09.02
Pressing tool Fig. 73
Clearance of multi-disk *BE27.50-P-1001-02B
brake B1
Transmission 722.6 as of AR27.50-P-0870-01AA
02.09.02
Pressing tool Fig. 73
Clearance of multi-disk *BE27.50-P-1001-02B
brake B1
Thickness of steel multi- Transmission 722.6 BT27.51-P-0002-01A
disks B1, K1 and K2
changed
External plate carrier B1 Transmission 722.6 BT27.50-P-0008-01A
modified
Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02
Survey of multi-disk Transmission 722.6 GF27.51-P-5200A
components, production
details
11 Insert snap ring (6h) For additional work,
see:?
Remove/install multi-disk AR27.50-P-0721A
brake B1 and oil pump
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission Transmission
722.6 up to 722.6 as of
01.09.02 with 02.09.02 with
double sided single-sided multi-
Number Designation multi-disks disks
BE27.50-P- Clearance of Number of 2 mm 2.30...2.70 2.20...2.60
1001-02B multi-disk multi-disks 3 mm 2.70...3.10 2.40...2.80
brake B1 4 mm 3.00...3.40 2.60...3.00
Fig. 72: Identifying Assembly Device (140 589 13 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 73: Identifying Pressing Tool (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE MULTI-DISK BRAKE B1 - AR27.50-P-0870W
TRANSMISSION 722.9
Fig. 74: Identifying Multi-Disk Brake Disassemble/Assemble Components
Courtesy of MERCEDES-BENZ USA
Fig. 75: Identifying External Plate Carrier, Circlip And Disk Spring
Courtesy of MERCEDES-BENZ USA
Fig. 76: Identifying External Plate Carrier
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
28.1.08 Check (do not remove) thrust bearing and bearing; repair method changed Step 3
Disassemble
1 Remove bearing (16l) Transmissions up to
manufacture year 12/04
On transmissions as of
manufacture year 01/05,
the bearing (16l) is
permanently seated on
the inside diameter of the
Ravigneaux set and is
removed when the
planetary gear set is
removed.
Checking
2 Check bearing (16l) Check the contact
surface and bearing (16l)
for swirl marks; replace
the bearing (16l) if
necessary.
3 Check thrust bearing Check the contact
(161) and bearing (162) surfaces, thrust bearing
(161), bearing (162) and
sealing rings (see arrow
in picture 1) for swirl
marks and damage;
replace if necessary.
The thrust bearing
(161) and bearing (162)
together with the external
plate carrier (16a) form a
single unit and must
always be replaced
together.
4 Remove circlip (105s)
and end disk (105)
5 Remove clutch pack (5) Check the disks for
and disk spring (5t) scorch marks and wear;
replace if necessary.
6 Place external plate On transmission
carrier (16a) in lever 722.93, the external plate
press carrier (16a) must not be
detached from the torque
converter housing.
Therefore place the
external plate carrier
(16a) together with the
torque converter housing
in the lever press.
7 Place thrust Position the
device on disk spring thrust device precisely
(16t) (see arrow in picture 2) to
enable the circlip (16s) to
be removed later.
Fig. 78
Fig. 77
8 Actuate lever press until Stop lever press stoke
circlip (16s) is exposed as soon as accessibility to
groove is sufficient.
Excessive clamping force
will damage the plate
supports.
9 Remove circlip (16s)
from groove
10 Move back lever press
11 Take thrust device
and external plate carrier
(16a) out of lever press
12 Remove circlip (16s)
13 Remove disk spring (16t)
14 Remove piston (16k) Check the vulcanized-
from external plate on seal; replace the piston
(16k) if necessary.
Checking
15 Check external plate If an external plate
carrier (16a) carrier (16a) without
inner phase (1a) is
installed (see picture 3), a
circlip (16s) with the
following replacement
part number must be used
when installing: 220 994
03 40
If an external plate
carrier (16a) with inner
phase (2a) is installed
(see picture 3), a circlip
(16s) with the following
replacement part number
must be used when
installing: 001 994 18 40
Assemble
16 Install piston (16k)
17 Install disk spring (16t) Insert the disk spring
(16t) in such a way that
the curvature of the inner
circumference points
toward the piston (16k).
18 Fit circlip (16s) Final installation is
only possible when the
lever press is actuated.
19 Place external plate
carrier (16a) in lever
press
20 Place thrust Position the
device on disk spring thrust device precisely
(16t) (see arrow in picture 2) to
enable the circlip (16s) to
be installed.
Fig. 78
Fig. 77
21 Actuate lever press until Stop lever press stoke
groove of circlip (16s) is as soon as accessibility to
exposed groove is sufficient.
Excessive clamping force
will damage the plate
22 Install circlip (16s) Pay attention to the
installation position of
the circlip (16s). If
installed incorrectly, the
disk spring (5t) jams.
23 Move back lever press
24 Take thrust device
and external plate carrier
(16a) out of lever press
25 Install disk spring (5t) Insert the disk spring
and disk pack (5) in (5t) in such a way that the
external plate carrier curvature of the inner
(16a) circumference points
toward the piston (16k).
Observe the insertion
sequence:
See Overview of disk GF27.51-P-5200W
assemblies (as-built
configuration)
26 Install end disk (105) and
circlip (105s)
Measure
27 Measure and adjust AR27.51-P-7229W
clearance
28 Insert bearing (16l) Transmissions up to
manufacture year 12/04
On transmissions as of
manufacture year 01/05,
the bearing (16l) is
mounted when the
planetary gear set is
installed.
Fig. 77: Identifying Set Of Drifts (722 589 04 15 00)
Courtesy of MERCEDES-BENZ USA
Fig. 78: Identifying Thrust Device (722 589 01 31 00)
Courtesy of MERCEDES-BENZ USA
ASSEMBLING PISTON GUIDE AND OUTER MULTIPLE-DISC CARRIER OF MULTIPLE-DISC
BRAKE - AR27.50-P-0880-01A
TRANSMISSION 722.6
Fig. 79: Identifying Outer Multiple-Disc Carrier/B2 Opening
Courtesy of MERCEDES-BENZ USA
1. Insert piston guide (32) in transmission housing (2) and tighten securely.
2. Press in outer multiple-disc carrier/B2 (14a) up to the stop in the piston guide (32).
The recess in the external splines or the opening in the outer multiple-disc carrier/B2 (14a) must point
downwards (arrow).
3. Remove assembled component from transmission housing again for further assembly work.
ASSEMBLING PISTON GUIDE AND EXTERNAL PLATE CARRIER OF MULTI-DISK BRAKE B2 -
AR27.50-P-0880-01W
TRANSMISSION 722.9, 724.2
1. Install piston guide (61b) in transmission housing (1) and secure with bolts (6s).
Push piston guide axially into housing to prevent canting while being secured with bolts.
2. Push external plate carrier (61a) into piston guide (61b) as far as it will go.
Recess in gearing and opening in external plate carrier (61a) must face downwards (arrow).
3. Remove preassembled multi-disk brake from transmission housing (1) again B2 to allow further assembly
operations to be performed.
Fig. 80: Identifying External Plate Carrier And Piston Guide
Courtesy of MERCEDES-BENZ USA
INSERTING AND MEASURING MULTIPLE-DISC PACK B2 - AR27.50-P-0880-02A
TRANSMISSION 722.6
MODIFICATION NOTES
Item 2 and 3 incorporated for the first
25.8.98 New special tool for clearance adjustment
time
New adjustment values for clearance of multi-disk
30.3.99
brake
Fig. 81: Identifying Thrust Device (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Number Designation Transmission 722.6
BE27.50-P- Play in Number of 4 mm 1, 90...2, 30
1002-02B multiple-disc multiple-discs 5 mm 2, 00...2, 40
brake B2 6 mm -
Fig. 82: Identifying Sequence Of Disks For Multi-Disk Brake B2
Courtesy of MERCEDES-BENZ USA
Place new friction plates in ATF fluid 1 hour before installation.
1. Assemble lamella for the multi-disk brake B2 in the sequence shown in the picture an insert individually.
2. Mount the pressure device (078) on the externally toothed plate (134a).
3. Compress the clutch pack; to do this, compress the pressure device as far as the stop using a lever press
(the marking ring is still visible, see small arrow).
4. Using a feeler gage, measure the clearance "L" at three points between the snap ring (144a) and externally
toothed plate (134a).
For the measuring procedure the snap ring (144a) must abut the upper contact surface of the groove in
the external plate carrier.
5. with snap ring (144a), adjust if necessary.
Snap rings are available in thicknesses of 2.9, 3.2, 3.5, 3.8 and 4.1 mm
Fig. 83: Identifying Clutch Pack Compression
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE MULTI-DISK BRAKE B2 - AR27.50-P-0880A
TRANSMISSION 722.6
Fig. 84: Identifying Disassemble/Assemble View Of Multi-Disk Brake B2 (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 85: Identifying Disassemble/Assemble View Of Multi-Disk Brake B2 (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 86: Identifying Assembly Tool And Snap Ring
Courtesy of MERCEDES-BENZ USA
Fig. 87: Identifying Piston B2, Piston Guide Ring And Valve
Courtesy of MERCEDES-BENZ USA
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
4.12.07 Reference to modified end disk inserted Step 16 BT27.50-P-0015-01W
Removing
AR27.50-P-
1 Remove disk pack B2 (134)
0781A
Disassemble
2 Remove snap ring (134a)
The external plate carrier B2 for
the multidisk brake B2 also serves
Remove disk pack B2 (134) and disk spring as the piston B3 for the multidisk
3
(134b) from external plate carrier B2 brake B3.
Check multi-disks for scorch
marks and wear.
Place assembly device (074) on disk spring
4 (29) and tension until groove for snap ring Fig. 89
(31) is exposed (picture C)
5 Remove snap ring (31)
6 Remove spring plate (30) and disk spring (29)
Separate piston guide ring (28) and piston/
multidisk brake B2 (27) from piston B3 (14a);
7
to do so, blow compressed air into hole (D)
(picture E)
Press piston guide ring (28) out of piston B2
8
(27)
BT27.50-P-
Peak-to-valley height on piston B2 changed
0009-01A
BT27.50-P-
Piston B2 modified
0010-01A
Separate piston guide (32) from piston B3
9 (14a); to do so, blow compressed air into hole
(A) (picture E)
Assemble
Assemble piston guide (32) and piston B3 AR27.50-P-
10
(14a) at correct position 0880-01A
Check all seal rings; replace if
necessary
Insert piston/multidisk brake B2 (27) into With seal rings (14c), (28a) and
11 (28b), the rounded edges must face
piston B3 (14a)
outward.
With seal ring (14d), the rounded
B)
The valve (137) in the piston
12 Insert piston guide ring (28) guide ring must be at the top
(picture D).
Insert the disk spring with the
13 Insert disk spring (29) and spring plate (30)
curvature toward the spring plate.
Place assembly device (074) on disk spring
14 (29) and tension until groove for snap ring Fig. 89
(31) is exposed
15 Insert snap ring (31)
Observe externally-toothed AR27.50-P-
Insert disk spring (134b) and disk pack B2 plate sequence. 0880-02A
16 (134) into external plate carrier B2 and *BE27.50-P-
Play in multiple-disc brake B2
measure 1002-02B
Fig. 90
Survey of multi-disk components, production GF27.51-P-
details 5200A
BT27.50-P-
End disk modified
0015-01W
17 Attach snap ring (134a)
Install
AR27.50-P-
18 Install disk pack B2 (134).
0781A
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Number Designation Transmission 722.6
BE27.50-P- Play in Number of 4 mm 1.90...2.30
1002-02B multiple-disc multiple-discs 5 mm 2.00...2.40
brake B2 6 mm -
Fig. 89: Identifying Assembly Tool (140 589 13 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 90: Identifying Thrust Device (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE MULTI-DISK BRAKE B2 - AR27.50-P-0880W
TRANSMISSION 722.9
Fig. 91: Identifying Disassemble/Assemble View Of Multi-Disk Brake B2 (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 92: Identifying Disassemble/Assemble View Of Multi-Disk Brake B2 (2 Of 2)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
10.4.08 Special tool added Steps 5, 15
Removing
1 Remove disk pack B2 (5) AR27.50-P-0782W
Disassemble
2 Remove circlip (105s)
and end disk (105)
3 Remove disk pack B2 Check disks for
(5), externally toothed scorch marks and wear.
plate (105a) and disk
spring (5t)
4 Place assembly Fig. 94
device on disk spring
(61t) and tension until
retaining ring (61s) is
exposed
5 Remove circlip (61s) Fig. 93
6 Remove assembly
device.
7 Remove spring cup (61f)
and disk spring (61t)
8 Remove guide ring (61r) Blow compressed air
and piston (61k); to do in carefully.
into hole (B) of piston
guide (61b)
9 Separate piston guide Blow compressed air
(61b) from external plate in carefully.
carrier B2 (61a); to do so, The external plate
blow compressed air into carrier B2 (61a) also
hole (A) serves as the piston for
the multidisk brake B3.
Assemble
10 Assemble piston guide Replace the sealing AR27.50-P-0880-01W
(61b) and external plate rings (161a, 161b, 161i).
carrier B2 (61a) With sealing rings (161a,
161b), the rounded edges
must face outward.
11 Install piston (61k) Replace the sealing
ring (161k).
The rounded off edges
must point outwards.
12 Insert guide ring (61r) Replace the sealing
ring (161r).
The rounded off edges
must point outwards.
13 Insert disk spring (61t) Insert the disk spring
and spring cup (61f) (61t) with the curvature
toward the spring cup
(61f).
14 Place assembly Fig. 94
device on disk spring
(61t) and tension until
groove for circlip (61s) is
exposed
15 Install circlip (61s) Fig. 93
16 Remove assembly
device.
17 Install disk spring (5t), Insert the disk spring
external plate (105a) and (5t) in such a way that the
disk pack B2 (5) curvature of the inner
circumference points
toward the piston (61k).
Observe the
installation sequence: ?
Survey of multi-disk GF27.51-P-5200W
components, production
details
18 Install end disk (105) and
circlip (105s)
End disk modified BT27.50-P-0015-01W
Measure
19 Measure and adjust AR27.51-P-7229W
clearance
Install
20 Install disk pack B2 (5). AR27.50-P-0782W
Fig. 93: Identifying Pliers (000 589 52 37 00)
Courtesy of MERCEDES-BENZ USA
Fig. 94: Identifying Assembly Tool (140 589 13 43 00)
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE MULTI-DISK BRAKE B3 - AR27.50-P-0890W
TRANSMISSION 722.9
Fig. 95: Identifying Multi-Disk Brake Disassemble/Assemble Components
Courtesy of MERCEDES-BENZ USA
Fig. 96: Identifying External Plate Carrier, Circlip And Disk Spring
Courtesy of MERCEDES-BENZ USA
Fig. 97: Identifying External Plate Carrier
Courtesy of MERCEDES-BENZ USA
Disassemble
1 Remove circlip (105s)
and end disk (105)
2 Remove disk pack (5) Check disks for
and disk spring (5t) scorch marks and wear.
3 Place multidisk brake in
lever press
4 Place clamping device on Position the clamping
disk spring (15t) in device precisely (see
external plate carrier arrow in picture 2) to
(15a) enable later removal of
the circlip (15s).
Fig. 99
Fig. 98
5 Operate lever press until Stop lever press stoke
circlip (15s) is exposed as soon as accessibility to
groove is sufficient.
Excessive clamping
forces will damage the
plate supports.
6 Remove circlip (15s)
from groove
7 Move back lever press
8 Take clamping device
of lever press
9 Remove circlip (15s)
10 Remove disk spring (15t)
11 Remove piston (15k) Check the vulcanized-
from external plate on seal.
carrier (15a)
Checking
12 Check external plate If an external plate
carrier (15a) carrier (15a) without
outer phase (1) is fitted
(see picture 3), a circlip
(15s) with the following
replacement part number
must be used when
installing: 220 994 03 40
If an external plate
carrier (15a) with outer
phase (2) is fitted (see
picture 3), a circlip (15s)
with the following
replacement part number
must be used when
installing: 001 994 18 40
Assemble
13 Install piston (15k)
14 Install disk spring (15t) Insert the disk spring
(15t) in such a way that
the camber of the inner
circumference faces the
piston (15k).
15 Position circlip (15s) Final installation only
after actuation of the
lever press.
16 Place multidisk brake in
lever press
17 Place clamping device on Position the clamping
disk spring (15t) device precisely (see
arrow in picture 2) to
enable installation of the
circlip (15s).
Fig. 99
Fig. 98
18 Operate lever press until Stop lever press stoke
groove of circlip (15s) is as soon as accessibility to
exposed groove is sufficient.
Excessive clamping
forces will damage the
plate supports.
19 Install circlip (15s) Observe the
installation position of
the circlip (15s). If
installed incorrectly, the
disk spring (5t) will jam.
20 Move back lever press
21 Take clamping device
and multidisk brake out
of lever press
22 Install disk spring (5t) Insert the disk spring
and disk pack (5) in (5t) in such a way that the
external plate carrier camber of the inner
(15a) circumference faces the
piston (15k).
Observe disk
sequence:
See Overview of GF27.51-P-5200W
multidisk components,
as-built configuration
23 Install end disk (105) and
circlip (105s)
24 Measure and adjust AR27.51-P-7229W
clearance
Fig. 98: Identifying Drift Set (722 589 04 15 00)
Courtesy of MERCEDES-BENZ USA
Fig. 99: Identifying Clamping Device (722 589 01 31 00)
Courtesy of MERCEDES-BENZ USA
DETACH/MOUNT START-UP CLUTCH ON DRIVEN PLATE - AR27.51-P-0400-01W
TRANSMISSION 722.93
START UP CLUTCH
Number Designation Transmission 722.93
Stage 1 Nm 4
BA27.51-P-1001-01A Bolt, start-up clutch to driven plate Stage 2 Nm 30
Stage 3 Angle° 90
Fig. 100: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 101: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Detaching
Do not use an impact wrench or compressed-air tools to unscrew and screw in the bolts, otherwise the
threaded unions in the driven plate will be damaged.
1. Remove cover (8).
2. Remove bolts (1 to 6) from start-up clutch.
Counterhold the engine at the center bolt of the crankshaft using the SI socket wrench bit and continue
turning in the direction of engine rotation.
Fig. 102: Identifying Cover And Start-Up Clutch Bolts
Courtesy of MERCEDES-BENZ USA
Checking
3. Check the driven plate (7) for damage.
Replace the driven plate (7) if the threaded unions (7a) are damaged or loose.
Fig. 103: Identifying Threaded Unions And Driven Plate
Courtesy of MERCEDES-BENZ USA
Attaching
4. Replace bolts (1 to 6) and attach start-up clutch (9) to driven plate (7).
Observe the tightening sequence and tightening torque, otherwise the start-up clutch (9) and driven
plate (7) will be damaged.
Fig. 104: Identifying Start-Up Clutch And Bolts
Courtesy of MERCEDES-BENZ USA
TIGHTENING SEQUENCE
Tightening
Screw Stage
sequence
1 Press start-up clutch (9) against driven plate (7) using long wedge
2 Attach the bolts (1 to 6) and position by hand
Tighten bolts (1, 2) and, while tightening, press start-up clutch (9) against Stage
3
driven plate (7) using long wedge 1
Stage
4 Tighten bolts (3 to 6)
1
Stage
5 Tighten bolts (1 to 6)
2
Stage
6 Tighten bolts (1 to 6)
3
REMOVE/INSERT START-UP CLUTCH - AR27.51-P-0400-02AMG
TRANSMISSION 722.93
TEST VALUES FOR START UP CLUTCH
Transmission
Number Designation
722.93
mm 9.5
BE27.51-P- Installed height Distance, bolt flange to transmission up
1001-02A of start clutch housing flange See
-
fig.
Fig. 105: Identifying Grab Handle (168 589 00 62 00)
Courtesy of MERCEDES-BENZ USA
Fig. 106: Identifying Parallel Support (126 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
Remove start-up clutch
1. Position transmission vertically.
2. Attach grab handles (065) to start-up clutch.
3. Remove start-up clutch without tilting.
4.1 If there are metal shavings in transmission oil pan, drain automatic transmission fluid from start-up
clutch through a clean cloth.
If there are metal shavings in the cloth: replace the start-up clutch as any remaining metal shavings
will damage the transmission.
4.2 If automatic transmission fluid is burnt or interspersed with abrasive particles: Rinse start-up clutch,
oil cooling lines and oil cooler.
Fig. 107: Identifying Start-Up Clutch Removal
Courtesy of MERCEDES-BENZ USA
Insert start-up clutch
5 Replace O-rings (1) and apply automatic transmission fluid.
6 Insert start-up clutch carefully without tilting.
Do not use force, otherwise the axial end stop of the start-up clutch will be irreparably damaged.
When doing so, move the start-up clutch back and forth until the drive spigots of the oil pump engage
in the disengagement shift tubes of the startup clutch.
Fig. 108: Identifying O-Rings
Courtesy of MERCEDES-BENZ USA
Fig. 109: Inserting Start-Up Clutch
Courtesy of MERCEDES-BENZ USA
Check that start-up clutch is seated correctly
An incorrectly inserted start-up clutch will be damaged when the transmission is installed, and will
cause damage to the oil pump.
Fig. 110: Checking Start-Up Clutch Seating
Courtesy of MERCEDES-BENZ USA
7 Place parallel gauge (01) on flange of transmission housing.
8 Using depth gauge, measure difference dimension (D1) between parallel gauge (01) and bolt
flange of start-up clutch.
9 Add measured difference dimension (D1) and specified distance dimension (D2) together.
If the start-up clutch is inserted correctly, the sum (D1 + D2) corresponds to the thickness (D3 = 20
mm) of the parallel gauge (01): D1 + D2 = D3.
If D1+ D2 is not equal to D3: remove and insert the start-up clutch again and check whether it is
seated correctly.
10 Detach grab handles (065) from start-up clutch.
Depth gauge
INSERT AND MEASURE MULTI-DISK PACK K1 - AR27.51-P-0800-02A
TRANSMISSION 722.6## ## up to 3947339 up to 1.9.02
Thickness of steel multi-disks B1, K1 and K2 changed BT27.51-P-0002-01A
MODIFICATION NOTES
25.8.98 New special tool for setting clearance Point 2 and 3 added
30.3.99 New values for clearance of multi-disk clutch
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission 722.6
double sided multi-
Number Designation disks
BE27.51-P- Clearance of Number of 3 mm 2.70...3.10
1001-01B multi-disk multi-disks 4 mm 3.00...3.40
clutch K1 5 mm 3.30...3.70
6 mm 3.60...4.00
Fig. 111: Identifying Pressing Tool (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 112: Identifying Sequence Of Disks For Multi-Disk Clutch
Courtesy of MERCEDES-BENZ USA
Soak new friction multi-disks in automatic transmission fluid for 1 hour before installation.
1. Assemble the disks for multi-disk clutch K1 in the sequence shown in the diagram and insert one at a
time.
2. Place pressing tool (078) on externally toothed plate (89c).
3. Press together multi-disk pack by pressing together pressing tool as far as stop using a lever press (the
marking ring can then still be seen, refer to small arrow).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (90) and the
externally toothed plate (89c).
During the measuring procedure, the snap ring (90) must touch the upper contact surface of the groove in
the external plate carrier.
5. Adjust clearance if necessary using appropriate snap ring (90).
Snap rings are available in thicknesses of 2.6, 2.9, 3.2, 3.5, 3.8 and 4.1 mm.
Fig. 113: Identifying Pressing Tool And Multi-Disk Pack
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE CLUTCH K1 - AR27.51-P-0800B
TRANSMISSIONS 722.6
Fig. 114: Identifying Disassemble/Assemble View Of Clutch K1 Components
Courtesy of MERCEDES-BENZ USA
Fig. 115: Identifying Assembly Tool And Snap Ring
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
New special tool for clearance AR27.51-P-0800-
25.8.98
adjustment 02A
Disks for B1, K1 and K3 Transmission 722.6 as from 02.09.02, see BT27.50-P-0013-
16.9.02
changed work step 12. 01A
Disassemble
Remove snap ring (90) from outer multiple-
1
disc carrier
Take multiple-disc pack (89) out of outer Check multi-disks for scorch
2
multiple-disc carrier marks and wear.
Place assembly device (072) on spring plate
3 (87) and tension until the snap ring (88) is Assembly device Fig. 116
exposed (figure A)
4 Remove snap ring (88)
Take out disk spring (86b) and remove
5 piston (86) by carefully blowing compressed
air into the bore (A) (figure B).
Remove snap ring (91) and take out front
6 According to condition.
freewheel (92).
Assemble
Check sealing rings (83b and
Install piston (86) in outer multiple-disc 86a), replace if necessary.
7
carrier The rounded off edges of the
sealing rings must face outwards
Insert disk spring with the
8 Insert disc spring (86b).
curvature towards the piston
Insert spring cup with curvature
9 Insert spring plate (87).
towards sun gear.
Place assembly device (072) on spring plate Assembly device
10 (87) and tension until the groove of the snap Check sealing ring (87a), Fig. 116
ring is exposed replace if necessary
After installing, check snap ring
11 Insert snap ring (88)
for correct seating
Observe externally-toothed plate
sequence. Insert and measure disk
pack K1:?
AR27.51-P-
Transmission 722.6 up to 01.09.02
0800-02A
Thrust device Fig. 117
Insert multiple-disc pack (89) in the outer
12 *BE27.51-P-
multiple-disc carrier and measure Play in multiple-disc clutch K1
1001-01B
AR27.51-P-
Transmission 722.6 as of 02.09.02
0800-02AA
Thrust device Fig. 117
*BE27.51-P-
Play in multiple-disc clutch K1
1001-01B
Strength of steel disks B1, K1 and K2 BT27.51-P-
Transmission 722.6
changed 0002-01A
BT27.50-P-
Disks for B1, K1 and K3 changed Transmission 722.6 as of 02.09.02
0013-01A
Survey of multi-disk components, GF27.51-P-
Transmission 722.6
production details 5200A
13 Insert snap ring (90)
The freewheel (92) must be
installed in direction of arrow
Insert front freewheel (92) and fit snap ring
14 Continuing operation, see:?
(91)
AR27.50-P-
Remove/install K1, K2 and K3
0621A
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission Transmission
722.6 up to 722.6 as of
01.09.02 with 02.09.02 with
double sided single-sided
Number Designation multiple-discs multiple-discs
BE27.51-P- Play in Number of 3 mm 2.70...3.10 2.40...2.80
1001-01B multiple- multiple- 4 mm 3.00...3.40 2.60...3.00
disc clutch discs 5 mm 3.30...3.70 2.80...3.20
K1
6 mm 3.60...4.00 2.90...3.30
Fig. 116: Identifying Assembly Tool (140 589 13 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 117: Identifying Clamping Device (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE K1 CLUTCH - AR27.51-P-0800W
TRANSMISSION 722.9
Fig. 118: Identifying Disassemble/Assemble View Of K1 Clutch
Courtesy of MERCEDES-BENZ USA
Fig. 119: Identifying External Plate Carrier, Circlip And Piston Cover
Courtesy of MERCEDES-BENZ USA
Disassemble
1 Remove circlip (105s)
and end disk (105)
2 Remove clutch pack (5) Check disks for
and disk spring (5t) scorch marks and wear.
3 Place multidisk clutch in
lever press
4 Place thrust Position the
device on piston cover thrust device precisely to
(14b) enable the circlip (14s) to
be removed later.
Transmission 722.9
except 722.93:
Fig. 120
Transmission 722.93:
Fig. 121
Fig. 122
5 Actuate lever press until Stop lever press stoke
circlip (14s) is exposed as soon as accessibility to
groove is sufficient.
Excess force can cause
damage.
6 Remove circlip (14s)
from groove
7 Move back lever press
8 Take thrust device
and multidisk clutch out
of lever press
9 Remove circlip (14s) and
piston cover (14b)
10 Remove spring support
(14f)
11 Remove piston (14k) Check the vulcanized-
on seal; replace the piston
(14k) if necessary.
Assemble
12 Install piston (14k)
13 Insert spring support
(14f)
14 Insert piston cover (14b)
15 Fit circlip (14s) Final installation is
only possible when the
lever press is actuated.
16 Place multidisk clutch in
lever press
17 Place thrust Position the
device on piston cover thrust device precisely to
(14b) enable the circlip (14s) to
be removed later.
Transmission 722.9
except 722.93:
Fig. 120
Transmission 722.93:
Fig. 121
Fig. 122
18 Actuate lever press until Stop lever press stoke
groove (arrow) is as soon as accessibility to
exposed, and install groove is sufficient.
circlip (14s) Excess force can cause
damage.
Pay attention to the
installation position of
the circlip (14s).
19 Move back lever press
20 Take thrust device
and multidisk clutch out
of lever press
21 Install disk spring (5t) Insert the disk spring
and disk pack (5) in (5t) in such a way that the
external plate carrier curvature of the inner
(14a) circumference points
toward the piston (14k).
Observe the
installation sequence: ?
assembly
22 Install end disk (105) and
circlip (105s)
Measure
23 Measure and adjust AR27.51-P-7229W
clearance
Fig. 120: Identifying Thrust Device (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 121: Identifying Thrust Device (722 589 01 31 00)
Courtesy of MERCEDES-BENZ USA
Fig. 122: Identifying Set Of Drifts (722 589 04 15 00)
Courtesy of MERCEDES-BENZ USA
INSERT/MEASURE K2 CLUTCH PACK - AR27.51-P-0820-02A
TRANSMISSION 722.6
Strength of steel disks B1, K1 and K2 changed BT27.51-P-0002-01A
Additional disk spring in clutch pack K2 BT27.51-P-0003-01A
MODIFICATION NOTES
25.8.98 New special tool for clearance adjustment Item 2 and 3 added
30.3.99 New adjustment values for clearance of multidisk clutch
Fig. 123: Identifying Thrust Device (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission Transmission
722.6 without cup 722.6 with cup
Number Designation spring spring
BE27.51-P- Play in Number of 3 mm 1.40 to 1.80 2.30 to 2.70
1002-01B multiple- multiple- 4 mm 1.50 to 1.90 2.40 to 2.80
disc clutch discs 5 mm 1.70 to 2.10 2.50 to 2.90
K2
6 mm 1.80 to 2.20 2.70 to 3.10
Fig. 124: Identifying Sequence Of Disks For Multi-Disk Clutch K2
Courtesy of MERCEDES-BENZ USA
Place new friction plates in ATF oil for 1 hour before installing.
1. Assemble and install the disks for the multi-disk clutch K2 in the sequence shown in the picture
individually.
2. Place pressure device (078) on external plate (105c).
3. Compress the clutch pack: to do this, compress the pressure device up to the end stop using a lever press
(the marking ring is then still visible, see small arrow).
4. Using the feeler gauge determine the clearance "L" at three points between the snap ring (106) and
external plate (105c).
During the measuring procedure, the snap ring (106) must lie against the upper contact surface of the
groove in the external plate carrier.
5. Adjust with snap ring (106) if necessary.
Snap rings are available in thicknesses of 2.3 2.6 2.9 3.2 3.5 and 3.8 mm.
Fig. 125: Identifying Clutch Pack Compression
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE K2 CLUTCH - AR27.51-P-0820W
TRANSMISSION 722.9
Fig. 126: Identifying Clutch Disassemble/Assemble Components
Courtesy of MERCEDES-BENZ USA
Fig. 127: Identifying Assembly Device And Circlip Groove
Courtesy of MERCEDES-BENZ USA
Disassemble
1 Remove bearing (11l) Check the contact
surface and bearing (11l)
for swirl marks and
damage; replace the
bearing (11l) if necessary.
2 Remove Torlon rings (1a)
3 Remove thrust bearing Check the contact
(2d) surface and radial bearing
(arrow) in the output
shaft guide for swirl
marks and damage;
replace the thrust bearing
(2d) and radial bearing if
necessary.
4 Remove circlip (105s)
and end disk (105)
5 Remove clutch pack (5) Check disks for
and disk spring (5t) scorch marks and wear.
6 Place multidisk clutch
(11) in lever press
7 Fit assembly Fig. 128
device (076) on spring
cup (11f)
8 Operate lever press and Stop lever press stoke
expose circlip groove as soon as accessibility to
(104) groove is sufficient.
Excess force can cause
damage.
9 Remove circlip (11s) Fig. 129
10 Move back lever press
11 Remove assembly
device (076) and
multidisk clutch (11)
from lever press
12 Remove spring cup (11f)
13 Remove disk spring (11t)
14 Remove piston (11k)
Assemble
15 Install piston (11k) Replace O-ring.
16 Insert disk spring (11t) Insert the disk spring
(11t) in such a way that
the curvature of the inner
circumference points
toward the spring cup
(11f).
17 Position spring cup (11f) Replace sealing ring.
sealing ring must face
outwards.
18 Place multidisk clutch
(11) in lever press
19 Fit assembly Fig. 128
device (076) on spring
cup (11f)
20 Operate lever press and Position the spring cup
expose circlip groove (11f) precisely in order to
(104) prevent it from tilting.
Stop lever press stoke
as soon as accessibility to
groove is sufficient.
Excess force can cause
damage.
21 Install circlip (11s) Fig. 129
22 Move back lever press
23 Remove assembly
device (076) and
multidisk clutch (11)
from lever press
24 Install disk spring (5t) Insert the disk spring
and clutch pack (5) (5t) in such a way that the
curvature of the inner
circumference points
toward the piston (11k).
Observe the
installation sequence: ?
Overview of disk GF27.51-P-5200W
assembly
25 Install end disk (105) and
circlip (105s)
Measure
26 Measure and adjust AR27.51-P-7229W
clearance
27 Insert thrust bearing (2d)
28 Install Torlon rings (1a) Replace the Torlon
rings (1a).
Fig. 130
29 Install bearing (11l)
Fig. 128: Identifying Assembly Tool (140 589 13 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 129: Identifying Pliers (000 589 52 37 00)
Courtesy of MERCEDES-BENZ USA
Fig. 130: Identifying Sleeve (722 589 01 14 00)
Courtesy of MERCEDES-BENZ USA
DISMANTLING AND ASSEMBLING DRIVE SHAFT WITH CLUTCH K2 AND FRONT GEAR SET -
AR27.51-P-0825A
TRANSMISSION 722.6
Fig. 131: Identifying Disassembled View Of Drive Shaft With Clutch K2 And Front Gear Set
Courtesy of MERCEDES-BENZ USA
Fig. 132: Identifying Snap Ring And Assembly Device
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Special tool for steps 8 and 13
1.8.97 New assembly device
modified
New special tool for setting loose AR27.51-P-0820-
25.8.98
play 02A
Disassembling
Detach transmission housing from torque AR27.50-P-
1
converter housing, fit on 0601A
Remove multiple-disk clutch K1, K2 and K3, AR27.50-P-
2
install 0621A
Remove snap ring (84b) from the inner multiple-
3 disc carrier / clutch K1 with integrated front gear
set (84) and take off hollow gear (84a)
Conversion from 18° to 23° teeth in front and BT27.50-P-
Transmission 722.6
rear planetary gear set 0012-01A
4 Remove drive shaft with clutch K2 (100)
Plain bearings of input shaft converted to BT27.50-P-
Transmission 722.6
antifriction bearings 0002-02A
5 Remove needle thrust bearing (85)
Remove snap ring (106) from outer multiple-
6
disc carrier / clutch K2
Inspect disks for scorch
7 Take out multiple-disc pack (105)
points and wear
8 Take out disk spring (107) As of transmission no.
1596205
BT27.51-P-
Additional disk spring in multiple-disk set K2 Transmission 722.6
0003-01A
Fit assembly device (076) onto spring retainer Fig. 133
9 (103) and press until snap ring (104) is released Operate assembly device
(Fig. A) with a lever press.
10 Remove snap ring (104)
Further work according to
Take out disc spring (102) and pull piston (101) condition:? AR27.50-P-
11
out of outer multiple-disc carrier Remove multiple-disk brake B1 0721A
and oil pump, install
Assembling
Inspect seals (101a and
101b), replace if necessary.
12 Install piston (101) in outer multiple-disc carrier
The rounded edges of the
seals must point to the outside.
Insert disk spring (102) with
curved side pointing toward
13 Insert disk spring (102) and spring retainer (103) spring retainer (103).
Inspect seal (103a), replace
if necessary.
Place assembly device (076) on spring plate
14 (103) and press until the groove of the snap ring Fig. 133
is exposed
15 Insert snap ring (104)
16 Insert disk spring (107). As of transmission no.
1596205
BT27.51-P-
Additional disk spring in multiple-disk set K2 Transmission 722.6
0003-01A
Insert multiple-disk set (105) into outer multiple- Pay attention to order of AR27.51-P-
17
disk carrier and measure outer disks. 0820-02A
Thickness of steel disks B1, K1 and K2 BT27.51-P-
Transmission 722.6
modified 0002-01A
GF27.51-P-
Survey of disks fitted as-built configuration Transmission 722.6
5200A
18 Fit snap ring (106)
Insert axial needle bearing (85) into inner Insert axial needle bearing *BR00.45-Z-
19 (85) with a little grease to
multiple-disk carrier/K1 1007-06A
prevent it slipping.
Install drive shaft in inner multiple-disc
20
carrier /clutch K1 with integrated front gear set
Pay attention to installation
position.
21 Fit internally-geared wheel (84a) Further work:
Remove multiple-disk clutch AR27.50-P-
K1, K2 and K3, install 0621A
Fig. 133: Identifying Assembly Device (140 589 13 43 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1007-06A Anticorrosion grease/DB supply specification 6834.00 A 001 989 37 51
INSERTING AND MEASURING MULTI-DISK PACK K3 - AR27.51-P-0830-01A
TRANSMISSION 722.6## ## up to 3947339 up to 1.9.02
Thickness of friction and steel multi-disks K3 changed BT27.51-P-0001-01A
MODIFICATION NOTES
25.8.98 New special tool for setting clearance Point 2 and 3 added
30.3.99 New values for clearance of multi-disk clutch
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission 722.6
up to 01.09.02 with
double sided multi-
Number Designation disks
BE27.51-P- Play in multi- Number of 3 mm 2.30...2.70
1003-01B disk clutch K3 multi-disks 4 mm 2.40...2.80
5 mm 2.50...2.90
Fig. 134: Identifying Pressing Tool (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 135: Identifying Sequence Of Disks For Multi-Disk Clutch K3
Courtesy of MERCEDES-BENZ USA
Soak new friction multi-disks in automatic transmission fluid for 1 hour before installation.
1. Assemble the disks for multi-disk clutch K3 in the sequence shown in the diagram and insert one at a
time.
2. Place pressing tool (078) on externally toothed plate (41a).
3. Press together multi-disk pack by pressing together pressing tool as far as stop using a lever press (the
marking ring can then still be seen, refer to small arrow).
4. Using a feeler gage, measure the clearance "L" at three locations between the snap ring (44g) and the
externally toothed plate (41a).
During the measuring procedure, the snap ring (44g) must touch the upper contact surface of the
groove in the external plate carrier.
5. Adjust clearance if necessary using appropriate snap ring (44g).
Snap rings are available in thicknesses of 2.0, 2.3, 2.6, 2.9, 3.2, and 3.5 mm.
Fig. 136: Identifying Pressing Tool And Multi-Disk Pack
Courtesy of MERCEDES-BENZ USA
INSERTING AND MEASURING MULTIPLE-DISC PACK K3 - AR27.51-P-0830-01AA
TRANSMISSION 722.6## ## as of 3947440 as of 2.9.02
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission 722.6
as of 02.09.02 with
single-sided
Number Designation multiple-discs
BE27.51-P- Play in Number of 3 mm 2, 30...2, 70
1003-01B multiple-disc multiple-discs 4 mm 2.40...2.80
clutch K3 5 mm 2.50...2.90
Fig. 137: Identifying Thrust Device (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
1. Assemble and install the disks for the multi-disk clutch K3 in the sequence shown in the picture
individually.
Insert the new disks in ATF oil before installation for 1 h.
Fig. 138: Identifying Sequence Of Disks For Multi-Disk Clutch K3
Courtesy of MERCEDES-BENZ USA
2. Mount pressure device (078) onto end disk (41a).
3. Compress the disk pack, to do so press the pressure device (078) together using a lever press up to
stop.
The marking ring (smaller arrow) is then still visible.
4. Use a feeler gauge to measure the clearance (L) at three points between the snap ring (44g) and end disk
(41a).
During the measuring procedure, the snap ring (44g) must lie against the upper contact surface of the
groove in the external plate carrier (44a).
5. Use corresponding snap ring (44g) to adjust clearance (L) if necessary.
The snap rings (44g) are available at sizes 2.0 mm, 2.3 mm, 2.6 mm, 2.9 mm, 3.2 mm and 3.5 mm.
Fig. 139: Identifying Disk Pack Compression
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE AND ASSEMBLE CLUTCH K3. - AR27.51-P-0830A
TRANSMISSION 722.6
Fig. 140: Identifying Disassembled View Of Clutch K3
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
New special tool for setting AR27.51-P-0830-
25.8.98
clearance 01A
Multi-disks for B1, K1 and K3 Transmission 722.6 as of 02.09.02, refer to BT27.50-P-0013-
16.9.02
changed step 10. 01A
Dismantling
1 Remove snap ring (44h)
from external plate
carrier
2 Remove multi-disk pack Check multi-disks for
(44g) and spring washer scorch marks and wear.
(44f) from external plate
carrier
3 Place assembly device Assembly device Fig. 141
(072) on spring plate
(44d) and tension until
the snap ring (44e) is
exposed
4 Remove snap ring (44e)
5 Remove spring plate
(44d) and piston (44c)
from the external plate
carrier
Assemble
6 Install piston (44c) in the Check sealing ring
external plate carrier (44b) and replace if
necessary.
The rounded off edges
of the sealing ring must
point outwards
7 Insert spring plate (44d) Insert spring washer
with the curvature
towards the piston
8 Place assembly device Assembly device Fig. 141
(072) on spring plate and
tension until the groove
of the snap ring is
exposed
9 Insert snap ring (44e) The collar of the snap
ring must point towards
the multi-disk pack.
10 Insert spring washer (44f) Observe outer multi-
and multi-disk pack (44g) disk sequence Inserting
in the external plate and measuring clutch
carrier and measure pack K3:?
Transmission 722.6 up to AR27.51-P-0830-01A
01.09.02
Pressing tool Fig. 142
Play in multi-disk clutch *BE27.51-P-1003-01B
K3
Transmission 722.6 as of AR27.51-P-0830-01AA
02.09.02
Pressing tool Fig. 142
Play in multi-disk clutch *BE27.51-P-1003-01B
K3
Thickness of friction and Transmission 722.6 BT27.51-P-0001-01A
steel multi-disks changed
Multi-disks for B1, K1 Transmission 722.6 as of BT27.50-P-0013-01A
and K3 changed 02.09.02
Survey of multi-disk Transmission 722.6 GF27.51-P-5200A
components, production
details
11 Insert snap ring (44h) For additional work,
see: ?
Install clutch K3 AR27.50-P-0810A
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission 722.6 up to Transmission 722.6 as of
Number Designation 01.09.02 with double sided 02.09.02 with single-sided
multi-disks multi-disks
Play in 3 mm 2.30...2.70 2.30...2.70
BE27.51-P- Number of
multi-disk 4 mm 2.40...2.80 2.40...2.80
1003-01B multi-disks
clutch K3 5 mm 2.50...2.90 2.50...2.90
Fig. 141: Identifying Assembly Device (140 589 13 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 142: Identifying Pressing Tool (208 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE CLUTCH K3 - AR27.51-P-0830W
TRANSMISSION 722.9
Fig. 143: Identifying Clutch Disassemble/Assemble Components
Courtesy of MERCEDES-BENZ USA
Fig. 144: Identifying Disk Spring, External Plate Carrier And Circlip
Courtesy of MERCEDES-BENZ USA
Dismantling
1 Remove circlip (105s)
and end disk (105)
2 Remove disk pack (5) Check disks for
and disk spring (5t) scorch marks and wear.
3 Place assembly device on Assembly device Fig. 145
disk spring (21t) and
tension until circlip (21s)
is exposed
4 Remove circlip (21s)
5 Remove assembly device
6 Remove disk spring (21t) Check sealing ring
and piston (21k) from (arrow) and stop faces for
external disk carrier (21a) damage and swirl marks.
Assembling
7 Install piston (21k) in
external plate carrier
(21a)
8 Insert spring plate (21) Install disk spring
(21t) such that curvature
of inner circumference
faces piston (21k)
9 Place assembly device on Assembly device Fig. 145
disk spring (21t) and
tension until circlip (21s)
is exposed
10 Install circlip (21s) Pay attention to
installation position of
circlip (21s). If installed
incorrectly, disk spring
(5t) will become jammed.
11 Remove assembly device
12 Install disk spring (5t) Install disk spring (5t)
and disk pack (5) such that curvature of
inner circumference faces
piston (21k)
Make sure that disks
are installed in correct
sequence: ?
Survey of multi-disk GF27.51-P-5200W
components, production
details
13 Installed end disk (105)
and circlip (105s)
14 Measure and adjust AR27.51-P-7229W
clearance
Fig. 145: Identifying Assembly Device (140 589 13 43 00)
Courtesy of MERCEDES-BENZ USA
MEASURE AND ADJUST CLEARANCE IN MULTIDISK BRAKE BR - AR27.51-P-7229-01W
TRANSMISSION 722.9, 724.2
SET VALUES FOR MULTI-DISK BRAKE
Transmission 722.9 except Transmission
Number Designation
722.93 722.93
BE27.50-P-1004- Clearance of multi-disk
mm 1, 00 to 1, 40 1, 00 to 1, 40
02C brake BR
Before the clearance measurement the disks must be immersed in automatic transmission fluid for at least
one hour so that the friction lining can swell up.
1. Using a feeler gauge determine the clearance at three points between the circlip (133a) and externally
toothed plate (133c).
For the measuring process the circlip (133a) must abut the upper contact surface of the groove in the
external plate carrier.
2. Remove circlip (133a) and determine its thickness.
3. Adjust clearance; to do this, install circlip (133a) of appropriate thickness.
The circlips (133a) are available as a replacement part with a thickness of 3.2 to 4.7 mm. The graduation is
0.3 mm.
Fig. 146: Measuring Clearance Between Circlip And Externally Toothed Plate
Courtesy of MERCEDES-BENZ USA
MEASURE AND ADJUST CLEARANCE - AR27.51-P-7229W
TRANSMISSION 722.9 Multidisk brake B1, B2, B3 and multidisk clutch K1, K2, K3
Fig. 147: Adjusting Clearance Of End Disk And Circlip
Courtesy of MERCEDES-BENZ USA
Fig. 148: Identifying Service Tool Marking
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
6.11.07 Play in multiple-disc Transmission 722.93 *BE27.51-P-1002-01C
clutch K2
Play in multiple-disc Transmission 722.93 *BE27.51-P-1003-01C
clutch K3
Measure
General information Before the clearance
measurement the disks
must be immersed in
automatic transmission
fluid for at least one hour
so that the friction lining
can swell up.
1 Place multidisk brake or
multidisk clutch in a lever
press
2 Put drifts of the thrust Position the drifts on
device on the end disk the end disk (105) so that
(105) slipping off during the
pressing process is
prevented.
Thrust device Fig. 149
Drift set Fig. 150
3 Operate lever press The markings (M1) to
(M4) identify the
required contact force.
Disks and plate supports
are damaged if the
contact force is exceeded.
(M1) applies to multidisk
brake B1
(M3) applies to multidisk
brake B2
(M1) applies to multidisk
brake B3
(M2) applies to multidisk
clutch K1.
(M4) applies to multidisk
clutch K2.
(M1) applies to multidisk
clutch K3
4 Put on parallel support Fig. 151
5 Determine distance Determine distance at
between the parallel two points of the
surface upper edge and circumference of the end
end disk (105) using disk (105) and note the
depth gauge (T) mean value as dimension
"a".
6 Move back lever press
7 Press end disk (105) Attach the tool (e.g.
against the circlip (105s) screwdriver) carefully
between end disk (105)
and first friction plate
(arrow). Do not twist the
tool otherwise the disks
will be bent and the
friction lining damaged.
8 Determine distance Determine distance at
between the parallel two points of the
surface upper edge and circumference of the end
end disk (105) using disk (105) and note the
depth gauge (T) mean value as dimension
"a".
The difference from
measurements "a" and
"b" gives the clearance.
Adjust clearance
9 Remove circlip (105s)
and determine its
thickness
10 Adjust clearance; to do Circlips (105s) are
this, install circlip (105s) available in a graduation
of appropriate thickness. of 0.3 mm.
Multidisk brake B1 *BE27.50-P-1001-02C
Multidisk brake B2 *BE27.50-P-1002-02C
Multidisk brake B3 *BE27.50-P-1003-02C
Multidisk clutch K1 *BE27.51-P-1001-01C
Multidisk clutch K2 *BE27.51-P-1002-01C
Multidisk clutch K3 *BE27.51-P-1003-01C
Assignment of number
of disks to the respective
transmission model
designation: ?
Survey of multi-disk GF27.51-P-5200W
components, production
details
SET VALUES FOR MULTI-DISK BRAKE
Transmission 722.9 Transmission
Number Designation
except 722.93 722.93
Contact force for
clearance adjustment M1 N 600 600
BE27.50-P- Play in multiple- B1
1001-02C disc brake B1 3 mm 2.00 to 2.40 -
Number of multiple-
4 mm 2.20 to 2.60 2.20 to 2.60
discs
5 mm - 2.30 to 2.70
Contact force for
clearance adjustment M3 N 1000 1000
B2
Number of disks of 4 mm 1.70...2.10 1.70...2.10
BE27.50-P- Play in multiple-
internally toothed
1002-02C disc brake B2 5 mm 1.80 to 2.20 1.80 to 2.20
plates
Number of disks of 5 mm 1.70...2.10 1.70...2.10
externally toothed
plates 6 mm 1.80 to 2.20 1.80 to 2.20
Contact force for
clearance adjustment M1 N 600 600
BE27.50-P- Play in multiple- B3
1003-02C disc brake B3 3 mm 2.00 to 2.40 2.00 to 2.40
Number of multiple-
4 mm 2.20 to 2.60 2.20 to 2.60
discs
5 mm 2.30 to 2.70 2.30 to 2.70
ADJUSTMENT VALUES OF MULTI-DISK CLUTCH
Transmission 722.9 Transmission
Number Designation
except 722.93 722.93
clearance adjustment
M2 N 800 800
K1
BE27.51-P- Play in multiple- 3 mm 2.00 to 2.40 -
1001-01C disc clutch K1 Number of internal 4 mm 2.20 to 2.60 -
plates 5 mm 2.40 to 2.80 2.40 to 2.80
6 mm - 2.40 to 2.80
Contact force for
clearance adjustment M4 N 1200 1200
K2
3 mm 1.70...2.10 -
BE27.51-P- Play in multiple- 4 mm 1.90 to 2.30 -
1002-01C disc clutch K2
Number of internal 5 mm 2.10 to 2.50 -
plates 6 mm 2.20 to 2.60 1.90 to 2.30
7 mm - 2.00 to 2.40
8 mm - 2.10 to 2.50
Contact force for
clearance adjustment M1 N 600 600
BE27.51-P- Play in multiple- K3
1003-01C disc clutch K3 3 mm - 2.40 to 2.80
Number of internal
4 mm 2.20 to 2.60 -
plates
5 mm 2.40 to 2.80 -
Fig. 149: Identifying Thrust Device (722 589 01 31 00)
Courtesy of MERCEDES-BENZ USA
Fig. 150: Identifying Set Of Drifts (722 589 04 15 00)
Courtesy of MERCEDES-BENZ USA
Fig. 151: Identifying Parallel Support (126 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
FLUSHING OUT OIL COOLER LINES AND OIL COOLER - AR27.55-P-0001A
TRANSMISSION 722.6/ 7
Fig. 152: Identifying Oil Cooler Lines And Oil Cooler Flush Out Components
Courtesy of MERCEDES-BENZ USA
Illustrated on model 168
Fig. 153: Identifying Oil Cooler Lines And Oil Cooler Flush Out Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Kerosene cleaning agent replaced by automatic transmission fluids (ATF, specification Step
30.5.07
236.10) 6
Extracting oil
Before opening the hydraulic system, thoroughly
clean the area surrounding the separation point.
Even the smallest dirt particles, introduced into the
hydraulic components, can lead to malfunctions and
a total failure of the hydraulic system
Connect pump (2) with vacuum connection to the
1 See picture A
reservoir (3)
Connect plastic hose to pressure fitting (1) and slide
2 through the oil filler pipe completely down into the
oil pan
3 Operate pump (2) The extracted oil runs into
the reservoir (3).
Flushing
Connect pump (2) with pressure fitting (1) to
4 See picture B
reservoir (3)
5 Fill reservoir (3) with transmission oil
Connect plastic hose to pressure fitting (1) and,
using a corresponding connector (4), screw onto Ensure that the transmission
6
one of the two oil cooling lines (5 or 6) and flush oil flows freely.
out with transmission oil
In the event of severe
contamination, change the
transmission oil several times.
BB00.40-
Automatic transmission fluids (ATF, Sheet 236.10) P-0236-
10A
Connect second plastic hose to the other oil cooling If necessary secure the
7 line (5 or 6) and collect transmission oil which plastic hose to the connection
flows out fitting using a hose clamp.
8 Install in the reverse order
Always observe work
procedure and Specifications
9 Fill transmission with gear oil
for Operating Fluids, otherwise
transmission will be damaged.
Fig. 154: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
FLUSHING OUT OIL COOLER LINES AND OIL COOLER - AR27.55-P-0001SX
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 without 4MATIC
Fig. 155: Identifying Oil Cooler Lines And Oil Cooler Flush Out Components (Without 4Matic)
Courtesy of MERCEDES-BENZ USA
Fig. 156: Identifying Right And Left Oil Cooling Lines (Feed And Return)
Courtesy of MERCEDES-BENZ USA
Fig. 157: Identifying Right And Left Oil Cooling Lines, Screws And Double Clamps
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Kerosene cleaning agent replaced by automatic transmission fluids (ATF, specification Step
30.5.07
236.12) for the flushing process. 5
Remove/install
Before opening the
hydraulic system,
thoroughly clean the area
surrounding the
separation point. Even the
smallest dirt particles,
introduced into the
hydraulic components,
can lead to malfunctions
and a total failure of the
hydraulic system
1 Remove oil drain screws *BA27.20-P-1001-01C
from the transmission oil
pan and unscrew torque
converter and drain *BA27.10-P-1001-03D
transmission oil
2 Remove screws (9, 11, *BA27.55-P-1006-01D
13) *BA27.55-P-1005-01D
3 Detach double hose
clamps (10, 12, 14) of oil
cooling lines (7, 8) from
engine oil pan
4 Remove bolts (19, 20) of Installation: Fit new
the oil cooling lines (7, 8) O-rings on the oil cooling
on the transmission and lines (7, 8).
pull oil cooling lines (7,
8) out of the transmission *BA27.55-P-1002-01D
Flushing
5 Fill reservoir (3) of hand Fig. 158
pump (2) with
transmission oil
Automatic transmission BB00.40-P-0236-12A
fluids (ATF, Sheet
236.12)
6 Connect hand pump (2) to
reservoir (3) with pressure
fitting
7 Connect plastic hose to Secure plastic hose to
connection fitting (1) and connection fitting (1)
connect appropriate using hose clamp if
connector (4) to oil necessary.
cooling lines (7, 8)
8 Operate hand pump (2) In the event of severe
and flush out oil cooling contamination change the
lines (7, 8) and oil cooler transmission oil several
with transmission oil times and ensure that the
transmission oil flows
freely.
9 Remove hand pump (2)
10 Install in the reverse order
11 Fill transmission with AR27.00-P-0270W
gear oil
12 Read out fault memory STAR DIAGNOSIS
with STAR DIAGNOSIS diagnostic system
and erase if necessary
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
13 Perform engine test run
and check transmission
for leaks with engine
running
TRANSMISSION OIL COOLING SYSTEM
Transmission
Number Designation
722.9
Stage
Nm 5
Banjo 1
BA27.55-P-1002- Bolt, transmission oil line to bolt Stage
01D transmission housing Angle° 90
2
Hexalobular bolt Nm 12
BA27.55-P-1005-
Bolt, oil cooling line double clamp to bracket Nm 8
01D
BA27.55-P-1006-
Bolt, oil cooling line double clamp to engine oil pan Nm 8
01D
TORQUE CONVERTER
Number Designation Transmission 722.9
M8 Nm 10
BA27.20-P-1001-01C Oil drain bolt to torque converter
M10 Nm 15
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation
BA27.10-P-1001-03D Oil drain screw to oil pan Nm
Fig. 158: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
FLUSHING OUT OIL COOLER LINES AND OIL COOLER - AR27.55-P-0001SYZ
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3, 204 with 4MATIC
Fig. 159: Identifying Oil Cooler Lines And Oil Cooler Flush Out Components
Courtesy of MERCEDES-BENZ USA
Fig. 160: Identifying Transfer Case Supply Line, Right And Left Oil Cooling Lines
Courtesy of MERCEDES-BENZ USA
Fig. 161: Identifying Transfer Case Supply Line, Throttle And Filter Cartridge
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Kerosene cleaning agent replaced by 7-speed automatic transmission fluids (ATF, Operation
30.5.07
specification 236.12) for the flushing process. step 6
Remove/install
Before opening the
hydraulic system the area
surrounding the
separation point should
be cleaned thoroughly.
Even the smallest dirt
particles, introduced into
the hydraulic
components, can lead to
malfunctions and a total
failure of the hydraulic
system.
1 Remove oil drain screws *BA27.20-P-1001-01C
from the transmission oil
pan and unscrew torque
converter and drain *BA27.10-P-1001-03D
transmission oil
2 Detach the double clamps Model 216, 221 AR27.55-P-0600SYZ
and retaining clamps of
the oil cooling lines (7, 8)
and supply line (6) on the Model 204 AR27.55-P-0600CWX
engine oil pan and on the
transmission
3 Remove bolts of oil Installation: Replace
cooling lines (7, 8) and O-rings of oil cooling
supply line (6) and pull lines (7, 8) and O-ring of
oil cooling lines (7, 8) out supply line (6).
of transmission and
supply line (6) from the
*BA27.55-P-1002-01D
transfer case
4 Remove restrictor (6a) Installation: Replace
and filter cartridge (6b) restrictor (6a) and filter
from supply line (6) cartridge (6b) and pay
attention to correct seat in
the supply line (6).
5 Seal connector of oil Fig. 163
cooling line (7)
Flushing
6 Fill reservoir (3) of hand Fig. 162
pump (2) with
transmission oil
Automatic transmission BB00.40-P-0236-12A
fluids (ATF, Sheet
236.12)
7 Connect hand pump (2) to
reservoir (3) with pressure
fitting
8 Insert plastic hose on Secure plastic hose to
connection fitting (1) and connection fitting (1)
connect corresponding using hose clamp if
connector (4) to the oil necessary.
cooling line (8) and
supply line (6)
9 Operate hand pump (2) While flushing, the
and flush out oil cooling connector (4) from the
line (8), supply line (6) supply line (6) must be
and oil cooler with removed and repositioned
transmission oil on the oil cooling line
(7). Meanwhile the
supply line (6) must be
sealed with stop plugs.
In the event of severe
contamination change the
transmission oil several
times and ensure that the
transmission oil flows
Fig. 163
10 Remove hand pump (2)
11 Install in the reverse order
12 Fill transmission with AR27.00-P-0270SYZ
gear oil
13 Read out fault memory
with STAR DIAGNOSIS
and erase if necessary
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
14 Perform engine test run
and check transmission
for leaks with engine
running
TRANSMISSION OIL COOLING SYSTEM
Transmission
Number Designation
722.9
Stage
Nm 5
Banjo 1
BA27.55-P-1002- Bolt, transmission oil line to bolt Stage
01D transmission housing Angle° 90
2
Hexalobular bolt Nm 12
TORQUE CONVERTER
Number Designation Transmission 722.9
M8 Nm 10
BA27.20-P-1001-01C Oil drain bolt to torque converter
M10 Nm 15
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation Transmission 722.9
BA27.10-P-1001-03D Drain plug on transmission oil pan Nm 22
Fig. 162: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
Fig. 163: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
FLUSH OUT AUTOMATIC TRANSMISSION AND TORQUE CONVERTER - AR27.55-P-0100A
TRANSMISSION 722.6 Without transmission rinsing device
Fig. 164: Identifying Cap, Plate And Locking Pin
Courtesy of MERCEDES-BENZ USA
Fig. 165: Identifying Oil Cooling Line Connection, Right Oil Cooling Line And Banjo Bolt
Courtesy of MERCEDES-BENZ USA
Fig. 166: Identifying Oil Cooling Line Connection, Right Oil Cooling Line, Banjo Bolt And Hose Clamp
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury to skin Depressurize the hydraulic system AS00.00-Z-0013-01A
or eyes caused by completely before starting any work
spraying out under clothing and safety glasses.
high pressure. Risk of
poisoning caused by
swallowing hydraulic
fluid
Risk of accident Secure vehicle to prevent it from AS00.00-Z-0005-01A
caused by vehicle moving by itself.
starting off by itself Wear closed and snug-fitting work
when engine is clothes. Do not touch hot or rotating
running. Risk of parts.
injury caused by
contusions and burns
during starting
procedure or when
working near the
engine as it is running
Risk of death caused Align vehicle between columns of AS00.00-Z-0010-01A
by vehicle slipping or vehicle lift and position four support
toppling off of the plates at vehicle lift support points
lifting platform. specified by vehicle manufacturer.
Notes on self-locking AH00.00-N-0001-
nuts and bolts 01A
Before opening the
hydraulic system,
thoroughly clean the
area surrounding the
separation point. Even
the smallest dirt
particles, introduced
into the hydraulic
components, can lead
to malfunctions and a
total failure of the
hydraulic system
1.1 Remove the rear Vehicles with gasoline engine
section of the engine except model 461 and 463
compartment paneling Model 129, 202, 208, 210 AR61.20-P-1105AB
Model 140
Model 163 except AR61.20-P-1105GH
163.113/128/136/154/157
Model 163.113/128/136/154/157
Model 170 AR61.20-P-1105A
Model 171 AR61.20-P-1105V
Model 199 AR61.20-P-1105SLR
Model 209, 203 with gasoline AR61.20-P-1105P
Model 211 AR61.20-P-1105T
Model 219 AR61.20-P-1105TX
Model 215, 220 AR61.20-P-1105M
Model 230 AR61.20-P-1105R
Model 240 AR61.20-P-1105H
1.2 Remove rear part of Vehicles with diesel engine except
bottom sections of model 461 and 463
soundproofing Model 140
Model 163 AR94.30-P-5400GH
Type 202.1 AR94.30-P-5300A
Model 209, 203 with diesel engine AR94.30-P-5300P
Model 210 AR94.30-P-5300AB
Model 211 AR94.30-P-5300T
Model 220 AR94.30-P-5300M
2 Remove drain plug The transmission oil should have
from the transmission an operating temperature of 80 °C.
oil pan and drain *BA27.10-P-1001-
transmission oil 03A
3 Detach transmission
oil pan and install a
new transmission oil CAUTION:
filter when removing the transmission
oil pan, approx. 2.5 liters of
transmission oil will still be in the
transmission oil pan.
4 Mount transmission Install new gasket.
oil pan *BA27.10-P-1002-
03A
5 Detach clamps for Model 163, 171, 211, 219, 220, *BA27.55-P-1008-
right oil cooling line 461, 463 01B
(2) from engine oil Model 199, 203, 209, 215, 230 *BA27.55-P-1003-
pan 01B
6 Remove banjo bolt (3) Model 163, 171, 211, 219, 220, *BA27.55-P-1002-
from connection (1) 461, 463 01B
on right oil cooling Model 199, 203, 209, 215, 230 *BA27.55-P-1002-
line (2) 01B
7 Join connection fitting Remove the connection fitting (4)
(4) with an approx. from the hand pump.
1.5 meter long hose
using a hose clamp (5) Fig. 168
8 Mount banjo bolt (3)
and oil cooling line
(2) to connection
fitting (4)
9 Hold hose into a The bucket should have a
bucket with a scale on capacity of 10 liters.
it
10 Unlock cap (93) Break off plate (93a) using a
suitable tool and press out locking
pin (93b) remaining in cap (93)
downwards.
11 Detach cap (93) from
oil filler pipe
12 Mount funnel The entire flushing procedure
onto oil filler pipe and requires 14 liters of transmission oil.
fill transmission with
5 liters of oil Fig. 167
Flushing
An assistant is
required for the
flushing procedure
13 Start the engine and Always observe work procedure
drain transmission oil and Specifications for Operating
via the hose into the Fluids, otherwise transmission will
bucket be damaged.
14 Once 3 liters of
transmission oil are in
the bucket stop the
engine immediately
15 Pour in 3 liters of
transmission oil
16 Repeat flushing
procedure twice
17 Check oil level in AR27.00-P-0100AC
automatic
transmission, correct
if necessary
18 Install in the reverse
order
19 Carry out engine test
run, checking the
transmission for
function and oil leaks
OIL PAN, AUTOMATIC TRANSMISSION
Transmission 722.6
Transmission Transmission Transmission
Number Designation except
722.628 722.648 722.649
BA27.10-P- Oil drain screw
Nm 20 20 20 22
1001-03A to oil pan
Bolt, oil pan to
BA27.10-P-
transmission Nm 8 8 8 8
1002-03A
housing
TRANSMISSION OIL COOLING
Transmission
Transmission Transmission 722.6 in model 170,
Number Designation 722.6 in model 722.6 in model 171, 203, 209, 210,
163 199 215, 219, 220, 230,
240
Banjo bolt or Stage 1 Nm 20 20 5
union nut, oil
BA27.55- Stage 2 Angle° - - 90
cooler line to
P-1002-
torque converter
01B
and transmission Hexalobular Nm - - -
housing bolt
BA27.55-
Bolt, oil cooler line to engine
P-1003- Nm 11 - 11
oil pan
01B
BA27.55-
Bolt, oil cooler line retaining
P-1008- Nm 8 - 8
clamp to oil pan
01B
TRANSMISSION OIL COOLING
Transmission Transmission Transmission
Number Designation 722.6 in model 722.6 in model 722.6 in model
204, 216, 221 211 461, 463
Banjo bolt or union Stage 1 Nm 5 5 20
BA27.55- nut, oil cooler line Stage 2 Angle° 90 90 -
P-1002- to torque converter
01B and transmission Hexalobular
Nm 12 - -
housing bolt
BA27.55-
Bolt, oil cooler line to engine oil
P-1003- Nm 11 11 -
pan
01B
BA27.55-
Bolt, oil cooler line retaining
P-1008- Nm - 8 8
clamp to oil pan
01B
Fig. 167: Identifying Funnel (126 589 12 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 168: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
FLUSH OUT AUTOMATIC TRANSMISSION AND TORQUE CONVERTER - AR27.55-P-0100B
TRANSMISSION 722.6 /9 With transmission rinsing device
Fig. 169: Identifying Return Flow Pipe And Feed Line
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury to Depressurize the hydraulic system completely AS00.00-Z-0013-
skin or eyes before starting any work on the system. Wear 01A
caused by protective clothing and safety glasses.
hydraulic fluid
spraying out under
high pressure.
Risk of poisoning
caused by
swallowing
hydraulic fluid
Risk of accident Secure vehicle to prevent it from moving by AS00.00-Z-0005-
caused by vehicle itself. 01A
starting off by Wear closed and snug-fitting work clothes.
itself when engine Do not touch hot or rotating parts.
is running. Risk of
injury caused by
contusions and
burns during
starting procedure
or when working
near the engine as
it is running
Risk of death Align vehicle between columns of vehicle lift AS00.00-Z-0010-
caused by vehicle and position four support plates at vehicle lift 01A
slipping or support points specified by vehicle
toppling off of the manufacturer.
lifting platform.
Notes on self- AH00.00-N-0001-
locking nuts and 01A
bolts
Before opening the hydraulic system the
area surrounding the separation point should be
cleaned thoroughly. Even the smallest dirt
particles, introduced into the hydraulic
components, can lead to malfunctions and a
total failure of the hydraulic system.
The transmission rinsing device can be
connected at any given point in the oil circuit.
Only the flow direction has to be observed
when connecting the rinsing device.
1 Expose connecting Define connecting point to match
point accessibility of feed line (2) or return line (1).
2 Detach feed line
(2) or return line
(1) at connecting
point
3 Connect Note direction of oil circuit flow.
transmission Automatic transmission rinsing system
rinsing device oWS/ATM-M
Set of adapters Fig. 170
4 Rinse transmission Note specifications from rinsing device
oil circuit manufacturer.
5 Install in the
reverse order
Checking
6 Check oil level in 722.6 AR27.00-P-
automatic 0100AC
transmission, 722.9 (except 722.950/960/961/962/ AR27.00-P-
correct if 963/964/965/966) 0270W
necessary 722.950/960/961/962/963/964/965/966 AR27.00-P-
0270SYZ
7 Carry out engine
test run, checking
the transmission
for function and
oil leaks
Fig. 170: Identifying Set Of Adapters (722 589 01 90 00)
Courtesy of MERCEDES-BENZ USA
FLUSH OUT AUTOMATIC TRANSMISSION AND TORQUE CONVERTER - AR27.55-P-0100SX
TRANSMISSION 722.9 in MODEL 221.00 /02 /05 /07 /10 /12 /15 /17, 216.37 Without transmission
rinsing device
Fig. 171: Identifying Right And Left Oil Cooling Lines (Feed And Return)
Courtesy of MERCEDES-BENZ USA
Fig. 172: Identifying Right And Left Oil Cooling Lines, Screws And Double Clamps
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
4.4.11 Work procedure adapted to new repair method
Remove/install
Risk of injury to skin or Depressurize hydraulic AS00.00-Z-0013-01A
eyes caused by hydraulic system completely before
fluid spraying out under starting any work on
high pressure. Risk of system. Wear protective
poisoning caused by clothing and safety
fluid
Before opening the
hydraulic system the area
surrounding the
separation point should
be cleaned thoroughly.
Even the smallest dirt
particles, introduced into
the hydraulic
components, can lead to
malfunctions and a total
failure of the hydraulic
system.
1 Remove oil drain screws The transmission oil
from the transmission oil should have an operating
pan and unscrew torque temperature of approx. 80
converter and drain °C.
transmission oil
2 Detach transmission oil Take care when
pan and install a new removing the
transmission oil filter transmission oil pan as it
still contains approx. 3 l
of transmission oil.
3 Attach transmission oil *BA27.10-P-1002-03D
pan
4 Screw oil drain screws *BA27.10-P-1001-03D
into transmission oil pan
and torque converter *BA27.20-P-1001-01C
5 Fill transmission with AR27.00-P-0270W
gear oil
6 Remove screws (9, 11, *BA27.55-P-1006-01D
13) *BA27.55-P-1005-01D
7 Detach double hose
clamps (10, 12, 14) of oil
cooling lines (7, 8) from
engine oil pan
8 Detach left oil cooling AR27.10-P-0501-03SX
line (return flow) (8) from
Fig. 173
cooler
Flushing
9 Hold left oil cooling line The bucket must have
(return flow) (8) in a a capacity of 10 l.
bucket with scale
10 Start engine and allow
transmission oil to drain
out through left oil
cooling line (return flow)
(8) and into bucket
11 Stop engine immediately
as soon as 3 l of
transmission oil have
been drained off
12 Refill 3 l of transmission AR27.00-P-0270W
oil
13 Repeat rinsing procedure
3 times
14 Install in the reverse order
15 Check transmission oil AR27.00-P-0270W
level and correct if
necessary
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes. Do
caused by contusions and not touch hot or rotating
burns during starting parts.
procedure or when
working near the engine
as it is running
16 Perform engine test run
and check transmission
for oil leaks and that it is
functioning correctly
OIL PAN, AUTOMATIC TRANSMISSION
Number Designation Transmission 722.9
BA27.10-P-1001-03D Drain plug on transmission oil pan Nm 22
Stage 1 Nm 4
BA27.10-P-1002-03D Bolt, oil pan to transmission housing
Stage 2 Angle° 180
TORQUE CONVERTER
Number Designation Transmission 722.9
M8 Nm 10
BA27.20-P-1001-01C Oil drain bolt to torque converter
M10 Nm 15
TRANSMISSION OIL COOLING SYSTEM
Number Designation Transmission 722.9
BA27.55-P-1005-01D Bolt, oil cooling line double clamp to bracket Nm 8
BA27.55-P-1006-01D Bolt, oil cooling line double clamp to engine oil pan Nm 8
Fig. 173: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL OIL LINES OF OIL COOLING FOR AUTOMATIC TRANSMISSION -
AR27.55-P-0600SX
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 without 4MATIC
TRANSMISSION 722.6 in MODEL 221.1, 216.3
Fig. 174: Identifying Right And Left Oil Cooling Lines (Feed And Return)
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury to skin or Depressurize the AS00.00-Z-0013-01A
eyes caused by hydraulic hydraulic system
fluid spraying out under completely before
high pressure. Risk of starting any work on the
poisoning caused by system. Wear protective
swallowing hydraulic clothing and safety
fluid glasses.
Risk of injury to skin and Wear safety gloves, AS00.00-Z-0002-01A
hot or glowing objects. safety glasses, if
necessary.
Risk of death caused by Align vehicle between AS00.00-Z-0010-01A
vehicle slipping or columns of vehicle lift
toppling off of the lifting and position four support
platform. plates at vehicle lift
support points specified
by vehicle manufacturer.
Before starting work,
the area around the oil
cooling lines (7, 8) must
be thoroughly cleaned at
the connecting points.
Even the smallest dirt
particles in the hydraulic
components can lead to
malfunctions and a total
failure of the
transmission.
1 Open engine hood and
raise to vertical position
2 Detach oil cooling lines Do not pull the oil AR27.10-P-0501-03SX
(7, 8) from radiator cooling lines (7, 8) out of
the radiator yet.
Fig. 175
3 Attach engine hoist Model 221.095/195 AR33.10-P-0105SX
4 Remove bolts of front Model 221.095/195 with AR22.10-P-1260SXH
engine mount from front engine 272.974
axle carrier and lift engine
5 Detach ground line from Model 221.095/195
bell housing *BA27.40-P-1001-01E
6 Remove double clamps Transmission 722.6 *BA27.55-P-1009-01B
and retaining clamps of Transmission 722.9 *BA27.55-P-1006-01D
oil cooling lines (7, 8)
Transmission 722.6 *BA27.55-P-1010-01B
Transmission 722.9 *BA27.55-P-1005-01D
7 Detach oil cooling lines AR27.10-P-0502-01SX
(7, 8) from automatic Transmission 722.6 *BA27.55-P-1002-01B
transmission
Transmission 722.6 *BA27.55-P-1009-01B
Transmission 722.6 *BA27.55-P-1010-01B
Transmission 722.9 *BA27.55-P-1002-01D
Transmission 722.9 *BA27.55-P-1005-01D
Transmission 722.9 *BA27.55-P-1006-01D
Cleaner from package *BR00.45-Z-1028-04A
8 Pull oil cooling lines (7, See "Disconnect and AR27.10-P-0501-03SX
8) out of radiator connect transmission oil
line".
Fig. 175
9 Remove oil cooling lines
(7, 8)
10 Install in the reverse order
11 Check oil level in Transmission 722.9 AR27.00-P-0270W
automatic transmission
and correct if necessary Transmission 722.6 AR27.00-P-0100AC
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
12 Perform engine test run
and check transmission
for proper function and
leaktightness.
HOUSING
Transmission 722.9 in Model 216,
Number Designation
221
BA27.40-P-1001- Bolt, automatic transmission to
Nm 39
01E crankcase
TRANSMISSION OIL COOLING SYSTEM
Transmission
Number Designation
722.9
Stage
Nm 5
Banjo 1
BA27.55-P-1002- Bolt, transmission oil line to bolt Stage
01D transmission housing Angle° 90
2
Hexalobular bolt Nm 12
BA27.55-P-1005-
Bolt, oil cooling line double clamp to bracket Nm 8
01D
BA27.55-P-1006-
Bolt, oil cooling line double clamp to engine oil pan Nm 8
01D
TRANSMISSION OIL COOLING
Transmission 722.6 in
Number Designation
model 204, 216, 221
Stage 1 Nm 5
Banjo bolt or union nut, oil cooler line to
BA27.55-P- Stage 2 Angle° 90
torque converter and transmission
1002-01B Hexalobular
housing Nm 12
bolt
BA27.55-P-
Bolt, oil cooling line double clamp to engine oil pan Nm 10
1009-01B
BA27.55-P-
Bolt, oil cooling line double clamp to bracket Nm 10
1010-01B
Fig. 175: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1028-04A Cleaner from package
REMOVE/INSTALL OIL LINES OF OIL COOLING FOR AUTOMATIC TRANSMISSION -
AR27.55-P-0600SYZ
TRANSMISSION 722.9 in MODEL 221.0 /1, 216.3 with 4MATIC
Fig. 176: Identifying Oil Lines Of Oil Cooling Remove/Install Components For Automatic Transmission
(1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 177: Identifying Oil Lines Of Oil Cooling Remove/Install Components For Automatic Transmission
(2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 178: Identifying Oil Lines Of Oil Cooling Remove/Install Components For Automatic Transmission
(3 Of 3)
Courtesy of MERCEDES-BENZ USA
Remove/install
Before starting work the
area surrounding the oil
cooling lines (7, 8) on the
transmission and the
supply line (6) on the
transfer case must be
thoroughly cleaned in the
area around the separation
points. Even the smallest
dirt particles, introduced
into the hydraulic
components, can lead to
malfunctions and a total
failure of the transmission
The right-hand oil cooling
line (7) and supply line
(6) are rigidly connected
to each other and can
therefore only be removed
together
In the supply line (6) a
restrictor (6a) and a filter
cartridge (6b) is fitted in
the connector to the
transfer case
1 Open engine hood and
raise to vertical position
2 Detach oil cooling lines AR27.10-P-0501-03SX
(7, 8) from radiator Fig. 179
Left oil cooling line (8)
3 Mount engine hoist Raise the engine until AR33.10-P-0105SX
the engine mounts are
completely relieved of
load.
4 Loosen engine mounts on Model 221 *BA22.10-P-1001-03D
front axle carrier Model 216 *BA22.10-P-1001-03C
5 Detach connector (1) of Installation: Replace
oil cooling line (8) on sealing rings.
transmission *BA27.55-P-1002-01D
6 Detach retaining clamps *BA27.55-P-1003-01D
(10, 12, 14) from engine
oil pan
7 Detach double clamp (4) *BA27.55-P-1005-01D
of oil cooling lines (7, 8)
8 Remove oil cooling line
(8)
Right-hand oil cooling
line (7) with supply line
(6)
9 Remove rear engine AR22.10-P-1180SW
crossmember
10 Detach retaining clamp *BA27.55-P-1006-01D
(5) of supply line (6) on
transmission housing
11 Detach connector (3) of Installation: Replace
supply line (6) on transfer restrictor (6a) and filter
case cartridge (6b) and pay
attention to correct seat in
the supply line (6).
Installation: Replace
sealing rings.
*BA27.55-P-1007-01D
12 Install rear engine AR22.10-P-1180SW
crossmember
13 Remove front axle carrier AR33.10-P-0100SYZ
14 Detach connector (1) of Installation: Replace
oil cooling line (8) on sealing rings.
transmission *BA27.55-P-1002-01D
15 Detach retaining clamps *BA27.55-P-1006-01D
(10, 12, 14) from engine
oil pan
16 Detach double clamp (4) *BA27.55-P-1005-01D
of oil cooling lines (7, 8)
17 Detach connector (2) of Installation: Replace
oil cooling line (7) on sealing rings.
transmission *BA27.55-P-1002-01D
18 Detach retaining clamps *BA27.55-P-1006-01D
(9, 11, 13) from engine oil
pan
19 Remove oil cooling line
(7) with supply line (6)
20 Install in the reverse order
21 Check transmission oil AR27.00-P-0270SYZ
level and correct if
necessary
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes.
caused by contusions and Do not touch hot or
burns during starting rotating parts.
procedure or when
working near the engine
as it is running
22 Perform engine test run;
when doing so, check
transmission for oil leaks
and that it is functioning
correctly
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Number Designation Model 221.08/094/18/194
BA22.10-P-1001-03D Bolt, front engine mount to front axle carrier Nm 30
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Number Designation Model 216.386/394
BA22.10-P-1001-03C Bolt, front engine mount to front axle carrier Nm 28
TRANSMISSION OIL COOLING SYSTEM
Transmission
Number Designation
722.9
Stage
Nm 5
Banjo 1
BA27.55-P-1002- Bolt, transmission oil line to bolt Stage
01D transmission housing Angle° 90
2
Hexalobular bolt Nm 12
BA27.55-P-1003-
Bolt, oil cooler line to engine oil pan Nm 12
01D
BA27.55-P-1005-
Bolt, oil cooling line double clamp to bracket Nm 8
01D
BA27.55-P-1006-
Bolt, oil cooling line double clamp to engine oil pan Nm 8
01D
BA27.55-P-1007-
Oil cooling line/oil supply line on transfer case Nm 12
01D
Fig. 179: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
ACCESSORIES & BODY, CAB
Electrical System, Equipment & Instructions - Retrofitting & Conversion - S-Class (221)
RETROFITTING & CONVERSION
RETROFIT SPLITVIEW DISPLAY WIRING HARNESS - AN54.30-P-1000-01SX
Connection scheme
Fig. 1: Splitview Display Wiring Harness Connection Diagram
Courtesy of MERCEDES-BENZ USA
Routing diagram
Fig. 2: Splitview Display Wiring Harness Routing Diagram
Courtesy of MERCEDES-BENZ USA
1. Rotate cockpit wiring harness and FFS [RBA] connector (X18) and detach from bracket (9).
2. Release blue connector (10-pin) (10) from white connector (20-pin) (6) and detach together with the
white connector (10-pin) (11).
3. Release bracket (12) at connector (20-pin) (6) and remove.
4. Release white coupling (20-pin) (5) and detach from white connector (20-pin) (6).
5. Release lock (13) on white connector (20-pin) (6) and detach in the direction of the arrow.
Fig. 3: Detaching Lock White Connector
Courtesy of MERCEDES-BENZ USA
6. Release locks (14) on blue coupling (12-pin) (7) of vehicle wiring harness.
7. Remove vehicle wiring harness from blue coupling (12-pin) (7) as follows:
Contact cavity 1= brown line (br)
Contact cavity 2= red/blue line (rt/bl)
Contact cavity 4= black line (sw)
Contact cavity 10= black/white line (sw/ws)
The blue coupling (12-pin) (7) of the vehicle wiring harness is no longer required.
Fig. 4: Identifying Blue Coupling Connector Terminals
Courtesy of MERCEDES-BENZ USA
8. Route SPLITVIEW display wiring harness (2) and headphones wiring harness (3) to the right to the glove
box.
9. Install vehicle wiring harness in blue coupling (12-pin) (7) on SPLITVIEW display wiring harness (2):
Contact cavity 1= brown line (br)
Contact cavity 2= red/blue line (rt/bl)
Contact cavity 4= black line (sw)
Contact cavity 10= black/white line (sw/ws)
10. Fix SPLITVIEW display wiring harness (2) and headphones wiring harness (3) in place on vehicle wiring
harness with a cable tie (15).
Fig. 5: Identifying Blue Coupling Wiring Harness
Courtesy of MERCEDES-BENZ USA
11. Route SPLITVIEW display wiring harness (2) and headphones wiring harness (3) over air duct (16).
12. Route headphones wiring harness (3) behind air conditioner housing (17) into front passenger footwell.
13. Route SPLITVIEW display wiring harness (2) in front of air conditioner housing (17) to white connector
(20-pin) (6) using a pull-through device.
14. Fix SPLITVIEW display wiring harness (2) and headphones wiring harness (3) in place on existing
wiring harnesses with cable ties.
Fig. 6: Routing Splitview Display Wiring Harness And Headphones Wiring Harness
Courtesy of MERCEDES-BENZ USA
15. Install SPLITVIEW display wiring harness (2) in white connector (20-pin) (6) as follows:
Contact cavity 17 = transparent line (tr)
Contact cavity 18 = yellow line (ge)
Contact cavity 19= brown line (br)
Contact cavity 20= black line (sw)
16. Install lock (13) and bracket (12) on white connector (20-pin) (6).
17. Connect blue connector (10-pin) (10) and white connector (10-pin) (11) to white connector (20-pin) (6).
Fig. 7: Identifying 20-Pin White Connector Terminals
Courtesy of MERCEDES-BENZ USA
18. Allow headphones wiring harness (3) to hang into the front passenger footwell with a length of approx.
300 mm measured from the attachment (arrow A) of the existing wiring harness on the air conditioner
housing (17).
19. Fix headphones wiring harness (3) in place on the existing wiring harness with a cable tie, place any
excess length in loops and also fix in place with cable ties.
Fig. 8: Identifying Headphones Wiring Harness And Air Conditioner Housing
Courtesy of MERCEDES-BENZ USA
Fig. 9: Identifying Black Contact Carrier (20-Pin) Connector Terminals
Courtesy of MERCEDES-BENZ USA
20. Release black contact carrier (20-pin) (5.1) of white coupling (20-pin) (5) (arrow B) and guide out of the
housing to the side.
21. Install COMAND wiring harness into black contact carrier (20-pin) (5.1) as follows:
Contact cavity 17 = transparent line (tr)
Contact cavity 18 = yellow line (ge)
Contact cavity 19= brown line (br)
Contact cavity 20= black line (sw)
22. Insert black contact carrier (20-pin) (5.1) into housing of white coupling (20-pin) (5) and lock.
23. Connect white coupling (20-pin) (5) and white connector (20-pin) (6) and lock.
24. Attach cockpit wiring harness and FFS [RBA] connector (X18) to bracket (9).
25. Using a pull-through device, route COMAND wiring harness (1) along existing wiring harnesses in front
of air conditioner housing (17) and over air duct (16) to installation opening of COMAND controller unit.
Fig. 10: Routing COMAND Wiring Harness In Front Of Air Conditioner Housing And Over Air
Duct
Courtesy of MERCEDES-BENZ USA
26. Release gray contact carrier (20-pin) (4.1) in black coupling (40-pin) (4) (arrow C) and guide out of the
housing to the side.
27. Install COMAND wiring harness into gray contact carrier (20-pin) (4.1) as follows:
Contact cavity 7 = yellow line (ge)
Contact cavity 8= brown line (br)
Contact cavity 17= black line (sw)
Contact cavity 18 = transparent line (tr)
28. Install gray contact carrier (20-pin) (4.1) into housing of black coupling (40-pin) (4).
Fig. 11: Identifying Gray Contact Carrier & Housing Of Black Coupling
Courtesy of MERCEDES-BENZ USA
29. Clip headphones jack (8) on headphones wiring harness (3) into the corresponding hole in the cover under
the instrument panel on the right (18).
30. Fix headphones wiring harness (3) to cover under instrument panel on right (18) (arrow D).
Fig. 12: Locating Headphones Jack, Wiring Harness & Cover Under Instrument Panel
Courtesy of MERCEDES-BENZ USA
PREPARE WIRING HARNESS FOR RETROFITTING TO SPLITVIEW DISPLAY - AN54.30-P-1000-
02SX
1. Spread main wiring harness for instrument panel over a worktable
2. Release and open cable duct (1).
3. Remove cable ties (2) on main wiring harness for instrument panel.
4. Remove felt tape on main wiring harness for instrument panel, starting from the blue 12-pin coupling (3)
and into the cable duct (1).
Fig. 13: Identifying Cable Duct, Cable Ties And 12-Pin Coupling
Courtesy of MERCEDES-BENZ USA
5. Remove cable ties (4) on main wiring harness for instrument panel.
6. Remove felt tape on the main wiring harness for the instrument panel, starting from the cable duct (1) up
to the white 20-pin plug (5), and expose the SPLITVIEW display (6) wiring harness and the headphones
wiring harness (7) by doing so.
Fig. 14: Identifying Cable Duct, Headphones Wiring Harness And White 20-Pin Plug
Courtesy of MERCEDES-BENZ USA
7. Release locks (8) on blue 12-pin coupling (3).
8. Remove main wiring harness for the instrument panel as follows from the blue 12-pin coupling (3):
Contact cavity 1= brown line (br)
Contact cavity 2= red/blue line (rt/bl)
Contact cavity 4= black line (sw)
Contact cavity 10= black/white line (sw/ws)
Fig. 15: Identifying 12-Pin Coupling Connector Terminals
Courtesy of MERCEDES-BENZ USA
9. Release blue 10-pin plug (9) from white 20-pin plug (5) and remove.
10. Release lock (10) from white 20-pin plug (5), slide out in direction of the arrow at side and remove.
11. Remove SPLITVIEW display wiring harness as follows from the white 20-pin plug (5):
Contact cavity 17 = transparent line (tr)
Contact cavity 18 = yellow line (ge)
Contact cavity 19 = brown line (br)
Contact cavity 20= black line (sw)
Fig. 16: Identifying White 20-Pin Plug Connector Terminals
Courtesy of MERCEDES-BENZ USA
12. Use felt tape to wrap the SPLITVIEW display (6) wiring harness together with the headphones wiring
harness (7) to a length of approx. 400 mm from the blue 12-pin coupling (3).
13. Wrap felt tape another approx. 400 mm around the SPLITVIEW display (6) wiring harness.
Fig. 17: Identifying Splitview Display Wiring Harness, Headphones Wiring Harness And Blue 12-
Pin Coupling
Courtesy of MERCEDES-BENZ USA
14. Use felt tape to wrap COMAND wiring harness (11) approx. 180 mm behind the red/gray marking
(arrow) to a length of approx. 600 mm.
Fig. 18: Wrapping COMAND Wiring Harness
Courtesy of MERCEDES-BENZ USA
RETROFIT SPLITVIEW DISPLAY - AN54.30-P-1000SX
MODEL 221.0## (except 221.077) 1# except CODE (494) USA version except CODE (498) Japan version
with CODE (800) Model year 2010
MODEL 221.1## (except 221.177) 1# except CODE (494) USA version except CODE (498) Japan version
except CODE (Z07) Top protection with CODE (800) Model year 2010
Fig. 19: Identifying SPLITVIEW Display Components
Courtesy of MERCEDES-BENZ USA
Removing
Information on preventing damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
Detach ground line of on-board electrical AR54.10-P-
1
system battery 0003SX
Installation: Install the cockpit AR54.25-P-
2 Remove cockpit switch group (S6/2) switch group (S6/2) included in the
1000SX
delivery contents.
Installation: Install the AR82.85-P-
3 Remove COMAND display (A40/8) SPLITVIEW display (A40/10)
7429SX
included in the delivery contents.
AR82.85-P-
4 Remove COMAND controller unit (A40/3)
1100SX
AR68.10-P-
5 Remove glove compartment (1)
1400SX
Fold the floor covering (2) in the front
6
passenger footwell to the rear
7 Unscrew nuts (3) and fold back footrest (4)
Install
Prepare wiring harness for retrofitting to AN54.30-P-
8
SPLITVIEW display (A40/10) 1000-02SX
Retrofit SPLITVIEW display wiring harness AN54.30-P-
9
(A40/10) 1000-01SX
10 Install remaining parts onto vehicle Operation steps 7 up to 1.
Open glove box lid and clip holder (5) for Note the installation position of
11 remote control (6) into corresponding cutouts the bracket (5). The rear cutout (arrow
(arrows A and B) in glove box (1) A) is T-shaped.
Insert remote control (6) into holder (5) and
12
place headphones into glove box (1)
13 Connect STAR DIAGNOSIS
Enter special equipment on the vehicle data Code (867) Retrofit
14
card and the online vehicle data card SPLITVIEW.
Carry out variant coding with the Diagnosis
15 Assistance System by means of Software
Calibration Number (SCN)
16 Close STAR DIAGNOSIS
PARTS ORDERING NOTES
Part no. Designation Quantity
DG 99 (see EPC) SPLITVIEW display delivery contents 1
RETROFIT BACKUP CAMERA CONTROL UNIT - AN54.65-P-0030-01SX
Fig. 20: Identifying Backup Camera Control Unit Components
Courtesy of MERCEDES-BENZ USA
Vehicles with voice control system (VCS [SBS]) control unit (N41/3)
1. Loosen nuts (4) and bolt (5), remove bracket (2) with voice control system (VCS [SBS]) control unit
(N41/3).
Do not disconnect electrical connectors of voice control system (VCS [SBS]) control unit
(N41/3).
2. Insert backup camera control unit (N66/2) with studs in bracket (2) and fasten with nuts (3).
3. Position bracket (2) with backup camera control unit (N66/2) on body studs and fasten with nuts (4) and
bolt (5).
Vehicles without voice control system (VCS [SBS]) control unit (N41/3)
4. Fasten backup camera control unit (N66/2) in new bracket (2) and with nuts (3).
5. Position bracket (2) with backup camera control unit (N66/2) on body studs and fasten with nuts (4) and
bolt (5).
RETROFIT CAMERA - AN54.65-P-0030-02SX
Fig. 21: Identifying Camera Components
Courtesy of MERCEDES-BENZ USA
1. Detach license plate from trunk lid (6).
2. Remove umbrella holder (7).
3. Remove hazard warning triangle (8) and remove bracket (9)
4. Remove cover (10).
5. Remove hinge bracket trim piece (11).
6. Remove trim of trunk lid (12).
7. Unscrew bolts (13) on inside of trunk lid release (14).
8. Unclip clips (16) of cover (15) starting from the right. Detach adhesive tape (17) and remove cover (15).
The cover (15) without cutout for backup camera is no longer required and later on is replaced by
a new cover (15) with cutout for backup camera.
Fig. 22: Identifying Backup Camera Components
Courtesy of MERCEDES-BENZ USA
9. Remove cap (18) from trunk lid (6).
The cap (18) is no longer required.
10. Insert black 4-pin connector (19) and line branch off (20) of backup camera (B84/3) from outside in the
trunk lid cutout and clip backup camera (B84/3) into the trunk lid (6) as per picture (6).
Later on connect black 4-pin connector (19) in the trunk lid (6) with the wiring harness of the
backup camera.
RETROFIT CAMERA - AN54.65-P-0030-02SY
Fig. 23: Identifying Camera Components
Courtesy of MERCEDES-BENZ USA
1. Take out hazard warning triangle (4) and remove holder (5).
2. Remove paneling (3).
3. Remove left and right hinge bracket trim piece (7).
4. Remove trim of trunk lid (8).
5. Remove bolts (9) from trunk lid switch group (S88).
6. Unclip clips (10) securing cover (11) starting from right. Detach adhesive pad (14) and remove cover (11)
from trunk lid (6).
The cover (11) is no longer required.
Fig. 24: Identifying Reversing Camera Components
Courtesy of MERCEDES-BENZ USA
7. Remove plug (18) from trunk lid (6).
The plug (18) is no longer required.
8. Guide black 4-pin connector (19) and line (20) of reversing camera (B84/3) from outside into cutout in
trunk lid (6) and clip reversing camera (B84/3) into trunk lid (6) as shown in picture.
Later, connect the black 4-pin connector (19) in the trunk lid (6) to the reversing camera wiring
harness.
RETROFIT BACKUP CAMERA WIRING HARNESS - AN54.65-P-0030-03SX
Fig. 25: Identifying Backup Camera Wiring Harness Component Connections
Courtesy of MERCEDES-BENZ USA
Routing diagram for backup camera wiring harness (1)
Fig. 26: Backup Camera Wiring Harness Routing Diagram
Courtesy of MERCEDES-BENZ USA
1. Contact white 32-pin coupling (21) and white 1-pin coupling (22) of backup camera wiring harness (1) at
backup camera control unit (N66/2) (see enlarged detail at bottom).
2. Route and fasten backup camera wiring harness (1) in luggage compartment as per picture.
Position white length adjustment marking (ws) of backup camera wiring harness (1) in alignment
on the white length adjustment markings of the vehicle's own wiring harnesses.
3. Connect brown line of ground (br) of backup camera wiring harness (1) to ground (left wheelhouse in
luggage compartment) (W6) and fasten to vehicle's own wiring harnesses (see enlarged detail at top).
Fig. 27: Routing & Connecting Backup Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
4. Route black 4-pin coupling of backup camera wiring harness (1) to the trunk lid (6) as per picture.
5. Route black fuse carrier of backup camera wiring harness (1) to the rear end SAM control unit with rear
fuse and relay module (N10/2) and attach to the vehicle's own wiring harnesses.
6. Route the remaining line branch offs of the backup camera wiring harness (1) through the body punched
hole from the luggage compartment into the left of the interior.
7. Contact the black fuse carrier (23) of the backup camera wiring harness (1) as per picture on slot 141 of
the rear end SAM control unit with rear fuse and relay module (N10/2) and equip with 5 amp fuse.
The slot 141 of the rear end SAM control unit with rear fuse and relay module (N10/2) is marked
in color and mechanically coded.
Fig. 28: Identifying 4-Pin Coupling Of Backup Camera Wiring Harness, Relay Module And Black
Fuse Carrier
Courtesy of MERCEDES-BENZ USA
8. Fix the line branch off with black 4-pin coupling of the backup camera wiring harness (1) in position with
the fixing clips attached to the line branch off as per picture (see arrows).
Fig. 29: Fixing Line Branch Off With Black 4-Pin Coupling Of Backup Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
9. Route black 4-pin coupling (24) of the backup camera wiring harness (1) in the trunk lid as per picture (6)
and fix in position with the fixing clips attached (see arrows).
10. Install line holder (25) (see enlarged detail).
Fig. 30: Locating Fixing Clips
Courtesy of MERCEDES-BENZ USA
11. Connect black 4-pin connector (19) of backup camera (B84/3) with black 4-pin coupling (24) of backup
camera wiring harness (1) and pull protective sleeve (26) over the backup camera connector.
12. Route line branch off (20) of backup camera (B84/3) as per picture into a loop and fasten to the vehicle's
own wiring harnesses with cable ties (see arrow).
Fig. 31: Identifying Black 4-Pin Connector Of Backup Camera, Black 4-Pin Coupling, Backup
Camera Wiring Harness And Protective Sleeve
Courtesy of MERCEDES-BENZ USA
Fig. 32: Identifying Backup Camera Components
Courtesy of MERCEDES-BENZ USA
13. Attach adhesive tape (17) to cover of the trunk lid release (15) with cutout for Backup camera.
14. Starting from the right clip in cover of trunk lid release (15) with clips (16) at the trunk lid (6) and press
on adhesive tape (17) of the cover of the trunk lid release (15) at the trunk lid (6)
15. Remove protective foil from lens of backup camera (B84/3).
16. Screw in the screws (13) on inside of trunk lid release (14).
17. Install trim of trunk lid (12).
18. Install hinge bracket trim piece (11).
19. Install cover (10).
20. Install holder (9) and insert hazard warning triangle (8).
21. Install umbrella holder (7).
22. Attach license plate to trunk lid (6).
23. Open covers of cable duct (27) (see enlarged detail).
24. Route backup camera wiring harness (1) as per picture from the body punched hole of the luggage
compartment into the rear footwell and fasten to the vehicle's own wiring harnesses.
Position green length adjustment marking (gn) of backup camera wiring harness (1) in alignment
on the green length adjustment markings of the vehicle's own wiring harnesses.
25. Close the covers of the cable duct (27).
Fig. 33: Identifying Back Up Camera Wiring Harness And Cable Duct
Courtesy of MERCEDES-BENZ USA
26. Route line branch off with blue (bl) length adjustment marking of the backup camera wiring harness(1)
(see enlarged detail) in the cable ducts up to the center console and fasten to the vehicle's own wiring
harnesses.
Route line branch off with blue (bl) length adjustment marking of the backup camera wiring
harness (1) with the pull-in aid when the cable duct covers are only partially open into the center console
and position the blue (bl) length adjustment marking in alignment on the blue (bl) length adjustment
markings of the vehicle's own wiring harnesses (see enlarged detail).
27. Route the line branch off with black 2-pin coupling of the backup camera wiring harness (1) to the
voltage distributor connector (X30/32), contact the black 2-pin coupling of the backup camera wiring
harness (1) at any free slot of the voltage distributor connector (X30/32) and fasten the line branch off to
the vehicle's own wiring harness.
Fig. 34: Routing Line Branch Off With Black 2-Pin Coupling Of Backup Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
28. Unlock lock (see arrow) to the side of the vehicle's own COMAND coupling housing (29) and remove
black 20-pin contact carrier (28) from the COMAND coupling housing (29).
29. Install transparent line (tr) of backup camera wiring harness (1) in contact cavity 7 of the black 20-pin
contact carrier (28).
Depending on the version the transparent line (tr) of the backup camera wiring harness (1) may
also be black.
30. Install screening line (sc) of the backup camera wiring harness (1) in contact cavity 17 of the black 20-pin
contact carrier (28).
The screening line (sc) of the backup camera wiring harness (1) is thicker than the transparent line
(tr) of the backup camera wiring harness (1).
31. Install 20-pin contact carrier (28) in COMAND coupling housing (29).
Fig. 35: Identifying 20-Pin Contact Carrier And COMAND Coupling Housing
Courtesy of MERCEDES-BENZ USA
RETROFIT BACKUP CAMERA WIRING HARNESS - AN54.65-P-0030-03SY
Fig. 36: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Courtesy of MERCEDES-BENZ USA
Connection diagram
Fig. 37: Backup Camera Wiring Harness Connection Diagram
Courtesy of MERCEDES-BENZ USA
Routing diagram
Fig. 38: Backup Camera Wiring Harness Routing Diagram
Courtesy of MERCEDES-BENZ USA
1. Connect white 6-pin connector (15) and black 4-pin connector (16) of reversing camera wiring harness
(1) to power supply module for reversing camera (N66/10).
2. Detach gray/black backup light signal line (gr/sw) from reversing camera wiring harness (1) and route to
rear of left taillamp (E3).
Fig. 39: Identifying Connectors Of Reversing Camera Wiring Harness, Power Supply Module And
Reversing Camera
Courtesy of MERCEDES-BENZ USA
3. Shorten gray/black backup light signal line (gr/sw).
The gray/black backup light signal line (gr/sw) is too long and must be shortened. The length must
be measured such that the gray/black backup light signal line (gr/sw) and the electrical line (17) can be
connected to a potential distributor (30).
4. Connect gray/black backup light signal line (gr/sw) and electrical line (17) to potential distributor (30).
The electrical line (17) is in slot 3 of coupling (31).
Use the potential distributor (30) from the basic wiring harness repair kit.
5. Secure gray/black backup light signal line (gr/sw) to on-board wiring harnesses.
Shown on code (432) Left and right dynamic multicontour seat
Fig. 40: Connecting Gray/Black Backup Light Signal Line And Electrical Line To Potential
Distributor
Courtesy of MERCEDES-BENZ USA
When carrying out the following work procedure, make sure that the reversing camera wiring harness
(1) is installed such that it is not kinked and does not rub against other components, otherwise the
reversing camera wiring harness (1) could be damaged.
The reversing camera wiring harness (1) must be routed and secured such that the existing length
reference markings correspond to the markings on the on-board wiring harnesses, otherwise it could
cause noises when the vehicle is in use.
6. Route and secure reversing camera wiring harness (1) in luggage compartment as shown in picture.
Observe the white length reference marking (ws) and the corresponding length reference markings
on the on-board wiring harnesses.
7. Connect brown ground line (br) of reversing camera wiring harness (1) to ground (left wheel well in
luggage compartment) (W6) and secure to vehicle's wiring harness.
8. Route branch-off line of reversing camera wiring harness (1) with black 4-pin connector for reversing
camera connector to trunk lid as shown in picture.
9. Route red power supply line (rt) of reversing camera wiring harness (1) to SAM control unit with rear
fuse and relay module (N10/2) as shown in picture and secure to on-board wiring harnesses.
10. Route remaining branch-off lines of reversing camera wiring harness (1) from luggage compartment to
vehicle interior through body opening on left C-pillar.
11. Connect black fuse carrier (23) of reversing camera wiring harness (1) to slot 141 on SAM control unit
with rear fuse and relay module (N10/2) as shown in picture and insert 5 A fuse.
mechanically coded.
Fig. 41: Routing Remaining Branch-Off Lines Of Reversing Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
12. Secure branch-off line of reversing camera wiring harness (1), with black 4-pin connector for reversing
camera connector, to left hinge lever of trunk lid (6) and to underside of rear shelf (arrows) as shown in
picture.
Secure the branch-off line of the reversing camera wiring harness (1) using the attached clips.
Fig. 42: Securing Branch-Off Line Of Reversing Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
13. Route black 4-pin connector (24) of reversing camera wiring harness (1) along trunk lid (6) as shown in
picture, and secure using clips attached to branch-off line (arrows).
14. Secure reversing camera wiring harness (1) along trunk lid (6) using cable tie (25) as shown in picture.
Fig. 43: Securing Reversing Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
15. Connect black 4-pin connector (41) of reversing camera (B84/3) to black 4-pin connector (24) of
reversing camera wiring harness (1).
The reversing camera connector (B84/3x1) is now complete.
16. Pull protective sleeve (26) over reversing camera connector (B84/3x1).
17. Route line (40) of reversing camera (B84/3) as shown in picture so that it forms a loop, and secure to on-
board wiring harnesses using cable tie (arrow).
Fig. 44: Routing Line Of Reversing Camera
Courtesy of MERCEDES-BENZ USA
Fig. 45: Identifying Adhesive Pad, Cover, Trunk Lid And Clips
Courtesy of MERCEDES-BENZ USA
18. Peel protective foil off adhesive pad (14).
19. Clip new cover (11) with recess into trunk lid (6) starting from right, and press adhesive pad (14) of cover
(11) firmly onto trunk lid (6).
Make sure that all clips (10) are engaged fully.
20. Remove protective foil from lens of reversing camera (B84/3).
21. Tighten bolts (9) on inside of trunk lid switch group (S88).
22. Install trim of trunk lid (8).
23. Install left and right hinge bracket trim piece (7).
24. Install panel (3).
25. Install holder (5) and insert hazard warning triangle (4).
Fig. 46: Identifying Expansion Clips, Floor Covering, Air Distribution Flap And Air Vent
Courtesy of MERCEDES-BENZ USA
26. Install air vent (32) below driver seat.
27. Unclip and remove line guide (33).
28. Remove expansion clips (34) and fold rear floor covering (35) over toward vehicle center.
29. Fold front floor covering (36) over until air distribution flap (37) is accessible.
30. Detach air distribution flap (37) from air ducts (38) and place to one side.
Fig. 47: Routing Reversing Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
31. Open cable duct covers (27).
32. Open cable duct (39) of left frame floor assembly.
33. Route reversing camera wiring harness (1), as shown, and fasten to vehicle's wiring harnesses.
Observe the white length reference marking (ws) and the corresponding length reference markings
on the on-board wiring harnesses.
34. Close cable duct covers (27).
35. Route reversing camera wiring harness (1) into cable duct (39) as shown in picture, and secure to on-
board wiring harness.
36. Using an insertion aid, route reversing camera wiring harness (1) forwards into corresponding cable ducts
as far as installation location of COMAND controller unit in center console. Position blue length
reference marking (bl) of reversing camera wiring harness (1) so that it is in alignment with length
reference marking of same color on on-board wiring harness.
37. Secure reversing camera wiring harness (1) to on-board wiring harness.
Fig. 48: Routing Reversing Camera Wiring Harness Into Cable Ducts
Courtesy of MERCEDES-BENZ USA
38. Unlock lock (arrow) on side of on-board COMAND coupling housing (29) and remove black 20-pin
contact carrier (28) from COMAND coupling housing (29).
39. Install transparent line (tr) of reversing camera wiring harness (1) in contact cavity 7 of black 20-pin
contact carrier (28).
40. Install screened line (sc) of reversing camera wiring harness (1) in contact cavity 17 of black 20-pin
contact carrier (28).
41. Install black 20-pin contact carrier (28) in COMAND coupling housing (29).
Fig. 49: Locating Black 20-Pin Contact Carrier
Courtesy of MERCEDES-BENZ USA
RETROFIT BACKUP CAMERA WIRING HARNESS - AN54.65-P-0030-03SZ
Fig. 50: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Courtesy of MERCEDES-BENZ USA
Connection scheme
Fig. 51: Backup Camera Wiring Harness Connection Diagram
Courtesy of MERCEDES-BENZ USA
Routing diagram
Fig. 52: Backup Camera Wiring Harness Routing Diagram
Courtesy of MERCEDES-BENZ USA
Ensure that the wiring harnesses are not damaged by chafing or being trapped otherwise the appropriate
wiring harness must be replaced.
1. Connect white 6-pin connector (15) and black 4-pin connector (16) of reversing camera wiring harness
(1) to power supply module for reversing camera (N66/10).
2. Route reversing camera wiring harness (1), as shown, along given wiring harnesses into trunk and fasten
in place.
Observe white and red length reference marking (L) and the corresponding length reference
markings on the on-board wiring harnesses.
3. Connect brown line (br) of reversing camera wiring harness (1) to ground (left wheel well in luggage
compartment) (W6) and secure to vehicle's wiring harness.
Fig. 53: Routing Reversing Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
4. Route gray/black line (gr/sw) along given wiring harnesses to left rear light unit (E3) and fasten in place.
5. Cut gray/black line (gr/sw) of reversing camera wiring harness and connect with a potential distributor
(30) to the gray/black line on the connector (31) of the left taillamp (E3).
The potential distributor (30) can be obtained from the wiring harness repair kit.
Fig. 54: Routing Gray/Black Line Along Wiring Harnesses
Courtesy of MERCEDES-BENZ USA
6. Route red line (rt) of reversing camera wiring harness (1) along given wiring harnesses to the rear SAM
control unit with fuse and relay module (N10/2) and fasten in place.
7. Connect black fuse carrier (23) of reversing camera wiring harness (1) to slot 141 on SAM control unit
with rear fuse and relay module (N10/2), as shown, and insert a 5 A fuse.
Slot 141 on the SAM control unit with rear fuse and relay module (N10/2) is colored and
mechanically coded.
8. Route remaining branch-off lines of reversing camera wiring harness (1) from luggage compartment to
vehicle interior through body opening on left C-pillar.
Fig. 55: Routing Red Line Of Reversing Camera Wiring Harness Along Wiring Harnesses
Courtesy of MERCEDES-BENZ USA
9. Secure branch-off line of reversing camera wiring harness (1), with black 4-pin connector for reversing
camera connector, to left hinge lever of trunk lid (6) and to underside of rear shelf (arrows) as shown in
picture.
Secure the branch-off line of the reversing camera wiring harness (1) using the attached clips.
Fig. 56: Securing Branch-Off Line Of Reversing Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
10. Route black 4-pin connector (24) of reversing camera wiring harness (1) along trunk lid (6) as shown in
picture, and secure using clips attached to branch-off line (arrows).
11. Secure reversing camera wiring harness (1) along trunk lid (6) using cable tie (25) as shown in picture.
Fig. 57: Locating Clips Attached To Branch-Off Line
Courtesy of MERCEDES-BENZ USA
12. Connect black 4-pin connector (41) of reversing camera (B84/3) to black 4-pin connector (24) of
reversing camera wiring harness (1).
The reversing camera connector (B84/3x1) is now complete.
13. Pull protective sleeve (26) over reversing camera connector (B84/3x1).
14. Route line (40) of reversing camera (B84/3) as shown in picture so that it forms a loop, and secure to on-
board wiring harnesses using cable tie (arrow).
Fig. 58: Routing Line Of Reversing Camera
Courtesy of MERCEDES-BENZ USA
15. Peel protective foil off adhesive pad (14).
16. Clip cover (11) into trunk lid (6) starting from right, and press adhesive pad (14) of cover (11) firmly onto
trunk lid (6).
Make sure that all clips (10) are engaged fully.
17. Remove protective foil from lens of reversing camera (B84/3).
18. Tighten screws (9) on inside of trunk lid external operation switch (S88/8).
Fig. 59: Identifying Clip Cover, Trunk Lid, Adhesive Pad, Clips And Reversing Camera
Courtesy of MERCEDES-BENZ USA
19. Fit trunk lid cover (8) to trunk lid (6).
20. Install left and right hinge bracket trim piece (7).
21. Install panel (3).
22. Install holder (5) and insert hazard warning triangle (4).
Fig. 60: Identifying Trunk Lid Cover, Trunk Lid, Hinge Bracket Trim Piece, Panel And Holder
Courtesy of MERCEDES-BENZ USA
23. Install air vent (32) below driver seat.
24. Unclip and remove line guide (33).
Fig. 61: Identifying Air Vent And Line Guide
Courtesy of MERCEDES-BENZ USA
25. Remove expansion clips (34) and fold rear floor covering (35) over toward vehicle center.
26. Fold front floor covering (36) over until air distribution flap (37) is accessible.
27. Detach air distribution flap (37) from air ducts (38) and place to one side.
Fig. 62: Identifying Rear Floor Covering, Expansion Clips, Front Floor Covering, Air Distribution
Flap And Air Ducts
Courtesy of MERCEDES-BENZ USA
28. Open cable duct (27).
29. Open cable duct (39) of left frame floor assembly.
30. Route reversing camera wiring harness (1), as shown, along given wiring harnesses into cable ducts (27,
39) and fasten in place.
Observe the white length reference marking (L) and the corresponding length reference markings
on the on-board wiring harnesses.
31. Close cable ducts (27, 39).
Fig. 63: Routing Reversing Camera Wiring Harness
Courtesy of MERCEDES-BENZ USA
32. Route reversing camera wiring harness (1), as shown, into cable duct (39).
33. Using an insertion aid, route reversing camera wiring harness (1) forwards into cable ducts as far as
installation location of COMAND controller unit in center console.
Observe blue length reference marking (L) and the corresponding length reference markings on
the on-board wiring harnesses.
34. Attach reversing camera wiring harness (1) to on-board wiring harness.
Insert excess length of branch-off line in area of cable duct (39) and fasten in place.
Fig. 64: Routing Reversing Camera Wiring Harness Into Cable Duct
Courtesy of MERCEDES-BENZ USA
35. Unlock lock (arrow) on side of on-board COMAND coupling housing (29) and remove black 20-pin
contact carrier (28) from COMAND coupling housing (29).
Use the black 20-pin contact carrier (28) with contact cavity assignment 21 to 40.
36. Install transparent line (tr) of reversing camera wiring harness (1) into contact cavity 21 of black 20-pin
contact carrier (28).
37. Install screened line (sc) of reversing camera wiring harness (1) into contact cavity 32 of black 20-pin
contact carrier (28).
The screened line (sc) is thicker than the transparent line (tr).
38. Install black 20-pin contact carrier (28) in COMAND coupling housing (29).
Fig. 65: Locating Lock On Side Of On-Board COMAND Coupling Housing
Courtesy of MERCEDES-BENZ USA
RETROFIT REVERSING CAMERA POWER SUPPLY MODULE - AN54.65-P-0030-06SY
Fig. 66: Locating Camera Power Supply Module Holes
Courtesy of MERCEDES-BENZ USA
1. Clip reversing camera power supply module (N66/10) into existing holes (arrow) in body.
The couplings (2) on the reversing camera power supply module (N66/10) must point downward.
RETROFIT BACKUP CAMERA - AN54.65-P-0030SX
MODEL 221.0## /1## 1A up to 122603 except CODE (494) USA version except CODE (498) Japan
version
MODEL 221.0## /1## 1A as of 122604 up to 154194 except CODE (494) USA version except CODE (498)
Japan version with CODE (806) Model year 2006 with CODE (807) Model year 2007
Fig. 67: Identifying Backup Camera Components
Courtesy of MERCEDES-BENZ USA
Removing
AH54.00-
Information on preventing damage to electronic
P-0001-
components due to electrostatic discharge
01A
1
Remove left front seat AR91.10-P-
1000SX
2 Remove rear seat backrest Left.
Model 221.0 with CODE (223) Rear
bench seat with electrically adjustable
outer seats with PRE-SAFE positioning
function for outer seats and outer head
Model 221.1 with CODE (223) Rear
bench seat with electrically adjustable
outer seats with PRE-SAFE positioning
function for outer seats and outer head AR91.12-P-
restraints, Model 221.1 1620SX
with CODE (224) Design individual
rear seats,
except CODE (Z07) Top protection.
Model 221.0
except code 223 Rear bench seat with
electrically adjustable outer seats with
PRE-SAFE positioning function for
outer seats and outer head restraints,
Model 221.1 AR91.12-P-
except CODE 223 Rear bench seat with 1620SY
electrically adjustable outer seats with
PRE-SAFE positioning function for
outer seats and outer head restraints
except CODE 224 Design individual
rear seats
Risk of explosion caused by oxyhydrogen gas.
Risk of poisoning and caustic burns caused by
No fire, sparks, open flames or AS54.10-Z-
swallowing battery acid. Risk of injury caused
by burns to skin and eyes from battery acid or smoking. Wear acid-resistant gloves, 0001-01A
when handling damaged lead-acid batteries clothing and glasses. Only pour battery
acid into suitable and appropriately
3 Disconnect battery ground line
marked containers.
AR54.10-P-
0003SX
4 Except right side coverings.
Remove trim in trunk Model 221.1 except CODE AR68.30-P-
(Z07) Top protection. 4600SX
5
Remove SAM control unit with fuse and relay Do not disconnect electrical
box in luggage compartment AR54.21-P-
connectors.
1258SX
6
Remove COMAND controller unit Except CODE (529) HIGH AR82.85-P-
Class Japan. 1100SX
Fold up left floor coverings and open cable ducts
7
of left frame floor assembly
Install
AN54.65-P-
8 Retrofit backup camera control unit
0030-01SX
AN54.65-P-
9 Retrofit camera
0030-02SX
10 Retrofit backup camera wiring harness 0030-03SX
11 Install in the reverse order Operation steps 7 up to 1.
12 Perform retrofit variant coding Using STAR DIAGNOSIS
Connect STAR DIAGNOSIS and read out fault carry out variant coding for activating AD00.00-P-
memory the backup camera functions. 2000-04A
13
Calibration of the backup camera AR54.65-P-
0022SX
Add special equipment to the vehicle data card
14 Enter code 218 Backup camera.
and to the online vehicle data card
PARTS ORDERING NOTES
Part no. Designation Quantity
DG 99 (see EPC) Backup camera retrofit kit 1
RETROFIT REVERSING CAMERA - AN54.65-P-0030SY
MODEL 221.0## /1## (except 221.074 /077 /174 /176 /177 /179) 1A as of 122604 up to 154194 with CODE
(808) Model year 2008 except CODE (494) USA version except CODE (498) Japan version except CODE
(Z07) Top protection
MODEL 221.0## /1## (except 221.074 /077 /174 /176 /177 /179) 1A as of 154195 except CODE (494) USA
version except CODE (498) Japan version except CODE (Z07) Top protection
Fig. 68: Identifying Reversing Camera Components
Courtesy of MERCEDES-BENZ USA
Removing
Information on preventing
AH54.00-P-
damage to electronic components
0001-01A
due to electrostatic discharge
AR91.10-P-
1 Remove left front seat
1000SX
On vehicles with code (223) Rear bench seat with
electrically adjustable outer seats with PRE-SAFE
AR91.12-P-
2.1 Remove left rear seat backrest positioning function for outer seats and outer head
1620SX
restraints,
Model 221.1 with code (224) Design rear bucket seats
On vehicles without code (223) Rear bench seat with
electrically adjustable outer seats with PRE-SAFE
AR91.12-P-
2.2 Remove rear seat backrest positioning function for outer seats and outer head
1620SY
restraints, model 221.1 without code (224) Individual
rear seat system design
AR54.10-P-
3 Disconnect battery ground line
0003SX
AR68.30-P-
4 Remove trim in trunk Except trim on right. 4600SX
Detach rear SAM control unit
with fuse and relay module
AR54.21-P-
5 (N10/2) and place to one side
1258SX
with electrical lines still
connected
Detach overpressure reservoir
On vehicles with code (409) Left/right front
and place to one side with AR91.25-P-
6 multicontour seats or code (432) Left and right
electrical and pneumatic lines still 1570SX
dynamic multicontour seat
connected
Remove COMAND controller AR82.85-P-
7
unit (A40/3) 1100SX
Install
Retrofit reversing camera power AN54.65-P-
8
supply module (N66/10) 0030-06SY
AN54.65-P-
9 Retrofit backup camera (B84/3)
0030-02SY
On vehicles without code (800) Model year 2010, or AN54.65-P-
up to production date 31.5.09 0030-03SY
Retrofit reversing camera wiring On vehicles with code (800) Model year 2010 or as AN54.65-P-
10
harness (1) from production date 1.6.09 0030-03SZ
Fig. 36
11 Install remaining parts
12 Connect STAR DIAGNOSIS
Carry out variant coding with the
Diagnosis Assistance System by
13
means of Software Calibration
Number (SCN)
Perform calibration of reversing AR54.65-P-
14
camera (B84/3) 0022SX
Enter special equipment on the
15 vehicle data card and the online Code (218) Enter reversing camera.
vehicle data card
16 Close STAR DIAGNOSIS
Check
Run function test on reversing
17
camera (B84/3)
Fig. 69: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Courtesy of MERCEDES-BENZ USA
PARTS ORDERING NOTES
Part no. Designation Quantity
DG 99 (see EPC) Backup camera retrofit kit 1
ACCESSORIES & BODY, CAB
Electrical System, Equipment & Instructions - General Information - S-Class (221)
GENERAL INFORMATION
INFORMATION ON PREVENTING DAMAGE TO ELECTRONIC COMPONENTS DUE TO
ELECTROSTATIC DISCHARGE - AH54.00-P-0001-01A
All models
Electrostatic charge
Every contact and each physical separation of materials or any movement of solid substances, fluids or
particulate loaded gases can generate electrostatic charges. Plastics generally produce the highest electrostatic
charge.
We come across electrostatic charge or discharge in lots of everyday situations, e.g. with:
Combs
Walking on carpets or plastic floors
Putting on and removing textiles made with synthetic fiber
Disembarking from the vehicle
Contact between various electrostatically chargeable packaging materials in shelves or in the transport
container
The following electrostatic discharge (Electro Static Discharge (ESD)) can be so strong that a small electric
shock is detected. Even the smallest discharges which people cannot detect can cause lasting damage to
electronic components and control units.
Effects and consequences of ESD
Electronic components and control units are very sensitive to ESD. The damage is often not immediately
obvious, but becomes apparent some time later. In order to avoid failures and damage due to ESD in vehicle
electronics, various procedures and safety precautions must be taken into account and followed. Risks of
damage occur during transport, handling, testing, removal and installation of electronic components in
production as well as during repair work.
The following electronic components listed as an example can be damaged by ESD:
Airbag components
Control units, in particular their bus connections (Control Area Network (data bus/CAN bus) (CAN),
local interconnect network (LIN) etc.)
Sensors
Antenna amplifier
Receivers and displays (Radio, TV, GPS, telephone etc.)
Modes of behavior and safety precautions
Electrostatic discharge from the fitter (e.g. due to brief contact with the vehicle body).
Suitable clothing, e.g. made of cotton.
Wear ESD safety shoes with conductive soles.
Keep workplace clean, remove unnecessary objects such as common plastics.
Special anti-static seat cushion protectors must be used when performing repair work inside a vehicle.
Leave replacement parts in the original packaging for as long as possible, Do not cut open seals, but cut
open carefully.
The ESD workplace must conform to the ESD guidelines. ESD protection
gotis://E 82 04.0
Before unpacking, discharge ESD protective packaging at the ESD workplace.
Avoidance of contact with electrostatic chargeable materials such as PE, PVC, styrofoam.
Use only original packaging or specially labeled and defined packaging and transport materials.
Electronic components which have been removed must be put down on an ESD workplace.
Touch connectors on electronic components and in the wiring harness on the housing only. Do not touch
the pins and contacts!
Electronic components must be installed before they are connected so that potential equalization with the
body can take place.
Shelves and worktables must stand directly on the floor, there must not be any insulating materials
between the base of the shelves/feet and the floor. If the above mentioned insulators cannot be removed,
the shelves and work tables must be grounded (e.g. low-resistance electrical connection/line from metal
shelf to a heating pipe).
Put down conductive transport container/box in a non insulated manner (e.g. on a wooden pallet),
otherwise no potential equalization takes place.
Do not place control units and electronic components removed from the vehicle on electrostatically
chargeable materials, such as PE, PVC, styrofoam. The electrostatic charge is transferred to the control
unit or electronic component. An ESD service kit or a connected ESD table mat must be used.
Training
We strongly advise that each company should appoint a trained ESD officer in accordance with DIN EN 61340-
5-1.
The ESD officer can hold employee training courses.
The objective of the training course measures is to familiarize the employees with the essential difficulties and
Creation of discharging
Reasoning behind safety precautions
Effects and consequences of ESD
ESD rules of conduct and safety precautions
Returning electronic components in warranty and goodwill cases
When returning electronic components it is absolutely essential to observe the procedure and safety precautions
listed. Electrostatic charge or discharge mean the original fault can be falsified or overlaid.
This can lead to distorted fault symptoms in the case of the fault analysis of the component concerned.
NOTE ON THE -VOLTAGE ON-BOARD ELECTRICAL SYSTEM - AH54.00-P-0010-01A
General
The high-voltage on-board electrical system consists of several components. The individual components are
connected to each other by high-voltage conducting electrical lines and voltage distributor.
Marking
All components of the high-voltage on-board electrical system are marked with a yellow adhesive warning label
on which the pictogram for high-voltage is represented.
All electrical lines for high voltages are marked by a warning color (orange).
Activities, general
A special qualification measure is required for repair, maintenance and diagnosis activities on vehicles with
high-voltage on-board electrical systems. (sensitization training when handling high-voltage on-board electrical
systems).
For enabling (de-energized) of the high-voltage on-board electrical system before activities on vehicles with
high-voltage on-board electrical system and for the following initial startup, a special electrotechnical training
as well as authorization is mandatory. Persons not proven to have taken part in special qualification measures
and who have neither completed a special electrotechnical training nor are authorized, may not carry out any
activities on high-voltage on-board electrical systems.
Measures for activities
Before starting activities on high-voltage on-board electrical systems, the production of a de-energized
condition and its safeguarding for the duration of the activities to be carried out, must be ensured.
This must be done while observing and complying with the following safety rules, the application of which
must be the rule:
Enable (de-energized)
Secure against switching on again
Check and secure safe isolation from supply
The measuring instruments, special tools and aids to be used must be checked for faultless condition before
their use.
When using test adapter (169 589 04 63 00), an electrical continuity check is additionally required.
For activities on high-voltage on-board electrical systems the following notes should be observed and adhered
to:
Cable lugs, contacts and electrical connectors should be protected against dirt with suitable protective
bags
Contacts, electrical lines and electrical connectors should be checked for dirt and damage before
assembly, if necessary they should be cleaned or replaced.
Screw contacts should be tightened with the specified torque and if necessary the tightening angle.
EVALUATING ELECTRONIC COMPONENTS AFTER REPAIR AND PAINTING WORK AND
AFTER ACCIDENTS - AH54.00-P-1000-01A
All models
1. With paint drying in drying oven
Electronic components, such as the switching unit for the ignition system, the control unit for the
electronic fuel/diesel injection system, the ABS system, airbag, emergency tensioning retractors etc. may
only be heated up to an object temperature of maximum 90 °C.
In cases of doubt the temperature at these points should be checked by a series of measurements (remove
electronic components beforehand) by means of a mercury maximum thermometer during the baking
phase.
If the maximum permissible temperature is not exceeded, the electronic components need not be
removed.
No particular safety measures are required at an object temperature up to max. 60 °C (air injection
temperature max. 90 °C).
2. With welding
Always disconnect and cover the negative terminal of the battery. Disconnect airbag 10-pin data link
connector (color red) in the right footwell after waiting for 2 seconds after disconnecting the battery or as
of 07/93 detach the coupling on the airbag control unit using the insertion and removal aid.
3. After accidents
Replacing electronic control units after an accident is only necessary if at least one of the following
conditions is met:
The housing is recognizably deformed or damaged.
The contact surface or bearing bracket is deformed; externally the unit does not appear damaged.
The connector is damaged or corroded by moisture.
Faults are established by a function test or self-diagnosis of the unit.
If electronic components, such as the ABS control unit, have been removed for repair and are then used
again, these should be checked for proper operation after assembly.
Read fault memory and erase
GENERAL NOTES: PASSENGER CARS: ELECTRICAL SYSTEM, EQUIPMENT AND
INSTRUMENTS - AH54.00-Z-9999AZ
MODEL all
Evaluating electronic
components after repair MODEL AH54.00-P-
all and painting work and after 1000-01A
accidents
Evaluation of high-voltage AH54.00-P-
MODEL 164.195, 169.090, 221.095 /195
components 6500-01SXH
Flow chart for offline MODEL 129, 163, 164, 166, 168, 169, 170, 171, 199,
AH54.21-P-
programming with Special 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218,
0001-04Z
Release CD 219, 220, 221, 230, 240, 245, 246, 251, 461, 463...
Information on preventing
AH54.00-P-
damage to electronic components MODEL all
0001-01A
due to electrostatic discharge
AH54.10-P-
Note on high-voltage battery MODEL 169.090
0006-01EZ
AH54.10-P-
Note on high-voltage battery MODEL 451.391 /491
0006-01MEV
AH54.00-P-
Note on high-voltage system MODEL 451.391 /491
0011-01MEV
AH54.10-P-
Note on the high-voltage battery MODEL 164, 221
0006-01A
Note on the -voltage on-board AH54.00-P-
MODEL all
electrical system 0010-01A
AH54.10-P-
Notes on AGM battery MODEL all
0002-01A
AH54.10-P-
Notes on AGM battery MODEL 451.334 /380 /480
0002-01MCC
AH54.10-P-
Notes on battery MODEL all
0001-01A
Notes on checking the battery AH54.10-P-
MODEL 454.0
condition 0005-01FF
Notes on checking the battery AH54.10-P-
MODEL 452.3 /4
condition 0005-01RR
Notes on checking the battery AH54.10-P-
MODEL 450.3 /4, 451.3 /4
condition 0005-01SM
Notes on distinguishing
AH54.18-P-
characteristics of wiring MODEL 168
0700-01A
harnesses
Notes on no-load current AH54.10-P-
MODEL 219.3
consumption 0003-01TX
MODEL 129, 163, 164, 166, 168, 169, 170, 171, 199,
Notes on programming control AH54.21-P-
203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218,
units 0001-03Z
219, 220, 221, 230, 240, 245, 246, 251, 461, 463...
MODEL 129, 163, 164, 166, 168, 169, 170, 171, 199,
Notes on programming control 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, AH54.21-P-
units 219, 220, 221, 230, 240, 245, 251, 450, 451, 452, 454, 0001-03Y
461, 463...
Notes on quiescent power AH54.10-P-
MODEL 211
consumption 0003-01T
MODEL 129, 163, 164, 168, 169, 170, 171, 199, 203,
Notes on SCN coding of control 204, 208, 209, 211, 215, 216, 219, 220, 221, 230, 240, AH54.21-P-
units 245, 251, 450, 451, 452, 454, 461, 463, 636, 639, 900, 0004-01X
906...
NOTES ON BATTERY - AH54.10-P-0001-01A
All models
General information on batteries
Do not store batteries over a longer period at a storage point with direct solar radiation.
Discharged or defective batteries can freeze, therefore store free from frost.
Avoid polarity reversal and short-circuits.
Do not place tool or other conducting objects on the battery (risk of short-circuit).
Before removal and installation of batteries all switchable current consumers should be switched off, as
well as the engine switched off so that inadvertent arcing is ruled out.
Always disconnect the negative terminal first and always connect the positive terminal first.
Only charge batteries with DC, 10 % of the capacity is recommended as charging current for slow
Only switch on the charger after connecting to the terminals and switch off before disconnecting.
We recommend greasing the batteries slightly with battery terminal grease.
If the battery is to remain in the parked vehicle for a longer time, the negative terminal should be
disconnected.
If possible batteries should be kept clean and dry.
Batteries should not be stored over a longer period without recharging.
Notes on lead-gel batteries (additional battery for special bodies)
Lead-gel batteries are free from gassing, acid does not run out of them and are completely independent of
position and maintenance free.
When fast charging ensure that the housing of the lead-gel battery does not heat up excessively otherwise
a pressure relief valve will be opened and the lead-gel battery will be defective.
Notes on lead acid batteries
Always store lead lead-acid batteries horizontally to prevent acid leaking out and do not tilt during
transportation.
When fast charging ensure that the housing of the lead-acid battery does not heat up excessively.
NOTES ON AGM BATTERY - AH54.10-P-0002-01A
All models
As of Autumn 2000 new batteries with AGM technology will be used.
The external differentiation features between these batteries and conventional batteries are:
Black housing
VRLA battery labeling
Non-detachable covers (A)
Fig. 1: Identifying Non Detachable Covers
Courtesy of MERCEDES-BENZ USA
AGM battery structure
Instead of the acid in a conventional battery, a conductive fabric (bonded fiber) (V) is used.
Special properties:
High cycle strength (long service life)
Improved cold starting characteristics
No escaping acid if housing damaged
Improved deep-discharge resistance
Absolutely maintenance-free
Fig. 2: Identifying Conductive Fabric (Bonded Fiber)
Courtesy of MERCEDES-BENZ USA
Distinguishing features
No stop plugs
No acid level markings
No externally vented stop plugs
Information plate on the battery
If the battery is replaced, the vent hose with an elbow to one side of the battery and the stop plugs on the
other side of the battery must be pressed in.
NOTE ON THE HIGH-VOLTAGE BATTERY - AH54.10-P-0006-01A
Model 164, 221 http://gms.aftersales.daimler.com gotis://O_01.0_04.0
General information on the high-voltage battery
When properly used the high-voltage battery will not present any hazard.
Avoid inhaling any dust, vapors or mist.
Additional information on handling and safety requirements is available in the High-voltage battery safety
data sheet in the Daimler Hazardous Materials Management System http://gms.aftersales.daimler.com.
Note on safe handling
There is a risk of explosion if mechanical forces or heat act on the high-voltage battery.
Do not subject high-voltage batteries to direct heat, welding and do not throw them into the fire.
Do not exert any pressure on high-voltage batteries and do not deform them.
Improper use can result in leakage, evaporating electrolyte flue gas, and - where ignition sources are
present - fire and explosions.
Ensure that there is always sufficient air exchange and/or evacuation in the working premises.
Wear personal protective equipment (for high-voltage batteries that are not transport protected):
Safety glasses
Electrical protective gloves gotis://O 01.0 04.0
Storeroom and container requirements
Because short circuits can result in burns, leakages and risk of explosion, the batteries must never be
stored in bulk containers.
Keep in a cool and well-ventilated location.
Protect against humidity.
Avoid any ingress of the product into the sewage system, water drains or the ground.
General information on transport
The high-voltage battery presents hazardous material and is classified in line with the international dangerous
goods regulations as:
UN 3480 lithium-ion battery, Class 9, Packaging group III.
High-voltage batteries may only be transported in compliance with the applicable international and national
dangerous goods regulations for each particular mode of transport.
Each high-voltage battery is to be checked with regard to suitability for transportation before any renewed
transport. High-voltage batteries that have been damaged, are to be classified as NOT safe for transport, where
in conjunction with the transport:
A hazardous increase in heat may exist.
High-voltage battery fires or short circuits may be caused.
In any other manner a hazard may be created, e.g. through release of liquid electrolyte or combustible,
etching or toxic vapors.
A shipment must be conducted or authorized by a qualified logistics staff member.
High-voltage batteries safe for transport
High-voltage batteries safe for transport may only be shipped in the original packaging, insofar as the high-
voltage battery was packed in accordance with the as-delivered condition. The following requirements must at
least be observed:
The high-voltage battery is to be safeguarded against external short circuits, e.g. by using a terminal cap.
All openings on the high-voltage battery, in particular, the coolant connections, must also be sealed.
The high-voltage battery is to be free of any hazardous contamination on the outside.
All requirements with regard to flawless condition of the packaging, the sealing of the packaging using adhesive
tape and dual strapping, the identification of the packaging as per the relevant dangerous goods regulations, as
well as additional requirements with regard to transport must be observed.
High-voltage batteries not safe to transport A high-voltage battery is deemed to be UNSAFE for transport
according to the following criteria:
Test with STAR DIAGNOSIS
High-voltage battery without diagnosis capability.
Insulation fault (clear assignment of high-voltage battery, fault code stored).
Contact closed status (after circuit 15 OFF, fault code stored).
Current notes are available in Star Diagnosis.
Visual inspection
Crack in housing
Housing deformed
Housing tarnished.
Electrolyte leakage
High-voltage connection damaged.
High-voltage batteries that are not safe for transport may only be transported in road traffic or maritime traffic
with exemptions issued by the responsible national authorities and in keeping with the systematic application of
the exemption's specified conditions. High-voltage batteries that are not safe for air traffic transport must never
be transported by air!
NOTES ON PROGRAMMING CONTROL UNITS - AH54.21-P-0001-03Y
Model 129, 163, 164, 166, 168, 169, 170 171, 199, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219,
220, 221, 230, 240, 245, 251, 450, 451, 452, 454, 461, 463 Offline programming with Release CD
Program using STAR DIAGNOSIS (Xentry flash)
Xentry Flash: The term Xentry flash is used to designate the Daimler AG standard for programming control
units.
In the process a distinction is made between two types of programming:
Offline programming with Release CD
Offline programming with Special Release CD
Further explanation of terms:
Flashing: Programming of control units
Software: Control unit software
Release CD: Control unit software integrated on Diagnosis Assistance System (DAS) DVD
Special Release CD: Special CD which contains software updates
Deliveries and costs
The release CD is integrated into the DAS-DVD and together with the Workshop Information System DVD is
delivered monthly by the Daimler AG. Delivery is free of charge for the case of repair.
Offline programming with Release CD
The control unit software of the Release CD can be installed on the hard disk in the case of the "STAR
DIAGNOSIS Compact" diagnosis system.
Installation of the data is not possible in the case of the "STAR DIAGNOSIS Basic" diagnosis system. In this
case, the Release CD must be inserted into the CD or DVD drive.
The information on the Release CD:
applies to all divisions
applies to all model series
applies to all control units
The information on the Release CD provides a "basic supply" of control unit software for the vehicle. The
current software releases of all programmable control units are located on the Release-CD. An old
software release can therefore be repeatedly replaced (updated) by a new software release.
If a plant service measure requires a change in software release in a programmable control unit, the
workshop can carry out this change with the Release CD.
NOTES ON PROGRAMMING CONTROL UNITS - AH54.21-P-0001-03Z
Offline programming with Special Release CD
Program using STAR DIAGNOSIS (Xentry flash)
Xentry Flash: The term Xentry flash is used to designate the Daimler AG standard for programming control
units.
In the process a distinction is made between two types of programming:
Offline programming with Release CD
Offline programming with Special Release CD
Further explanation of terms:
Flashing: Programming of control units
Software: Control unit software
Release CD: Control unit software, integrated onto DAS DVD
Special Release CD: Special CD which contains software updates
Offline programming with Special Release CD
The Special Release CD is a special CD which contains software updates
The workshop must ask for the Special Release CD at the STAR DIAGNOSIS user help desk and request
it via the usual ordering channels
Manual redocumentation required in the vehicle documentation system (FDOK)
FLOW CHART FOR OFFLINE PROGRAMMING WITH SPECIAL RELEASE CD - AH54.21-P-0001-
04Z
Offline programming with Special Release CD
Fig. 3: Offline Programming With Special Release CD Flow Chart
Courtesy of MERCEDES-BENZ USA
NOTES ON SCN CODING OF CONTROL UNITS - AH54.21-P-0004-01X
Model 129, 163, 164, 168, 169, 170, 171 199, 203, 204, 208, 209, 211, 215, 216, 219, 220, 221, 230, 240, 245
(except 245.286), 251, 461, 463, 450, 451, 452, 454, 636, 639, 900, 906
The "Software Calibration Number" (SCN) is specified by law in Europe and USA for all control units relevant
to exhaust emission as of model year 2002.
Accordingly the software and coding of such a control unit must be clearly identifiable by means of the SCN.
As a number the SCN consists of 16 numbers. The first 10 places correspond to the object number to be coded
(mostly object number of control unit software). The next 2 places designate the manufacturing plant or field
organization, in which the vehicle has been coded. The last 4 places are a number of the variants of the coding
string of the vehicle-specific as-built configuration. This number is serially numbered for each newly formed
variant.
If special equipment has been installed or removed in the vehicle (e.g. retrofitting a telephone), these retrofit
codes must be added to the central system before requesting the SCN coding data. The appropriate national
organization must be contacted (MPC) for this.
ACCESSORIES & BODY, CAB
Body Sealing, Corrosion Protection - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: BODY SEALING, CORROSION PROTECTION - AH97.00-
Z-9999AZ
MODEL all
Instructions for
processing AH97.20-P-
MODEL 450, 451, 452, 454
permanent 9409-01FF
underbody protection
MODEL wd1, wd2, wd3, wd6, wd7, xd1, xd2, xd3, xd4, xd5, xd6,
Instructions for
xd7, yd1, yd2, yd3, yd4, yd5, yd6, yd7, 124, 126, 129, 140, 163, 164,
processing AH97.20-P-
166, 168, 169, 170, 171, 172, 197, 199, 201, 202, 203, 204, 207, 208,
permanent underfloor 9409-01A
209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 251,
protection
414, 461, 463, 671, 690, 900, 901, 902, 903, 904, 905, 906...
Notes on cavity AH97.20-P-
MODEL all
preservation 0001-01C
Notes on cavity AH97.20-P-
MODEL all
preservation 0001-01B
Notes on cavity AH97.20-P-
MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0
preservation 0001-01FF
AH97.10-P-
Notes on seam seal MODEL all
0002-02A
Notes on seam AH97.10-P-
MODEL all
sealing 0003-01A
Notes on sprayable AH97.10-P-
MODEL all
joint sealant 0002-01A
Notes on sprayable AH97.10-P-
MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0
seam sealing 0002-01FF
Notes on
AH97.20-P-
transportation MODEL all
9409-03A
sheeting
Special notes
AH97.20-P-
regarding wax MODEL all with fire-extinguishing system
1000-02PV
preservation
MODEL 124, 126, 129, 140, 163, 164, 166, 168, 169, 170, 171, 172,
Underfloor 197, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, AH97.20-P-
preservation 219, 220, 221, 230, 240, 245, 251, 414, 461, 463, 638, 671, 900, 2000-01A
906...
preservation MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 2000-01FF
NOTES ON SPRAYABLE JOINT SEALANT - AH97.10-P-0002-01A
All models
Application areas:
With this material, when applied over large surfaces on areas such as the wheelhouses, longitudinal members
(rocker panels) and vehicle floor elements, the characteristics are visually equivalent to the standard or plant
seals in terms of the processing.
When applying the material from the standard cartridge (300 ml), a special compressed air gun is required
which allows different types of application for structured joints, surface coatings, stone-impact protection and
sound deadening in combination with the associated plastic injection nozzles.
Processing:
Wet-in-wet painting possible between 30 min. and 8 h after application without paint additives. Forced
drying is necessary between 8 h and 72 h. Longer standing times should be avoided to exclude paint
adhesion losses.
Adhesion surfaces must be clean, dry and free of grease.
Spray filler/filler primer before application of sprayable joint sealing agent.
Never apply the sprayable joint sealing agent to fresh (unhardened) 1K polyurethane material.
Specific material advantages of "sprayable joint sealing agent":
Does not contain any isocyanates, silicone, PVCs and no dangerous agent.
The replaceable nozzle makes cleaning unnecessary.
Visual repair of the plant seals and underbody coating.
Good stability.
UV-resistant.
Material offers a number of application possibilities.
With the proper gun setting, the sprayable joint seal can be applied as joint seal and surface coating in
sequence.
It is necessary, however, to wait for the end of the skin formation period of about 15 min. for the sprayed
seam.
Can be painted over well.
NOTES ON SEAM SEAL - AH97.10-P-0002-02A
Seal connecting flange of repaired area with body sealant to prevent corrosion and leakage.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
Application of the materials for different application shapes is possible and permissible (structured seams,
surface coating, protection against flying rocks and sound deadening).
Do not apply seam seal on fresh (uncured) 1-component polyurethane material.
Maintain drying time for overpainting.
NOTES ON SEAM SEALING - AH97.10-P-0003-01A
Curing rate for joint seals
Curing rate at 50% relative humidity at coat thickness of (mm).
Fig. 1: Curing Rate For Joint Seals
Courtesy of MERCEDES-BENZ USA
Product description:
Single-component polyurethane sealant is hardened to an elastomer by the moisture in the air
Application range:
This material is suitable for resilient and permanent sealing with good adhesion.
Suitable substrates include metals, metal with primer finish and enamel finishes (2-component systems).
Processing:
The joint subsurfaces must be clean, dry and free of dust and grease.
Fillers/primers must be applied before applying the joint seal. Apply joint seal only after filler/primer has
dried completely.
Cut off nozzle tip to match joint width and apply sealant to the joint without entraining air bubbles using
piston rod compressed air, battery powered or manual gun.
The optimum processing temperature is between 15°C and 25°C.
Paint over joint seal only after it has cured completely. The cross-linking reaction is caused by contact
with moisture in the air. At low temperatures the moisture content in the air is low and the cross-linking
reaction takes slightly longer (see diagram).
Longer standing times should be avoided to exclude paint adhesion losses.
NOTES ON CAVITY PRESERVATION - AH97.20-P-0001-01B
The cavity preservation with wax already performed at the factory completes the corrosion prevention
measures.
No repetition of this preservation work is necessary.
Repair preservation
Following body repairs, spray hollow cavities with wax in the repaired area. When replacing detachable body
components, e.g. front fender, engine hood, doors, trunk lid as well as during welding, riveting and soldering
work, also perform repair preservation.
As a matter of principle, apply two coats of repair preservation agent one after another with an air drying time
of 5 min. in between.
After drying, ensure that drain holes are not plugged.
It is important that the wax is applied following sealing and paintwork, however, before assembly. Otherwise
paint damage can occur or installation parts can be soiled with wax.
Crash box clamping area and contact surfaces in longitudinal member must be free of wax. Preserve only after
assembling.
Also preserve replacement bodies twice after painting.
Replacement bodyshells top-coated in the factory have already been treated with the standard cavity
preservation.
Processing instructions
The application temperature of the wax should not be below +15 °C.
The cavities should be dry for preservation. Before starting preservation work, check spray pattern of spraying
hose or spray can. The wax must spray uniformly from the openings in a circular pattern.
Particularly advantageous are nozzles which spray toward the front as well as at an angle toward the rear.
Avoid wax fog in vehicle interior to prevent damage to interior equipment.
The spraying hose of the hand-held lance must be "stiff". Spraying hoses that tend to roll up are not suitable.
When preserving, insert the spraying hose into the cavities in all directions as far as possible. Spray while
slowly inserting and pulling out spraying hose.
After preservation work clean spraying nozzle and spraying hose together with sprayer.
NOTES ON CAVITY PRESERVATION - AH97.20-P-0001-01C
Prepare preservation surfaces
Always clean surfaces and hollow cavities to be preserved.
Surfaces and hollow cavities must be dry before application.
Spray probe
The spray probe must be "stiff". Spray probes that tend to roll up are not suitable.
Processing notes
The optimum application temperature is 20- 35°C. It should not be less than +15 °C
Before starting application, check spray pattern. The preservation agent should spray uniformly out of the
openings in the shape of a cone.
Optimum application can be achieved by slowly retracting/extending and simultaneously turning the spray
probe during application.
Always apply two coats one after another with an air drying time of 5 min. in between.
Always cover brake disks, brake linings, belt drive and propeller shaft to prevent brake failure or
propeller shaft imbalance.
Always cover exhaust, otherwise the preservation agent could catch fire or emit unpleasant odors.
Avoid preservation mist in vehicle interior to prevent damage to interior equipment.
Avoid preservation mist on inner side of bumper to prevent bumper deformation.
Clean tools after application.
After drying preservation, ensure that all drain holes are free.
SPECIAL NOTES REGARDING WAX PRESERVATION - AH97.20-P-1000-02PV
All models with fire extinguishing system
When applying preservation wax, pressurize the entire extinguishing pipe system (approx. 10
bars) during the spraying operation to prevent clogging the exit holes for extinguishing agent. Start by
disconnecting the extinguishing agent reservoir from the extinguishing pipe.
UNDERFLOOR PRESERVATION - AH97.20-P-2000-01A
Model 124, 126, 129, 140, 163, 164.1 /8 166, 168, 169, 170, 171, 172, 197, 201, 202, 203, 204, 207, 208, 209,
210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245.2 (except 245.286), 251, 461, 463, 671, 414, 638,
900, 906
Repair damage on permanent underfloor protection as well as paint damage on door bottom edges, wheel arch
lips and entrance.
Apply preservation agent to underbody in area repaired following accident. Replacement body shells must have
preservation agent applied to their underfloors when the vehicle is fully assembled.
The underside of the vehicle is to be cleaned before waxing. Spray the preservation wax on the dry underfloor.
Do not spray following parts with preservation wax and cover if possible to prevent damage and extensive
cleaning work:
Brake linings and brake disks
Exhaust pipes, center mufflers and rear mufflers
Propeller shafts
INSTRUCTIONS FOR PROCESSING PERMANENT UNDERFLOOR PROTECTION - AH97.20-P-
9409-01A
Model 124, 126, 129, 140, 163, 164, 166 168, 169, 170, 171, 172, 197, 199, 201, 202, 203, 204, 207, 208, 209,
210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245.2, 251, 461, 463, 671, 690.6, 414, 900, 901, 902,
903, 904, 905, 906 Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1,
YD2, YD3, YD4, YD5, YD6, YD7
The frame floor is coated with PVC permanent underfloor protection as standard, see "Paintwork and Corrosion
Protection Manual". PVC is used as a standard material for sealing work in areas such as spot welds and door
folds.
When PVC materials burn, they release a highly corrosive hydrochloric acid.
The new permanent underfloor protection does not adhere well to the burned PVC allowing rust to form later.
For this reason, always remove PVC underfloor protection as well as PVC joint seals before starting any
brazing or welding work. This also applies for work such as cutting or grinding.
For the same reasons, it is preferable to separate damaged body parts using "cold" separating methods.
NOTES ON TRANSPORTATION SHEETING - AH97.20-P-9409-03A
Since 1st July 1995 the outer skin conservation is discontinued on all vehicle model series with code (524) Paint
protection. Instead, a protective sheeting is applied to the following surfaces on the vehicle in the factory:
Horizontal surfaces (engine hood, roof, trunk lid)
Front and rear fenders
Front and rear doors on driver's side
Outside mirror housings
Bumper (with code (494) USA version)
As a rule the transport foil remains on the painted surface until the vehicle is prepared for sale. Remove
transport foil 24 h before preparing for sale.
Time transport foil remains on vehicle.
The time the foil remains on the vehicle is limited to 180 days (new).
The film is therefore provided with a sticker on the engine hood which marks the latest removal date of the film.
After expiration date, it is necessary to remove the foil by pulling off of the vehicle.
Removal of transport foil
In exceptional cases (transport film missing or damaged, length of stay has elapsed or paintwork rectification is
required) it is necessary to provide the complete vehicle or parts of the originally protected surfaces with a
transport film again. For this the film and adhesive tapes should be detached by hand.
If the temperature is too high (>50 °C), adhesive residues may be left behind on the painted surfaces.
On iced up vehicles the film may crack during removal due to the influence of ice and snow.
Snow and ice residues can be thawed by heating up the surface temperature of the vehicle in a heated hall or
with the help of a hot air gun.
Heating also makes it easier to remove stubborn tape/adhesive residues.
A heat source and benzine must not be used at the same time.
In rare cases, localized swellings of the paintwork may be visible after the sheeting is removed. However,
Disposal of transport foil
The transport foil, the safety adhesive tape and the label for marking the expiration date consist of polyolefin
materials (PE/PP). Dispose of separated foil waste properly. Observe legal regulations applicable in country.
MAINTENANCE
PROCESSING INSTRUCTIONS FOR CAVITY PRESERVATION AGENT - AP97.20-P-0640-01SX
The cavity preservation with wax already performed at the factory completes the corrosion prevention
measures.
No repetition of this preservation work is necessary.
Repair preservation
Following accident repairs, spray hollow cavities with wax in the repaired area. When replacing detachable
body components, e.g. front fender, engine hood, doors, trunk lid as well as during welding, riveting and
soldering work, also perform repair preservation.
Always carry out the repair preservation twice in succession after a drying time of 5 minutes.
After drying, ensure that drain holes are not plugged.
It is important that the wax preservation agent is applied following sealing and paintwork, however, before
assembly. Otherwise painting defects can occur or attached parts may be contaminated with wax.
Likewise preserve replacement bodies after painting twice in succession.
Replacement bodyshells top-coated in the factory have already been treated with the standard cavity
preservation.
Working instructions
The cavities must be dry before preserving. Before commencing preservation work, check the spray pattern
from the spraying hose or spray can. The wax must spray uniformly from the openings in a circular pattern.
Particularly advantageous are nozzles which spray toward the front as well as at an angle toward the rear.
The spraying hose of the hand-held lance must be "stiff". Hoses that tend to roll up are not suitable.
When preserving move the spray hose as far as possible to all sides in the cavities. Spray while slowly inserting
and retracting the hose (processing temperature not below +15 °C). Clean spray nozzle and spray hose together
with spray equipment.
PRESERVATION - AP97.20-P-0640SX
MODEL 216
MODEL 221
Application
Underfloor AH97.20-P-
preservation 2000-01A
Instructions for
AH97.20-P-
processing permanent
9409-01A
underbody protection
Apply seam seal Seam
AR97.10-P-
1 sealing following
4000SX
repair
Notes on sprayable AH97.10-P-
seam sealing 0002-01A
Apply hollow cavity Before use, shake or stir preservation wax
2
preservation thoroughly.
Cavity preservation AR97.20-P-
Model 221
following repair work 1500SX
AR97.20-P-
Model 216
1500SC
Notes on cavity AH97.20-P-
preservation 0001-01B
Processing instructions
AP97.20-P-
for cavity preservation
0640-01SX
agent
For represervation work on the
underbody, brake parts such as brake disks and brake
Apply underbody
3 hoses should be suitably covered in order to prevent
preservation agent
them from being sprayed or subsequent time-
consuming cleaning.
Processing permanent
AR97.20-P-
underfloor protection
0500-03SX
agent for painting
*BR00.45-Z-
Underfloor protection
1001-05A
Remove wax fog
residues on outer
4
surface with silicon
remover
Treat outer surface
*BR00.45-Z-
5 with polish and gloss Polish
1013-04A
preservation agent
*BR00.45-Z-
Gloss preserver
1014-04A
Install transport
6 As replacement for exterior preservation.
protection foil
AR97.20-P-
Installing transport foil
4000SX
Notes on transportation AH97.20-P-
sheeting 9409-03A
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013-04A Polish, silicone free 5 l, DB supply specification 7545.00 A 000 986 45 74
BR00.45-Z-1014-04A Gloss preservation, 500 ml, DB supply specification 7551.10 A 000 986 44 74
BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: BODY SEALING, CORROSION
PROTECTION - AR97.00-Z-9221AA
MODEL 221
Cavity preservation following repair work MODEL 221 AR97.20-P-1500SX
Installing transport foil MODEL 216, 221 AR97.20-P-4000SX
Processing corrosion protection materials before painting MODEL 216, 221 AR97.20-P-0500SX
Seam sealing following repair MODEL 216, 221 AR97.10-P-4000SX
PROCESSING OF BODY SEALANT (PAINTABLE) BEFORE PAINTING - AR97.10-P-0500-02SX
When replacing sheet attached parts (doors, trunk lid, etc.) and also body parts welded in place, carefully
seal the folds and openings with body sealant in order to avoid corrosion and leaks. Seal spot weld seams and
rivets on both sides.
Observe following procedure:
1. Carefully clean affected body parts.
2. Apply sealant uniformly.
3. Spread body sealant evenly.
4. Maintain drying time (paintable).
Always clean brushes, wooden spatulas, etc., used for spreading body sealant, with naphtha.
If these objects are cleaned with paint thinner or other alcoholic liquids before applying the body sealant, the
sealant does not cure and remains sticky.
SEAM SEALING FOLLOWING REPAIR, FRONT END DAMAGE - AR97.10-P-4000-01SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
1 Seal spot welds and rivets in repaired area with seam sealant material.
Insert plastic plugs and rubber grommets with sealing compound.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
It is necessary to seal accessible spot weld flanges on both sides.
If accessible from one side, only seal corresponding surface. Observe standard seals!
Fig. 2: Identifying Spot Weld Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of wheel well and outer front A-pillar, shown on left side of vehicle on model 221
Fig. 3: Identifying Wheel Well And Outer Front A-Pillar Spot Weld Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of A-pillar on longitudinal member and outer connector, shown on left side of vehicle on model 221
Area of inner A-pillar, shown on left side of vehicle on model 221
Fig. 4: Identifying Inner A-Pillar Spot Weld Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of A-pillar paneling, shown on left side of vehicle on model 221
Fig. 5: Identifying A-Pillar Paneling Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
SEAM SEALING FOLLOWING REPAIR, FRONT END DAMAGE - AR97.10-P-4000-01SXS
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
1 Seal spot welds, rivets and MAG seams in repaired area with seam sealant material.
Do not seal openings between MAG seams.
Leave openings open between MAG seams for coating with wax.
Insert plastic plugs and grommets with sealing compound.
When sealing seams we differentiate between:
a smoothing/wiping
B spreading
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
It is necessary to seal accessible spot weld flanges on both sides.
If accessible from one side, only seal corresponding surface. Observe standard seals!
Fig. 6: Identifying Smoothing/Wiping & Spreading Seam Sealing
Courtesy of MERCEDES-BENZ USA
Area of left front outer wheel arch and A-pillar, shown on model 221 without code Z07
Fig. 7: Identifying Left Front Outer Wheel Arch And A-Pillar Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of A-pillar on longitudinal member and left outer connection, shown on model 221 without code
Z07
Fig. 8: Identifying Longitudinal Member And Left Outer Connection Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left inner A-pillar, shown on model 221 without code Z07
Fig. 9: Identifying Left Inner A-Pillar Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left A-pillar paneling, shown on model 221 without code Z07
Fig. 10: Identifying Left A-Pillar Paneling Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of right front water trough
Area of front end
Fig. 11: Identifying Front End And Front Water Trough Sealing Area
Courtesy of MERCEDES-BENZ USA
Fig. 12: Identifying Interior Compartment Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of interior compartment
Area of wheel well front end and left water trough
Fig. 13: Identifying Wheel Well Front End And Left Water Trough Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left bottom front wheel well
Area of left front wheel well
Fig. 14: Identifying Left Bottom Front Wheel Well Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of lower right front wheel well
Fig. 15: Identifying Right Front Wheel Well Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left front wheel well on pedal floor panel
Fig. 16: Identifying Left Front Wheel Well Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of roof duct windshield padding
Fig. 17: Identifying Roof Duct Windshield Padding Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of windshield support on crossmember A-pillar below windshield
Fig. 18: Identifying Windshield Support Sealing Area
Courtesy of MERCEDES-BENZ USA
SEAM SEALING FOLLOWING REPAIR, REAR END DAMAGE - AR97.10-P-4000-02SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
1 Seal spot welds and rivets in repaired area with seam sealant material.
Insert plastic plugs and rubber grommets with sealing compound.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
It is necessary to seal accessible spot weld flanges on both sides.
If accessible from one side, only seal corresponding surface. Observe standard seals!
Area of entire rear fender, shown on left side of vehicle on model 221
Fig. 19: Identifying Rear Fender Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of rear fender, side paneling below bumper and rear lamp cutout, shown on left side of vehicle on
model 221
Fig. 20: Identifying Rear Fender Sealing Area
Courtesy of MERCEDES-BENZ USA
Complete rear end and bottom, shown on model 221
Fig. 21: Identifying Complete Rear End And Bottom Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of top and bottom inner rear crossmember, shown on left side of vehicle on model 221
Fig. 22: Identifying Top & Bottom Inner Rear Crossmember Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of entire underbody, shown on model 221
Fig. 23: Identifying Underbody Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
SEAM SEALING FOLLOWING REPAIR, REAR END DAMAGE - AR97.10-P-4000-02SXS
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
1 Seal spot welds, rivets and MAG seams in repaired area with seam sealant material.
Do not seal openings between MAG seams.
Leave openings open between MAG seams for coating with wax.
Insert plastic plugs and grommets with sealing compound.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
It is necessary to seal accessible spot weld flanges on both sides.
If accessible from one side, only seal corresponding surface. Observe standard seals!
When sealing seams we differentiate between:
A smoothing/wiping
B spreading
Fig. 24: Identifying Smoothing/Wiping & Spreading Seam Sealing
Courtesy of MERCEDES-BENZ USA
Area of entire left rear fender, shown on model 221 without code Z07
Fig. 25: Identifying Entire Left Rear Fender Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of rear fender, side paneling below bumper and left rear lamp cutout, shown on model 221 without
code Z07
Fig. 26: Identifying Rear Fender, Side Paneling Below Bumper And Left Rear Lamp Cutout Sealing
Area
Courtesy of MERCEDES-BENZ USA
Fig. 27: Identifying Complete Rear End Assembly Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of lower inner rear and left upper crossmember, shown on model 221 without code Z07
Fig. 28: Identifying Lower Inner Rear And Left Upper Crossmember Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of entire underfloor, shown on model 221 without code Z07
Fig. 29: Identifying Underfloor Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of rear tunnel underfloor
Fig. 30: Identifying Rear Tunnel Underfloor Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left rear wheel well
Fig. 31: Identifying Left Rear Wheel Well Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of spare wheel well
Fig. 32: Identifying Spare Wheel Well Sealing Area
Courtesy of MERCEDES-BENZ USA
SEAM SEALING FOLLOWING REPAIR, SIDE DAMAGE - AR97.10-P-4000-03SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
1 Seal spot welds and rivets in repaired area with seam sealant material.
Insert plastic plugs and rubber grommets with sealing compound.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
It is necessary to seal accessible spot weld flanges on both sides.
If accessible from one side, only seal corresponding surface. Observe standard seals!
Area of A-pillar on longitudinal member and left outer connection element
Fig. 33: Identifying Longitudinal Member A-Pillar Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left inner A-pillar
Fig. 34: Identifying Left Inner A-Pillar Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left A-pillar paneling
Fig. 35: Identifying Left A-Pillar Paneling Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of B-pillar with left inner longitudinal member
Fig. 36: Identifying B-Pillar With Left Inner Longitudinal Member Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of entire left outer side longitudinal member
Fig. 37: Identifying Left Outer Side Longitudinal Member Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of entire left rear fender
Fig. 38: Identifying Left Rear Fender Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of rear fender, side paneling below bumper and left taillamp cutout
Courtesy of MERCEDES-BENZ USA
Overall underfloor area
Fig. 40: Identifying Underfloor Sealing Area
Courtesy of MERCEDES-BENZ USA
SEAM SEALING FOLLOWING REPAIR, SIDE DAMAGE - AR97.10-P-4000-03SXS
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
1 Seal spot welds, rivets and MAG seams in repaired area with seam sealant material.
Do not seal openings between MAG seams.
Leave openings open between MAG seams for coating with wax.
Insert plastic plugs and grommets with sealing compound.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
It is necessary to seal accessible spot weld flanges on both sides. If accessible from one side, only seal
corresponding surface. Observe standard seals!
When sealing seams we differentiate between:
A smoothing/wiping
B spreading
Fig. 41: Identifying Smoothing/Wiping And Spreading Sealing Seams
Courtesy of MERCEDES-BENZ USA
Area of A-pillar on longitudinal member and left outer connection, shown on model 221 without code
Z07
Fig. 42: Identifying Longitudinal Member And Left Outer Connection Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left inner A-pillar, shown on model 221 without code Z07
Fig. 43: Identifying Left Inner A-Pillar Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left A-pillar paneling, shown on model 221 without code Z07
Fig. 44: Identifying Left A-Pillar Paneling Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of B-pillar with left inner longitudinal member, shown on model 221 without code Z07
Fig. 45: Identifying Left Inner Longitudinal Member B-Pillar Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of entire side left outer longitudinal member, shown on model 221 without code Z07
Fig. 46: Identifying Left Outer Longitudinal Member Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of entire left rear fender, shown on model 221 without code Z07
Fig. 47: Identifying Left Rear Fender Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of rear fender, side paneling below bumper and left rear lamp cutout, shown on model 221 without
code Z07
Fig. 48: Identifying Rear Fender, Side Paneling Below Bumper And Left Rear Lamp Cutout Sealing
Area
Courtesy of MERCEDES-BENZ USA
Area of entire underfloor, shown on model 221 without code Z07
Fig. 49: Identifying Underfloor Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of left rear interior compartment
Area of left rear interior compartment
Fig. 50: Identifying Left Rear Interior Compartment Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of door stop bracket
Fig. 51: Identifying Door Stop Bracket Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of lower left B-pillar
Area of lower right B-pillar
Courtesy of MERCEDES-BENZ USA
Area of right B-pillar rear wall
Area of left B-pillar rear wall
Fig. 53: Identifying Left And Right B-Pillar Rear Wall Sealing Area
Courtesy of MERCEDES-BENZ USA
SEAM SEALING FOLLOWING REPAIR, DETACHABLE BODY COMPONENTS - AR97.10-P-4000-
04SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
1 Seal spot welds and rivets in repaired area with seam sealing material.
Insert plastic plugs and grommets with sealing compound.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
It is necessary to seal accessible spot weld flanges on both sides.
If accessible from one side, only seal corresponding surface. Observe standard seals!
SEALING SEAM AFTER REPAIRING ROOF - AR97.10-P-4000-05SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20
BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20
1 Seal spot welds of area to be repaired with seam sealing material
Insert plastic plugs and rubber grommets with sealing compound.
Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves.
Also keep drain openings and contact surfaces for axle attachments, windows and detachable parts free of
sealant.
It is necessary to seal accessible spot weld flanges on both sides. If accessible from one side, only seal
corresponding surface. Observe standard seals!
Area of front inner roof frame with center roof paneling, shown on model 221
Fig. 54: Identifying Front Inner Roof Frame With Center Roof Paneling Seam Sealing Area
Area of inner side roof frame with side roof paneling, shown on left side of vehicle on model 221
Fig. 55: Identifying Inner Side Roof Frame With Side Roof Paneling Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of rear inner roof frame with center roof paneling, shown on model 221
Fig. 56: Identifying Rear Inner Roof Frame With Center Roof Paneling Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
Area of outer roof paneling and center roof paneling, shown on right side of vehicle on model 221
Fig. 57: Identifying Outer Roof Paneling And Center Roof Paneling Seam Sealing Area
Courtesy of MERCEDES-BENZ USA
SEAM SEALING FOLLOWING REPAIR - AR97.10-P-4000SX
MODEL 216, 221
Picture item,
Work instructions
etc.
Risk of explosion and poisoning Never spray anticorrosion agents on flames
caused by solvent vapors and or glowing hot objects and keep them well
AS97.00-Z-
gasses. Risk of injury to skin and away from all potential sources of ignition.
0001-01A
eyes when working with Use them only in well-ventilated rooms;
anticorrosion agents wear respiratory protection.
AH97.20-P-
Underfloor preservation
2000-01A
Cavity preservation following AR97.20-P-
Model 216
repair work 1500SC
AR97.20-P-
Model 221
1500SX
Processing of body sealant AR97.10-P-
Seam sealing following repair, Model 216, 221.0, model 221.1 except AR97.10-P-
front end damage code (Z07) Top protection 4000-01SX
AR97.10-P-
Model 221.1 with code (Z07) Top
4000-
protection
01SXS
Seam sealing following repair, Model 216, 221.0, model 221.1 except AR97.10-P-
rear end damage code (Z07) Top protection 4000-02SX
AR97.10-P-
Model 221.1 with code (Z07) Top
4000-
protection
02SXS
Seam sealing following repair, AR97.10-P-
Model 216
side damage 4000-03SC
Model 221.0, model 221.1 except code AR97.10-P-
(Z07) Top protection 4000-03SX
AR97.10-P-
Model 221.1 with code (Z07) Top
4000-
protection
03SXS
Seam sealing following repair, AR97.10-P-
detachable body components 4000-04SX
AR97.10-P-
Sealing seam after repairing roof
4000-05SX
Service Information sprayable SI97.10-P-
seam seal 0001A
PROCESSING ZINC DUST PAINT BEFORE PAINTING - AR97.20-P-0500-01SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
Observe following procedure when processing zinc dust:
Carefully clean affected body parts. All bare sheet metal parts must be completely clean and free of rust,
oil and wax.
Uniformly apply zinc dust paint with brush or paint spray gun.
Maintain drying time (paintable).
Zinc dust paint serves for preventing corrosion on welds, sheet metal contact points and surfaces, which
cannot be painted or are difficult to paint following assembly.
Do not use for painting outer surface.
PROCESSING PERMANENT UNDERBODY PROTECTION AGENT FOR PAINTING - AR97.20-P-
0500-03SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10
Dark-gray permanent underfloor protection (synthetic rubber)
The permanent underfloor protection has a synthetic rubber base and is suitable for application to fender bottom
parts, underbody as well as transitions to underfloor protection processed at the factory
Permanent underfloor protection (water-base dispersion), gray
The permanent underfloor protection is a water-thinnable dispersion suitable for application to the underbody,
fender bottom sections and exterior surface.
For processing on the outer surface (e.g. front fender below bumper or longitudinal members at entrance), thin
material with 5 % water to achieve better coverage.
The permanent underfloor protection is not suited for sealing work (seam sealant).
Observe the following procedure when processing:
All areas to which permanent underfloor protection is to be applied must be thoroughly cleaned (steam
cleaner). In particular, remove wax and oil residues as well as loose pieces of PVC thoroughly. Grind
corroded points down to bare metal and prime.
A hot air blower and flat nozzle with integrated scraper or rotating wire brushes are suitable for removing the
PVC material.
Apply permanent underfloor protection uniformly with spray gun.
Do not spray permanent underfloor protection on major assemblies; otherwise, function
impairment is possible. Blow out spray gun with solvent after use. Expose air hole on screw-in thread to prevent
spraying gun from sticking.
Maintain drying time (paintable).
PROCESSING CORROSION PROTECTION MATERIALS BEFORE PAINTING - AR97.20-P-0500SX
MODEL 216, 221
Figure item,
Work instructions
etc.
Instructions for processing
AH97.20-P-
permanent underbody
9409-01A
protection
Processing of body sealant For sealing plans see paint and corrosion AR97.10-P-
(paintable) before painting protection manual. 0500-02SX
Do not use for painting outer surface. All
Processing zinc dust paint AR97.20-P-
bare sheet metal parts must be completely
before painting 0500-01SX
clean and free of rust, oil and wax.
Processing permanent
AR97.20-P-
underfloor protection agent
0500-03SX
for painting
CAVITY PRESERVATION FOLLOWING REPAIR WORK - AR97.20-P-1500SX
MODEL 221
Wheelhouse with complete front longitudinal member
Fig. 58: Identifying Wheelhouse With Complete Front Longitudinal Member Cavity Preservation Repair
Area
Courtesy of MERCEDES-BENZ USA
A-pillar on longitudinal member and inner and outer connection element
Fig. 59: Identifying Longitudinal Member And Inner And Outer Connection Element Cavity
Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
B-pillar on longitudinal member, outer side paneling and inner roof frame
Fig. 60: Identifying Longitudinal Member, Outer Side Paneling And Inner Roof Frame Cavity
Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Fig. 61: Identifying Side Longitudinal Member Cavity Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Entire rear fender Complete rear end
Fig. 62: Identifying Rear Fender Cavity Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Fig. 63: Identifying Complete Rear End Cavity Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Front roof frame
Fig. 64: Identifying Front Roof Frame Cavity Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Inner roof frame
Fig. 65: Identifying Inner Roof Frame Cavity Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Rear roof frame
Fig. 66: Identifying Rear Roof Frame Cavity Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Rear longitudinal member
Fig. 67: Identifying Rear Longitudinal Member Cavity Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Complete underbody
Fig. 68: Identifying Underbody Cavity Preservation Repair Area
Courtesy of MERCEDES-BENZ USA
Risk of explosion and
Never spray anticorrosion agents on flames or
poisoning caused by solvent
glowing hot objects and keep them well away AS97.00-
vapors and gasses. Risk of
from all potential sources of ignition. Use them Z-0001-
injury to skin and eyes when
only in well-ventilated rooms; wear respiratory 01A
handling anticorrosion
protection.
agents.
AH97.20-
Notes on cavity preservation P-0001-
01B
Apply cavity sealant from inside in cross-
hatched areas following sealing and paintwork,
however, before performing assembly work.
Apply repair preservation agent twice with a
Perform repair preservation
drying time of 5 minutes in between.
in cross-hatched areas
1 The spraying hose should be stiff and the
through vehicle openings
(arrows). nozzles should spray at angle to the front and
rear. The cavities should be dry.
Insert spray hoses as far as possible into
cavities. Spray while inserting and pulling out
slowly.
The processing temperature should not be less
than 15 °C. Additional preservation measures
may be required depending on the repair area
deviating from the standard cavity preservation
illustrated.
AP97.20-
Processing instructions for
P-0640-
cavity preservation agent
01SX
Cavity preservation gun Sata HRS no. 11072 *BR00.45-
http://gotis.aftersales.mercedes-benz.com Z-1003-
MB cavity wax preservation, 1 l 05A
Openings (a, b, c) not visible on finished
vehicle.
Apply cavity sealant from inside in cross-
hatched areas following sealing and paintwork,
however, before performing assembly work.
2.1 Perform repair preservation Apply repair preservation agent twice with a
in area of rear inner roof drying time of 5 minutes in between.
frame (A), upper B-pillar (B) The spraying hose should be stiff and the
and front inner front frame nozzles should spray at angle to the front and
(C) through side roof rear. The cavities should be dry.
paneling opening (a), B-pillar Insert spray hoses as far as possible into
roof paneling opening (c). slowly.
The processing temperature should not be less
than 15 °C. Additional preservation measures
may be required depending on the repair area
deviating from the standard cavity preservation
illustrated.
AP97.20-
Processing instructions for
P-0640-
cavity preservation agent
01SX
Cavity preservation gun Sata HRS no. 11072 *BR00.45-
http://gotis.aftersales.mercedes-benz.com Z-1003-
Preservation agent 05A
Remove cavity sealant from
3
drain holes
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1003-05A Cavity preservation, solvent-free (1 l container) A 000 986 72 70 05
INSTALLING TRANSPORT FOIL - AR97.20-P-4000SX
MODEL 216, 221
Notes on
AH97.20-P-
transportation
9409-03A
sheeting
Heat old foils and Heat foils only to the extent that they can still be
1
remove. touched; otherwise, the paint could be damaged.
2 Clean the vehicle Chamois the vehicle dry.
When replacing foil, the edges of the adhesive tape may
remain visible. These edges are removed when preparing the
Check paint surfaces
3 paint.
of vehicle
Minor swelling is of no significance when replacing. The new
foil can be applied to this painted surface.
Install new transport Do not glue foil on plastic parts and rubber seals
4
foil by hand (risk of adhesive residues).
SAFETY PRECAUTIONS
RISK OF EXPLOSION AND POISONING CAUSED BY SOLVENT VAPORS AND GASSES. RISK
OF INJURY TO SKIN AND EYES WHEN WORKING WITH ANTICORROSION AGENTS - AS97.00-
Z-0001-01A
Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential
sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection.
Potential risks
Risk of explosion
The solvents contained in anticorrosion agents (such as underfloor protective coatings, cavity wax, engine
compartment wax) are flammable, and may burst into flame if sprayed onto glowing hot components or open
flames.
Risk of poisoning
Inhaling spray and solvent vapors can lead to damage of the respiratory system and lungs. Symptoms of
poisoning include headache, breathing difficulty, nausea and loss of consciousness.
With underfloor protection, the following risks are also posed:
Risk of damage to liver and kidneys.
Central nervous system disorders, loss of consciousness.
When these substances burn they produce toxic gases with a noxious odor; these gases are dangerous in
high concentrations.
Risk of injury
If anticorrosion agents come in contact with the eyes they can cause severe eye damage.
In the event of frequent or prolonged contact with the skin, these substances can lead to inflammation of the
skin and to the removal of the skin's natural oils.
Safety instructions/precautions
Always remove all PVC undercoating and PVC seam sealer from the areas before performing any
welding or soldering work. This also applies for work such as cutting, sanding or similar work.
When removing damaged bodywork sections use "cold" separating methods where possible. With these
methods, smoke and toxic fumes are avoided.
Do not expose containers to direct sunlight or to temperatures in excess of 50 °C.
Always maintain the prescribed application pressure.
Never spray corrosion protection agents into flames or onto hot objects; keep well away from sparks and
all potential sources of ignition, and do not smoke.
Take precautions to avoid sparks from electrostatic discharge.
Avoid all contact with eyes and skin.
Wear tight-fitting safety glasses and solvent-resistant gloves.
Work in well ventilated areas; wear respiratory protection.
If clothing becomes soaked or contaminated, remove and wash it immediately.
Keep well away from food and drinks.
Seal containers tightly and store them in a well-ventilated area.
First aid measures
In case of eye contact
Flush thoroughly with water and consult a physician (eye doctor) immediately.
In case of ingestion
Give medicinal activated charcoal; do not induce vomiting; consult a physician immediately.
In case of inhalation
Move victim to fresh air, have victim lie down and remain calm, avoid strenuous activity.
In case of skin contact
Immediately wash with soap and water, apply protective skin ointment.
Fire protection measures
Rescue, extinguishing and cleanup operations in areas contaminated by fumes should only be undertaken by
individuals wearing respiratory protection. Do not inhale fumes from flames or explosions.
Suitable extinguishing agents:
Indirect water spray
Foam
Extinguishing powder
Carbon dioxide
Non-suitable extinguishing agents:
Direct high-pressure water spray
SAFETY INFORMATION: BODY SEALING, CORROSION PROTECTION - AS97.00-Z-9999ZZ
MODEL all
116, 123, 124, 126, 129, 140, 163, 164, 166, 168, 169,
Risk of explosion and
170, 171, 172, 197, 201, 202, 203, 204, 207, 208, 209,
poisoning caused by
210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, AS97.00-
solvent vapors and gasses.
Danger! 245, 251, 405, 414, 436, 437, 450, 451, 452, 454, 461, Z-0001-
Risk of injury to skin and
463, 613, 636, 638, 639, 671, 690, 900, 901, 902, 903, 01A
eyes when working with
904, 905, 906, 930, 932, 933, 934, 940, 942, 943, 944,
anticorrosion agents
950, 952, 953, 954, 970, 972, 974, 975, 976...
GENERAL INFORMATION
Body - General - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL INFORMATION ON BODY REPAIR - AH60.00-N-0001-01A
All models
General information on repair instructions
The repair instructions form the basis for proper and competent maintenance and repair.
The content of the work procedures described is based on the training level of a fully qualified auto mechanic
with extensive product expertise. This level of knowledge is essential for carrying out the described work.
Basic prerequisites for properly performing body repairs include:
Use of genuine Mercedes-Benz parts.
Strict observance of the Mercedes-Benz guidelines for bodywork.
Workshop equipped with suitable special tools and workshop equipment.
Notes on repair method
Repair of damaged body panels is one of the most economical and time-saving measures and is preferable to
replacing assemblies.
A precise check should always be made to determine which repair procedure is most economical. Repair should
always be considered to be the "first choice", because this has the least effect on the strength, dimensional
accuracy and corrosion resistance, etc. achieved at the factory
If repair work is not possible, the connection type priorities should be observed as follows during the repair:
1. Resistance spot welding
2. Rivets
3. MAG plug welds and other weld joints
Work protection and safety information
In order to rule out any risk of personal injury, to avoid impairing the reliability and safety of the vehicle, and to
prevent damage to the vehicle as a result of work improperly carried out, these instructions are to be read
carefully and complied with in full.
Consequently, it is not possible for Daimler AG to evaluate in the last consequence every situation which might
present a risk of injury for the operative. It is therefore urgent that everyone who carries out repair operations on
MB passenger cars applies their professional knowledge to ensure that their own safety is not at risk and that the
vehicle will not be adversely affected (in particular with regards to safety) as a result of the repair procedure
chosen It is therefore expressly pointed out that all work of the operations described shall be carried out only by
complying with valid directives and instructions of the local, competent authorities and those relating to health
and safety at work, and environmental protection.
Sectional repairs
We recommend the following procedure for repairing body sections or sectional repairs:
Inert gas welds which are not in the immediately visible area or which are concealed by installed parts when the
vehicle is completed should not be ground down smooth or filled for reasons of economy and operating
stability.
Labor protection equipment
In addition to personal occupational clothing to include cap and safety shoes, working gloves, safety glasses, ear
protection, dust protection mask, etc. must be worn as required when working.
Battery
Before performing any type of welding work or other work causing sparks in the area of the vehicle battery,
always remove the battery and store in a protected location.
Components
During repair work following accidents, visually check electronic components, steering and seat belts.
Air conditioning
Do not weld or perform similar types of work on components in the closed air conditioning system or in its
immediate vicinity.
Drill, saw
Before drilling or sawing, remove electric lines and pipes installed in cavities as well as reservoirs located in
concealed locations (e.g. battery) and electronic components from hazard area.
Helicoil-compatible thread
Defective metric threads (as of M8) are helicoil-compatible in coordination with the Daimler development
department. However, this is basically possible only with tubes produced according to MBN 10349. Tubes
deviating from the standard, must be checked for repair suitability. Further information is given in the KG 00
"Notes on threaded connections with self-tapping screws".
Vehicles
Shield vehicles located in the body repair area against possible damage to paint and glass surfaces as well as fire
hazard from flying sparks using dividing walls or cover with fire-resistant tarp
Lifting platform
The vehicle can fall from the lifting platform due to weight transfer caused by removed parts (e.g. engine,
shafts, etc.). Secure vehicle or add sand bags to compensate the weight.
Corrosion protection
After painting, treat areas affected by repair with appropriate corrosion protection measures (e.g. wax, cavity
sealing agent, underbody protection, if present).
Metal shavings
Do not use compressed air to blow away metal shavings produced by machining work on the body; remove with
vacuum cleaner instead.
Engine and auxiliary equipment
Before performing any type of machining work on the body (e.g. with ball cutter), cover engine including all
auxiliary assemblies (e.g. alternator, solenoids, etc.) to prevent damage from metal shavings.
Straightening work
Welding vapors
Evacuate noxious gases, vapors, dust and welding smoke in the area where these occur.
Welding and related work
During all welding work, observe accident prevention regulations for welding, cutting and related types of work
In addition, before performing electric welding work, observe safety precautions for electronic control units.
Moreover, remove easily combustible and flammable materials and liquids from the hazard area. Use shields to
protect against flying
When performing straightening work never stand in a direct line in front of the pull chains when introducing
straightening forces to the frame or body.
Secure pull chains with catch cables or chains to prevent it from snapping away.
Observe notes on straightening and verify position of check bores. If necessary, detach body from straightening
bench and realign.
sparks and heat radiation and protect electric lines and piping installed in cavities.
When spot welding, maintain a spot weld interval of approx. 20 mm Clean, smooth electrode tips are required.
Set the current time or power according to the sheet metal thickness (new part) on the spot welder.
Continuation: Welding and related procedures
Corresponding welding parameter settings on the Daimler AG tested and approved spot welders for each
specific type are available in the WIS for the P Division. The parameters serve as a default setting for the spot
welder.
Always observe these setting specifications to ensure operating stability A spot-weld sample must be made
before the repair is conducted.
Standard bonded load-bearing sections
For standard bonded load-bearing sections that are not rebonded following accident repair, the number of spot
welds is indicated in the specific repair description.
Always observe these specifications to ensure operating stability
Welding procedures, connections and symbols
Resistance spot welding
Single-row spot weld
Double-row spot weld
Double-row spot weld offset
Brazing
MAG welding
Stitch weld
Continuous weld
Continuous weld interrupted
Plug weld
Fig. 1: Assembly Examples For Spot Welding Fittings
Courtesy of MERCEDES-BENZ USA
Assembly examples for spot welding fittings
GENERAL INFORMATION ON BODY REPAIR - AH60.00-P-0001-01A
Work protection and safety information
Always observe country specific and generally applicable protective equipment/safety information
Notes on repair method
Repair of damaged body panels is one of the most economical and time-saving measures and is preferable to
replacing assemblies. If repair work is not possible, the connection type priorities should be observed as follows
during the repair:
1. Resistance spot welding
2. Rivets
3. MAG weld joints, MIG solder connections
Basic requirements for correct execution of a body repair are:
1. Use of genuine Mercedes-Benz parts.
2. Use of approved materials (see repair descriptions).
3. Use of approved tools and machines (see Gotis)
4. Strict observance of repair descriptions
5. MAG welt joints and MI G solder connections which are not in the immediately visible area or which are
concealed by installed assembly parts when the vehicle is completed should not be ground down smooth
or filled for reasons of economy and operating stability.
Paneling
Separating points on paneling can generally be selected freely.
Separating points should not be located in the area of the foam pieces (for exceptions see repair description)
Structural parts
Cut and replace structural parts only at standard joints and service separating points (see repair description)
Standard bonded load-bearing sections
Always restore standard glued structural areas during repair
Structural foams/structural reinforcements
Always replace structural foams/structural reinforcements
Glue adhesive points
Ensure on glued multiple-layer sheet metal connections, that the maximum permissible temperature does
not exceed 120 C°. Higher temperatures permanently destroy the glue.
Always check temperature during heating (e.g. temperature measuring instrument, see Gotis).
Prepare gluing points
Always observe detailed work instructions included in gluing set, otherwise secure bonding of the glued
connection cannot be ensured.
Welding, soldering method
Perform welding or soldering test before repair
Welding procedures, connections and symbols
Resistance spot welding
Single-row spot weld
Double-row spot weld
Double-row spot weld offset
Inert gas welding (MAG/MIG method)
Stitch weld
Continuous weld
Continuous weld interrupted
Plug weld
Soldering (brazing, MIG soldering)
Soldering
On multiple-layer sheet metal connections with hardened glue, ensure that the resistance spot welds
coincide with the original spot welds, otherwise the components to be welded can be damaged.
Engine and auxiliary equipment
Before performing any type of machining work on the body, cover engine including all additional equipment
(e.g. alternator, magnetic clutches, etc.) to prevent damage from metal chips.
Metal shavings
Remove metal shavings with vacuum cleaner only.
Corrosion protection
Apply preservation agent to repair points after body and paintwork.
Components
Following accidents, visually check electronic components, steering and seat belts.
Air conditioning
Do not weld or perform similar types of work on components in the closed air conditioning system or in its
immediate vicinity.
Drill, saw
Before drilling or sawing, remove electric lines and pipes installed in cavities as well as reservoirs located in
concealed locations (e.g. battery) and electronic components from hazard area.
Thread repair
Defective metric threads (as of M8) can be repaired (e.g. Helicoil or Timesert). However, this is only possible
with threaded tubes.
Thread-rolling thread
Thread rolling screws can be used several times.
Thread-rolling thread can be repaired (e.g. Helicoil or Timesert).
Thread-rollling threads should only be recut with a thread tap.
Only use original bolts.
Used materials
Low-carbon steel
up to 300 N/mm2 tensile strength
High-strength steel
- 550 N/mm2 tensile strength
Modern high-strength steel
- 1000 N/mm2 tensile strength
Ultra-high-strength steel
1000- 1500 N/mm2 tensile strength
Aluminum
Magnesium
Plastics
Always observe processing notes (see repair description).
MEASURES FOR PREVENTING DAMAGE TO COMPONENTS WHEN PERFORMING ELECTRIC
WELDING AND SOLDERING WORK - AH60.00-P-0001-02A
All models
In order to prevent damage to vehicle components, the following measures must be taken before
welding/soldering:
1. Disconnect ignition key and disconnect/insulate ground line from battery.
2. When performing electrical welding and soldering work in the area of the airbag control unit (distance <
0.5 m), disconnect electrical connector from airbag control unit.
3. The high-voltage battery, the gas tank and the gas-routing components should not exceed a temperature of
> 60 °C.
4. Before welding and soldering, cover all components to protect against flying sparks and radiant heat or
remove from hazardous area (including lines and components in hollow cavities).
5. Do not touch electronics housings or electrical lines with welding electrode or ground line from the
welder/solder.
6. Directly connect ground terminal from electrical welding and soldering unit to component to be
welded/soldered. Ensure that there are no electrically insulating parts between the ground terminal and the
welding/soldering point.
7. Do not connect ground terminal from electrical welding/ soldering unit to major assemblies (e.g.
transmission, engine, etc.).
GENERAL INFORMATION ON RIVETING - AH60.00-P-0003-01N
Model 168, 169, 171, 172, 199, 203, 204 207, 209, 211, 212, 215, 216, 218, 219, 221, 230, 240, 245.2, 414,
461, 463, 636, 639, 903, 906
General information
DIN 8593 describes rivets as non-detachable fasteners for parts of the same or different materials.
The connection is accomplished by the deformation of the fastening element (rivet).
Riveting is a type of connection which has been tested and approved by Daimler AG and which has significant
advantages over inert gas plug welding in terms of corrosion protection following repair work.
Deformation of joined parts due to heating does not occur during riveting as connections are made cold.
For this reason, the priorities for fastening techniques for repair have been redefined as follows:
1. Resistance spot welding
2. Rivets
3. MAG plug welds and other weld joints
Rivet types, their application and positioning are described in the respective repair documents.
For the repair of hybrid construction vehicles, joints are both riveted and bonded.
Gluing achieves higher strength as well as a sealed connection.
Standard bonded load-bearing sections
For standard bonded load-bearing sections which are not bonded again following accident repair, the number of
rivets is specified in the specific repair description. Always observe these specifications to ensure operating
stability
Always seal riveted body flange with body sealant.
Rivet forms for hybrid construction vehicles
Various types of rivets
Preparation of rivet points
Always drill and deburr rivet holes.
To prevent that the rivet is notched and to provide for good flow characteristics of the shaft material in the hole,
the edges of the rivet holes should be chamfered or countersunk.
Ultra-high strength materials
When processing ultra-high-strength materials, use only high-strength rivets approved by Daimler AG. Only a
riveter with increased draw-off strength can be used for this.
Rivet materials
Basically, the rivet should consist of the same material as the components to be connected, however, at least a
similar material to prevent destruction from electro-mechanical corrosion or looseness by different thermal
expansion.
The primary rivet materials are:
Steel
Aluminum alloys
Riveting procedure
Clean connecting points
Insert rivet
Pull back pin with hand riveter or electric or hydraulic riveter until it tears off at the predetermined
fracture point.
GENERAL NOTES ON WELDING - AH60.00-P-0005-01N
All models
General information on welding aluminum:
Metal electrode inert gas welding (MIG) is the process used most frequently for repairing aluminum. In this
process an arc is present between the component to be welded and the wire electrode to be melted. The wire
electrode serves as the welding material and transfers the energy required to melt the metal.
The process uses direct current; the electrode is the positive pole.
Welding aluminum requires a great deal of practice and experience. It required steady guidance of the arc and a
Welding is accomplished at an angle of approx. 75 to 80° from right to left with slight jabbing motion. This
allows the welder to clearly see the electrode tip and the welding operation. If held to flat, the heat and
protective gas dissipate too highly over the surface. This can lead to faulty welding results.
Preparation of aluminum welding areas:
Repair welding on aluminum body/body parts cannot be compared with conventional sheet steel weld joints.
For this reason it is absolutely necessary to prepare the welding areas observing extreme cleanliness and to
perform a test spot-weld on a specimen panel (e.g. cut from old damaged part) before performing any welding
work on the vehicle or components.
Approved welders are listed under the following link:
Insert gas welder (aluminum)
gotis://K_60-65_17.1
Typical welding errors:
Fissures in the weld result, for example, when the welding current is to high or when the wrong wire
electrodes are used.
When repairing cracks, grind out the weld over the length of the fissure down to twice the depth of the
crack before rewelding. After rewelding check again for fissures.
Fissures in the external paneling can be repaired by first drilling a 2 mm diameter hole at both ends of the
crack to prevent further cracking. Then the crack and holes can be welded.
Pores in the weld are the fault which occurs most frequently, whereby the tendency to form pores
decreases at increasing solidification interval. Pores result from inclusion of gas bubbles during poor
cooling. Other causes for pores include:
instable arc,
incorrect burner position
quantity of inert gas too low
effect of air drafts,
nozzles too small or clogged by metal spatter.
contamination in area of weld from grease, oil, paint or dirt
If pores are present, grind out weld and weld over, then check weld seam.
End craters
Craters are formed at the end of each weld seam, which require filling. This can be accomplished by not
switching off the burner immediately at the end of the weld seam. The molten welding wire then fills up the
crater.
Cold weld points
The danger of cold weld points exists at the beginning and end of a seam; this can impair the strength of the
connection by notching. For this reason an additional length of approx. 5 mm should be provided at the
beginning as well as at the end of the weld.
PRETREATMENT OF BONDING SURFACES - AH60.00-P-0008-01N
Model 169, 171, 172, 204, 211, 215, 216, 219, 221, 240, 245.2, 414, 636, 639
Preliminary treatment of surfaces to be glued
Careful preparation of the surfaces to be glued is required to ensure proper connection between the glue and the
surface of the parts to be connected.
After removing old glue, dirt, rust, paint or oxide layers from bonding surfaces
Grind gluing flange down to bare metal
On aluminum surfaces use CrNi wire brush. Then treat flange with Saco-Roc abrasive paper (both included
in Al package).
Apply mixed primer only on bare flange areas, if they were cleaned previously with a brush or lint-free cloth.
Do not touch cleaned areas without gloves (transfer of sweat from hands).
Then the mixed primer can be applied to the prepared bonding surfaces with a flat brush
The result is positive when a uniform coat of primer is visible. If this is not the case, repeat treatment.
Start bonding work after primer has been wiped off with lint-free cloth after positive result has been achieved.
PRETREATMENT OF BONDING SURFACES - AH60.00-P-0008-01SX
Model 166, 172, 197, 204, 207, 209, 212, 216, 218, 221
Pretreatment of aluminum and steel surfaces to be bonded
It is necessary to carefully prepare the surfaces to be glued in order to obtain a good connection between the
glue and surfaces of the parts to be connected.
After removing old glue, dirt, rust, paint or oxidation layers from bonding surfaces grind gluing flange down to
bare metal
On aluminum surfaces use CrNi wire brush.
Apply mixed primer only on bare flange areas, if they were cleaned previously with a brush or lint-free rag
soaked with the cleaning agent provided.
After use, dispose of cleaning rag as special wastes due to residue of cleaning agent.
Do not touch cleaned areas without gloves (transfer of sweat from hands).
Primer
Metal connections require pretreatment with primer for bonding. This primer is required to ensure surface
cleanliness as well as improved long-term stability of bonding.
Bond primed surfaces immediately after applying the primer to prevent corrosion and contamination on the
surfaces. Apply mixed primer in thin layer with a flat brush to prepared surface to be glued.
Work mixed primer into surface with unused abrasive paper from the package.
The result is positive when a uniform coat of primer is visible. If this is not the case, repeat treatment.
The gluing operation can be started as soon as the primer has been wiped off with a lint-free paper towel after
obtaining a positive result.
Always observe the specified work steps and work instructions given in the gluing set!
NOTES ON VARIOUS BODY MATERIALS - AH60.00-P-0011-01SX
Model 216, 221
Illustrated on model 221
Hot-shaped steel (Usibor)
Fig. 2: Identifying Inner B-Pillar And Inner Side Longitudinal Member
Courtesy of MERCEDES-BENZ USA
Shown on model 221
Fig. 3: Identifying Plastic And Aluminum Components - Shown On Model 221
Courtesy of MERCEDES-BENZ USA
GENERAL INFORMATION ON DENT REMOVAL AND STRAIGHTENING ALUMINUM PARTS -
AH60.00-P-0012-01N
Model 215, 216, 221
Dent removal:
On aluminum parts, it is possible to remove dents up to a certain deformation depth. In the event of higher
deformation, it is necessary to replace the damaged parts. Comprehensive dent removal work can be
accomplished only under the effect of heat. In contrast to sheet steel, on aluminum plate the dent removal
operations should be started in the middle of the dent. If possible, attempt to eliminate the dents by pressing out.
Replace sharp-edged and hard dent removing tools with plastic, wood or aluminum hammers. If stretched too
highly, e.g. with steel tools, aluminum tends to work-harden (blocking of the displacement motion), which can
lead to embrittlement or crack formation.
Procedure for dent removal:
As with sheet steel, first feel the surface and localize high/low spots. Then remove dent.
On aluminum, then feel the smooth surface again to determine the pulling point for the next heat draw-in.
The working technique heating - dent removal - cooling must be accomplished quickly one after another and be
matched exactly to one another.
Use only special tools for aluminum processing for all types of repair work!
Drawing in:
To draw in, first heat up the aluminum plate with "neutral" welding flame to approx. 150 °C - 450 °C and then
allow to cool down punctually at the drawing point. The rapid temperature change causes the surface to contract
and the aluminum plate assumes its original shape. The heated point is flattened because the surrounding colder
material expands less, preventing thermal expansion of the heated material. When it cools, the heated, flattened
material contracts.
Important working rules for drawing in and straightening work:
1. Clean aluminum surface. Do not burn any contamination into the surface.
2. Heat up point to be repaired. Limit thermal expansion within repair area.
3. Use larger burner inserts. Adapt burner setting to material and part to be repaired.
Avoid settings with excess oxygen!
4. Heat up quickly point to be repaired. Determine temperature of straightening area.
With unhardened aluminum alloys, use wooden wedge or temperature color pen; with hardened
aluminum alloys, use digital thermometer, to determine temperature!
5. Cool down point to be repaired again quickly. This maintains the mechanical material properties.
Straightening, reshaping:
The reshaping characteristics of aluminum present more problems than steel. Structural damage can only be
straightened or reshaped under the effect of heat. After reaching the temperature for reshaping (250 °C to 300 °
C), release tension present by tapping carefully with a hammer. It is necessary to check the temperature of the
repair point frequently because the rebound effect resulting from resilient deformation is significantly higher
with aluminum than with steel. Avoid jerky drawing operations due to the increased risk of cracking. Aluminum
tends to tear out very quickly when notches or crimps are present in the reshaping area.
This also applies for high force in the area of weld joints. Reshaping also results in hardening, which can be and
must be reduced again by heating up to approx. 170 °C to prevent cracking.
Aluminum die-cast channels are extremely resistant to bending and cannot be reshaped. If damaged, they must
be replaced. Extruded aluminum channels can be reshaped to a limited extent when heated up properly
assuming that they are freely accessible.
Temperature check:
The following procedures can be used for determining the temperature:
Thermal colors to be applied to the edge area of the heating zone at interval of approx. 25 mm.
Temperature determination with soft wood (spruce, willow). Heat up point to be repaired. Stroke piece of
wood across heated point with medium pressure. Lines appear for the specific temperatures (approx. 350
°C - light brown, 400 °C -medium brown, 450 °C - dark brown, 500 °C - black).
Use uncarbonized wooden tip, otherwise the aluminum can tear due to incorrect temperature display
when reshaping.
Colored pins.
Observe specifications of specific manufacturer!
Self-adhesive temperature measuring strips.
When a certain temperature is exceeded, the corresponding fields on the temperature measuring strips
change color.
Infrared thermometer or pyrometer.
Observe specifications of specific manufacturer!
GENERAL INFORMATION ON CRACK DIAGNOSIS OF ALUMINUM PARTS - AH60.00-P-0014-
01N
All models
It is necessary to check whether any cracks, inclusions or other weld faults are present before and after
performing repair work on aluminum components.
A suitable method of testing is the simple dye penetration test, which accentuates faults starting at the surface or
in immediate connection with it which cannot be seen with the naked eye, through color contrast. This method
utilizes the capillary effect of fine surface openings. Liquids containing dyes with low surface tension penetrate
into these openings and can be verified there with suitable contrasting agents.
Usually luminous red or yellow-green fluorescent dyes are used a penetration agents, which can be washed off
with water. The penetration agent can be sprayed on or applied with a brush.
During the penetration time, the penetration agent should never be allowed to dry out. The smaller the surface
faults, the longer the penetration time (approx. 5 to 30 minutes).
The developer used subsequently requires a high absorption capacity, to suck the penetration agent out of the
damaged spot. This makes the fault visible by contrast in the developer layer. The development time is analog
to the penetration time. As a matter of principle, however, faults can only be verified on the material surface.
Always observe the specific Safety instructions of the individual manufacturers before using the cleaner,
contrast agent, and developer.
All three diagnostic agents are highly inflammable. The contrast agent also poses a health hazard.
Detection process:
1. Crack after cleaning.
2. Crack after application of contrast agent.
3. After removal of quantity which has not penetrated into the damaged point
4. After application of the developer, damaged point is indicated.
Courtesy of MERCEDES-BENZ USA
Typical damage indications with dye penetration method
1. Cold fissures
2. Hot fissures
3. Ground fissures
4. Fissures with strong blistering
5. Pores of various sizes
6. Nests of pores
7. Spongy structure
8. Pores with strong blistering
9. Stress
Fig. 5: Identifying Damage Indications With Dye Penetration Method
Courtesy of MERCEDES-BENZ USA
GENERAL INFORMATION ON BODY CONNECTION TECHNIQUES - AH60.00-P-0015-01SX
Model 216, 221
Fig. 6: Locating Clinch/Punch Rivets
Courtesy of MERCEDES-BENZ USA
Illustrated on model 221
Illustration shows standard clinch/punch rivet
When performing repair work use only specified blind rivet.
INFORMATION ON MACHINING/TREATING MAGNESIUM COMPONENTS - AH60.00-P-0023-
01R
General:
Magnesium has the property of forming a compound with oxygen extremely quickly. Nevertheless it is
corrosion-resistant when exposed to air, because it forms a tight, continuous thin oxide skin which protects the
metal beneath from further oxidation.
If magnesium is ignited, it burns at approx. > 500 °C with dazzling white light and severe heat development
(approx. 2400 °C).
Magnesium dust combusts and explodes just as easily as aluminum dust.
For additional information see Accident Prevention Regulations or the regulations of the trade association.
Machining/treating magnesium:
Machining/treating magnesium components by means of an open flame (welding, cutting, soldering,
heating, etc.) or by spark-creating grinding is prohibited.
Any components that suffer structural damage must be replaced completely.
Corrosion protection:
Faulty coatings and points affected by corrosion should never be repaired for corrosion reasons.
Repair over large surfaces should not be performed for reasons of corrosion.
To prevent contact corrosion at the threaded connections on the components (e.g. inner door parts), coat
contact surfaces and bolt shafts with paint after removal or replace bolts.
Do not use zinc dust paint!
Plastic bushings and disks installed as standard must not be removed and damaged parts must be
replaced.
Due to extremely severe contact corrosion, damaged threads in the magnesium pressure castings may
only be repaired with the MB-approved Helicoil thread inserts made of aluminum.
GENERAL INFORMATION ON REPAIR OF VEHICLES WITH ULTRA - STRENGTH STEELS. -
AH60.00-P-0024-01N
Failure to observe instructions when straightening/repairing, separating, preparing adhesive points,
joining/ connecting, resistance spot welding, MIG welding, MIG brazing can lead to considerable damage
to ultra-strength steels and their joints.
Straightening/repairing ultra-high-strength steels
Straightening work
Do not heat above 300 °C
Use commercially available pulling tool to planish the side longitudinal member, for example. Observe
welding suitability resistance when installing pulling adapter (e.g. shims) on ultra high-strength steels.
Straightening work on ultra high-strength steels can only be accomplished in the event of minor damage
(dents).
Cutting ultra-high-strength steels
Heating gluing points
The maximum permissible temperature for heating the flange connection to be loosened is 200 °C.
The ideal temperature for loosening the flange, e.g. with a chisel, is approx. 100 to 120 °C
Do not heat adhesive connections, consisting of 3 sheets of metal, to temperatures exceeding 200 °C to
preserve the connection without permanent damage.
After the component has cooled down, the adhesive resumes its original strength.
We recommend a hot air gun as heat source.
Drill out spot welds with special bits (see workshop equipment manual).
Cut out spot welds with special spot weld milling cutter (see workshop equipment manual).
Cut with 30 mm dia. cutting disks (see workshop equipment manual).
Use suitable machines for individual tools (see Workshop Equipment Manual).
Drill rivet holes with special bits (see workshop equipment manual).
Prepare gluing points
Observe pretreatment of bonding surfaces.
The detailed work description included with glue set must be strictly observed!
Joining/connecting ultra-high-strength steels
Rivet joints
When processing ultra-high-strength materials, use only high-strength rivets approved by DC.
For this purpose, a riveter with increased draw-off strength is required (see Workshop Equipment
Manual).
Resistance spot welding
The spot welding tongs (inverter technology) should be approved for these materials (see Workshop
Equipment Manual).
The extension of the electrode arms is limited to the short standard electrode.
To determine the optimum welding parameter settings and the electrode pressure, perform a snap-out test
on a sample plate before performing resistance spot welding on the vehicle (see following picture).
Only this ensures optimum welds
MIG soldering
MIG soldering is only permissible on repair points described in WIS.
Snap-out test on sample panel (old part) on ultra high-strength steels to determine the optimal welding
parameter setting
Determine suitable welding parameters on sample panel (to be removed from old part) in combination
with approved spot welders. By completing spot-weld specimen (with adhesive) and performing snap-out
test with measuring weld nugget diameter using formula 4Xsq. roott (t = panel thickness).
Weld nugget diameter (a) should be at least 5 mm.
Take adhesive from glue cartridge without mixing tube (mix manually).
Fig. 7: Identifying Weld Nugget Diameter
Courtesy of MERCEDES-BENZ USA
PRODUCT LIABILITY, TRADEMARK AND TRAFFIC LAWS - AH60.00-P-0800-01Z
Model 163, 164, 166, 168, 169, 170, 171, 172, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219,
220, 221, 230, 240, 245.2, 251, 414.700, 690.6, 636, 638, 639, 900, 901, 902, 903, 904, 905, 906
Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4,
YD5, YD6, YD7
For legal reasons (product liability, trademark and traffic laws) and to prevent negative effects to the Daimler
corporation and employees of the specific Mercedes-Benz dealerships, we recommend that the vehicle
identification number and Mercedes stars at the end (trademark) only be stamped on a vehicle if the body or the
vehicle was replaced or repaired within the Mercedes-Benz service organization.
This recommendation is based on the following reasons:
Some companies have specialized in rebuilding Mercedes-Benz vehicles with used or new bodies and often
finishing these vehicles with second-hand parts from various accident vehicles of the same model.
Cases are repeatedly reported where other companies have then asked service outlets or authorized workshops
to mark the vehicle with the vehicle identification number of the original (accident) vehicle
We request you to never perform such work, even when the other company assures that they have rebuilt the
vehicle for themselves or at the request of a customer.
Legal problems relating to the protection of our trademark could result from unreservedly marking such
vehicles with the vehicle identification number with stars at the end (trademark).
The new product liability laws consider the manufacturer to be the company who attaches its trademark to a
product, regardless of whether the product was actually produced by this manufacturer.
Moreover, the Daimler corporation could, under certain circumstances, be considered to be the manufacturer
and be liable in the event of damage.
Assembly of used or new bodies with various parts is the equivalent of new production. If such assembly is
performed by another company, the Daimler corporation does not consider itself to be the manufacturer.
For this reason it is necessary for the registration authorities to issue a new vehicle title, which is legally
possible, in which the assembling company is entered as the manufacturer and the serial number of the technical
testing point becomes the vehicle identification number.
Moreover, such rebuilt vehicles usually require an operating permit. According to Section 59, Paragraph 2 of
the German vehicle licensing regulations (StVZO), this requires notification of the responsible registration
authority.
On the other hand, if a dealership or authorized workshop marks the rebuilt vehicle with the vehicle
identification number of the original (accident) vehicle, the assembling company would be given the
opportunity of circumventing its liability according to Section 59, Paragraph 2 of the German vehicle licensing
regulations.
Companies requesting that rebuilt vehicles be marked with the vehicle identification number should be advised
accordingly and referred to the responsible registration authority.
VEHICLE IDENTIFICATION NUMBER - AH60.00-P-0800-02A
All EU vehicles
Fig. 8: Identifying Vehicle Identification Number
Courtesy of MERCEDES-BENZ USA
The vehicle identification number starts and ends with the "Mercedes star" (trademark) and has 19 punched
numbers with a total length of 106 +/-4 mm.
If, in case of repair, the area where the vehicle identification number has been embossed is replaced, it is
necessary to punch it in at the same point.
This involves a change to the vehicle which is subject to compulsory notification. In the Federal Republic of
Germany immediately inform motor vehicle registration authorities in writing .
The vehicle holder is required to complete a certificate for the vehicle licensing authority which indicates that
the vehicle identification number has been re-stamped after completing body repairs.
As prove, the original vehicle identification number cut out of the old part, may also be enclosed.
A vehicle identification number incompletely punched in by the workshop must be crossed out and pinched in
correctly in the spare field on the right crossmember, the right side of the drive shaft tunnel, the rear partition
wall or the firewall.
This procedure should be noted additionally in the certificate for the vehicle licensing authority as follows:
"The incorrectly or incompletely punched vehicle identification number was crossed out and the correct vehicle
identification number punched in the spare field."
Export countries must observe their relevant vehicle licensing provisions and legal regulations.
VEHICLE IDENTIFICATION NUMBER - AH60.00-P-0800-02B
All vehicles with USA version, code 491, 494
Fig. 9: Identifying Vehicle Identification Number
Courtesy of MERCEDES-BENZ USA
The vehicle identification number starts and ends with the "Mercedes star" trademark (1, 19) and has 19
punched numbers with a total length of 103 mm.
If, in case of repair, the area where the vehicle identification number has been embossed is replaced, it is
necessary to punch in the vehicle identification number at the same point.
This involves a change to the vehicle which is subject to compulsory notification. In the Federal Republic of
Germany immediately inform the vehicle licensing authority in writing .
The vehicle owner is required to complete a certificate for the vehicle licensing authority which indicates that
the vehicle identification number has been re-stamped after completing body repairs.
As prove, the original vehicle identification number cut out of the old part, may also be enclosed.
A vehicle identification number incompletely punched in by the workshop must be crossed out and pinched in
correctly in the spare field on the right crossmember, the right side of the drive shaft tunnel, the rear partition
wall or the firewall.
This procedure should be noted additionally in the certificate for the vehicle licensing authority as follows:
"The incorrectly or incompletely punched vehicle identification number was crossed out and the correct vehicle
identification number punched in the spare field."
Export countries must observe their relevant vehicle licensing provisions and legal regulations.
GUIDELINES FOR REMOVING FUEL TANK WHEN PERFORMING WELDING WORK ON
BODIES - AH60.00-P-3000-01V
Model 171.4, 211.2, 169.0/3, 219.3, 221, 245.2
171.4 211.2 169.0/3 219.3 245.2 221
Left rear fender
Right rear fender
Main floor panel X X X X X X
Bottom rear center section
Rear floor X X X
Spare wheel recess X X
Rear longitudinal member X X X
B-pillar X
Outer C-pillar X
Outer side longitudinal member
Rear inner wheelhouse X X
X Removal of fuel tank
When a repair or partial rebuilding of the listed parts is being carried out, a supervisor must decide whether
to remove the fuel tank depending on the nature and extent of the damage in each individual case.
On vehicles with fuel evaporation system, it is necessary to cover the system in the area of the feed to the
when performing welding work.
GUIDELINES FOR REMOVING FUEL TANK WHEN PERFORMING WELDING WORK ON
BODIES - AH60.00-P-3000-01Z
All models
When a repair or partial rebuilding of the listed parts is being carried out, a supervisor must decide whether to
remove the fuel tank depending on the nature and extent of the damage in each individual case.
In vehicles with a fuel evaporation control system, the system must be covered with a welding protection
blanket or removed when welding work is being carried out near the incoming vent pipe or activated charcoal
canister.
REPLACE -
Rear
Rear Rear
fender, C-
Rear fender Main center Spare Rear Longitudinal
left floor Rear B- pillar,
fender, front piece, wheel longitudinal member on
(petrol floor pillar outer
right section, (3) bottom recess member outside
models section
complete section
only)
W (1) (1) (1) (1) (1) (1) (1)
- - - -
114/115
R 107/ (1) (1) (1) (1) (1) (1) (1)
- - - -
W 116
W 123 (1) (1) - (1) - (1) (1) (1) - (1) -
S 123 (1) (1) - (1) (1) (1) (1) (1) - - -
W/C (1) (1) (1) (1) (1) (1) (1)
- - - -
126
Offroad
veh. (1) (1) - - (1) (1) - (1) - (1) -
460/61
201 W (1) (1) - (1) - (1) (1) (1) - (1) -
W/C (1) (1) (1) (1) (1) (1) (1)
- - - -
124
124 s (1) (1) - (1) (1) (1) (1) (1) - - -
Offroad
veh. (1) (1) - - (1) (1) - (1) - (1) -
463
R 129 (1) (1) - (1) - (1) (1) (1) - - -
W/C (1) (1) (1) (1) (1) (1) (1)
- - - -
140
202 W - (4) (1) (1) - (1) - (1) - - (1)
202 s - (4) (1) (1) - (1) - (1) - - (1)
210 W (1) (1) - (1) - (1) (1) (1) - (1) -
210 s (1) (1) - (1) - (1) (1) (1) - (1) -
(1) (1) - (1) - (1) (1) (1) - - -
C 208 (2)1 (2)1 - (1) - (1) - (1) - - (1)
A 208 - (4) - (1) - (1) - (1) (1) - (1)
W168 - (1) - (1) - (1) - (1) - - -
W220 (1) (1) - (1) - (1) - (1) - (1) -
C215 - - - (1) - (1) - (1) - - -
W 203 - (4) (1) (1) - (1) - (1) - - (1)
CL 203 - (4) (1) (1) - (1) - (1) - - (1)
203 s - (4) (1) (1) - (1) - (1) - - (1)
- (1) - - - (1) (1) (1) (1) - -
414 C - (1) - (1) - (1) - (1) - - -
211 W - (4) (1) (1) - (1) - (1) - (4) -
A/C (1) (1) (1) (1)
- - - - - - -
209.3
240 W - (1) - (1) - (1) - (1) - (1) -
(1) Removal of fuel tank.
If the damage is more extensive and welding work is required at the wheel arch panel or C-pillar, the fuel
tank must also be removed in diesel vehicles.
(2) Fuel tank removal, optional depending on repair method.
(3) Fuel tank removal, depending on nature and scope of damage.
(4) Remove fuel filler neck and vent pipe.
Seal airtight with the (cover set) and attach heat guard.
GENERAL NOTES: PASSENGER CARS: BODY - GENERAL - AH60.00-Z-9999AZ
MODEL all
Decision-making criteria for repair AH60.00-P-
MODEL 215
in fully equipped repair workshop 0019-01N
General information on body AH60.00-P-
MODEL 216, 221
connection techniques 0015-01SX
General information on body AH60.00-P-
MODEL all
repair 0001-01A
General information on body AH60.00-P-
MODEL 169.090 with ENGINE 780.992
repair 0001-01EZ
AH60.00-
General information on body
MODEL all N-0001-
repair
01A
General information on crack AH60.00-P-
MODEL all
diagnosis of aluminum parts 0014-01N
General information on dent
AH60.00-P-
removal and straightening MODEL 215, 216, 221
0012-01N
aluminum parts
General information on repair of AH60.00-P-
MODEL 166, 204, 207, 212, 216, 218, 221
vehicles with ultra-strength steels. 0024-01N
General information on repairs to AH60.00-P-
MODEL 450.3 /4
body 0001-01SM
General information on repairs to AH60.00-P-
MODEL 452.3 /4
body 0001-01RC
General information on repairs to AH60.00-P-
MODEL 451.3 /4, 454.0
body 0001-01FF
AH60.00-P-
General information on riveting MODEL 451.3 /4 0003-
01MCC
MODEL 166, 168, 169, 171, 172, 199, 203, 204, 207,
AH60.00-P-
General information on riveting 209, 211, 212, 215, 216, 218, 219, 221, 230, 240, 245,
0003-01N
414, 461, 463, 636, 639, 903, 906...
General information on workshop
and repair concept on vehicles AH60.00-P-
MODEL 215
with newly introduced materials 0016-01N
and joining technology
General note on use of 2-
AH60.00-P-
component acoustic filler foam MODEL 197
0033-01RQ
following repairs
General notes for body repair on AH60.10-P-
MODEL 169, 245.2
straightening systems 1000-01AK
General notes on jointing AH60.00-P-
MODEL 215
techniques in bodywork 0015-01N
General notes on spot welding of AH60.00-P-
MODEL 215
aluminum parts 0017-01N
AH60.00-P-
General notes on welding MODEL all
0005-01N
Guidelines for removing fuel tank
AH60.00-P-
when performing welding work on MODEL all
3000-01Z
bodies
Guidelines for removing fuel tank
AH60.00-P-
when performing welding work on MODEL 171.4, 211.2, 169.0 /3, 219.3, 221, 245.2
3000-01V
bodies
Guidelines for welding welding AH60.00-P-
MODEL 450.4 /3
bolts 0025-01SM
Information on machining/treating AH60.00-P-
MODEL all
magnesium components 0023-01R
AH60.00-P-
Information on processing resin
MODEL 199 0029-
and hardener for fiber composites
01SLR
Measures for preventing damage
to components when performing AH60.00-P-
MODEL all
electric welding and soldering 0001-02A
work
Note for working on aluminum AH60.00-P-
MODEL 197
components and vehicles 0034-01N
Notes on aluminum threads in AH60.00-P-
MODEL 197
body 0035-01A
AH60.00-P-
Notes on body MODEL 208.4
0002-01KA
Notes on bonded and foam-lined AH60.00-P-
MODEL 215
body areas 0010-01N
AH60.00-P-
Notes on crash boxes MODEL 450.3 /4
0026-01SM
AH60.00-P-
Notes on different body materials MODEL 215
0011-01N
Notes on processing filler for fiber AH60.00-P-
composites with sandwich MODEL 199 0031-
construction 01SLR
AH60.00-P-
Notes on processing glue for metal
MODEL 199 0030-
bushings in fiber composites
01SLR
Notes on recording temperature AH60.00-P-
and humidity during fiber MODEL 199 0032-
composite repair 01SLR
AH60.00-P-
Notes on replacing body parts MODEL 452.3 /4
0027-01RC
AH60.00-P-
Notes on replacing body parts MODEL 451.3 /4, 454.0
0027-01FF
AH60.00-P-
Notes on replacing body parts* MODEL 450.3 /4
0027-01SM
AH60.00-P-
Notes on various body materials MODEL 216, 221
0011-01SX
MODEL 199, 405, 638, 901, 902, 903, 904, 905
to be glued 0008-01A
MODEL 169, 171, 172, 204, 211, 215, 216, 219, 221, AH60.00-P-
Pretreatment of bonding surfaces
240, 245.2, 414, 636, 639 0008-01N
AH60.00-P-
Pretreatment of bonding surfaces MODEL 451.3 /4 0008-
01MCC
MODEL 166, 172, 197, 204, 207, 209, 212, 216, 218, AH60.00-P-
Pretreatment of bonding surfaces
221 0008-01SX
MODEL wd1, wd2, wd3, wd6, wd7, xd1, xd2, xd3,
xd4, xd5, xd6, xd7, yd1, yd2, yd3, yd4, yd5, yd6, yd7,
Product liability, trademark and 163, 164, 166, 168, 169, 170, 171, 172, 202, 203, 204, AH60.00-P-
traffic laws 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 0800-01Z
221, 230, 240, 245, 251, 414, 636, 638, 639, 690, 900,
901, 902, 903, 904, 905, 906...
MODEL all with CODE (491) USA version with AH60.00-P-
Vehicle identification number
CODE (494) USA version 0800-02B
AH60.00-P-
Vehicle identification number MODEL all EU-Fahrzeuge
0800-02A
GAP DIMENSIONS ON HOODS, DOORS AND LIDS - AR60.00-P-0700-01SC
CHECK VALUES FOR GAPS
Model 216 up Model 216 as
to model year of model year
Number Designation 2011 2011
BE60.00-P- Gap dimension Engine hood to fender Dimension "A" mm 3.5 (±0.5) 3.5 (±0.5)
1001-01T Engine hood to Dimension "B" mm 3.5 (±0.5) 3.5 (±0.5)
headlamp
Engine hood to A- Dimension "D" mm 4.0 (±0.5) 4.0 (±0.5)
pillar
Radiator Dimension "C" mm 5.0 (±1.0) 2.0 (±1.0)
grille/bumper
Engine hood to Dimension "P" mm 5.0 (±1.0) 5.0 (±1.0)
bumper
Bumper to headlamp Dimension "Q" mm 3.5 (±0.5) 3.5 (±0.5)
See picture AR60.00-P- AR60.00-P-
0700-01 SC 0700-01 SC
BE60.00-P- Gap dimension Front door to fender Dimension "E" mm 4.0 (±0.5) 4.0 (±0.5)
1002-01T Front door to rear Dimension "F" mm 4.0 (±0.5) 4.0 (±0.5)
fender
Front fender to A- Dimension "G" mm 3.5 (±0.5) 3.5 (±0.5)
pillar
Front fender to Dimension "H" mm 3.5 (0.5) 3.5 (0.5)
headlamp
See picture AR60.00-P- AR60.00-P-
0700-01 SC 0700-01 SC
BE60.00-P- Gap dimension Trunk lid to rear Dimension "J" mm 3.5 (±0.8) 3.5 (±0.8)
1003-01T fender, top
Trunk lid to rear lamp Dimension "K" mm 3.5 (±0.8) 3.5 (±0.8)
unit
Trunk lid to bumper Dimension "L" mm 5, 5 (±1.5) 5, 5 (±1.5)
Rear fender to rear Dimension "M" mm 2.5 (±0.5) 2.5 (±0.5)
lamp unit
See picture AR60.00-P- AR60.00-P-
0700-01 SC 0700-01 SC
BE60.00-P- Gap dimension Fuel filler flap Dimension "O" mm 3.0 (±0.5) 3.0 (±0.5)
1004-01T See AR60.00-P- AR60.00-P-
picture 0700-01 SC 0700-01 SC
Fig. 10: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
1. Check gaps on hoods, doors and covers.
The corresponding gap dimension should not run wedge-shaped or be too narrow at points. The gap
dimension should not deviate from parallel over or below the specified tolerance range. If the inside
clearance of body gaps is too large or too small, the hang-on parts must be centered accordingly.
Fig. 11: Identifying Gaps On Hoods, Doors And Covers (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 12: Identifying Gaps On Hoods, Doors And Covers (2 Of 2)
Courtesy of MERCEDES-BENZ USA
GAP DIMENSIONS ON HOODS, DOORS AND LIDS - AR60.00-P-0700-01SX
TEST VALUES FOR GAP DIMENSIONS
Number Designation Model 221
BE60.00-P- Gap dimension Engine hood to fender Dimension "A" mm 3.5 (±0.5)
1001-01R Engine hood to headlamp Dimension "B" mm 3.5 (±0.5)
Radiator grille/bumper Dimension "C" mm 5 (±1)
Engine hood to bumper Dimension "P" mm 5 (±1.5)
Bumper to /headlamps Dimension "Q" mm 3.5 (±0.5)
Bumper to fender Dimension "R" mm 3.5 (±0.5)
See picture in AR60.00-P-
0700-01S X
BE60.00-P- Gap dimension Front door to A-pillar Dimension "D" mm 4.5 (±0.5)
1002-01R Front door to fender Dimension "E" mm 4 (±0.5)
Front door to rear door Dimension "F" mm 4.5 (±0.5)
Trim strip at front door to roof Dimension "G" mm 4.5 (±0.5)
frame
Trim strip at rear door to roof Dimension "H" mm 4.5 (±0.5)
frame
Rear door to side section, Dimension "I" mm 4.5 (±0.5)
bottom
Front door cover to rear door Dimension "S" mm 4.5 (±0.5)
cover See picture in AR60.00-P-
0700-01S X
BE60.00-P- Gap dimension Trunk lid to rear fender, top Dimension "J" mm 4 (±0.5)
1003-01R Trunk lid to taillamp Dimension "K" mm 4 (±0.5)
Trunk lid to bumper Dimension "L" mm 5.5 (±1.5)
Rear fender to taillamp Dimension "M" mm 2.5 (±0.5)
Trunk lid cover to taillamp Dimension "N" mm 4 (±0.5)
See picture in AR60.00-P-
0700-01S X
BE60.00-P- Gap dimension Fuel filler flap Dimension "O" mm 3.5 (±0.5)
1004-01R See picture in AR60.00-P-
0700-01S X
Fig. 13: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
Adjust hoods, doors and lids as shown in drawing. The gap should not run wedge-shaped or be too narrow at
points. Deviations from parallel gap should be max. 0.5 mm over the entire length. If the inside clearance is too
large or too small, the movable body parts must be centered accordingly. The reference measurements apply
only for repair work on vehicles damaged in accidents.
Fig. 14: Locating Hoods, Doors And Lids Gaps (Vehicle Left Side)
Courtesy of MERCEDES-BENZ USA
Fig. 15: Locating Hoods, Doors And Lids Gaps (Vehicle Back Side)
Courtesy of MERCEDES-BENZ USA
TESTING & REPAIR
MOUNT STAMPING GUIDE - AR60.00-P-0800-01SX
Fig. 16: Identifying Stamping Guide (171 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
Parts for stamping guide
Fig. 17: Identifying Window Plate, Anvil, Washers And Bolts
Courtesy of MERCEDES-BENZ USA
1. Drill out rear partition wall (5) in increments to diameter of 10 mm at punch marks provided at the
factory (area A).
2. Debur holes on both sides.
3. Remove drilling shavings with wet/dry vacuum cleaner.
Illustrated on model 221
Fig. 18: Identifying Rear Partition Wall & Punch Marks
Courtesy of MERCEDES-BENZ USA
Illustrated on model 221
The required position for the punch field (B) or the reserve field (C) can be determined by turning the
window plate (1)
Fig. 19: Fastening Window Plate To Rear Partition Wall
Courtesy of MERCEDES-BENZ USA
4. Fasten window plate (1) to rear partition wall (5) with bolts (3), anvil (2) and washers (4) in the position
for the punch field (B).
Install washers (4) between window plate (1) and rear partition wall (5).
STAMPING IN VEHICLE IDENTIFICATION NUMBER - AR60.00-P-0800-02SX
Fig. 20: Identifying Stamping Guide (171 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 21: Identifying Set Of Number Stamps (140 589 26 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 22: Identifying Set Of Letter Stamps (140 589 26 63 05)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1001-15A Rubber pad A 110 987 00 39
1. Start with number stamp (4) "Mercedes star" in punch filed (area B) on window plate (1) at left.
The tip of the Mercedes star must point upward in the script.
2 Then position letter stamp (6) "W" with left edge at first increment of window plate (1) in
punch field (area B) and punch in.
Illustrated on model 221
Fig. 23: Positioning Window Plate And Letter Stamp
Courtesy of MERCEDES-BENZ USA
3 Move forward with each subsequent letter punch (6) one increment on the scale in the window
plate (1) until the complete vehicle identification number and the final Mercedes star have been punched
on the rear partition wall (5) (area B).
4 Remove stamping guide.
5 Coat inner holes with zinc dust paint (area A).
6 Close holes with rubber buffer (area A).
CROSSING OUT VEHICLE IDENTIFICATION NUMBER AND RESTAMP IN SPARE FIELD -
AR60.00-P-0800-05SX
Fig. 24: Identifying Stamping Guide (171 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 25: Identifying Set Of Number Stamps (140 589 26 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 26: Identifying Set Of Letter Stamps (140 589 26 63 05)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
R00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
R00.45-Z-1001-15A Rubber pad A 110 987 00 39
1. Cross out incorrect vehicle identification number in punch field (area B) with letter stamp (4)
"X".
The required position for the punch field (area B) or the reserve field (area C) can be determined by
turning the window plate (1).
2. Turn window plate (1) to reserve field (area C)
Illustrated on model 221
Fig. 27: Restamping Vehicle Identification Number
Courtesy of MERCEDES-BENZ USA
3. Start with "Mercedes star" symbol punch at left in window plate (1)
The tip of the Mercedes star must point upward in the script.
4. Move forward with each subsequent number punch one increment on the scale in the window
plate (1) until the complete vehicle identification number and the final Mercedes star have been punched
on the rear partition wall (5) (area C).
5. Remove stamping guide.
6. Coat holes with zinc dust paint (area A).
7. Close holes with rubber buffer (area A).
STAMP IN VEHICLE IDENTIFICATION NUMBER - AR60.00-P-0800SX
MODEL 221, 216
Illustrated on model 221
Fig. 28: Identifying Stamping Guide And Vehicle Identification Number
Courtesy of MERCEDES-BENZ USA
Product liability, trademark and AH60.00-P-
traffic laws 0800-01Z
AH60.00-P-
Vehicle identification number All EC vehicles
0800-02A
AH60.00-P-
Vehicle identification number (2) All vehicles with USA version, code 491, 494
0800-02B
AR60.00-P-
1 Install stamping guide (1).
0800-01SX
Stamping guide Drill Fig. 16
(electric/pneumatic) Wet/dry vacuum cleaner
Punch in vehicle identification AR60.00-P-
2
number (2). 0800-02SX
Stamping guide Fig. 16
Set of number stamps Fig. 21
Set of letter stamps Fig. 22
*BR00.45-Z-
Zinc dust paint suitable for spot welding
1001-07A
*BR00.45-Z-
Rubber pad
1001-15A
Cross out vehicle identification
Only if vehicle identification number (2) AR60.00-P-
3.1 number (2) and punch into spare
was punched in incorrectly previously. 0800-05SX
field.
Stamping guide Fig. 16
Set of number stamps Fig. 21
Set of letter stamps Fig. 22
*BR00.45-Z-
Zinc dust paint suitable for spot welding
1001-07A
*BR00.45-Z-
Rubber pad
1001-15A
Fig. 29: Identifying Stamping Guide (171 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 30: Identifying Set Of Number Stamps (140 589 26 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 31: Identifying Set Of Letter Stamps (140 589 26 63 05)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
BR00.45-Z-1001-15A Rubber pad A 110 987 00 39
TESTING AND REPAIR WORK: PASSENGER CARS: BODY - GENERAL - AR60.00-Z-9221AA
MODEL 221
Stamp in vehicle identification number MODEL 221, 216 AR60.00-P-0800SX
SAFETY PRECAUTIONS
RISK OF EXPLOSION FROM ALUMINUM GRINDING DUST, RISK OF INJURY TO
RESPIRATORY SYSTEM FROM INHALING DUST - AS60.00-Z-0007-01N
Wear protective respiratory mask, protective gloves and safety glasses. Use suitable, grounded vacuum
cleaner
Risk of explosion
When grinding and polishing aluminum as well as its alloys, dust is created. It is combustible and capable of
exploding when mixed with air. Aluminum dust is one of the types of dust which can cause extremely severe
reactions in terms of its combustion and explosive properties.
When mixed with air, aluminum dust reacts just as violently as magnesium. The following areas are considered
to be explosion hazard areas : grinding equipment stands, inner chambers of protective hoods, ventilation and
evacuation ducts, separators and an area within a radius of 3.00 m. In addition to this fire hazard areas are
those areas within a radius of 5.00 m around the source of the dust.
Risk of injury
Aluminum dust is produced when working on aluminum components by cutting, grinding, polishing, etc. This
dust irritates the bronchial tubes and may damage the lungs.
Safety precautions/instructions
A basic safety precaution is to remove the aluminum dust as it is generated.
When working with aluminum wear dust filter mask, eye protection and protective gloves.
Avoid stirring up the dust created, evacuate immediately while working.
The evacuation equipment must be grounded to prevent a dust explosion.
During the drying process with wet separation , the dust should be moistened immediately behind the source
so that it is bound completely together and forms a sludge-like substance.
During the drying procedure with dry separation , the following precautions are necessary:
Set up dust remover outside of immediate work area.
The dust remover should be pressure-resistant and equipped with an explosion suppression feature to
prevent any possible dust explosions from exploding into the working room.
Evacuation and protective hoods should be produced using non-sparking materials.
The working rooms should have two exits and be designed so that the least possible quantity of dust can
deposit and settle.
Access to rooms with explosion-hazard areas must be marked with the proper prohibition sign
"Fire, ope n flames and smoking prohibited"
Suitable powder fire extinguishers must be present.
Equipment such as heavy-duty emergency showers are urgently required for extinguishing clothing fires
outside of the work rooms.
For further information, see accident prevention regulations.
RISK OF INJURY CAUSED BY IRRITATION OF THE SKIN, EYES AND RESPIRATORY SYSTEM
THROUGH CONTACT OR INHALATION OF SUBSTANCES CONTAINED IN THE MIRROR
LENS. - AS60.00-Z-0008-01R
Wear protective gloves and safety glasses.
Risk of injury
The liquid electrolyte contained in the mirror lens may escape if the lens is broken.
This liquid electrolyte is an irritant. It is therefore important that the liquid electrolyte does not come into
contact with unprotected skin, eyes or respiratory organs.
For further information see the accident prevention regulations (UVV) or the trade association
regulations.
Safety precautions/instructions
Wear protective gloves and safety glasses.
First aid measures
Immediately rinse affected skin areas with plenty of clean water and dry or dress with sterile bandages.
A medical service and/or physician should be consulted after first aid has been applied.
SAFETY INFORMATION: BODY - GENERAL - AS60.00-Z-9999ZZ
MODEL all
AS60.00-
Danger Hazards when working with magnesium parts MODEL 215 Z-0005-
01N
MODEL 374, 375, 405, 436,
Risk of death caused by improper lifting of cab. Risk 437, 930, 932, 933, 934, 940, AS60.80-
Danger! of injury caused by body parts being trapped and 942, 943, 944, 950, 952, 953, Z-0002-
crushed when lowering cab 954, 957, 958, 970, 972, 974, 01A
975, 976...
Risk of explosion caused by dust produced by
AS60.00-
sanding/grinding. Risk of injury caused by irritation
Danger! MODEL 405, 903, 906, 957... Z-0002-
of respiratory paths when glass fibers are inhaled or
01A
by contact with the eyes and skin.
Risk of explosion caused by handling polyester and AS60.00-
Danger! epoxy resins. Risk of injury caused by skin and eye MODEL 199, 405, 957... Z-0004-
contact with polyester and epoxy resins. 01A
Risk of explosion caused by sanding/grinding dust.
AS60.00-
Risk of injury caused by irritation of respiratory
Danger! MODEL 199, 230, 405... Z-0001-
paths when inhaled or from eye and skin contact
01A
with carbon fibers.
Risk of explosion from acetone vapors. Risk of
AS60.00-
poisoning when acetone is inhaled, swallowed or
Danger! MODEL 405, 668, 670, 957... Z-0003-
absorbed through skin. Risk of injury from skin and
01A
eye contact with acetone vapors.
of injury to respiratory system from inhaling dust 212, 215, 216, 219, 221, 957... Z-0007-
Danger!
01N
Risk of explosion. There is a risk of explosion from
grinding dust. Risk of injury. There is a risk of MODEL 405.210 /230 with AS60.00-
Danger! injury from glass fibers which can cause irritation of BODY 405.830 nur fur Z-0002-
respiratory paths when inhaled or from contact with USA/Kanada 01NA
the eyes and skin.
Risk of explosion. There is a risk of explosion when
MODEL 405.210 /230 with AS60.00-
handling polyester and epoxy resins. Risk of Injury.
Danger! BODY 405.830 nur fur Z-0004-
There is a risk of injury from skin and eye contact
USA/Kanada 01NA
with polyester and epoxy resins
Risk of explosion. There is a risk of explosive from
dust caused by grinding work. Risk of injury. There MODEL 405.210 /230 with AS60.00-
Danger! is a risk of injury from carbon fibers which can BODY 405.830 nur fur Z-0001-
cause irritation of respiratory paths when inhaled or USA/Kanada 01NA
from contact with the eyes and skin.
AS60.00-
Risk of fire and explosion caused by MODEL 171, 172, 211, 215,
Danger! Z-0006-
machining/treating magnesium components 219, 230, 450, 451, 452
01R
AS60.80-
Risk of injury caused by body parts being pinched or
Danger! MODEL all Z-0001-
crushed as cab is tilted
01A
Risk of injury caused by irritation of the skin, eyes AS60.00-
Danger! and respiratory system through contact or inhalation MODEL all Z-0008-
of substances contained in the mirror lens. 01R
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: BODY - GENERAL - BA60.00-Z-9999AZ
MODEL all
Cab, cab mounting MODEL 163, 461, 463 BA60.80-P-1000-01A
Celette straightening tool set MODEL 202.0 /1, 208.3 /4 BA60.10-P-1000-01A
TEST & ADJUSTMENT VALUES
GAP DIMENSIONS - BE60.00-P-1000-01R
Model 221
CHECK VALUES FOR GAPS
Number Designation Model 221
BE60.00-P- Gap dimension Engine hood to fender Dimension "A" mm 3.5 (±0.5)
1001-01R Engine hood to headlamp Dimension "B" mm 3.5 (±0.5)
Radiator grille/bumper Dimension "C" mm 5 (±1)
Engine hood to bumper Dimension "P" mm 5 (±1.5)
Bumper to headlamp Dimension "Q" mm 3.5 (±0.5)
Bumper to fender Dimension "R" mm 3.5 (±0.5)
See picture AR60.00-P-
0700-01S X
BE60.00-P- Gap dimension Front door to A-pillar Dimension "D" mm 4.5 (±0.5)
1002-01R Front door to fender Dimension "E" mm 4 (±0.5)
Front door to rear door Dimension "F" mm 4.5 (±0.5)
Trim strip at front door to roof Dimension "G" mm 4.5 (±40.5)
frame
Trim strip at rear door to roof Dimension "H" mm 4.5 (±40.5)
frame
Rear door to side section, bottom Dimension "I" mm 4.5 (±40.5)
Front door cover to rear door Dimension "S" mm 4.5 (±40.5)
cover See picture AR60.00-P-
0700-01S X
BE60.00-P- Gap dimension Trunk lid to rear fender, top Dimension "J" mm 4 (±0.5)
1003-01R Trunk lid to rear lamp unit Dimension "K" mm 4 (±0.5)
Trunk lid to bumper Dimension "L" mm 5.5 (±1.5)
Rear fender to rear lamp unit Dimension "M" mm 2.5 (±0.5)
Trunk lid license plate panel to Dimension "N" mm 4 (±0.5)
rear lamp unit See picture AR60.00-P-
0700-01S X
BE60.00-P- Gap dimension Fuel filler flap Dimension "O" mm 3.5 (±0.5)
1004-01R See picture AR60.00-P-
0700-01SX
BE60.00-P- Gap dimension Center door to front door Dimension "T" mm 4.5 (±0.5)
1005-01R Center door to rear door Dimension "U" mm 4.5 (±0.5)
Trim strip of center door to roof Dimension "V" mm 4.5 (±0.5)
frame See picture -
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: BODY - GENERAL - BE60.00-Z-9999AZ
MODEL all
Gap
MODEL 172 BE60.00-P-1000-01Y
dimensions
MODEL 246
dimensions 01AA
Gap
TYP 216 BE60.00-P-1000-01T
dimensions
Gap
MODEL 218.3, 219 BE60.00-P-1000-01O
dimensions
Gap
MODEL 171 BE60.00-P-1000-01L
dimensions
Gap
MODEL 251 BE60.00-P-1000-01S
dimensions
Gap
MODEL 240 BE60.00-P-1000-01I
dimensions
Gap
MODEL 203... BE60.00-P-1000-01E
dimensions
Gap MODEL 168, 170, 202, 208, 210, 215, 220.0 /1 /875 /878, 230,
BE60.00-P-1000-01A
dimensions 414.700
Gap
MODEL 199 BE60.00-P-1000-01K
dimensions
Gap
MODEL 140 BE60.00-P-1000-01C
dimensions
Gap BE60.00-P-1000-
MODEL 221
dimensions 01R
Gap
MODEL 209.3 /4 BE60.00-P-1000-01G
dimensions
Gap
MODEL 163 BE60.00-P-1000-01D
dimensions
Gap
MODEL 211.0 /2 /6 BE60.00-P-1000-01F
dimensions
Gap
MODEL 245.2 BE60.00-P-1000-01Q
dimensions
Gap
MODEL 169.0 /3 BE60.00-P-1000-01N
dimensions
Gap
MODEL 129 BE60.00-P-1000-01B
dimensions
Gap
MODEL 164.1 /8 BE60.00-P-1000-01P
dimensions
Gap
MODEL 204.0 /2 /9, 212.0 /1 /2 BE60.00-P-1000-01U
dimensions
Gap BE60.00-P-1000-
MODEL 204.3, 207.3 /4
dimensions 01W
Gap
MODEL 197 BE60.00-P-1000-01X
dimensions
Gap
MODEL 166 BE60.00-P-1000-01Z
dimensions
MISCELLANEOUS NOTES
RECYCLE ALUMINUM PARTS - OS60.00-P-0001-01N
Due to the increasing environmental consciousness and intent of the legislation to require proof of recycling of
old cars and old parts when the old car code becomes effective, it is necessary to specifically recycle non-
ferrous metals, such as aluminum.
This means for repair shops to separate the various materials such as steel or aluminum as precisely and
carefully as possible.
The main objective of the shredder technology primarily used in vehicle and old part recycling is to reach a
clean steel/iron fraction and to separate the largest possible percentage of nonferrous metals.
The objective of the legislation is to increase the recycling quota for old vehicles and old parts to 95 %.
SPECIAL TOOLS
108 589 00 76 01 PLASTIC HAMMER - WS60.00-P-0002-01K
FG 60/Set K
MODEL all
Use/specification:
Plastic hammer for rebuilding work on body parts
Fig. 32: Identifying Plastic Hammer (108 589 00 76 01)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 02 HAND DOLLY - WS60.00-P-0002-02K
FG 60/Set K
MODEL all
Use/specification:
Hand dolly for counter holding when carrying out rebuilding work
Fig. 33: Identifying Hand Dolly (108 589 00 76 02)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 03 STRAIGHTENING AND DRESSING HOOK - WS60.00-P-0002-03K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing hook for straightening dents which are close to outer panelling openings
Fig. 34: Identifying Straightening And Dressing Hook (108 589 00 76 03)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 04 STRAIGHTENING AND DRESSING HOOK - WS60.00-P-0002-04K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing hook for straightening dents which are close to outer panelling openings
Fig. 35: Identifying Straightening And Dressing Hook (108 589 00 76 04)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 05 STRAIGHTENING AND DRESSING HOOK - WS60.00-P-0002-05K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing hook for straightening dents which are close to outer panelling openings
Fig. 36: Identifying Straightening And Dressing Hook (108 589 00 76 05)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 06 STRAIGHTENING AND DRESSING HOOK - WS60.00-P-0002-06K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing hook for straightening dents which are close to outer panelling openings
Fig. 37: Identifying Straightening And Dressing Hook (108 589 00 76 06)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 07 STRAIGHTENING AND DRESSING HOOK - WS60.00-P-0002-07K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing hook for straightening dents which are close to outer panelling openings
Fig. 38: Identifying Straightening And Dressing Hook (108 589 00 76 07)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 08 STRAIGHTENING AND DRESSING HOOK - WS60.00-P-0002-08K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing hook for straightening dents which are close to outer panelling openings
Fig. 39: Identifying Straightening And Dressing Hook (108 589 00 76 08)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 09 STRAIGHTENING AND DRESSING HOOK - WS60.00-P-0002-09K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing hook for straightening dents which are close to outer panelling openings
Fig. 40: Identifying Straightening And Dressing Hook (108 589 00 76 09)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 10 STRAIGHTENING AND DRESSING IRON - WS60.00-P-0002-10K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing iron for straightening dents which are at inaccessible points behind posts and beams
Fig. 41: Identifying Straightening And Dressing Iron (108 589 00 76 10)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 11 STRAIGHTENING AND DRESSING IRON - WS60.00-P-0002-11K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing iron for straightening dents which are at inaccessible points behind posts and beams
Fig. 42: Identifying Straightening And Dressing Iron (108 589 00 76 11)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 12 STRAIGHTENING AND DRESSING IRON - WS60.00-P-0002-12K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing iron for straightening dents which are at inaccessible points behind posts and beams
Fig. 43: Identifying Straightening And Dressing Iron (108 589 00 76 12)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 13 STRAIGHTENING AND DRESSING IRON - WS60.00-P-0002-13K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing iron for straightening dents which are at inaccessible points behind posts and beams
Fig. 44: Identifying Straightening And Dressing Iron (108 589 00 76 13)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 14 STRAIGHTENING AND DRESSING IRON - WS60.00-P-0002-14K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing iron for straightening dents which are at inaccessible points behind posts and beams
Fig. 45: Identifying Straightening And Dressing Iron (108 589 00 76 14)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 15 STRAIGHTENING AND DRESSING IRON - WS60.00-P-0002-15K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing iron for rebuilding of damage which is behind double-skinned outer panelled parts
Fig. 46: Identifying Straightening And Dressing Iron (108 589 00 76 15)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 16 STRAIGHTENING AND DRESSING IRON - WS60.00-P-0002-16K
FG 60/Set K
MODEL all
Use/specification:
Straightening and dressing iron for rebuilding of damage which is behind double-skinned outer panelled parts
Fig. 47: Identifying Straightening And Dressing Iron (108 589 00 76 16)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 17 PLANISHING LEVER - WS60.00-P-0002-17K
FG 60/Set K
MODEL all
Use/specification:
Planishing lever with 20°-bows for straightening small dents in the area of the reinforced frame
Fig. 48: Identifying Planishing Lever (108 589 00 76 17)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 18 PLANISHING LEVER - WS60.00-P-0002-18K
FG 60/Set K
MODEL all
Use/specification:
Planishing lever with 30°-bows for straightening small dents in the area of the reinforced frame
Fig. 49: Identifying Planishing Lever (108 589 00 76 18)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 19 PLANISHING LEVER - WS60.00-P-0002-19K
FG 60/Set K
MODEL all
Use/specification:
Planishing lever with 110°-bows for rebuilding damage mainly on front fender
Fig. 50: Identifying Planishing Lever (108 589 00 76 19)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 20 SQUARE FILE - WS60.00-P-0002-20K
FG 60/Set K
MODEL all
Use/specification:
With this square file dents and bumps can be made visible during rebuilding work
Fig. 51: Identifying Square File (108 589 00 76 20)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 21 PLASTIC HAMMER - WS60.00-P-0002-21K
FG 60/Set K
MODEL all
Use/specification:
With this plastic hammer small bumps (little horns) for parts without paint damage can be remolded into shape
Fig. 52: Identifying Plastic Hammer (108 589 00 76 21)
Courtesy of MERCEDES-BENZ USA
108 589 00 76 00 SET OF PLANISHING TOOLS - WS60.00-P-0002K
FG 60/Set K
MODEL all
Component part 108 589 00 76 01 Plastic hammer FG 60/Set K WS60.00-P-0002-01K
Component part 108 589 00 76 02 Hand dolly FG 60/Set K WS60.00-P-0002-02K
Component part 108 589 00 76 03 Straightening and dressing hook FG 60/Set K WS60.00-P-0002-03K
Component part 108 589 00 76 04 Straightening and dressing hook FG 60/Set K WS60.00-P-0002-04K
Component part 108 589 00 76 05 Straightening and dressing hook FG 60/Set K WS60.00-P-0002-05K
Component part 108 589 00 76 06 Straightening and dressing hook FG 60/Set K WS60.00-P-0002-06K
Component part 108 589 00 76 07 Straightening and dressing hook FG 60/Set K WS60.00-P-0002-07K
Component part 108 589 00 76 08 Straightening and dressing hook FG 60/Set K WS60.00-P-0002-08K
Component part 108 589 00 76 09 Straightening and dressing hook FG 60/Set K WS60.00-P-0002-09K
Component part 108 589 00 76 10 Straightening and dressing iron FG 60/Set K WS60.00-P-0002-10K
Component part 108 589 00 76 11 Straightening and dressing iron FG 60/Set K WS60.00-P-0002-11K
Component part 108 589 00 76 12 Straightening and dressing iron FG 60/Set K WS60.00-P-0002-12K
Component part 108 589 00 76 13 Straightening and dressing iron FG 60/Set K WS60.00-P-0002-13K
Component part 108 589 00 76 14 Straightening and dressing iron FG 60/Set K WS60.00-P-0002-14K
Component part 108 589 00 76 15 Straightening and dressing iron FG 60/Set K WS60.00-P-0002-15K
Component part 108 589 00 76 16 Straightening and dressing iron FG 60/Set K WS60.00-P-0002-16K
Component part 108 589 00 76 17 Planishing lever FG 60/Set K WS60.00-P-0002-17K
Component part 108 589 00 76 18 Planishing lever FG 60/Set K WS60.00-P-0002-18K
Component part 108 589 00 76 19 Planishing lever FG 60/Set K WS60.00-P-0002-19K
Component part 108 589 00 76 20 Square file FG 60/Set K WS60.00-P-0002-20K
Component part 108 589 00 76 21 Plastic hammer FG 60/Set K WS60.00-P-0002-21K
Use/specification:
Set of planishing tools for removal of small dents and bumps
NOTE: 1 set comprises 21 single items.
Fig. 53: Identifying Set Of Planishing Tools (108 589 00 76 00)
Courtesy of MERCEDES-BENZ USA
110 589 11 63 00 ANGULAR SCRAPER - WS60.00-P-0003K
FG 60/Set K
MODEL all
Use/specification:
Angular scraper for rough cast work
Fig. 54: Removing Rough Cast
Courtesy of MERCEDES-BENZ USA
Fig. 55: Identifying Angular Scraper (110 589 11 63 00)
Courtesy of MERCEDES-BENZ USA
115 589 28 63 00 SMOOTHING BLOCK - WS60.00-P-0005K
FG 60/Set K
MODEL all
Use/specification:
Smoothing block for flattening and molding of loaded pools of tin
Fig. 56: Flattening And Molding Of Loaded Pools Of Tin
Courtesy of MERCEDES-BENZ USA
Fig. 57: Identifying Smoothing Block (115 589 28 63 00)
Courtesy of MERCEDES-BENZ USA
115 589 29 63 00 SMOOTHING BLOCK - WS60.00-P-0006K
FG 60/Set K
MODEL all
Use/specification:
Smoothing block for flattening and molding of loaded pools of tin
Fig. 58: Flattening And Molding Of Loaded Pools Of Tin
Courtesy of MERCEDES-BENZ USA
Fig. 59: Identifying Smoothing Block (115 589 29 63 00)
Courtesy of MERCEDES-BENZ USA
115 589 30 63 00 SMOOTHING BLOCK - WS60.00-P-0007K
FG 60/Set K
MODEL all
Use/specification:
Smoothing block for flattening and molding of loaded pools of tin
Fig. 60: Flattening And Molding Of Loaded Pools Of Tin
Courtesy of MERCEDES-BENZ USA
Fig. 61: Identifying Smoothing Block (115 589 30 63 00)
Courtesy of MERCEDES-BENZ USA
115 589 31 63 00 SMOOTHING BLOCK - WS60.00-P-0008K
FG 60/Set K
MODEL all
Use/specification:
Smoothing block for flattening and molding of loaded pools of tin
Fig. 62: Flattening And Molding Of Loaded Pools Of Tin
Courtesy of MERCEDES-BENZ USA
Fig. 63: Identifying Smoothing Block (115 589 31 63 00)
Courtesy of MERCEDES-BENZ USA
129 589 03 21 00 FEELER GAUGE - WS60.00-P-0027K
FG 60/62/63/64/65/ 67/72/77/82/88/ Set K
MODEL all
MODIFICATION NOTES
30.6.08 Replacement for 452 589 01 21 00 feeler gauge WS60.00-P-0107K
Use:
Feeler gauge for checking and adjusting gaps on body and detachable body components
Fig. 64: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
201 589 00 51 01 MILLING BIT CROWN - WS60.00-P-0033-01K
Group 60/61/62/63/64/65/Set K
MODEL all
MODIFICATION NOTES
19.3.86 Replacement for:126 589 00 51 01
Use:
Milling bit crown for cutting spot welds when performing body repair
NOTE: Available in packs of 2 each
Fig. 65: Identifying Milling Bit Crown (201 589 00 51 01)
Courtesy of MERCEDES-BENZ USA
201 589 00 51 00 SPOT WELD MILLING CUTTER - WS60.00-P-0033K
Group 60/61/62/63/64/ 65/ Set K
MODEL all
MODIFICATION NOTES
20.10.83 Replacement for:126 589 00 51 00
Part 201 589 00 51 01 Milling bit crown Group 60/61/62/63/64/65/Set K WS60.00-P-0033-01K
Use:
Spot weld milling cutter with exchangeable milling bit crown for repair work on body
Fig. 66: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
Courtesy of MERCEDES-BENZ USA
000 589 86 63 00 ADAPTER - WS60.00-P-0085K
FG 60/67/72/Set K
MODEL all
Use:
Intermediate element for inserting into cartridge to press out remaining quantity.
Fig. 67: Identifying Adapter (000 589 86 63 00)
Courtesy of MERCEDES-BENZ USA
215 589 00 51 01 CUTTING HEAD - WS60.00-P-3012-01K
FG 60/62/63/64/65/Kit K
MODEL 215, 221
Use:
Cutting head for spot welds for aluminum body repairs.
NOTE: Packaging units 2 each.
Fig. 68: Identifying Cutting Head (215 589 00 51 01)
Courtesy of MERCEDES-BENZ USA
215 589 00 51 00 SPOT - WELD CUTTER - WS60.00-P-3012K
FG 60/62/63/64/65/ Set K
MODEL 215, 216, 221
Part 215 589 00 51 01 Cutter head FG 60/62/63/64/65/Set K WS60.00-P-3012-01K
Application
Spot weld cutter with replaceable cutter head for aluminum body repair
Fig. 69: Identifying Spot-Weld Cutter (215 589 00 51 00)
Courtesy of MERCEDES-BENZ USA
203 589 02 31 00 ADAPTER KIT - WS60.00-P-3015K
FG 60/61/Set K
MODEL 164, 171, 172, 203, 204, 207, 209.3 /4, 211, 212, 216, 218, 219, 221, 246, 251
Use:
Adapter for hoisting platform mount
NOTE: Only required when removing underbody paneling
Fig. 70: Identifying Adapter Kit (203 589 02 31 00)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS: PASSENGER CARS: BODY - GENERAL - WS60.00-Z-9999AZ
MODEL all
WS60.00-P-
000 589 86 63 00 Adapter FG 60/67/72/Set K
0085K
WS60.00-P-
107 589 02 61 00 Engine support frame FG 60/Set K
0001K
WS60.00-P-
108 589 00 76 00 Set of planishing tools FG 60/Set K
0002K
WS60.00-P-0002-
108 589 00 76 01 Plastic hammer FG 60/Set K
01K
WS60.00-P-0002-
108 589 00 76 02 Hand dolly FG 60/Set K
02K
108 589 00 76 03 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
hook 03K
108 589 00 76 04 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
hook 04K
108 589 00 76 05 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
hook 05K
108 589 00 76 06 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
hook 06K
108 589 00 76 07 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
hook 07K
108 589 00 76 08 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
hook 08K
108 589 00 76 09 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
hook 09K
108 589 00 76 10 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
iron 10K
108 589 00 76 11 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
iron 11K
108 589 00 76 12 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
iron 12K
108 589 00 76 13 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
iron 13K
108 589 00 76 14 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
iron 14K
108 589 00 76 15 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
iron 15K
108 589 00 76 16 Straightening and dressing WS60.00-P-0002-
FG 60/Set K
iron 16K
WS60.00-P-0002-
108 589 00 76 17 Planishing lever FG 60/Set K
17K
WS60.00-P-0002-
108 589 00 76 18 Planishing lever FG 60/Set K
18K
WS60.00-P-0002-
108 589 00 76 19 Planishing lever FG 60/Set K
19K
WS60.00-P-0002-
108 589 00 76 20 Square file FG 60/Set K
20K
WS60.00-P-0002-
108 589 00 76 21 Plastic hammer FG 60/Set K
21K
WS60.00-P-
110 589 11 63 00 Angular scraper FG 60/Set K
0003K
WS60.00-P-
115 589 28 63 00 Smoothing block FG 60/Set K
0005K
WS60.00-P-
115 589 29 63 00 Smoothing block FG 60/Set K
0006K
WS60.00-P-
115 589 30 63 00 Smoothing block FG 60/Set K
0007K
WS60.00-P-
115 589 31 63 00 Smoothing block FG 60/Set K
0008K
WS40.00-P-
124 589 01 19 00 Telescopic measuring rod FG 40/60/Set C
0014C
WS60.00-P-
124 589 01 61 00 Set of shaped blocks FG 60/Set K
0013K
WS40.00-P-
124 589 02 19 00 Telescopic measuring rod FG 40/60/Set C
0016C
WS60.00-P-
124 589 02 27 00 Pulling device FG 60/Set K
0015K
WS60.00-P-
124 589 02 61 00 Set of shaped blocks FG 60/Set K
0016K
124 589 03 19 00 Set of measuring tips and WS60.00-P-
FG 60/Set K
measuring joint 0017K
WS60.00-P-0017-
124 589 03 19 01 Test joint FG 60/Set K
01K
WS60.00-P-0017-
124 589 03 19 02 Measuring tips FG 60/Set K
02K
WS60.00-P-0017-
124 589 03 19 03 Measuring tips FG 60/Set K
03K
WS60.00-P-0017-
124 589 03 19 04 Perforated board FG 60/Set K
04K
WS60.00-P-
124 589 03 27 00 Pulling device FG 60/Set K
0018K
WS60.00-P-
124 589 04 27 00 Pulling device FG 60/Set K
0019K
WS60.00-P-
124 589 14 23 00 Portal straightening set FG 60/Set K
0020K
WS60.00-P-
129 589 01 27 00 Pulling device FG 60/Set K
0026K
FG 60/62/63/64/65/ 67/72/77/82/88/ WS60.00-P-
129 589 03 21 00 Feeler gauge
Set K 0027K
WS60.00-P-
129 589 03 23 00 Portal frame FG 60/63/64/65/ Set K
0028K
129 589 03 23 01 Extension boom, left or right WS60.00-P-0028-
GROUP 60/63/64/65/Set K
side 01K
WS60.00-P-0028-
129 589 03 23 02 Extension boom, right side GROUP 60/63/64/65/Set K
02K
WS60.00-P-
129 589 09 23 00 Portal straightening set FG 60/63/Set K
0029K
WS60.00-P-
140 589 00 27 00 Pulling device FG 60/Set K
0030K
WS60.00-P-
140 589 01 27 00 Pulling device FG 60/Set K
0031K
140 589 01 61 00 Engine support frame FG 01/33/60/Set C WS01.00-P-0032C
WS63.00-P-
140 589 26 23 00 Multi-Z elements MZ 260 FG 60/63/Set K
0020K
WS62.00-P-
140 589 26 63 00 Stamping symbols set FG 43/60/62/Set K
0018K
WS62.00-P-0018-
140 589 26 63 05 Steel stamping letters set FG 43/60/62/Set K
05K
WS60.00-P-
163 589 00 31 00 Centering punch FG 60/Set A
0081A
WS60.00-P-
163 589 01 31 00 Centering mount FG 60/Set A
0082A
164 589 00 23 00 Inspection and welding WS60.00-P-
Group 60/Set K
device 0116K
WS60.00-P-
164 589 03 23 00 Welding device Group 60/Set K
0118K
164 589 12 23 00 Inspection and welding WS60.00-P-
Group 60/61/Set K
device 0115K
164 589 17 23 00 Adapter GROUP 60/Set B WS60.00-P-0117B
168 589 00 23 00 Check and welding gages for WS63.00-P-
FG 60/62/63/64/65/ Set K
A-B-C-pillars 0037K
168 589 01 23 00 Welding gage for seat WS60.00-P-
FG 60/Set K
brackets 0042K
WS62.00-P-
168 589 01 63 00 Number punch guide FG 60/62/Set K
0028K
WS60.00-P-
168 589 07 23 00 Welding gauge FG 60/Satz K fehlt
0043K
WS60.00-P-
169 589 00 23 00 Check and welding device FG 60/63/Set K
0110K
169 589 00 61 00 Engine bridge FG 33/46/60/Set B WS33.00-P-0164B
WS33.00-P-0164-
169 589 00 61 01 Engine bridge adaptation FG33/46/60/Set B
01B
170 589 01 63 00 Number punch guide FG 60/62/Set K 0025K
WS63.00-P-
170 589 02 23 00 Portal straightening set FG 60/62/63/64/Set K
0034K
WS60.00-P-
170 589 06 23 00 Welding gage FG 60/Set K
0041K
WS60.00-P-
171 589 00 23 00 Weld in device FG 60/63/Set K
0109K
WS61.00-P-
171 589 00 63 00 Stamping guide Group 60/set K
0002K
WS60.00-P-
201 589 00 51 00 Spot weld milling cutter Group 60/61/62/63/64/ 65/ Set K
0033K
WS60.00-P-0033-
201 589 00 51 01 Milling bit crown Group 60/61/62/63/64/65/Set K
01K
WS60.00-P-
201 589 01 61 00 Set of shaped blocks FG 60/Set K
0034K
WS60.00-P-
201 589 02 61 00 Set of shaped blocks FG 60/Set K
0035K
WS60.00-P-
201 589 03 27 00 Pulling device FG 60/Set K
0036K
WS60.00-P-
201 589 05 27 00 Pulling device FG 60/Set K
0037K
WS60.00-P-
201 589 10 31 00 Set of clamps FG 60/62/63/Set K
0038K
WS60.00-P-
202 589 00 27 00 Pulling device FG 60/Set K
0039K
WS60.00-P-
202 589 09 63 00 Marking punch guide FG 60/Set K
0040K
202 589 13 23 00 Set of test and welding WS63.00-P-
FG 60/63/65/Set K
gauges 0032K
WS60.00-P-
203 589 00 63 00 Number punch guide FG 60/Set K
0044K
203 589 01 31 00 Tensioning device FG 32/60/Set B WS32.00-P-0052B
WS32.00-P-0052-
203 589 01 31 28 Repair kit FG32/60/Set B
01B
WS60.00-P-
203 589 02 31 00 Adapter kit FG 60/61/Set K
3015K
208 589 00 23 00 Test and welding gauge for WS63.00-P-
FG 60/63/Set K
B-pillar 0036K
209 589 00 23 00 Inspection and welding WS60.00-P-
Group 60/Set K
equipment 0045K
WS60.00-P-
209 589 05 23 00 Welding devices FG 60/Set K
0106K
WS60.00-P-
209 589 08 23 00 Welding device FG 60/63/Set K
0094K
WS60.00-P-
209 589 09 23 00 Welding device FG 60/63/Set K
0095K
210 589 00 61 00 Supports for engine support WS60.00-P-
FG 60/Set K
bracket (2 each) 0080K
210 589 04 23 00 Set of test and welding WS63.00-P-
FG 60/63/Set K
gauges 0058K
WS63.00-P-
210 589 17 23 00 Side portal frame FG 60/62/63/64/65/ Set K
0059K
211 589 00 23 00 Inspection and welding WS60.00-P-
FG 60/Set K
device 0083K
WS60.00-P-
211 589 02 63 00 Stamping character guide FG 60/62 Set K
0090K
WS60.00-P-
215 589 00 51 00 Spot-weld cutter FG 60/62/63/64/65/ Set K
3012K
WS60.00-P-3012-
215 589 00 51 01 Cutting head FG 60/62/63/64/65/Kit K
01K
WS60.00-P-
219 589 00 23 00 Welding devices FG 60/63/set K
0111K
WS60.00-P-
230 589 00 31 00 Adapter set FG 60/61/88/Set K
0084K
WS60.00-P-
230 589 03 23 00 Test and locating tool FG 60/set K
0119K
240 589 00 23 00 Inspection and welding WS60.00-P-
Group 60/set K
device 0086K
WS01.00-P-
240 589 00 32 00 Adaptation plates AEJ 01/22/27/33/60/ Set B
0150B
WS01.00-P-
240 589 00 61 00 Engine lifting device FG 01/33/60/Set C
0104C
240 589 00 63 00 Maybach emblem number WS60.00-P-
FG 60/Set K
punch 0087K
WS01.00-P-
240 589 01 31 00 Adapter kit FG 01/22/27/33/60/ Set B
0085B
WS01.00-P-
240 589 01 32 00 Adaptation plates FG 01/22/27/33/60/ Set B
0156B
240 589 01 32 00 Adaptation plates FG 01/22/60/Set C WS01.00-P-0156C
WS60.00-P-
240 589 01 63 00 Number punch guide Group 60/Set K
0088K
251 589 00 23 00 Inspection and welding WS63.00-P-
FG 60/63/Set K
device 0138K
WS60.00-P-
251 589 00 63 00 Stamping guide Group 60/Set K
0114K
WS60.00-P-
251 589 01 23 00 Set of spacer blocks Group 60/Set K
0113K
251 589 02 27 00 Set of pullers Group 60/Set K 0112K
251 589 24 23 00 Inspection and welding WS63.00-P-
Group 60/63/Set K
device 0139K
BRAKES
Brakes - Basic Knowledge - S-Class (221)
BASIC KNOWLEDGE
ELECTRIC PARKING BRAKE, LOCATION OF COMPONENTS - GF42.20-P-0001-01LE
Illustrated on model 221.0
Fig. 1: Locating Electric Parking Brake Components
Courtesy of MERCEDES-BENZ USA
ELECTRIC PARKING BRAKE, LOCATION OF COMPONENTS - GF42.20-P-0001-01SX
Shown on model 221.0
Fig. 2: Locating Electric Parking Brake Components
Courtesy of MERCEDES-BENZ USA
ELECTRIC PARKING BRAKE, BLOCK DIAGRAM - GF42.20-P-0001-02LE
Fig. 3: Electric Parking Brake Block Diagram
Courtesy of MERCEDES-BENZ USA
ELECTRIC PARKING BRAKE, BLOCK DIAGRAM - GF42.20-P-0001-02SX
Fig. 4: Electric Parking Brake Block Diagram
Courtesy of MERCEDES-BENZ USA
ELECTRIC PARKING BRAKE, FUNCTION - GF42.20-P-0001LE
MODEL 216.3, 221.0 /1 as of Model Year 09 /modification year 08
Function requirements - electric parking brake (EFB) general
C. 30 ON
Electronic parking brake (EFB) general
The electronic parking brake makes it possible to hold the vehicle at a standstill on gradients even in the
absence of the driver, the braking parts being held de-energized in the brake position by a self-locking
mechanical effect.
The EFB operates the parking brake at the rear axle via cables by an electric motor integrated in the electric
parking brake controller unit (A13).
Activation takes place manually via the electric parking brake switch (S76/15) or automatically depending on
the driving condition.
Depending on the operating condition of the parking brake the driver's wish is converted into a corresponding
tension force build up or reduction at the actuators.
Mechanical release makes it possible to release the electronic parking brake in the event of a defect and in
the de-energized condition. The release cable is located at the fuel filler flap and can be operated using the
vehicle tool kit.
The electronic parking brake (EFB) function is comprised of the following partial functions:
Function sequence - apply and release parking brake
Function sequence - release parking brake automatically
Function sequence - emergency braking
Function sequence - dynamometer test mode
Additional function requirements - applying and releasing parking brake
Vehicle speed v < 3.5 km/h
Terminal 15R On or with code (889) Keyless Go terminal 15 On (only for releasing the parking brake)
Function sequence - applying and releasing the parking brake
The electric parking brake controller unit calculates the vehicle speed from the wheel speeds which the ESP
control unit (N47-5) provides on the chassis CAN.
The EIS [EZS] control unit makes available the circuit status circuit 15 on the chassis CAN N73
The central gateway control unit (N93) passes on all the relevant information to the electric parking brake
controller unit via the front end CAN
By operating the electric parking brake switch, applying or releasing the parking brake is requested
corresponding to the operating condition.
The electric parking brake controller unit reads in the status of the electric parking brake switch directly,
transmits this on the front end CAN and actuates the integrated electric motor accordingly. The parking brake is
applied or released via the brake cables. The operating period of the electric parking brake switch does not have
any influence on the function.
The central gateway control unit passes on the status of the electric parking brake switch to the instrument
cluster (A1) via the central CAN. The instrument cluster receives this and actuates the electric parking brake
warning light (red).
Additional function requirements - release parking brake automatically
Engine running (circuit 61 ON)
Selector lever position "D" or "R"
Engine hood closed
Trunk lid closed
(only for selector lever position "R")
Driver door closed (only if driver is not wearing the seat belt)
Function sequence - release parking brake automatically
The function of release parking brake automatically is carried out as soon as the accelerator pedal position
exceeds a certain threshold value. The accelerator pedal position is recorded via the accelerator pedal sensor
(B37), the signals of which are read in by the CDI control unit (N3/9) (with diesel engine) or by the motor
electronics control unit (N3/10) (with gasoline engine).
The CDI control unit or motor electronics transmits circuit status circuit 61 and the accelerator pedal position on
the chassis CAN. The intelligent servo module for DIRECT SELECT (A80) transmits the current transmission
selector lever on the drive train CAN. The CDI control unit or motor electronics control unit passes this on the
chassis CAN.
The left door control unit (N69/1) (model 216) or left front door control unit (N69/1) (model 221) makes
available the status of the driver door on the interior CAN.
The rear SAM control unit with fuse and relay module (N10/2) transmits the status of the trunk lid and engine
hood on the interior CAN.
The central gateway control unit) passes on all the relevant information to the electric parking brake controller
unit via the front end CAN
The electric parking brake controller unit is woken up by the corresponding CAN messages and releases the
parking brake by actuating the integrated electric motor.
If the electronic parking brake is not released as a result of a fault, the instrument cluster outputs the message
"Release parking brake" via the multifunction display (A1p13) and in addition an acoustic warning sounds.
If circuit 30 has been interrupted automatic release is not possible. The electronic parking brake must be
woken up via the electric parking brake switch or circuit 87. The electric parking brake controller unit receives
the signal circuit 87 directly from the front SAM control unit with fuse and relay module (N10/1).
Additional function requirements - emergency braking
Vehicle speed v > 3.5 km/h
(calculated by electric parking brake controller unit)
Function sequence - emergency braking
If the electric parking brake switch is operated and held while driving, the electric parking brake controller unit
transmits a brake request on the front end CAN. The central gateway control unit passes this on to the following
control units:
ESP control unit via the chassis CAN
Instrument cluster via the central CAN
In the event of a service brake malfunction (e.g. CAN communication faulty) the brake application only takes
place by the electric parking brake control unit via the parking brake. For this the electric parking brake
controller unit evaluates the signals from the left front RPM sensor (L6/1), right front RPM sensor (L6/2), left
rear RPM sensor (L6/3) and right rear RPM sensor(L6/4) in order to prevent the rear wheels locking. The
signals from the RPM sensors are provided on the chassis CAN by the ESP control unit and passed on to the
electric parking brake controller unit by the central gateway control unit via the front end CAN.
The request from the brake light actuation is likewise issued by the
Rear SAM control unit with fuse and relay module via the interior CAN
The vehicle is now braked via the service brake. The rear SAM control unit activates the brake light actuation.
The instrument cluster gives the message "Release parking brake" via the multifunction display and in addition
an acoustic warning sounds.
electric parking brake controller unit.
In addition the electric parking brake warning lamp (yellow) is actuated in the instrument cluster. The electric
parking brake controller unit transmits corresponding requests on the front end CAN. The central gateway
control unit passes these on to the instrument cluster via the central CAN.
Additional function requirements - test bench mode
Front wheel "stationary" and rear wheels turn slowly (roller brake test stand)
ESP Off switch (S6/2s11) operated
Function sequence - dynamometer test mode
Activation of the roller test mode prevents faults being stored in the ESP control unit.
The electric parking brake controller unit is actuated by operating the electric parking brake switch.
The force is built up at the brake cables in a constantly rising manner until the maximum force is applied.
As a result the deceleration values of the parking brake can be recorded and the brakes of the parking brake
bedded in if necessary.
The process can be repeated up to 3-times, in which a cooling off time should be maintained between the brake
applications.
To replace the brake cables the electronic parking brake is either brought into the assembly position or
unlocked manually. Once the work is complete the electronic parking brake is again put into the operational
condition by pressing the electric parking brake switch.
GF42.20-P-0001-
Electric parking brake, location of components
01LE
PE42.20-P-2050-
Electrical function schematic for electric parking brake Model 216
97CAB
PE42.20-P-2050-
Model 221
97SAB
GF42.20-P-0001-
Electric parking brake, block diagram
02LE
Instrument cluster, component description A1 GF54.30-P-6000LE
Electric parking brake controller unit, component
A13 GF42.20-P-5000LE
description
Intelligent servo module for DIRECT SELECT, A80 GF27.19-P-
component description Transmission 722.6 4020ACS
GF27.19-P-
Transmission 722.9
4020AHS
N3/9
GF07.16-P-
Component description for CDI control unit On engine 629 in model
6000OA
221
On engine 642 in model GF07.16-P-
221 6000OHL
N3/10 GF07.61-P-
ME-SFI [ME] control unit, component description
On engine 156 6000MAS
GF07.61-P-
On engine 272
6000MIS
GF07.61-P-
On engine 273
6000MLS
GF07.61-P-
On engine 275
6000MOS
Rear SAM control unit with fuse and relay module,
N10/2 GF54.21-P-6030LE
component description
ESP control unit, component description N47-5 GF42.45-P-5118LE
N69/1
Left door control unit, component description GF72.29-P-4124LA
Model 216
N69/1
Left front door control unit, component description GF72.29-P-4141LE
Model 221
Component description for the EZS control unit N73 GF80.57-P-6003LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
ELECTRIC PARKING BRAKE, FUNCTION - GF42.20-P-0001SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 5: Electric Parking Brake Function Diagram
Courtesy of MERCEDES-BENZ USA
Function
The electric parking brake (EFB) operates the parking brake at the rear axle via cables by an electric motor
integrated in the controller unit.
Activation takes place manually via the electric parking brake switch or automatically depending on the driving
condition.
The electronic parking brake is operational as soon as the power supply terminal 30 is present.
A manual unlocking makes it possible to release the EFB also in the event of a defect and in the de-
energized condition. The release cable is located in the fuel filler flap and can be operated with the help of the
vehicle tool kit.
The electronic parking brake contains the following functions:
Apply and release the parking brake
Automatic parking brake release
Emergency braking
Test bench mode
Apply and release the parking brake
Function requirement
Speed less than 3.5 km/h or vehicle stationary
Terminal 15R On or with code (889) Keyless Go terminal 15 On (only for releasing the parking brake)
Function
When the electric parking brake switch is operated a signal is transmitted directly to the controller unit.
Depending on the condition the controller unit releases or tensions the brake cables via the integrated electric
motor.
The operating period of the electric parking brake switch does not have any influence on the function.
Automatic parking brake release
Function requirement
Engine runs (terminal 61)
Selector lever position "D" or "R"
Engine hood closed
Trunk lid closed (only in selector lever position "R")
Driver door closed (only if driver is not wearing the seat belt)
Function
The function is triggered when the accelerator pedal position exceeds a certain threshold. The controller unit is
awoken via the corresponding CAN-messages and releases the brake cables via the integrated electric motor.
For the case that the electronic parking brake does not release the display "Release parking brake" is displayed
in the instrument cluster and a warning tone sounds.
If terminal 30 has been interrupted, automatic release is not possible. The electronic parking brake must first
be woken via the Electric parking brake switch or terminal 87. The controller unit receives the signal terminal
87 directly from the front SAM control unit with fuse and relay module (N10/1).
Emergency case braking with the electric parking brake switch
Function requirement
Speed greater than 3, 5 km/h
Function
When the Electric parking brake switch is operated and held, the braking request is transmitted to the ESP
control unit. The vehicle is now braked via the service brake, ABS or ESP interventions are also performed if
necessary
The stop lamp actuation is activated.
The display "Release parking brake" appears in the instrument cluster and a warning tone sounds.
In the event of a service brake malfunction (e.g. CAN communication faulty) the brake application takes place
by the controller via the parking brake.
Similar to an ABS a control intervention takes place when blocking of a rear wheel is detected by the RPM
sensor.
Test stand mode
Function requirement
Front wheels "stationary" and rear wheels turn slowly (roller brake test stand)
ESP Off switch (S6/2s11) operated
Function
The controller unit is actuated by operating the electric parking brake switch. The force is built up at the brake
cables in a constantly rising manner until the maximum force is applied. As a result for example the linings of
the parking brake can be bedded in or the deceleration values determined.
The process can be repeated up to 3-times, in which a cooling off time should be maintained between the brake
applications.
Brake cable replacement
To replace the brake cables the electronic parking brake is either brought into the assembly position or unlocked
manually. Once the work is complete the electronic parking brake is again put into the operational condition by
pressing the electric parking brake switch.
GF42.20-P-0001-
Electric parking brake, location of components
01SX
GF42.20-P-0001-
Electric parking brake, block diagram
02SX
Electric parking brake controller unit, component GF42.20-P-
A13
description 5000SX
A80
description 722.9 4015SX
Model 221 with transmission GF27.19-P-
722.6 4015SXA
B37
Component description for the accelerator pedal GF30.20-P-
Model 221.0/1 with engine
sensor 2010SX
642
Model 221 with engine GF30.20-P-
272.965, 273.961 2010V
GF42.45-P-
Wheel RPM sensor, component description L6/1, L6/2, L6/3, L6/4
5134SX
GF42.45-P-
Description of components in ESP control unit N47-5
5118SX
Electronic ignition/starter switch control unit (EIS) GF80.57-P-
N73
component description 6000SX
GF54.21-P-
Central gateway control unit, component description N93
4170SX
GF42.20-P-
Electric parking brake switch, component description S76/15
5001SX
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, ELECTRIC PARKING BRAKE -
GF42.20-P-0999LE
MODEL 216.3, 221.0 /1 as of Model Year 09 /modification year 08
Electric parking brake, function GF42.20-P-0001LE
GF42.20-P-0001-
Electric parking brake, location of components
01LE
GF42.20-P-0001-
Electric parking brake, block diagram
02LE
Overview of system components for electric parking brake, component
GF42.20-P-9999LE
description
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, ELECTRIC PARKING BRAKE -
GF42.20-P-0999SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Electric parking brake, function GF42.20-P-0001SX
GF42.20-P-0001-
Electric parking brake, location of components
01SX
GF42.20-P-0001-
Electric parking brake, block diagram
02SX
Overview of system components for electric parking brake, component
GF42.20-P-9999SX
description
ELECTRIC PARKING BRAKE CONTROLLER UNIT, COMPONENT DESCRIPTION - GF42.20-P-
5000LE
MODEL 216.3, 221.0 /1 as of Model Year 09 /modification year 08
Illustrated on model 221.0
Fig. 6: Locating Electric Parking Brake Controller Unit
Courtesy of MERCEDES-BENZ USA
Location
The electric parking brake controller unit is located on the left of the rear axle.
Task
The electric parking brake controller unit has the following tasks:
Reading in of sensors, pickups and signals
Evaluation of input factors
Actuation of components
Reading in of sensors, pickups and signals
The input factors are read in via the following connections:
Direct line
Front end CAN
Direct line
The signals from the following component are read in via a direct connection:
Status of electric parking brake switch (S76/15)
Front end CAN
The following information is read in via the interior CAN:
Status of circuit 15 (provided by the EIS [EZS] control unit (N73) on the chassis CAN and passed on by
the central gateway control unit (N93) on the front end CAN)
Evaluation of input factors
The input factors that have been read in are evaluated by the integrated microprocessor and the relevant
components are then actuated.
Actuation of components
The actuation of the components takes place via the following connections:
Direct line
Front end CAN
Direct line
The electric parking brake controller unit operates the integrated electric motor for operating the parking brake
at the rear axle via a direct line.
Front end CAN
The following components are actuated via the front end CAN:
Instrument cluster (A1)
(output of messages and warnings)
ESP control unit (N47-5) (introduction of emergency stop)
The requests are passed on to the respective control unit by the central gateway control unit.
Wiring diagram for electric parking brake Model 216 PE42.20-P-2101-99CAA
Model 221 PE42.20-P-2101-99SAA
ELECTRIC PARKING BRAKE CONTROLLER UNIT, COMPONENT DESCRIPTION - GF42.20-P-
5000SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221.0
Fig. 7: Locating Electric Parking Brake Controller Unit
Courtesy of MERCEDES-BENZ USA
Location
The controller unit is located on the left of the rear axle.
Task
Depending on the request the controller unit operates the parking brake (duo servo brake) on the rear axle.
The brake position is held by a self-locking mechanical action.
The controller unit makes possible the following functions:
Apply and release the parking brake
Automatic parking brake release
Emergency braking with parking brake
Test bench mode
Discrete inputs
Circuit 30
Circuit 31
Circuit 87
Electric parking brake switch (S76/15)
CAN signals
The controller unit is a subscriber on the front end CAN.
ELECTRIC PARKING BRAKE SWITCH, COMPONENT DESCRIPTION - GF42.20-P-5001SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 8: Locating Electric Parking Brake Switch
Courtesy of MERCEDES-BENZ USA
Location
The electric parking brake switch is located on the left under the rotary light switch in the instrument panel
Task
The electric parking brake (EFB) can be applied or released via the electric parking brake (EFB).
In addition an emergency braking can be realized by operating the switch while driving.
The electric parking brake switch is connected directly to the electric parking brake controller unit (A13).
OVERVIEW OF SYSTEM COMPONENTS FOR ELECTRIC PARKING BRAKE, COMPONENT
DESCRIPTION - GF42.20-P-9999LE
MODEL 216.3, 221.0 /1 as of Model Year 09 /modification year 08
GF54.30-P-
Instrument cluster, component description A1
6000LE
Electric parking brake controller unit, component GF42.20-P-
A13
description 5000LE
Intelligent servo module for DIRECT SELECT, A80 GF27.19-P-
component description Transmission 722.6 4020ACS
GF27.19-P-
Transmission 722.9
4020AHS
N3/9
GF07.16-P-
Component description for CDI control unit On engine 629 in model
6000OA
221
On engine 642 in model GF07.16-P-
221 6000OHL
N3/10 GF07.61-P-
ME-SFI [ME] control unit, component description
On engine 156 6000MAS
GF07.61-P-
On engine 272
6000MIS
GF07.61-P-
On engine 273
6000MLS
GF07.61-P-
On engine 275
6000MOS
Rear SAM control unit with fuse and relay module, GF54.21-P-
N10/2
component description 6030LE
GF42.45-P-
ESP control unit, component description N47-5
5118LE
N69/1 GF72.29-P-
Left door control unit, component description
Model 216 4124LA
N69/1 GF72.29-P-
Left front door control unit, component description
Model 221 4141LE
GF80.57-P-
Component description for the EZS control unit N73
6003LE
GF54.21-P-
Central gateway control unit, component description N93
4170LE
Table of contents for function description, electric parking GF42.20-P-
brake 0999LE
OVERVIEW OF SYSTEM COMPONENTS FOR ELECTRIC PARKING BRAKE, COMPONENT
DESCRIPTION - GF42.20-P-9999SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Electric parking brake controller unit, component GF42.20-P-
A13
description 5000SX
A80
Intelligent servo module (ISM) component GF27.19-P-
Model 221 with transmission
description 4015SX
722.9
Model 221 with transmission GF27.19-P-
722.6 4015SXA
Component description for the accelerator pedal B37 GF30.20-P-
sensor Model 221.0/1 with engine 642 2010SX
Model 221 with engine GF30.20-P-
272.965, 273.961 2010V
GF42.45-P-
Wheel RPM sensor, component description L6/1, L6/2, L6/3, L6/4
5134SX
GF42.45-P-
Description of components in ESP control unit N47-5
5118SX
Electronic ignition/starter switch control unit (EIS) GF80.57-P-
N73
component description 6000SX
GF54.21-P-
Central gateway control unit, component description N93
4170SX
Electric parking brake switch, component description S76/15
5001SX
Table of contents for function description, electric GF42.20-P-
parking brake 0999SX
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF REGENERATIVE BRAKE SYSTEM -
GF42.22-P-0999LEH
MODEL 221.095/ 195
Do not touch components and open lines of the
Risk of death when
high-voltage on-board electrical system. Persons
touching components on AS54.00-Z-
who are carriers of electronic implants (e.g.
vehicles with high-voltage 0001-01A
cardiac pacemakers), must not carry out any work
on-board electrical system
on high-voltage on-board electrical systems.
Regenerative braking GF42.22-P-
system, function 0001LEH
GF42.22-P-
Regenerative braking
0001-
system block diagram
01LEH
Regenerative braking GF42.22-P-
system location of 0001-
components 02LEH
GF42.22-P-
Flashing of regenerative
0001-
braking system control unit
04LEH
Regenerative brake mode, GF42.22-P-
function 1000LEH
Regenerative and hydraulic GF42.22-P-
brake mode, function 1001LEH
Hydraulic brake mode, GF42.22-P-
function 1002LEH
Emergency brake mode, GF42.22-P-
function 1003LEH
GF42.22-P-
Vacuum supply, function
1004LEH
Overview of system
components for GF42.22-P-
regenerative braking 9999LEH
system
COMPONENT DESCRIPTION FOR REGENERATIVE BRAKING SYSTEM CONTROL UNIT -
GF42.22-P-1100LEH
MODEL 221.095/ 195
Phantom view of left front of vehicle
Fig. 9: Locating Regenerative Braking System Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The regenerative braking system control unit is located on the traction system hydraulic unit in the right front of
the engine compartment.
Task
General
The regenerative braking system is a brake and vehicle dynamics control system of a modular design (only the
affected functions are switched off in the event of a fault) The regenerative braking system is a further
development of the Electronic Stability Program (ESP) and contains the functions of the ESP.
If the vehicle reaches the critical limits of road-holding or if a control intervention function of the controllable
speed limiter (without code (494) USA version) or of cruise control is necessary, the regenerative braking
system control unit causes active interventions by the brake system or interventions in the engine control.
If necessary the required wheel-individual brake pressure is calculated taking into account the "ESP", "ABS",
"ASR" algorithms or the "added value functions" by the regenerative braking system control unit and adjusted
in the solenoid valves of the hydraulic components. The pressure regulator adjusts the required brake pressure
in each wheel.
The regenerative braking system control unit contains the control for the following systems:
Electronic stability program (ESP)
Acceleration Slip Regulation (ASR)
Engine drag torque control (MSR)
Antilock brake system (ABS)
Brake Assist (BAS)
Electronic Traction System (ETS)
Tire pressure loss warning (except code (475) Tire pressure monitor (Siemens))
PRE-SAFE
Speed-sensitive power steering (SPS [PML])
Cruise control
Limiter (except code (494) USA version)
Added value functions (SBC hold, precharging and dry braking)
Deceleration coordination of DISTRONIC PLUS (with code (233) DISTRONIC PLUS)
Flashing
The regenerative braking system control unit is flashable i.e. the complete software in the control unit can be
updated (replaced). The software required to program the control units is stored on the STAR DIAGNOSIS
DAS Update DVD.
CAN data bus
The regenerative braking system control unit is connected to the CAN interconnection of the vehicle via the
chassis CAN (CAN E) and vehicle dynamics CAN (CAN H) and exchanges data with other control units.
Input and output signals
The following input signals are evaluated by the regenerative braking system control unit and the corresponding
output signals issued:
Direct input signals
Direct output signals
CAN input signals
CAN output signals
Direct input signals
Terminal 30
Terminal 87
Terminal 31
BAS diaphragm travel sensor (A7/7b1)
Vacuum sensor (A7/7b3)
Hybrid brake light switch (S9/3)
Direct output signals
Stop lamp actuation via rear SAM control unit with fuse and relay module (N10/2)
Traction system hydraulic unit (A7/3)
Brake pressure simulator valve (Y113)
Vacuum pump relay (+) (K109)
Vacuum pump relay (-) (K109/1)
SPS [PML] solenoid valve (Y10)
Vacuum pump relay (+) (K109)
Brake pressure simulator valve pressure sensor (B18/5)
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
Power supply for yaw rate sensor for lateral and longitudinal acceleration (B24/15)
Power supply for BAS membrane travel sensor (A7/7b1)
Power supply for BAS solenoid valve (A7/7y1)
Power supply for pedal angle sensor (B37/1)
Power supply for brake pressure simulator valve pressure sensor (B18/5)
Power supply for vacuum sensor (A7/7b3)
Power supply for hybrid brake light switch (S9/3)
CAN input signals
Yaw rate sensor for lateral and longitudinal acceleration (B24/15)
Yaw rate sensor for lateral and longitudinal acceleration signal
ME-SFI [ME] control unit (N3/10)
Engine hood closed/open
Upper control panel control unit (N72/1)
ESP OFF button signal (S6/2s11)
EIS [EZS] control unit (N73)
Ignition ON
Steering column tube module (N80)
Steering angle sensor signal (N49)
Central gateway control unit (N93)
Diagnostic CAN (CAN-D) interface
Electric parking brake controller unit (A13)
Electric parking brake switch (S76/15), status
CAN output signals
Instrument cluster (A1)
ABS indicator lamp (A1e17)
ESP warning lamp (A1e41)
Multifunction display (A1p13)
Rear SAM control unit with fuse and relay module (N10/2)
Brake lights, taillights and left parking light signal (E3e9)
Brake lights, taillights and right parking light signal (E4e9)
ME-SFI [ME] control unit (N3/10)
Wheel speed
Requested regenerative braking torque
Wiring diagram for regenerative braking system control unit N30/6 PE42.22-P-2101-97SAA
OVERVIEW OF SYSTEM COMPONENTS FOR REGENERATIVE BRAKING SYSTEM - GF42.22-P-
9999LEH
MODEL 221.095/ 195
Do not touch components and open lines of the
Risk of death when
high-voltage on-board electrical system. Persons
touching components on AS54.00-Z-
who are carriers of electronic implants (e.g. cardiac
vehicles with high-voltage 0001-01A
pacemakers), must not carry out any work on high-
on-board electrical system
voltage on-board electrical systems.
Instrument cluster, GF54.30-P-
A1
component description 6000LEH
regenerative braking GF42.22-P-
N30/6
system control unit 1100LEH
Component description for
GF08.20-P-
power electronics control N129/1
1001MEH
unit
Table of contents for
GF42.22-P-
function description of
0999LEH
regenerative brake system
BRAKING ASSISTANT (BAS) - OPERATION - GF42.31-P-0001SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 10: Braking Assistant Reference Graph
Courtesy of MERCEDES-BENZ USA
Investigations with normal drivers in the driving simulator and on the test track have shown that most drivers in
emergency braking situations, above all in the initial phase of braking, operate the brake pedal quickly but not
hard enough.
A distinction is made between:
Hesitant brake application
in the initial phase the driver applies too little pedal force and increases it too slowly
Inadequate brake application
the driver applies too little pedal force throughout the entire brake application
To improve these situations, the active safety system Brake Assist (BAS) has been developed. The Brake Assist
System is active when the driver brakes very rapidly in an emergency situation. The system detects whether an
emergency braking situation exists on the basis of the speed at which the driver presses the brake pedal.
The speed of brake actuation is recorded via the BAS diaphragm travel sensor (A7/7b1) in the BAS brake
booster (A7/7). The BAS function is terminated corresponding to the signal of the BAS release switch (A7/7s1)
(Pedal not actuated).
The deceleration through BAS is achieved by actuation of the BAS solenoid valve (A7/7y1) in the brake
booster.
Benefits:
Basic reduction in brake distance in the event of hesitant or inadequate brake application
Assisting the antilock brake system (ABS) by as large as possible brake force boosting
ABS maintains the full steerability also in the event of intervention by BAS
The BAS function is triggered by the ESP control unit (N47-5).
BAS brake booster, component description A7/7 GF42.31-P-4004SX
ESP control unit, component description N47-5 GF42.45-P-5118SX
BAS BRAKE BOOSTER, COMPONENT DESCRIPTION - GF42.31-P-4004SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Fig. 11: Locating Brake Booster
Courtesy of MERCEDES-BENZ USA
Location
The brake booster is located in the left of the major assemblies compartment.
Task
Like a conventional brake booster the brake booster assists the pedal force of the driver when braking but
activates, in the case of emergency braking, the Brake Assist (BAS).
Design
The brake booster contains the following electrical components:
BAS diaphragm travel sensor
BAS release switch
BAS solenoid valve
Brake fluid indicator switch
Function
The brake booster is constantly supplied with vacuum via a vacuum line. When the brake is not operated the
same vacuum acts on both sides of the diaphragm. A push spring holds the diaphragm plate in its starting
position.
During the brake application outside air is lead to the back of the diaphragm via a port. Between the front and
rear chamber of the amplifier a pressure difference occurs which acts in the direction of the master brake
cylinder and thus assists the foot force.
In the event of emergency braking the brake booster is actuated by the ESP control unit via the BAS solenoid
valve (N47-5).
4MATIC ELECTRONIC TRACTION SYSTEM, FUNCTION - GF42.35-P-1000AV
MODEL 204.0 with TRANSMISSION 722.960 /962 /963 /964 /965 as of Model Year 2009 /modification ye
MODEL 204.2 with TRANSMISSION 722.962 /965 as of Model Year 2009 /modification year 08
MODEL 204.9 with TRANSMISSION 722.960 /962 /964 /965
MODEL 212 with TRANSMISSION 722.960 /961 /962
MODEL 216 with TRANSMISSION 722.961 as of Model Year 2009 /modification year 08
MODEL 221 with TRANSMISSION 722.960 /961 /962 as of Model Year 2009 /modification year 08
Function requirements of electronic traction system (ETS) 4MATIC, general
Circuit 61 (engine running)
Electronic Stability Program (ESP) not deactivated
Electronic traction system (ETS) 4MATIC general
The ETS is a system which operated automatically to improve the starting off and acceleration ability on
different road surface condition. It replaces the automatic locking differential (ASD). The system operates via
an intervention by the brakes at the driven wheels. No engine control cycle is activated. The ETS prevents one-
sided spinning of the drive wheels when starting off and accelerating as well as the drive wheels spinning
briefly on both sides when cornering within specified speed ranges.
Function sequence - 4MATIC electronic traction system
Should one or more wheels spin on a smooth base the necessary brake pressure is automatically built up at each
wheel in order to brake the spinning wheels
Simultaneously due to the locking differential effect the drive torque is shifted to the wheels which are not
spinning.
The ESP warning lamp or Electronic Stability Program (A1e41) signals in the IC (A1) when a wheel speed no
longer agrees with the vehicle speed. It thus warns the driver that he has approached the physical driving limits
with his vehicle.
Model 204.0/2 (except 204.077 /277) with code (442)
Instrument cluster, GF54.30-P-
A1 Comfort multifunction steering wheel model 204.9
component description 6000CEA
with code (442) Comfort multifunction steering wheel
Model 204.0/2 (except 204.077 /277) except code
(442) Comfort multifunction steering wheel model GF54.30-P-
A1
204.9 except code (442) Comfort multifunction 6000CEB
steering wheel
GF54.30-P-
A1 Model 212.0
6000FL
GF54.30-P-
A1 Model 216.3, 221.0/1 except 221.095/195
6000LE
Component description for
GF42.45-P-
the Electronic Stability N30/4 Model 204.0/2/9
5119CE
Program control unit
on model 212.0, except code (233) DISTRONIC
N30/4 GF42.45-P-
PLUS on model 212.0 with code (233) DISTRONIC
N30/7 5119FL
PLUS
ESP control unit, GF42.45-P-
N47-5 Model 216.3, 221.0/1 except 221.095/195
component description 5118LE
ELECTRONIC STABILITY PROGRAM (ESP) FUNCTION - GF42.45-P-0001SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Schematic representation
Fig. 12: Identifying Vehicle Understeer & Oversteer
Courtesy of MERCEDES-BENZ USA
Function on example of an understeering vehicle (A)
If the vehicle understeers the drive torque is reduced as a first measure. If as a result the developing instability
cannot be prevented, a brake pressure is built up at the left rear wheel. Due to the reduction in lateral stability
and the build up of brake force at the left rear wheel a yawing moment occurs which causes the desired turning
in of the vehicle. The speed decreases as a result of the brake force at the rear wheel, which also enhances
stability.
Function on the example of an oversteering vehicle (B)
If the vehicle starts to oversteer, the drive torque is first reduced. If this cannot prevent the developing
instability, brake pressure is built up at the right front wheel. This causes a yawing moment which counteracts
the turning in motion of the vehicle. The speed decreases as a result of the brake force at the front wheel, which
also enhances stability.
General
The Electronic Stability Program) (ESP) is an active safety system for improving the vehicle stability in all
driving situations. It operates by individual brake intervention at one or more wheels on the front or rear axle.
The ESP stabilizes the vehicle when cornering, when braking or when rolling without drive and keeps it safely
on course. It supplements the familiar functions of the antilock brake system (ABS), the acceleration slip
regulation (ASR) and the engine braking regulation (MAR).
The function of the stability control overrides the ABS and ASR control systems.
In addition to active ESP brake intervention there is also an influence on the engine/transmission management
The ESP controls under the following driving conditions:
when cornering (vehicle under- or oversteered)
when driving straight ahead (vehicle deviates off course due to uneven road conditions)
Advantages of ESP:
Improvement in the starting-off and acceleration capability due to increased traction, particularly on a
road with different adhesion and on curves
Automatic adaptation of the engine torque depending on the traction condition of the wheels
Reduction in the risk of skidding under all road surface conditions by automatic stabilization when
braking, accelerating or rolling
Improvement in the lane stability of the vehicle when cornering, also up to the critical limits
Increase in active driving dynamics safety, as only one wheel which is not spinning permits the optimum
traction without loss of lateral stability
The ESP contains the following systems:
ABS: Avoidance of locking of individual wheels by reducing the brake pressure at the wheels in question
ASR: Prevents a too high slip of the driven wheels when starting off and accelerating due to torque
reduction
MAR: Reduction in wheel slip of the drive wheels in overrun mode and as a result better directional
stability and road adhesion
Fig. 13: Electronic Stability Program Function Diagram
Courtesy of MERCEDES-BENZ USA
Function overview
Brake forces, driving forces and side forces which act on the vehicle endeavor to turn the vehicle about the
vertical axis. The ESP records the vehicle characteristics and for correction specifically brakes individual
wheels or several wheels. It regulates when cornering (vehicle understeers or oversteers) and when driving
straight ahead (vehicle deviates from course due to dissimilar road conditions).
Sensor system
A distinction is made between sensors which detect the driver's requirement (e.g. the steering angle sensor) and
sensors which record the actual vehicle handling. These include:
Yaw rate, lateral and longitudinal acceleration sensor
Wheel speed sensor
The ESP control unit is constantly supplied with the current data via engine torque and transmission ratio.
Via the turn rate, lateral and longitudinal acceleration sensor the brake forces, drive forces and side forces
are recorded which want to turn the vehicle about the vertical axis (yaw rate). The torque acting on the
vehicle can be calculated from the information listed. If this value exceeds certain control thresholds then
the wheels in question are braked by the ESP control unit to neutralize the torque acting.
For drive torque reduction a torque requirement is specified to the ME-SFI [ME] control unit or CDI
control unit. A downshift is prevented by the VGS control unit or ETC [EGS] control unit. The selective
and accurately modulated intervention takes place in a few fractions of a second.
Active brake intervention and drive torque reduction by the ESP ensure optimum vehicle stability. The
following processes are performed:
ESP brake torque control circuit
ABS control
ASR control
ESP drive torque control circuit
ESP braking torque control circuit
ASR control
The brake pressure at the spinning wheel is increased via the ESP control unit to brake the spinning
wheel. A locking differential effect can be achieved as a result.
ESP drive torque control circuit
ASR-control
MSR-control
ESP braking torque control circuit
ABS control
If one wheel tends to lock the brake pressure at this wheel is reduced. The brake pressure is controlled via
the ESP control unit.
ASR control
To reduce a too large drive torque and as a result to achieve optimum traction, a drive torque reduction
takes place via the chassis CAN between the ESP control unit and the ME-SFI [ME] control unit or CDI
control unit. The ESP control unit checks constantly whether, the control function can be canceled for
example, as a result of a sudden improvement in road adhesion. So the drive torque specified by the
driver via the accelerator pedal sensor (B37) can be permitted again as soon as possible.
ESP drive torque control circuit
EBR control
If slip occurs at the drive wheels in overrun mode, this is detected by the ESP control unit. The signal is
transmitted via the chassis CAN to the ME-SFI [ME] control unit or the CDI control unit. With this
information wheel slip is reduced by increasing drive torque and as a result the lateral control of the
vehicle is increased. This process take place without the ESP warning lamp being switched on.
ESP brake torque and drive torque control circuit
ESP control
If oversteer or understeer is detected, a calculated brake intervention is arranged at the appropriate wheel.
This braking action deliberately counteracts the undesirable vehicle motion.
A signal to the ME-SFI [ME] control unit or CDI control unit via chassis CAN achieves the reduction in
drive torque to suit the requirements by reducing the engine torque.
ESP OFF mode
The response threshold for ESP can be set up via the ESP OFF switch. The ESP "Shutoff" is displayed by
the ESP warning lamp (A1e41) in the instrument cluster which lights up permanently. This can provide
better traction (grinding effect) in deep snow or when snow chains are fitted. ESP is always active during
a brake application. ASR only controls through individual wheel brake interventions at the drive wheels,
but not through influencing the engine management. ABS cannot be deactivated by the driver.
Optical status indication
The current condition of the ESP can be reported to the driver via the ESP warning lamp.
There are the following displays:
ESP warning lamp flashes
ESP currently controlling
ESP is switched off and there is slip at least one wheel
ESP warning lamp lights up
ESP is switched off there no slip at any wheel
ESP is inoperative (fault), a corresponding text message is also output in the
multifunction display (A1p13)
A1 GF54.30-P-
Instrument cluster, component description
Model 221 6000SX
Yaw rate and lateral acceleration sensor, GF42.45-P-
B24/15
component description 5120SX
GF42.45-P-
Wheel RPM sensor, component description L6/1, L6/2, L6/3 and L6/4
5134SX
CDI control unit component description Model 221 with engine 642 6000SX
N3/10
GF07.61-P-
ME-SFI [ME] control unit, component description Model 221 with engine 272.965
6000V
and 273.961
N3/10
ME-SFI control unit, location/task/design/ GF07.61-P-
Model 221 with engine
function 5000M
275.953/982
N15/3
GF27.19-P-
ETC [EGS] control unit component description Model 221 with transmission
4018G
722.6
GF42.45-P-
ESP control unit, component description N47-5
5118SX
GF42.45-P-
Steering angle sensor, component description N49
5107SX
Upper control panel control module component GF54.21-P-
N72/1
description 6040SX
GF54.21-P-
Steering column module component description N80
6050SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
GF42.45-P-
ESP Off switch, component description S6/2s11
5121SX
Y3/8n4
GF27.19-P-
VGS control unit, component description Model 221 with transmission
4016SX
722.9
YAW RATE, LATERAL AND LONGITUDINAL ACCELERATION SENSOR, COMPONENT
DESCRIPTION - GF42.45-P-4810LE
MODEL 216.3, 221.0 /1 as of Model Year 09 /modification year 08
Illustrated on model 221.0
Fig. 14: Locating Yaw Rate, Lateral And Longitudinal Acceleration Sensor
Courtesy of MERCEDES-BENZ USA
Location
The turn rate, lateral and longitudinal acceleration sensor is located in the luggage compartment in the center at
the partition wall to the passenger compartment.
Task
The yaw rate sensor for lateral and longitudinal acceleration measures the rotational speed about the vehicle
perpendicular axis. The integrated lateral acceleration sensor (AY sensor) measures the lateral acceleration.
The data from the yaw rate sensor for lateral and longitudinal acceleration are read in by the ESP control unit
(N47-5) via the vehicle dynamics CAN.
Design
The yaw rate sensor for lateral and longitudinal acceleration is a combined sensor for yaw rate, lateral and
longitudinal acceleration in micromechanical construction.
STEERING ANGLE SENSOR, COMPONENT DESCRIPTION - GF42.45-P-5107SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Illustrated on model 221
Fig. 15: Locating Steering Angle Sensor
Courtesy of MERCEDES-BENZ USA
Location
The steering angle sensor is integrated in the steering column module (N80).
Task
The steering angle sensor records the current position of the steering wheel and makes available to the steering
column module an electrical voltage signal proportional to the steering lock angle. The steering column module
conveys the data to the ESP control unit (N47-5) via the chassis CAN.
COMPONENT DESCRIPTION FOR ESP CONTROL UNIT - GF42.45-P-5118LE
MODEL 216.3, 221.0 /1 (except, 221.095 /195) as of model year 2009 /YoM 08
Shown on model 221
Fig. 16: Locating ESP Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The ESP control unit is located at the right front traction system hydraulic unit in the engine compartment
behind the right front lamp unit (E2).
Model 221 as of 1.6.09, model 216 as of 1.9.10
Adaptive Brake (ABR) is available in 2 variants:
Basic ABR system (except code 233 (DISTRONIC PLUS) and code 239 (Adaptive cruise control Plus
Light))
Premium ABR system (with code 233 (DISTRONIC PLUS) and code 239 (Adaptive cruise control Plus
Light))
Task
The ESP control unit has the following tasks:
Control of functions
Reading in of sensors, pickups and signals
Evaluating input factors
Actuation of components
The ESP control unit actuates the following systems:
Electronic Stability Program (ESP)
Antilock brake system (ABS)
Acceleration skid control (ASR)
Electronic traction system (ETS)
Engine braking regulation (MAR)
Brake Assist (BAS)
Tire pressure loss warning (RDW), except code (475) Tire pressure monitor (premium)
PRE-SAFE® system, PRE-SENSE, model 221 as of 2.6.09, model 216 as of 1.9.10
Cruise control (CC)
Variable speed limiter, except code (494) USA version
Speed-sensitive power steering (SPS)
Added value functions (e.g. HOLD function, precharging, dry braking, Hill-Start Assist)
Deceleration coordination of Distronic (DTR), with code (219) Distronic (DTR)
ATTENTION ASSIST (tiredness detection system), model 221 as of 2.6.09, model 216 as of 1.9.10
Reading in of sensors, pickups and signals
The input factors are read in via the following connections:
Direct line
Chassis CAN (CAN E)
Vehicle dynamics CAN (CAN H)
Direct line
The following components are read in via direct lines:
BAS membrane travel sensor (A7/7b1), model 221 up to 31.5.09, model 216 up to 31.8.10, model 221 as
of 1.6.09 or model 216 as of 1.9.10 with premium system
BAS release switch (A7/7s1), model 221 up to 31.5.09, model 216 up to 31.8.10, model 221 as of 1.6.09
or model 216 as of 1.9.10 with premium system
Attention assistance system sensor (B24/8), model 221 as of 1.6.09, model 216 as of 1.9.10
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
Brake light switch (S9/1), model 221 as of 1.6.09 or model 216 as of 1.9.10 with basic system
Brake vacuum sensor (B64/1) with code (B03) ECO start/ stop function
Chassis CAN
The ESP control unit is a subscriber of the chassis CAN. It communicates for instance with the following
control units:
Central gateway control unit (N93)
Instrument cluster (A1)
Vehicle dynamics CAN
The ESP control unit is a subscriber of the vehicle dynamics CAN. It communicates, for example, with the
following sensor and control unit:
Yaw rate sensor for lateral and longitudinal acceleration (B24/15)
DTR controller unit (A89), with code (219) Distronic (DTR)
Evaluation of input factors
The input factors that have been read in are evaluated by the integrated microprocessor and the relevant
components are then actuated.
Actuation of components
Chassis CAN
The signals are transmitted by the ESP control unit via the chassis CAN. The functions resulting therefrom are
described in the corresponding function descriptions (see block diagram or function schematic).
Components are actuated via the following lines:
Direct line
Chassis CAN
Direct line
The following components are actuated via direct lines:
BAS solenoid valve (A7/7y1), model 221 up to 31.5.09, model 216 up to 31.8.10, model 221 as of 1.6.09
or model 216 as of 1.9.10 with premium system
Brake light actuation (circuit 54) to rear SAM control unit with fuse and relay module (N10/2)
PML solenoid valve (Y10) (except electrohydraulic power steering)
Model 216
Wiring diagram for Adaptive PE42.47-P-2000-
Up to model year 2011 /YoM 10 model
Brake (ABR) 97CAA
refinement package
Model 216
PE42.47-P-2000-
As of model year 2011 /YoM 10 model
97CAB
refinement package
Model 221
PE42.47-P-2000-
Up to model year 2010 /YoM 09 model
97SAA
refinement package
Model 221
PE42.47-P-2000-
As of model year 2010 /YoM 09 model
97SAB
refinement package
DESCRIPTION OF COMPONENTS IN ESP CONTROL UNIT - GF42.45-P-5118SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Illustrated on model 221
Fig. 17: Locating ESP Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The ESP control unit is located on the right front traction system hydraulic unit in the engine compartment
behind the lamp unit.
Task
The ESP control unit includes the open-loop control for the following systems:
Start-off assist
Antilock brake system (ABS)
Acceleration Slip Regulation (ASR)
Brake Assist (BAS)
Electronic stability program (ESP)
Electronic traction system (ETS)
Engine braking regulation control (MAR)
Speed-sensitive power steering (SPS [PML])
Tire pressure loss warning
PRE-SAFE
Cruise control
Multivalent functions (holding, precharging and dry braking)
Deceleration coordination of Distronic (DTR) (with code (219) Distronic (DTR))
Trailer stabilization
Discrete inputs
Circuit 30
Circuit 87
BAS diaphragm travel sensor (A7/7b1)
BAS travel differential sensor (A7/7b2) (with engine 275)
BAS release switch (A7/7s1)
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
Discrete outputs
BAS solenoid valve (A7/7y1)
Stop lamp actuation via rear SAM control unit with fuse and relay module (N10/2)
SPS [PML] solenoid valve (Y10)
Voltage supply
Yaw rate and lateral acceleration sensor (B24/15)
CAN signals
The ESP control unit is connected to the chassis CAN and the vehicle dynamics CAN.
If the ESP control unit fails, only basic braking without ABS is available.
Since the ESP control unit is only awoken via the chassis CAN, the system will no longer function if the
CAN fails completely. Only the stop light signal is displayed.
YAW RATE AND LATERAL ACCELERATION SENSOR, COMPONENT DESCRIPTION - GF42.45-
P-5120SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221.0
Fig. 18: Locating Yaw Rate, Lateral And Longitudinal Acceleration Sensor
Courtesy of MERCEDES-BENZ USA
Location
The turn rate, lateral and longitudinal acceleration sensor is located in the luggage compartment, in the center at
the partition wall to the passenger compartment.
Task
Recording the rotational speed (yaw angle velocity) of the vehicle about the vertical axis as well as the lateral
and longitudinal acceleration.
The ESP control unit determines the lateral forces at the wheels from the yaw angle velocity, the lateral and
longitudinal acceleration and the steer angle of the front wheels which is calculated from the steering wheel
angle(N47-5).
Design
Combined sensor for rotational speed and transverse and longitudinal acceleration in micromechanical
construction.
ESP OFF SWITCH, COMPONENT DESCRIPTION - GF42.45-P-5121SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Illustrated on model 221
Fig. 19: Locating Cockpit Switch Group And ESP OFF Switch
Courtesy of MERCEDES-BENZ USA
Location
The cockpit switch group with the ESP OFF switch is located on the right next to the instrument cluster (A1).
Task
The Electronic Stability Program) (ESP) can be switched active and passive using the ESP OFF switch.
Function
The ESP OFF switch signal is read in via the OBF-LIN [upper control panel-local interconnect network] by the
upper control panel control unit (N72/1). The upper control panel control unit transmits the signal on the interior
CAN.
The ESP control unit (N47-5) switches the ESP function passive. ESP is always active during a brake
application.
The ESP warning lamp (A1e41) in the instrument cluster lights up permanently when ESP is switched
passive.
WHEEL RPM SENSOR, COMPONENT DESCRIPTION - GF42.45-P-5134SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221.0
Fig. 20: Locating Wheel RPM Sensors
Courtesy of MERCEDES-BENZ USA
Location
The left and right front RPM sensor are located in the steering knuckle of the front axle.
The left and right rear RPM sensor are located in the wheel carrier of the rear axle.
Task
The RPM sensors supply the current wheel speeds as a square wave signal to the ESP control unit (N47-5). The
ESP control unit evaluates these signals with regard to direction of rotation, wheel speed and fault detection.
Fig. 21: RPM Sensor Signal Waveform
Courtesy of MERCEDES-BENZ USA
The display shows the current curve through the active RPM sensor during an acceleration phase.
Function
A change in internal resistance inside the RPM sensor is caused by the strength and direction of an external
magnetic field. Via an electronic analysis system accommodated in the speed sensor (supplied with voltage
from the ESP control unit) a square wave signal is produced, the frequency of which depends on the RPM,
however the amplitude is constant. Due to a different signal pattern when the wheel is moving to the left or right
the direction of travel is detected. This signal is read in by the ESP control unit and transmitted on the chassis
CAN.
The external magnetic field is produced by a multipole ring. This consists of an elastomer plastic with metal
particles embedded in it. Via a special magnetization process these have been aligned so that various magnets
arise, the polarity of which changes from North to South at the periphery.
Advantages compared with a passive (inductive) RPM sensor:
Sensing of low RPM possible (makes possible recording of speed from 0 km/h)
Improvement in signal quality (digital signal).
Signal largely insensitive to vibrations and temperature differences
Low weight and compact construction
ADAPTIVE BRAKE (ABR) LOCATION OF COMPONENTS - GF42.47-P-0001-02LE
Shown on model 221.0
Fig. 22: Locating Adaptive Brake Components
Courtesy of MERCEDES-BENZ USA
ADAPTIVE BRAKE (ABR) LOCATION OF COMPONENTS - GF42.47-P-0001-02LEA
Shown on model 221.0 up to 31.8.10 (with basic system)
Fig. 23: Locating Adaptive Brake Components - Up To 31.8.10
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0 as of 1.9.10 (with basic system)
Fig. 24: Locating Adaptive Brake Components - As Of 1.9.10
Courtesy of MERCEDES-BENZ USA
ADAPTIVE BRAKE (ABR) LOCATION OF COMPONENTS - GF42.47-P-0001-02SX
Shown on model 221.0
Fig. 25: Locating Adaptive Brake Components
Courtesy of MERCEDES-BENZ USA
ADAPTIVE BRAKE (ABR) BLOCK DIAGRAM - GF42.47-P-0001-03LE
Fig. 26: Adaptive Brake Block Diagram
Courtesy of MERCEDES-BENZ USA
ADAPTIVE BRAKE (ABR) BLOCK DIAGRAM - GF42.47-P-0001-03LEA
Shown up to 31.8.10
Fig. 27: Adaptive Brake Block Diagram - Up To 31.8.10
Courtesy of MERCEDES-BENZ USA
Shown as of 1.9.10
Fig. 28: Adaptive Brake Block Diagram - As Of 1.9.10
Courtesy of MERCEDES-BENZ USA
ADAPTIVE BRAKE (ABR) BLOCK DIAGRAM - GF42.47-P-0001-03SX
Fig. 29: Adaptive Brake Block Diagram
Courtesy of MERCEDES-BENZ USA
ADAPTIVE BRAKE (ABR), FUNCTION - GF42.47-P-0001LE
MODEL 216.3, 221.0 /1 (except, 221.095 /195) as of model year 2009 /YoM 08
Function requirements, general
Status Circuit 61 ON
The status "Circuit 61 ON" is sent to the chassis CAN (CAN E) by the CDI control unit (N3/9) (with diesel
engine) or the ME-SFI [ME] control unit (N3/10) (with gasoline engine).
Model 221 as of 1.6.09, model 216 as of 1.9.10
There are 2 ABR variants in use:
Basic ABR system (except code 233 (DISTRONIC PLUS) and code 239 (Adaptive cruise control Plus
Light))
Premium ABR system (with code 233 (DISTRONIC PLUS) and code 239 (Adaptive cruise control Plus
Light))
General
The Adaptive Brake (ABR) system assists the driver in dangerous situations which suddenly occur and thus
serves active safety. The ABR system is an electrohydraulic brake system which regulates the braking
requirements for each wheel individually.
The following components are involved:
Traction system hydraulic unit (A7/3)
BAS brake booster (A7/7)
Accelerator pedal sensor (B37)
Yaw rate sensor for lateral and longitudinal acceleration (B24/15)
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
Steering angle sensor (N49)
ESP control unit (N47-5)
Brake light switch (S9/1), (basic system, model 221 as of 1.6.09, model 216 as of 1.9.10)
For vehicle test purposes the ABR system can be set to dynamometer test mode, if the workshop menu is
activated via the instrument cluster (A1) and afterwards the engine is started. The vehicle dynamics control
systems are switched passive. The ESP warning lamp (A1e41) and ABS indicator lamp (A1e17) in the
instrument cluster light up. In addition, a message is displayed in the multifunction display (A1p13) of the
instrument cluster. Roller dynamometer mode can also be activated via diagnosis.
The ABR system is comprised of the following partial functions:
Electronic Stability Program (ESP) function sequence
Electronic brake force distribution (EBD) function sequence
Antilock brake system (ABS) function sequence
Acceleration skid control (ASR) function sequence
Brake Assist function sequence (BAS) (model 221 up to 31.5.09, model 216 up to 31.8.10)
Brake Assist function sequence (BAS) (model 221 as of 1.6.09, model 216 as of 1.9.10 with basic and
premium system)
Tire pressure loss warning (RDW) function sequence (except code (475) Tire pressure monitor
(Premium))
Speed-sensitive power steering (SPS) function sequence
HOLD function sequence (starting-off aid)
Precharging function sequence
Dry braking function sequence
Function sequence for switching ASR and ESP to passive mode (model 216 and model 221 up to
31.5.09)
Function sequence for switching ASR and ESP to passive mode (model 216 and model 221 as of
1.6.09)
PRE-SAFE® system, PRE-SENSE function sequence (model 221 as of 1.6.09, model 216 as of
2.9.10)
Hill Start Assist function sequence
Failed Boost function sequence (with code (Z07) Highest protection, model 216.3 and model 221
with code (B03) ECO start/stop function)
Over Boost function sequence (model 216.3 and model 221 with engine 273 and code (B03) ECO
start/stop function)
Function sequence - Fading Brake Support
Air gap reduction function sequence
Function sequence - Standstill coordinator
System fault display function sequence
Function sequence, ESP
ESP prevents breakaway when the vehicle oversteers or understeers. Within physical limits it ensures that the
vehicle does not deviate from the course specified by the driver. Brake forces are produced selectively at the
individual wheels to correct any deviations. Furthermore, reduction of the drive torque takes place in order to
increase directional stability and road adhesion.
The ESP control unit immediately carries out a self-test upon "circuit 15 ON". If there are no system errors, the
ESP becomes operational and starts carrying out its functions.
Furthermore, the ESP control unit carries out system tests continuously during operation. Malfunctions and
faults are stored in the fault memory.
To determine the vehicle handling the ESP control unit processes the following measured quantities:
Yaw velocity and lateral acceleration recorded by the yaw rate sensor for lateral and longitudinal
acceleration
Steering wheel angle recorded by the steering angle sensor
Brake pressure, recorded by left front pressure sensor (A7/3b3), right front pressure sensor (A7/3b4), left
rear pressure sensor (A7/3b5), right rear pressure sensor (A7/3b6) (except model 221 as of YoM 09
model refinement package) and by the front axle brake pressure sensor (A7/3b1) in the traction system
hydraulic unit
Transmission shift stage, provided by the ETC [EGS] control unit (N15/3) (with transmission 722.6) or
fully integrated transmission control unit (VGS) (Y3/8n4) (with transmission 722.9) on the drive train
CAN (CAN C) and passed on by the central gateway control unit (N93) to the chassis CAN
The side-slip angle (angle between vehicle longitudinal axis and direction of movement of the vehicle's center
of gravity) is calculated using the yaw rate (speed of vehicle rotation about vertical axis of vehicle).
The yaw rate, the lateral acceleration and the turning angle of the front wheels (calculated from the steering
wheel angle) can be used to determine the lateral forces on the wheels.
The longitudinal forces at the wheels are calculated from the engine torque, transmission shift stage and brake
pressure. If the yaw angle velocity measured does not match the specified value or if the determined side-slip
angle is too large, the ESP control unit generates a signal for brake force build-up or reduction for the relevant
wheel. The resulting forces stabilize the vehicle.
A distinction is made between the following interventions:
Intervention in the case of oversteer
Intervention in the case of understeer
Intervention in the case of oversteer
If the vehicle begins to oversteer, brake pressure is built up at the outer front wheel. The resulting reduction in
lateral force at the outer front wheel generates a yawing moment which counteracts the tendency of the vehicle
to rotate inward. The vehicle speed decreases as a result of the brake force at the front wheel, which also
enhances stability.
Intervention in the case of understeer
If the vehicle understeers, the maximum possible lateral force at the front axle has been exceeded. This means
that the vehicle pushes itself over the front axle and toward the outer edge of the corner. If at this point the
driver depresses the accelerator pedal, the drive torque is first of all reduced. If this is not sufficient, brake
pressure is built up at the rear wheel on the inside of the curve.
Depending on the brake force, a torque is generated which causes the vehicle to rotate inward with a
simultaneous reduction in speed.
This has a considerable stabilizing effect.
To reduce the drive torque the ESP control unit transmits a signal via the chassis CAN to the CDI control unit
or to motor electronics control unit which thereupon reduces the engine power accordingly.
A pending shift operation is suppressed for the duration of control intervention.
For this the ESP control unit transmits the "Downshift suppression" signal on the chassis CAN. The CDI control
unit or the motor electronics control unit passes this on to the ETC [EGS] control unit or VGS control unit. The
ETC [EGS] control unit or VGS control unit suppresses any imminent shift operation.
EBD function sequence
EBD assists the driver in the partial braking area. Overbraking of the rear axle is prevented. Vehicle stability is
increased while braking in the curve, while if necessary the pressure at the rear wheel on the inside of the curve
is reduced or at the front wheel on the outside of the curve is increased.
ABS function sequence
ABS prevents the wheels from locking up when braking and as a result maintains the steerability and directional
stability and road adhesion during vehicle deceleration. If a locking wheel is detected by the ESP control unit on
the basis of the signals from the RPM sensors, the brake pressure is reduced at the appropriate brake cylinder
until the wheel begins to turn again.
ASR function sequence
ASR prevents the drive wheels from spinning while driving. In addition it causes improved driving stability for
increased traction potential over the entire speed range.
ASR is comprised of the following partial functions:
Function sequence - drive torque control
Function sequence - brake torque control
Function sequence for drive torque control
The ESP control unit records the spinning of the drive wheels via the signals from the RPM sensors.
Wheel spinning is countered by reduction of the drive torque. For this the ESP control unit transmits a signal for
drive torque reduction via the chassis CAN to the CDI control unit or to the motor electronics control unit
which reduces the engine power accordingly.
The system constantly checks whether the drive torque specified by the driver via the accelerator pedal sensor
can be allowed again e.g. due to improved road adhesion.
Function sequence - brake torque control
Selective interventions by the brake system at the spinning drive wheel means that the drive torque is
transmitted to the opposite drive wheel which is running normally.
Brake Assist (BAS) function sequence (model 221 up to 31.5.09 and model 216 up to 31.8.10)
BAS detects emergency braking situations by means of a rapid brake pedal operation via the BAS membrane
travel sensor (A7/7b1) and if necessary increases the brake pressure via the BAS solenoid valve (A7/7y1) in
order to achieve maximum possible deceleration.
The ESP control unit evaluates the increase in pressure in the brake system and initiates an emergency stop if a
certain triggering threshold is exceeded.
Brake Assist (BAS) function sequence (model 221 as of 1.6.09, model 216 as of 1.9.10)
BAS detects emergency braking situations by means of a rapid brake pedal operation via the front axle brake
pressure sensor (A7/3b1) in the traction system hydraulic unit and if necessary increases the brake pressure via
the high pressure and return flow pump (A7/3m1) of the traction system hydraulic unit in order to achieve
maximum possible deceleration. The ESP control unit evaluates the increase in pressure in the brake system and
initiates an emergency stop if a certain triggering threshold is exceeded.
On the basic system with brake light switch (S9/1), the following components on the BAS brake booster are
not needed:
BAS diaphragm travel sensor
BAS solenoid valve
Tire pressure loss warning function sequence (except code (475) Tire pressure monitor (Premium))
The tire pressure loss warning (RDW) system detects a significant pressure loss at a tire and then displays a
warning message in the instrument cluster.
Functional principle of tire pressure loss warning system:
On tires, there is a link between the rolling circumference and the tire inflation pressure. This link is evaluated
by performing a relative comparison of the wheel speeds.
Furthermore, the following ESP sensor signals recorded by the yaw rate sensor for lateral and longitudinal
acceleration are included in the calculation:
Lateral acceleration
Turn rate
Wheel moments
BAS release switch (A7/7s1)
Properties of function:
Detection of significant pressure loss at a wheel.
Active from a minimum speed (v > approx. 15 km/h).
Active during straight-ahead travel, lateral acceleration less than 1.5 m/s2 , during uniform driving,
longitudinal acceleration less than 1 m/s2 .
Inactive during control interventions (ABS, ASR, ESP).
Inactive with high drive torque and during braking.
Partially active with a low coefficient of friction, on rough roads, snow chains.
The tire pressure loss warning (without position indication) takes place after a few minutes of driving. In
the subsequent ignition sequences, a reminder message is displayed, provided that the system has not
been reactivated.
The tire pressure loss warning system has to be reactivated in the instrument cluster's menu if tires or
wheels are changed or the tire inflation pressures are changed. This erases any pending warning
messages.
After reactivation by the driver, the system automatically teaches in the new conditions. The teach-in
process takes roughly 10 min per speed interval. There are 7 intervals. The system is able to issue
warnings in the intervals which have been taught in (and the directly adjacent intervals).
Uniform pressure loss at all 4 tires (e.g. due to diffusion) cannot be detected.
Incorrect operation by the driver cannot be detected (e.g. reactivation despite significantly low pressure).
Speed-sensitive power steering (SPS) function sequence
The task of speed-sensitive power steering is to adjust the steering assistance depending on the vehicle speed.
This is achieved by a current-controlled SPS solenoid valve (Y10) on the steering gear which is actuated by the
ESP control unit. Greater steering assistance is provided at low vehicle speeds and less steering assistance is
provided at high vehicle speeds. The ESP control unit receives the vehicle speed signal from the instrument
cluster via the chassis CAN.
Additional function requirements for HOLD function (starting-off aid)
Transmission selector lever not in position "P"
Vehicle not secured with parking brake
Incline detected with vehicle at standstill
HOLD function sequence (starting-off aid)
The HOLD function assists the driver when starting off on a hill or during waiting times in traffic. The HOLD
function is activated by briskly depressing the brake pedal at a standstill.
The activation of the HOLD function is displayed to the driver by the message "HOLD" in the instrument
cluster.
The adjusted brake pressure is held until the driver again presses with a certain pressure on the brake pedal or
starts off.
The intelligent servo module for DIRECT SELECT (A80) transmits the transmission selector lever position on
the drive train CAN. The CDI control unit or ME-SFI [ME] control unit passes this status on to the ESP control
unit via the chassis CAN.
The electric parking brake controller unit (A13) transmits the status of the parking brake via the front end CAN
(CAN G). The central gateway control unit passes this status on to the ESP control unit via the chassis CAN.
The yaw rate sensor for lateral and longitudinal acceleration transmits information on a detected incline to the
ESP control unit via the vehicle dynamics CAN (CAN H).
Furthermore, the HOLD function will be deactivated automatically under the following conditions:
Operation of parking brake
Change of transmission selector lever position into position "P"
Under the following conditions the HOLD function is switched off automatically before the driver leaves the
vehicle:
Driver door opened with "Circuit 15 ON" and seat belt not fastened (message on multifunction display)
The status "Circuit 15 ON" is sent to the chassis CAN by the EZS control unit (N73).
On model 216 the status of the driver door is defined via the status of the left rotary tumbler switch (A85s1)
which is read in by the left door control unit (N69/1).
On model 221 the status of the driver door is defined via the status of the left front rotary tumbler switch
(A85s1) which is read in by the left door control unit (N69/1).
The status of the driver door is transmitted in each case on the interior CAN (CAN B). The central gateway
control unit passes this status on to the ESP control unit via the chassis CAN.
Additional function requirements - precharging
No active control intervention function by ABS, ASR or ESP
ESP not switched passive
Precharging function sequence
The precharging function applies the brake pads to the brake disk in the event of a supposed emergency braking
situation being detected
The clearance between the brake pad and brake disk is thus compensated before the driver operates the brake.
The response time of the brake is improved and therefore contributes to the reduction in braking distance.
Emergency braking detection takes place via the release gradient of the accelerator pedal sensor, which is based
on the (Controller Area Network (data bus/CAN Bus) (CAN) signal) "Accelerator pedal position".
Additional function requirements - dry braking
No active control intervention function by ABS, ASR or ESP
Windshield wiper active
The front SAM control unit with fuse and relay module (N10/1) transmits the status "windshield wiper
active" on the interior CAN. The central gateway control unit passes this status on to the ESP control unit via
the chassis CAN.
Dry braking function sequence
Dry braking assists the performance capability of the front axle brake under wet conditions. The water film is
wiped off the brake disk by cyclically applying the brake pads for t = 0.5 s with a brake pressure p < or = bar.
This improves the response time of the brake.
If a rapid release of the accelerator pedal is detected, the system assumes that the driver intends to brake. The
precharging function is activated and a brake pressure of p = 3 to 4 bar is requested.
Function sequence for switching ASR and ESP to passive mode (model 216 and model 221 up to 31.5.09)
The ASR and ESP functions can be switched passive by operating the ESP OFF switch (S6/2s11) in the cockpit
switch group (S6/2).
The upper control panel control unit (N72/1) reads in the status of the ESP OFF switch via the instrument panel
LIN (LIN 1) and transmits this status on the interior CAN. The central gateway control unit passes this status on
to the ESP control unit via the chassis CAN. If the functions are switched passive, the ESP warning lamp lights
up in the instrument cluster. The control thresholds are raised when the ASR and ESP functions are switched
passive.
ABS cannot be deactivated. ESP is always active during a brake application.
Function sequence for switching ASR and ESP to passive mode (model 216 and model 221 as of 1.6.09)
In driving mode the ASR and ESP functions can be switched passive with the left multifunction steering wheel
button group (S110) and right multifunction steering wheel button group (S111) via the "Assist" menu and
"ESP" submenu in the instrument cluster.
The IC receives control signals from the multifunction steering wheel (MFL) in the following way:
Steering LIN (LIN E1)
Steering column tube module (N80)
Chassis CAN
Central gateway control unit
Central CAN (CAN F)
The instrument cluster then transmits the request "ESP_OFF" to the central gateway control unit. The central
gateway control unit passes this on to the ESP control unit via the chassis CAN.
If the functions are switched passive, the ESP warning lamp lights up in the instrument cluster. The control
thresholds are raised when the ASR and ESP functions are switched passive.
ABS cannot be deactivated. ESP is always active during a brake application.
PRE-SAFE® system, PRE-SENSE function sequence, (model 221 as of 1.6.09, model 216 as of 2.9.10)
The PRE-SAFE® system, PRE-SENSE is activated in critical driving conditions, i.e. in a potential accident
situation. The goal is to create the most favorable conditions possible for the occupants during the expected
accident by activating the functions before the actual impact. The PRE-SAFE® system, PRE-SENSE is
integrated in the ESP control unit. If the ESP control unit detects one of the following situations, the PRE-
SAFE® system, PRE-SENSE is activated:
Panic after-braking (the driver's braking wish is greater than physically possible)
Pronounced oversteer (breaking away of vehicle rear in combination with severe ESP control intervention
functions)
Severe understeer (the vehicle leans heavily over the front wheels for an extensive period))
Rapid steering movements at high speeds, which suggest a shock reaction from the driver and may lead to
vehicle instability
The PRE-SAFE® system, PRE-SENSE is described in a separate function description.
Additional function requirements for the Hill Start Assist
Transmission not in position "N"
Vehicle not secured with parking brake
Incline detected with vehicle at standstill
Hill Start Assist function sequence
When starting off Hill Start Assist prevents the vehicle rolling back opposite to the gear range engaged during
the time it takes for the driver to move his/her foot from the brake pedal to the accelerator pedal.
The function is triggered automatically, if when the vehicle is at a standstill an incline is detected via the yaw
rate sensor for lateral and longitudinal acceleration which would cause rolling in the opposite direction to the
gear range engaged.
The data from the yaw rate sensor for lateral and longitudinal acceleration is read in by the ESP control unit via
the vehicle dynamics CAN. For this the brake pressure applied by the driver is maintained by the traction
system hydraulic unit for a period of t = 0.8 to 1.5 s and switched off by a sufficiently large starting off torque.
The intelligent servo module for DIRECT SELECT transmits the transmission selector lever position on the
drive train CAN. The CDI control unit or ME-SFI [ME] control unit passes this status on to the ESP control unit
via the chassis CAN.
The electric parking brake controller unit transmits the status of the parking brake on the front end CAN.
The central gateway control unit passes this status on to the ESP control unit via the chassis CAN.
Failed Boost function sequence (with code (Z07) Highest protection, model 216.3 and model 221 with
code (B03) ECO start/stop function)
The Failed Boost function serves to safeguard a sufficiently high brake pressure level in the system in the event
of a shortage of brake boosting by the BAS brake booster.
If, during brake application by the driver, the front axle brake pressure sensor (with engine 275 with code (Z07)
Highest protection) or the brake vacuum sensor (B64/1) (model 216.3 and model 221 with code (B03) ECO
start/stop function) detects that the BAS brake booster is not providing any driver assistance, the Failed Boost
function actuates the high-pressure and return flow pump (A7/3m1) to ensure the driver receives support. On
engine 275 with code (Z07) Highest protection, hydraulic amplification is provided with an appropriate
amplification factor.
Over Boost function sequence (model 216.3 and model 221 with code (B03) ECO start/stop function)
If the brake booster reaches the limits of its pneumatic boost, the brake pressure is increased through actuation
of the high pressure and return flow pump, thereby ensuring that the usual level of brake boost is then provided.
The function sequence for Failed Boost and the function sequence for Over Boost differ in terms of the
triggering thresholds and hydraulic boost.
Function sequence - Fading Brake Support
The Fading Brake Support function assists the driver when the brakes overheat and thus the brake force
decreases.
With extreme overheating a message is output via the multifunction display. The fading brake support function
serves to provide additional driver assistance when the brake system is hot in order to achieve the best possible
deceleration in this operating case as well.
During extreme overheating, a driver information message can also be provided via the multifunction display of
the instrument cluster. Overheating (fading) is detected based on a brake disk temperature model. If a particular
threshold is exceeded fading is assumed, "Fading Brake Support" becomes active. In addition this function can
also be activated by comparison of the brake pressure level with the actual deceleration or by direct request
through the ABS system.
Air gap reduction function sequence
After dynamic cornering is detected (evaluation of yaw rate by yaw rate sensor for lateral and longitudinal
acceleration), the air gap reduction function applies the brake pads to the front axle brake disks. Consequently
the clearance between the brake pad and brake disk is compensated in order to receive the required braking
power at the corresponding wheel as quickly as possible in the event of any ESP intervention by the brake
system.
Function sequence - standstill coordinator
The standstill coordinator requests the changeover of the vehicle into a safe condition when the support systems
are activated, such as HOLD function, and the driver status is not clear.
The driver status is deemed to be unclear, if the driver door is open and the belt buckle of the drive seat belt is
not inserted into the belt lock. The plugging in of the seat belt tongue into the seat belt buckle is detected by the
driver seat belt buckle switch and seat belt reminder warning switch (S68/1). The restraint systems control unit
(N2/7) reads in the status of the driver seat belt buckle switch and seat belt reminder warning switch directly
and transmits this to the ESP control unit via the chassis CAN.
The support systems cannot be operated.
System fault display function sequence
The ESP control unit carries out system tests continuously while driving. If malfunctions or faults are detected,
the ESP control unit transmits corresponding information on the chassis CAN. The central gateway control unit
passes these on to the instrument cluster via the central CAN.
The driver is informed about the system status or about faults occurring by the following displays:
ABS indicator lamp
ESP warning lamp
Messages in the multifunction display in the instrument cluster
In order to avoid malfunction due to too low fill level of brake fluid, the brake fluid control switch (S11)
monitors the fill level in the brake fluid reservoir. The status of the brake fluid control switch is read in directly
by the front SAM control unit and provided on the interior CAN. The central gateway control unit passes this on
to the ESP control unit via the chassis CAN. A basic brake function is always available in the event of failure of
the ESP control unit.
Electrical function schematic forModel 216 PE42.47-P-2050-
Adaptive Brake (ABR) Up to model year 2010 /modification year 09 97CAB
Model 221
PE42.47-P-2050-
Up to model year 2010 /YoM 09 model
97SAB
refinement package
Model 216 PE42.47-P-2050-
As of model year 2010 /modification year 09 97CAC
Model 221
PE42.47-P-2050-
As of model year 2010 /YoM 09 model
97SAC
refinement package
Model 216
Up to model year 2010 /modification year 09
Adaptive Brake (ABR) location of GF42.47-P-0001-
Model 221
components 02LE
Up to model year 2010 /YoM 09 model
refinement package
Model 216
As of model year 2010 /modification year 09
As of model year 2010 /YoM 09 model 02LEA
refinement package
Model 216
Up to model year 2010 /modification year 09
Adaptive Brake (ABR) block GF42.47-P-0001-
Model 221
diagram 03LE
Up to model year 2010 /YoM 09 model
refinement package
Model 216
As of model year 2010 /modification year 09 GF42.47-P-0001-
Model 221 As of model year 2010 /YoM 09 03LEA
model refinement package
Overview of system components, GF42.47-P-
Adaptive Brake (ABR) 9997LE
ADAPTIVE BRAKE (ABR), FUNCTION - GF42.47-P-0001SX
MODEL 221.0 /1, 216.3 up to Model Year 08 /modification year 07
Function of Adaptive Brake (ABR)
ABR assists the driver in dangerous situations which occur suddenly and thus serves active safety.
ABR contains the following functions:
Electronic Stability Program (ESP)
Antilock brake system (ABS)
Acceleration Slip Regulation (ASR)
Brake Assist (BAS)
Electronic brake force distribution (EBV)
Electronic Traction System (ETS)
as well as additional functions:
HOLD
Precharging
Dry braking
Hill start assist
Failed boost function (on engine 275)
Fading brake support
Air gap reduction (Airgap)
Standstill coordinator
Trailer stabilization
The ESP control unit (N47-5) evaluates the data from the following components to record the current driving
situation:
BAS diaphragm travel sensor (A7/7b1)
BAS travel differential sensor (A7/7b2) (with engine 275)
BAS release switch (A7/7s1)
Yaw rate, lateral and longitudinal acceleration sensor (B24/15)
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
Steering angle sensor (N49)
Pressure sensors in the traction system hydraulic unit (A7/3)
ABS
ABS prevents the wheels from locking up when braking and as a result maintains the steerability and directional
stability and road adhesion during vehicle deceleration.
ASR/ETS
ASR/ETS prevents the driven wheels from spinning when the vehicle is being driven. In addition it causes an
improved directional stability and road adhesion with an increased traction potential over the entire vehicle
speed range.
ESP
ESP prevents breakaway when the vehicle oversteers or understeers. It ensures that the vehicle does not deviate
from the course specified by the driver (within physical limits). Brake forces are produced selectively at the
individual wheels to correct any deviations. Furthermore a torque reduction takes place to increase directional
stability and road adhesion.
BAS
BAS detects emergency braking situations by means of a rapid brake pedal operation and increases the brake
pressure if necessary via the BAS solenoid valve (A7/7y1).
BAS PLUS
BAS Plus increases the brake pressure depending on the speed of the brake pedal operation and the distance of
the vehicle driving in front.
EBD (Electronic brake force distribution)
EBV assists the driver in the partial braking area. It prevents overbraking of the rear axle and increases vehicle
stability when braking in the curve, by reducing the pressure at the rear wheel on the inside of the curve or
increasing it at the front wheel on the outside of the curve as required.
HOLD
HOLD assists the driver when starting off on a hill or when waiting in traffic. HOLD is activated by briskly
continuing to depress the brake pedal at a standstill. The adjusted brake pressure is maintained until the driver
depresses the brake pedal again rapidly or starts off.
With and the additional HOLD function is deactivated by coding in the ESP control unit. This
takes place by the coding information of the central gateway control unit (N93).
Precharging
Precharging already builds up brake pressure when the accelerator pedal sensor (B37) is released suddenly in
order to reduce the response time for a brake application which possibly occurs subsequently (e.g. through
BAS).
Dry braking
Dry braking assists the performance of the brake in the wet. The water film is wiped off the brake disk by
applying the brake linings in cycles. This improves the response time of the brake.
Hill start assist
Hill start assist prevents the vehicle from rolling back when starting off on a hill during the time it takes for the
driver to move his foot from the brake pedal to the accelerator pedal. For this the brake pressure applied by the
driver is maintained for a period of 0.8 to 1.5 s by the traction system hydraulic unit and switched off by a
suitably large starting off torque.
Failed boost function
The failed boost function serves to ensure a sufficiently high brake pressure level in the system with a shortage
of brake boost through the BAS brake booster (A7/7).
Fading brake support
Fading brake support assists the driver when the brake is overheated and thus the brake force is reduced. With
extreme overheating a message can appear in the multifunction display (A1p13) of the instrument cluster (A1).
Air gap reduction (Airgap)
Airgap reduces the air gap between the brake disk in order to possibly accelerate the following ASR or ESP
pressure buildups.
When the assistance systems are activated such as HOLD and an unclear driver status the standstill coordinator
requests the changeover of the vehicle into a secured condition.
Trailer stabilization
The trailer stabilization reduces any vehicle combination instability which may occur.
Function statuses
The function scope can vary depending on the signals received. The following table represents the function
shutdown due to component failure or defect.
Component failure
Function Pressure more
Steering BAS
shutoff Position Release sensors of the 1 RPM than 1
angle/turn solenoid CAN
sensor switch traction system sensor RPM
rate sensor valve
hydraulic unit sensor
ESP/BAS X X X X X X X X
ASR/ETS X X X X X X
ABS X X
EBD (Electronic
brake force X
distribution)
System faults
The driver is informed about the system condition or about faults by messages in the multifunction display or by
the lighting up of the ABS indicator lamp (A1e17), the ESP warning lamp (A1e41) or the ESP indicator lamp
(A1e42) in the instrument cluster.
The status of the brake fluid indicator switch (S11) is read in by the front SAM control unit with fuse and relay
module (N10/1) and transmitted to the central gateway control unit via the interior CAN.
The central gateway control unit transmits the information about the chassis CAN to the ESP control unit. When
the brake fluid level is too low the driver is informed via the brake fluid warning lamp (A1e7).
In the event of a failure of the ESP control unit a basic brake function without ABS is always available.
Stop lamp actuation
The stop lamps light up during a brake application.
These are actuated by the rear SAM control unit with fuse and relay module (N10/2). The ESP control unit
transmits discreet signal and a CAN signal for stop lamp actuation to the rear SAM control unit. The CAN-
signal is routed from the central gateway control unit from the chassis CAN on the interior CAN to the rear
SAM control unit.
Adaptive Brake (ABR) location of components GF42.47-P-0001-02SX
Adaptive Brake (ABR) block diagram GF42.47-P-0001-03SX
Brake assistant (BAS), function GF42.31-P-0001SX
Electronic stability program (ESP) function GF42.45-P-0001SX
Additional functions, Adaptive Brake (ABR), function GF42.47-P-2000SX
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, ADAPTIVE BRAKE (ABR) - GF42.47-P-
0999LE
MODEL 216.3, 221.0 /1 (except, 221.095 /195) as of Model Year 2009 /CY 08
GF42.47-P-
Adaptive brake (ABR), function
0001LE
Model 216
Up to model year 2010 /CY 09
Adaptive Brake (ABR) location of GF42.47-P-0001-
Model 221
components 02LE
Up to model year 2010 /CY 09 model
refinement package
Model 216
As of model year 2010 /CY 09
GF42.47-P-0001-
Model 221
02LEA
As of model year 2010 /CY 09 model
refinement package
Model 216
Up to model year 2010 /CY 09
GF42.47-P-0001-
Adaptive Brake (ABR) block diagram Model 221
03LE
Up to model year 2010 /CY 09 model
refinement package
Model 216
As of model year 2010 /CY 09
GF42.47-P-0001-
Model 221
03LEA
As of model year 2010 /CY 09 model
refinement package
Overview of system components, GF42.47-P-
Adaptive Brake (ABR) 9997LE
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF ADAPTIVE BRAKE (ABR) - GF42.47-
P-0999SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Adaptive brake (ABR), function GF42.47-P-0001SX
GF42.47-P-0001-
Adaptive Brake (ABR) location of components
02SX
Adaptive Brake (ABR) block diagram 03SX
Braking Assistant (BAS) - Operation GF42.31-P-0001SX
Electronic stability program (ESP) function GF42.45-P-0001SX
Additional functions, adaptive brake (ABR), function GF42.47-P-2000SX
Overview of system components, Adaptive Brake (ABR), component
GF42.47-P-9998SX
description
ADDITIONAL FUNCTIONS, ADAPTIVE BRAKE (ABR), FUNCTION - GF42.47-P-2000SX
MODEL 221.0 /1, 216.3 up to Model Year 8
The following additional functions are integrated in the Adaptive Brake (ABR) and are coordinated by the ESP
control unit (N47-5):
HOLD
Precharging
Dry braking
Hill start assist
Failed boost function (on engine 275)
Fading brake support
Air gap reduction (Airgap)
Standstill coordinator
Trailer stabilization
Additional function
HOLD
HOLD makes life easier for the driver optionally:
When starting off uphill
When maneuvering on mountain roads
When waiting in traffic
With and the additional HOLD function is deactivated by coding in the ESP control unit. This
takes place by the coding information of the central gateway control unit (N93).
Function description of HOLD
When the vehicle is at a standstill HOLD can be switched on by actuating the brake pedal. The actuation of the
brake pedal is detected via the BAS diaphragm travel sensor (A7/7b1). The vehicle is then held in position
without any further actuation of the brake pedal. The braking effect is canceled when starting off by pressing
the accelerator, via the accelerator pedal sensor (B37).
Switching on HOLD
HOLD can be switched on when
the vehicle is stationary
the electronic parking brake is not closed
the trunk lid is closed with DIRECT SELECT gear selector switch (S16/13) in position "R"
always when the seat belt is worn or the transmission is shifted out of position "P" when the driver door is
closed
the engine hood is closed
the engine be running
the gear selector switch is not in position "P"
Histrionic Plus (with code (233) Histrionic Plus) is not active
Actuate the brake pedal, then depress the brake pedal briskly again until the message "HOLD" appears in the
multifunction display (A1p13). The vehicle is held automatically when the brake pedal is released afterwards.
Switching off HOLD
HOLD is switched off automatically when
the accelerator pedal sensor (B37) is actuated
the gear selector switch is switched into position "P"
the brake pedal is actuated again until the display "HOLD" disappears in the multifunction display
the parking brake is actuated via the electric parking brake switch (S76/15)
Histrionic Plus (with code (233) Histrionic Plus) is activated
Driver status
A belt tongue inserted into the seat belt buckle or shifting out of position "P" when the driver door is closed is
interpreted as the presence of the driver. When the driver door is open and a belt tongue is not inserted into the
seat belt buckle the driver status is not clear and the driver is thus presumed absent. HOLD is not activated
when the driver status is not clear.
The status of the seat belt buckle is detected by the restraint systems control unit (N2/7) and the driver seat belt
buckle and seat belt warning switch (S68/1). The opening of the driver door on model 216 is detected by the left
door control unit (N69/1) and the left rotary tumbler switch (A85s1) and in model 221 by the left front door
control unit and the left front rotary tumbler switch (A85s1).
Additional function Precharging
The function is permanently active and assists the performance of the brake system by already applying the
brake linings (precharging) when the accelerator pedal sensor is released. As a result the response time of the
brake is reduced and the stopping distance reduced during emergency stops.
Function description of precharging
To reduce the response time during panic braking the air gap of the wheel brake system is already overcome
when the accelerator pedal sensor is overcome and the brake linings are applied. If the driver subsequently
depresses the brake pedal, a spontaneous braking effect is achieved and thus the stopping distance is reduced. In
the process the release gradient of the accelerator pedal sensor is used to detect the rapid braking requirement.
The precharging process is terminated after a short time if the driver does not apply the brake.
Determination of the triggering threshold for precharging
If the boundary conditions are met, the associated release gradient is determined each time the accelerator pedal
sensor is released completely. The triggering threshold depends on the pedal travel. With small pedal travels
before the pedal is released a smaller pedal release gradient is needed in order to activate precharging, than with
large pedal travels before the pedal is released.
Precharging is not active when:
ESP faults are present
Control intervention functions take place through ABS, ESP or ASR
Faults are present in the engine control
CAN faults are present
Additional function
Dry braking
Function description of dry braking
Dry braking is activated as soon as the windshield wiper leaves its basic position. Dry braking itself is only
carried out at the front axle for a few seconds with a very small brake pressure (< 1 bar).
Hill start assist
In the case of starting off uphill (longitudinal gradient) when changing from the brake to the accelerator pedal
sensor a delayed depressurization is carried out in the brake system in order to prevent the vehicle rolling back
unintentionally.
A longitudinal gradient is detected by the ESP control unit via the turn rate, lateral and longitudinal acceleration
sensor (B24/15)
The function is permanently active and assists the performance of the brake system in the wet. The response
time of the brake is reduced by cyclical dry braking of the brake disks.
Hill start assist is not active when
the vehicle is driven on the level or downhill
the transmission is in position "N"
the parking brake is actuated
ESP faults are present
Additional function
Failed boost function
In combination with signals from the BAS travel differential sensor (A7/7b2) (only with engine 275) the failed
boot function serves to ensure a sufficiently high brake pressure level in the system in the event of a shortage of
brake boost through the BAS brake booster (A7/7).
Function description of failed boost function
If during a brake application by the driver it is detected by the BAS travel differential sensor and the ESP
control unit that the BAS brake booster does not provide adequate driver assistance, then failed boost ensures
driver assistance by hydraulic brake boost.
Additional function
Fading brake support
The fading brake support function serves to provide additional driver assistance when the brake system is hot in
order to achieve the best possible deceleration in this operating case as well. In the event of a particularly severe
heating up an information message is shown in the multifunction display of the instrument cluster (A1).
Function description of fading brake support
Heating up is determined based on a temperature model of the brake disk. If a particular threshold is exceeded
fading is assumed, fading brake support becomes active. In addition this function can also be activated by the
comparison of the brake pressure level with the actual deceleration or by the direct request through the antilock
brake system (ABS).
Additional function
Air gap reduction (Airgap)
Airgap reduces the air gap between the brake disk and lining in order to speed up any subsequent brake
applications through ASR or ESP.
Additional function
Standstill coordinator
When the support systems are active when the vehicle is stationary the standstill coordinator promotes the
actuation of the electric parking brake (EFB) or shifting into position "P" by the Intelligent servo module for
DIRECT SELECT (A80). This changes over the vehicle into a secured condition.
The following event lead to actuation of the electric parking brake controller unit (A13):
Engine hood open
Trunk lid open and reverse gear engaged
The following events lead to actuation of the EFB and the Intelligent servo module for DIRECT SELECT:
Faults in a security system or the ESP control unit
ABR overload protection system
Driver presence unclear
Critical condition of on-board electrical system
Engine OFF
Additional function
Trailer stabilization
Trailer stabilization reduces vehicle combination swinging by specific brake interventions in order to stabilize
the vehicle and trailer.
Instrument cluster, component A1 GF54.30-P-
description Model 221 6000SX
BAS brake booster, component GF42.31-P-
A7/7
description 4004SX
Electric parking brake controller unit, GF42.20-P-
A13
component description 5000SX
Intelligent servo module (ISM) GF27.19-P-
A80
component description 4015SXA
Model 221 with transmission 722.6 GF27.19-P-
Model 221 with transmission 722.9 4015SX
Yaw rate and lateral acceleration sensor, GF42.45-P-
B24/15
component description 5120SX
Accelerator pedal sensor, component GF30.20-P-
B37
description 2010SX
Model 221 with engine 642 Model 221 with GF30.20-P-
engine 272.965, 273.961 2010V
Restraint systems control unit, N2/7 GF91.60-P-
component description Model 221 4048SX
GF42.45-P-
ESP control unit, component description N47-5
5118SX
Driver-side front door control unit, N69/1 GF72.29-P-
component description Model 216 6000SC
GF72.29-P-
Model 221
6000SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
Gear selector switch, component S16/13 GF27.19-P-
description Model 221 with transmission 722.6 5148SXA
GF27.19-P-
Model 221 with transmission 722.9
5148SX
Seat belt buckle switch, component S68/1 GF91.60-P-
description Model 221 4045SX
Electric parking brake switch, component GF42.20-P-
S76/15
description 5001SX
OVERVIEW OF SYSTEM COMPONENTS, ADAPTIVE BRAKE (ABR) - GF42.47-P-9997LE
MODEL 216.3, 221.0 /1 (except, 221.095 /195) as of Model Year 2009 /CY 08
GF54.30-P-
Instrument cluster, component description A1
6000LE
Electric parking brake controller unit, component GF42.20-P-
A13
description 5000LE
Component description for intelligent servo A80 GF27.19-P-
module for DIRECT SELECT With transmission 722.6 4020ACS
A80
GF27.19-P-
For transmission 722.9 except
4020AHS
transmission 722.950
Yaw rate, lateral and longitudinal acceleration GF42.45-P-
B24/15
sensor, component description 4810LE
Restraint systems control unit, component GF91.60-P-
N2/7
description 4048LE
N3/9
GF07.16-P-
Component description for CDI control unit Model 221
6000OA
With engine 629.9
N3/9
GF07.16-P-
Model 221
6000OHL
With engine 642.9
ME-SFI [ME] control unit, component N3/10 GF07.61-P-
description With engine 156 6000MAS
N3/10
Model 221 GF07.61-P-
With engine 272 except engine 6000MIS
272.974
N3/10 GF07.61-P-
With engine 273 6000MLS
With engine 275 6000MOS
Front SAM control unit with fuse and relay GF54.21-P-
N10/1
module, component description 6070LE
Electronic transmission-control unit, component N15/3 GF27.60-P-
description With transmission 722.6 5164ACS
GF42.45-P-
ESP control unit, component description N47-5
5118LE
N69/1 GF72.29-P-
Left door control unit, component description
Model 216 4124LA
Left front door control unit, component N69/1 GF72.29-P-
description Model 221.0/1 4141LE
N69/1
Model 221.1 GF72.29-P-
With code (Z07) Maximum 4141LES
protection
Upper control panel control unit, component GF54.21-P-
N72/1
description 6040LE
GF80.57-P-
Component description for EIS [EZS] control unit N73
6003LE
Component description for steering column tube GF54.21-P-
N80
module 6050LE
Central gateway control unit, component GF54.21-P-
N93
description 4170LE
Fully integrated transmission control unit, Y3/8n4 GF27.60-P-
component description With transmission 722.9 5165AHS
Table of contents for function description, GF42.47-P-
adaptive brake (ABR) 0999LE
OVERVIEW OF SYSTEM COMPONENTS, ADAPTIVE BRAKE (ABR), COMPONENT
DESCRIPTION - GF42.47-P-9998SX
MODEL 221.0 /1, 216.3 up to Model Year 8
GF54.30-P-
Instrument cluster, component description A1 Model 221
6000SX
GF42.31-P-
BAS brake booster, component description A7/7
4004SX
Electric parking brake controller unit, component GF42.20-P-
A13
description 5000SX
A80
GF27.19-P-
Intelligent servo module (ISM) component description Model 221 with transmission
4015SXA
722.6
Model 221 with transmission GF27.19-P-
722.9 4015SX
Yaw rate and lateral acceleration sensor, component GF42.45-P-
B24/15
description 5120SX
B37 GF30.20-P-
Accelerator pedal sensor, component description
Model 221 with engine 642 2010SX
Model 221 with engine
F30.20-P-2010V
272.965, 273.961
GF42.45-P-
Wheel RPM sensor, component description L6/1, L6/2, L6/3 and L6/4
5134SX
N2/7 GF91.60-P-
Restraint systems control unit, component description
Model 221 4048SX
N3/9 GF07.16-P-
CDI control unit component description
Model 221 with engine 642 6000SX
N3/10
GF07.61-P-
ME-SFI [ME] control unit, component description Model 221 with engine
6000V
272.965 and 273.961
N3/10
GF07.61-P-
ME-SFI control unit, location/task/design/ function Model 221 with engine
5000M
275.953/982
Driver-side SAM control unit with fuse and relay GF54.21-P-
N10/1
module, component description 6010SX
Rear SAM control unit with fuse and relay module, GF54.21-P-
N10/2
component description 6030SX
N15/3
GF27.19-P-
ETC [EGS] control unit component description Model 221 with transmission
4018G
722.6
GF42.45-P-
ESP control unit, component description N47-5
5118SX
GF42.45-P-
Steering angle sensor, component description N49
5107SX
Driver-side front door control unit, component N69/1 GF72.29-P-
description Model 216 6000SC
GF72.29-P-
Model 221
6000SX
Upper control panel control module component GF54.21-P-
N72/1
description 6040SX
GF54.21-P-
Steering column module component description N80
6050SX
GF54.21-P-
Central gateway control unit, component description N93
4170SX
GF42.45-P-
ESP Off switch, component description S6/2s11
5121SX
S16/13
GF27.19-P-
Gear selector switch, component description Model 221 with transmission
5148SXA
722.6
Model 221 with transmission GF27.19-P-
722.9 5148SX
S68/1 GF91.60-P-
Seat belt buckle switch, component description
Model 221 4045SX
GF42.20-P-
Electric parking brake switch, component description S76/15
5001SX
Y3/8n4
GF27.19-P-
VGS control unit, component description Model 221 with transmission
4016SX
722.9
Table of contents for function description of adaptive GF42.47-P-
brake (ABR) 0999SX
BRAKES
Brakes - Pneumatic System - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY
BRAKES - AH43.00-Z-9999AZ
MODEL all
Notes on brake servo MODEL 129, 140, 168, 170, 202, 203, 208, 209, 210, 463 AH43.20-P-0001-01A
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: BRAKES - PNEUMATIC SYSTEM AND
AUXILIARY BRAKES - AR43.00-Z-9221AA
MODEL 221
AR43.10-P-
Checking brake booster MODEL 216.### 1# MODEL 221.### 1#
0325SX
AR43.10-P-
Checking check valve MODEL 216.### 1# MODEL 221.### 1#
0023SX
AR43.10-P-
Remove/install brake booster MODEL 216.### 1# MODEL 221.### 1#
0350SX
Remove/install brake booster AR43.10-P-
MODEL 216, 221...
vacuum line 0355SX
Remove/install brake booster AR43.10-P-
MODEL 221.095 /195 with ENGINE 272.974
vacuum line 0355SXH
MODEL 166, 204, 207, 212, 218, 221 with AR43.05-P-
Remove/install vacuum pump
ENGINE 651 1320CD
Remove/install vacuum pump MODEL 212, 218, 221 with ENGINE 642.8 AR43.05-P-1320EO
AR43.05-P-
Remove/install vacuum pump MODEL 221 with ENGINE 276
1320MMA
AR43.05-P-
Remove/install vacuum pump MODEL 216, 221 with ENGINE 157, 278
1320MMB
AR43.05-P-
Remove/install vacuum pump MODEL 221 with ENGINE 629
1320SXD
AR43.05-P-
Remove/install vacuum pump MODEL 221.095 /195 with ENGINE 272.974
1320SXH
CHECKING CHECK VALVE - AR43.10-P-0023SX
MODEL 216.### 1#
MODEL 221.### 1#
Fig. 1: Checking Check Valve
Courtesy of MERCEDES-BENZ USA
Remove/install
Operate the brake pedal several times when the Until the vacuum in the brake
1
engine is switched off booster (A7/7) is reduced.
Connect vacuum tester (01) to brake booster AR43.10-P-
2
(A7/7) with test connection (02) 0024-01V
Fig. 2
Fig. 3
Checking
Start the engine and produce a vacuum of 0.75 Reduce vacuum >0.8 bar by
3 to 0.8 bar by pressing and suddenly releasing depressing the brake pedal several
the accelerator pedal times.
The vacuum must not reduce by
more than 0.2 bar within 30 seconds.
4 Turn off engine In the event of a vacuum loss >
0.2 bar: Replace vacuum line (1) with
check valve (2): ?
AR43.10-P-
Except model 221.095/ 195
0355SX
Model 221.095 / 195 If necessary: ?
0355SXH
AR43.10-P-
Check brake booster.
0325SX
5 Install in the reverse order
Fig. 2: Identifying Vacuum Tester (201 589 13 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 3: Identifying Test Connection (168 589 08 63 00)
Courtesy of MERCEDES-BENZ USA
CONNECT/DISCONNECT TESTING UNIT AT BRAKE BOOSTER - AR43.10-P-0024-01V
Fig. 4: Identifying Vacuum Tester (201 589 13 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 5: Identifying Test Connection (168 589 08 63 00)
Courtesy of MERCEDES-BENZ USA
Shown on model 171
1. Detach check valve (17) of vacuum line (8) from brake booster (1) (model 211, 219) or BAS brake
booster (A7/7) (except model 211, 219).
2. Connect test connection (031) between brake booster (1) (model 211, 219) or BAS brake booster
(A7/7) (except model 211, 219) and vacuum line (8).
3. Connect vacuum tester (030) to test connection (031).
Courtesy of MERCEDES-BENZ USA
CHECKING BRAKE BOOSTER - AR43.10-P-0325SX
MODEL 216.### 1#
MODEL 221.### 1#
Fig. 7: Checking Brake Booster
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value changed: Bleed screw to brake *BA42.10-P-1001-
29.7.09
caliper 10M
Model 216 except 216.377/379
Value changed: Bleed screw to brake *BA42.10-P-1001-
Model 221 except model
caliper 12M
221.077/177/179
Checking
Operate the brake pedal several times Until the vacuum in the brake booster
1
when the engine is switched off (A7/7) is reduced.
Connect vacuum tester (01) to brake AR43.10-P-
2
booster (A7/7) with test connection (02) 0024-01V
*BE43.10-P-
Brake booster diameter
1001-01A
*BE43.10-P-
Boost factor
1002-01A
Connect pressure tester (03) with (pitch, taper etc.), otherwise leakage and
3
connection fitting to brake caliper measurement errors will occur. Front axle:
Bleed screw to brake caliper *BA42.10-
Rear axle P-1001-10M
*BA42.10-
Bleed screw to brake caliper
P-1001-12M
Connect pedal force measuring
4
instrument (04) at brake pedal
If this vacuum is not attained or it drops
immediately, the seal between the brake
Start engine and by opening the throttle
5 booster (A7/7) and master brake cylinder
produce a vacuum of 0.75 to 0.80 bar
may be damaged or the check valve (2) in
the vacuum line (1) may be defective:?
AR43.10-P-
Check non-return valve.
0023SX
Remove/install master brake cylinder, AR42.10-P-
replace seal. 0300SX
In order to cover measurement errors
Apply the specified force to the brake (incorrect force on the brake pedal, incorrect
6 pedal and read off the line pressure on vacuum) and scatter of the measuring
the pressure tester (03) devices, a tolerance of ±10 bar on the
specified value is permissible.
The measured value must be within the *BE43.10-P-
value range. 1003-01A
Brake pipe line pressure
Detach vacuum tester (01) with test
7 connection (02) from brake booster Test connection Fig. 3
(A7/7)
Vacuum tester Fig. 2
Detach pressure tester (03) with
8
connection fitting from brake caliper
9 Remove pedal force meter (04)
10 Bleed brake system Only bleed the brake caliper to which the AR42.10-P-
pressure tester (03) was connected. 0010SX
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving by
running. Risk of injury caused by itself. AS00.00-Z-
contusions and burns during starting Wear closed and snug-fitting work clothes. 0005-01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
AR42.10-P-
11 Check brake system for leaks
0100-01V
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model Model
Number Designation
216 221
BE43.10-P-1001-
Brake booster dia. mm 265/265 265/265
01A
inches 9.5/95 9.5/95
BE43.10-P-1002-
Boost factor 8.9 8.9
01A
BE43.10-P-1003- Brake pipe line pressure Intake pipe vacuum Force on brake
27 to 37 27 to 37
01A pedal 50 N bar
0.75...0.8 bar 100 N bar 47 to 65 47 to 65
150 N bar 75 to 90 75 to 90
200 N bar 98 to 121 98 to 121
114 to 114 to
250 N bar
138 138
FRONT AXLE BRAKE CALIPER
Model 216 except model Model 221 except model
Number Designation
216.374/377/379 221.074/077/174 /177/179
BA42.10-P- Bleed screw to brake
14 14
1001-10M caliper Nm
REAR AXLE BRAKE CALIPER
Model 216 Model Model 221 except Model 221.074/
Number Designation except 216.374/ 216.374/ model 221.074/ 077/174/
377/379 377/379 077/174/ 177/179 177/179
BA42.10-P- Bleed screw to
14 23 14 23
1001-12M brake caliper Nm
Fig. 8: Identifying Test Connection (168 589 08 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 9: Identifying Vacuum Tester (201 589 13 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL BRAKE BOOSTER - AR43.10-P-0350SX
MODEL 216.### 1#
MODEL 221.### 1#
Fig. 10: Identifying Brake Booster Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
15.4.08 Operation step split up into in plugged in and screwed bolts Operation step 10.1, 10.2
Information on bolt availability added Step 15
Remove/install
1 Switch off ignition
Push down brake pedal Until the vacuum in the brake booster (A7/7) is
2
several times reduced.
Remove upper engine AR01.10-P-
3 Model 216.376, 221.176
cover 2405LA
AR01.10-P-
Model 216.379, 221.179
2405IM
Remove master brake AR42.10-P-
4
cylinder (2) 0300SX
Detach vacuum line (3) on
5 brake booster (A7/7) and
place to one side
Disconnect connectors
6
(A7/7x1, A7/7x2)
Disconnect connector
7
(A7/7x3)
Remove left cover below AR68.10-P-
8
dashboard 1500SX
Remove cover of brake
9.1 Except model 221.095 /195
pedal bearing bracket
Remove counterholder for
9.2 hybrid brake light switch Model 221.095 / 195
of pedal assembly
Detach safety clamp (5a) With plug-in pin (5)
10.1
and pull out pin (5) Installation : Replace safety clip (5a).
With screwed-in bolt (5)
10.2 Remove bolt (5)
Installation : Replace bolt
*BA29.10-P-
1003-02F
Unscrew nuts (4) of brake *BA29.10-P-
11
pedal bearing bracket 1001-02F
Remove cover (9) from
12
fuse box
Unclip cover (6) upwards
13 (arrow) from retaining
clamp (arrow)
Loosen water drain
14 channel (7) and place to
one side
Remove brake booster
15 Do not deform brake lines.
(A7/7)
Do not damage the rubber boot (8) when removing
and installing the brake booster (A7/7).
When removing the brake booster (A7/7) press the
brake lines carefully to one side and hold the cover (6)
upwards.
Except model 221.095/ 195: Check bolt (5) when Fig. 11
replacing the brake booster (A7/7). If a screwed-in bolt (5)
and a metallic sleeve are installed in the brake pedal, then
these are to be replaced by a plugged-in bolt (5) and two
plastic sleeves.
16 Install in the reverse order
PEDALS, BEARING BRACKET
Number Designation Model 216 Model 221
BA29.10-P-1001-02F Nut, brake pedal assembly to body Nm 22 22
BA29.10-P-1003-02F Bolts, brake pedal to brake booster Nm 22 22
Fig. 11: Identifying Drift (722 589 03 15 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL BRAKE BOOSTER VACUUM LINE - AR43.10-P-0355SX
MODEL 216.### 1# with ENGINE 156, 273, 275
MODEL 221.### 1# with ENGINE 156, 272, 273, 275, 642, 629 (except, 272.974)
Shown on engine 273
Fig. 12: Identifying Brake Booster Vacuum Line Components (Engine 273)
Courtesy of MERCEDES-BENZ USA
Shown on engine 275
Fig. 13: Identifying Brake Booster Vacuum Line Components (Engine 275)
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Switch off ignition
Until the vacuum in the brake
2 Push down brake pedal several times
booster (A7/7) is reduced.
AR09.10-P-
3.1 Remove air filter housing Engine 156
1150SMG
AR09.10-P-
Engine 272, 273
1150SX
AR09.10-P-
Engine 629
1150SXD
AR01.10-P-
3.2 Remove upper engine cover Engine 275.953
2405LA
AR01.10-P-
Engine 275.982
2405IM
AR01.10-P-
Engine 642
2405SXI
Remove the left hot film mass air flow sensor AR07.07-P-
4 Engine 629
with the air intake pipe 1453SXD
Disconnect vacuum line (1) from brake
5
booster (A7/7)
Loosen rubber piping (3) from firewall and
6
place to one side
7 Remove center part of firewall (9) Engine 275
Unlock vacuum line (1) at the engine end and
8.1 Engines 156, 272, 273, 275
detach from connection fitting (2)
Unlock and pull off vacuum line (1) at vacuum
8.2 Engine 642, 629
pump (10)
Detach hose (11) from T-piece of vacuum line
9 Engine 629
(1)
10 Detach retaining clamps (12) Engine 629
Unclip wiring harness (4) from U-frame (5)
11
and place to one side upwards
Unclip cover (6) for vacuum line (1) from U-
12
frame (5)
Expose vacuum line (1) and remove with Installation : Install new cable
13
grommet (7) ties.
Replace rubber seal (8) on brake booster
14
(A7/7)
15 Install in the reverse order
SAFETY PRECAUTIONS
SAFETY INFORMATION: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES -
AS43.00-Z-9999ZZ
MODEL all
Risk of death caused by working on permanent
magnet retarder for groups of persons with MODEL 970, 972, 974, 975, AS43.40-Z-
Danger!
implants. Risk of injury caused by burns that may 976 0001-01A
occur due to contact with the hot rotor.
Risk of injury caused by touching hot retarder and MODEL 000, 374, 375, 613,
by scalding from hot retarder oil. Risk of injury to 671, 930, 932, 933, 934, 940, AS43.30-Z-
Danger!
skin or eyes caused by retarder oil escaping under 942, 943, 944, 950, 952, 953, 0001-01A
high pressure 954, 958...
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: BRAKES - PNEUMATIC SYSTEM AND
AUXILIARY BRAKES - BA43.00-Z-9999AZ
MODEL all
Pneumatic brake booster MODEL 251 BA43.10-P-1000-01H
Pneumatic brake booster MODEL 169, 245 BA43.10-P-1000-01F
Pneumatic brake booster MODEL 129, 140, 163, BA43.10-P-1000-01A
170, 171, 202, 203, 208,
209, 210, 215, 220, 230
Pneumatic brake booster MODEL 211, 219 BA43.10-P-1000-01I
Vacuum pump MODEL 210, 461, 636, BA43.05-N-1000-01A
638, 639...
Vacuum pump MODEL 164, 172, 204, BA43.05-P-1000-01I
207, 211, 212, 221...
Vacuum pump MODEL 169, 245 BA43.05-P-1000-01F
Vacuum pump ENGINE 629, 642 BA43.05-P-1000-01H
ENGINE 642
Vacuum pump MODEL 168, 414, BA43.05-P-1000-01C
211.028
Vacuum pump MODEL 163, 170, 171 BA43.05-P-1000-01D
MODEL 202, 208, 210
with ENGINE 111 with
TRANSMISSION 722.6
Vacuum pump MODEL 140, 203, 209, BA43.05-P-1000-01A
220 MODEL 203, 209
with ENGINE 271, 272
Vacuum pump MODEL 164, 172, 204, BA43.05-P-1000-01I
207, 211, 212, 221...
Vacuum pump MODEL 166, 204, 207, BA43.05-P-1000-01J
212, 218, 221, 246 with
ENGINE 651
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: BRAKES - PNEUMATIC SYSTEM AND
AUXILIARY BRAKES - BE43.00-Z-9999AZ
MODEL all
Pneumatic brake booster test BE43.10-P-
MODEL 172, 204, 207, 212, 218
specifications 1000-01F
Pneumatic brake booster test MODEL 129, 140, 163, 168, 170, 171, 202, 203, 208, BE43.10-P-
specifications 210, 211, 215, 216, 219, 220, 221, 414... 1000-01A
Pneumatic brake booster test BE43.10-P-
MODEL 164.1 /8, 251
specifications 1000-01E
Test values for pneumatic BE43.10-P-
MODEL 169, 245
brake booster 1000-01D
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS - BE43.10-P-1000-01A
Model 129, 140, 163, 168, 170, 171, 202 203, 208, 210, 211, 215, 219, 220, 221, 414
MODIFICATION NOTES
14.8.06 Brake booster dia. Model 216
Brake booster dia. Model 221
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 129.05/06 (ATE Model 129.076
Number Designation T52/4A 225-210 or Lucas (ATE T52/4A 225-
LSC 115) 210)
BE43.10-P-
Brake booster dia. mm 203/2286 203/2286
1001-01A
inch 8/9 8/9
BE43.10-P-
Boost factor ~5, 6 ~5, 6
1002-01A
Brake pipe line pressure Intake
BE43.10-P-
manifold vacuum Force on brake 14 to 25 14 to 25
1003-01A
pedal 50 N bar
0.75...0.8 bar 100 N bar 35 to 45 35 to 45
150 N bar 53 to 63 53 to 63
200 N bar 71 to 81 71 to 81
250 N bar 87 to 98 87 to 98
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 140.02/03/1 (ATE Model Series
Number Designation T52/4A 225-210 or Lucas 140.04/05/06/07 (ATE T52/
LSC 115) 4A 255-225)
BE43.10-P-
Brake booster dia. mm 203/2286 228.6/254
1001-01A
inch 8/9 9/10
BE43.10-P-
Boost factor ~5, 6 6.85
1002-01A
Brake pipe line pressure Intake
BE43.10-P-
manifold vacuum Force on brake 14 to 25 13 to 25
1003-01A
pedal 50 N bar
0.75...0.8 bar 100 N bar 35 to 45 35 to 47
150 N bar 53 to 63 57 to 69
200 N bar 71 to 81 78 to 92
250 N bar 87 to 98 95 to 105
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model Model
Number Designation
163 168
BE43.10-P-1001-
Brake booster dia. mm 279 203
01A
inch 11 8
BE43.10-P-1002-
Boost factor ~5, 6 ~4, 5
01A
BE43.10-P-1003- Brake pipe line pressure Intake manifold vacuum Force on brake
9 to 20 12
01A pedal 50 N bar
0.75...0.8 bar 100 N bar 36 to 48 30
150 N bar 53 to 68 50
200 N bar 70 to 85 63
250 N bar 82 to 96 70
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 170.435/444/445/ Model
Number Designation
447/449/465/466 171
BE43.10-P- 177,
Brake booster dia. mm 254
1001-01A 8/203
inch 10 7/8
1002-01A Boost factor 4.5 5, 6
BE43.10-P- Brake pipe line pressure Intake manifold 7.5 to
13 to 23
1003-01A vacuum Force on brake pedal 50 N bar 11.5
0.75...0.8 bar 100 N bar 32 to 44 25 to 31
42.5 to
150 N bar 48 to 62
50
59.5 to
200 N bar 62 to 78
70
250 N bar 75 to 91 74 to 87
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 202.018 to 9/93 and Models 202.02/078/08/ 128/13/18/19
model 202.120/ 121/122/125 Model 202.018 as of 10/93 Models
Number Designation
to 04/94 (Lucas LSC 65 or 202.120/121/ 122/ 125 as of 05/94
Bendix Isovac dia. 225) (ATE T52/4A/255 or Lucas LSC 80)
BE43.10-
P-1001- Brake booster dia. mm 228.6 254
01A
inch 9 10
BE43.10-
P-1002- Boost factor 3.85 4.5
01A
Brake pipe line pressure
BE43.10-
Intake manifold vacuum
P-1003- 7 to 15 13 to 23
Force on brake pedal 50
01A
N bar
0.75...0.8 bar 100 N bar 26 to 38 32 to 44
150 N bar 43 to 58 48 to 62
200 N bar 62 to 75 62 to 78
250 N bar 78 to 88 75 to 91
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 203.016/061/ 064/076/081/
Model 203.004/
Number Designation 084/087/092/ 261/276/281/
006/035/045
284/287/292
BE43.10-P-
Brake booster dia. mm 177, 8/203 177, 8/203
1001-01A
inch 7/8 7/8
BE43.10-P-
Boost factor ~5, 6 ~5, 6
1002-01A
Brake pipe line pressure Intake
BE43.10-P-
pipe vacuum Force on brake pedal 8.5 to 13 7.5 to 11.5
1003-01A
50 N bar
150 N bar 48.5 to 5.7 42.5 to 50
200 N bar 68 to 80 59.5 to 70
250 N bar 84.5 to 100 74 to 87
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 208.335/344/ 345/347/348/ Model
Number Designation
365/435/444/ 445/447/448/ 465 208.370/470
BE43.10-P-
Brake booster dia. mm 254 203/2286
1001-01A
inch 10 8/9
BE43.10-P-
Boost factor 4.5 5.6
1002-01A
Brake pipe line Intake manifold
BE43.10-P-
pressure vacuum Force on brake pedal 13 to 23 8 to 18
1003-01A
50 N bar
0.75...0.8 bar 100 N bar 32 to 44 33 to 40
150 N bar 48 to 62 52 to 61
200 N bar 62 to 78 68 to 79
250 N bar 75 to 91 82 to 95
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 210.003/004/
Model 210.015/016/025/
006/010/017/
026/045/053/055/063/ 065/070/072/081/082/
020/035/037/
210/215/216/225/226/ 245/265/270/272/281/
Number Designation 206/210/235/ 237,
282/606/610/617/663, 210.217 from 01/97
210.217 up to 01/97
(Teves), 202.033/093, 210.074/274,
(Teves), 210.061/261
210.061/261 with ESP
without ESP
BE43.10-
Brake booster dia.
P-1001- 254 203/2286
mm
01A
inch 10 8/9
BE43.10-
P-1002- Boost factor 5.0 5.6
01A
Brake pipe line
BE43.10- pressure Intake
P-1003- manifold vacuum 15 to 25 8 to 18
01A Force on brake
pedal 50 N bar
0.75...0.8 bar 100 N
38 to 50 33 to 40
bar
150 N bar 57 to 70 52 to 61
200 N bar 72 to 83 68 to 79
250 N bar 82 to 91 82 to 95
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 211 with ABR Model Model
Number Designation
[Adaptive Brake] 215 216
BE43.10-P-
Brake booster dia. mm 203/228 203/2286 265/265
1001-01A
inch 8/9 8/9 9.5/95
BE43.10-P-
Boost factor 7.0 ~6, 3 8.9
1002-01A
BE43.10-P- Brake pipe line pressure Intake manifold
28...45 22 to 30 27 to 37
1003-01A vacuum Force on brake pedal 50 N bar
0.75...0.8 bar 100 N bar 55...70 42 to 52 47 to 65
150 N bar 80...95 60 to 70 75 to 90
200 N bar 102...118 80...95 98 to 121
100 to 114 to
250 N bar 115...122
120 138
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model 219 with ABR Model Model
Number Designation
[Adaptive Brake] 220 221
BE43.10-P-
Brake booster dia. mm 203/228 203/2286 265/265
1001-01A
inch 8/9 8/9 9.5/95
BE43.10-P-
Boost factor 7.0 ~6, 3 8.9
1002-01A
BE43.10-P- Brake pipe line Intake pipe pressure
28...45 22 to 30 27 to 37
1003-01A vacuum Force on brake pedal 50 N bar
0.75...0.8 bar 100 N bar 55...70 42 to 52 47 to 65
150 N bar 80...95 60 to 70 75 to 90
200 N bar 102...118 80...95 98 to 121
100 to 114 to
250 N bar 115...122
120 138
PNEUMATIC BRAKE BOOSTER TEST SPECIFICATIONS
Model
Number Designation
414.700
BE43.10-P-1001-
Brake booster dia. mm 178/203
01A
inch 7/8
BE43.10-P-1002-
Boost factor 5, 6
01A
01A N bar 17
0.75...0.8 bar 100 N bar 37
150 N bar 53 to 57
200 N bar 68 to 75
250 N bar 76 to 88
WIRING DIAGRAMS
ELECTRIC WIRING DIAGRAMS: PASSENGER CARS: BRAKES - PNEUMATIC SYSTEM AND
AUXILIARY BRAKES - PE43.00-Z-9999AZ
MODEL all
Overview of wiring diagrams for brakes MODEL 169.09 with ENGINE PE43.00-P-
pneumatic systems and auxiliary brakes 780.992 as of model year 2011 1100QB
SPECIAL TOOLS
SPECIAL TOOLS: PASSENGER CARS: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY
BRAKES - WS43.00-Z-9999AZ
MODEL all
WS32.00-N-
000 589 12 28 00 Knife FG 07/31/32/42/43/47/ 83/Set D
3046D
WS32.00-N-3046-
000 589 12 28 02 Replacement knife FG 31/32/42/43/47/83/set D
01D
WS00.00-N-
000 589 28 33 00 Puller dia. 28-37 mm FG 00/03/05/26/27/ 28/33/43/46/Set B
3026Z
WS00.00-N-
000 589 33 33 00 Counter stay FG 00/03/05/26/27/ 28/33/43/46/Set B
0051Z
WS27.00-N-
112 589 00 72 00 Hand pump FG 01/27/43/Set A
0003A
140 589 12 21 00 Baseline current draw
FG 42/43/54/Set B WS54.00-P-0015B
test adapter 1
140 589 13 21 00 Quiescent current test
FG 42/43/54/Set B WS54.00-P-0016B
adapter 2
WS62.00-P-
140 589 26 63 00 Stamping symbols set FG 43/60/62/Set K
0018K
140 589 26 63 01 Steel stamping letters WS62.00-P-0018-
Group 43/62/Set K
set 01K
140 589 26 63 02 Steel stamping letters WS62.00-P-0018-
Group 43/62/Set K
retrofit kit 02K
WS62.00-P-0018-
140 589 26 63 03 Stamping numbers set Group 43/62/Set K
03K
WS62.00-P-0018-
140 589 26 63 04 Star die FG 43/62/Set K
04K
140 589 26 63 05 Steel stamping letters WS62.00-P-0018-
FG 43/60/62/Set K
set 05K
201 589 13 21 00 Vacuum tester FG 42/43/09/14/Set B WS42.00-P-0036B
FG 00/01/07/09/20/25/
210 589 00 71 00 Hand pump WS00.00-P-0280Z
27/32/33/43/46/88
220 589 00 99 00 Electrical connection FG 00 FG 01/13/15/20/25/42/
WS54.00-P-0050B
kit 43/47/54/72/ Set B
WS54.00-P-0050-
220 589 00 99 01 Adapter cable FG 42/43/54/Set B
01B
WS54.00-P-0050-
220 589 00 99 02 Adapter line FG 42/43/54/Set B
02B
WS54.00-P-0050-
220 589 00 99 03 Adapter line FG 42/43/54/Set B
03B
WS54.00-P-0050-
220 589 00 99 04 Adapter line FG 42/43/54/Set B
04B
WS54.00-P-0050-
220 589 00 99 05 Adapter line FG 42/43/54/Set B
05B
WS54.00-P-0050-
220 589 00 99 06 Adapter line FG 42/43/54/Set B
06B
WS54.00-P-0050-
220 589 00 99 07 Adapter line FG 15/25/42/43/54/Set B
07B
WS54.00-P-0050-
220 589 00 99 08 Adapter line FG 15/42/43/54 / Set B
08B
WS54.00-P-0050-
220 589 00 99 09 Adapter line FG 15/42/43/54/Set B
09B
WS54.00-P-0050-
220 589 00 99 10 Adapter line FG 15/42/43/54/Set B
10B
WS54.00-P-0050-
220 589 00 99 11 Adapter line FG 00/09/15/42/43/54/ Set B
11B
WS54.00-P-0050-
220 589 00 99 12 Adapter line FG 15/42/43/54/ Set B
12B
WS54.00-P-0050-
220 589 00 99 13 Adapter line FG 15/42/43/54 / Set B
13B
WS54.00-P-0050-
220 589 00 99 20 Test cable FG 15/20/25/42/43/54/ Set B
14B
WS54.00-P-0050-
220 589 00 99 21 Alligator clip FG 15/42/43/54/ Set B
15B
WS54.00-P-0050-
220 589 00 99 22 Safety clamp FG 15/25/42/43/54/Set B
16B
220 589 00 99 23 Clamp test probe FG 15/42/43/54 / Set B 17B
WS54.00-P-0050-
220 589 00 99 24 Connection plug FG 42/43/54/Set B
18B
WS54.00-P-0050-
220 589 00 99 30 Adapter cable FG 42/43/54/Set B
19B
WS54.00-P-0050-
220 589 00 99 31 Adapter cable FG 42/43/54/Set B
20B
WS54.00-P-0050-
220 589 00 99 33 Safety cable FG 42/43/54/Set B
22B
WS54.00-P-0050-
220 589 00 99 34 Adapter cable Group 42/43/54/Set B
23B
WS54.00-P-0050-
220 589 00 99 35 Adapter cable FG 00/09/20/42/43/54/Set B
24B
220 589 05 99 00 Electrical connection FG 00/01/09/13/15/ 20/25/42/43/47/54/
WS00.00-P-0279Z
kit 72/ Set B
BRAKES
Brakes - Testing & Repair - S-Class (221)
TESTING & REPAIR
INSTALLING PROTECTIVE WASHERS TO PROTECT BRAKE DISK DUST SHIELDS - AR42.00-P-
0100-01A
Fig. 1: Identifying Guard Plate (220 589 01 31 00)
Courtesy of MERCEDES-BENZ USA
Guard plates (060) are not a substitute for complete wheels. The vehicle must not be lowered onto the
mounted guard plates (060). When the engine is running, do not engage a gear or gear range, otherwise the
guard plates (060) can be damaged.
1 Attach guard plate (060) to the wheel hub using 3 wheel bolts.
Wheel bolts for light alloy rims are too long and must therefore not be used. Use only short wheel bolts.
Fig. 2: Identifying Guard Plate
Courtesy of MERCEDES-BENZ USA
LOCATE NOISES FROM THE BRAKE - AR42.00-P-2000A
MODEL all
Example shown on model 204
Fig. 3: Identifying Cable And Clamp Pliers With Microphone
Courtesy of MERCEDES-BENZ USA
Example shown on model 211 front axle
Fig. 4: Identifying Cable And Selection Switch
Courtesy of MERCEDES-BENZ USA
Remove/install
Attach the clamp pliers as close as possible to suspect components.
For evaluation purposes (normal noise -defect noise) listen to the
Attach clamp pliers with same components, e.g. compare noise from left supporting ball joint
1
microphone (1) with right supporting ball joint.
Up to 6 clamp pliers with microphone can be attached.
movement of chassis components is not impaired.
It is essential to check whether the clamp pliers impair the
steering function. Risk of accident!
STEELMAN ChassisEAR refer to GOTIS
http://gotis.aftersales.mercedes-benz.com
Fasten line (2) of clamp Fasten the lines with velcro strip, cable ties or adhesive tape.
2 pliers with microphone (1) Route the lines so that while driving the freedom of movement
(arrows) of the chassis components is not impaired.
Guide line (2) of clamp pliers
Route the lines so that contact with the road is ruled out.
3 with microphone (1) into the
interior Route lines so that damage by a door or window is ruled out.
Connect line (2) to the The lines and connectors on the selection switch are color coded.
4
selection switch (3) Note the color assignment of components which are to be listened to.
Carry out road test for noise Only carry out road test with a second person present.
5
diagnosis The headphones must not be worn by the driver.
Locate defective components Reduce the volume before each
6 by listening to the channel change otherwise hearing can be damaged
microphone If necessary:? Replace faulty components.
TESTING AND REPAIR WORK: PASSENGER CARS: BRAKES - HYDRAULIC AND
MECHANICAL SYSTEMS - AR42.00-Z-9000AA
MODEL all
Locate noises from the brake MODEL all AR42.00-P-2000A
TESTING AND REPAIR WORK: PASSENGER CARS: BRAKES - HYDRAULIC AND
MECHANICAL SYSTEMS - AR42.00-Z-9221AA
MODEL 221
AR42.20-P-
Adjust parking brake MODEL 216 MODEL 221.0/ 1
0540SX
AR42.10-P-
Bleed brake system MODEL 216 MODEL 221
0010SX
MODEL 216.### 1# MODEL AR42.31-P-
Remove/install BAS diaphragm travel sensor
221.### 1# 6002SX
AR42.10-P-
Remove/install brake disc MODEL 216 MODEL 221
0220SX
MODEL 216.### 1# MODEL AR42.10-P-
Remove/install brake fluid reservoir
221.### 1# 0301SX
AR42.10-P-
Remove/install brake pad on floating brake caliper MODEL 216, 221
0160SX
Remove/install brake pads on fixed caliper MODEL 216, 221 0161SX
AR42.20-P-
Remove/install brake shoes of parking brake MODEL 216 MODEL 221
0530SX
Remove/install electric parking brake controller AR42.20-P-
MODEL 216 MODEL 221
unit 0590SX
AR42.20-P-
Remove/install electric parking brake switch MODEL 216 MODEL 221.0 /1
0505SX
Remove/install electronic stability program (ESP) MODEL 216.### 1# MODEL AR42.45-P-
control unit 221.### 1# 0820SX
MODEL 216.### 1# MODEL AR42.40-P-
Remove/install ETS/ASR/ESP hydraulic unit
221.### 1# 0816SX
AR42.10-P-
Remove/install front axle brake caliper MODEL 216 MODEL 221
0070SX
AR42.30-P-
Remove/install left front or right RPM sensor MODEL 216 MODEL 221
0712SX
AR42.40-P-
Remove/install left or right rear axle speed sensor MODEL 216 MODEL 221
0820SX
MODEL 216.### 1# MODEL AR42.10-P-
Remove/install master brake cylinder
221.### 1# 0300SX
AR42.10-P-
Remove/install rear axle brake caliper MODEL 216 MODEL 221
0080SX
AR42.20-P-
Remove/install rear brake control cable MODEL 216 MODEL 221
0525SX
Remove/install yaw rate and lateral acceleration AR42.45-P-
MODEL 216, 221
sensor 0841SX
AR42.10-P-
Replace brake hoses MODEL 216 MODEL 221
0013SX
AR42.10-P-
Test brake system with pressure tester for leaks MODEL 216 MODEL 221
0015SX
CARRYING OUT BLEEDING OPERATION - AR42.10-P-0010-02SX
FRONT AXLE BRAKE CALIPER
Model 221 except model Model
Number Designation
221.074/077/174/ 177/179 221.074/077/174 /177/179
BA42.10-P- Bleed screw to
Nm 14 16
1001-10M brake caliper
REAR AXLE BRAKE CALIPER
Model 216 Model Model 221 except Model 221.074/
Number Designation except 216.374/ 216.374/ model 221.074/ 077/174/
377/379 377/379 077/174/ 177/179 177/179
Bleed screw Nm 14 23 14 23
1001-12M caliper
Opening sequence on 1, 2 or 4 piston brake calipers on front axle
Fig. 5: Opening Sequence On 1, 2 Or 4 Piston Brake Calipers On Front Axle
Courtesy of MERCEDES-BENZ USA
Opening sequence on 6 or 8 piston brake calipers on front axle
Fig. 6: Opening Sequence On 6 Or 8 Piston Brake Calipers On Front Axle
Courtesy of MERCEDES-BENZ USA
Opening sequence for model 221 with code (Z07) maximum protection
Fig. 7: Opening Sequence For Model 221 With Code (Z07) Maximum Protection
Courtesy of MERCEDES-BENZ USA
1. Set bleeding pressure on filling and bleeding unit to 2 bar.
2. Remove caps (10) for bleed screws (1, 2, 3, 4, 5, 6) on brake calipers.
3. Fit bleed wrench (03) and bleed hose (02) on bleed screw (1).
4. Open bleed screw (1).
5.1 Bleed the hydraulic system of the brake system (after the hydraulic system was opened for repair):
Fully depress brake pedal repeatedly, until new bubble-free brake fluid flows out at the bleed screw (1).
To bleeding the brake system correctly it is absolutely essential to pump the brake pedal
throughout the entire bleeding process. Otherwise brake system malfunctions and a failure of the brake
system can occur due to remaining residual air.
In order to avoid the intake of air, do not pump the brake pedal in a jerking manner, but gradually
release. The bleed screw (1) can remain open during the entire pumping process.
Required total quantity of brake fluid: approx. 1.5 l.
5.2 Replace brake fluid (service 4, hydraulic system of brake system was not previously opened for
repair): Keep bleed screw (1) open until new brake fluid flows out.
Pumping the brake pedal not required.
6 Close bleed screw (1).
For 6, or 8-piston brake calipers on the front axle and for vehicles with code (Z07) Maximum protection:
Note different sequence for left and right-hand drive vehicles.
7 Repeat process at bleed screws (2, 3, 4, 5, 6).
The numbering of the bleed screws (1, 2, 3, 4, 5, 6) indicates the opening sequence.
Required total quantity of brake fluid: approx. 0.75 l.
8 Detach bleed hose (02) and bleed wrench (03) and fit caps (10) to bleed screws (1, 2, 3, 4, 5, 6).
BLEED BRAKE SYSTEM - AR42.10-P-0010SX
MODEL 216
MODEL 221
Fig. 8: Bleeding Brake System
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of poisoning caused by Only pour brake fluid into suitable and
swallowing brake fluid. Risk of injury appropriately marked containers. Wear AS42.50-Z-
caused by brake fluid coming into protective clothing and eye protection 0001-01A
contact with skin and eyes. when handling brake fluid.
Risk of injury to skin and eyes caused Wear safety gloves, protective clothing AS00.00-Z-
by handling hot or glowing objects. and safety glasses, if necessary. 0002-01A
Clean
1 Clean area around cap (1)
2 Unscrew cap (1).
AH42.00-P-
Notes on repairs to brake system
0003-01A
AH42.50-P-
Brake fluid notes
0001-01A
Add new brake fluid up to the "MAX."
3
mark in the expansion reservoir (2)
Connect brake fluid changing unit (01)
Pay attention to manufacturer's
4 on expansion reservoir (2) and switch
operating instructions.
on
Remove the front wheels AP40.10-P-
5 If necessary
Remove/install wheels 4050SX
AR42.10-P-
6 Carrying out bleeding operation
0010-02SX
*BA42.10-P-
Front axle
1001-10M
*BA42.10-P-
Rear axle 1001-12M
7 Install in the reverse order
Checking
AR42.10-P-
8 Check brake system for leaks
0100-01V
Correct fluid level in expansion
AP42.10-P-
9 reservoir (2) Brake system - inspect
4210SX
fluid level
FRONT AXLE BRAKE CALIPER
Model 221 except model Model
Number Designation
221.074/077/174/ 177/179 221.074/077/174 /177/179
BA42.10-P- Bleed screw to
Nm 14 16
1001-10M brake caliper
REAR AXLE BRAKE CALIPER
Model 216 Model Model 221 except Model 221.074/
Number Designation except 216.374/ 216.374/ model 221.074/ 077/174/
377/379 377/379 077/174/ 177/179 177/179
Bleed screw
BA42.10-P-
to brake Nm 14 23 14 23
1001-12M
caliper
REPLACE BRAKE HOSES - AR42.10-P-0013SX
MODEL 216
MODEL 221
Front brake hose
Fig. 9: Identifying Front Brake Hose Components
Courtesy of MERCEDES-BENZ USA
Rear brake hose
Fig. 10: Identifying Rear Brake Hose Components
Model 221.179
Fig. 11: Identifying Brake Caliper, Banjo Bolt And Brake Hose
Courtesy of MERCEDES-BENZ USA
Model 221 with code Z07 Top protection
Fig. 12: Identifying Brake Hose Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of poisoning caused by
Only pour brake fluid into suitable and
swallowing brake fluid. Risk of
appropriately marked containers. Wear AS42.50-Z-
injury caused by brake fluid
protective clothing and eye protection when 0001-01A
coming into contact with skin
handling brake fluid.
and eyes.
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and AS00.00-Z-
caused by handling hot or
safety glasses, if necessary. 0002-01A
glowing objects.
AH42.50-P-
Brake fluid notes
0001-01A
AH42.00-P-
Notes on repairs to brake system
0003-01A
AH42.10-P-
Notes on installing brake hoses
9406-01A
1 Remove wheel.
AP40.10-P-
Remove/install wheels
4050SX
Unlock and open brake hose clip Vehicles with code Z07 Top protection, when
2
(3a) removing brake hose (3) on the front axle
Press catch tabs (3b) in the direction of the
arrow using a screwdriver and press out
upwards out of the brake hose clip (3a).
Installation: Check that the catch tabs
(3b) have engaged correctly, otherwise the
brake hose (3) could be damaged as a result of
chafing.
Remove union nut (1) of brake *BA42.10-P-
3
line (2) from brake hose (3) 1001-04K
Fig. 13
Fig. 16
Seal off both line ends immediately with
stop plugs to prevent dirt from entering. The
Pull brake hose (3) out of
4 brake fluid expansion reservoir must not run *12958900910
retaining plate (4)
empty.
Vehicles without top protection
Seal off both line ends immediately with
stop plugs to prevent dirt from entering.
Unscrew brake hose (3) from *BA42.10-P-
5.1 Installation: Lead front brake hose (3)
brake caliper (5) 1002-04K
through bracket (6).
Except model
221.074/077/174/177/179, 216.374/377/379
216.374/377/379 front axle 1006-04K
Model 221 except *BA42.10-P-
221.074/077/174/177/179, 216 except 1007-04K
216.374/377/ 379 rear axle
Fig. 14
Fig. 13
Vehicles with code Z07 Top protection
When unfastening and tightening the
brake hose (3), counterhold the T-piece (9)
Unscrew brake hose (3) from T- using an open end wrench, otherwise the brake *BA42.10-P-
5.2
piece (9) lines (2) could be damaged. 1008-04K
Seal off both line ends immediately with
stop plugs to prevent dirt from entering.
Fig. 14
Model 216.374/ 377/ 379, 221.074/ 077/ 174/
177/ 179
Seal line connections immediately with
Remove banjo bolts (7) and stop plugs in order to prevent the ingress of *BA42.10-P-
6 remove brake hose (8) from dirt. The brake fluid expansion reservoir must 1005-04K
brake calipers (5) not run empty.
Installation: Replace sealing rings.
7 Install in the reverse order
AR42.10-P-
8 Bleed brake system
0010SX
BRAKE LINES, BRAKE HOSES
Model 221 except Model
Number Designation
221.074/077/174/ 177/179 221.074/077/174 /177/179
BA42.10-P- Union nut, brake line to
Nm 17 17
1001-04K brake hose
BA42.10-P- Brake hose to fixed or
Nm 18 -
1002-04K floating caliper
Banjo bolt, brake hose to
BA42.10-P-
front axle floating brake Nm - 38
1005-04K
caliper
BA42.10-P- Brake hose to front axle
Nm - 22
1006-04K floating brake caliper
BA42.10-P- Brake hose to rear axle
Nm - 18
1007-04K floating caliper
BA42.10-P-
Brake hose to T-piece Nm 18 -
1008-04K
Fig. 13: Identifying Box Wrench Bit (000 589 75 03 00)
Courtesy of MERCEDES-BENZ USA
Fig. 14: Identifying Ring Wrench (000 589 76 03 00)
Courtesy of MERCEDES-BENZ USA
Fig. 15: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 16: Identifying Torque Wrench (001 589 87 21 00)
Courtesy of MERCEDES-BENZ USA
TEST BRAKE SYSTEM WITH PRESSURE TESTER FOR LEAKS - AR42.10-P-0015SX
MODEL 216
MODEL 221
Fig. 17: Testing Brake System For Leaks
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
29.7.09 Value changed: bleed screw to brake caliper *BA42.10-P-1001-10M
Checking
Risk of poisoning caused by swallowing Only pour brake fluid into suitable and
AS42.50-Z-
brake fluid. Risk of injury caused by brake appropriately marked containers. Wear
0001-01A
eyes. when handling brake fluid.
Risk of injury to skin and eyes caused by Wear safety gloves, protective clothing AS00.00-Z-
handling hot or glowing objects. and safety glasses, if necessary. 0002-01A
AH42.50-P-
Brake fluid notes
0001-01A
Notes on externally invisible brake fluid AH42.10-P-
loss 9406-02V
AH42.00-P-
Notes on repairs to brake system
0003-01A
Vehicles with memory package (driver
AR54.30-P-
1 Deactivate easy entry/exit seat, steering column, mirrors) code
1000-02ESX
275
Connect brake fluid changing unit to Observe manufacturer's operating
2
expansion reservoir (1) instructions!
Vehicles with engine 275 and engine
3 Detach left front wheel
629 with top protection, code Z07
AP40.10-P-
Remove/install wheels
4050SX
Pressure testers (3) for hydraulic
oil systems must not be used for
systems with brake fluid otherwise the
Remove the bleed screw on the left front brake fluid is mixed with mineral oil
4 brake caliper (2) and connect pressure which can lead to brake failure!
tester (3) Observe manufacturer's
operating instructions in order to
prevent measurement errors or incorrect
operation!
5 Bleed pressure tester (3)
Switch off brake fluid changing unit and
6
release pressure
High-pressure check
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk moving by itself.
AS00.00-Z-
of injury caused by contusions and burns Wear closed and snug-fitting work
0005-01A
during starting procedure or when working clothes. Do not touch hot or rotating
near the engine as it is running parts.
To create the strongest possible
Allow the engine to run at moderate speed
7
and release the accelerator pedal suddenly vacuum in the BAS brake booster
(A7/7).
Immediately press down brake pedal as far
Protect brake pedal and seat
as possible and insert brake pedal jack
8 against damage. Fig. 19
(010) with adapter between brake pedal
and seat
Fig. 18
Read off and note brake pressure on high-
9
pressure gauge of pressure tester (3)
Read off and note brake pressure again During the 5 min duration of the
10 after 5 minutes on the high-pressure gauge test, the brake pressure may not drop
of the pressure tester (3) more than 5 %.
Low-pressure testing
Switch off engine and remove brake
11
pedal jack (010) with adapter
In order to reduce the vacuum in the
12 Push down brake pedal several times
BAS brake booster (A7/7).
Press down brake pedal as far as possible
Protect brake pedal and seat
13 and insert brake pedal jack (010) with
against damage.
adapter between brake pedal and seat
Move back the brake pedal jack (010)
slowly until a brake pressure of approx. 3
14
bar is displayed on the low pressure gauge
of the pressure tester (3)
Read off and note the brake pressure after 2
The brake pressure must not drop
15 minutes on the low pressure gauge of the
during the 2 min duration of the test.
pressure tester (3)
Remove brake pedal jack (010) and
16
adapter
Detach pressure tester (3) and screw bleed *BA42.10-
17 Brake caliper
screw into brake caliper (2) P-1001-10M
AR42.10-P-
18 Bleed brake system
0010-02SX
Vehicles with engine 275 and engine
19 Mount left front wheel
629 with top protection, code Z07
AP40.10-P-
Remove/install wheels
4050SX
20 Detach brake fluid changing unit
Correct fluid level in expansion reservoir
21
(1)
AP42.10-P-
Brake system - inspect fluid level
4210SX
FRONT AXLE BRAKE CALIPER
Model 216 except model Model 221 except model
Number Designation
216.374/377/379 221.074/077/174 /177/179
BA42.10-P- Bleed screw to
Nm 14 14
1001-10M brake caliper
Fig. 18: Identifying Brake Pedal Jack (000 589 18 31 00)
Courtesy of MERCEDES-BENZ USA
Fig. 19: Identifying Adapter For Brake Pedal Jack (211 589 00 31 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL FRONT AXLE BRAKE CALIPER - AR42.10-P-0070SX
MODEL 216
MODEL 221
1-piston dual floating brake caliper
Fig. 20: Identifying Front Axle Brake Caliper Components (1-Piston Dual Floating Brake Caliper)
Courtesy of MERCEDES-BENZ USA
4-piston brake caliper
Fig. 21: Identifying Front Axle Brake Caliper Components (4-Piston Brake Caliper)
Courtesy of MERCEDES-BENZ USA
8-piston brake caliper
Fig. 22: Identifying Front Axle Brake Caliper Components (8-Piston Brake Caliper)
Courtesy of MERCEDES-BENZ USA
Model 221 with code Z07 Top protection
Fig. 23: Identifying Front Axle Brake Caliper Components (With Code Z07 Top Protection)
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and AS00.00-Z-
caused by handling hot or glowing
safety glasses, if necessary. 0002-01A
objects.
Notes on self-locking nuts and bolts
0001-01A
Remove brake pads (43) from brake AR42.10-P-
1 Fixed caliper
caliper (31) 0161SX
AR42.10-P-
Floating caliper
0160SX
Model 221 with code Z07 Top protection:
When removing the right-hand brake caliper
Remove bolt (1) and remove right (31) behind the axle center, Model 216, 221
*BA42.10-P-
2 front brake pad contact sensor without Top protection:
(S10/2x1) from brake caliper (31) When removing the right-hand brake caliper 1003-10M
(31), not on 8-piston brake caliper
AR42.10-P-
3.1 Remove brake hose (51) Vehicles without top protection
0013SX
Detach brake line (52) from brake
3.2 Vehicles with code Z07 Top protection
caliper (31)
Seal off both line ends immediately with
stop plugs to prevent dirt from entering.
The brake fluid expansion reservoir must not Fig. 15
run empty.
Under no circumstances loosen the
Remove bolts (31s) and remove
bolts (31n) on the 8-piston-brake calipers
brake caliper (31) or brake caliper *BA42.10-P-
4 otherwise brake system malfunctions can
support (32) from steering knuckle 1005-10M
occur
(7)
5 Install in the reverse order
FRONT AXLE BRAKE CALIPER
Model 216 except model Model 221 except model
Number Designation
216.374/377/379 221.074/077/174 /177/179
BA42.10-P- Bolt, brake pad contact
Nm 8 8
1003-10M sensor to brake caliper
Self-locking bolt,
BA42.10-P-
caliper support to Nm 180 180
1005-10M
steering knuckle
FRONT AXLE BRAKE CALIPER
Model Model
Number Designation
216.374/377/379 221.074/077/174 /177/179
BA42.10-P- Bolt, brake pad contact sensor
Nm 8 8
1003-10M to brake caliper
BA42.10-P- Self-locking bolt, caliper
Nm 180 180
1005-10M support to steering knuckle
Fig. 24: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REAR AXLE BRAKE CALIPER - AR42.10-P-0080SX
MODEL 216
MODEL 221
1-piston brake caliper
Fig. 25: Identifying Rear Axle Brake Caliper Components (1-Piston Brake Caliper)
Courtesy of MERCEDES-BENZ USA
4-piston brake caliper
Fig. 26: Identifying Rear Axle Brake Caliper Components (4-Piston Brake Caliper)
Courtesy of MERCEDES-BENZ USA
Remove/install
Wear safety gloves, protective
Risk of injury to skin and eyes caused by AS00.00-Z-
clothing and safety glasses, if
handling hot or glowing objects. 0002-01A
necessary.
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
AR42.10-P-
1 Remove brake pads on rear axle with 1-piston brake caliper
0160SX
AR42.10-P-
with 4-piston brake caliper
0161SX
Remove bolt (1) and remove right rear brake When removing the right brake
caliper (2) *BA42.10-P-
2 pad contact sensor connector (S10/4x1) from
1002-12M
brake caliper (2)
AR42.10-P-
3 Remove brake hose (3)
0013SX
When replacing the 1-piston
Remove bolts (4a) and detach brake caliper brake caliper (2) *BA42.10-P-
4.1
support (4) from wheel carrier (5) 1004-12M
Remove bolts (2a) and detach brake caliper (2) With 4-piston brake caliper (2) *BA42.10-P-
4.2
from wheel carrier (5) 1004-12M
5 Install in the reverse order
REAR AXLE BRAKE CALIPER
Model
Model 216 Model Model 221 except
221.074/
Number Designation except 216.374/ 216.374/ model 221.074/
077/174/
377/379 377/379 077/174/ 177/179
177/179
1002-12M contact sensor to
Nm 8 8 8 8
brake caliper
Self-locking bolt,
BA42.10-P-
brake caliper to Nm 110 110 110 110
1004-12M
wheel carrier
CHECK BRAKE SYSTEM FOR LEAKS - AR42.10-P-0100-01V
1. After bleeding the brake system, press the brake pedal firmly several times in order to bring the brake
pads into contact with the brake disks.
2. Start the engine and press the brake pedal with approx. 200 to 300 N.
3. Check brake system for leaks.
The pressure built up in the brake system must be held without it being possible to depress the brake
pedal further.
4. Check line and hose connections as well as all components of the brake system for leaks.
5. Check fluid level in brake fluid expansion reservoir, and correct if necessary.
REMOVE/INSTALL BRAKE PAD ON FLOATING BRAKE CALIPER - AR42.10-P-0160SX
MODEL 216, 221
Shows model 221.071
Fig. 27: Identifying Floating Brake Caliper Brake Pad Components - Model 221.071
Courtesy of MERCEDES-BENZ USA
Shown on model 221.177, front axle
Fig. 28: Identifying Floating Brake Caliper Brake Pad Components - Model 221.177, Front Axle
Courtesy of MERCEDES-BENZ USA
Shown on model 221.056, rear axle
Fig. 29: Identifying Floating Brake Caliper Brake Pad Components - Model 221.056, Rear Axle
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
1.9.10 "Perform brake test on test bench" reference changed Test sequence augmented/revised
Remove/install
Risk of poisoning caused by
swallowing brake fluid. Risk Only pour brake fluid into suitable and appropriately
AS42.50-Z-
of injury caused by brake fluid marked containers. Wear protective clothing and eye
0001-01A
coming into contact with skin protection when handling brake fluid.
and eyes.
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and safety AS00.00-Z-
caused by handling hot or
glasses, if necessary. 0002-01A
glowing objects.
AR54.10-P-
1 Ensure vehicle idle (bus idle) Model 221.095 / 195
2000-01SX
Unscrew cap of brake fluid
In order to prevent the brake fluid reservoir from
2 reservoir and extract some
brake fluid overflowing when pressing back the brake pistons.
AH42.50-P-
Brake fluid notes
0001-01A
Notes on repairs to brake AH42.00-P-
system 0003-01A
AP40.10-P-
3 Remove wheels
4050SX
Model 216.374 /377 /379,
221.074 /077 /174 /177 /179 on front axle
Installation: Replace bolts (10s). Coat ATE
Remove bolts (10s) and brake cylinder paste lightly on the contact surfaces *BR00.45-
4
remove cover panel (10) of the bolt heads. Do not grease the thread Z-1078-06A
Wipe off excess brake cylinder paste after tightening
the bolts (10s).
ATE brake cylinder paste
Separate brake pad contact
When removing the brake pads (5) on the right-hand
5 sensor (S10/2, S10/4) from
side of the vehicle
electrical feed line (1)
Unclip the electrical feed line
When removing the brake pads (5) from the rear
6 (1) from the cable retainer (1a)
axle on the right-hand side of the vehicle
on the wheel carrier
Pry off spring steel sheet (2)
7
and remove
Pry off and remove protective
8
caps (3a) from boots (3b)
*BA42.10-
9 Remove guide pin (3) P-1003-
12M
*BA42.10-
10M
Do not subject brake hoses (6) to tensile
loads or kink. Attach brake caliper (4) without
10 Remove brake caliper (4) tension to vehicle to relieve load on brake hose (6),
otherwise the brake hose (6) will be damaged.
Do not detach brake hoses (6).
Brake pads (5) are to be disposed of as special
waste. The local authorities can provide information
11 Take out brake pads (5)
regarding whether disposal is also permitted as
industrial waste similar to domestic waste.
Only complete sets of brake pads (5) approved by
Mercedes-Benz may be installed.
Installation: Insert inner brake pad (5) with
riveted-on spring in brake piston.
Vehicles without engine 156 /157 at rear axle: Slide
outer brake pad (5) into brake caliper support (7) and
install brake caliper (4).
Vehicles with engine 156 / 157, at the rear axle:
Insert outer brake pad (5) with spring riveted on into
brake caliper (4) and mount brake caliper (4).
Pull brake pad contact sensor When removing the brake pads (5) on the right-hand
(S10/2, S10/4) out of the pad side of the vehicle
12
backing plate of the brake pad Installation: Replace defective brake pad contact
(5) sensor (S10/2, S10/4).
Notes on installing brake wear AH42.10-P-
indicator contact sensors 0003-01A
Checking
Check brake pads (5) and Replace brake pads (5) and brake disks (8) in
13
brake disks (8) complete sets if necessary.
AP42.10-P-
Check brake lining thickness
4253A
Inspect condition of brake AP42.10-P-
disks 4258SX
Check brake caliper (4) for In the event of leaks: ? AR42.10-P-
14
leaks Replace rear axle brake caliper. 0080SX
AR42.10-P-
Install new front axle brake caliper.
0070SX
Check dust boot (9) on brake If dust boot (9) is damaged: ? AR42.10-P-
15
piston for damage Replace rear axle brake caliper. 0080SX
AR42.10-P-
Install new front axle brake caliper.
0070SX
Press back brake piston using If the brake piston is difficult to move: ? AR42.10-P-
16
pusher tool (01) Replace rear axle brake caliper. 0080SX
Install new front axle brake caliper.
0070SX
Fig. 30
Clean
Clean contact surfaces of brake Do not damage dust boot (9) in the process.
pads (5) on brake caliper (4) Do not use sharp-edged or pointed tools, otherwise *BR00.45-
17
and brake caliper support (7) the brake caliper (4) or brake caliper support (7) will Z-1028-04A
using rags be damaged. Cleaner from package
All models except model 216.374 /377 /379,
221.074 /077 /174 /177 /179
Only use the brake pastes listed in the linked AR42.10-P-
18 Coat brake paste
description, and apply it solely at the specified 0161-01B
positions, otherwise there may be problems with
noise or damage to the brake system!
*BR00.45-
MB brake paste Molykote (copper colored)
Z-1057-06A
MB Plastilube brake paste (brownish) Model
216.374 /377 /379, 221.074 /077 /174 /177 /179: Use *BR00.45-
ATE Plastilube paste only on the front and rear Z-1084-06A
axles.
*BR00.45-
ATE brake pad paste (ATE Plastilube)
Z-1054-06A
19 Install in the reverse order
Risk of accident when
commissioning the vehicle due
Before starting engine, actuate brake pedal several
to a lack of braking effect AS42.50-Z-
times until the pressure is built up and maintained in
when the service brake is 0002-01A
the brake system.
operated for the first time after
repair work
Model 221.095 /195: Fully depress brake pedal 10-
times in quick succession.
Push down brake pedal several
20 Model 216, 221, except 221.095 / 195:
times
Depress brake pedal several times until a firm
resistance is noticeable.
Check fluid level in the brake
AP42.10-P-
21 fluid reservoir, correct if
4210SX
necessary
Never leave the vehicle unattended on the rollers
Risk of death caused by limbs
except in an emergency. Ensure that no one is under
being caught or crushed by AS42.00-Z-
the vehicle or near rotating parts during testing. In
rotating parts when performing 0001-01A
case of emergency, use the EMERGENCY STOP
tests on the brake test stand
switch to shut down test stand.
Carry out brake test on the test AP42.00-P-
22
stand 4290BA
FRONT AXLE BRAKE CALIPER
Model 221 except model Model
Number Designation
221.074/077/174/ 177/179 221.074/077/174 /177/179
BA42.10-P- Guide pin, brake caliper
Nm 28 28
1004-10M to brake caliper support
REAR AXLE BRAKE CALIPER
Model 216 Model Model 221 except Model 221.074/
Number Designation except 216.374/ 216.374/ model 221.074/ 077/174/
377/379 377/379 077/174/ 177/179 177/179
Guide pin on
BA42.10-P-
caliper Nm 28 28 28 28
1003-12M
support
Fig. 30: Identifying Pusher Tool (000 589 52 43 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Adolf Wurth GmbH & Co. KG Reinhold-Wurth-Str. 12-17
BR00.45-Z-
Cleaner from package 74653 Kunzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax
1028-04A
+49 7940 15-1000 www.wuerth.de
ATE brake pad paste (ATE
Plastilube)
Continental Teves AG & Co. oHG Guerickestr. 7 60488
BR00.45-Z- Article number: 03.9902-
Frankfurt Germany Tel. +49 69 7603-1 Fax +49 69 761061
1054-06A 1001.2 (35 ml)
www.conti-online.com
Article number: 03.9902-
1002.2 (75 ml)
BR00.45-Z- MB brake paste Molykote
A 001 989 87 51
1057-06A (copper colored)
ATE brake cylinder paste Continental Teves AG & Co. oHG Guerickestr. 7 60488
BR00.45-Z-
188 ml. Article no.: Frankfurt Germany Tel. +49 69 7603-1 Fax +49 69 761061
1078-06A
03.9902-0501.2 www.conti-online.com
BR00.45-Z- MB Plastilube brake paste
A 002 989 37 51
1084-06A (brownish)
APPLY BRAKE PAD PASTE TO BRAKE PADS - AR42.10-P-0161-01B
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1057-06A MB brake paste Molykote (copper colored) A 001 989 87 51
BR00.45-Z-1083-06A MB Never Seeze brake paste (gray) A 001 989 94 51 12
BR00.45-Z-1084-06A MB Plastilube brake paste (brownish) A 002 989 37 51
1 or 2 piston floating brake caliper "ATE","Bosch","TRW" or "Lucas" in model 204, 207, 212, 218
on front or rear axle and 1 piston floating brake caliper "TRW" in model 166 on rear axle.
Contact surfaces may not be greased.
2, 4, 6 or 8-piston fixed brake caliper "Brembo"
1. Apply light coating of grease to contact surfaces with arrows only!
Only model 197, 212, 218 without code (B07) Ceramic brake system and only on the rear axle:
Lightly grease brake pad backing plates in the contact area of the brake pistons.
Only use MB brake paste Molycote (copper colored).
Fig. 31: Locating Contact Surfaces
Courtesy of MERCEDES-BENZ USA
4-piston fixed brake caliper "ATE" in model 463 on front axle or 2-piston fixed brake caliper "ATE" in
model 171, 203, 209 on rear axle
1. Apply light coating of grease to contact surfaces with arrows only!
For brake pads with damper plates: Fill grease pockets (1) MB brake paste.
Only use MB brake paste Never Seeze (gray).
Fig. 32: Locating Contact Surfaces (Model 171, 203 And 209 On Rear Axle)
Courtesy of MERCEDES-BENZ USA
1-piston floating brake caliper "Bosch" in model 211 on front axle or in model 463 on rear axle
1. Apply light coating of grease to contact surfaces with arrows only!
Do not grease damper plates of inner brake pads, as otherwise the rubber boots may swell up!
Only use MB brake paste Never Seeze (gray).
Fig. 33: Locating Contact Surfaces (Model 211)
Courtesy of MERCEDES-BENZ USA
1-piston floating brake caliper "TRW" or "Lucas" in model 171, 203, 209 on front axle
1. Apply light coating of grease to contact surfaces with arrows only!
Do not grease the pad and brake carriers, otherwise there may be problems with noise!
Only use MB brake paste Never Seeze (gray).
Fig. 34: Locating Contact Surfaces (Model 171, 203 And 209 On Front Axle)
Courtesy of MERCEDES-BENZ USA
1-piston floating brake caliper "TRW" or "Lucas" in model 168, 169, 245 on front or rear axle
1. Apply light coating of grease to contact surfaces with arrows only!
For brake pads with self-adhesive pad carriers do not grease the contact surfaces in the floating
brake caliper (2)!
Grease contact surfaces on brake carrier (3) before assembling the anti-rattle springs (4)! Do not
grease the anti-rattle springs (4)!
Only use MB brake paste Never Seeze (gray).
Fig. 35: Locating Contact Surfaces (Model 168, 169 And 245)
Courtesy of MERCEDES-BENZ USA
1, or 2-piston floating brake caliper "ATE" on front or rear axle
1. Apply light coating of grease to contact surfaces with arrows only!
Only use MB brake paste Plastilube (brownish).
Fig. 36: Locating Contact Surfaces
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL BRAKE PADS ON FIXED CALIPER - AR42.10-P-0161SX
MODEL 216, 221
Shown on 4-piston brake caliper on front axle
Fig. 37: Identifying Fixed Caliper Brake Pad Components - 4-Piston Brake Caliper
Courtesy of MERCEDES-BENZ USA
Shown on 8-piston brake caliper
Fig. 38: Identifying Fixed Caliper Brake Pad Components - 8-Piston Brake Caliper
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
1.9.10 "Perform brake test on test bench" reference changed Test sequence augmented/revised
Remove/install
Risk of poisoning caused by
Only pour brake fluid into suitable and
swallowing brake fluid. Risk of
appropriately marked containers. Wear protective AS42.50-Z-
injury caused by brake fluid
clothing and eye protection when handling brake 0001-01A
coming into contact with skin and
fluid.
eyes.
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and safety AS00.00-Z-
caused by handling hot or
glasses, if necessary. 0002-01A
glowing objects.
AR54.10-P-
1 Ensure vehicle idle (bus idle) Model 221.095 / 195
2000-01SX
Unscrew cap of brake fluid In order to prevent the expansion reservoir
2 reservoir and extract some brake overflowing when pressing back the brake pistons
fluid (47)
AH42.50-P-
Brake fluid notes
0001-01A
AH42.00-P-
Notes on repairs to brake system
0003-01A
AP40.10-P-
3 Remove wheels
4050SX
Checking
Check brake pads (43) and brake Replace brake pads (43) and brake disks (61)
4
disks (61) in complete sets if necessary.
AP42.10-P-
Check brake lining thickness
4253A
AP42.10-P-
Inspect condition of brake disks
4258SX
Separate electrical connector of
front right contact sensor or rear When removing brake pads (43) on right brake
5
right contact sensor (S10/2, caliper (31)
S10/4)
Pull out right front brake pad When removing the brake pads (43) on the right
6.1 contact sensor (S10/2) from 4-piston brake caliper (31) of the front axle, not
bracket on spring steel sheet (42) for model 221 with code (Z07) Top protection
Remove bolt (1) and remove
right front brake pad contact When removing the brake pads (43) on the right-
6.2
sensor (S10/2x1) from brake hand 8-piston brake caliper (31) of front axle
caliper (31)
Hammer out retaining pins (41) Installation: Drive retaining pins (41) all the
7
using a drift way into brake caliper (31).
8 Remove spring steel sheet (42)
4-piston brake caliper (31): Press out seized
brake pads (43) with lever (01). 8-piston brake
caliper (31): Pull out seized brake pads (43) with
pliers.
Brake pads (43) are to be disposed of as special
waste. The local authorities can provide
information regarding whether disposal is also
permitted as industrial waste similar to domestic
Pull brake pads (43) out of the waste.
9 Installation: Only the brake pads (43) Fig. 39
brake caliper (31)
approved by Mercedes-Benz may be built-in as a
set.
Installation: As of 12/05 running-direction
bound brake pads (43) are fitted in the 4-piston
brake calipers (31) on the front axle. Mount all
brake pads (43) so that the arrow on the lining
caliper (43p) points in the direction of rotation of
the wheel when driving forwards.
In the event of noise complaints only fit running
direction-bound brake pads (43).
Pull right front or right rear brake
Installation: Replace defective right front or
10 pad contact sensor (S10/2, S10/4)
right rear brake linings (S10/2, S10/4).
out of the brake pad (43)
Notes on installing brake wear AH42.10-P-
indicator contact sensors 0003-01A
Checking
Check brake caliper (31) for In the event of leaks: ? AR42.10-P-
11
leaks Install new front axle brake caliper. 0070SX
AR42.10-P-
Replace rear axle brake caliper.
0080SX
Check dust boots (47a) for damage and correct
Check dust boots (47a) of brake AR42.10-P-
12 seating, if necessary: ?
pistons (47) 0070SX
Install new front axle brake caliper.
AR42.10-P-
Replace rear axle brake caliper.
0080SX
Secure further pairs of pistons of the brake
caliper (31) before with the wedges (03) to
prevent them from falling out. If the brake pads
Press back brake piston (47) (43) are removed from several brake calipers (31),
13 their brake pistons (47) must also be secured to Fig. 40
using pusher tool (02)
prevent them from falling out.
Do not fit the pusher tool (02) to the
brake disk (61), but push back the opposite brake
Fig. 41
If brake pistons (47) are sluggish, the brake AR42.10-P-
caliper (31) must be replaced: ? 0070SX
Install new front axle brake caliper.
AR42.10-P-
Replace rear axle brake caliper.
0080SX
Clean
Do not damage the dust boots (47a) Do not
Clean the contact surfaces of the
14 brake pads (43) in the brake use any sharp-edged or pointed tools, otherwise *BR00.45-
the brake caliper (31) will be damaged. Z-1028-04A
caliper (31) with a rag
Cleaner from package
Only use the brake pastes listed in the
linked description, and apply it solely at the AR42.10-P-
15 Coat brake paste specified positions, otherwise there may be 0161-01B
problems with noise or damage to the brake
system!
*BR00.45-
MB brake paste Molykote (copper colored)
Z-1057-06A
*BR00.45-
MB Plastilube brake paste (brownish)
Z-1084-06A
16 Install in the reverse order
Risk of accident when
commissioning the vehicle due to Before starting engine, actuate brake pedal several
AS42.50-Z-
a lack of braking effect when the times until the pressure is built up and maintained
0002-01A
service brake is operated for the in the brake system.
first time after repair work
Model 221.095 /195: Fully depress brake pedal
10-times in quick succession.
Push down brake pedal several Model 216, 221 except 221.095 / 195:
17
times Operate brake pedal several times in succession,
until the brake pads (43) make contact with the
brake disks (61) and a solid resistance can be felt.
Checking
Check fluid level in brake fluid
AP42.10-P-
18 reservoir, and correct if
4210SX
necessary.
Never leave the vehicle unattended on the rollers
Risk of death caused by limbs except in an emergency. Ensure that no one is
being caught or crushed by under the vehicle or near rotating parts during AS42.00-Z-
rotating parts when performing testing. In case of emergency, use the 0001-01A
tests on the brake test stand EMERGENCY STOP switch to shut down test
stand.
Carry out brake test on the test AP42.00-P-
19
Fig. 39: Identifying Lever (123 589 13 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 40: Identifying Pusher Tool (000 589 52 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 41: Identifying Wedge (601 589 07 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Adolf Wurth GmbH & Co. KG Reinhold-Wurth-Str. 12-17 74653
BR00.45-Z-
Cleaner from package Kunzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940
1028-04A
15-1000 www.wuerth.de
MB brake paste A 001 989 87 51
1057-06A colored)
BR00.45-Z- MB Plastilube brake
A 002 989 37 51
1084-06A paste (brownish)
REMOVE/INSTALL BRAKE DISC - AR42.10-P-0220SX
MODEL 216
MODEL 221
Fig. 42: Identifying Brake Disc Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 43: Identifying Brake Disc Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 44: Identifying Brake Disc Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
17.3.11 Perform brake test on dynamometer, added Step 15
Remove/install
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and safety AS00.00-Z-
caused by handling hot or
glasses, if necessary. 0002-01A
glowing objects.
AH42.00-P-
Notes on repairs to brake system
0003-01A
Notes on self-locking nuts and AH00.00-N-
bolts 0001-01A
Information on preventing
damage to electronic AH54.00-P-
components due to electrostatic 0001-01A
discharge
1 Release parking brake Only if removing brake disk (1) on rear axle
Remove wheels AP40.10-P-
2
Remove/install wheels 4050SX
Clean
Clean electrical connector (A)
3 and its surroundings on control Only if removing brake disk (1) on rear axle
unit (A13)
Release and detach electrical
4 connector (A) on controller unit Only if removing brake disk (1) on rear axle
(A13)
sensor (L6/1 or L6/2) with
When removing brake disk (1) on the front axle AR42.30-P-
5 bracket (6b) out of the steering
except model 221.179, 216.379 0712SX
knuckle (7)
AR42.10-P-
6 Remove brake pads With fixed-caliper brake
0161SX
AR42.10-P-
With floating caliper brake
0160SX
Detach brake caliper support (2)
Vehicles with floating caliper brake: AR42.10-P-
7.1 from wheel carrier (10) or
Remove/install at front axle. 0070SX
steering knuckle (7)
AR42.10-P-
Remove/install at rear axle.
0080SX
Vehicles with fixed-caliper brake except model
Detach brake caliper (8) from
221 with code Z07 Top protection when removing AR42.10-P-
7.2 steering knuckle (7) or wheel
brake disk (1) on front axle: 0070SX
carrier (10)
Remove/install at front axle.
Remove/install at rear axle.
Fasten the brake caliper (8) to the vehicle
with hook. The brake hose (9) must not be AR42.10-P-
subjected to tensile loads or kinked, otherwise it 0080SX
will be damaged.
Do not detach brake hose (9).
Model 221 with code Z07 Top protection when AR42.10-P-
7.3 Remove both brake calipers (8)
removing brake disk (1) on front axle 0070SX
Checking
Check brake lining thickness and Only replace brake pads and brake disks (1) in
8
brake disks (1) complete sets if necessary.
AP42.10-P-
Check brake lining thickness
4253A
AP42.10-P-
Inspect condition of brake disks
4258SX
When removing the brake disk (1) on the
Remove locking bolt (3) and rear axle: On run-in parking brake drums turn AR42.20-P-
9 back the adjusting mechanism (4) beforehand.
remove brake disk (1) 0540SX
Otherwise the brake shoes (5) will be damaged:
See adjust parking brake.
*BA42.10-P-
1001-06G
*BA42.10-P-
1002-06G
Clean
Clean the contact surfaces (1a,
10 1b) and snug fit (1c) of brake
disk (1) if necessary
Grease the snug fit (1c) of the *BR00.45-Z-
11 Long-life grease
brake disk (1) slightly 1001-06A
Checking
After removing the brake disk (1) on the rear axle,
Check condition of brake shoes AR42.20-P-
12 if necessary: ?
(5) of parking brake 0530SX
Replace brake shoes (5) for parking brake.
13 Install in the reverse order
AR42.20-P-
14 Adjust parking brake After installing brake disks (1) on rear axle
0540SX
Carry out brake test on the test AP42.00-P-
15
stand 4290BA
BRAKE DISCS, BRAKE COVER PLATE
Number Designation Model 216 Model 221
BA42.10-P-1001-06G Safety bolt, rear axle brake disk to flange Nm 10 10
BA42.10-P-1002-06G Locking bolt, brake disk of front axle to wheel hub Nm 10 10
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11
REMOVE/INSTALL MASTER BRAKE CYLINDER - AR42.10-P-0300SX
MODEL 216.### 1#
MODEL 221.### 1#
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
1.9.10 "Perform brake test on test bench" reference changed Test sequence augmented/revised
Remove/install
Risk of poisoning caused by
Only pour brake fluid into suitable and
swallowing brake fluid. Risk of
appropriately marked containers. Wear protective AS42.50-Z-
injury caused by brake fluid
clothing and eye protection when handling brake 0001-01A
coming into contact with skin and
fluid.
eyes.
Notes on externally invisible AH42.10-P-
brake fluid loss 9406-02V
AR42.10-P-
1 Remove expansion reservoir (1)
0301SX
Mark brake lines (2) for
2
corresponding connection
Seal brake lines (2) and connections on
Detach brake lines (2) from master brake cylinder (3) immediately in order to *BA42.10-
3
master brake cylinder (3) prevent the ingress of foreign objects. P-1003-04K
Fig. 15
Fig. 13
Unscrew nuts (4) from brake *BA42.10-
4 h
booster (A7/7) P-1001-05J
The master brake cylinder (3) must not be
tilted , but rather removed straight out the front of
the brake booster (A7/7), as otherwise the thrust
Take out master brake cylinder rod will be pushed out of its axial location.
5
(3) Installation: Replace seal (6).
Installation: When inserting the master brake
cylinder (3) pay attention to the correct seat of the
pendulum support (5).
6 Install in the reverse order
AR42.10-P-
7 Bleed brake system
0010SX
Checking
Never leave the vehicle unattended on the rollers
Risk of death caused by limbs except in an emergency. Ensure that no one is
being caught or crushed by under the vehicle or near rotating parts during AS42.00-Z-
rotating parts when performing testing. In case of emergency, use the 0001-01A
tests on the brake test stand EMERGENCY STOP switch to shut down test
stand.
8 stand 4290BA
BRAKE LINES, BRAKE HOSES
Model 221 except Model
Number Designation
221.074/077/174/ 177/179 221.074/077/174 /177/179
BA42.10-P- Union nut, brake line to
Nm 17 17
1003-04K master brake cylinder
MASTER BRAKE CYLINDER
Number Designation Model 216 Model 221
BA42.10-P-1001-05J Nut, brake master cylinder to brake booster Nm 25 25
Fig. 46: Identifying Box Wrench Bit (000 589 75 03 00)
Courtesy of MERCEDES-BENZ USA
Fig. 47: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL BRAKE FLUID RESERVOIR - AR42.10-P-0301SX
MODEL 216.### 1#
MODEL 221.### 1#
Fig. 48: Identifying Brake Fluid Reservoir Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of poisoning caused by swallowing Only pour brake fluid into suitable and
brake fluid. Risk of injury caused by appropriately marked containers. Wear AS42.50-Z-
brake fluid coming into contact with skin protective clothing and eye protection 0001-01A
and eyes. when handling brake fluid.
AH42.00-P-
Notes on repairs to brake system
0003-01A
AH42.50-P-
Brake fluid notes
0001-01A
Unscrew screw cap (3) from expansion
1
reservoir (1)
Suction off brake fluid from the
2
expansion reservoir (1)
Disconnect the electrical connector (2)
3 from the brake fluid indicator switch
(S11)
*BA42.10-P-
4 Remove screw (5)
1002-05J
Seal the connections on the master
brake cylinder (4) in order to avoid the
Detach expansion reservoir (1) from
5 ingress of foreign objects. Fig. 15
master brake cylinder (4)
Installation: Replace seals (6)..
6 Install in the reverse order
Checking
Check brake system for leaks in the area
7
of the expansion reservoir (1)
MASTER BRAKE CYLINDER
Number Designation Model 216 Model 221
BA42.10-P-1002-05J Bolt, reservoir to master brake cylinder Nm 4 4
Fig. 49: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ELECTRIC PARKING BRAKE SWITCH - AR42.20-P-0505SX
MODEL 216
MODEL 221.0 /1
Fig. 50: Identifying Electric Parking Brake Switch Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Turn off ignition
Disconnect ground lines from AR54.10-
2
batteries P-0003SX
Lever out and remove left side
3 Fig. 51
cover (1) from instrument panel
4 Loosen screw (2)
Do not close driver door when left
instrument panel fuse box (F1/7) is removed,
Pull left instrument panel fuse box otherwise the instrument panel, door lining and left
5
(F1/7) out of instrument panel instrument panel fuse box (F1/7) will be damaged.
Installation: Observe routing of electrical
feed lines. Do not squeeze electrical feed lines!
Press catch springs (3) and pull
electric parking brake switch
6
(S76/15) forwards out of
instrument panel
Unplug electrical connector and
7 remove electric parking brake
switch (S76/15)
8 Install in the reverse order
Check
Check function of electric parking
9
brake switch (S76/15)
Fig. 51: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REAR BRAKE CABLE AT WHEEL CARRIER - AR42.20-P-0525-03SX
Removal
1. Press toggle (1a) of brake cable (1) upwards against the spring (2) in the expanding lock (3) using a
2. Pull brake cable (1) out of wheel carrier (4).
Mounting
3. Insert brake cable (1) into the wheel carrier (4) until the toggle (1a) latches into the expanding lock (3).
Fig. 52: Identifying Rear Brake Cable Components
Courtesy of MERCEDES-BENZ USA
DETACH/ATTACH BRAKE CABLES TO ELECTRIC PARKING BRAKE CONTROLLER UNIT -
AR42.20-P-0525-04SX
PARKING BRAKE
Model Model
Number Designation
216 221
BA42.20-P-1002- Union nut, brake cable to electric parking brake control
Nm 6 6
01K unit
Fig. 53: Identifying Tool Kit (000 589 10 99 00)
Courtesy of MERCEDES-BENZ USA
Fig. 54: Identifying Torque Wrench (001 589 72 21 00)
Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1005-06A Square support adapter 9x12 to 14x18
Detach/attach left brake cable
1. Unscrew union nut (1).
Installation: Observe tightening torque
Fig. 55: Identifying Left Brake Cable Components
Courtesy of MERCEDES-BENZ USA
2. Pull stop (2) out of electric parking brake controller unit (A13).
Installation: Guide anti-twist lock (2b) into the notch on the electric parking brake controller unit
(A13).
3. Release the claw tension retainer (3a) using a screwdriver and detach from tension claw (3).
Installation: Align the flat moldings (arrow) of the claw tension retainer (3a) and the tension claw (3)
with each other.
4. Detach tension claw (3) from electric parking brake controller unit (A13) and detach left brake cable (4).
5. Install in the reverse order.
Detach/attach right brake cable
1. Guide mechanical release cable (6) out of cable guide (5).
2. Unclip and detach cable guide (5).
3. Unscrew union nut (1).
Installation: Observe tightening torque
4. Pull stop (2) out of electric parking brake controller unit (A13).
Installation: Guide anti-twist lock (2b) into the notch on the electric parking brake controller unit
(A13).
5. Unscrew spindle (3) clockwise out of electric parking brake controller unit (A13) and detach right brake
cable (4).
revolutions into the electric parking brake controller unit (A13).
6. Install in the reverse order.
Fig. 56: Identifying Right Brake Cable Components
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REAR BRAKE CONTROL CABLE - AR42.20-P-0525SX
MODEL 216
MODEL 221
Fig. 57: Identifying Rear Brake Control Cable Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
1.9.10 "Perform brake test on test bench" reference changed Test sequence augmented/revised
Remove/install
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off of the lifting
support points specified by vehicle 0010-01A
platform.
manufacturer.
Information on preventing damage
AH54.00-P-
to electronic components due to
0001-01A
electrostatic discharge
The electric parking brake controller
unit (A13) may only be removed
and installed together with the brake
cables (1a, 1b) and the manual
release cable (2).
The brake cables (1a, 1b) may not
be detached from the electric
parking brake controller unit (A13)
which has been installed .
Under no circumstances may the
manual release cable (2) be
detached from the electric parking
brake controller unit (A13)
otherwise it will be damaged
Read out the number of actuations
If the permissible number of actuations is *BE42.20-
1 of the electric parking brake using
exceeded: ? P-1001-01G
STAR DIAGNOSIS
Replace electric parking brake controller unit AR42.20-P-
(A13). 0590SX
Use STAR DIAGNOSIS to bring
2 the brake cables (1a, 1b) into the
assembly position
AR42.10-P-
3 Remove rear brake disks
0220SX
Remove electric parking brake AR42.20-P-
4
controller unit (A13) 0590SX
Detach brake cables (1a, 1b) from
The brake cables (1a, 1b) may only be AR42.20-P-
5 the electric parking brake controller
replaced in pairs. 0525-04SX
unit (A13)
6 Install in the reverse order
AR42.20-P-
7 Adjust parking brake
0540SX
Checking
Never leave the vehicle unattended on the
Risk of death caused by limbs rollers except in an emergency. Ensure that no AS42.00-Z-
being caught or crushed by one is under the vehicle or near rotating parts 0001-01A
on the brake test stand EMERGENCY STOP switch to shut down test
stand.
AP42.00-P-
8 Carry out brake test on the test stand
4290BA
CHECK VALUES FOR ELECTRIC PARKING BRAKE
Model 221 Model 221
Model
Number Designation without code with code
216
Z07 Z07
Max. permissible number of actuations of
BE42.20-P- electric parking brake after which a new
Actuations 50.000 50.000 35.000
1001-01G electric parking brake controller unit must be
installed.
CONDITION BRAKE SHOES OF ELECTRIC PARKING BRAKE - AR42.20-P-0530-02SX
MODIFICATION NOTES
If a roller brake test stand is not available, condition the parking brake with STAR
27.3.06
DIAGNOSIS, note added
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
WORKSHOP EQUIPMENT
WE58.40-Z-1002-07A Roller brake test stand
Fig. 58: Identifying Electric Parking Brake Components
Courtesy of MERCEDES-BENZ USA
1. Switch off the Electronic Stability Program ESP; to do this, press the ESP Off switch (S6/2s11) in the
cockpit switch group (S6/2).
In order to avoid an active brake intervention of the Electronic Stability Program ESP.
ESP warning lamp (A1e41) in instrument cluster (A1) must light up.
2. Drive the vehicle with the rear axle onto the roller brake test stand and shift the transmission into position
"N" with the engine running
Have the wheels of the rear axle driven by the roller brake test stand for at least 10 seconds. In
order to avoid damage the brake shoes are then applied with a delay.
3. Press electric parking brake switch (S76/15) once briefly.
The brake shoes are brought into contact with the parking brake drums within 8 seconds, the roller
brake test stand switches off.
4. Loosen parking brake by pulling electric parking brake switch (S76/15)
5. Allow the parking brake to cool down for approx. 3 minutes.
6.1 Vehicles with code Z07 Top protection: Repeat process 4 times.
In order to avoid damage to the brake system, it is essential to comply with cooling down
6.2 Vehicles without code Z07 Top protection: Repeat process 3 times.
In order to avoid damage to the brake system, it is essential to comply with cooling down phases
7 Drive the vehicle off the roller brake test stand.
If the roller brake test stand is not available, condition parking brake using STAR DIAGNOSIS. Run
through the following steps: Select menu item "chassis"/"EFB-electric parking brake"/
"commissioning"/"bed in the brakes". Then process all the individual steps.
8 Switch on the Electronic Stability Program ESP; to do this, press the ESP Off switch (S6/2s11) in the
cockpit switch group (S6/2).
ESP warning lamp (A1e41) in instrument cluster (A1) must go out.
REMOVE/INSTALL BRAKE SHOES OF PARKING BRAKE - AR42.20-P-0530SX
MODEL 216
MODEL 221
Fig. 59: Identifying Parking Brake Shoe Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
1.9.10 "Perform brake test on test bench" reference changed Test sequence augmented/revised
Remove/install
Risk of death caused by Align vehicle between columns of vehicle lift and
AS00.00-Z-
vehicle slipping or toppling off position four support plates at vehicle lift support
0010-01A
of the lifting platform. points specified by vehicle manufacturer.
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and safety AS00.00-Z-
caused by handling hot or
glasses, if necessary. 0002-01A
glowing objects.
Notes on repairs to brake AH42.00-P-
system 0003-01A
Use STAR DIAGNOSIS to
1 bring the brake cables into the
assembly position
Hoist vehicle with lifting
2
platform until wheels are free
AP40.10-P-
3 Remove rear wheels
4050SX
AR42.10-P-
4 Remove rear brake disks (1)
0220SX
Unhook front retracting spring
5 (2) using the removal and Fig. 60
installation tool and remove
To do this, press together retaining spring (3)
Remove retaining springs (3) and turn through 90° counterclockwise or
6 Fig. 61
with installation tool clockwise.
Remove brake shoes (4) with
adjusting mechanism (5) and
7
rear retracting spring (6) over
the rear axle shaft flange
Remove adjusting mechanism
8 (5) and rear retracting spring (6) Installation: Turn back adjusting mechanism
(5). The adjusting wheel (5a) must point upwards.
from the brake shoe (4)
Installation: The bolt (7a) must point
9 Remove expansion lock (7) downwards, otherwise the correct function of the
parking brake is not provided
Checking
Check for damage. If the brake shoes (4) are
burnt or the parking brake drums are damaged (1a),
Check brake shoes (4) and
10 the brake shoes (4), retracting springs (2, 6),
parking brake drum (1a)
retaining springs (3), brake disks (1) and adjusting
mechanisms (5) should be replaced.
Check adjusting mechanism (5) Check for damage and ease of movement,
11
and expansion lock (7) replace if necessary.
12 Check cap (8) on brake stator marks and deformation, replace if necessary.
Notes on installing the cap on AH42.20-P-
the brake stator 0530-01T
13 Check brake cables Check for damage, if necessary: ? Replace rear AR42.20-P-
brake cables. 0525SX
Installation: Grease thread of thrust piece (5b)
*BR00.45-
14 Grease adjusting mechanism (5) and inner cylinder of adjusting mechanism (5)
lightly with MB-long-life grease. Z-1001-06A
Long-life grease
Installation: Grease pin (7a) and contact
surfaces on the expansion lock (7) lightly with MB *BR00.45-
15 Grease expansion lock (7)
long-life grease. Z-1001-06A
Long-life grease
16 Install in the reverse order
AR42.20-P-
17 Adjust parking brake
0540SX
Condition brake shoes of AR42.20-P-
18
electric parking brake 0530-02SX
Checking
Never leave the vehicle unattended on the rollers
Risk of death caused by limbs except in an emergency. Ensure that no one is
being caught or crushed by under the vehicle or near rotating parts during AS42.00-Z-
rotating parts when performing testing. In case of emergency, use the 0001-01A
tests on the brake test stand EMERGENCY STOP switch to shut down test
stand.
Carry out brake test on the test AP42.00-P-
19
stand 4290BA
Fig. 60: Identifying Removal And Installation Tool (116 589 01 62 00)
Courtesy of MERCEDES-BENZ USA
Fig. 61: Identifying Installation Tool (112 589 09 61 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11
ADJUST PARKING BRAKE - AR42.20-P-0540SX
MODEL 216
MODEL 221.0/ 1
Fig. 62: Identifying Thumbwheel, Parking Brake Shoe And Brake Disk
Courtesy of MERCEDES-BENZ USA
Adjust
Align vehicle between columns of vehicle
Risk of death caused by vehicle
lift and position four support plates at AS00.00-Z-
slipping or toppling off of the lifting
vehicle lift support points specified by 0010-01A
platform.
vehicle manufacturer.
Notes on repairs to brake system
0003-01A
1 Release parking brake
Hoist vehicle with lifting platform until
2
wheels are free
3 Remove rear wheels
AP40.10-P-
Remove/install wheels
4050SX
Direction of rotation for applying the
Turn right-hand and left-hand adjusting parking brake shoes (2):
wheel (1) with screwdriver until the Turn right-hand adjusting wheel (1)
4
parking brake shoes (2) abut the parking opposite to the direction of travel.
brake drums Turn the left-hand adjusting wheel (1) in
the direction of travel.
Checking
Check brake disks (3) for locking by It must not be possible to turn the
5
turning manually brake disks (3) by hand.
Release the left-hand and right-hand
Release the left-hand and right-hand *BE42.20-P-
6 adjusting wheel (1) by the same number
adjusting wheel (1) 1002-01G
of teeth.
Check brake disks (3) for unobstructed It must be possible to turn the brake
7
movement disks (3) completely freely by hand.
8 Operate parking brake
Check brake disks (3) for locking by It must not be possible to turn the
9
turning manually brake disks (3) by hand.
10 Release parking brake
Check brake disks (3) for unobstructed It must be possible to turn the brake
11
movement disks (3) completely freely by hand.
12 Fit rear wheels
AP40.10-P-
Remove/install wheels
4050SX
13 Lower vehicle
CHECK VALUES FOR ELECTRIC PARKING BRAKE
Model 221 Model 221
Model
Number Designation without code with code
216
Z07 Z07
Number of teeth by which adjusting wheel
BE42.20-P- Number
of adjusting mechanism must be loosened 10 (±1) 10 (±1) 10 (±1)
1002-01G of teeth
after the parking brake shoes make contact.
DETACH/ATTACH MECHANICAL RELEASE CABLE - AR42.20-P-0590-01SX
1. Open fuel filler flap.
2. Lever out plug (1).
3. Press catch springs (2a) carefully in the direction of the arrow using a screwdriver and pull out
mechanical release cable (2) downwards.
Installation: Replace O-ring (3) if necessary.
Fig. 63: Identifying Mechanical Release Cable Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 64: Identifying Mechanical Release Cable Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
4. Remove cable tie (arrow).
5. Remove mechanical release cable (2) from retaining clamps (4a) on fuel filler pipe (4).
Installation: Align the mechanical release cable (2) such that both colored marks (2b) are located at
the retaining clamps (4a).
6. Install in the reverse order.
REMOVE/INSTALL ELECTRIC PARKING BRAKE CONTROLLER UNIT - AR42.20-P-0590SX
MODEL 216
MODEL 221
Fig. 65: Identifying Electric Parking Brake Controller Unit Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
1.9.10 "Perform brake test on test bench" reference changed Test sequence augmented/revised
Remove/install
Risk of death caused by vehicle Align vehicle between columns of vehicle lift and
AS00.00-Z-
slipping or toppling off of the position four support plates at vehicle lift support
0010-01A
lifting platform. points specified by vehicle manufacturer.
Notes on self-locking nuts and
AH00.00-N-0001-01A
bolts
Information on preventing
AH54.00-P-
damage to electronic components
0001-01A
due to electrostatic discharge
The electric parking brake controller unit
(A13) may only be removed and installed
together with the brake cables (1a, 1b) and the
manual release cable (2).
The brake cables (1a, 1b) may not be detached
from the electric parking brake controller unit
(A13) which has been installed .
The mechanical release cable (2) must not be
detached from the electric parking brake
controller unit (A13) otherwise it will be
damaged.
Use STAR DIAGNOSIS to bring
1 the brake cables (1a, 1b) into the
assembly position
AP40.10-P-
2 Remove rear wheels
4050SX
Clean
Clean the electrical connector and
3 the area around it on the
controller unit (A13)
Remove cover (4) of electrical
connector from the electric
4
parking brake controller unit
(A13)
Release and disconnect electrical
5 connector on the electric parking
brake controller unit (A13)
AR42.10-P-
6 Remove rear brake disks
0220SX
Unhook brake cables (1a, 1b) AR42.20-P-
7
from the wheel carriers 0525-03SX
Remove fender liner in right rear
8
fender
Detach and expose manual
release cable (2) from the filler AR42.20-P-
9
neck recess in the right-hand rear 0590-01SX
fender
Unhook rubber grommet of the
10 right-hand brake cable (1b) from
the right-hand bearing bracket
Remove bolts (3a) and remove
11
heat shield (3)
Unscrew nuts (5) and remove
12 electric parking brake controller
1b) and remove manual release P-1001-01K
cable (2)
13 Install in the reverse order
AR42.20-P-
14 Adjust parking brake
0540SX
When replacing the electric parking brake
controller unit (A13)
Commission control unit of the
Run through the following steps: Select menu
electric parking brake controller
15 item "suspension" - "EFB-electric parking brake"
unit (A13) using STAR
- "commissioning" -"commissioning with manual
DIAGNOSIS, added
adjustment of the control unit". Then process all
the individual steps.
Checking
Never leave the vehicle unattended on the rollers
Risk of death caused by limbs except in an emergency. Ensure that no one is
being caught or crushed by under the vehicle or near rotating parts during AS42.00-Z-
rotating parts when performing testing. In case of emergency, use the 0001-01A
tests on the brake test stand EMERGENCY STOP switch to shut down test
stand.
Carry out brake test on the test AP42.00-P-
16
stand 4290BA
PARKING BRAKE
Number Designation Model 216 Model 221
BA42.20-P-1001-01K Nut, electric parking brake controller unit to bracket Nm 7 7
REMOVE/INSTALL LEFT FRONT OR RIGHT RPM SENSOR - AR42.30-P-0712SX
MODEL 216
MODEL 221
Fig. 66: Identifying RPM Sensor Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.176 with code Z07 Top protection
Fig. 67: Identifying RPM Sensor Components - Model 221.176 With Code Z07 Top Protection
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing
damage to electronic AH54.00-P-
components due to 0001-01A
electrostatic discharge
Notes on self-locking nuts AH00.00-N-
and bolts 0001-01A
1 Switch off ignition
Remove front wheel AP40.10-P-
2
Remove/install wheels 4050SX
Separate electrical connector
(1) from the RPM sensor See "Disconnect/connect front axle electrical AR33.10-P-
3
(L6/1, L6/2) and expose feed distributor connector". 0100-06SX
line
Model 221 with code Z07, top protection. *BA42.10-P-
4 Slacken bolt (5a)
1011-04K
Installation: Mount bracket (3) with RPM sensor
*BA42.30-P-
5 Remove bolt (2) (L6/1, L6/2).
1001-01J
Model 221 with code Z07, top protection.
Installation: Screw down the bolt (5a) until
Remove bolt (5a) and remove
6 finger-tight and do not tighten until the bolt (2) has
T-piece (5) from bracket (3)
been installed, otherwise the brake lines (6) could be
damaged as a result of deformation!
Pull RPM sensor (L6/1, L6/2)
7
out of steering knuckle (4)
Clean
Clean the mounting hole of
8 RPM sensor (L6/1, L6/2) in
steering knuckle (4)
Clean the RPM sensor (L6/1,
9 When reusing the RPM sensor (L6/1, L6/2)
L6/2)
10 Install in the reverse order
Read out fault memory and
erase if necessary AD00.00-P-
11
Connect STAR DIAGNOSIS 2000-04A
and read out fault memory
FRONT AXLE RPM SENSOR
Model Model
Number Designation
216 221
BA42.30-P-1001- Self-locking bolt, front axle RPM sensor to steering
Nm 25 25
01J knuckle
BRAKE LINES, BRAKE HOSES
Number Designation Model 221 except 221.074/077/174 /177/179
BA42.10-P-1011-04K Bolt, T-piece to bracket Nm 10
REMOVE/INSTALL BAS DIAPHRAGM TRAVEL SENSOR - AR42.31-P-6002SX
MODEL 216.### 1#
MODEL 221.### 1#
Fig. 68: Identifying BAS Diaphragm Travel Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Operate the brake pedal several times Until the vacuum in the brake booster (A7/7) is
1
when the engine is switched off reduced
Seal the vacuum line (1) and the connection on
Detach vacuum line (1) from brake the brake booster (A7/7) in order to prevent the ingress Fig.
2
booster (A7/7) and place to one side of foreign objects. 15
3 Disconnect connector (A7/7x1)
4 Pry circlip (2) out of groove (arrow) Installation: Note correct seating of circlip (2).
Pull out diaphragm travel sensor
5
(A7/7b1).
Check O-ring (3) on diaphragm travel
6 sensor (A7/7b1) and replace if
necessary
7 Install in the reverse order
Fig. 69: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ETS/ASR/ESP HYDRAULIC UNIT - AR42.40-P-0816SX
MODEL 216.### 1#
MODEL 221.### 1#
Fig. 70: Identifying ETS/ASR/ESP Hydraulic Unit Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
29.10.08 Value changed: Union nut, brake line to hydraulic unit *BA42.10-P-1004-04K
Remove/install
Risk of poisoning caused by Only pour brake fluid into suitable and
swallowing brake fluid. Risk of appropriately marked containers. Wear AS42.50-Z-
injury caused by brake fluid coming protective clothing and eye protection when 0001-01A
into contact with skin and eyes. handling brake fluid.
Information on preventing damage
AH54.00-P-
to electronic components due to
0001-01A
electrostatic discharge
AH42.50-P-
Brake fluid notes
0001-01A
AH42.00-P-
Notes on repairs to brake system
0003-01A
1 Switch off ignition
Remove right engine intake air duct
2 Except engine 642
(1)
Detach electrical connector from
coolant expansion reservoir (2) and
3
place coolant expansion reservoir
(2) to one side with lines connected
Vehicles with electrohydraulic power
4 Unhook power steering expansion steering (EHPS)
the connected lines reservoir, remove upwards and set aside with
connected lines.
Clean
Clean the hydraulic unit (A7/3) in
*BR00.45-
5 the area of the brake line Cleaner from package
Z-1028-04A
connections
Observe notes, otherwise damage to
the locking mechanism can occur!
Separate electrical connector (3) In order to avoid damage and AR42.45-P-
6 malfunctions, do not touch, deform or
from control unit (N47-5) 0820-02T
damage contacts of connector and jack! Do
not allow any foreign objects, dirt fluids to
enter the jack or connector!
Mark brake lines (4) for
7
corresponding connection
Seal brake lines (4) and connections
Detach brake lines (4) from
8 on the hydraulic unit (A7/3) in order to
hydraulic unit (A7/3)
prevent the ingress of foreign objects.
Installation: Pay attention to stress/
*BA42.10-
chafe-free routing of brake lines (4).
P-1004-04K
Fig. 15
Fig. 13
Fig. 16
Fig. 74
Fig. 72
Remove hydraulic unit (A7/3) with
9 Check rubber plugs fro damage and
bracket (5) upwards out of the
rubber plugs correct seat and replace if necessary.
Unscrew bolt (6) and remove When replacing the hydraulic unit (A7/3) *BA42.45-
10
bracket (5) P-1001-01L
11 Install in the reverse order
Carry out software update of control
12 unit (N47-5) using STAR
DIAGNOSIS
AR42.10-P-
13 Bleed brake system
0010SX
Checking
Read out fault memory and erase if
14
necessary
Connect STAR DIAGNOSIS and AD00.00-P-
read out fault memory 2000-04A
ELECTRONIC STABILITY PROGRAM (ESP)
Number Designation Model 216 Model 221
BA42.45-P-1001-01L Bolt, traction system hydraulic unit to bracket Nm 18 20
BRAKE LINES, BRAKE HOSES
Model 221 except Model
Number Designation
221.074/077/174/ 177/179 221.074/077/174 /177/179
BA42.10-P- Union nut, brake line
Nm 17 17
1004-04K to hydraulic unit
Fig. 71: Identifying Box Wrench Bit (000 589 75 03 00)
Courtesy of MERCEDES-BENZ USA
Fig. 72: Identifying Box Wrench Bit (140 589 00 03 00)
Courtesy of MERCEDES-BENZ USA
Fig. 73: Identifying Torque Wrench (001 589 87 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 74: Identifying Plug-In Joint Adapter (001 589 00 16 00)
Courtesy of MERCEDES-BENZ USA
Fig. 75: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Adolf Wurth GmbH & Co. KG Reinhold-Wurth-Str. 12-17 74653
BR00.45-Z- Cleaner from
Kunzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-
1028-04A package
1000 www.wuerth.de
REMOVE/INSTALL LEFT OR RIGHT REAR AXLE SPEED SENSOR - AR42.40-P-0820SX
MODEL 216 MODEL 221
Fig. 76: Identifying Rear Axle Speed Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to electronic components AH54.00-P-
due to electrostatic discharge 0001-01A
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
1 Remove rear wheel
AP40.10-P-
Remove/install wheels
4050SX
2 Unscrew plastic nuts (1a)
3 Remove expansion clip (2a)
loosen water shield (1) and fender liner (2) in rear
4
fender and fold away to the side
Press spring detent (3) in direction of the arrow and
5 pull plug (A) of the RPM sensor (L6/3, L6/4) out of
the distributor (B)
Remove feed line of RPM sensor (L6/3, L6/4) from Installation: Ensure
6 lines are installed
brackets (4a, 4b)
correctly.
*BA42.30-P-
7 Unscrew bolt (5) on RPM sensor (L6/3, L6/4)
1001-02I
Press bracket (4b) to one side and pull RPM sensor
8
(L6/3, L6/4) out of wheel carrier (6)
Clean
Clean contact surface of RPM sensor (L6/3, L6/4) on
9
When reusing the RPM
10 Clean RPM sensor (L6/3, L6/4)
sensor (L6/3, L6/4)
11 Install in the reverse order
Read out diagnostic trouble code memory using
12
STAR DIAGNOSIS and erase if necessary
Connect STAR DIAGNOSIS and read out fault AD00.00-P-
memory 2000-04A
REAR AXLE RPM SENSOR
Model Model
Number Designation
216 221
BA42.30-P-1001- Self-locking bolt of rear axle RPM sensor to wheel
Nm 8 8
02I carrier
DETACH/MOUNT CONNECTOR - AR42.45-P-0820-02T
Connector on ESP control unit
Fig. 77: Detaching/Mounting Connector
Courtesy of MERCEDES-BENZ USA
Disconnect electrical connector
In the event of damage to the bracket (1), connector (2) or connector locking mechanism it is essential to
replace the appropriate pars, otherwise the connector (2) can detach from the control unit (N47-5).
1. Open the connector locking mechanism; to do this, press both release buttons (1e) carefully from the
bottom upwards.
Do not use a tool! Do not open snap-in bracket (1n)!
2. Swivel bracket (1) upwards approx. 90°.
The connector (2) is pushed slightly out of the jack (3) on the control unit (N47-5).
3. Pull connector (2) out of jack (3).
In the process do not handle the connector (2) at the bracket (1), otherwise damage to the bracket
(1) and connector locking mechanism can occur!
4. Swivel bracket (1) downwards until the connector locking mechanism latches.
In order to avoid damage to the bracket (1) and connector locking mechanism.
Connect electrical connector
5. Open connector locking mechanism (see operation step 1).
6. Swivel bracket (1) upwards approx. 90°.
7. Insert connector (2) in jack (3) on control unit (N47-5) until this contacts the base of the jack (3) evenly
over its entire length.
In the process do not handle the connector (2) at the bracket (1), otherwise damage to the bracket
(1) and connector locking mechanism can occur!
8. Swivel bracket (1) downwards until the connector locking mechanism latches.
The connector (2) is drawn into its end position and locked.
REMOVE/INSTALL ELECTRONIC STABILITY PROGRAM (ESP) CONTROL UNIT - AR42.45-P-
0820SX
MODEL 216.### 1#
MODEL 221.### 1#
Fig. 78: Identifying Electronic Stability Program Control Unit Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 79: Identifying Electronic Stability Program Control Unit Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing
AH54.00-P-
damage to electronic components
0001-01A
due to electrostatic discharge
1 Switch off ignition
Remove right engine intake air
2
duct
3 Remove expansion reservoir (1) Vehicles with electrohydraulic power steering
(1a) Release expansion reservoir (1), remove
upwards and place to one side with hoses attached.
Remove holder (1a) for power
4.1 Vehicles with EHPS
steering expansion reservoir (1)
Detach electrical connector from
coolant expansion reservoir (2)
4.2 and place coolant expansion Vehicles without EHPS
reservoir (2) to one side with
lines connected
Clean
Before opening the brake system the area
around the separation point should be cleaned
thoroughly. Even the smallest particles of dirt,
introduced into the hydraulic components, can
Clean the surroundings of the
*BR00.45-
5 electrical connector (3) and the lead to malfunctions and a total failure of the
brake system. Z-1028-04A
control unit (N47-5)
Only use clean, lint free rags and cleaner free of
mineral oil. Do not use any compressed-air for
cleaning when the brake system is open.
Cleaner from package
Observe notes, otherwise damage to the
locking mechanism can occur!
Separate electrical connector (3) In order to avoid damage and AR42.45-P-
6 malfunctions, do not touch, deform or damage
from control unit (N47-5) 0820-02T
contacts of connector and jack! Do not allow any
foreign objects, dirt fluids to enter the jack or
connector!
Installation: Maintain torque exactly Too
large torque values lead to damage to the control
7 Remove bolts (5) unit (N47-5), too low to a defective connection of
the contact areas.
Installation: Replace bolts (5).
*BA42.45-
P-1002-01L
In order to avoid damage, neither touch the
Detach control unit (N47-5) from
8
hydraulic unit (A7/3) and remove contact areas and silicon seal by hand nor with a
tool.
Remove O-rings (6) of valve Do not use a tool otherwise the hydraulic
9
dome (7) by hand unit (A7/3) will be damaged.
Clean
Clean the sealing surface on the *BR00.45-
10 Cleaner from package
hydraulic unit (A7/3) Z-1028-04A
11 Install in the reverse order
using STAR DIAGNOSIS select the menu item "commissioning" and process
12
all steps.
Connect STAR DIAGNOSIS and AD00.00-P-
read out fault memory 2000-04A
ELECTRONIC STABILITY PROGRAM (ESP)
Number Designation Model 216 Model 221
BA42.45-P-1002-01L Bolt, ESP control unit to traction system hydraulic unit Nm 2 2
REPAIR MATERIALS
Number Designation Order number
Adolf Wurth GmbH & Co. KG Reinhold-Wurth-Str. 12-17 74653
R00.45-Z- Cleaner from
Kunzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000
1028-04A package
www.wuerth.de
REMOVE/INSTALL YAW RATE AND LATERAL ACCELERATION SENSOR - AR42.45-P-0841SX
MODEL 216, 221
Fig. 80: Identifying Yaw Rate And Lateral Acceleration Sensor Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Road test procedure with STAR DIAGNOSIS restricted (after replacing Operation step
25.11.08
sensor) 7
Perform initialization of DTR control unit after replacing sensor, added Step 8
Remove/install
Information on preventing damage
AH54.00-P-
to electronic components due to
0001-01A
electrostatic discharge
1 Switch off ignition
Loosen control unit (N10/2) and
AR54.21-P-
2 place to one side with lines
1258SX
connected
Release and disconnect electrical
3
connector from sensor (B24/15)
Unscrew nuts (1) and remove sensor Handle sensor (B24/15) with care. It is
4
(B24/15) sensitive to shocks.
5 Install in the reverse order
Read out fault memory and erase if
6
necessary
After replacing the sensor (B24/15)
Carry out road test as per STAR Under "control units" - "suspension" -
7
DIAGNOSIS "ABR" - "control unit adaptations" select the
menu item "road test" and process all steps.
Perform initialization of DTR After replacing sensor (B24/15) on vehicles
8 control unit with STAR with code (219) Distronic (DTR) or code
DIAGNOSIS (233) DISTRONIC PLUS
CABIN AIR FILTER
Mercedes - 216 & 221 Chassis
REMOVAL & INSTALLATION
NOTE: Manufacturer's terminology for this filter is Combination Filter.
CABIN AIR FILTER
NOTE: Numbers in parenthesis refer to numbers in illustrations.
Removal & Installation
1. The filters are located below the right side of the instrument panel, in passenger footwell (1). See Fig. 1.
Fig. 1: Removing Combinatin Filters
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Remove cover below instrument panel: Unscrew bolts (2). Lower cover (1). Disconnect electrical
Fig. 2: Removing Instrument Panel Cover
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Move sliding pieces (2) in direction of arrows and remove combination filter cover (3). See Fig. 1.
4. Remove combination filters (6) from air conditioner housing (5). See Fig. 1
5. To install filters, reverse removal procedure.
TRANSMISSION
Clutch - S-Class (221)
SAFETY PRECAUTIONS
SAFETY INFORMATION: CLUTCH - AS25.00-Z-9999ZZ
MODEL all
Risk of injury caused by body parts being trapped or
MODEL 375, 930, 932, AS25.00-Z-
Danger! crushed when working on the pressurized clutch
933, 934, 940, 944... 0001-01A
actuator
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: CLUTCH - BA25.00-Z-9999AZ
MODEL all
Clutch BA25.20-P-1000-
MODEL 168, 211, 414
actuation 01A
BA25.10-P-1000-
Clutch MODEL 172, 204, 207, 212
01H
MODEL 129, 140, 163, 170, 171, 203, 202, 208, 209, 210, 211, BA25.10-P-1000-
Clutch
230, 461, 463 01A
BA25.10-P-1000-
Clutch MODEL 168, 414
01B
BA25.10-P-1000-
Clutch MODEL 169, 245
01G
Clutch BA25.20-P-1000-
MODEL 245.2 with TRANSMISSION 711, 716
operation 01F
Clutch BA25.20-P-1000-
TRANSMISSION 711.6, 716.6
operator 01B
Clutch BA25.20-P-1000-
MODEL 169.0 /3 with TRANSMISSION 711, 716
operator 01E
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: CLUTCH - BE25.00-Z-9999AZ
MODEL all
Clutch MODEL 202, 203... BE25.10-P-1000-01B
Clutch MODEL 163, 170, 208, 209, 210, 211... BE25.10-P-1000-01C
Clutch MODEL 169, 245... BE25.10-P-1000-01D
Clutch MODEL 129, 140, 171, 202... BE25.10-P-1000-01A
Clutch actuation MODEL 129, 140, 202 BE25.20-P-1000-01A
WIRING DIAGRAMS
ELECTRIC WIRING DIAGRAMS: PASSENGER CARS: CLUTCH - PE25.00-Z-9999AZ
MODEL all
Survey of wiring diagrams clutch MODEL 168 with TRANSMISSION 716.5 PE25.00-P-1100GC
SPECIAL TOOLS
SPECIAL TOOLS: PASSENGER CARS: CLUTCH - WS25.00-Z-9999AZ
MODEL all
000 589 47 31 00 WS25.00-P-
FG 25/Set B
Alignment tool 0003B
115 589 07 23 00 WS25.00-P-
FG 25/Set A
Inspection gauge 0001A
129 589 00 91 00 Record FG 00/Set Z FG 01/05/06/07/09/14/15/18/20/22/25/26/ WS00.00-P-
plug 27/29/32/33/35/42/46/47/68/82/83/88/ 91/Set B 0255Z
140 589 03 09 00 Socket WS42.00-P-
FG 42/25/Set B
wrench 0032B
169 589 01 62 00 WS33.00-P-
FG 01/25/26/27/ 33/set B
Support fixture 0163B
169 589 02 31 00 Vehicle WS00.00-P-
FG 00/01/25/26/27/32/ 33/35
hoist securing tool 0281Z
171 589 01 31 00 Vehicle WS00.00-P-
FG 00/01/25/26/27/32/ 33/35/46
hoist securing tool 0282Z
201 589 08 15 00 WS25.00-N-
FG 25/Set B
Alignment punch 0002B
201 589 13 21 00 WS25.00-P-
FG 25/09/Set B
Vacuum tester 0012B
210 589 00 71 00 Hand WS00.00-P-
FG 00/01/07/09/20/25/ 27/32/33/43/46/88
pump 0280Z
220 589 00 99 00 WS54.00-P-
FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B
Electrical connection kit 0050B
220 589 00 99 07 WS54.00-P-
FG 15/25/42/43/54/Set B
Adapter line 0050-07B
220 589 00 99 20 Test WS54.00-P-
FG 15/20/25/42/43/54/ Set B
cable 0050-14B
220 589 00 99 22 Safety WS54.00-P-
FG 15/25/42/43/54/Set B
clamp 0050-16B
220 589 05 99 00 WS00.00-P-
FG 00/01/09/13/15/ 20/25/42/43/47/54/ 72/ Set B
Electrical connection kit 0279Z
651 589 00 40 00 WS03.00-P-
FG 01/03/05/07/18/ 25/27/Set B
Counterholder 0114B
ACCESSORIES & BODY, CAB
Electrical System, Equipment & Instructions - Basic Knowledge - S-Class (221)
BASIC KNOWLEDGE
NIGHT VIEW ASSIST, LOCATION OF COMPONENTS - GF54.30-P-0005-01LE
Shown on model 221.0 as of 1.6.09
Fig. 1: Locating Night View Assist Components
Courtesy of MERCEDES-BENZ USA
NIGHT VISION ASSIST, LOCATION OF COMPONENTS - GF54.30-P-0005-01SX
Shown on model 221.0
Fig. 2: Locating Night Vision Assist Components
Courtesy of MERCEDES-BENZ USA
NIGHT VISION ASSIST, NETWORKING OF COMPONENTS - GF54.30-P-0005-02SX
Fig. 3: Night Vision Assist Components Networking Diagram
Courtesy of MERCEDES-BENZ USA
NIGHT VIEW ASSIST, BLOCK DIAGRAM - GF54.30-P-0005-03LE
Fig. 4: Night View Assist Block Diagram
Courtesy of MERCEDES-BENZ USA
NIGHT VIEW ASSIST, FUNCTION - GF54.30-P-0005LE
MODEL 216.3, 221.0 /1 with CODE (610) Night vision assist as of model year 2009 /YoM 08
Function requirements, general
Circuit 15 ON
Rain/light sensor (B38/2) detects "twilight" or "night" with rotary light switch (S1) set to position
"AUTO" or "manual driving lights" (low beams ON)
Speed v < or =260 km/h
Vehicle in forward movement, gear range "R" not engaged
The request to "switch on low beams" can only be issued with a circuit 15 ON status. The EZS control unit
(N73) sends the status of circuit 15 via the interior CAN (CAN B) to the front SAM control unit with fuse and
relay module (N10/1). The upper control panel control unit (N72/1) reads in the status of the rotary light switch
via the instrument panel LIN (LIN 1) and sends it via the interior CAN to the front SAM control unit.
Night View Assist general
The Night View Assist system records people and obstacles in the driver's field of view, which are on the
roadway, before they appear in the conventional headlamp light cone. For this purpose, the Night View Assist
camera (B84/2) is located near the rain/light sensor. This is designed for infrared light and records the routing of
the road in front of the vehicle before dusk.
The image from the Night View Assist camera corresponds to the view through the windshield when the high
beams are switched on. After the images have been processed by the Night View Assist control unit (N101),
they are shown on the multifunction display (A1p13) of the instrument cluster (A1).
Fig. 5: View Of Night View Assist Image
Courtesy of MERCEDES-BENZ USA
The Night View Assist camera operates like a conventional camera, but with an extended infrared light
spectrum. The video picture is therefore also displayed when the infrared illumination is not activated.
The windshield must allow infrared light to pass through in the field of view of the Night View Assist camera
(possible negative influences are: barrier film, black print, adhesive labels, stone chippings, ice or dirt).
The Night View Assist camera must be recalibrated after replacement of the windshield or a component of
the Night View Assist system or after removal of the Night View Assist camera. The routing of the road is also
illuminated with infrared light at night and at a vehicle speed of v < 15 km/h.
Because infrared light is invisible to the human eye, oncoming traffic is not dazzled.
According to ambient brightness, the Night View Assist system differentiates between the following operating
modes:
Twilight mode
Night mode (low beams activated by "Auto on/off headlamps")
In twilight mode, only pictures recorded by the Night View Assist camera are shown in the multifunction
display.
Additionally, in night mode, the left infrared lamp (E1e11) is activated in the left front lamp unit (E1) and the
right infrared lamp (E2e11) is activated in the right front lamp unit (E2). The road in front of the vehicle is then
illuminated with infrared light up to s = 150 m.
The infrared light function test is carried out using a diagnosis tester and is possible for approx. t = 10 s. For
this purpose, a white surface (e.g. a piece of white paper) has to be held in front of the infrared lamp.
When observed from the side, a red-green shimmer can be seen on the white surface. A repeat of the function
test is only possible after t = 5 min.
The master control unit of the Night View Assist system is the Night View Assist control unit. This processes
all relevant information, evaluates it and controls the output of the pictures recorded by the Night View Assist
camera on the multifunction display of the instrument cluster.
Vehicles up to 31.5.09:
The Night View Assist control unit is a station on the vehicle dynamics CAN (CAN H). The ESP control unit
(N47-5) receives system-relevant information via the chassis CAN (CAN E) and sends this information via the
vehicle dynamics CAN to the Night View Assist control unit.
Vehicles as of 1.6.09:
The Night View Assist control unit is a station on the chassis CAN. This allows all system-relevant information
to be received directly by the Night View Assist control unit via the chassis CAN.
On model 221 as of 1.6.09 and on model 216 as of 1.6.10, the Night View Assist system also has the person
detection function "Intelligent Nightview" (night view with person detection) with which persons who are on
unlit roads outside built-up areas can be detected. The detected persons are shown with highlighted edges on the
multifunction display. Person detection is possible up to a distance of s = 90 m in front of the vehicle.
On vehicles as of 1.6.11, the headlamp light cone is additionally deflected toward the detected persons. This
function is referred to as "hazard illumination".
The Night View Assist system includes the following subfunctions:
Function sequence for Night View Assist
Intelligent Nightview, function sequence (model 221 as of 1.6.09 and on model 216 as of 1.6.10)
Hazard illumination ON, function sequence (as of 1.6.11)
Display of system messages, function sequence
Function sequence for Night View Assist
The Night View Assist system is activated by pressing the Night View Assist button (S1s9).
The upper control panel control unit reads in the status of the Night View Assist button via the instrument panel
LIN and sends this via the interior CAN, central gateway control unit (N93) and central CAN (CAN F) to the
instrument cluster and additionally to the Night View Assist control unit.
The Night View Assist control unit receives the status of the Night View Assist button via the following:
Upper control panel control unit
Interior CAN
Central gateway control unit
Chassis CAN
ESP control unit (up to 31.5.09)
Vehicle dynamics CAN (up to 31.5.09)
In addition, the instrument cluster checks the following conditions for display of the video images recorded by
the Night View Assist camera on the multifunction display:
Circuit status: circuit 15 ON
Low beams ON (daytime running lights ON or low beams ON request (auto on/off driving lights) set or
low beams switched on manually)
Rain/light sensor signals "twilight" or "night"
Speed v < or =260 km/h
Drive position "R" not engaged
The low beams can be switched on manually using the rotary light switch or automatically owing to the auto
on/off headlamps function (the rain/light sensor signals "twilight" or "night") or the daytime running lights.
The EZS control unit sends the status of circuit 15 via the chassis CAN, central gateway control unit and central
CAN to the instrument cluster.
The upper control panel control unit reads in the status of the rotary light switch via the instrument panel LIN
and sends this via the interior CAN, central gateway control unit and central CAN to the instrument cluster.
The rain/light sensor detects the ambient brightness. The overhead control panel control unit (N70) reads in the
data from the rain/light sensor and sends it via the interior CAN, central gateway control unit and central CAN
to the instrument cluster.
In addition, the overhead control panel control unit sends the "low beams ON" request (generated from the data
from the rain/light sensor (auto on/off driving lights)) via the interior CAN to the front SAM control unit. The
instrument cluster sends the request for the daytime running lights function via the central CAN, central
gateway control unit and interior CAN to the front SAM control unit. The front SAM control unit then sends the
"low beams ON" status (resulting from the request for manual or auto on/off driving lights or daytime running
lights) via the interior CAN, central gateway control unit and central CAN to the instrument cluster.
The instrument cluster calculates the vehicle speed from the wheel speeds that are detected by the following
sensors:
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
The ESP control unit (without model 221.095/195) or the regenerative braking system control unit (N30/6)
(model 221.095/195) reads in the signals from the RPM sensors and sends them via the chassis CAN, central
gateway control unit and central CAN to the instrument cluster.
If the function requirements are satisfied, the instrument cluster changes from the standard display of the
electronic speedometer (dial-type gauge) to the bar display with Night View Assist video image.
The "gear range R engaged" status is defined by the position of the transmission selector lever. The intelligent
servo module for DIRECT SELECT (A80) sends the transmission selector lever position via the drive train
CAN (CAN C), CDI control unit (N3/9) (with diesel engine) or ME-SFI control unit (N3/10) (with gasoline
engine), chassis CAN, central gateway control unit and central CAN to the instrument cluster.
With gear range R engaged or at a vehicle speed of v > 260 km/h, the video images recorded by the Night
View Assist camera are not displayed.
The instrument cluster then sends the "NightView mode active" status and information regarding the brightness
and contrast of the image shown in the multifunction display to the Night View Assist control unit.
The Night View Assist control unit receives this information via the following:
Instrument cluster
Central CAN
Central gateway control unit
Chassis CAN
ESP control unit (up to 31.5.09)
Vehicle dynamics CAN (up to 31.5.09)
The Night View Assist camera sends the video images via the digital video interface (low voltage differential
signal (LVDS) line) to the Night View Assist control unit.
The Night View Assist control unit evaluates the information from the instrument cluster and processes the
brightness distribution in the video images recorded by the Night View Assist camera. Extremely bright image
areas that could dazzle the driver are filtered out.
The Night View Assist control unit then also checks the following conditions for display of the video images
recorded by the Night View Assist camera on the multifunction display:
Low beams ON (up to 31.5.11)
Rain/light sensor signals "twilight" or "night"
Speed v < or =260 km/h
Gear range "R" not engaged (up to 31.5.11)
The overhead control panel control unit sends the "low beams ON" request (generated from the data from the
rain/light sensor (auto on/off driving lights)) via the interior CAN to the front SAM control unit. The front SAM
control unit then sends the "low beams ON" status (resulting from the request for manual or auto on/off driving
lights or daytime running lights) to the Night View Assist control unit.
The Night View Assist control unit receives this information via the following:
Front SAM control unit or overhead control panel control unit
Interior CAN
Central gateway control unit
Chassis CAN
ESP control unit (up to 31.5.09)
Vehicle dynamics CAN (up to 31.5.09)
The Night View Assist control unit receives the data from the rain/ light sensor via the following:
Overhead control panel control unit Interior CAN
Central gateway control unit
Chassis CAN
ESP control unit (up to 31.5.09)
Vehicle dynamics CAN (up to 31.5.09)
The Night View Assist control unit receives information regarding vehicle speed via the following:
Instrument cluster
Central CAN
Central gateway control unit
Chassis CAN
ESP control unit (up to 31.5.09)
Vehicle dynamics CAN (up to 31.5.09)
The Night View Assist control unit also receives the signals from the RPM sensors redundantly.
The Night View Assist control unit receives the position of the transmission selector lever via the following:
Intelligent servo module for DIRECT SELECT
Drive train CAN
CDI control unit or ME-SFI [ME] control unit
Chassis CAN
ESP control unit (up to 31.5.09)
Vehicle dynamics CAN (up to 31.5.09)
If the function requirements are satisfied, the Night View Assist control unit sends the processed video images
via the digital video interface (LVDS line) to the instrument cluster.
The video images recorded by the Night View Assist camera and processed by the Night View Assist control
unit are now shown on the multifunction display.
The rain/light sensor makes a distinction between the following brightness values on the basis of the ambient
brightness:
Day: Night View Assist system disabled
Twilight: Twilight mode (Night View Assist display activated)
Night: Night View Assist fully activated (infrared emitters additionally active)
In night mode, the infrared emitters in the front lamp unit are additionally switched on. The Night View Assist
control unit sends the request for this after the following input factors have been evaluated:
Rain/light sensor signals "Night"
Speed v < or =15 km/h
The front SAM control unit receives this "infrared emitters ON" request via the following:
Night vision assist control unit
Vehicle dynamics CAN (up to 31.5.09)
ESP control unit (up to 31.5.09)
Chassis CAN
Central gateway control unit
Interior CAN
The front SAM control unit then actuates the infrared emitters. If the vehicle speed drops below v = 5 km/h, the
infrared emitters are switched off.
Intelligent Nightview, function sequence (model 221 as of 1.6.09 and model 216 as of 1.6.10)
The multifunction camera sends corresponding information via the
The Intelligent Nightview function is intended to prevent accidents involving persons who are on unlit roads
outside built-up areas. As soon as the Night View Assist camera detects persons in its field of view during night
mode, they are shown with highlighted edges on the multifunction display.
For this it has to be defined whether the vehicle is in a town or on a non-illuminated country road. This is
accomplished by evaluating the data from the multifunction camera (A40/11).
The multifunction camera differentiates between light sources originating from one's own vehicle and
surrounding light sources (e.g. street lamps).
When the multifunction camera detects light sources not generated by the vehicle in the area surrounding the
vehicle, the Intelligent Nightview function (person detection) is deactivated.
chassis CAN to the Night View Assist control unit.
The Night View Assist system additionally evaluates the following information to predict the vehicle's own
movement:
Yaw behavior
Rotation angle and steering angle rate of change
The yaw rate sensor for lateral and longitudinal acceleration (B24/15) sends information regarding the yaw
behavior of the vehicle via the vehicle dynamics CAN, ESP control unit or regenerative braking system control
unit and chassis CAN to the multifunction camera and, on vehicles up to 31.5.11, also to the Night View Assist
control unit.
The steering angle and the steering angle speed are detected by the steering angle sensor (N49).
The steering column tube module (N80) reads in the data from the steering angle sensor and sends it via the
chassis CAN to the multifunction camera and, on vehicles up to 31.5.11, also to the Night View Assist control
unit.
On vehicles as of 1.6.11, this information is evaluated by the multifunction camera (A40/11) only.
Because of the way the person detection system works, misinterpretations can occur, e.g. objects are
perceived as individuals and shown with highlighted photo edges.
The identification rate drops off with increasingly unfavorable conditions (e.g. strong backlighting, rain, snow,
bright background or very darkly clothed people) and individuals are not shown highlighted.
Intelligent Nightview (person detection), function (model 221 as of 1.6.09, model 216 as of 1.6.10)
Fig. 6: View Of Intelligent Nightview (Person Detection) With Symbols
Courtesy of MERCEDES-BENZ USA
Additional function requirements for hazard illumination ON (as of 1.6.11)
Adaptive high beams function activated (combination switch (S4) in position "high beams")
Hazard illumination ON, function sequence (as of 1.6.11)
With the hazard illumination function, the headlamp light cone of the front lamp unit next to the road edge is
deflected toward the detected person.
The driver can thus avoid a potential collision with the detected person.
Vehicles ahead and oncoming road users are not dazzled. The hazard illumination function is always active and
can be deactivated by briefly holding down the Night View Assist button. The status icon in the multifunction
display disappears to indicate deactivation to the driver.
The multifunction camera sends status information for the adaptive high beams function to the Night View
Assist control unit. The Night View Assist control unit calculates the expected position of the detected person in
the driver's field of vision on the basis of various variables (e.g. vehicle speed) and sends corresponding data via
the chassis CAN, central gateway control unit and front end CAN (CAN G) to the xenon headlamp control unit
(E1n1) (on right-hand drive vehicles) or to the xenon headlamp control unit (E2n1) (on left-hand drive
vehicles). The corresponding xenon headlamp control unit then actuates the left light distribution actuator motor
(E1m3) (on right-hand drive vehicles) or the right light distribution actuator motor (E2m3) (on left-hand drive
vehicles) accordingly.
The cover that partially obstructs the low beam light cone is moved so that the low beam light cone is deflected
toward the detected person.
Hazard illumination active, function
Fig. 7: View Of Person Detection By System With Hazard Illumination Active Symbol
Courtesy of MERCEDES-BENZ USA
Display of system messages, function sequence
The Night View Assist control unit monitors the Night View Assist system. Detected malfunctions or faults are
recorded and shown to the driver as fault messages in the multifunction display.
The currently active function is indicated by means of an appropriate status icon.
The Night View Assist control unit sends corresponding data via the following:
Vehicle dynamics CAN (up to 31.5.09)
ESP control unit (up to 31.5.09)
Chassis CAN
Central gateway control unit
Central CAN
System messages:
"Nightview fault, drive to workshop!":
Faulty connection of the LVDS line
Faulty CAN connection
Infrared emitters defective
"Nightview currently unavailable":
Faulty CAN connection
"Nightview only when dark":
Rain/light sensor transmits "day"
Rain/light sensor defective
Faulty connection of the rain/light sensor
"Nightview lights ON or Auto not in R gear":
Exterior lights switch in left parking lights or right parking lights or standing light position
Gear range "R" engaged
"Nightview light switch set to Auto or low beams":
Exterior lights switch in left parking lights or right parking lights or standing light position
"Nightview no display in R gear"
Gear range "R" engaged
"Nightview no display above x km/h"
Vehicle speed v > 260 km/h
"Nightview available again":
Source of faults have been removed
GF54.30-P-0005-
Night View Assist, location of components
01LE
Electrical function schematic, Night View PE54.30-P-2053-
Model 216 up to 31.5.09
Assist 97CAB
PE54.30-P-2053-
Model 216 as of 1.6.09
97CAC
PE54.30-P-2053-
Model 221 up to 31.5.09
97SAB
PE54.30-P-2053-
Model 221 as of 1.6.09
97SAC
GF54.30-P-0005-
Night View Assist, block diagram
03LE
GF54.30-P-
Component description for instrument cluster A1
6000LE
Model 216, 221 (except
GF54.30-P-
221.095/195)
6000LEH
Model 221.095/195
A40/11
Component description for multifunction GF54.21-P-
Model 221 as of 1.6.09,
camera 3300LE
Model 216 as of 1.6.10
Component description for intelligent servo A80 GF27.19-P-
module for DIRECT SELECT Transmission 722.6 4020ACS
Transmission 722.9 (except GF27.19-P-
722.931/950) 4020AHS
GF27.19-P-
Transmission 722.931
4020AHT
GF27.19-P-
Transmission 722.950
4020LEH
Component description for yaw rate sensor for GF42.45-P-
B24/15
lateral and longitudinal acceleration 4810LE
Component description for Xenon headlamp E1n1, E2n1 GF82.10-P-
control unit As of 1.6.11 2114LE
N3/9 GF07.16-P-
Component description for CDI control unit
With engine 629 6000OA
GF07.16-P-
With engine 642.8
6000OHS
GF07.16-P-
On engine 642.9
6000OHL
GF07.16-P-
With engine 651
6000OLS
Component description for ME-SFI [ME] N3/10 GF07.61-P-
control unit With engine 156 6000MAS
With engine 272 (except GF07.61-P-
272.974) 6000MIS
GF07.61-P-
With engine 272.974
6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
With engine 276.9
6000MMB
GF07.61-P-
With engine 157.9, 278.9.
6000MMC
Component description for front SAM control GF54.21-P-
N10/1
unit with fuse and relay module 6070LE
Component description for regenerative N30/6 GF42.22-P-
braking system control unit On model 221.095/195 1100LEH
N47-5
GF42.45-P-
Component description for ESP control unit On model 216, 221 (except
5118LE
221.095/195)
Component description for overhead control GF82.20-P-
N70
panel control unit 5216LE
Upper control panel control unit, component GF54.21-P-
N72/1
description 6040LE
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for steering column GF54.21-P-
N80
tube module 6050LE
control unit N93 4170LE
Night View Assist control unit, component GF54.30-P-
N101
description 6200LE
NIGHT VISION ASSIST, FUNCTION - GF54.30-P-0005SX
MODEL 221.0 /1, 216.3 with CODE (610) Night vision assist up to Model Year 8
Fig. 8: Night Vision Assist Function Diagram
Courtesy of MERCEDES-BENZ USA
Function
With the night view assist system the course of the road is displayed visually in darkness in order to recognize
obstacles before they become visible in the conventional headlamp beam. To this end, the road in front of the
vehicle is illuminated by infrared lamps.
Infrared light is invisible to the human eye. Oncoming traffic is thus not dazzled.
The night view assist camera mounted in the area of the overhead control panel control unit is designed for
infrared light and records the direction of the road.
During the picture display the electronic speedometer is displayed as a bar graph. The Night View Assist
camera recordings are shown in the instrument cluster.
The display corresponds to the view through the windshield when the high beam is switched on. This means
that the driver still enjoys a "high beam" visible area.
The infrared lamps are activated depending on the degree of darkness and the speed of the vehicle.
The night view assist camera operates like a conventional camera, but with an increased infrared light
spectrum. For this reason a picture is not displayed when the infrared lamps are not activated.
Function requirements
Circuit 15 ON
After enable by the night view assist control unit the multifunction display in the instrument cluster changes
speedometer display and the display appears.
Rain/light sensor detects twilight or night
Active low beam
Drive position "R" not engaged
Vehicle speed above 15 km/h
Function sequence
The night view assist system is activated by pressing the night view assist button.
The request is read in by the upper control panel control unit via the upper control panel LIN and transmitted by
the ESP control unit to the night view assist control unit via the central gateway control unit.
Extremely bright picture areas, which could dazzle the driver, are suppressed and thus the driver is able to
perceive the other content in the picture (e.g. obstacles, pedestrians or cyclists). The brightness distribution is
processed in the night view assist control unit.
The rain/light sensor detects three brightness levels:
Day: Night view assist deactivated (no display)
Twilight: Night view assist partially activated (display only)
Night: Night view assist system fully activated (display and infrared lamps active)
GF54.30-P-
Night vision assist, location of components
0005-01SX
GF54.30-P-
Night vision assist, networking of components
0005-02SX
A1 GF54.30-P-
Instrument cluster, component description
Model 221 6000SX
Intelligent servo module (ISM) component A80 GF27.19-P-
description Model 221 with transmission 722.6 4015SXA
GF27.19-P-
Model 221 with transmission 722.9
4015SX
GF54.21-P-
Rain/light sensor, component description B38/2
6000SX
Night vision assist camera, component GF54.30-P-
B84/2
description 6220SX
E1, E2 GF82.10-P-
Lamp unit, component description
Model 221 2017SX
GF42.45-P-
Wheel RPM sensor, component description L6/1, L6/2, L6/3 and L6/4
5134SX
Driver-side SAM control unit with fuse and GF54.21-P-
N10/1
relay module, component description 6010SX
GF42.45-P-
Description of components in ESP control unit N47-5
5118SX
N62/1
Component description for radar sensors GF30.30-P-
Model 221 with engine 272, 273 and
control unit 3301SX
Code (233) Distronic Plus
Overhead control panel control unit, GF82.20-P-
N70
component description 5216SX
Upper control panel control module component GF54.21-P-
N72/1
description 6040SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
Night vision assist control unit, component GF54.30-P-
N101
description 6200SX
S1 GF82.10-P-
Rotary light switch, component description
Model 221 4106SX
ATTENTION ASSIST, LOCATION OF COMPONENTS - GF54.30-P-0009-02LE
Illustrated on model 221.0
Fig. 9: Locating Attention Assist Components
Courtesy of MERCEDES-BENZ USA
ATTENTION ASSIST, BLOCK DIAGRAM - GF54.30-P-0009-03LE
Fig. 10: Attention Assist Block Diagram
Courtesy of MERCEDES-BENZ USA
ATTENTION ASSIST, FUNCTION - GF54.30-P-0009LE
MODEL 216.3 as of model year 2011 /YoM 10 model refinement package
MODEL 221.0 /1 as of model year 2010 /YoM 09 model refinement package
Function requirements, general
Circuit 15 ON
Attention assist activated via menu in instrument cluster (A1)
Vehicle speed v = 80 to 180 km/h
The EZS control unit (N73) makes the status of circuit 15 available on the chassis CAN (CAN E).
Attention assist general
The ATTENTION ASSIST function assists the driver on long monotonous journeys, e.g. on freeways and
expressways, in a vehicle speed range of v = 80 to 180 km/h.
If attention assist establishes driver fatigue or increasing inattentiveness, it proposes a break.
The attention assist assesses driver fatigue or increasing inattentiveness by the analysis of steering ability by
means of steering wheel angle signals as well as driving conditions (time of day/night, driving time).
In the first t = 20 min. of monotonous driving individual parameters and a warning threshold are determined by
the driver. When the warning threshold is reached a visual as well as an acoustic warning message is issued by
the instrument cluster. Other factors are included in the assessment in order to increase reliability.
Attention assist functions in a restricted manner and a warning does not take place or takes place after a delay in
the case of:
Sporty driving style
Active driving situations (high cornering speeds, hard acceleration, lane change)
Very poor road surface condition (surface undulations, pot holes)
Continuous strong crosswind
Use of audio equipment, telephone or other systems
The master control unit for the ATTENTION ASSIST function is the ESP control unit (N47-5) (except model
221.095/195) or the regenerative braking system control unit (N30/6) (model 221.095/195).
The attention assist function is comprised of the following partial functions:
Activate attention assist function sequence
Recording steering movement function sequence
Evaluating steering movement function sequence
Output of warning message function sequence
Activate attention assist function sequence
Attention assist is activated as follows in the instrument cluster:
Select the "Assistance" menu with the system selection button (S110s3)
Select the "Attention assist" menu item with the scroll forward and back button (S110s1)
Confirm selection with the OK button (S110s6)
The status of the left multifunction steering wheel button group (S110) and right multifunction steering wheel
button group (S111) is read in by the steering column tube module (N80) via the steering LIN (LIN E1) and
made available to the ESP control unit or regenerative braking system control unit via the chassis CAN.
When the ATTENTION ASSIST function is active, the coffee cup symbol (1) appears in the instrument
cluster.
Attention assist can be deactivated by pressing the OK button again.
Fig. 11: Identifying Coffee Cup Symbol In Instrument Cluster
Courtesy of MERCEDES-BENZ USA
Recording steering movement function sequence
The steering movements are detected by the ATTENTION ASSIST sensor (B24/8) and read in directly by the
ESP control unit or by the regenerative braking system control unit.
Evaluating steering movement function sequence
Depending on the various variables, the ESP control unit or regenerative braking system control unit evaluates
the current data from the ATTENTION ASSIST sensor. The algorithm detects steering patterns in the steering
angle signal which occur more frequently with increasing fatigue and inattentiveness.
The algorithm is active and detects steering patterns in the case of:
a speed between v = 80 and 180 km/h
- monotonous trip (without high longitudinal or lateral acceleration)
no considerable external excitations (such as surface undulations or crosswind)
no operating interventions (e.g. audio equipment, various switches)
The individual driver parameters for detecting steering patterns are adapted continuously when the algorithm is
active. An individual warning threshold is also determined after driving for t = 20 min when the algorithm is
active. The sensitivity of the algorithm is adjusted depending on the driving time and time of day:
Determining time of day function sequence
Checking plausibility of time of day function sequence
Recording operating interventions function sequence
Determining time of day function sequence
The instrument cluster makes information on the current time of day available on the central CAN (CAN F).
The central gateway control unit (N93) reads in this information and passes it on to the ESP control unit or
regenerative braking system control unit via the chassis CAN.
Checking plausibility of time of day function sequence
The time of day is checked for plausibility via the rain/light sensor (B38/2). In the event of a dusk transition
implausible for the time of day, an entry is made in the diagnosis memory of the ESP control unit or
regenerative braking system control unit.
The overhead control panel control unit (N70) makes information from the rain/light sensor available on the
interior CAN (CAN B). The central gateway control unit passes this on to the ESP control unit or regenerative
braking system control unit via the chassis CAN.
Recording operating interventions function sequence
The recognition of steering patterns is suppressed in the event of a recognized control intervention at one of the
following components:
COMAND controller unit (A40/3)
Combination switch (S4)
Cruise control pushbutton switch (S40/4)
Steering column adjustment switch (S59) (without code (443) Steering wheel heater) or steering column
adjustment/steering wheel heater switch (S59/1) (with code (443) Steering wheel heater)
Left multifunction steering wheel button group and right multifunction steering wheel button group
The signals from the combination switch, cruise control push button, steering column adjustment switch or
steering column adjustment/steering wheel heater switch and multifunction steering wheel button groups are
transmitted by the steering column tube module on the chassis CAN. The signals from the COMAND controller
unit are transmitted via the central CAN to the central gateway control unit and from there on the chassis CAN.
The ESP control unit or regenerative braking system control unit receives all the data via the chassis CAN.
Additional function requirements, output of warning message
A relevant steering pattern recognized
Output of warning message function sequence
The ESP control unit or regenerative braking system control unit transmits the warning message request to the
central gateway control unit via the chassis CAN. The central gateway control unit passes on the request to the
instrument cluster via the central CAN.
The instrument cluster then displays a prompt telling the driver to take a break, and a double four-tone warning
signal sounds.
An active warning can be confirmed and thus ended with the OK button in the left multifunction steering
wheel button group. The next warning is only possible again after t < 15 min.
The status of the multifunction steering wheel button group is read in by the steering column tube module via
the steering LIN and made available to the ESP control unit or regenerative braking system control unit via the
chassis CAN.
Fig. 12: View Of Attention Assist Pause Message In Instrument Cluster
Courtesy of MERCEDES-BENZ USA
Attention assist, location of GF54.30-P-
components 0009-02LE
Electrical function schematic
PE54.71-P-
of ATTENTION ASSIST Model 221
2050-97SAA
function
PE54.71-P-
Model 216
2050-97CAA
Attention assist, block GF54.30-P-
diagram 0009-03LE
Component description for A1 GF54.30-P-
instrument cluster Model 216.3, model 221 (except 221.095/195) 6000LE
GF54.30-P-
Model 221.095/195
6000LEH
A40/3
Component description for With code (526) COMAND with single DVD drive GF82.85-P-
COMAND controller unit (without navigation) or code (527) COMAND APS 3136LE
with single DVD drive (with navigation system)
GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
Component description for
N30/6 GF42.22-P-
regenerative braking system
On model 221.095/195 1100LEH
control unit
Component description for N47-5 GF42.45-P-
ESP control unit Model 216.3, 221 (except 221.095/195) 5118LE
Component description for
GF82.20-P-
overhead control panel N70
5216LE
control unit
description N73 6003LE
Component description for GF54.21-P-
N80
steering column tube module 6050LE
Component description for GF54.21-P-
N93
central gateway control unit 4170LE
SPEED LIMIT ASSIST, LOCATION OF COMPONENTS - GF54.30-P-0012-01LE
Shown on model 221
Fig. 13: Locating Speed Limit Assist Components
Courtesy of MERCEDES-BENZ USA
SPEED LIMIT ASSIST, BLOCK DIAGRAM - GF54.30-P-0012-02LE
Fig. 14: Speed Limit Assist Block Diagram
Courtesy of MERCEDES-BENZ USA
SPEED LIMIT ASSIST, FUNCTION - GF54.30-P-0012LE
MODEL 216.3 with CODE (513) Speed Limit Assist as of model year 2011 /YoM 10 model refinement
package
MODEL 221.0 /1 with CODE (513) Speed Limit Assist as of Model Year 2010 /modification year 09
model refinement package
Function requirements general
Circuit 61 ON
Vehicle moving forward
The CDI control unit (N3/9) (with diesel engine) or the ME-SFI control unit (N3/10) (with gasoline engine)
transmits the status of terminal 61 ON via the chassis CAN (CAN E) to the MFK [multifunction camera]
(A40/11).
Speed Limit Assist, general
The following traffic signs are recorded and evaluated on the stretch of road being driven on by the vehicle. :
Speed limits
Speed limits, restricted through supplementary signs (as of 1.6.10)
Derestriction signs (as of 1.6.10)
As of 1.6.10, the attributes verified in the digital map of the navigation system are also evaluated.
The appropriate traffic signs are shown in the multifunction display (A1p13) and in the COMAND display
(A40/8) (without code (867) SPLITVIEW) or in the SPLITVIEW display (A40/10) (with code (867)
SPLITVIEW).
As a result information on the current permissible speed is available to the driver.
The function Speed Limit Assist is permanently active in the background.
In other words, the corresponding traffic signs are permanently recorded and evaluated by the MFK
[multifunction camera]. The manner in which the traffic signs are shown depends on the settings in the "Speed
Limit Asst." menu in the instrument cluster (A1).
The function Speed Limit Assist is currently available for the following countries:
Andorra (AD)
Belgium (BE)
Denmark (DK)
Germany (DE)
Great Britain (GB)
Gibraltar (GI)
France (FR)
Italy (IT)
Ireland (IE)
Luxembourg (LU)
Liechtenstein (LI)
Monaco (MC)
Netherlands (NL)
Austria (AT)
San Marino (SM)
Switzerland (CH)
Spain (ES)
In which of the countries listed the vehicle is located is defined by way of Global Positioning System (GPS)
signals.
These are read in and evaluated by the COMAND control unit (A40/3). The navigation data is sent from the
COMAND controller unit via the central CAN (CAN F) to the central gateway control unit (N93) which
forwards the data via the chassis CAN to the multifunction camera.
The Speed Limit Assist function is not available in the event of failure of the COMAND controller unit.
In the event of a temporary failure, the Speed Limit Assist function is only maintained for a travel distance of s
= 30 km.
The Speed Limit Assist function is permanently active, but must be activated in the "Assistance" menu of the
instrument cluster in order for information to be displayed. The instrument cluster sends the status via the
central CAN to the central gateway control unit which forwards the appropriate status via the chassis CAN to
the multifunction camera.
Function sequence of Speed Limit Assist
The Speed Limit Assist function consists of the following partial functions:
Picture recognition and evaluation function sequence
Function sequence for control and display concept
Picture recognition and evaluation function sequence
During a journey, the multifunction camera records - at a horizontal detection angle of Angle° = 34° - pictures
of the traffic signs mounted above or at the side of the road.
The recorded pictures are transmitted to the integrated picture recognition module which compares these with
the stored data records and assigns the traffic signs to the respective valid road traffic regulations.
The picture recognition module assigns credibility to all results.
The national regulations for the design and attachment of traffic signs are taken into account for this.
In addition the multifunction camera evaluates information on the area around the vehicle and on the vehicle's
own movement. These include:
Distance and angle to other road users and objects recorded by the multifunction camera itself
Navigation data from COMAND controller unit
Vehicle's intrinsic motion and yaw behavior, provided via chassis CAN by ESP control unit (N47-5)
(without model 221.095/195) or by regenerative braking system control unit (N30/6) (model
221.095/195)
The navigation data serve the plausibility check of objects recorded by the multifunction camera as well as the
fading out of speed limits displayed when driving into built-up areas.
If the camera does not detect any speed limits, the values verified in the digital card of the navigation system are
displayed. It is not necessary to actuate the navigation function (navigation system "sleep-mode").
Because speed limits are subject to alteration, the digital map
Information on the vehicle' own movement is derived from the wheel speeds as an indicator of vehicle speed.
The yaw rate sensor for lateral and longitudinal acceleration (B24/15) provides information on the yaw behavior
of the vehicle and transmits this via the vehicle dynamics CAN (CAN H) to the ESP control unit or to the
regenerative braking system control unit which passes on this information to the multifunction camera via the
chassis CAN.
data has to be regularly updated.
Generally valid speed limits in built-up areas, on expressways and freeways are not displayed.
After evaluation of the data, the multifunction camera sends a request to control the display of the currently
detected speed limit, to the instrument cluster and the COMAND controller unit via the chassis CAN, central
gateway control unit and central CAN.
If a data source (picture recognition, vehicle data or navigation data) fails, the most credible result is deduced
from the remaining data together with the stored past history data.
The multifunction camera combines this information to form a result even when the individual items of
information are contradictory.
Traffic signs recognized by multifunction camera:
Fig. 15: Identifying Traffic Signs Of Multifunction Camera
Courtesy of MERCEDES-BENZ USA
The MFK records all picture objects and evaluates circular as well as square contours.
Speed limits and derestriction symbols including additional restrictions in countries with signage according to
the Vienna convention are accordingly recorded.
If the navigation system is active, supplementary signs will be shown immediately if they are relevant for the
currently active navigation.
Supplementary signs not relevant for passenger cars (e.g. speed limits for trucks) are not shown. The number of
these traffic signs amounts to approx. 10% of all traffic signs.
Situations are listed as an example in the following, in which pictures recorded by the multifunction camera are
not usable and are not used for the display in the multifunction display.
Speed limits marked by town/village entry and town/village exit signs or by freeway start and finish signs are
not recorded. These traffic signs however, are filed through the road definition feature (e.g. freeway) in the
digital navigation map.
Fig. 16: Identifying Town/Village Entry And Exit Signs
Courtesy of MERCEDES-BENZ USA
Electronically actuated changing traffic signs can be "missed" or interpreted incorrectly. With alternating traffic
signs that pulse or flash, there may be a difference in the fixed cycle time for picture recording with regard to
the frequency of the alternating traffic sign, which in turn leads to only fragments of such alternating traffic
signs being detected.
If the picture cannot be fully recognized as a traffic sign it is not shown on the display.
Fig. 17: Identifying Traffic Sign In Red Color
Courtesy of MERCEDES-BENZ USA
Changing traffic signs on which the outer circle is missing are not shown either.
Fig. 18: Identifying Traffic Sign (Outer Circle Missing)
Courtesy of MERCEDES-BENZ USA
The horizontal angle of vision of the multifunction camera is limited.
Traffic signs erected immediately after junctions, turn-offs which the vehicle takes, can be "missed" by the
multifunction camera.
The horizontal recording angle of the multifunction camera is a = 34°.
Fig. 19: Identifying Horizontal Recording Angle Of Multifunction Camera
Courtesy of MERCEDES-BENZ USA
The vertical angle of vision of the multifunction camera is limited.
Traffic signs on sign bridges are only interpreted reliably up to a vehicle speed of v = 160 km/h.
In order to keep recognition certainty homogeneous over all vehicle speed ranges, the evaluation window of the
multifunction camera is downsized as the vehicle speed increases. The consequence of limiting the evaluation
window of the multifunction camera is that traffic signs installed low down, as used in construction sites, are
"missed" if they are passed at high speed.
Fig. 20: Identifying Dimensions Of Evaluation Window At Vehicle Speed
Courtesy of MERCEDES-BENZ USA
The resolution of the multifunction camera is limited.
Traffic signs on wide or multilane roads can be "missed" as they do not reach the size required for clear
identification in the evaluation window of the multifunction camera.
Fig. 21: Display Resolution Of Multifunction Camera
Courtesy of MERCEDES-BENZ USA
The sensitivity and dynamics of the multifunction camera is limited. This results in traffic signs not being
recognized under the following conditions:
Traffic signs with low contrast
Extreme oncoming lights or lights from the rear
Low levels of lighting, darkness
The focus and alignment of the multifunction camera are fixed. As a result recorded objects are represented
with a movement blur depending on the exposure time.
This movement blur and sensitivity of the multifunction camera limit its usefulness at night.
The result of the fixed focus and viewing direction is that the traffic signs to be recorded must be completely
visible in a small observation time window.
Recognition is not possible if the traffic sign is concealed by other objects within this observation window.
Unfavorably designed back-end sections of commercial vehicles may be interpreted as destriction signs by
mistake (left picture).
Signage on the back-end section of commercial vehicles may be interpreted as traffic signs by mistake (right
picture).
Fig. 22: Display Unfavorably Designed Back-End Sections Of Commercial Vehicle
Courtesy of MERCEDES-BENZ USA
Fig. 23: Display Signage On Back-End Section Of Commercial Vehicle
Courtesy of MERCEDES-BENZ USA
Information on the classification of roads and regional development are deduced from the navigation data
provided by COMAND controller unit.
By this means the system recognizes that the vehicle is leaving a road for which a speed limit identified earlier
was displayed. Since the picture recognition system is unable to cancel the display of a speed limit identified
outside a town/village when passing a town/ village entry sign, use is made of the navigation data.
With a change from a non-built-up area to a built-up area as defined by the markings for buildings on the
navigation map, the display of the last identified speed limit is canceled.
As the town/village limits do not always match the built-up area markings on the navigation map, the result of
this is that possibly the display of the last detected speed limit is either masked out too soon or continues to
remain displayed in the built-up area.
Situations resulting in the display not being removed or being removed unnecessarily are shown in the
following pictures.
Fig. 24: Display Information On Classification Of Roads And Regional Development
Courtesy of MERCEDES-BENZ USA
Function sequence for control and display concept
The graphical display of the Speed Limit Assist function is output via the multifunction display and also via the
COMAND display (without code (867) SPLITVIEW) or SPLITVIEW display (with code (867) SPLITVIEW).
Operation is via the menu of the instrument cluster using the left multifunction steering wheel button group
(S110).
The control and display concept is split up into the following subfunctions:
Operating concept
Display concept
Operating concept
Operation is via the "Speed Limit Asst." menu level of the instrument cluster using the following controls:
Left multifunction steering wheel button group
Scroll forward/back button (S110s1)
System selection button (S110s3)
OK button (S110s6)
The control signals of the left multifunction steering wheel button group are sent by the steering wheel
electronics (N135) via the steering LIN (LIN E1) to the steering column tube module (N80). The steering
column tube module sends the control signals via the chassis CAN to the central gateway control unit which
forwards the control signals to the instrument cluster via the central CAN.
The Speed Limit Assist function is selected as follows in the instrument cluster:
Selection of "Assistance" main menu (using scroll forward and back button and system selection button)
Confirmation of selection (using OK button)
Selection option: permanent display or information model
Display concept
The display concept distinguishes between the following variants:
Information mode
Permanent display
Error messages
Information mode
In the information mode, a detected traffic sign can be shown on any menu level on the instrument cluster for a
duration of t = 5 s and can be acknowledged within this time using the OK button.
The information mode can be switched on and off in the "Speed Limit Asst." submenu in the "Assistance"
menu.
The status is displayed by the fading in of the appropriate pictogram.
Permanent display
When the "Speed Limit" submenu in the "Assist" menu in the instrument cluster is selected, the detected traffic
sign is shown until the submenu is exited again.
If the information mode is switched off, recognized traffic signs are not shown permanently either.
The traffic signs are shown in the map view of the COMAND display regardless of the display selected in
the instrument cluster. This can be activated or deactivated in the "Speed Limit Information" navigation menu
of the COMAND controller unit.
The following events induce a display change or cancellation:
Recognition of a new speed limit
Recognition of a derestriction sign
No identification of a new road sign for a certain distance, depending on the type of road.
Passing recognized local limits
Change of road type (turnoff procedure)
Following this, a limit of the navigation system's digital road map is shown where available.
Error messages
of multifunction camera) or "System nonfunctional" (e.g. failure of multifunction camera or the navigation
system) is shown in the multifunction display.
The Speed Limit Assist pictogram also disappears in the multifunction display.
In countries in which the function Speed Limit Assist is basically not available the following message is issued:
"Speed limit assist not available in this country".
Display in multifunction display
Fig. 25: Display Speed Limit Assist Pictogram And Recognized Speed Limit
Courtesy of MERCEDES-BENZ USA
Visual output of derestriction sign
The following events cause the derestriction sign to be displayed (picture F):
Passing by a derestriction sign (picture F).
Passing by a derestriction sign with a speed value (picture G), if previously no traffic sign with a speed
value has been recognized.
The following events cause the derestriction sign to be displayed (picture G):
Passing by a derestriction sign with a speed value (picture G).
Passing by a derestriction sign restricted by a supplementary sign (picture G1) with speed value.
The following event leads to the display of a derestriction sign (picture H):
Passing a derestriction sign with speed value (picture G) which deviates from the speed value of the
traffic sign recorded in prior history (picture H1).
Fig. 26: Visual Output Of Derestriction Sign
Courtesy of MERCEDES-BENZ USA
GF54.30-P-0012-
Speed Limit Assist, location of components
01LE
Electrical function schematic, Speed Limit PE54.30-P-2059-
Model 216
Assist 97CAA
PE54.30-P-2059-
Model 221
97SAA
GF54.30-P-0012-
Speed Limit Assist, block diagram
02LE
A1
GF54.30-P-
Component description for instrument cluster Model 216.3, model 221
6000LE
(except 221.095/195)
GF54.30-P-
Model 221.095/195
6000LEH
Component description for COMAND GF82.85-P-
A40/3
controller unit 3136LE
A40/8
GF54.30-P-
COMAND display, component description Without code (867)
6110LE
SPLITVIEW
A40/10
GF54.30-P-
SPLITVIEW display, component description with code (867) SPLITVIEW
6120LE
as of 1.6.09
Component description for multifunction GF54.21-P-
A40/11
camera 3300LE
Yaw rate sensor for lateral and longitudinal GF42.45-P-
B24/15
acceleration, component description 4810LE
N3/9
GF07.16-P-
Component description for CDI control unit On model 221 with engine
6000OA
629.9
On model 221 with engine GF07.16-P-
642.8 6000OHS
On model 221 with engine GF07.16-P-
642.9 6000OHL
N3/10
Component description for ME-SFI [ME] GF07.61-P-
On model 221 with engine
control unit 6000MIS
272 (except 272.974)
On model 221 with engine GF07.61-P-
272.974 6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
On model 221 with engine GF07.61-P-
276 6000MMB
GF07.61-P-
On engine 157, 278
6000MMC
Component description for regenerative N30/6 GF42.22-P-
braking system control unit On model 221.095/195 1100LEH
N47-5
GF42.45-P-
Component description for ESP control unit Model 216.3, model 221
5118LE
(except 221.095/195)
Component description for steering column GF54.21-P-
N80
tube module 6050LE
Component description for central gateway GF54.21-P-
N93
control unit 4170LE
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, SPEED LIMIT ASSIST - GF54.30-P-
0991LE
MODEL 216.3 with CODE (513) Speed Limit Assist as of model year 2011 /YoM 10 model refinement
package
MODEL 221.0 /1 with CODE (513) Speed Limit Assist as of Model Year 2010 /modification year 09
Speed Limit Assist, function GF54.30-P-0012LE
Speed Limit Assist, location of components GF54.30-P-0012-01LE
Speed Limit Assist, block diagram GF54.30-P-0012-02LE
Overview of system components, Speed Limit Assist GF54.30-P-9990LE
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, ATTENTION ASSIST - GF54.30-P-
0992LE
MODEL 216.3 as of model year 2011 /YoM 10 model refinement package
MODEL 221.0 /1 as of model year 2010 /YoM 09 model refinement package
Attention assist, function GF54.30-P-0009LE
Attention assist, location of components GF54.30-P-0009-02LE
Attention assist, block diagram GF54.30-P-0009-03LE
Overview of system components, attention assist GF54.30-P-9991LE
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF COCKPIT CENTRAL DISPLAY -
GF54.30-P-0993SX
MODEL 221.0 /1, 216.3 up to Model Year 8
GF54.30-P-
Cockpit central display, function
0004SX
Cockpit central display, location GF54.30-P-
Model 221.0/1 up to 31.8.06
of components 0004-01SX
GF54.30-P-
Model 216.3, 221.0/1 as of 1.9.06
0004-01SXC
Cockpit central display, GF54.30-P-
Model 221.0/1 up to 31.8.06
networking of components 0004-02SX
GF54.30-P-
Model 216.3, 221.0/1 as of 1.9.06
0004-02SXC
Cockpit central display, GF54.30-P-
information on operation 0004-03SX
Activate cockpit central display, GF54.30-P-
function 2200SX
Adjust cockpit central display, GF54.30-P-
function 2210SX
Day and night design of cockpit GF54.30-P-
central display, function 2220SX
Full-screen mode of cockpit GF54.30-P-
central display, function 2230SX
Systems displayed in cockpit GF54.30-P-
central display, function 2240SX
With code (527) COMAND APS with Single DVD
GF54.30-P-
Navigation menu item, function disk drive (with navigation) with CODE (494) USA
3120SX
version
GF54.30-P-
with CODE (498) Japanese version
3120SXJ
with CODE (494) USA version except code (498)
Japanese version GF54.30-P-
Audio menu item, function
With code (527) COMAND APS with Single DVD 3130SXA
disk drive (with navigation)
GF54.30-P-
with CODE (498) Japanese version
3130SXJ
Except code (863) Digital/analog TV tuner with code
GF54.30-P-
Video menu item, function (527) COMAND APS with single DVD drive (with
3140SX
navigation), except code (863) Digital/analog TV tuner
With code (863) Digital/analog TV tuner with code
GF54.30-P-
(527) COMAND APS with single DVD drive (with
3140SXA
navigation), with code (863) Digital/analog TV tuner
GF54.30-P-
with CODE (498) Japanese version
3140SXJ
Communication and telephone GF54.30-P-
with code (388) Universal Portable CTEL
menu item, function 3150SX
Interface System
with code (386) Preinstallation for portable
CTEL UPCI [UHI] system
with CODE (494) USA version
With code (387) preinstallation for portable
CTEL UPCI system, USA/Canada
With code (389) Mobile phone preinstallation with
universal interface, USA/Canada
GF54.30-P-
with CODE (498) Japanese version
3150SXJ
GF54.30-P-
Vehicle menu item, function except code (498) Japanese version
3160SX
GF54.30-P-
with CODE (498) Japanese version
3160SXJ
Operation of climate control, GF54.30-P-
function 3170SX
Overview of cockpit central
GF54.30-P-
display system components,
9993SX
component description
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, NIGHT VIEW ASSIST - GF54.30-P-
0995LE
MODEL 216.3, 221.0 /1 with CODE (610) Night View Assist as of Model Year 2009 YoM 08
Night View Assist, function GF54.30-P-0005LE
Night View Assist, location of components GF54.30-P-0005-01LE
Night View Assist, block diagram GF54.30-P-0005-03LE
Overview of system components, Night View Assist GF54.30-P-9995LE
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, NIGHT VISION ASSIST - GF54.30-P-
0995SX
MODEL 221.0 /1, 216.3 with CODE (610) Night vision assist up to Model Year 8
Night vision assist, function GF54.30-P-0005SX
Night vision assist, location of components GF54.30-P-0005-01SX
Night vision assist, networking of components GF54.30-P-0005-02SX
Overview of system components, night vision assist GF54.30-P-9995SX
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF INSTRUMENT CLUSTER (IC) -
GF54.30-P-0997LE
MODEL 216.3, 221.0 /1 as of model year 2009 /YoM 08
Do not touch components and open lines of the
high-voltage on-board electrical system.
Risk of death when touching
Persons who are carriers of electronic implants AS54.00-Z-
components on vehicles with high-
(e.g. cardiac pacemakers), must not carry out 0001-01A
voltage on-board electrical system
any work on high-voltage onboard electrical
systems.
GF54.30-P-
Instrument cluster (IC), function
0002LE
Instrument cluster (IC), location of GF54.30-P-
components 0002-04LE
Instrument cluster (IC), block GF54.30-P-
diagram 0002-01LE
Instrument cluster (IC), operating GF54.30-P-
information 0002-05LE
GF54.30-P-
control/warning messages, function
2001LE
Display operating conditions, GF54.30-P-
function 3041LE
GF54.30-P-
Comfort displays, function
3043LE
GF54.30-P-
Trip computer, function
3044LE
GF54.30-P-
Settings on workshop level, function
2020LE
Overview of system components,
GF54.30-P-
instrument cluster (IC) component
9996LE
description
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF INSTRUMENT CLUSTER (IC) -
GF54.30-P-0997SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Instrument cluster (IC), function GF54.30-P-0002SX
GF54.30-P-0002-
Instrument cluster (IC), operating information
05SX
GF54.30-P-0002-
Instrument cluster (IC), networking of components
06SX
Activate instrument cluster, function GF54.30-P-2006SX
Instrument cluster illumination, function GF54.30-P-2007SX
Display monitoring/warning messages via indicator lamps, function GF54.30-P-2011SX
Display monitoring/warning messages via multifunction display, function GF54.30-P-2012SX
Output acoustic warning messages, function GF54.30-P-2013SX
Settings on workshop level, function GF54.30-P-2020SX
Display speed, function GF54.30-P-3025SX
Display operating conditions, function GF54.30-P-3041SX
Coolant/washer fluid level voltage coding, function GF54.30-P-4001SX
Overview of system components, instrument cluster (IC) component
GF54.30-P-9996SX
description
CONTROL/WARNING MESSAGES, FUNCTION - GF54.30-P-2001LE
MODEL 216.3, 221.0 /1 as of model year 2009 /YoM 08
Function requirements, general
Circuit 15R ON
The EZS control unit (N73) sends the status of circuit 15 to the instrument cluster (A1) via the chassis CAN
(CAN E), central gateway control unit (N93) and central CAN (CAN F).
control/warning messages, general
The instrument cluster control/warning messages notify the driver about the current state of the systems
installed in the vehicle. The instrument cluster can issue indicator and warning messages in the following ways:
Optical issue of indicator and warning messages
Acoustic output of indicator and warning messages
Visual control/warning messages:
The visual indicator and warning messages are displayed using the following instrument cluster components:
Multifunction display (A1p13) (e.g. variable indicator lamps and warning lamps, indicator/warning
messages)
Indicator/warning lamps
Audible control/warning messages:
The acoustic indicator and warning messages are issued using the following instrument cluster components:
Warning buzzer (A1h1)
Acoustic turn signal indicator (A1h2)
Variable indicator lamps and warning lamps in multifunction display: The variable indicator and warning lamps
are displayed in the multifunction display. They can change their position in the multifunction display
depending on the request. The following indicator and warning lamp are variable indicator and warning lamps:
Electric parking brake warning lamp (yellow)
Electric parking brake warning lamp (red)
Automatic lane recognition indicator lamp (with code (238) Active Lane Keeping Assist or with code
(476) Automatic lane recognition)
Attention Assist indicator lamp
Speed Limit Assist indicator lamp (with code (513) Speed Limit Assist)
ECO indicator lamp (with code (B03) ECO start/stop function)
READY indicator lamp (on model 221.095/195)
Speed warning lamp (with code (623) Gulf States version)
Left turn signal indicator lamp (A1e1)
Right turn signal indicator lamp (A1e2)
Brake fluid warning lamp (A1e7)
Seat belt warning lamp (A1e9)
ESP warning lamp (A1e41)
ESP indicator lamp (A1e42)
DTR warning lamp (A1e59) (with code (233) DISTRONIC PLUS or on model 216 with code (219)
Distronic (DTR) up to 31.8.10)
Tire pressure monitor warning lamp (A1e66) (with code (475) Tire pressure monitor (Premium))
The messages inserted in the multifunction display are subdivided into four categories corresponding to their
urgency:
Category 1 (messages with highest priority) Messages in category 1 refer to safety-endangering
conditions and situations and are displayed within a maximum of t = 2 s after their occurrence. These
messages cannot be acknowledged. When they occur, a brief warning is emitted by the buzzer.
Category 2 (messages with medium priority) Messages in category 2 require the intervention of the driver
and appear with a time delay of a maximum of t = 2 s. These messages also include operating feedbacks.
Category 2 messages can be acknowledged with the left multifunction steering wheel button group
(S110). When they occur, a brief warning is emitted by the buzzer.
Category 3 and 4 (messages with low priority)
These messages are menu displays and only serve as driver information (e.g. low washer fluid level). There is
no acoustic warning.
Messages with low priority are overlaid by messages with high priority. If several messages with the same
priority occur, the message currently displayed is cross-faded by the new message after expiry of the minimum
display time.
The control/warning messages consist of the following subfunctions:
Function sequence for hybrid readiness indicator (on model 221.095/195)
Function sequence for regenerative braking system control/ warning messages (on model
221.095/195)
Function sequence for passive Electronic Stability Program (ESP) switching
Function sequence for cruise control control/warning messages (on model 216 without code (219)
Distronic (DTR) or without code (233) DISTRONIC PLUS)
Function sequence for Distronic control/warning messages (with code (233) DISTRONIC PLUS or
on model 216 up to 31.8.10 with code (219) Distronic (DTR))
Function sequence for Safety-Brake-Control indicator/ warning messages
Function sequence for stationary heater (STH) warning messages (with code (228) Stationary
heater)
Function sequence for tire pressure loss warning (without code (475) Tire pressure monitor
(Premium))
Function sequence for tire pressure monitor warning messages (with code (475) Tire pressure
monitor (Premium))
Function sequence for memory adjustment control messages (on model 216, on model 221 with
code (275) Memory package (driver seat, steering column, mirrors))
Function sequence for audio/navigation/communication control messages
Function sequence for Keyless-Go control/warning messages (with code (889) Keyless Go)
Function sequence for control/warning messages for supplemental restraint system
PRE-SAFE warning messages function sequence
Function sequence for emergency call system control/ warning messages (with code (359) TELE
AID emergency call system)
Function sequence for AIRmatic control/warning messages (on model 221 without code (487)
Active Body Control (ABC), on model 216 with code (489) AIRmatic (air suspension with
Function sequence for Active Body Control (ABC) control/ warning messages (on model 221 with
code (487) Active Body Control (ABC), on model 216 without code (489) AIRmatic (air suspension
with continuous damper adjustment))
Function sequence for parking system control/warning messages (with code (220) PARKTRONIC
or on model 221 as of 1.6.09 and model 216 as of 1.9.10 with code (230) Exclusive parking assist)
Function sequence for antitheft alarm system (ATA [EDW]) control/warning messages (with code
(551) Antitheft alarm system (ATA [EDW]))
Night View Assist warning messages function sequence (with code (610) Night View Assist)
Function sequence for ATTENTION ASSIST control/ warning messages (on model 221 as of 1.6.09
and model 216 as of 1.9.10)
Function sequence for automatic lane recognition warning messages (as of 1.9.10 with code (238)
Active Lane Keeping Assist or on model 221 as of 1.6.09 and model 216 as of 1.9.10 with code (476)
Automatic lane recognition)
Function sequence for Speed Limit Assist control/warning messages (on model 221 as of 1.6.09 and
model 216 as of 1.9.10 with code (513) Speed Limit Assist)
Function sequence for Adaptive Highbeam Assist control message (on model 221 as of 1.6.09 or
model 216 as of 1.9.10 with code (608) Adaptive Highbeam Assist)
Function sequence for trailer recognition control/warning messages (on model 221 with code (550)
Trailer hitch)
Door open reminder warning function sequence
Function sequence for warning messages for the exterior lights (ABL)
Function sequence for lights on reminder warning
Parking brake warning function sequence
Function sequence for speed warning (with code (623) Gulf States version)
Function sequence, national seat belt reminder warning
Function sequence for coolant level and coolant temperature warning
Function sequence, engine oil level warning
Function sequence for preglow indicator lamp (with diesel engine)
Function sequence for brake wear indicator warning messages
Function sequence for brake fluid level warning messages
Function sequence for windshield washer system fluid level warning messages
Function sequence, turn signal confirmation
Function sequence for engine-control control/warning messages
Function sequence for filler cap warning (with code (494) USA version)
Function sequence for central locking acoustic feedback (as of 1.9.10)
Function sequence for ECO start/stop function (with code (B03) ECO start/stop function)
Function sequence for hybrid readiness indicator (on model 221.095/195)
When the ignition is switched on, the ME-SFI [ME] control unit (N3/10) and the battery management system
control unit (N82/2) check whether the hybrid drive is ready for operation. If the internal combustion engine is
switched off due to a hybrid request, the readiness indicator "Ready" appears in the instrument cluster.
As soon as the internal combustion engine is started again due to a hybrid request, this display disappears. The
battery management system control unit transmits the appropriate information to the instrument cluster via the
drive train sensor CAN (CAN I), ME-SFI control unit, chassis CAN, central gateway control unit and central
CAN.
Additional function requirements for regenerative braking system control/warning messages (on model
221.095/195)
Circuit 15 ON
Function sequence for regenerative braking system control/ warning messages (on model 221.095/195)
With regenerative braking a part of or the total braking torque is produced by the integrated starter alternator
(A79). The electrical energy produced here is used to charge the high-voltage battery (A100g1) in the high-
voltage battery module (A100). During regenerative braking, the instrument cluster actuates the regenerative
braking system indicator lamp (A1e20). The ME-SFI control unit transmits the corresponding request to the
instrument cluster via the chassis CAN, central gateway control unit and central CAN.
If the regenerative braking system control unit (N30/6) detects an ESP malfunction, the ABS indicator lamp
(A1e17) lights up and appropriate messages additionally appear in the multifunction display. The instrument
cluster actuates the ESP warning lamp in the event of an ESP control intervention function.
The regenerative braking system control unit transmits malfunction messages and fault messages via the chassis
CAN. The central gateway control unit passes on all the relevant information to the instrument cluster via the
central CAN.
Function sequence for passive ESP switching
Up to 31.8.09:
The ESP can be switched to passive mode manually by pressing the ESP OFF switch (S6/2s11) while the
engine is running. The upper control panel control unit (N72/1) reads in the status of the ESP OFF switch via
the instrument panel LIN (LIN 1) and sends it via the interior CAN (CAN B) to the central gateway control unit
and from there via the chassis CAN to the ESP control unit (N47-5) and via the central CAN to the instrument
cluster in order to actuate the ESP indicator lamp.
As of 1.9.09
The ESP can be switched to passive mode manually in the "Assistance" menu. If the ESP is switched to passive
mode, the instrument cluster actuates the ESP indicator lamp. The instrument cluster sends the ESP status
"activated" or "deactivated" via the central CAN to the central gateway control unit and via the chassis CAN to
the ESP control unit (except model 221.095/195) or to the regenerative braking system control unit (on model
221.095/195).
Additional function requirements for cruise control control/ warning messages (on model 216 without
code (219) Distronic (DTR) or without code (233) DISTRONIC PLUS)
Vehicle speed v > 30 km/h
The vehicle speed is calculated from the wheel speeds that the ESP control unit (except model 221.095/195)
or the regenerative braking system control unit (on model 221.095/195) makes available via the chassis CAN,
central gateway control unit and central CAN.
Function sequence for cruise control control/warning messages
(on model 216 without code (219) Distronic (DTR) or without code (233) DISTRONIC PLUS)
The cruise control then regulates the vehicle speed to an adjustable value. The cruise control is activated using
the CC [TPM] push button (S40/4).
The cruise-control control/warning messages consist of the following subfunctions:
Function sequence for cruise control display
Function sequence for variable speed limiter display (without code (494) USA version)
Permanent limiter display function sequence (without code (494) USA version)
Function sequence for cruise control display
If the cruise control is on, the stored speed is shown for t =5 s in the multifunction display and by a triangle in
the electronic speedometer (A1p8).
The speedo scale in the electronic speedometer is shown in the form of an open segment ring. The individual
segments symbolize various speed ranges and are actuated with different brightness and color.
The segment ring lights up between the set speed and the maximum speed.
Function sequence for variable speed limiter display (without code (494) USA version)
The variable speed limiter governs the vehicle speed to a configurable value that lies between v = 30 km/h
and the maximum speed. If the variable speed limiter is switched on, the segment ring in the electronic
speedometer lights up between the minimum speed and the set speed limit.
Permanent limiter display function sequence (without code (494) USA version)
The vehicle's maximum speed can be permanently governed on the instrument cluster to a value between 160
km/h (e.g. for winter tire operation) and the maximum speed.
A warning message appears in the multifunction display if the set speed is exceeded. In addition, the instrument
cluster actuates the warning buzzer. The permanent limiter can only be switched on and off in the corresponding
menu in the instrument cluster.
Additional function requirements for Distronic control/warning messages (with code (233) DISTRONIC
PLUS or on model 216 up to 31.8.10 with code (219) Distronic (DTR))
Vehicle speed v > 30 km/h (calculated by instrument cluster)
Function sequence for Distronic control/warning messages (with code (233) DISTRONIC PLUS or on
model 216 up to 31.8.10 with code (219) Distronic (DTR))
Distronic regulates the vehicle speed so that a minimum distance to the vehicle ahead is maintained. Distronic is
activated by pressing the cruise control push button. If the Distronic is switched on, the stored speed is marked
by a triangle in the electronic speedometer.
If the Distronic recognizes a vehicle ahead, the segment ring in the electronic speedometer lights up brightly
between the speed of the vehicle in front and the stored speed.
In addition, a tracking graphic appears in the multifunction display. In this pursuit graphic one's own vehicle is
shown on the right on the edge of the picture as well as the vehicle ahead shown on the left on the edge of the
picture.
In addition the following information is displayed:
Vehicle speed set
Current distance to vehicle ahead
Following distance
Additionally, if distance warning is switched on, the distance warning status indication (A1e23) lights up. If the
vehicle undershoots the safe distance to the vehicle in front, the DTR controller unit (A89) sends an appropriate
signal via the vehicle dynamics CAN (CAN H) to the radar sensors control unit (SGR) (N62/1) (with code (233)
DISTRONIC PLUS, without code (237) Active Blind Spot Assist, without code (238) Active Lane Keeping
Assist, model 221 with code (239) Plus Light adaptive cruise control) or to the video and radar sensor system
control unit (N62/2) (with code (237) Active Blind Spot Assist, with code (238) Active Lane Keeping Assist).
The radar sensors control unit or the video and radar sensor system control unit forwards this signal via the
chassis CAN, central gateway control unit and central CAN to the instrument cluster. The instrument cluster
receives the signal and actuates the DTR warning lamp.
Additional function requirements for Safety Brake Control indicator/warning messages
Circuit 15 ON (provided by EZS control unit)
Additional function requirements for supplemental restraint system control/warning messages
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for Safety Brake Control indicator/warning messages
If the ESP is switched to passive mode or with an ESP control intervention function, the instrument cluster
actuates the ESP warning lamp. If the ESP control unit (except model 221.095/195) or the regenerative braking
system control unit (on model 221.095/195) detects ESP malfunctions, the ABS indicator lamp (A1e17) lights
up and appropriate messages additionally appear in the multifunction display. Fault messages are placed on the
chassis CAN by the ESP control unit (except model 221.095/195) or the regenerative braking system control
unit (on model 221.095/195). The central gateway control unit passes on all the relevant information to the
instrument cluster via the central CAN.
Function sequence for control/warning messages for supplemental restraint system
If there is a fault in the supplemental restraint system, the restraint systems control unit (N2/7) sends
corresponding information via the chassis CAN, central gateway control unit and central CAN to the instrument
cluster.
The instrument cluster receives this information, actuates the airbag indicator and warning lamp (A1e15) and
issues appropriate messages via the multifunction display.
Additional function requirements, PRE-SAFE warning messages
Circuit 15 On (provided by EIS [EZS] control unit)
PRE-SAFE warning messages function sequence
If a fault is present in the PRE-SAFE system, the left front reversible emergency tensioning retractor (A76) (on
model 221) or the right front reversible emergency tensioning retractor (A76/1) (on model 221) sends
appropriate information via the chassis CAN, central gateway control unit and central CAN to the instrument
cluster. The instrument cluster receives this information, actuates the airbag indicator and warning lamp
(A1e15) and issues appropriate messages via the multifunction display.
Function sequence for STH warning messages (with code (228) Stationary heater)
The function of the STH is monitored by the STH control unit (A6n1) (model 216) or by STH or ZUH control
unit (A6n1) (model 221).
If the STH control unit detects an error or a malfunction in the STH, it sends a corresponding signal via the
interior CAN, central gateway control unit and central CAN to the instrument cluster. The instrument cluster
receives the signal and issues a corresponding message via the multifunction display.
Additional function requirements for tire pressure loss warning (without code (475) Tire pressure
monitor (Premium))
Vehicle speed v > 0 km/h (calculated by instrument cluster)
Tire pressure loss warning function sequence (without code (475) Tire pressure monitor (Premium)
A pressure loss at one of the tires is recognized by the change in wheel circumference and the associated change
in wheel speed. If the ESP control unit (except model 221.095/195) or the regenerative braking system control
unit (on model 221.095/195) detects a pressure loss at a tire, it sends a corresponding signal via the chassis
CAN, central gateway control unit and central CAN to the instrument cluster.
The instrument cluster receives this signal and issues a corresponding message on the multifunction display.
Additional function requirements for tire pressure monitor warning messages
(with code (475) Tire pressure monitor (Premium))
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for tire pressure monitor warning messages
(with code (475) Tire pressure monitor (Premium))
If the RDK control unit (N88) identifies a pressure loss on a tire, it transmits a corresponding signal
up to 31.5.09 on the interior CAN or
as of 1.6.09 on the chassis CAN.
The central gateway control unit relays the signal via the central CAN to the instrument cluster.
The instrument cluster receives this information, actuates the tire pressure monitor warning lamp (A1e66) and
issues appropriate messages via the multifunction display.
Function sequence for memory adjustment control messages (on model 216, on model 221 with code (275)
Memory package (driver seat, steering column, mirrors))
When storing a memory position, the left front seat control unit (N32/1) or right front seat control unit (N32/2)
transmits a request to output an acknowledgment tone to the instrument cluster via the interior CAN, central
gateway control unit and central CAN. The instrument cluster receives this request and outputs the
acknowledgment tone.
Additional function requirements for audio/communication/ navigation control messages
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for audio/communication/navigation control messages
The information on audio systems fitted in the vehicle is shown in the multifunction display.
Furthermore navigation information is shown in the multifunction display. The instrument cluster receives the
information from the COMAND controller unit (A40/3) via the central CAN.
In addition the telephone book is displayed via the multifunction display and can be processed accordingly. The
COMAND controller unit passes on the required information to the instrument cluster via the central CAN.
Additional function requirements for Keyless-Go control/ warning messages (with code (889) Keyless Go)
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for Keyless-Go control/warning messages (with code (889) Keyless Go)
If, during a start attempt, the KEYLESS-GO control unit (N69/5) does not recognize a valid transmitter key
(A8/1) or the DIRECT SELECT gear selector switch (S16/13) is not in the "P" or "N" position, a message
appears in the multifunction display. The KEYLESS-GO control unit transmits the corresponding information
via the interior CAN.
Function sequence emergency call system indicator/warning messages
(with code (359) TELE AID emergency call system)
The vehicle-related services are shown in the multifunction display. If the emergency call system control unit
(N123/4) establishes a fault on a self-test or if the emergency call system is activated, an appropriate message
appears in the multifunction display. The emergency call system control unit transmits the information
necessary for this via the diagnostic CAN (CAN D), central gateway control unit and central CAN to the
instrument cluster
The steering column tube module (N80) transmits the status of the DIRECT SELECT gear selector switch via
the chassis CAN. The central gateway control unit passes on all the relevant information to the instrument
cluster via the central CAN.
Additional function requirements for AIRmatic control/warning messages
(on model 221 without code (487) Active Body Control (ABC), on model 216 with code (489) AIRmatic
(air suspension with continuous damper adjustment))
Circuit 61 ON
The status of circuit 61 is sent by the CDI control unit (N3/9) (with diesel engine) or the ME-SFI [ME]
control unit (with gasoline engine) via the chassis CAN, central gateway control unit and central CAN to the
instrument cluster.
Function sequence for AIRmatic control/warning messages (on model 221 without code (487) Active
Body Control (ABC), on model 216 with code (489) AIRmatic (air suspension with continuous damper
adjustment))
If the AIRMATIC with ADS control unit (N51) identifies a fault in the AIRMATIC system, it sends
corresponding information via the chassis CAN, central gateway control unit and central CAN to the instrument
cluster. The instrument cluster receives this information and issues corresponding messages via the
multifunction display. There are various system messages or warning messages with different fault priorities. If
several faults exist at the same time, they are all displayed.
Additional function requirements for Active Body Control
(ABC) control/warning messages (on model 221 with code (487) Active Body Control (ABC), on model
216 without code (489) AIRmatic (air suspension with continuous damper adjustment))
Circuit 61 ON
(provided by CDI control unit or ME-SFI [ME] control unit)
Function sequence for ABC control/warning messages (on model 221 with code (487) Active Body
Control (ABC), on model 216 without code (489) AIRmatic (air suspension with continuous damper
adjustment))
The ABC system offers the driver different vehicle level settings. The set vehicle level is shown in the
multifunction display. Setting is performed via the level control switch (S6/2s10).
It is also possible to change the suspension tuning using the transmission mode button (A40/9s8). The
corresponding selection is shown in the multifunction display as well. The upper control panel control unit
reads in the status of the level control switch and the status of the transmission mode button via the instrument
panel LIN and transmits them on the interior CAN. System and warning messages with operating instructions
for the driver are also shown on the multifunction display. For this purpose, the ABC control unit (N51/2)
transmits corresponding information on the chassis CAN. The central gateway control unit forwards this to the
instrument cluster via the central CAN.
Additional function requirements for parking system control/ warning messages
(with code (220) PARKTRONIC or on model 221 as of 1.6.09 and model 216 as of 1.9.10 with code (230)
Exclusive parking assist)
Vehicle speed v < 16 km/h (calculated by instrument cluster)
No trailer operation (with code (550) trailer hitch)
No control intervention by the following systems within the past t = 5 s:
Antilock brake system (ABS)
ESP
The "trailer recognized" status is transmitted by the trailer recognition control unit (N28/1) on the interior
CAN. The ESP control unit (except model 221.095/195) or the regenerative braking system control unit (on
model 221.095/195) sends active ABS/ESP control intervention functions to the instrument cluster via the
chassis CAN, central gateway control unit and central CAN.
Function sequence for parking system control/warning messages
(with code (220) PARKTRONIC or on model 221 as of 1.6.09 and model 216 as of 1.9.10 with code (230)
Exclusive parking assist)
PARKTRONIC:
PARKTRONIC is displayed by means of a bar graph display in the electronic speedometer and on the rear
headliner. In addition an acoustic warning sounds depending on the distance to the obstacle.
The PTS control unit (N62) transmits the corresponding requests
up to 31.5.09 on the interior CAN or
as of 1.6.09 on the chassis CAN.
The central gateway control unit forwards them to the instrument cluster via the central CAN.
The PARKTRONIC function can be manually deactivated or activated using the PTS OFF switch (S6/2s12).
The light emitting diode in the PTS OFF switch lights up when the PARKTRONIC function is deactivated.
The status of the PTS OFF switch is read in by the upper control panel control unit via the instrument panel LIN
and is passed on to the PTS control unit via the interior CAN, central gateway control unit and chassis CAN. As
a result of this the PTS control unit deactivates or activates the PARKTRONIC function.
Parking system (without code (498) Japan version in model 221 as of 1.6.09 or in model 216 as of 1.9.10):
Based on the PARKTRONIC function the parking assist system indicates potential longitudinal parking spaces
in the multifunction display after it has measured them.
If the system measures a possible lengthwise (parallel) parking space, a white highlighted "P" symbol appears in
the multifunction display. Provided that the longitudinal parking space is defined as suitable, a blue stored "P"
symbol with direction arrow appears in the multifunction display.
The PTS control unit transmits corresponding information for this to the instrument cluster via the chassis CAN,
central gateway control unit and central CAN.
Provided that the vehicle has stopped with the usual parking distance to the longitudinal parking space shown
and reverse gear is engaged, the multifunction display in the strip speedometer changes and shows the vehicle
schematically from a bird's eye view in its position relative to the parking space.
Guide lines and steering instructions are displayed to ensure the driver parks the vehicle optimally. The output
of chimes points out
The measurements are made by the outer left front PTS ultrasonic sensor (B8/1) or outer right front PTS
ultrasonic sensor (B8/6), located in the side of the front bumper.
The data from the corresponding PTS ultrasonic sensor are read in and evaluated by the PTS control unit.
the proximity to an obstacle.
The intelligent servo module for DIRECT SELECT (A80) sends information about the current transmission
selector lever position to the PTS control unit via the drive train CAN (CAN C), ME-SFI [ME] control unit or
CDI control unit and chassis CAN.
(ATA))
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for ATA control/warning messages (with code (551) Antitheft alarm system (ATA))
The rear SAM control unit with fuse and relay module (N10/2) is the master control unit for the antitheft alarm
system. The rear SAM control unit transmits fault messages and information messages to the instrument cluster
via the interior CAN, central gateway control unit and central CAN. The instrument cluster receives this data
and then issues corresponding messages on the multifunction display.
Function sequence for Night View Assist warning messages (with code (610) Night View Assist)
The Night View Assist control unit (N101) monitors the Night View Assist function. If the Night View Assist
control unit identifies an error or a malfunction, it sends corresponding information
up to 31.5.09 via the vehicle dynamics CAN, ESP control unit, chassis CAN, central gateway control unit
and central CAN to the instrument cluster.
as of 1.6.09 via chassis CAN, central gateway control unit and central CAN to the instrument cluster.
The instrument cluster receives this data and then issues corresponding messages on the multifunction display.
Additional function requirements for ATTENTION ASSIST control/warning messages
(on model 221 as of 1.6.09 and model 216 as of 1.9.10)
Vehicle speed v = 80 to 180 km/h (calculated by ESP control unit (except model 221.095/195) or
regenerative braking system control unit (on model 221.095/195))
Function sequence for Attention Assist control/warning messages
(on model 221 as of 1.6.09 and model 216 as of 1.9.10)
Attention assist assists the driver on long monotonous trips e.g. on freeways and expressways in a vehicle speed
range of v = 80 to 180 km/h.
If attention assist establishes driver fatigue or increasing inattentiveness, it proposes a break. The attention assist
assesses driver fatigue or increasing inattentiveness by the analysis of steering ability by means of steering
wheel angle signals as well as driving conditions (time of day/night, driving time).
In the first t = 20 min. of monotonous driving individual parameters and a warning threshold are determined by
the driver. When the warning threshold is reached a visual as well as an acoustic warning message are issued by
the instrument cluster.
The ESP control unit (except model 221.095/195) or the regenerative braking system control unit (on model
221.095/195) sends the appropriate request to the instrument cluster via the chassis CAN, central gateway
the driver to take a break, and a warning tone sounds.
An active warning can be confirmed and thus terminated using the OK button (S110s6) on the left
multifunction steering wheel button group (S110). The next warning is only possible after t > 15 minutes. The
status of the multifunction steering wheel button group is made available to the ESP control unit (except model
221.095/195) or the regenerative braking system control unit (on model 221.095/195) via the steering LIN (LIN
E1), steering column tube module and chassis CAN.
Additional function requirements for automatic lane recognition warning messages (as of 1.9.10 with
code (238) Active Lane Keeping Assist or on model 221 as of 1.6.09 and model 216 as of 1.9.10 with code
(476) Automatic lane recognition)
Circuit 15 On (provided by EIS [EZS] control unit)
Function enabled via the instrument cluster
Radius of curve r > 150 m
Track width s = 2.2 up to 4.6 m
Identifiable lane markings present
Vehicle speed v = 60 to 250 km/h (calculated by instrument cluster)
Function sequence for automatic lane recognition warning messages (on model 221 as of 1.6.09 and model
216 as of 1.9.10 with code (476) Automatic lane recognition or as of 1.9.10 with code (238) Active Lane
Keeping Assist)
The automatic lane recognition function recognizes when the vehicle pulls out of a lane and warns the driver so
that he/she can react accordingly.
The traffic space in front of the vehicle is recorded and evaluated by the multifunction camera (A40/11). As
soon as a front wheel touches or drives over the road marking, the multifunction camera issues the request to
output the haptic warning. This takes place by actuating the steering wheel vibration motor (M99).
The current status of the automatic lane recognition function is shown in the multifunction display.
With code (238) Active Lane Keeping Assist, lane-correcting intervention by the brake system is requested if
the driver does not react fast enough.
Additional function requirements for Speed Limit Assist control/warning messages (on model 221 as of
1.6.09 and model 216 as of 1.9.10 with code (513) Speed Limit Assist)
Circuit 61 ON (provided by CDI control unit or ME-SFI [ME] control unit)
Vehicle moving forward
Permanent display:
In the case of permanent display in the multifunction display, the detected speed limit is displayed permanently
until one of the following events occurs:
Recognition of a new speed limit
Recognition of a derestriction sign
Function sequence for Speed Limit Assist control/warning messages (on model 221 as of 1.6.09 and model
216 as of 1.9.10 with code (513) Speed Limit Assist)
The Speed Limit Assist function records the speed limits shown for the stretch being driven on by the vehicle.
These are shown in the form of a traffic sign in the multifunction display.
The Speed Limit Assist function status is shown by a symbol in the multifunction display.
The display concept distinguishes between the following modes:
Permanent display
Information mode
Passing recognized local limits
Recognition of turning off process
Change of road type
Information mode:
In information mode the recognized speed limit can be displayed in the form of a traffic sign for a period of t =
5 s. This information can be acknowledged within this period. The information mode can be switched on or off
by the driver.
The multifunction camera transmits corresponding requests for the control of the display via the chassis CAN,
the central gateway control unit and central-CAN to the instrument cluster.
Additional function requirements for Adaptive Highbeam Assist control message
(on model 221 as of 1.6.09 or model 216 as of 1.9.10 with code (608) Adaptive Highbeam Assist)
Function enabled in instrument cluster
Function sequence for Adaptive Highbeam Assist control message (on model 221 as of 1.6.09 or model
216 as of 1.9.10 with code (608) Adaptive Highbeam Assist)
The adaptive highbeam function is an assistance function in which the headlamp range of the xenon bulbs is
adapted to the distance of the nearest road user in front or approaching from the opposite direction. The status of
the adaptive high beams function is shown in the multifunction display.
For this purpose, the multifunction camera transmits corresponding information via the chassis CAN, central
gateway control unit and central CAN to the instrument cluster.
Additional function requirements for trailer recognition control/warning messages
(on model 221 with code (550) Trailer hitch)
Circuit 15 On (provided by EIS [EZS] control unit)
Trailer detected
Function sequence for trailer recognition control/warning messages (on model 221 with code (550)
Trailer hitch)
If the trailer recognition control unit identifies a malfunction in the electrical system (e.g. exterior lights) then a
corresponding signal is relayed via the interior CAN, central gateway control unit and central CAN to the
instrument cluster.
The instrument cluster outputs the respective fault message in the multifunction display.
Additional function requirements for door open reminder warning
Vehicle speed v > 3 km/h (calculated by instrument cluster)
Function sequence, door open reminder warning
If an open door, open trunk lid or open engine hood (with code (551) Antitheft alarm system (ATA [EDW])) is
detected at a speed of v > 3 km/h, the instrument cluster issues an acoustic warning and displays an appropriate
message in the multifunction display. The following control units provide the status of the doors, trunk lid and
engine hood available via the interior CAN:
Left door control unit (N69/1) (model 216) or left front door control unit (N69/1) (model 221): left front
door status
Right door control unit (N69/2) (model 216) or right front door control unit (N69/2) (model 221): right
front door status
Left rear door control unit (N69/3) (model 221): left rear door status
Right rear door control unit (N69/4) (model 221): right rear door status
Rear SAM control unit: trunk lid status and engine hood status
The central gateway control unit passes on all the relevant information to the instrument cluster via the central
CAN.
Additional function requirements for exterior lighting (ABL) warning messages
Circuit 15 On (provided by EIS [EZS] control unit)
Exterior lighting (ABL) function sequence
The functions of the relevant exterior lighting (ABL) components are permanently monitored.
If a fault is detected at a component, the monitoring control unit transmits an appropriate signal on the interior
central CAN. The instrument cluster receives this data and issues a corresponding message on the multifunction
display.
The following control units monitor the function of the relevant exterior lighting (ABL) components:
Front SAM control unit with fuse and relay module (N10/1)
Rear SAM control unit
Left door control unit or front left door control unit
Right door control unit or front right door control unit
Trailer recognition control unit (on model 221 with code (550) Trailer hitch)
Xenon headlamp control unit (E1n1) at left front lamp unit (E1) (on model 221 up to 31.5.09 with code
(615) Bi-xenon headlamp unit with integrated curve illumination or code (616) Bi-xenon headlamp unit
with integrated asymmetrical curve illumination, model 221 as of 1.6.09, on model 216)
Xenon headlamp control unit (E2n1) at right front lamp unit (E2) (on model 221 up to 31.5.09 with code
(615) Bi-xenon headlamp unit with integrated curve illumination or code (616) Bi-xenon headlamp unit
with integrated asymmetrical curve illumination, model 221 as of 1.6.09, on model 216)
On model 216, model 221 (as of 1.6.09) and model 221 with code (615) Bi-xenon headlamp unit with
integrated curve illumination or code (616) Bi-xenon headlamp unit with integrated asymmetrical curve
illumination) (up to 31.5.09), the xenon headlamp control unit at the left front lamp unit and the xenon
headlamp control unit at the right front lamp unit monitor the cornering lights and dynamic curve illumination
functions.
If a xenon headlamp control unit identifies a fault or the failure of a relevant component, it sends corresponding
information via the front end CAN (CAN G), central gateway control unit and central CAN to the instrument
cluster. The instrument cluster receives this data and then issues corresponding messages on the multifunction
display.
Additional function requirements for lights on reminder
Standing lights ON
Driver door OPEN
Transmitter key removed
Lights on reminder function sequence
The logic for actuating the lights on reminder warning function is stored in the instrument cluster. The front
SAM control unit transmits the status "Standing lights actuation active" to the instrument cluster via the interior
CAN, central gateway control unit and central CAN.
The status of the driver door is provided by the left door control unit or left front door control unit on the
interior CAN and the current status of circuit 15 is provided by the EZS control unit on the chassis CAN.
The central gateway control unit passes on all the relevant information to the instrument cluster via the central
CAN. The instrument cluster combines this with the status of the headlamp switch-off delay (SWA) function
and actuates the warning buzzer accordingly.
The message "Switch off lights" appears in the multifunction display.
Standing lights may be on due to low beams having been switched on manually, auto on/off headlamps having
been switched on, daytime running lights being on or because they have been switched on manually by means
of the rotary light switch (S1). If the standing lights have been activated by manually switching on the low
beams, the auto on/off headlamps or the daytime running lights and the driver door is then opened when a
transmitter key is inserted in the EIS [EZS] control unit, the standing lights are switched off.
If the transmitter key is removed from the EIS [EZS] control unit when the rear fog light actuation is active, and
then the driver door is opened, the instrument cluster actuates the warning buzzer and issues a corresponding
message on the multifunction display. The request to deactivate rear fog light actuation prevents the rear fog
light actuation from being activated automatically the next time the vehicle is driven with the low beams
switched on.
Additional function requirements for parking brake on reminder warning
Vehicle speed v > 5 km/h (calculated by instrument cluster)
Parking brake warning function sequence
If the electric parking brake switch (S76/15) is activated at a speed of v > 5 km/h or the electric parking brake
controller unit (A13) detects a fault in the system, the instrument cluster actuates the electric parking brake
warning light (red) and issues a chime as well as a corresponding message in the multifunction display. The
electric parking brake controller unit reads in the status of the electric parking brake switch and transmits this as
well as system fault messages to the instrument cluster via the front end CAN, central gateway control unit and
central CAN.
Additional function requirements for speed warning (with code (623) Gulf States version)
Vehicle speed v > 120 km/h (calculated by instrument cluster)
Vehicle speed warning function sequence (with code (623) Arab States of the Gulf version)
At speeds of v > 120 km/h, the instrument cluster issues a warning by means of:
Message in the multifunction display (up to 31.8.10)
Speed warning lamp (as of 1.9.10)
Acoustic warning
The instrument cluster calculates the vehicle speed from the wheel speeds that are provided by the ESP control
unit (except model 221.095/195) or by the regenerative braking system control unit (on model 221.095/195) via
the chassis CAN and forwarded by the central gateway control unit on the central CAN.
Additional function requirements, national seat belt reminder warning
Circuit 61 ON (provided by CDI control unit or ME-SFI [ME] control unit)
Circuit 15 ON (with code (498) Japan version) (provided by EZS control unit)
National seat belt reminder warning function sequence
If, immediately prior to starting a journey or during a journey, a seat belt is detected to be not fitted, the
instrument cluster issues a country-specific optical and acoustic seat belt reminder warning. The instrument
cluster reads in the following information in order to issue the country-specific seat belt reminder warning:
Internal:
Vehicle speed
From WSS (weight sensing system) control unit (N2/13) (model 221 with code (494) USA version up to
31.8.08):
Front passenger seat occupancy status
From restraint systems control unit:
Driver seat belt buckle and seat belt reminder warning switch status (S68/1)
Status of front passenger seat belt buckle switch and seat belt reminder warning (S68/2) (with
recognized seat occupation)
Front passenger seat occupation status (without code (494) USA version)
From weight sensing system (WSS) control unit (N110) (model 221 with code (494) USA version as of
1.9.08, model 216 with code (494) USA version):
Front passenger seat occupancy status
On model 216:
From the left door control unit:
Left rotary tumbler switch (A85s1)
From the right door control unit:
Right rotary tumbler switch (A85/1s1)
On model 221:
From the left front door control unit:
Left front rotary tumbler switch (A85s1)
From the right front door control unit:
Right front rotary tumbler switch (A85/1s1)
From the left rear door control unit:
Left rear rotary tumbler switch (A85/3s1)
From the right rear door control unit:
Right rear rotary tumbler switch (A85/4s1)
By the rear SAM control unit:
The manner of how the seat belt reminder warning is issued differs in whether the seat belt reminder warning is
prescribed by law or not and is incorporated into the assessment through the New Car Assessment Program
(NCAP).
NCAP is an assessment program for safety in new vehicles in:
Countries with seat belt reminder warning prescribed by law (extended NCAP): Japan, USA, Canada,
Arab States of the Gulf and Korea
Countries without seat belt reminder warning specified by law
Left rear seat buckle switch (S68/11)
Right rear seat buckle switch (S68/12)
Center rear seat belt buckle switch (S68/14)
The central gateway control unit passes on this information to the instrument cluster via the central CAN.
(European New Car Assessment Program (Euro NCAP)): Europe (Economic Commission for Europe (ECE)),
China and Australia
In countries in which the seat belt reminder warning is prescribed by law (extended NCAP), the seat belt
warning lamp is activated for a time interval of t = 6 ±2 s. It is irrelevant here whether the driver seat belt is
fitted or not.
If the driver is not wearing the seat belt, the instrument cluster also issues an acoustic warning over the internal
warning buzzer. For this the instrument cluster evaluates the status of the driver seat belt buckle switch and seat
belt reminder warning. The central gateway control unit passes on this information to the instrument cluster via
the central CAN.
If the driver seat belt is fastened during this time interval, the warning tone stops sounding.
An assessment of whether the front passenger seat belt is fitted or not given during this time interval.
Only after the time interval of t = 6 s has expired, does the assessment of both seat belts occur.
In countries in which the seat belt reminder warning is not prescribed by law, the seat belt warning lamp is only
actuated during the indicator lamp test.
Immediately after engine running is detected (circuit 61), both the status of the driver seat belt buckle and seat
belt reminder warning switch as well as the status of the front passenger seat belt buckle and seat belt reminder
warning switch are evaluated. If a seat belt is defined to not be fitted, the instrument cluster actuates the seat
belt warning lamp.
If the vehicle starts to move, when it reaches a speed of v > or = 25 km/h, further successive acoustic warnings
are issued. Three or four acoustic warnings are issued in accordance with the seat belt reminder warning. While
they are being issued the seat belt warning lamp is actuated at a frequency of f = 1 Hz.
As the vehicle starts to drive off, acoustic warning phase 1 also starts in the background. When a speed of
v > or =25 km/h is reached a quiet acoustic warning is sounded at an interval of t = 2 s. The acoustic
warning phase 1 lasts for a maximum t = 20 s. This is then followed by a transition to acoustic warning
phase 2.
Acoustic warning phase 2:
After expiry of acoustic warning phase 1 and as from a speed of v > or =25 km/h a quiet acoustic warning
is sounded for maximum t = 20 s at an interval of t = 1 s. This is then followed by a transition to acoustic
warning phase 3.
Acoustic warning phase 3:
After expiry of acoustic warning phase 2 and as from a speed of v > or =25 km/h a quiet acoustic warning
is sounded for maximum t = 20 s at an interval of t = 0.4 s. This is then followed by a transition to
acoustic warning phase 4.
Acoustic warning phase 4 (EURO NCAP only:
After expiry of acoustic warning phase 3 and as from a speed of v > or =25 km/h a quiet acoustic warning
is sounded for maximum t = 93 s at an interval of t = 0.5 s.
If during an ignition sequence the driver or front passenger belt buckle is opened a second time, the
duration of warning tone phase 1 to 3 is shortened to t = 10 s.
Cancellation of seat belt reminder warning:
The last acoustic warning phase is fully completed.
The belt was fitted during the active seat belt reminder warning.
The driver door or front passenger door is opened in a stationary vehicle.
Seat belt reminder warning cancellation as of 1.9.09: If the seat belt reminder warning is active and the vehicle
is brought to a standstill (v = 0 km/h) and the vehicle door on the actuating side is opened, the seat belt reminder
warning is terminated.
Seat belt reminder warning reactivation:
Seat belt release has been detected again.
If the vehicle is at a standstill and the driver or front passenger door is opened and then closed again
A new ignition sequence starting with circuit 61 ON and circuit 15 ON (with code (498) Japan version) is
detected
The seat belt reminder warning for the rear passengers is realized by monitoring the total number of belt tabs
inserted into the seat belt buckles in the rear.
being opened, a warning message appears in the multifunction display. Opening one of the inserted seat belt
buckles while the vehicle is in motion causes a warning message to be displayed in the multifunction display.
An acoustic seat belt reminder warning is additionally issued by the warning buzzer.
If the seat belt reminder warning is issued when the vehicle is moving, it is displayed again another t = 30 s
when the vehicle is determined to be at rest.
This is contingent on a change in the door status for the left rear door or the right rear door while the vehicle is
at a standstill. The seat belt reminder warning, however, does not have an effect on the deployment of the
restraint equipment, it only serves as information for the driver.
Additional function requirements for coolant level and coolant temperature warning
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for coolant level and coolant temperature warning
The coolant level in the expansion reservoir is monitored by the coolant level indicator switch (S41).
The status of the coolant level indicator switch is read in by the front SAM control unit. When the coolant level
is too low the front SAM control unit transmits a corresponding signal to the instrument cluster via the interior
CAN, central gateway control unit and central CAN.
The instrument cluster receives this signal and issues a corresponding message on the multifunction display.
The coolant temperature is recorded by the coolant temperature sensor (B11/4). The CDI control unit or the
ME-SFI [ME] control unit reads in the coolant temperature sensor signal and transmits the corresponding
temperature value on the chassis CAN. The central gateway control unit passes this on to the instrument cluster
via the central CAN.
When a coolant temperature of T > 130 °C is reached the instrument cluster actuates the coolant temperature
warning lamp (A1e54) and issues a corresponding message via the multifunction display.
Additional function requirements, engine oil level warning
Circuit 15 On (provided by EIS [EZS] control unit)
Circuit 61 OFF (provided by CDI control unit or ME-SFI [ME] control unit)
Engine oil level warning function sequence
In order to monitor the engine oil level, the oil level check switch (S43) (with engine 156, 272, 273, 276, 278,
642) or the oil sensor (oil level, temperature and quality) (B40) (with engine 157, 275, 629) is installed in the
engine oil pan.
While the oil level check switch only identifies if the engine oil level is at the minimum or not, the oil sensor
monitors the engine oil level, the engine oil temperature and the engine oil quality. The signals from the oil
level check switch or from the oil sensor are read in by the CDI control unit or the ME-SFI [ME] control unit
gateway control unit evaluates the signals from the oil level check switch or from the oil sensor and, if
necessary, requests via the central CAN that an appropriate message be issued in the instrument cluster.
The instrument cluster receives the signal and issues one of the following messages via the multifunction
display:
"Engine oil level. Stop vehicle. Switch off engine" (red)
"Engine oil. Service required" (red) (with engine 275, 629)
"During refueling stop, top up with 1 liter of engine oil" (yellow) (with engine 275, 629)
"Engine oil level. Reduce oil level" (yellow) (with engine 275, 629)
"During refueling stop, check engine oil level" (yellow) (with engine 156, 272, 273, 642)
Additional function requirements, preglow indicator (with diesel engine)
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence, preglow indicator (with diesel engine)
Preglowing is controlled by the CDI control unit. For the period in which preglowing is active, the CDI control
unit transmits a corresponding signal via the chassis CAN, central gateway control unit and central CAN to the
instrument cluster. The instrument cluster receives the signal and actuates the preglow indicator lamp (A1e16)
accordingly.
Additional function requirements for brake pad wear indicator warning messages
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for brake wear indicator warning messages
The reaching of the wear limit for the front axle brake pads is detected by the right front brake pad contact
sensor (S10/2) and the reaching of the wear limit for the rear axle brake pads is detected by the right rear brake
pad contact sensor (S10/4).
When the wear limit for the front brake pads is reached, the vehicle ground is switched through to the front
SAM control unit via the front brake pad contact sensor.
When the wear limit for the rear brake pads is reached, the vehicle ground is switched through to the rear SAM
control unit via the rear brake pad contact sensor.
The respective SAM control unit then transmits a corresponding signal via the interior CAN, central gateway
control unit and central CAN to the instrument cluster.
The instrument cluster receives this signal, actuates the brake fluid warning lamp and outputs a corresponding
message via the multifunction display.
Additional function requirements for brake fluid level warning messages
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for brake fluid level warning messages
If the fluid level in the brake fluid reservoir is too low it is detected by the brake fluid check switch (S11).
The status of the brake fluid check switch is read in by the front SAM control unit. When the fill level is too low
the front SAM control unit transmits a corresponding signal to the instrument cluster via the interior CAN,
central gateway control unit and central CAN.
The instrument cluster receives the signal, actuates the brake fluid warning lamp and issues a corresponding
message via the multifunction display.
Additional function requirements for windshield washer system fluid level warning messages
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for windshield washer system fluid level warning messages
The fluid level in the washer fluid reservoir is monitored by the windshield washer system fluid level indicator
switch (S42). The status of the windshield washer system fluid level indicator switch is read in by the front
SAM control unit. When the fill level is too low the front SAM control unit transmits a corresponding signal to
the instrument cluster via the interior CAN, central gateway control unit and central CAN. The instrument
cluster receives this signal and issues a corresponding message on the multifunction display.
Turn signal confirmation function sequence
Acoustic feedback about the active turn signal light actuation is realized by the acoustic turn signal indicator
integrated into the instrument cluster.
Visual feedback takes place via the left turn signal indicator lamp and right turn signal indicator lamp.
Additional function requirements for engine-control control/ warning messages
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for engine-control control/warning messages
If a fault is present in the injection system, ignition system or exhaust gas system, the ME-SFI control unit
transmits a corresponding signal to the instrument cluster via the chassis CAN, central gateway control unit and
central CAN. The instrument cluster then actuates the engine diagnosis indicator lamp (A1e58).
Additional function requirements for tank cap warning (with code (494) USA version)
Circuit 15 On (provided by EIS [EZS] control unit)
Function sequence for tank cap warning (with code (494) USA version)
If the rear SAM control unit identifies an open tank cap, it transmits a corresponding signal via the interior
CAN, central gateway control unit and central CAN to the instrument cluster. The instrument cluster receives
this signal, actuates the fuel reserve warning lamp (A1e4) so that it flashes and issues a corresponding message
via the multifunction display.
Function sequence for central locking acoustic feedback (as of 1.9.10)
The acoustic feedback must be selected and activated in the multifunction display using the left multifunction
steering wheel button group and right multifunction steering wheel button group (S111). The status of the
acoustic feedback is sent by the instrument cluster via the central CAN to the central gateway control unit and
from there to the front SAM control unit via the interior CAN.
Function sequence for ECO start/stop function (with code (B03) ECO start/stop function)
The ECO start/stop function can be activated or deactivated using a menu in the instrument cluster.
The status of the ECO start/stop function is signaled by the ECO indicator in the multifunction display.
The request for this is sent by the ME-SFI [ME] control unit via the central CAN to the central gateway control
unit and from there via the chassis CAN to the instrument cluster. The ECO indicator can be displayed in two
colors:
Green: ECO start/stop function active and operational
Yellow: ECO start/stop function active, but stop function has been prevented by specific requirements
(e.g. air conditioning system active, undervoltage)
Electrical function
schematic of instrument PE54.30-P-
Model 216
cluster, control/warning 2054-97CAA
message
PE54.30-P-
Model 221 (except model 221.095/195)
2054-97SAA
PE54.30-P-
Model 221.095/195
2054-97SAB
Component description for A1 GF54.30-P-
instrument cluster Model 221 (except 221.095/195) 6000LE
GF54.30-P-
Model 221.095/195
6000LEH
STH control unit, A6n1 GF83.70-P-
component description With code (228) Stationary heater 4200LE
Component description for
GF42.20-P-
electric parking brake A13
5000LE
controller unit
A40/3
Component description for With code (526) COMAND with single DVD drive GF82.85-P-
COMAND controller unit (without navigation) or code (527) COMAND APS 3136LE
with single DVD drive (with navigation system)
GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
A40/11
On model 221 as of 1.6.09 or model 216 as of 1.9.10
Component description for with code (238) Active Lane Keeping Assist or code GF54.21-P-
multifunction camera (476) Automatic lane recognition or code (513) Speed 3300LE
Limit Assist or with code (608) Adaptive Highbeam
Assist
Component description for
A76, A76/1 GF91.40-P-
front reversible emergency
Model 221 4020LE
tensioning retractor
Component description for
A80 GF27.19-P-
intelligent servo module
With transmission 722.6 4020ACS
for DIRECT SELECT
GF27.19-P-
With transmission 722.9 (except 722.931/950)
4020AHS
GF27.19-P-
With transmission 722.931
4020AHT
GF27.19-P-
With transmission 722.950
4020LEH
A89
On model 216 up to 31.8.10 with engine 156, 273, 275
DTR controller unit, GF30.30-P-
and code (219) Distronic (DTR) Model 221 up to
component description 3210LEA
31.8.10 with engine 156, 272, 273, 275, 642, 629 and
code (219) Distronic (DTR)
On model 216 up to 31.8.10 with engine 156, 273, 275
and code (233) DISTRONIC PLUS Model 221 up to GF30.30-P-
31.8.10 with engine 156, 272, 273, 275, 642, 629 and 3210LE
code (233) DISTRONIC PLUS
On model 216 as of 1.6.09 up to 31.8.10 with engine
156, 273, 275 and code (233) Distronic Plus GF30.30-P-
Model 221 as of 1.6.09 up to 31.8.10 with engine 156, 3210LEB
272, 273, 275, 642, 629 and code (233) Distronic Plus
On model 221 as of 1.6.09 up to 31.8.10 with engine
GF30.30-P-
156, 272, 273, 275, 629, 642 and code (239) Plus
3210LEC
Light adaptive cruise control
On model 216.3 as of 1.9.10 With code (233)
DISTRONIC PLUS with code (237) Active Blind Spot
Model 221 (except 221.095/195) as of 1.9.10 with 3210LED
code (233) DISTRONIC PLUS or with code (237)
Active Blind Spot Assist or with code (239) Plus Light
adaptive cruise control
E1n1, E2n1
Model 221 up to 31.5.09 with code (615) Bi-xenon
Component description for headlamp unit with integrated curve illumination or
GF82.10-P-
Xenon headlamp control code (616) Xenon headlamp unit with asymmetrical
2114LE
unit integrated curve illumination or
Model 221 as of 1.6.09
Model 216
Component description for
GF91.60-P-
restraint systems control N2/7
4048LE
unit
Component description for N2/13
GF91.60-P-
Weight Sensing System MODEL 221 up to 31.8.08 with CODE (494) USA
4046LEU
(WSS) control unit version
Component description for N3/9 GF07.16-P-
CDI control unit On model 221 with engine 629.9 6000OA
GF07.16-P-
On model 221 with engine 642.8
6000OHS
GF07.16-P-
On model 221 with engine 642.9
6000OHL
Component description for N3/10 GF07.61-P-
ME-SFI [ME] control unit With engine 156 6000MAS
GF07.61-P-
On model 221 with engine 272 (except 272.974)
6000MIS
GF07.61-P-
On model 221 with engine 272.974
6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
On model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278
6000MMC
Component description for
front SAM control unit GF54.21-P-
N10/1
with fuse and relay 6070LE
module
Component description for
rear SAM control unit GF54.21-P-
N10/2
with fuse and relay 6030LE
module
Component description for
N28/1 GF31.19-P-
trailer recognition control
For model 221 with code (550) Trailer hitch 4050LE
unit
Component description for
N30/6 GF42.22-P-
regenerative braking
On model 221.095/195 1100LEH
system control unit
Left front seat control unit, GF91.29-P-
N32/1
component description 5230LE
Right front seat control
GF91.29-P-
unit, component N32/2
5240LE
description
Component description for N47-5 GF42.45-P-
ESP control unit Model 216.3, 221 (except 221.095/195) 5118LE
N51
On model 221 up to 31.5.09 without code (487) Active
AIRmatic with ADS
Body Control (ABC), Model 221.1 with code (Z07) GF32.22-P-
control unit, component
Highest protection, Model 216.3 up to 31.5.09 with 5108LE
description
code (489) AIRmatic (air suspension with continuous
damper adjustment)
On model 221 as of 1.6.09 without code (487) Active
Body Control (ABC) and without code (Z07) Highest
GF32.22-P-
protection, on model 216.3 as of 1.6.09 with code
5108LEA
(489) AIRmatic (air suspension with continuous
damper adjustment))
N51/2
ABC control unit, On model 221 with code (487) Active Body Control GF32.50-P-
component description (ABC), on model 216.3 without code (489) AIRmatic 4501LE
(air suspension with continuous damper adjustment)
Component description for N62
GF54.65-P-
PARKTRONIC control On model 221 up to 31.5.09 with code (220)
5001LE
unit PARKTRONIC, on model 216 up to 31.8.10
On model 221 as of 1.6.09 with code (220)
PARKTRONIC or code (230) Exclusive parking assist GF54.65-P-
on model 216 as of 1.9.10 with code (220) 5001LEA
PARKTRONIC or code (230) Exclusive parking assist
Component description for N62/1 GF30.30-P-
radar sensors control unit Up to 31.8.10 with code (233) DISTRONIC PLUS 3301LE
Up to 31.8.10 with code (234) Blind Spot Assist, on
model 221 (except 221.095/195) as of 1.9.10 with
GF30.30-P-
code (239) Plus Light adaptive cruise control, on
3301LEB
model 221.095/195 as of 1.9.10 with code (234) Blind
Spot Assist
Model 221 up to 31.8.10 with code (239) Plus Light GF30.30-P-
adaptive cruise control 3301LEC
On model 216.3, 221 (except 221.095 /195) as of
Video and radar sensor
1.9.10 with code (233) DISTRONIC PLUS with code GF30.30-P-
system control unit,
(237) Active Blind Spot Assist with code (238) Active 3304LE
component description
Lane Keeping Assist
Component description for N69/1 GF72.29-P-
left door control unit Model 216 4124LA
Component description for N69/1 GF72.29-P-
left front door control unit Model 221 4141LE
Component description for N69/2 GF72.29-P-
right door control unit Model 216 4128LA
Component description for
N69/2 GF72.29-P-
right front door control
Model 221 4142LE
unit
Rear door control unit, N69/3, N69/4 GF72.29-P-
component description On model 221 6020LE
Component description for N69/5 GF80.61-P-
Keyless-Go control unit With CODE (889) Keyless Go 4204LE
Upper control panel
GF54.21-P-
control unit, component N72/1
6040LE
description
EZS control unit, GF80.57-P-
N73
component description 6003LE
Component description for
GF54.21-P-
steering column tube N80
6050LE
module
Component description for
N82/2 GF54.10-P-
battery management
On model 221.095/195 3012MEH
system control unit
N88
Component description for GF40.15-P-
For code (494) USA version or code (475) Tire
TPM [RDK] control unit 5123LE
pressure monitor (Premium), Siemens up to 31.5.09
With code (475) Tire pressure monitor (Premium), GF40.15-P-
Schrader As of 1.6.09 5123LEA
Component description for
GF54.21-P-
central gateway control N93
4170LE
unit
Night View Assist control
N101 GF54.30-P-
unit, component
with code (610) Night View Assist 6200LE
description
Component description for N110
GF91.60-P-
Weight Sensing System MODEL 221 as of 1.9.08 with CODE (494) USA
4069LAU
(WSS) control unit version Model 216 with code (494) USA version
Component description for
N123/4 GF82.95-P-
emergency call system
With code (359) TELE AID emergency call system 3212LEU
control unit
ACTIVATE INSTRUMENT CLUSTER, FUNCTION - GF54.30-P-2006SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Activation
With the activation of the instrument cluster (A1) both the multifunction display (A1p13) and the scale
illumination switch on automatically, the basic display of the menu trip computer (RRE) of the instrument
cluster is always visible first.
The instrument cluster is activated by one of the following conditions:
Driver door open or closed (flank signal changes)
Switching on the light (circuit 58 ON)
Circuit 15R ON
Pressing the OK button (S110s6)
Pressing the "Back" and VCS Off button (S110s4)
Pressing the "ON" button (A40/9s6) in the front central operating unit (A40/9)
Pressing the button, free programming (A40/9s10) in the front central operating unit
Activation of the hazard warning system
Pressing one of the keys of the transmitter key (A8/1)
Information flow from driver door to the instrument cluster, shown on model 221 up to 31.8.06
Fig. 27: Activate Instrument Cluster Information Flow Diagram
Courtesy of MERCEDES-BENZ USA
The information flows from the driver door to the instrument cluster as follows:
The right front rotary tumbler switch is read in discreetly by the right front door control unit.
The left front rotary tumbler switch is read in discreetly by the left front door control unit.
The left front door control unit and right front door control unit place signals on the interior CAN.
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and activates the scale illumination and
the multifunction display.
Information flow from rotary light switch (S1) and from EIS [EZS] control unit (N73) to the instrument
cluster, shown on model 221 up to 31.8.06
Fig. 28: Information Flow Diagram (From Rotary Light Switch And From EIS Control Unit)
Courtesy of MERCEDES-BENZ USA
The information flows from the rotary light switch to the instrument cluster as follows:
The rotary light switch is read in by the upper control panel control unit via the upper control panel LIN.
The information flows from the EIS [EZS] control unit as follows:
The circuit status is established by the position of the transmitter key in the EIS [EZS] control unit.
The upper control panel control unit places the signals on the interior CAN.
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and activates the scale illumination and
the multifunction display.
The EIS [EZS] control unit places the signal of the circuit status on the interior CAN.
The central gateway control unit reads in the signal from the interior CAN and places it on the central
CAN.
The instrument cluster reads in the signal from the central CAN and activates the scale illumination and
the multifunction display.
Information flow from multifunction steering wheel (MFL) and from the front central operating unit to
the instrument cluster, shown on model 221 up to 31.8.06
Fig. 29: Information Flow Diagram (From Multifunction Steering Wheel/Front Central Operating Unit
To Instrument Cluster)
Courtesy of MERCEDES-BENZ USA
The information flows from the multifunction steering wheel [MFL] to the instrument cluster as follows:
The "Back" and VCS Off button and OK button are read in by the steering column module via the
steering LIN.
The steering column module places the signals on the chassis CAN.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and activates the scale illumination and
the multifunction display.
When button is "ON" the information flows to the instrument cluster as follows:
The "ON" button is read in by the front central operating unit.
The front central operating unit places the signals on the telematics CAN.
The COMAND controller unit reads in the signals from the telematics CAN and places them on the
central CAN.
The instrument cluster reads in the signals from the central CAN and activates the scale illumination and
the multifunction display.
The free programming button is located in the front central operating unit and is read in discreetly by the
upper control panel control unit.
The upper control panel control unit places the signals on the interior CAN.
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and activates the scale illumination and
the multifunction display.
Information flow from transmitter key to the instrument cluster, shown on model 221 up to 31.8.06
Fig. 30: Information Flow Diagram (From Transmitter Key To Instrument Cluster)
Courtesy of MERCEDES-BENZ USA
The information flows from the transmitter key to the instrument cluster as follows:
When one of the transmitter keys is pressed this sends a coded radio signal to the vehicle.
The antenna in the rear window receives the coded signals and passes them on to the rear window antenna
amplifier module.
The rear window antenna amplifier module amplifies the coded signals and passes them on to the rear
SAM with fuse and relay module control unit.
The rear SAM with fuse and relay module control unit places the coded signals on the interior CAN.
The EIS [EZS] control unit reads in the coded signals from the interior CAN, evaluates them and places
the respective signal on the interior CAN.
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and activates the scale illumination and
the multifunction display.
Instrument cluster, component description GF54.30-P-6000SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221 up to 31.8.06
Fig. 31: Instrument Cluster Illumination Function Diagram
Courtesy of MERCEDES-BENZ USA
Activate
The instrument cluster illumination switches on automatically as soon as the instrument cluster is activated. The
details of the Instrument cluster are only now clearly visible on account of the "Black-Screen Technology".
Illumination
The instrument cluster illumination depends on the following factors:
Light falling directly on the instrument cluster (measured by the left brightness sensor and right
brightness sensor.)
Detected light intensity outside the vehicle (measured by the rain/light sensor (day/night signal).
Adjustment of switch and controls illumination/Night View Assist display brightness control
Day/night signal
The rain/light sensor measures the light intensity outside the vehicle, converts this into electrical signals and
passes on the signals to the overhead control panel control unit. The overhead control panel control unit
evaluates the signals and places the day or night signal on the interior CAN. The central gateway control unit
(N93) reads in the signal from the interior CAN and places it on the central CAN. The instrument cluster reads
in the signal from the central CAN and actuates the brightness of the instrument illumination and multifunction
display accordingly. For the day signal the instrument cluster is illuminated more brightly than for the night
signal.
In addition to a limited extent the brightness of the instrument illumination and multifunction display can be
readjusted individually via the switch and controls illumination/Night View Assist display brightness control in
the cockpit switch group.
Direct solar radiation on the instrument cluster
The left brightness sensor and right brightness sensor are integrated in the instrument cluster. These brightness
sensors measure the light falling on the Instrument cluster. If, for example, the sun shines directly on the
instrument cluster, the brightness of the instrument illumination and multifunction display is increased
accordingly, in order to achieve ideal legibility of the displays.
In addition to a limited extent the brightness of the instrument illumination and multifunction display can be
readjusted individually via the switch and controls illumination/Night View Assist display brightness control in
the cockpit switch group.
Adjust switch and controls illumination, schematic representation of duty cycle
Fig. 32: Schematic Representation Of Adjust Switch And Controls Illumination Duty Cycles
Courtesy of MERCEDES-BENZ USA
circuit 58d on/off ratio
The lamps of the switch and controls illumination are actuated with a square-wave voltage.
The lamps are actuated in the on-time, afterwards followed by a break until the end of the period. This process
is continuously repeated. The change happens so quickly that the eye does not notice the lamps flickering. The
ratio of the on-time to the cycle duration is called the duty cycle. In the process the cycle duration is constant
and the on-time is the time in which voltage is applied within a period. The greater the duty cycle, the greater
applies at the outputs "circuit 58d" of the various control units is drawn in the figure. The upper drawing in the
figure shows a duty cycle of 80 %, the lower a duty cycle of 40 %. A pulse-duty factor of 100 % corresponds to
DC power. Power is not supplied when the duty cycle is 0 %.
Switch and controls illumination
The brightness of the switch and controls illumination can be adjusted with the factors listed. Control takes
place via the duty cycle of "circuit 58d". The duty cycle of "circuit 58d" is placed on the Controller Area
Network (data bus/CAN bus) (CAN) by the instrument cluster and can thus be received by any control unit
connected to the CAN. Any control unit, which regulates a switch and controls illumination, can now actuate
this independently based on the duty cycle. Advantages of this type of brightness control:
The brightness of the switch and controls illumination is independent of the number of lamps or control
units fitted.
Each control unit, which is connected to the CAN, can actuate its lamps with the brightness specified by
the instrument cluster.
With "circuit 58d OFF" (standing lamp OFF) the instrument cluster transmits the message "duty cycle circuit
58d = 0 %". With "Tml. 58d ON" (standing lamps ON), the transmitted duty cycle can vary from 0 % to 100 %
depending on the setting.
Instrument cluster, component description GF54.30-P-6000SX
DISPLAY MONITORING/WARNING MESSAGES VIA INDICATOR LAMPS, FUNCTION -
GF54.30-P-2011SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221 up to 31.8.06
Fig. 33: Identifying Display Monitoring/Warning Messages
Courtesy of MERCEDES-BENZ USA
High beam indicator lamp
Information flow:
The signal for actuating the high beam indicator lamp is placed on the interior CAN by the front SAM
control unit with fuse and relay module (N10/1).
The central gateway control unit (N93) reads in the signals from the interior CAN and places them on the
central CAN.
The instrument cluster reads in the signals from the central CAN and actuates the high beam indicator
lamp accordingly
Fuel reserve indicator lamp
The fuel reserve warning lamp is actuated as soon as the reserve range is reached. Its actuation is linked to the
fuel level and reserve indicator.
Information flow:
The signal for actuating the fuel level and reserve indicator is placed on the interior CAN by the front
SAM control unit with fuse and relay module.
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the fuel level and reserve
indicator accordingly.
Airbag indicator and warning lamp
The airbag indicator and warning lamp is actuated when there is a fault in the supplemental restraint system
(SRS). Information flow:
The signal for actuating the airbag indicator and warning lamp is placed on the chassis CAN by the
restraint systems control unit (N2/7).
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the airbag indicator and
warning lamp accordingly.
Preglow indicator lamp, only with engine 642 (model 221)
The preglow indicator lamp is only fitted to vehicles with engine 642. It is actuated with "circuit 15 ON" as long
as the preheating time runs. Information flow:
The signal for actuating the preglow indicator lamp is placed on the chassis CAN by the CDI control unit
(N3/9).
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the preglow indicator lamp
accordingly
In the event of a defect in the preglow indicator lamp a fault code is set in the instrument cluster and a
corresponding message is transmitted to the CDI control unit via the Controller Area Network (data bus/CAN
bus) (CAN). However no error message appears in the multifunction display.
ABS indicator lamp
The ABS indicator lamp is actuated when there is a fault in the antilock brake system (ABS). Information flow:
The signal for actuating the ABS indicator lamp is placed on the chassis CAN by the ESP control unit
(N47-5).
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the ABS indicator lamp
Engine diagnosis indicator lamp, except code (494) USA version
The engine diagnosis indicator lamp is actuated if a fault is present in the injection system, ignition system or in
the exhaust emission system.
Information flow:
The signal for actuating the engine diagnosis indicator lamp is placed on the chassis CAN by the CDI
control unit (model 221) or by the ME-SFI [ME] control unit (N3/10).
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the engine diagnosis
indicator lamp accordingly.
CHECK ENGINE indicator lamp (A1e26), with code (494) USA version
The CHECK ENGINE indicator lamp is actuated if a fault is present in the injection system, ignition system or
exhaust emission system. Information flow:
The signal for actuating the CHECK ENGINE indicator lamp is placed on the chassis CAN by the CDI
control unit (model 221) or ME-SFI [ME] control unit.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the CHECK ENGINE
indicator lamp accordingly
With some indicator and warning lamps a fault message in the multifunction display ensues at the same time
as actuation. While most messages in the multifunction display can be acknowledged, the indicator and warning
lamps light up as long as the fault is present. Messages cannot be acknowledged.
All fixed indicator and warning lamps in the Instrument cluster are equipped with light emitting diodes.
Shown on model 221 up to 31.8.06 with code (610) Night View Assist
Fig. 34: Identifying Multifunction Display Components
Courtesy of MERCEDES-BENZ USA
Variable indicator and warning lamps in the multifunction display
The variable indicator and warning lamps are displayed in the multifunction display. They can change their
position in the multifunction display depending on the request.
The following indicator and warning lamp are variable indicator and warning lamps:
Left turn signal indicator lamp
Right turn signal indicator lamp
Brake fluid warning lamp
Seat belt warning lamp
ESP warning lamp
DTR warning lamp (with code (219) Distronic (DTR) or with code (233) Distronic Plus)
Tire pressure monitor warning lamp (with code (494) USA version)
electronic parking brake warning lamp (red)
electronic parking brake warning lamp (yellow)
Left turn signal indicator lamp and right turn signal indicator lamp
These are activated differently according to function. The following functions are available:
Turn signals
Hazard warning flashing
Turn signals
With turn signaling either the left turn signal indicator lamp or right turn signal indicator lamp are actuated by
the instrument cluster. Information flow:
The signal for actuating the left turn signal indicator lamp or right turn signal indicator lamp is placed on
the interior CAN by the rear SAM control unit with fuse and relay module (N10/2).
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the left turn signal indicator
lamp or right turn signal indicator lamp accordingly.
In addition to the visual indicator of the turn signaling a turn signal knocking of the audible turn signal indicator
(A1h2) sounds in the instrument cluster.
If one of the turn signal lamps fails, the left turn signal indicator lamp or right turn signal indicator lamp is
actuated at twice the frequency.
Hazard warning flashing
With hazard warning flashing the left turn signal indicator lamp and right turn signal indicator lamp are always
actuated by the instrument cluster. Hazard warning flashing can be triggered by various functions. The main
control unit for hazard warning flashing is the rear SAM control unit with fuse and relay module.
The following functions can trigger hazard warning flashing:
Manual actuation of the hazard warning system button (A40/9s3)
Triggering of an airbag
Triggering the anti-theft alarm system [EDW] alarm on vehicles with code (551) Anti-theft alarm system
(ATA [EDW])
Information flow:
The signal for actuating the left turn signal indicator lamp and right turn signal indicator lamp is placed
on the interior CAN by the rear SAM control unit with fuse and relay module.
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the left turn signal indicator
lamp or right turn signal indicator lamp accordingly.
A warning tone sounds in the instrument cluster in addition to the visual indicator of the warning flashing.
Brake fluid warning lamp
The brake fluid warning lamp is actuated if the minimum level of the brake fluid is dropped below. Information
flow:
The signal for actuating the brake fluid warning lamp is placed on the interior CAN by the front SAM
control unit with fuse and relay module
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the brake fluid warning
lamp accordingly.
Seat belt warning lamp
The seat belt warning lamp is actuated depending on the country. On vehicles with code (494) USA version or
with code (623) Gulf States version the seat belt warning lamp lights as of "circuit 61 ON" for 6 s, irrespective
of the following components:
Driver seat belt buckle and seat belt warning switch (S68/1)
Front passenger seat belt buckle and seat belt warning switch (S68/2)
Front passenger seat occupied and child seat recognition sensor (B48)
On vehicles with code (498) Japan version the seat belt warning lamp lights up as of "circuit 15 ON" for 6 s,
irrespective of the following components:
Driver seat belt buckle and seat belt warning switch
Front passenger seat belt buckle and seat belt warning switch
Front passenger seat occupied and child seat recognition sensor
When the seat belt warning lamp is actuated, on the above national versions a warning tone sounds
simultaneously in the first 6 s. After the first 6 s the actuation characteristics of the seat belt warning lamp
correspond to those of the other national versions. The actuation characteristics are as follows:
The seat belt warning lamp lights up if the status "circuit 61 ON" is present as well the vehicle speed is >
25 km/h and the driver seat belt buckle and seat belt warning switch is not closed. The seat belt warning
lamp goes out as soon as the driver seat belt buckle and seat belt warning switch is closed.
The seat belt warning lamp lights up if the status "circuit 61 ON" is present and the vehicle speed is > 25
km/h as well as the front passenger seat occupied and child seat recognition sensor has detected a person
or child seat on the front passenger seat and the front passenger seat belt buckle and seat belt warning
switch is not closed. The seat belt warning lamp goes out as soon as the front passenger seat belt buckle
and seat belt warning switch is closed
A warning chime sequence sounds simultaneously when the seat belt warning lamp is actuated.
The warning chime sequence of the seat belt reminder warning is deactivated immediately if the driver /
front passenger have fastened their seat belts. The maximum actuation time of 110 s continues running in the
background. If a belt is unfastened within this time, the warning chime sequence is output again.
Information flow:
The signal for actuating the seat belt warning lamp is placed on the chassis CAN by the restraint systems
control unit.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the seat belt warning lamp
accordingly.
The seat belt reminder warning is issued once for the journey, but can be set active again when:
Vehicle speed < 5 km/h
The driver door is opened and closed again
ESP warning lamp
The ESP warning lamp is actuated as soon as the ESP system intervenes in the traffic activities. The ESP
warning lamp flashes or lights up depending on the warning message or error message. Information flow:
The signal for actuating the ESP warning lamp is placed on the chassis CAN by the ESP control unit.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the ESP warning lamp
accordingly.
DTR warning lamp, with code (219) Distronic (DTR) or with code (233) Distronic Plus
The DTR warning lamp is actuated if the driving situation necessitates manual intervention from the driver in
the interests of driving safety. Information flow:
The signal for actuating the DTR warning lamp is placed on the chassis CAN by the ESP control unit
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and actuates the DTR warning lamp
accordingly.
Tire pressure monitor warning lamp, with code (494) USA version
The tire pressure monitor warning lamp is actuated if a "pressure loss" or "rapid pressure loss" is established in
one of the vehicle tires.
Information flow:
The signal for actuating the tire pressure monitor warning lamp is either placed on the chassis CAN by
the ESP control unit or on the interior CAN by the TPM [RDK] control unit (N88).
The central gateway control unit reads in the signals from the chassis CAN or from the interior CAN and
places them on the central CAN.
The instrument cluster reads in the signals from the central CAN and actuates the tire pressure monitor
warning lamp accordingly.
Electronic parking brake warning lamps
The electronic parking brake warning lamps indicate the function status and fault status of the electronic
parking brake. Information flow:
The signal for actuating the electronic parking brake warning lamp (red) and electronic parking brake
(yellow) is placed on the front end CAN by the electric parking brake controller unit (A13).
The central gateway control unit reads in the signals from the front end CAN and places them on the
central CAN.
The instrument cluster reads in the signals from the central CAN and actuates the electronic parking brake
warning lamps accordingly.
With some indicator and warning lamps a fault message in the multifunction display ensues at the same time
as actuation. While most of the messages can be acknowledged, the indication and warning lamps remain lit as
long as the fault is present. Messages cannot be acknowledged.
Instrument cluster, component description GF54.30-P-6000SX
DISPLAY MONITORING/WARNING MESSAGES VIA MULTIFUNCTION DISPLAY, FUNCTION -
GF54.30-P-2012SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221 up to 31.8.06
Fig. 35: Identifying Display Monitoring/Warning Messages
Courtesy of MERCEDES-BENZ USA
With operating faults warning messages are faded in the multifunction display. The warning messages are faded
in below the electronic speedometer with the respective symbol. These warning messages are divided up into
the following priorities:
Priority 1
Warning messages with high priority
Priority 2
Warning messages with low priority
Priority 1, warning messages with high priority
These warning messages cannot be acknowledged sometimes. When they occur the fault is shown in the
multifunction display. New warning messages with the same priority are faded in automatically as soon as the
previous warning message was displayed for 5 s.
The display changes between the warning messages every 5 s. Any priority 2 warning messages are cross-faded.
Priority 2, warning messages with low priority
If a priority 1 warning message is present, the priority 2 warning message is not displayed until the priority 1
warning message has been acknowledged or the fault is no longer present. New warning messages with the
same priority are faded in automatically as soon as the previous warning message was displayed for 5 s. The
display changes between the warning messages every 5 s.
Most warning messages can be acknowledged with the OK button (S110s6) of the left multifunction steering
wheel button group (S110)
In addition to the display of warning messages in the multifunction display warning lamps or indicator lamps
are actuated for some faults. These lightup as long as the fault is present and, like most warning messages,
cannot be acknowledged in the multifunction display.
Displaying warning and fault messages
Except for a few exceptions fault messages are first displayed when the engine is running. Current fault
messages are faded in immediately.
A warning chime sounds simultaneously for many of the warning messages.
Reminder about faults at the end of a trip
With "circuit 15 OFF" the faults are stored in an error list and a displayed again as a reminder.
Warning message of priority 1, car is too low, shown on model 221 up to 31.8.06
Fig. 36: Screen Display - Car Too Low
Courtesy of MERCEDES-BENZ USA
Warning message of priority 2, coolant level, shown on model 221 up to 31.8.06
Fig. 37: Screen Display - Coolant Level Low
Courtesy of MERCEDES-BENZ USA
Warning message of priority 2, washer fluid level, shown on model 221 up to 31.8.06
Fig. 38: Screen Display - Washer Fluid Level Low
Courtesy of MERCEDES-BENZ USA
Example of display priority
Three of the many possible messages are shown below with a short description.
The sequence in which messages are displayed in the case of several faults is explained using an example:
If the washer fluid level is too low a priority 2 message which calls up refilling the washer fluid is shown
in the multifunction display.
If the coolant level is also too low as well, the priority 2 message which calls up checking the coolant
level is also displayed. The display now changes every 5 seconds between this message and the message
which calls up the refilling of washer fluid as 2 messages of the same priority exist.
If now in addition a fault in the level control occurs the priority 1 message which requests stopping the
vehicle is displayed. This message cross-fades the two priority 2 messages due to its higher priority.
The example is based on the assumption that none of the messages is acknowledged and canceled.
Instrument cluster, component description GF54.30-P-6000SX
OUTPUT ACOUSTIC WARNING MESSAGES, FUNCTION - GF54.30-P-2013SX
MODEL 221.0 /1, 216.3 up to Model Year 8
For acoustic fault and warning signals 2 different sound patterns are available to the instrument cluster (A1). On
the one hand the instrument cluster generates chime. The chime is emitted via the internal speaker. On the other
hand the instrument cluster can produce and output a warning tone (audible beep) via the internal warning
buzzer (A1h1). The warning tones can be output as a single chime or single beep as well as intermittent chime
or intermittent beep. The audible turn signal indicator (A1h2) with turn signal knocking forms an exception.
This is produced via a relay located in the instrument cluster and is actuated depending on the function (turn
signaling or hazard warning flasher).
Audible turn signal indicator, hazard warning flashing
Turn signal knocking always sounds at the same time as hazard warning flashing. The following functions can
trigger hazard warning flashing:
Manual actuation of the hazard warning system button (A40/9s3)
Triggering of an airbag
Triggering the anti-theft alarm system [EDW] alarm on vehicles with code (551) Anti-theft alarm system
(ATA [EDW])
Turn signals
The turn signal knocking of the audible turn signal indicator always sounds at the same time as turn signaling.
If one of the turn signal lamps fails, the audible turn signal indicator is actuated at twice the frequency.
Information flow, audible turn signal indicator:
The signal for actuating the audible turn signal indicator is placed on the interior CAN by the rear SAM
control unit with fuse and relay module (N10/2).
The central gateway control unit (N93) reads in the signals from the interior CAN and places them on the
central CAN.
The instrument cluster reads in the signals from the central CAN and actuates the audible turn signal
indicator accordingly
Single chime (with system warnings)
The following systems use the speaker for acoustic warning as a single chime at the same time as the indicator
message and warning message in the multifunction display (A1p13):
Active Body Control (ABC)
Active Steering Control (ASC)
Electronic Stability Program (ESP)
Antilock brake system (ABS)
Supplemental restraint system (SRS)
Central locking (CL [ZV])
Distronic, with code (219) Distronic (DTR)
Distronic Plus, with code (233) Distronic Plus
Sensotronic Brake Control (SBC)
Electronic parking brake
Tire pressure monitor (RDK), with code (475) Tire pressure monitor (Beru)
Brake fluid indicator switch
On-board electrical system indicator
Engine oil level indicator
Trailer hitch, with code (550) Trailer hitch (model 221)
Limiter, except code (494) USA version
Cruise control
intermittent gong
The following systems use the speaker for acoustic warning as a single chime at the same time as the indicator
message and warning message in the multifunction display:
Distronic, with code (219) Distronic (DTR)
Distronic Plus, with code (233) Distronic Plus
Limiter, except code (494) USA version
Cruise control
Electronic parking brake
Lights on warning
Key warning
CL
Single beep (in the event of system faults)
The following systems use the warning buzzer for acoustic warning as a single beep at the same time as the
indicator message and warning message in the multifunction display:
Active Body Control (ABC)
System fault
Active Steering Control (ASC)
System fault
Supplemental restraint system (SRS)
Seat belt reminders
Cooling system
Coolant temperature in range critical for the engine
Engine oil system
Engine oil level too low
Intermittent beep
The following systems use the warning buzzer as a single beep at the same time as the indicator message and
warning message in the multifunction display:
Distronic, with code (219) Distronic (DTR)
Distronic Plus, with code (233) Distronic Plus
Sensotronic Brake Control (SBC)
Park Assist, with code (229) Park Assist
Warning tone functionality with seat belt reminder warning
The seat belt reminder warning chime is output depending on the country.
On vehicles with code (494) USA version or with code (623) Gulf States version the warning buzzer is actuated
as of "circuit 61 ON" for 6 s, irrespective of the following components:
Driver seat belt buckle and seat belt warning switch (S68/1)
On vehicles with code (498) Japan version the seat belt warning lamp lights up as of "circuit 15 ON" for 6 s,
irrespective of the following components:
Driver seat belt buckle and seat belt warning switch
Front passenger seat belt buckle and seat belt warning switch
Front passenger seat occupied and child seat recognition sensor
After the first 6 s the actuation characteristics of the seat belt warning lamp correspond to those of the other
national versions. The actuation characteristics of the warning buzzer are then as follows:
The warning chime is output if the status "circuit 61 ON" is present, the vehicle speed > 25 km/h and the
driver seat belt
Front passenger seat belt buckle and seat belt warning switch (S68/2)
Front passenger seat occupied and child seat recognition sensor (B48)
buckle and seat belt warning switch is not closed. The warning chime is muted as soon as the driver seat
belt buckle and seat belt warning switch is closed.
The seat belt warning lamp lights up if the status "circuit 61 ON" is present, the vehicle speed > 25 km/h,
the front passenger seat occupied and child seat recognition sensor has detected a person or a child seat on
the front passenger seat and the front passenger seat belt buckle and seat belt warning switch is not
closed. The warning tone is deactivated as soon as the front passenger seat belt buckle and seat belt
warning switch is closed.
Warning chime sequence
The warning chime sounds intermittently (missing temporarily and repeats at an interval of 5 s On and 3 s Off).
The warning tone sequence of the seat belt reminder warning is deactivated immediately if the driver / front
passenger have fastened their seat belts. The maximum actuation time of 110 s continues running in the
background. If a belt is unfastened within this time, the warning chime sequence is output again. The seat belt
warning lamp lights up during the warning chime sequence (A1e9).
The seat belt reminder warning is given once for each journey but can be activated again by driving the
vehicle at a speed below 5 km/h.
Instrument cluster, component description GF54.30-P-6000SX
SETTINGS ON WORKSHOP LEVEL, FUNCTION - GF54.30-P-2020LE
MODEL 216.3, 221.0 /1 as of model year 2009 /YoM 08
Function requirements, general
Circuit 15R ON
The EZS control unit (N73) places the status of circuit 15 on the chassis CAN (CAN E). The central gateway
control unit (N93) forwards this to the instrument cluster (A1) via the central CAN (CAN F).
Function sequence for workshop level settings in general
The workshop level is used by the technician in the workshop for reading out vehicle and service data and
provides assistance with carrying out the service.
The "Workshop level" menu is activated as follows:
Press accept and end phone call button (S111s3) and OK button (S110s6) simultaneously for t > 1 s
The display in the multifunction display (A1p13) changes to the workshop level. (S110) It is possible to scroll
between the respective menus and submenus or in various lists using the left multifunction steering wheel
button group.
The steering column tube module (N80) reads in the selection via the steering LIN (LIN E1) and transmits it on
the interior CAN (CAN B). The central gateway control unit passes these on to the instrument cluster via the
central CAN.
The following menus are accessible:
"Vehicle data" menu
"Dynamometer test" menu
"Active Service System PLUS workshop" menu
"Vehicle data" menu
The following data can be called up in the Vehicle data menu:
Voltage "U" in V and current consumption "I" in A in on-board electrical system
Data from instrument cluster (e.g. version numbers, software releases)
Engine data (e.g. engine number)
Oil data (e.g. filling capacity, temperature)
Vehicle data (e.g. chassis number)
AdBlue (tank full/tank not full)
High-voltage voltage status (on model 221.095/195) (de-energized/not de-energized)
High-voltage system status indication (on model 221.095/195)
Display for:
Circuit 15R ON
Irrespective of status of interlock circuit
Circuit 15 ON
Successful high-voltage system power disconnect
Open interlock circuit (fault)
Fig. 39: Screen Display - High-Voltage System Status Indication
Courtesy of MERCEDES-BENZ USA
High-voltage system status indication (on model 221.095/195)
Display for:
Circuit 15R ON
Fault in high-voltage system
Circuit 15 ON
High-voltage system operational (no fault)
Unsuccessful high-voltage system power disconnect
Fig. 40: Screen Display - High-Voltage System Status Indication
Courtesy of MERCEDES-BENZ USA
Activation of the dynamometer test prevents faults from being entered in the ESP control unit (N47-5) (except
model 221.095/195) or in the regenerative braking system control unit (N30/6) (on model 221.095/195) during
the brake test on the roller dynamometer.
It is possible to switch between the following settings in the roller dynamometer mode submenu using the left
multifunction steering wheel button group:
"On"
"With circuit 15 OFF"
When the Workshop level menu is exited and, if the dynamometer test mode was not deactivated beforehand,
the Dynamometer test mode menu is automatically called up the next time the ignition sequence is initiated.
ASSYST-PLUS workshop menu
The following submenus can be selected in the ASSYST-PLUS workshop menu:
Service scope
Service carried out (entry for service work performed)
Vehicle handover
Oil measurement (only with engine 275, 629)
A1 Model 216.3, model 221 (except GF54.30-P-
Component description for instrument cluster
221.095/195) 6000LE
GF54.30-P-
Model 221.095/195
6000LEH
Component description for regenerative GF42.22-P-
N30/6 On model 221.095/195
braking system control unit 1100LEH
N47-5 Model 216.3, model 221 GF42.45-P-
Component description for ESP control unit
(except 221.095/195) 5118LE
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for steering column GF54.21-P-
N80
tube module 6050LE
Component description for central gateway GF54.21-P-
N93
control unit 4170LE
SETTINGS ON WORKSHOP LEVEL, FUNCTION - GF54.30-P-2020SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Adjust workshop level in the instrument cluster (A1)
The function requirements for adjusting the workshop level:
Circuit 15R ON
The basic display of the trip computer is shown in the multifunction display (A1p13) of the instrument
cluster
The following steps must be carried out in order to get into the workshop level which is shown in the
multifunction display of the instrument cluster:
Press the accept phone call button of the accept/terminate phone call button (S111s3) and keep pressed.
Within 1 s of pressing and when keeping the accept/terminate phone call button pressed, press the OK
button (S110s6) as well and keep it pressed.
Keep both buttons pressed down for at least 5 seconds until the basic display of the workshop level is
displayed.
The workshop level can be exited again using the "Back" and SBS off button (S110s4) again.
Basic display of workshop level shown on model 221 up to 31.8.06
It is possible to change between the following submenus using the scroll forward/back button (S110s1) of the
multifunction steering wheel (MFL):
Vehicle data
Dynamometer test mode
ASSYST Plus workshop
Fig. 41: Screen Display - Workshop Level
Courtesy of MERCEDES-BENZ USA
Vehicle data
It is possible to inquire after the following information in the vehicle data submenu:
On-board electrical system voltage display
Vehicle model
Installed engine variant
Vehicle identification number (VIN)
Switch on roller test mode
With the roller test mode the wheel speeds of the driven axle are reflected in the non-driven axle. This is
necessary on the brake test stand so that no error is entered in the ESP control unit (N47-5).
To do this, the following adjustment must be made:
Adjust the workshop level in the multifunction display.
Operate the scroll forward/back button until the roller test mode appears in the multifunction display.
Switch on the roller test mode with the OK button.
In the roller test mode submenu it is possible to choose between the function "ON" and "Off with circuit 15
OFF". The respective function is activated with the "Back" and SBS off button.
The functions "ON" and "Off with circuit 15 OFF" differ as follows:
If the condition "ON" is selected the roller test mode submenu is shown again after a status change from
"circuit 15R OFF" to "circuit 15R ON" (reminder notification).
If the condition "Off with circuit 15 OFF" is selected, the basic display of the trip computer is shown after
a status change from "circuit 15R OFF" to "circuit 15R ON".
Dynamometer test condition "ON" shown on model 221 up to 31.8.06
If the condition "ON" is selected the roller test mode submenu is shown again after a status change from "circuit
15R OFF" to "circuit 15R ON" (reminder notification).
Fig. 42: Screen Display - Dynamometer Test Condition (On)
Courtesy of MERCEDES-BENZ USA
Dynamometer test condition "Off with circuit 15 OFF" shown on model 221 up to 31.8.06
If the condition "Off with circuit 15 OFF" is selected, the basic display of the trip computer is shown after a
status change from "circuit 15R OFF" to "circuit 15R ON".
Fig. 43: Screen Display - Dynamometer Test Condition (Off)
Courtesy of MERCEDES-BENZ USA
Instrument cluster, component description GF54.30-P-6000SX
ACTIVATE COCKPIT CENTRAL DISPLAY, FUNCTION - GF54.30-P-2200SX
MODEL 221.0 /1, 216.3 up to Model Year 8
System status
The man-machine interface (MMI) has the following 3 system states:
"HU ON" (head unit ON)
"HU USER OFF" (head unit user OFF)
"SCREEN OFF"
Toggling between system status "HU ON" and "HU USER OFF"
By pressing the "ON" button (A40/9s6) of the front central operating unit (A40/9) a changeover is made
between the system status "HU ON" and "HU user OFF".
Toggling the system status changes the range of functions and displays in the COMAND display (A40/8).
System status "HU ON"
The main functions (audio, video, telephone, etc.) are available and are displayed in the COMAND display.
Some functions remain unavailable irrespective of the terminal status. These functions are grayed out in the
COMAND display.
The main functions have been deactivated using the "ON" button on the front central operating unit or by
removing the transmitter key (A8/1) "Tml. 15C OFF". The COMAND controller unit (A40/3) continues to be
active. The screen of the COMAND display is black. However the climate functions line is displayed depending
on the circuit status. The functions not available in the climate functions line are grayed out in the COMAND
display.
System status "SCREEN OFF"
The background illumination of the COMAND display is switched off. The main functions are available, but no
information is displayed. This status is activated by selecting the following option via the menu:
Activate "Vehicle" in the submenu line
Activate the "System settings" submenu in the "Vehicle" menu
Activate the "Display" submenu in the "System settings" menu
Activate the "Display OFF" function in the "Display" menu
Display in COMAND display with different system states and terminal states
If the transmitter key is removed ("Tml. 15C OFF"), the COMAND display remains inactive in both the state
"HU USER OFF" and "HU ON".
The COMAND display can, however, be switched on by pressing the "ON" button on the front central operating
unit even if the "Tml. 15C OFF" state exists. It switches off again after 30 minutes if the status does not change
to "Tml. 15R ON" beforehand.
Shown on model 221 up to 31.8.06
Further behavior of COMAND display
System status is "HU ON" and terminal status is "Tml. 15C ON"; the currently selected function is displayed
and executed.
The screen is completely black with system status "HU USER OFF" and terminal status "Tml. 15C ON"
Fig. 44: Screen Display - System And Terminal Status (HU ON, 15C ON)
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.8.06
System status is "HU ON" and terminal status is "Tml. 15R ON"; the currently selected function is displayed
and executed.
Fig. 45: Screen Display - System And Terminal Status (HU ON, 15R ON)
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.8.06
System status is "HU USER OFF" and terminal status is "Tml. 15R ON".
Fig. 46: Screen Display - System And Terminal Status (HU User Off, 15R ON)
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.8.06
System status is "HU ON" and terminal status is "Tml. 15 ON"; the currently selected function is displayed and
executed.
Fig. 47: Screen Display - System And Terminal Status (HU ON, 15 ON)
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.8.06
System status is "HU USER OFF" and terminal status is "Tml. 15 ON".
Fig. 48: Screen Display - System And Terminal Status (HU User Off, 15 ON)
Courtesy of MERCEDES-BENZ USA
MMI system start
The MMI system is run up if the status changes to "Tml. 15C ON" or the "ON" button on the front central
operating unit is pressed.
If the status changes to "Tml. 15R ON" or the "ON" button on the front central operating unit is pressed, the
corporate identity screen is displayed first followed by the disclaimer screen. The application which was called
up via the COMAND display before the system was last switched off is then started.
Shown on model 221 up to 31.8.06
Corporate identity screen
The corporate identity screen is displayed in the COMAND display first each time the system is started.
Fig. 49: Screen Display - Corporate Identity Screen
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.8.06
Disclaimer screen
The disclaimer screen is displayed in the COMAND display following the corporate identity screen each time
the system is started.
Fig. 50: Screen Display - Disclaimer Screen
Courtesy of MERCEDES-BENZ USA
COMAND display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
ADJUST COCKPIT CENTRAL DISPLAY, FUNCTION - GF54.30-P-2210SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221
Fig. 51: Identifying Cockpit Switch Group Components
Courtesy of MERCEDES-BENZ USA
Moving screen
The function requirement for moving the screen of the COMAND display (A40/8) is "Tml. 15R ON".
The COMAND display swivel left switch and the COMAND display swivel right switch can be used to move
the screen in 3 steps to the left or right by max. 10° about the vertical axis.
The COMAND display swivel left switch and COMAND display swivel right switch are fitted in the cockpit
switch group next to the COMAND display.
Screen dimming
The screen can be dimmed manually or automatically. Two photo sensors integrated in the COMAND display
are used for the automatic dimming function.
The COMAND display brightness control in the cockpit switch group is used for manual dimming. The
brightness of the COMAND display can be adjusted to the needs of the user by means of the COMAND display
brightness control.
Information flow for adjusting screen in COMAND display
The COMAND display swivel left switch, the COMAND display swivel right switch and the COMAND
display brightness control are integrated in the cockpit switch group.
The cockpit switch group is read in by the upper control panel control unit (N72/1) via the upper control
panel LIN.
The upper control panel control unit places the signals on the interior CAN.
The central gateway control unit (N93) receives the signals on the interior CAN and places them on the
central CAN.
The COMAND controller unit (A40/3) reads the signals from the central CAN and places them on the
telematics CAN.
The COMAND display reads in the signals from the telematics CAN and actuates the screen display
accordingly.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
DAY AND NIGHT DESIGN OF COCKPIT CENTRAL DISPLAY, FUNCTION - GF54.30-P-2220SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Day design, shown on model 221 up to 31.8.06
Fig. 52: Screen Display - Day Design Of Cockpit Central Display
Courtesy of MERCEDES-BENZ USA
Night design, shown on model 221 up to 31.8.06
Fig. 53: Screen Display - Night Design Of Cockpit Central Display
Courtesy of MERCEDES-BENZ USA
Special design variants for day and night mode are available to ensure optimum readability of the displayed
information and functions under different light conditions.
The design variants can be toggled manually or automatically.
Manual toggling between day and night design in menu item "Vehicle", shown on model 221 up to
31.8.06
Fig. 54: Screen Display - Manual Toggling Between Day And Night Design
Courtesy of MERCEDES-BENZ USA
Manual and automatic toggling between design variants
The manual changeover between day and night takes place in the main menu line in the "Vehicle" menu item.
If the "Display" submenu item is activated, the following settings
If the "Vehicle" menu item is activated, the "System settings" menu item can be selected in the submenu line.
If the "System settings" menu item is activated, the following submenu items are then available:
Time
Language
Voice
Linguatronic
Services
Display
Reset
can be selected:
Day design
Night design
Automatic
If the "Day design" setting is activated, the day design is also active at night.
If the "Night design" setting is activated, the night design is also active during the day.
If the "Automatic" setting is activated, the day or night design is set automatically according to the light
conditions.
Information flow for automatic design variant toggling
The information as to whether the day or night design is activated is supplied by the rain/light sensor (B38/2).
The rain/light sensor measures the light intensity, converts this into a digital value and passes on the
signals discretely to the overhead control panel control unit (N70).
The overhead control panel control unit reads in the signals and places them on the interior CAN.
The central gateway control unit (N93) receives the signals on the interior CAN and places them on the
central CAN.
The COMAND controller unit (A40/3) reads the signals from the central CAN and actuates the day or
night design of the COMAND display (A40/8) accordingly via a Low Voltage Differential Signal
(LVDS) interface.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
FULL-SCREEN MODE OF COCKPIT CENTRAL DISPLAY, FUNCTION - GF54.30-P-2230SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Full-screen mode in COMAND display (A40/8)
In full-screen mode, the entire screen of the COMAND display without menus is used to display an application.
Full-screen mode can be selected for the following applications:
Video picture of "TV" and "DVD-Video" applications
Map display for "navigation" application
In full-screen mode, the following screen sections are hidden:
Status line
Main menu row
Submenu row
Air conditioning functions row
The video picture or navigation map which have previously been shown in the main menu selection range now
fill the complete screen.
Video image in "normal screen mode" with screen divided into 5 areas, shown on model 221 up to 31.8.06
Fig. 55: Screen Display - Video Image In Normal Screen Mode
Courtesy of MERCEDES-BENZ USA
Activation of full-screen mode
If the cursor is located in the main menu selection range the "full screen" option can be selected. The effect of
this is that the menu lines status bar, main menu line, submenu line, climate functions line are removed and the
video picture fills the complete screen.
Video image in "full-screen mode" without screen division, shown on model 221 up to 31.8.06
Fig. 56: Screen Display - Video Image In Full Screen Mode Without Screen Division
Courtesy of MERCEDES-BENZ USA
Displaying info menu in full-screen mode
The information menu is blended in the full screen display, while the turn/push control (A40/9s11) of the front
central operating unit (A40/9) is turned or pressed in one direction (not vertically downwards).
Video image in "full-screen mode" with activated info menu, shown on model 221 up to 31.8.06
Fig. 57: Screen Display - Video Image In Full Screen Mode With Activated Info Menu
Courtesy of MERCEDES-BENZ USA
Deactivating full-screen mode
Full-screen mode is deactivated by pressing the rotary pushbutton on the front central operating unit down
vertically. The menu lines status bar, main menu line, climate functions line are faded in immediately again and
the video picture is still only shown in the main menu selection range.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
SYSTEMS DISPLAYED IN COCKPIT CENTRAL DISPLAY, FUNCTION - GF54.30-P-2240SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Layout of COMAND display (A40/8), shown on model 221 up to 31.8.06
Fig. 58: Screen Display - Cockpit Central Display
Courtesy of MERCEDES-BENZ USA
Menu items in the main menu line
The following systems displayed in the main menu line can be selected in the COMAND display:
"Navi"
Menu item for navigation settings
"Audio"
Menu item for audio component settings (radio, audio CD/ DVD, MP3)
"Tel"
Menu item for communication component settings (telephone, SMS, address book)
"Video"
Menu item for video component settings (TV, video DVD)
"Vehicle"
Menu item for configuring vehicle components which can be operated in COMAND display
Menu items which are not available to the user are displayed with a gray background and cannot be selected.
Climate control
The climate functions line is faded in and switched active depending on the circuit status and system status.
Navigation menu item, With code (527) COMAND APS with Single DVD disk drive GF54.30-P-
function (with navigation) 3120SX
with CODE (494) USA version with CODE (498) Japanese GF54.30-P-
version 3120SXJ
with CODE (494) USA version except code (498) Japanese
GF54.30-P-
Audio menu item, function version With code (527) COMAND APS with Single DVD
3130SXA
disk drive (with navigation)
GF54.30-P-
with CODE (498) Japanese version
3130SXJ
Except code (863) Digital/analog TV tuner with code (527)
GF54.30-P-
Video menu item, function COMAND APS with single DVD drive (with navigation),
3140SX
except code (863) Digital/analog TV tuner
With code (863) Digital/analog TV tuner with code (527)
GF54.30-P-
COMAND APS with single DVD drive (with navigation),
3140SXA
with code (863)
GF54.30-P-
Digital/analog TV tuner with CODE (498) Japanese version
3140SXJ
Communication and with code (388) Universal Portable CTEL Interface System
GF54.30-P-
telephone menu item, with code (386) Preinstallation for portable CTEL UPCI
3150SX
function [UHI] system with CODE (494) USA version
With code (387) preinstallation for portable CTEL UPCI
system, USA/Canada GF54.30-P-
With code (389) Mobile phone preinstallation with universal 3150SXJ
interface, USA/Canada with CODE (498) Japanese version
Vehicle menu item, GF54.30-P-
except code (498) Japanese version
function 3160SX
GF54.30-P-
with CODE (498) Japanese version
3160SXJ
Operation of climate GF54.30-P-
control, function 3170SX
DISPLAY SPEED, FUNCTION - GF54.30-P-3025SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221 up to 31.8.06
Fig. 59: Identifying Multifunction Display Components
Courtesy of MERCEDES-BENZ USA
Night View Assist activated shown on model 221 up to 31.8.06 with code (610) Night View Assist
Fig. 60: Screen Display - Night View Assist Activated
Courtesy of MERCEDES-BENZ USA
General
The electronic speedometer is used to display vehicle speed. The electronic speedometer is displayed in the
multifunction display.
The electronic speedometer can be displayed as follows:
Ring speedometer
Strip speedometer (on vehicles with code (610) Night View Assist)
In addition to the electronic speedometer an additional speedo can be faded in in the multifunction display.
Measuring the vehicle speed
The wheel speeds from the following sensors are evaluated to calculate the vehicle speed:
Left front RPM sensor (L6/1/)
Right front RPM sensor (L6/2/)
Left rear RPM sensor (L6/3/)
Right rear RPM sensor (L6/4/)
Additional speedometer shown on model 221 up to 31.8.06
Function
The additional speedometer indicates the speed of the vehicle in a digital numerical display in the lower left
multifunction display. The dimensional unit of speedometer scale of the electronic speedometer is as follows in
relation to the dimensional unit of the additional speedometer:
If the dimensional unit of the speedometer scale of the electronic speedometer is kilometers, the
additional speedo is displayed in miles.
If the dimensional unit of the speedometer scale of the electronic speedometer is miles, the additional
speedo is displayed in kilometers.
Fig. 61: Screen Display - Additional Speedometer
Courtesy of MERCEDES-BENZ USA
Switch on additional speedometer shown on model 221 up to 31.8.06
Fig. 62: Screen Display - Switched On Additional Speedometer
Courtesy of MERCEDES-BENZ USA
Switching on or off additional speedometer
The additional speedometer is switched on or off as follows:
use the system selection button (S110s3) of the left multifunction steering wheel button group (S110) to
select the "Settings" menu item.
Using the scroll forward/back button (S110s1) of the Left multifunction steering wheel button group
select the "additional speedometer" menu item and confirm with the OK button (S110s6).
Use the OK button to switch the additional speedo on or off.
The displayed function is stored and exited using the "Back" and SBS off button (S110s4).
Evaluating the wheel speed signals
Since the wheels do not always rotate at the same speed, all 4 wheel speeds must be evaluated. As the
evaluation procedure is very complex, a simplified version is described here:
The individual wheel speeds are compared and submitted to a plausibility check. If there are no
significant differences, the vehicle speed is determined using the rotational speed of the left front wheel.
If the individual wheel speed signals differ considerably, the speed signals may be faulty or the vehicle
may be cornering.
If appropriate comparison of the wheel speeds (between the two sides of the vehicle) by the instrument
cluster indicates that the vehicle is cornering, the speed is determined from the mean value of the front
wheel speeds.
If the comparisons indicate one or more incorrect wheel speeds, the speed is calculated from the highest
wheel speed. This also applies if an error message is received instead of a rotational wheel speed. In this
case a corresponding fault message is also output.
If error messages are received for all wheel speeds, the speed 0 km/h or 0 mph is displayed (speed display
pointer at start of scale).
Networking shown on model 221 up to 31.8.06
Fig. 63: Instrument Cluster CAN Networking Diagram
Courtesy of MERCEDES-BENZ USA
Reading in the data for the vehicle speed signal:
The left front RPM sensor, right front RPM sensor, left rear RPM sensor and right rear RPM sensor are
read in by the ESP control unit.
The ESP control unit places the RPM sensor signals on the chassis CAN.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and calculates the vehicle speed from
them. The instrument cluster indicates the vehicle speed as a ring or strip speedometer (only on code
(610) Night View Assist) in the electronic speedometer and places the vehicle speed signal on the central
CAN.
Cruise control display
For the cruise control function the speedometer scale in the multifunction display is displayed in the form of a
segment band in the ring speedometer or band speedometer of the electronic speedometer. The individual
segments symbolize various vehicle speed ranges and can be actuated individually with different brightness and
color.
The brightened segments are shown as follows:
The cruise control without limiter is displayed with a brightened segment above the speed to be regulated
by the cruise control.
The cruise control with limiter (except code (494) USA version) is displayed with a brightened segment
between the cruise control speed and limiter speed.
The cruise control with Distronic (with code (219) Distronic (DTR)) or cruise control with Distronic Plus
(with code (233) Distronic Plus) is displayed by a brightened segment between the measured speed of the
vehicle driving in front and the adjusted speed.
Limiter, except code (494) USA version
With the functionality of the limiter a maximum speed below the maximum speed of the vehicle actually
achievable or (if switched on) up to the adjusted speed of the "Permanent Limiters". If the vehicle gets close to
the adjusted speed, the limiter ensures that the adjusted maximum vehicle speed is maintained by engine
intervention. The limiter is adjustable in the range from 30 km/h up to the maximum speed. The adjustment
takes place via the CC [TPM] switch (S40/4) in steps of ten and one (km/h or mph). In the electronic
speedometer in the multifunction display the segments of the ring speedometer or the strip speedometer then
light up from the scale start up to the adjusted value.
Permanent Limiter, except code (494) USA version
A permanent speed limit (adjustable in 10-km/h steps of 160 km/h to 240 km/h or in 10-mph steps from 100
mph to 150 mph) can be adjusted via the "Settings" menu and the "Speedtronik" submenu item in the
multifunction display. The adjustment takes place via the buttons of the left multifunction steering wheel button
group and the "Back" and VCS [SBS] off button. The permanent speed limit is displayed by a segment band
above the electronic speedometer from the start of the scale up to the adjusted speed limit value.
Correspondingly a warning message appears in the multifunction display and a warning chime is output when
the adjusted vehicle speed is exceeded.
Instrument cluster, component description GF54.30-P-6000SX
DISPLAY OPERATING CONDITIONS, FUNCTION - GF54.30-P-3041LE
MODEL 216.3, 221.0 /1 as of model year 2009 /YoM 08
Function requirements, general
Circuit 15 ON
The EZS control unit (N73) places the status of circuit 15 on the chassis CAN (CAN E). The central gateway
control unit (N93) forwards this to the instrument cluster (A1) via the central CAN (CAN F).
Display operating state function (general)
The operating conditions display provides the driver with permanent information about the current operating
conditions of the vehicle.
The Display operating conditions function is comprised of the following partial functions:
Function sequence for vehicle speed display
Display of engine speed function sequence
Display of coolant temperature function sequence
Display of fuel quantity function sequence
Display of travel distance function sequence
Function sequence, gear display and transmission mode display
Function sequence for display of charge level of high-voltage battery (A100g1) (on model
221.095/195)
Additional function requirements for vehicle speed display
Vehicle speed v > 0 km/h
Function sequence for vehicle speed display
The ESP control unit (N47-5) (except model 221.095/195) or the regenerative braking system control unit
(N30/6) (on model 221.095/195) reads in the signals from the left front RPM sensor (L6/1), right front RPM
sensor (L6/2), left rear RPM sensor (L6/3) and right rear RPM sensor (L6/4) directly and transmits them via the
chassis CAN.
The central gateway control unit forwards these signals to the instrument cluster via the central CAN. The
instrument cluster receives the signals from the RPM sensors, calculates the current vehicle speed and actuates
the electronic speedometer (A1p8) by means of a stepper motor.
In the multifunction display (A1p13), the vehicle speed can also be displayed digitally. This function is
selected in the "Trip" menu.
In the "Settings" menu, it is also possible to select an additional speedometer. This additional speedometer
always shows the vehicle speed in the units not shown in the display in the instrument cluster, i.e. in miles per
hour (mph) in the kilometers speedometer and in kilometers per hour (km/h) in the miles speedometer.
On vehicles with code (833) Great Britain version, the additional speedometer is displayed permanently and
cannot be deselected.
Additional function requirements for display of engine speed
Circuit 61 ON
Display of engine speed function sequence
The engine speed is detected by the crankshaft Hall sensor (B70) (except engine 275) or by the crankshaft
position sensor (L5) (with engine 275). The CDI control unit (N3/9) (with diesel engine) or the ME-SFI [ME]
control unit (N3/10) (with gasoline engine) reads in the signals from the crankshaft Hall sensor or the crankshaft
position sensor, uses them to calculate the engine speed and transmits a corresponding value on the chassis
CAN. The central gateway control unit forwards this to the instrument cluster via the central CAN. The
instrument cluster receives the value for the engine speed and actuates the tachometer (A1p5) accordingly by
way of a stepper motor.
Display of coolant temperature function sequence
Coolant temperatures are monitored by the coolant temperature sensor (B11/4). The CDI control unit or the
ME-SFI [ME] control unit reads in the signal from the coolant temperature sensor, uses it to calculate the
coolant temperature and transmits a corresponding value on the chassis CAN. The central gateway control unit
passes this value on to the instrument cluster via the central CAN. The instrument cluster receives the value for
the coolant temperature and actuates the coolant temperature display (A1p1) accordingly.
Function sequence for fuel quantity display
The left tank half fuel level indicator sensor (B4/1) and the right tank half fuel level indicator sensor (B4/2)
detect the fill level of the fuel tank. The rear SAM control unit with fuse and relay module (N10/2) reads in the
signals from the fuel level indicator sensor and transmits them on the interior CAN (CAN B). The central
gateway control unit forwards these signals to the instrument cluster via the central CAN.
The instrument cluster receives these signals, evaluates them and actuates the fuel level and reserve indicator
(A1p2) accordingly by means of a stepper motor.
When the reserve range is reached, the instrument cluster actuates the fuel reserve warning lamp (A1e4). The
reserve range is defined by comparing the measured fill level against a stored tank characteristic.
If the reserve range drops to approx. 50 %, a gas station symbol in the form of a gasoline pump is shown in the
Range menu instead of the distance reading.
Display characteristics of fuel level indicator:
After switching on circuit 15, the current fill level is displayed. In the process, the pointer runs up without
being buffered.
While the vehicle is driving, the display is updated via a buffering system.
After circuit 15 is switched off, the pointer of the fuel level and reserve indicator is moved back to zero.
A fuel level indicator sensor which is jammed tight is detected by comparing the change in fill level of the
fuel tank with the calculated composite mileage. If the fill level drops faster over a particular distance than is
technically feasible with the composite mileage, a defective fuel level indicator sensor is detected and an
appropriate message is shown in the multifunction display.
Display of travel distance function sequence
The travel distance display function is made up of the following subfunctions:
Determination of travel distance function sequence
Display of main odometer reading function sequence
Display of trip distance function sequence
Storage of counter readings function sequence
Determination of travel distance function sequence
The instrument cluster calculates the travel distance from the signals received from the RPM sensors taking the
tire circumference into consideration.
The tire size is coded via the diagnostics tester.
Function sequence, display of main odometer reading
The main odometer reading display is shown in the multifunction display. The maximum displayed counter
reading on the main odometer is 1, 700, 000.
The display does not then start again at zero.
Display of trip distance function sequence
The trip distance display is shown in the multifunction display. The maximum displayed counter reading of the
trip distance is 9999.9. If this value is achieved, the figure returns to zero.
Storage of counter readings function sequence
The main odometer reading is saved continuously to the nonvolatile part of the instrument cluster's internal
memory. This memory guarantees the retention of the counter reading for at least five years even when the on-
board electrical system battery (G1) is disconnected.
The current reading of the trip odometer is likewise stored in the nonvolatile memory of the instrument cluster.
Function sequence, gear display and transmission mode display
The data required for the gear indicator is transmitted by the EGS control unit (N15/3) (with transmission
722.6) or the fully integrated transmission control unit (VGS) (Y3/8n4) (with transmission 722.9) on the drive
train CAN (CAN C).
The transmission mode information is made available on the drive train CAN by the intelligent servo module
for DIRECT SELECT (A80). The CDI control unit or the ME-SFI [ME] control unit passes the information on
to the central gateway control unit via the chassis CAN.
The central gateway control unit forwards the information to the instrument cluster via the central CAN.
Possible transmission modes are:
"C" = Comfort (up to 31.8.10)
"E" = Economy (as of 1.9.10)
"S" = Sport
"M" = Manual
The current gear is shown in the gear indicator (A1p12) and the current transmission mode is shown in the
transmission mode display (A1p16) in the multifunction display.
Function sequence for display of charge level of high-voltage battery (on model 221.095/195)
The charge level of the high-voltage battery is indicated in the multifunction display in the form of a battery
symbol together with power level as a percentage.
The display is called up by the following selection:
Select "Trip" menu using system selection button (S110s3)
Select hybrid display by scrolling using scroll forward and back button (S110s1)
Fig. 64: Display - Charge Level Of High-Voltage Battery
Courtesy of MERCEDES-BENZ USA
The charge level of the high-voltage battery is also shown in the COMAND display (A40/8) (without code
(867) SPLITVIEW) or in the SPLITVIEW display (A40/10) (with code (867) SPLITVIEW). Here too, the
power level is given as a percentage.
Additionally, the energy flow of the hybrid drive is shown by arrows.
The data required to display this is sent by the battery management system control unit (N82/2) to the
COMAND display or the SPLITVIEW display via the drive train sensor CAN (CAN I), ME-SFI [ME] control
unit, chassis CAN, central gateway control unit and central CAN.
The instrument cluster and the COMAND display or the SPLITVIEW display receive this data and evaluate it
accordingly so that it can be displayed.
Fig. 65: Identifying Energy Flow Of Hybrid Drive
Courtesy of MERCEDES-BENZ USA
Electrical function schematic of instrument PE54.30-P-2055-
Model 216
cluster, operating condition display 97CAA
Model 221 (except model PE54.30-P-2055-
221.095/195) 97SAA
PE54.30-P-2055-
Model 221.095/195
97SAB
A1
GF54.30-P-
Component description for instrument cluster Model 216.3, model 221
6000LE
(except 221.095/195)
GF54.30-P-
Model 221.095/195
6000LEH
Component description for intelligent servo A80 GF27.19-P-
module for DIRECT SELECT With transmission 722.6 4020ACS
With transmission 722.9 GF27.19-P-
(except 722.931/950) 4020AHS
GF27.19-P-
With transmission 722.931
4020AHT
GF27.19-P-
With transmission 722.950
4020LEH
N3/9
GF07.16-P-
Component description for CDI control unit On model 221 with engine
6000OA
629.9
642.8 6000OHS
On model 221 with engine GF07.16-P-
642.9 6000OHL
Component description for ME-SFI [ME] N3/10 GF07.61-P-
control unit With engine 156 6000MAS
On model 221 with engine 272 GF07.61-P-
(except 272.974) 6000MIS
On model 221 with engine GF07.61-P-
272.974 6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
On model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278
6000MMC
Component description for rear SAM control GF54.21-P-
N10/2
unit with fuse and relay module 6030LE
Component description for electronic N15/3 GF27.60-P-
transmission control unit With transmission 722.6 5164ACS
Component description for regenerative N30/6 GF42.22-P-
braking system control unit On model 221.095/195 1100LEH
N47-5
GF42.45-P-
Component description for ESP control unit Model 216.3, model 221
5118LE
(except 221.095/195)
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for battery N82/2 GF54.10-P-
management system control unit On model 221.095/195 3012MEH
Component description for central gateway GF54.21-P-
N93
control unit 4170LE
Y3/8n4
Component description for fully integrated GF27.60-P-
With transmission 722.9
transmission control unit 5165AHS
(except 722.931/950)
GF27.60-P-
With transmission 722.931
5165AHT
GF27.60-P-
With transmission 722.950
5165LEH
DISPLAY OPERATING CONDITIONS, FUNCTION - GF54.30-P-3041SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Display fuel supply, networking shown on model 221 up to 31.8.06
Fig. 66: Display Operating Conditions Function Diagram
Courtesy of MERCEDES-BENZ USA
General
The fuel level and reserve indicator is located in the left of the Instrument cluster and is designed as an analog
display. The fuel level and reserve indicator is driven by a stepper motor. If the "circuit 15 ON" status exists, the
pointer of the fuel level and reserve indicator is run up slowly to the respective value.
Refueling recognition of fuel level and reserve indicator with "circuit 15 OFF"
If the vehicle is refueled with "circuit 15 OFF", the fuel level and reserve indicator is updated when the "circuit
15 ON" state exists again, provided that approx. 3 liters of fuel have been added.
Refueling recognition of fuel level and reserve indicator with "circuit 15 ON"
With "circuit 15 ON", the current tank content is displayed on the fuel level and reserve indicator.
If the vehicle is refueled with "circuit 15 ON", the fuel level and reserve indicator is not updated until approx. 7
liters of fuel have been added.
The fuel level and reserve indicator is always updated after a delay and the pointer of the fuel level and
reserve indicator always runs up to the new fuel value slowly. This ensures that fluctuations in the fuel level
resulting from vehicle movement are not shown on the fuel level and reserve indicator.
Reserve indication range
If the reserve range is reached, the fuel reserve warning lamp lights up yellow. The lamp is triggered with a
delay period to prevent the lamp flickering. The tank contents are still approx. 12 l when the fuel reserve
Information flow and networking
The flow of information is as follows:
The left tank half fuel level sensor and right tank half fuel level sensor measure the tank capacity and are
read in by the rear SAM control unit with fuse and relay module.
The signals from the fuel level sensor, left tank half and fuel level sensor, right tank half are converted
into a percent value by the Rear SAM control unit with fuse and relay module and interior CAN.
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The Instrument cluster receives these signals from the central CAN and actuates the stepper motor of the
fuel level and reserve indicator corresponding to the tank contents
Jammed fuel tank sensor recognition
The jammed fuel tank sensor recognition function becomes active after the vehicle has covered a distance of s >
160 km. Tank sensor seized is detected, if the sensor resistance value of the Left tank half fuel level sensor or
right tank half fuel level sensor does not change by at least a defined resistance value within a certain distance.
If this condition occurs, a corresponding fault bit is set in the fault memory of the rear SAM control unit with
fuse and relay module. The erroneous bit is erased again if the requested change in resistance value of the left
tank half fuel level sensor or right tank half fuel level sensor has occurred.
If a fault occurs, the pointer of the fuel level and reserve indicator moves to the beginning of the scale. The
fuel reserve indicator lamp is not actuated.
Networking of outside temperature indicator, shown on model 221 with engine 272 up to 31.8.06
Fig. 67: Networking Of Outside Temperature Indicator
Courtesy of MERCEDES-BENZ USA
The outside temperature indicator takes account of the following data to display the temperature value:
Outside temperature value
Vehicle speed signal
Coolant temperature
Engine running time
The instrument cluster processes this data and actuates the outside temperature indicator in the multifunction
display accordingly. The outside temperature indicator is actuated as of circuit status "circuit 15 ON".
The fact that the outside temperature indicator is dependent on the outside temperature, coolant temperature,
vehicle speed and engine operating time prevents too high a temperature as can be caused by engine heat
dissipation being displayed when the vehicle is stationary or driving slowly.
coolant temperature < 60 °C
When the coolant temperature is < 60 °C, the current outside temperature value is displayed continuously when
the instrument cluster is activated.
Coolant temperature > or =60 °C
If the coolant temperature is > or =60 °C, with a status change from "Circuit 15 ON" to "Circuit 15 OFF" the
temperature value last measured is stored and displayed in the instrument cluster. When the instrument cluster is
activated, the stored temperature is always displayed. If the measured outside temperature drops below the
stored value, the current measured temperature is displayed with a delay period of 8 s.
When the vehicle is being driven, the delay periods also depend on the vehicle speed:
At speeds of 20 to 45 km/h rising outside temperatures are displayed after a delay period of 3 minutes.
At speeds > 45 km/h rising outside temperatures are displayed after a delay period of 90 s.
With a reduction in speed < 20 km/h the display is only changed when the measured outside temperature
value drops.
If the instrument cluster does not receive a valid coolant temperature from the central CAN, the outside
temperature is determined in the same way as for a coolant temperature > or = 60 °C.
Rising outside temperature with engine OFF following engine running period
If the outside temperature rises above the stored value with the engine OFF, the outside temperature currently
measured is only shown in the outside temperature indicator of the multifunction display after 6-times the
engine running time, however after a maximum of one hour.
If the coolant temperature drops below 60 °C, the delay time counter is canceled immediately and rising
temperatures are shown in the outside temperature indicator of the multifunction display.
Example: Delay period for outside temperature indicator
The preceding engine running time was 5 minutes. The delay time is then 6x5 minutes. The current temperature
is thus only displayed after 30 minutes.
If the engine running time was more than 10 minutes, a maximum of 10 minutes is taken into account when
calculating the delay time. The maximum delay period is thus 60 min.
Information flow and networking
Reading in the data required for the coolant temperature value:
Reading in data required for the outside temperature value:
The outside temperature indicator temperature sensor
The coolant temperature sensor changes its resistance corresponding to the coolant temperature. The
sensor has a negative temperature coefficient (NTC) resistance, i.e. the resistance reduces as temperature
increases.
The resistance of the coolant temperature sensor is read in by the ME-SFI [ME] control unit or by the
CDI control unit (N3/9) (model 221).
The ME-SFI [ME] control unit or CDI control unit (model 221) converts the measured resistance values
of the coolant temperature sensor into a temperature value and places this on the chassis CAN.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and processes them.
changes its resistance according to the outside temperature. The sensor is an NTC resistor.
The resistance value of the outside temperature display temperature sensor is read in discretely by the
front SAM control unit with fuse and relay module.
The front SAM control unit with fuse and relay module places the signal on the interior CAN.
The central gateway control unit reads in the signals from the interior CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and processes them.
Reading in the data for the vehicle speed signal:
The left front RPM sensor, right front RPM sensor, left rear RPM sensor and right rear RPM sensor are
read in by the ESP control unit.
The ESP control unit places the RPM sensor signals on the chassis CAN.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN and processes them.
The Instrument cluster processes all the data received and actuates the outside temperature indicator in the
multifunction display.
Range
The display range is -40 to +85 °C or -40 to +185 °F. The resolution of the outside temperature indicator is 0.5 °
C or 1 °F. If the outside temperature measured exceeds the display range the maximum display value of the
display range is shown. If the outside temperature measured drops below the display range, the minimum
display value of the display range is shown.
Adjustment from degrees Celsius (°C) or degrees Fahrenheit (°F)
The dimensional unit of the outside temperature indicator is adjusted at the end of the assembly line to (°C) or (°
F) depending on the country.
Display coolant temperature shown on model 221 with engine 272 up to 31.8.06
Fig. 68: Display Coolant Temperature Communication Diagram
Courtesy of MERCEDES-BENZ USA
General
The coolant temperature display is located on the left of the instrument cluster and is designed as an analog
display. The display is driven by a stepper motor. It is actuated as of circuit status "Circuit 15 ON".
Fault behavior
If the Controller Area Network (data bus/CAN bus) (CAN) signal is defective or if the instrument cluster does
not receive a coolant temperature signal, the pointer is moved back to the start of the scale in a damped manner.
In addition an erroneous bit is set in the fault memory of the instrument cluster.
Networking and information flow
Information flow, engine fan defective:
If there is a defect in the engine fan, a fault signal is placed on the chassis CAN by the ME-SFI [ME]
control unit or by the CDI control unit (model 221).
The central gateway control unit reads in the signal from the chassis CAN and places it on the central
CAN.
The instrument cluster reads in the signal from the central CAN and processes it
Coolant temperature characteristics
Fig. 69: Coolant Temperature Characteristics Graph
Courtesy of MERCEDES-BENZ USA
Display range of the coolant temperature display in normal mode (plateau characteristic):
In the measured coolant temperature range of > or = °C to < 120 °C the values of the plateau
characteristic are displayed in the coolant temperature display.
In the measured coolant temperature range of > or =120 °C to < 130 °C the values of the plateau
characteristic are displayed in the coolant temperature display.
In the measured coolant temperature range of > or =130 °C the pointer of the coolant temperature display
is controlled at the scale end value.
The plateau characteristic should prevent the driver being unnecessarily disturbed by a high temperature but one
which is not critical for the vehicle, e.g. at a high outside temperature.
If the engine fan is defective the plateau characteristic is exited and the measured coolant temperature is
always displayed in the coolant temperature display.
Warning range
The warning range of the coolant temperature display highlighted in red starts at 120 °C.
If the coolant temperature is too high a warning is output in the multifunction display and in addition a warning
tone sounds.
Display engine speed, shown on model 221 with engine 272 up to 31.8.06
Fig. 70: Display Engine Speed Function Diagram
Courtesy of MERCEDES-BENZ USA
General
The tachometer is located in the right of the instrument cluster and is designed as an analog display. The display
is driven by a stepper motor.
Networking
The flow of information is as follows:
The RPM is recorded by the crankshaft Hall sensor.
The signals from the crankshaft Hall sensor are read in by the ME-SFI [ME] control unit or by the CDI
control unit (model 221) and placed on the chassis CAN.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster receives these signals from the central CAN and actuates the tachometer stepper
motor corresponding to the RPM.
In the event of the implausible values from the CAN the pointer of the tachometer is controlled to the start of
the scale. An error message is also stored in the fault memory.
Networking of vehicle speed signal, shown on model 221 up to 31.8.06
Fig. 71: Vehicle Speed Function Diagram
Courtesy of MERCEDES-BENZ USA
Calculation of mileage
The travel distance is derived from the speed of the vehicle and the length of time that the respective speed was
maintained.
Information flow and networking
Reading in the data for the vehicle speed signal:
The left front RPM sensor, right front RPM sensor, left rear RPM sensor and right rear RPM sensor are
read in by the ESP control unit.
The ESP control unit places the RPM sensor signals on the chassis CAN.
The central gateway control unit reads in the signals from the chassis CAN and places them on the central
CAN.
The instrument cluster reads in the signals from the central CAN, calculates the vehicle speed from them
and places them on the central CAN.
The time period is determined internally in the instrument cluster.
Displaying the total mileage
The total mileage is a 6-digit display in kilometers or miles in the basic display of the multifunction display as
The range for the main odometer is from 0 to 999, 999 kilometers or miles. If the maximum mileage is reached,
the counter is not reset to 0 kilometers or miles. The instrument cluster must be replaced in this case.
Displaying the trip mileage
The trip odometer is a 5-digit display in kilometers or miles in the basic display of the multifunction display as
soon as the instrument cluster has been activated.
The range for the trip odometer is from 0 to 9999.9 kilometers or miles. Once the maximum reading is reached
the display reverts to 0 kilometers or miles.
Resetting the trip odometer
In order to reset the trip odometer, the instrument cluster must be activated and the basic display of the trip
computer (RRE) must be shown.
The trip odometer is reset to 0 km or miles by pressing "Back" and SBS off button (S110s4) for at least 3
seconds.
Storage of data
When the on-board electrical system battery is disconnected the main odometer reading remains stored G1 for
at least 5 years in the instrument cluster memory and in the memory of the EIS [EZS] control unit (N73).
The trip odometer is also protected against data loss when the onboard electrical system battery is disconnected.
Fault behavior and shutdown interlock:
A shutdown interlock protects the odometer against speed values which are not in the plausible range.
In the event of a defective RPM sensor fault value is placed on the CAN by the ESP control unit. The
instrument cluster receives this fault value and determines the travel distance from the remaining RPM
values. In addition, an erroneous bit is set for the faulty RPM sensor in the fault memory.
If the instrument cluster cannot receive a valid speed signal via the central CAN, the mileage display is
set to the value 0 km or miles in the multifunction display or miles and a fault bit is set in the fault
memory.
Shown on model 221 up to 31.8.06
Fig. 72: Identifying Gear Indicator And Transmission Mode Display
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.8.06 with code (494) USA version
Fig. 73: Identifying Gear Indicator And Transmission Mode Display (With Code (494) USA Version)
Courtesy of MERCEDES-BENZ USA
Gear indicator in instrument cluster in sport program "S" and in comfort program "C"
It shows the driver the currently selected shift range "1", "2", "3", "4", "5", "6" or selector lever position "D",
"R", "N" (neutral) or "P" (park).
Gear indicator in the instrument cluster in manual program "M", on vehicles except code (494) USA
version
It shows the driver the engaged gear "1", "2", "3", "4", "5", "6", "7".
The arrows in the gear indicator show the driver which permissible gear selector switch position he can
change to. The decisive factor here is whether the speed, at which the vehicle is moving, is under or above the
speed threshold of 5 km/h.
Transmission mode display in instrument cluster
It indicates to the driver the program selection (S16/5) program selection "S" (Sport-program), "C" (comfort
program) or "M" (manual program) performed at the driving mode switch (on vehicles except code (494) USA
version).
Instrument cluster, component description GF54.30-P-6000SX
COMFORT DISPLAYS, FUNCTION - GF54.30-P-3043LE
MODEL 216.3, 221.0 /1 as of model year 2009 /YoM 08
Function requirements, general
Instrument cluster (A1) activated
Comfort displays, function (general)
The comfort displays provide a fast overview of the information, which is not required to operate the vehicle.
The comfort display function is made up of the following subfunctions:
Function sequence for displaying outside temperature
Function sequence for displaying the time
Night View Assist display function sequence (with code (610) Night View Assist)
Function sequence for illumination of instrument cluster
Function sequence for displaying outside temperature
The outside temperature value is defined through the resistance value of the outside temperature indicator
temperature sensor (B14). The front SAM control unit with fuse and relay module (N10/1) reads in the
resistance value of the outside temperature indicator temperature sensor directly, calculates from this the outside
temperature T in °C and transmits a corresponding signal to the instrument cluster via the interior CAN (CAN
B), central gateway control unit (N93) and central CAN (CAN F). The instrument cluster receives the signal
and actuates the outside temperature indicator (A1p4) accordingly.
The outside temperature is displayed according to the country coding in either °C or °F.
The following parameters must also be taken into account to determine a correct value of outside temperature:
Vehicle speed (falsification of value through airstream)
Coolant temperature (falsification of value through radiant heat)
The vehicle speed is calculated on the basis of the wheel speeds. The wheel speeds are recorded by the
following components:
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
The ESP control unit (N47-5) (except model 221.095/195) or the regenerative braking system control unit
(N30/6) (with model 221.095/195) reads in the signals from the RPM sensors and sends them to the instrument
cluster via the chassis CAN, central gateway control unit and central CAN.
The instrument cluster receives the signals from the RPM sensors and uses them to calculate the current vehicle
speed.
The coolant temperature is recorded by the coolant temperature sensor (B11/4). The CDI control unit (N3/9)
(for diesel engine) or the ME-SFI [ME] control unit (N3/10) (for gasoline engine) reads in the coolant
temperature sensor signal, calculates the coolant temperature and transmits the corresponding value via the
chassis CAN. The central gateway control unit passes this value on to the instrument cluster via the central
CAN.
The coolant temperature values have an influence on the outside temperature indicator as follows:
Coolant temperature T < 60 °C:
The current outside temperature value is always displayed.
Coolant temperature T > 60 °C and circuit 61 ON:
At vehicle speeds of v < 20 km/h (12 mph), the outside temperature display only changes if the measured
outside temperature value drops.
At vehicle speeds of v = 20 to 45 km/h, rising outside temperatures are displayed after a delay period of t
= 3 min. At vehicle speeds of v > 45 km/h rising outside temperatures are displayed after a delay period
of t = 90 s.
Coolant temperature T > 60 °C and circuit 61 OFF:
A delay period (maximum t = 2 h) ensures that any apparent increase in outside temperature due to heat
dissipated from the engine is not displayed. A rise in display value is not permitted during this delay
period.
With circuit 15 OFF, the coolant temperature value last measured is stored and displayed when the circuit is
reactivated. The display range is between -40 °C and +85 °C or between -40 °F and +185 °F. The display
appears in the lower range of the multifunction display (A1p13).
The EZS control unit (N73) sends the status of circuit 15 to the instrument cluster via the chassis CAN (CAN
E), central gateway control unit and central CAN.
If the instrument cluster receives implausible or no values at all from the temperature sensor for the outside
temperature indicator, then the display of outside temperature is controlled as if the coolant temperature were T
> 60 °C.
Function sequence for displaying the time
The time is shown on the analog clock (A70/1).
The time is adjusted via the COMAND controller unit (A40/3).
When adjusting, the instrument cluster reads in the signals directly via the central CAN.
For vehicles with code (527) COMAND APS with single DVD drive (with navigation) or code (529) HIGH
Class Japan or code (530) COMAND APS USA (with navigation) the time synchronizes itself automatically via
the Global Positioning System (GPS) signal received by the COMAND controller unit.
Manual adjustment of the time is only possible here if automatic synchronization is switched off on the
instrument cluster.
After updating the internal time, the instrument cluster transmits a corresponding signal via the central CAN,
central gateway control unit and interior CAN to the upper control panel control unit (N72/1).
The upper control panel control unit actuates the analog clock via the instrument panel LIN (LIN 1).
Additional function requirements, Night View Assist display (with code (610) Night View Assist)
Night View Assist active
The instrument cluster replaces the standard display of the electronic speedometer (A1p8) with the bar graph
display with video image. The Night View Assist control unit transmits the
Night View Assist display function sequence (with code (610) Night View Assist)
By pressing the Night View Assist button (S1s9) the display of Night View Assist camera (B84/2) pictures on
the multifunction display is requested. The upper control panel control unit reads in the status of the Night View
Assist button via the instrument panel LIN and transmits this on the interior CAN. The central gateway control
unit forwards this via the central CAN to the instrument cluster and, up to 31.5.09, via the chassis CAN to the
ESP control unit and via the vehicle dynamics CAN (CAN H) to the Night View Assist control unit (N101) or,
as of 1.6.09, via the chassis CAN to the Night View Assist control unit.
video images from the Night View Assist camera via the low voltage differential signal (LVDS) line to the
instrument cluster.
image areas that blind the driver are suppressed. Consequently it is made possible for the driver to be aware of
other picture contents (e.g. obstacles, pedestrians or cyclists).
The brightness distribution is controlled by the Night View Assist control unit.
Instrument cluster illumination function sequence
The following events will activate the background illumination of the multifunction display and the scale
illumination of the instrument cluster:
Unlock the vehicle with the transmitter key (A8/1)
Open or close driver door
Change of status "Transmitter key inserted"
Switching on the standing lights
Switching on circuit 15R
Operation of OK button (S110s6)
Operation of "Back" and VCS OFF button (S110s4)
Operation of electric parking brake switch (S76/15)
If the scale illumination of the instrument cluster has been activated and no further action takes place, the
instrument cluster switches off the scale illumination after a time interval of t = 30 s has passed. If a fault
message is displayed, this time interval increases to t = 120 s.
The EIS [EZS] control unit transmits the central locking status and the circuit status of circuit 15R to the
instrument cluster via the chassis CAN, central gateway control unit and central CAN.
The left door control unit (N69/1) (model 216) or the front left door control unit (N69/1) (model 221) transmits
the driver door status via the interior CAN, central gateway control unit and central CAN to the instrument
cluster.
The front SAM control unit transmits the status of the standing light actuation to the instrument cluster via the
interior CAN, central gateway control unit and central CAN.
The steering column tube module transmits the status of the left multifunction steering wheel button group
(S110) to the instrument cluster (N80) via the steering LIN (LIN E1), chassis CAN, central gateway control unit
and central CAN.
The electric parking brake controller unit (A13) transmits the electric parking brake switch status via the front
end CAN (CAN G), central gateway control unit and central CAN to the instrument cluster.
The instrument cluster illumination is automatically adapted to the brightness conditions of the interior
corresponding to the signals from the right brightness sensor (A1b2) and left brightness sensor (A1b3).
Depending on the light incidence the instrument cluster regulates the illumination between P = 80 and 100 % of
the maximum brightness.
When the rain/light sensor (B38/2) transmits the status "Darkness recognized" the instrument cluster switches
over to night mode automatically.
The brightness is then approx. 50 % of day mode. As soon as the rain/light sensor transmits the "Day" status,
the instrument cluster regulates the lighting again to between P = 80 % and 100 % of the maximum brightness.
The overhead control panel control unit (N70) reads in the rain/ light sensor signal and sends this via the interior
CAN, central gateway control unit and central CAN to the instrument cluster. The instrument illumination
brightness can also be changed individually by using the switch and controls illumination/Night View Assist
display brightness control (S6/2r1), provided that the exterior lighting is turned on.
Electrical function schematic
PE54.30-P-
of instrument cluster, Model 216
2056-97CAA
comfort display
PE54.30-P-
Model 221 (except model 221.095/195)
2056-97SAA
PE54.30-P-
Model 221.095/195
2056-97SAB
Component description for A1 GF54.30-P-
instrument cluster Model 216.3, model 221 (except 221.095/195) 6000LE
GF54.30-P-
Model 221.095/195
6000LEH
Component description for
GF42.20-P-
electric parking brake A13
5000LE
controller unit
A40/3
With code (526) COMAND with single DVD drive
Component description for GF82.85-P-
(without navigation system) or with code (527)
COMAND controller unit 3136LE
COMAND APS with single DVD drive (with
navigation system)
With code (529) HIGH Class Japan with code (498) GF82.85-P-
Japan version 3136LEJ
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
Component description for N3/9 GF07.16-P-
CDI control unit On model 221 with engine 629.9 6000OA
GF07.16-P-
On model 221 with engine 642.8
6000OHS
GF07.16-P-
On model 221 with engine 642.9
6000OHL
Component description for N3/10 GF07.61-P-
ME-SFI [ME] control unit With engine 156 6000MAS
GF07.61-P-
On model 221 with engine 272 (except 272.974)
6000MIS
On model 221 with engine 272.974 6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
On model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278
6000MMC
Component description for
GF54.21-P-
front SAM control unit with N10/1
6070LE
fuse and relay module
Component description for
N30/6 GF42.22-P-
regenerative braking system
On model 221.095/195 1100LEH
control unit
Component description for N47-5 GF42.45-P-
ESP control unit Model 216.3, model 221 (except 221.095/195) 5118LE
Component description for N69/1 GF72.29-P-
left door control unit Model 216 4124LA
Component description for N69/1 GF72.29-P-
left front door control unit Model 221 4141LE
Component description for
GF82.20-P-
overhead control panel N70
5216LE
control unit
Upper control panel control GF54.21-P-
N72/1
unit, component description 6040LE
EZS control unit, component GF80.57-P-
N73
description 6003LE
Component description for GF54.21-P-
N80
steering column tube module 6050LE
Component description for GF54.21-P-
N93
central gateway control unit 4170LE
Night View Assist control GF54.30-P-
N101 with code (610) Night View Assist
unit, component description 6200LE
TRIP COMPUTER, FUNCTION - GF54.30-P-3044LE
MODEL 216.3, 221.0 /1 as of model year 2009 /YoM 08
Function requirements, general
Circuit 15 ON
The EZS control unit (N73) sends the status of circuit 15 to the instrument cluster (A1) via the chassis CAN
(CAN E), central gateway control unit (N93) and central CAN (CAN F).
Trip computer (TRIP) function, general
The trip computer provides data and information on average fuel consumption, trip time, average speed, travel
distance and remaining range. The information is shown in the multifunction display (A1p13) in the instrument
cluster.
The trip computer provides the following display screens:
"AFTER START" (short-distance memory)
"After reset" (long-distance memory)
The information displayed refers to the point in time of the last reset of the short-distance memory ("After
start") or of the long distance memory ("After reset").
The following content can be shown on the trip computer:
Selected display screen "After start" or "After reset"
Travel distance driven "After start" or "After reset"
Time passed "After start" or "After reset"
Average transportation speed
Average fuel consumption
The corresponding display screen can be selected by scrolling with the scroll forward and back button (S110s1)
and then selecting with the system selection button (S110s3).
The steering column tube module (N80) reads in the corresponding selection via the steering LIN (LIN E1) and
transmits this to the instrument cluster via the interior CAN (CAN B), central gateway control unit and central
CAN.
The trip computer function is made up of the following component functions:
Display of travel distance function sequence
Function sequence for the time display
Function sequence for the average speed display
Function sequence for displaying average and present consumption
Function sequence for remaining distance display
Function sequence for reset display
Display of travel distance function sequence
The travel distance is calculated in the instrument cluster from the wheel speeds.
The wheel speeds are recorded by the following components:
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
The ESP control unit (N47-5) (except model 221.095/195) or the regenerative braking system control unit
(N30/6) (with model 221.095/195) reads in the signals from the RPM sensors and sends them to the instrument
cluster via the chassis CAN, central gateway control unit and central CAN. The instrument cluster receives the
signals from the RPM sensors and uses them to calculate the travel distance.
The travel distance "After start" is displayed in a range of 0 to 9999 km. An automatic reset is performed
following a travel distance "After start" overflow.
If a period of more than t = 4 h lies between the time when circuit 15 is switched off and then switched on
again, then the "After start" odometer is automatically reset to 0.
The "AFTER RESET" travel distance display is shown in a range of 0 to 99, 999 km. An automatic reset takes
place at a value of the travel distance "After reset" of more than 100.000 km.
Depending on the setting in the instrument cluster and the national version code, the travel distance is displayed
in:
Kilometers (e.g. Economic Commission for Europe (ECE))
Miles (e.g. USA)
When changing over from kilometers to miles a changeover from liters to gallons also takes place
automatically.
Function sequence for the time display
With circuit 15 ON, a time counter in the instrument cluster adds up the time "After start" or "After reset". The
display ranges from 0 to 999 h and 59 min.
The time "After reset" is determined analog to determining the time "After start", though here the display takes
place in a range of 0 to 9999 h and 59 min.
Function sequence for the average speed display
The trip computer calculates the average speed from the ratio between the travel distance driven and the
time passed (trip time) since the last reset of the short-distance memory or long-distance memory.
Depending on the setting (kilometers/miles) and national version code, the average speed display is shown
in:
mph (miles per hour)
Function sequence for displaying average and present consumption
The trip computer calculates the fuel consumption using the following information:
Consumption signal from CDI control unit (N3/9) (for diesel engine) or from ME-SFI [ME] control unit
(N3/10) (for gasoline engine)
Travel distance covered "After start" or "After reset"
Depending on the unit setting (kilometers/miles) and the national variant coding of the instrument cluster the
fuel consumption is displayed in:
l/100 km (liters per 100 kilometers)
mpg (miles per gallon)
km/l (kilometers per liter)
The CDI control unit or the ME-SFI [ME] control unit transmits the relevant information over the chassis CAN,
central gateway control unit and central CAN to the instrument cluster.
Bar graph display of present consumption (as of 1.6.09):
Function sequence for remaining distance display
The trip computer determines the expected range from the ratio between the current tank capacity and the
average fuel consumption.
The current tank contents are recorded by the fuel level sensor, left tank half (B4/1) and fuel level sensor, right
tank half (B4/2). The rear SAM control unit with fuse and relay module (N10/2) reads in the signals from the
fuel level indicator sensors and transmits them via the interior CAN, central gateway control unit and central
CAN to the instrument cluster. The average fuel consumption is gathered from the short-distance memory or
long-
The following static displays are possible in the multifunction display:
At vehicle standstill v = 0 km/h and circuit 15 OFF, a present consumption of "0 l/100 km" is shown.
At vehicle standstill v = 0 km/h and circuit 15 ON, a present consumption of "0 l/100 km" is shown.
At vehicle standstill v = 0 km/h and circuit 61 ON, the maximum present consumption is shown.
distance memory.
Function sequence for reset display
The trip computer is reset by pressing the OK button (S110s6) in the left multifunction steering wheel button
group (S110). Only the currently displayed information is reset.
Electrical function schematic, instrument PE54.30-P-2057-
Model 216
cluster trip computer 97CAA
Model 221 (except model PE54.30-P-2057-
221.095/195) 97SAA
PE54.30-P-2057-
Model 221.095/195
97SAB
A1 Model 216.3, model 221 GF54.30-P-
Component description for instrument cluster
(except 221.095/195) 6000LE
GF54.30-P-
Model 221.095/195
6000LEH
N3/9
GF07.16-P-
Component description for CDI control unit On model 221 with engine
6000OA
629.9
On model 221 with engine GF07.16-P-
642.8 6000OHS
On model 221 with engine GF07.16-P-
642.9 6000OHL
Component description for ME-SFI [ME] N3/10 GF07.61-P-
control unit With engine 156 6000MAS
On model 221 with engine 272 GF07.61-P-
(except 272.974) 6000MIS
On model 221 with engine GF07.61-P-
272.974 6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
On model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278
6000MMC
Component description for rear SAM control GF54.21-P-
N10/2
unit with fuse and relay module 6030LE
Component description for regenerative N30/6 GF42.22-P-
braking system control unit On model 221.095/195 1100LEH
N47-5
GF42.45-P-
Component description for ESP control unit Model 216.3, 221 (except
5118LE
221.095/195)
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for steering column GF54.21-P-
N80
tube module 6050LE
Component description for central gateway GF54.21-P-
N93
control unit 4170LE
NAVIGATION MENU ITEM, FUNCTION - GF54.30-P-3120SX
MODEL 221.0 /1 with CODE (527) COMAND APS with single DVD drive (with navigation) up to Model
Year 8
MODEL 216.3 with CODE (527) COMAND APS with single DVD drive (with navigation) up to Model
Year 8
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
"Navi" menu item
If the "Navi" menu item in the main menu line is activated, the navigation screen appears on the COMAND
display (A40/8). Navigation can also be called up directly via the telephone/ navigation quick select button
(A40/9s5) on the front central operating unit (A40/9).
The main menu contains the following submenu items:
"Guide"
Point of Interest (POI) functions
"Route"
Route information (destination information, route browser, disable route)
"Position"
Submenu in which the current vehicle position or the current destination is displayed and saved on the
map
Graphic symbol
Repeats the acoustic route recommendations
"Destination"
Submenu in which destination options can be configured (destination entry, stopover, cancel)
Vehicles with code (527) COMAND APS with single DVD drive (with navigation) also have the
"TMC" (traffic message channel) submenu item.
"Destination" menu item
"Stop destination-oriented navigation"
Destination-oriented navigation is stopped; after activation, the "Continue navigation" menu item appears
"Enter address"
Used to enter an address
"Memory"
Used to call up an address from the destination memory
"Recent destinations"
Used to call up an address from the "Recent destinations" memory
"Point of interest"
Used to call up a point of interest (POI)
"Map"
Used to enter a destination via the map
"Stopover"
Used to define a stopover point
"Save destination"
Used to save an entered address in the destination memory
"Position" menu item
If the "Position" submenu item is activated in the submenu line, the following adjustments can be performed:
"Save position"
The current position is saved as a memory point
"Vehicle position on map"
The map shows the vehicle on the map background
"Destination on map"
The map shows the journey destination on the map background
"Guide" menu item
By activating the "Guide" menu item in the submenu line the POI of the surroundings are displayed and can be
scrolled through using the "Previous" and "Next" menu entries. The "Details" menu item displays more detailed
information on the selected POI. "Start" starts route guidance to the currently selected POI.
Menu item "TMC" on vehicles with code (527) COMAND APS with single DVD drive (with navigation)
If the "TMC" submenu item is activated in the submenu line, the following adjustments can be performed:
Display all messages
All TMC messages are displayed
Spoken route messages
The displayed route messages are output via the vehicle speaker system (text-to-speech (TTS) required)
The displayed messages are sorted according to country and road
"Route" menu item
If the "Route menu" submenu item is activated in the submenu line, the following adjustments can be
performed:
"Route info"
Information such as distance and required time to destination, interim stop
"Route browser"
In the route browser the calculated route can be scrolled through via the "next" and "previous" menu
items
"Disable route"
Sections of the calculated route can be disabled
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
NAVIGATION MENU ITEM, FUNCTION - GF54.30-P-3120SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
"Navi" menu items
If the "Navi" menu item in the main menu line is activated, the current vehicle position on the navigation map
background appears on the screen of the COMAND display (A40/8).
Navigation can also be called up directly via the telephone/ navigation quick select button (A40/9s5) on the
front central operating unit (A40/9).
If the turn/push control (A40/9s11) of the front central operating unit is pressed vertically downwards, the
navigation menu line is called up.
The menu in the submenu line contains the following submenu items:
"Route"
Route settings (e.g. route options, route calculation, manual disabling)
"DISP"
Display settings for navigation information (e.g. 2D or 3D map display)
"Guide"
Point of Interest (POI) functions
"Set Mem. Pt"
Used to store the current position in the "Memory Points" memory
"Dest."
Destination options (setting destinations, intermediate destinations and stopovers via the map, and display
of information regarding the current destination)
"REPEAT"
Repeats the acoustic route recommendations
If the "Navi" menu item is activated again in the main menu line when the navigation is active, the following
selection menu appears:
"Set destination"
Submenu item for setting the destination
"Delete destination"
Submenu item for deleting the destination
"Memory Point"
Used to call up "Memory Points" from the memory
"POI facility"
POI settings
"VICS information"
Display of Vehicle Information and Communication System (VICS) information (traffic information)
"ETC history"
Used to display the most recent toll payments
"Setting"
Used to make Navi, VICS and ETC settings and to correct the current position
"Avoid area"
Used to display and enter localities which are to be avoided
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
AUDIO MENU ITEM, FUNCTION - GF54.30-P-3130SXA
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 except CODE (498) Japan version up to Model Year 8
MODEL 221.0 /1 with CODE (527) COMAND APS with single DVD drive (with navigation) up to Model
Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
MODEL 216.3 except CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (527) COMAND APS with single DVD drive (with navigation) up to Model
Year 8
"Audio" menu item
If the "Audio" menu item in the main menu line is activated, the audio screen appears on the COMAND display
(A40/8) and the audio application last executed is started. Should another audio application be started, then a
change must be made to the main menu line again and the "Audio" menu item selected.
The following submenu items are available:
"Radio"
"CD"
Audio CD
"DVD-A" with code (810) Sound system or with code (494) USA version
Playback of audio DVDs
"MP3" on vehicles with code (494) USA version, on CD/DVD or PCMCIA
"Rear"
The audio signals can be controlled from the rear of the vehicle
"Aux"
"Audio OFF"
The "Audio OFF" submenu item switches the audio sources off.
"Radio" submenu item
If the "Radio" submenu item has been activated, then the following functions can be selected in the submenu
line:
"Radio"
Setting menu (station list, store station, enter frequency)
"Memory"
List of stored stations, automatic memory function used to automatically search for and store the 20
stations with the best reception
"FM"
Used to select various frequency bands
"AM", only on vehicles with code (494) USA version
Used to select the AM frequency band
"Sound"
Used to configure the audio output
On vehicles with code (494) USA version, the frequency band "WB" (weather band) can also be selected in the
submenu line.
The following contents are displayed in the main menu selection range:
the currently receivable stations and the numbers of their memory locations (the name of the station is
displayed for stations with radio data system (RDS); the frequency is displayed for stations without RDS)
A pointer with which another station can be selected (by turning or pushing the turn/push control
(A40/9s11) of the front central operating unit (A40/9) counterclockwise or clockwise)
"CD" submenu item
If the "CD" submenu item has been activated, then the following functions can be selected in the submenu line:
"CD"
Playback mode
"Track"
List of tracks on the CD
"Changer", with code (814) DVD changer or with code (494) USA version
List of the CDs/DVDs loaded in the changer
"Sound"
Sound settings
The following information is shown in the main menu:
Name of the current track
Name of the CD
Number of current title
"DVD-A" submenu item
If the "DVD-A" submenu item has been activated, the following functions can be selected in the submenu line:
"DVD-A"
Playback mode (group, normal track sequence, track shuffle)
"Pause"
Temporarily interrupts playback; the current position is stored and the menu item changes to "Play"
"Stop"
Stops playback
"Track"
Track list
"Changer", with code (814) DVD changer or with code (494) USA version
List of the CDs/DVDs loaded in the changer
"Sound"
Sound settings
Elapsed time of the current track
Number of tracks on the CD
Playback mode
The following contents are displayed in the main menu selection range:
Name of the current track
Name of the DVD
Number of current title
Elapsed time of the current track
Number of tracks on the DVD
Playback mode
"MP3" submenu item
If the "MP3" submenu item has been activated, then the following functions can be selected in the submenu
line:
"MP3"
"Track A-Z"
List of tracks in alphabetical order
"Folder"
Tracks in the MP3 folder
"Medium"
Used to select the medium
"Changer", with code (814) DVD changer or with code (494) USA version
List of the CDs/DVDs loaded in the changer
"Sound"
Sound settings
The following contents are displayed in the main menu selection range:
Name of the current track
Path of the current folder
Elapsed time of the current track
Number of tracks in the folder (depends on the selected playback mode)
Playback mode
MP3 files can be read by the following media:
CD
DVD
Storage medium via the PCMCIA drive
"Sat Radio" submenu item, with code (536) SIRIUS satellite radio
If the "Radio" submenu item has been activated, then the following functions can be selected in the submenu
line:
"Sat Radio"
Satellite radio settings
"Presets"
Presets
"Info"
Information
"Category"
Station category
"Tone"
Sound settings
The stations of the category last selected appear after the system has been started. The memory location is
also displayed in the case of stations that have already been stored.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
AUDIO MENU ITEM, FUNCTION - GF54.30-P-3130SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
"Audio" menu item
If the "Audio" menu item in the main menu line is activated, the audio screen appears on the COMAND display
(A40/8) and the audio application last executed is started. Should another audio application be started, then a
change must be made to the main menu line again and the "Audio" menu item selected.
The following submenu items are available:
"FM"
"AM"
"CD"
Audio CD
"DVD-A"
Playback of audio DVDs
"MP3"
"Music servers"
"Aux"
"AVS"
The audio signals can be controlled from the rear of the vehicle
"Audio OFF"
The "Audio OFF" submenu item switches the audio sources off.
"Radio" submenu item
If the "Radio" submenu item has been activated, then the following functions can be selected in the submenu
line:
"FM1"
Used to select "FM1" or "FM2"
"Memory"
List of the stored stations
"Tone"
Used to configure the audio output
The following contents are displayed in the main menu selection range:
the current station, the frequency and the number of the memory location
A pointer with which another station can be selected (by turning or pushing the turn/push control
(A40/9s11) of the front central operating unit (A40/9) counterclockwise or clockwise)
"CD" submenu item
If the "CD" submenu item has been activated, then the following functions can be selected in the submenu line:
"CD"
Playback mode (normal track sequence, track shuffle)
"Track list"
List of tracks on the CD
List of the CDs/DVDs loaded in the changer
"Tone"
Sound settings
The following contents are displayed in the main menu selection range:
Name of the current track
Name of the CD
Number of current title
Elapsed time of the current track
Number of tracks on the CD
Playback mode
"DVD-A" submenu item
If the "DVD-A" submenu item has been activated, the following functions can be selected in the submenu line:
"DVD-A"
Playback mode (group, normal track sequence, repeat track, random track sequence)
"Pause"
Temporarily interrupts playback; the current position is stored and the menu item changes to "Play"
"Stop"
Stops playback
"Track list"
Track list
"Changer"
List of the CDs/DVDs loaded in the changer
"Tone"
Sound settings
The following contents are displayed in the main menu selection range:
Name of the current track
Name of the DVD
Number of current title
Elapsed time of the current track
Number of tracks on the DVD
Playback mode
"AVS" submenu item on model 221
Selecting the "AVS" submenu item allows audio signals to be output at the rear of the vehicle via the speaker
system fitted in the vehicle.
"MP3" submenu item
If the "MP3" submenu item has been activated, then the following functions can be selected in the submenu
line:
"MP3"
Playback mode
"Title A-Z"
Number of tracks (depends on the playback mode)
Playback mode
MP3 files can be read by the following media: CD
List of tracks in alphabetical order
"Folder"
Tracks in the MP3 folder
"Changer"
List of the CDs/DVDs loaded in the changer
"Tone"
Sound settings
The following contents are displayed in the main menu selection range:
Name of the current track
Path of the current folder
Elapsed time of the current track
DVD
Storage medium via the PCMCIA drive
The following contents are displayed in the main menu selection range:
Name of the current track
Name of the CD
Number of current title
Elapsed time of the current track
"Music Server" submenu item
If the "Music Server" submenu item has been activated, the following functions can be selected in the submenu
line:
"Music Register"
Play and recording function
"Edit"
Used for editing memory entries
"Play list"
List of the memory entries
"Changer"
List of the CDs/DVDs loaded in the changer
"Tone"
Sound settings
The following contents are displayed in the main menu selection range:
Name of the current track
Name of the CD
Number of current title
Elapsed time of the current track
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
VIDEO MENU ITEM, FUNCTION - GF54.30-P-3140SX
MODEL 221.0 /1 except CODE (863) Digital/analog TV tuner up to Model Year 8
MODEL 221.0 /1 with CODE (527) COMAND APS with single DVD drive (with navigation) except
CODE (863) Digital/analog TV tuner up to Model Year 8
MODEL 216.3 except CODE (863) Digital/analog TV tuner up to Model Year 8
MODEL 216.3 with CODE (527) COMAND APS with single DVD drive (with navigation) except CODE
(863) Digital/analog TV tuner up to Model Year 8
"Video" menu item
If the "Video" menu item in the application line is activated, the video application last executed is started.
Should another video application be started, then a change must be made to the main menu line again and the
"Video" menu item selected. The following submenu items are available:
"DVD-V"
"Aux"
"Video OFF"
The "Video OFF" menu item switches the video sources off.
"DVD-V" menu item (video DVD)
If a video-DVD is inserted in the DVD-drive, then the following adjustment options appear in the submenu line
when the "DVD-V" menu item is activated:
"DVD-V"
Setting menu (DVD functions, brightness, contrast, color, picture format)
"Pause/Play"
Temporarily interrupts playback
"Stop"
Stops playback
"Changer", with code (814) DVD changer
List of the CDs/DVDs loaded in the changer
"Sound"
Used to set the sound properties
The DVD video picture is simultaneously displayed in the main menu selection range.
All video sources can be operated when the vehicle is stationary. For safety reasons, no video image is
displayed when the vehicle is moving at speeds above 5 km/h.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
VIDEO MENU ITEM, FUNCTION - GF54.30-P-3140SXA
MODEL 221.0 /1 with CODE (863) Digital/analog TV tuner up to Model Year 8
MODEL 221.0 /1 with CODE (527) COMAND APS with single DVD drive (with navigation) with CODE
(863) Digital/analog TV tuner up to Model Year 8
MODEL 216.3 with CODE (863) Digital/analog TV tuner up to Model Year 8
MODEL 216.3 with CODE (527) COMAND APS with single DVD drive (with navigation) with CODE
(863) Digital/analog TV tuner up to Model Year 8
"Video" menu item
If the "Video" menu item in the application line is activated, the video application last executed is started.
Should another video application be started, then a change must be made to the main menu line again and the
"Video" menu item selected.
The following submenu items are available:
"TV"
"DVD-V"
"Aux"
"Video OFF"
The "Video OFF" menu item switches the video sources off.
"DVD-V" menu item (video DVD)
If a video-DVD is inserted in the DVD-drive, then the following adjustment options appear in the submenu line
when the "DVD-V" menu item is activated:
"DVD-V"
Setting menu (DVD functions, brightness, contrast, color, picture format)
"Pause/Play"
Temporarily interrupts playback
"Stop"
Stops playback
"Changer", with code (814) DVD changer
List of the CDs/DVDs loaded in the changer
"Sound"
Setting menu for sound properties
The DVD video picture is simultaneously displayed in the main menu selection range.
"TV" menu item
If the "TV" menu item has been activated and the TV combination tuner (analog/digital) (A90/1) is ready, the
following functions can be selected in the submenu line:
"TV"
Setting menu (TV functions, brightness, contrast, color, picture format)
"Memory"
"Info"
"Video text"
Setting menu for video text
"Sound"
Setting menu for sound properties
The TV picture is simultaneously displayed in the main menu selection range.
All video sources can be operated when the vehicle is stationary. For safety reasons, no video image is
displayed when the vehicle is moving at speeds above 5 km/h.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
VIDEO MENU ITEM, FUNCTION - GF54.30-P-3140SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
"Video" menu item
If the "Video" menu item in the application line is activated, the video application last executed is started.
Should another video application be started, then a change must be made to the main menu line again and the
"Video" menu item selected.
The following submenu items are available:
"TV"
"Video DVD"
"AUX Video"
"Video off"
The "Video off" menu item switches off the video sources.
"Video DVD" menu item
If a video-DVD is inserted in the DVD-drive, then the following adjustment options appear in the submenu line
when the "DVD-Video" menu item is activated:
"Video DVD"
Setting menu (DVD functions, brightness, contrast, color, picture format)
"Pause/Play"
Temporarily interrupts playback
"Stop"
Stops playback
"Changer"
List of the CDs/DVDs loaded in the changer
"Tone"
Setting menu for sound properties
The DVD video picture is simultaneously displayed in the main menu selection range.
All video sources can be operated when the vehicle is stationary. For safety reasons, no video image is
displayed when the vehicle is moving at speeds above 5 km/h.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
COMMUNICATION AND TELEPHONE MENU ITEM, FUNCTION - GF54.30-P-3150SX
MODEL 221.0 /1 with CODE (388) Telephone "Handy", UPCI system up to Model Year 8
MODEL 221.0 /1 with CODE (386) Preinstallation for telephone "Handy", UPCI system up to Model
Year 8
MODEL 216.3 with CODE (386) Preinstallation for telephone "Handy", UPCI system up to Model Year
8
MODEL 216.3 with CODE (388) Telephone "Handy", UPCI system up to Model Year 8
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (387) Preinstallation for telephone "Handy", UPCI system, USA/Canada
up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
"Tel" [Telephone] menu item
If the "Tel" menu item is activated in the main menu row, then the communication application last carried out is
started. Should another communication application be started, then a change into the main menu row must be
made again and the "Tel" menu item selected.
The telephone function can also be started by pressing the telephone/navigation quick select button (A40/9s5)
on the front central operating unit (A40/9).
The following functions can be used:
"Telephone"
Configuring and using the telephone system
"Address book"
Administration menu for the address book (settings, search lists, creation of new entries)
"SMS"
Used to receive, write and read SMS messages
"WAP" only on vehicles with code (386) Preinstallation for telephone "Handy", UPCI system and with
code (388) Telephone "Handy", UPCI system
Configuring and using WAP
"Telephone OFF"
Switches the communication application off
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
COMMUNICATION AND TELEPHONE MENU ITEM, FUNCTION - GF54.30-P-3150SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
"Tel" menu item
If the "Tel" menu item is activated in the main menu line, then the communication application last listed is
started. Should another communication application be started, then a change must be made to the main menu
line again and the "Tel" menu item selected.
The following submenu items are available:
"Telephone"
Setting menu for the telephone
"Address book"
Administration menu for the address book (settings, search lists, creation of new entries)
"E-Mail"
Setting menu for the E-mail system (provider, inbox, outbox, drafts)
"Internet"
Setting menu for the Internet (browser control, favorites, history, URL)
"FM multi"
Used to call up various information (news, weather, earthquake warnings)
"Telephone OFF"
Switches the communication application off
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
VEHICLE MENU ITEM, FUNCTION - GF54.30-P-3160SX
MODEL 221.0 /1 except CODE (498) Japan version up to Model Year 8
MODEL 216.3 except CODE (498) Japan version up to Model Year 8
"Vehicle" menu item shown on model 221 up to 31.8.06
Fig. 74: Screen Display - Vehicle Menu
Courtesy of MERCEDES-BENZ USA
Menu item "Vehicle" of main menu row
If the "Vehicle" menu item of the main menu row is activated, it is possible to select the "System settings" menu
item in the submenu row.
"System settings" menu item
If the "System settings" menu item is activated in the submenu row, it is possible to select under the following
submenu items:
"Display"
"Time"
"Read out"
"Linguatronic"
"Language"
"Favorite"
"Services"
"Reset"
"Display" submenu item in system settings
If the "Display" submenu item is activated, the following settings can be selected:
"Day screen"
Night screen"
"Automatic"
"Time" submenu item in system settings
If the "Time" submenu item is activated, the following settings can be selected:
"Clock"
"Date"
"Format"
"Time zone"
"Read out" submenu item in system settings
The reading speed of the read out function can be set as follows:
"Slow"
"Medium"
"high-speed" range
Apart from the reading speed, on vehicles with code (494) USA version it is possible to select between the
sex (female or male) of the voice reading aloud.
"Linguatronic" submenu item in system settings
The following settings can be selected for Linguatronic:
"Display help window"
"Further training"
"Erase further training"
"Language" submenu item in system settings
One of the following languages can be selected for the display in the COMAND display (A40/8):
"German"
"English"
"US English" only on vehicles with code (494) USA version
"French"
"Spanish"
"Italian"
"Dutch"
"Danish"
"Swedish"
"Portuguese"
"Turkish"
"Russian"
"Chinese"
"Favorite" submenu item in system settings
With this setting the freely programmable button (A40/9s10) on the front central operating unit (A40/9) can be
assigned with one of the following functions:
"Rear roller blind"
"Display off"
"Tow away protection"
The scope of the functions available is depends on the special equipment fitted in the vehicle
"Services" submenu item in system settings
The following settings can be selected via the "Services" submenu:
"Repeat acoustic driver"
In addition the following equipment variants are available on vehicles except code (494) USA version:
"Two-way radio connection" (only for special-purpose vehicles and not driver-configurable)
"Activate data protection"
"Interior protection"
"Tow away and interior protection"
"Services status"
Display and change the status of the available services
"Find Bluetooth devices"
Find new Bluetooth devices
"Disable Bluetooth"
Disable all Bluetooth connections
"Reset" submenu item in system settings
All adjusted settings are reset to the factory settings by selecting the "Reset" submenu item. This erases all
individual settings and all address book entries.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
VEHICLE MENU ITEM, FUNCTION - GF54.30-P-3160SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
"Vehicle" menu item shown on model 221 up to 31.8.06
Fig. 75: Screen Display - Vehicle Menu
Courtesy of MERCEDES-BENZ USA
Menu item "Vehicle" of main menu row
If the "Vehicle" menu item of the main menu row is activated, it is possible to select the "System settings" menu
item in the submenu row.
"System settings" menu item
If the "System settings" menu item is activated in the submenu row, it is possible to select under the following
submenu items:
"Display"
"Beep"
"Language"
"Favorite"
"Delete user data"
"Bluetooth"
"Show Navi Map Version"
"Display" submenu item in system settings
If the "Display" submenu item is activated, the following settings can be selected:
"Fix to day screen" (day design)
"Fix to night screen" (night design)
"Auto" (automatic)
"Display off (Display off)"
"Beep" submenu item in system settings
If the "Beep" submenu item is activated, the following settings can be selected:
"Acknowledgment signal"
"Information signal"
"Language" submenu item in system settings
One of the following languages can be selected for the display in the COMAND display (A40/8):
"Japanese"
"English"
"Favorite" submenu item in system settings
Using the "Favorite" submenu item the freely programmable button (A40/9s10) on the front central operating
unit (A40/9) can be assigned with one of the following functions:
"Rear roller blind"
"Display off (Display off)"
"Tow away protection"
"Repeat acoustic driver"
"Navigation current position"
"Navigation and repeat"
The scope of the functions available is depends on the special equipment fitted in the vehicle
"Bluetooth" submenu item in system settings
A list of the Bluetooth devices that have been detected can be accessed via the "Bluetooth" menu item. There is
also the option of searching for new Bluetooth devices.
"Delete user data" submenu item in system settings
By selecting the "Delete user data" submenu item all individual user settings are erased e.g.:
"Navigation" (recent destinations, saved destinations, home registration, ETC history, destination history,
avoid area)
"Radio" (stored AM and FM stations)
"TV" (stored stations)
"Address book data"
"Browser data"
"E-mail data"
"Music Register"
"System settings"
"Show Navi Map Version" submenu item of system settings
The version of the map data for navigation is displayed by selecting the "Show Navi Map Version" submenu
item
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
OPERATION OF CLIMATE CONTROL, FUNCTION - GF54.30-P-3170SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Operation of climate control system via the Man Machine Interface (MMI)
In the air conditioning row the values currently adjusted can be displayed in the COMAND display (A40/8).
The values can be set in the air conditioning functions row via the turn/push control (A40/9s11) of the front
central operating unit (A40/9).
The climate control settings can be separately adjusted using the MMI, both for the driver, front passenger and
rear passengers.
The following climate control functions can be operated using the MMI:
Temperature
Air distribution
Air volume
Switch off air conditioning "AC off"
Operate climate control centrally "Mono"
Footwell temperature
Ventilation nozzle air flow
Rear air conditioning
Departure time with stationary heater
The marked air conditioning functions row in the COMAND display shown on model 221 up to 31.8.06
Fig. 76: Screen Display - Air Conditioning Functions
Courtesy of MERCEDES-BENZ USA
The position indicator is on the settings menu item for the climate control system. The settings menu is
activated by pressing the rotating control button of the front central operating unit.
Settings menu of the air conditioning system in the air conditioning row shown on model 221 up to
31.8.06
Fig. 77: Screen Display - Air Conditioning System Settings Menu
Courtesy of MERCEDES-BENZ USA
The following settings can be selected:
"Climate control off"
Switch off the air conditioning system
"Defrost"
Defrost the windows
"AC off"
Switch off the air conditioning
"Mono"
Operate the climate control centrally
"Footwell temperature"
Adjust the temperature in the footwell
"Air flow focused/medium/diffuse"
Adjust the air flow from the ventilation nozzles
Adjust the rear climate control from the front
"Stationary heater departure time"
Set stationary heater
Shown on model 221 up to 31.8.06
Setting of air volume in the air conditioning functions row for the right side of the vehicle
The air volume can be set separately for the driver and front passenger.
Fig. 78: Screen Display - Setting Of Air Volume
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.8.06
Setting of air distribution in the air conditioning functions row for the right side of the vehicle
The air distribution can be set separately for the driver and front passenger.
Fig. 79: Screen Display - Air Distribution Setting
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.8.06
Setting of temperature in the air conditioning functions row for the left side of the vehicle
The temperature can be set separately for the driver and front passenger.
Fig. 80: Screen Display - Temperature Setting
Courtesy of MERCEDES-BENZ USA
Activated air conditioning row for the rear area of the air conditioning system shown only for model 221
up to 31.8.06
The operation of the rear climate control is modeled on the operation of the climate control for the driver and
front passenger.
Fig. 81: Screen Display - Activated Air Conditioning Row For Rear Area
Courtesy of MERCEDES-BENZ USA
Shown only for model 221 up to 31.8.06.
Setting menu for the rear area of the air conditioning system in the air conditioning functions row
The following settings can be selected:
"front climate control"
"Rear climate control off"
Switch off the rear climate control
"Rear automatic"
Switch off or switch on the rear air conditioning automatic
"Rear manual"
Set the rear climate control manually
Fig. 82: Screen Display - Setting Menu For Area Of Air Conditioning System
Courtesy of MERCEDES-BENZ USA
On model 216 only the blower setting can be adjusted for the left and right side for the rear area.
Cockpit central display, component description GF54.30-P-6100SX
Front central operating unit, component description GF54.21-P-4500SX
COOLANT/WASHER FLUID LEVEL VOLTAGE CODING, FUNCTION - GF54.30-P-4001SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Diagram for low washer fluid level
Fig. 83: Coolant/Washer Fluid Level Voltage Circuit Diagram
Courtesy of MERCEDES-BENZ USA
The coolant level indicator switch and windshield washer fluid level indicator switch are connected in series
and are read in by the front SAM control unit with fuse and relay module.
Voltage coding
The switch (s1 ) and switch (s2 ) are connected in parallel for voltage coding of the resistor (r1 ) and the resistor
(r2 ), the values of resistance (r1 ) and resistor (r2 ) must differ. These resistors (r1 , r2 ) form, when switches
(s1 , s2 ) are open, together with the resistor (r3 ) of the front SAM control unit with fuse and relay module, a
voltage divider which is supplied with constant voltage (u). The voltage (ue ) at the input of the Front SAM
control unit with fuse and relay module is dependent on the positions of the switch (s1 ) and switch (s2 ) and the
values of the resistances (r1 , r2 , r3 ). Each of the switch combinations (s1 , s2 ) produces a different voltage
value (ue ) at the input of the front SAM control unit with fuse and relay module.
Evaluation
The voltage (u e) is applied at the input of the ADC of the front SAM control unit with fuse and relay module.
The ADC converts the analog voltage into a digital value. The processor compares the digitized value with the
threshold values stored in a memory and if necessary places the corresponding messages ("Refill washer fluid",
"Check coolant level") on the interior CAN.
The messages can be acknowledged with the OK button (S110s6) of the left multifunction steering wheel
button group (S110) of the multifunction steering wheel (MFL).
Switch status and messages
The coolant level indicator switch and the windshield washer fluid level indicator switch result in a total of the
following 4 switch combination options and the resultant requests in the multifunction display (A1p13):
When the coolant level indicator switch is open and the windshield washer fluid level indicator switch is
open, there is no message in the multifunction display.
When the coolant level indicator switch is open and the windshield washer fluid level indicator switch is
closed, a request to replenish the washer fluid appears in the multifunction display.
When the coolant level indicator switch is closed and the windshield washer fluid level indicator switch is
open, a request to check the coolant level appears in the multifunction display.
When the coolant level indicator switch is closed and the Windshield washer fluid level indicator switch
is closed, the requests to check the washer fluid and to check the coolant level appear alternately in the
multifunction display.
Instrument cluster, component description GF54.30-P-6000SX
"CHECK ENGINE" INDICATOR LAMP, LOCATION/TASK/FUNCTION - GF54.30-P-4101M
MODEL 215, 220 with ENGINE 275.950 with CODE (494) USA version
MODEL 230 with ENGINE 275.951 with CODE (494) USA version
MODEL 216, 221 with ENGINE 275.953 with CODE (494) USA version
MODEL 230 with ENGINE 275.954 with CODE (494) USA version
MODEL 215, 220 with ENGINE 275.980 with CODE (494) USA version
MODEL 230 with ENGINE 275.981 with CODE (494) USA version
MODEL 216, 221 with ENGINE 275.982 with CODE (494) USA version
MODEL 240 with ENGINE 285.950 with CODE (494) USA version
MODEL 240 with ENGINE 285.980 with CODE (494) USA version
Shown on the instrument cluster of model 220
Fig. 84: Identifying Check Engine Indicator Lamp
Courtesy of MERCEDES-BENZ USA
CHECK
ENGINE
The CHECK ENGINE indicator lamp is located in the instrument cluster.
indicator lamp,
location
CHECK
ENGINE
To indicate faults in the fuel injection system
indicator lamp,
task
CHECK The indicator lamp is actuated by the instrument cluster via a CAN message from
ENGINE the engine control unit. As a check of the function it lights up when the ignition is
indicator lamp, ON and for approx. 1 second as of an engine speed of approx. 500 RPM. The
function indicator lamp goes out if there is no fault present.
ENGINE DIAGNOSIS INDICATOR LAMP, LOCATION/TASK/FUNCTION - GF54.30-P-4102M
MODEL 215, 220 with ENGINE 275.950 except CODE (494) USA version
MODEL 230 with ENGINE 275.951 except CODE (494) USA version
MODEL 216, 221 with ENGINE 275.953 except CODE (494) USA version
MODEL 230 with ENGINE 275.954 except CODE (494) USA version
MODEL 215, 220 with ENGINE 275.980 except CODE (494) USA version
MODEL 230 with ENGINE 275.981 except CODE (494) USA version
MODEL 216, 221 with ENGINE 275.982 except CODE (494) USA version
MODEL 240 with ENGINE 285.950 except CODE (494) USA version
MODEL 240 with ENGINE 285.980 except CODE (494) USA version
Shown on the instrument cluster of model 240
Fig. 85: Identifying Engine Diagnosis Indicator Lamp
Courtesy of MERCEDES-BENZ USA
Engine diagnosis
The engine diagnosis indicator lamp (engine symbol) is located in the instrument
indicator lamp,
cluster.
location
Engine diagnosis
indicator lamp, To indicate faults in the fuel injection system
task
The indicator lamp is actuated by the instrument cluster via a CAN message from the
Engine diagnosis
engine control unit. As a check of the function it lights up when the ignition is ON
indicator lamp,
and for approx. 1 second as of an engine speed of approx. 500 RPM. The indicator
function
lamp goes out if there is no fault present.
ENGINE DIAGNOSIS INDICATOR LAMP, COMPONENT DESCRIPTION - GF54.30-P-5010AMG
MODEL 164, 251 with ENGINE 156.980 except CODE (494) USA version up to Model Year 8
MODEL 209 with ENGINE 156.982 except CODE (494) USA version
MODEL 211, 219 with ENGINE 156.983 except CODE (494) USA version
MODEL 216, 221 with ENGINE 156.984 up to Model Year 8
Location for model 216, 221
The engine diagnosis indicator lamp (with the yellow engine symbol) is located at the right in the instrument
cluster (A1).
Fig. 86: Locating Engine Diagnosis Indicator Lamp
Courtesy of MERCEDES-BENZ USA
Task
The indicator lamp alerts the driver to the reoccurrence of faults relevant to exhaust emissions.
Function
The ME-SFI control unit (N3/10) actuates the indicator lamp by transmitting an appropriate signal via the CAN
data bus to the instrument cluster.
As a function check the indicator lamp is actuated at "Ignition ON". It goes out after engine start if there are no
faults relevant to exhaust emissions.
COMPONENT DESCRIPTION FOR AN ENGINE DIAGNOSIS INDICATOR LAMP - GF54.30-P-
5010V
MODEL 203 with ENGINE 272.920 except CODE (494) USA version up to Model Year 8
MODEL 211 with ENGINE 272.922 except CODE (494) USA version MODEL 203 with ENGINE
272.940 except CODE (494) USA version up to Model Year 8
MODEL 203 with ENGINE 272.941 except CODE (494) USA version up to Model Year 8
MODEL 171 with ENGINE 272.942 except CODE (494) USA version up to Model Year 8
MODEL 211, 219 with ENGINE 272.943 except CODE (494) USA version
MODEL 211 with ENGINE 272.944 except CODE (494) USA version
MODEL 251 with ENGINE 272.945 except CODE (494) USA version up to Model Year 8
MODEL 221 with ENGINE 272.946 except CODE (494) USA version up to Model Year 8
MODEL 203 with ENGINE 272.960 except CODE (494) USA version up to Model Year 8
MODEL 171 with ENGINE 272.963 except CODE (494) USA version up to Model Year 8
MODEL 211, 219 with ENGINE 272.964 except CODE (494) USA version
MODEL 221 with ENGINE 272.965 except CODE (494) USA version up to Model Year 8
MODEL 230 with ENGINE 272.966 except CODE (494) USA version up to Model Year 8
MODEL 164, 251 with ENGINE 272.967 except CODE (494) USA version up to Model Year 8
MODEL 203 with ENGINE 272.970 except CODE (494) USA version up to Model Year 8
MODEL 211 with ENGINE 272.972 except CODE (494) USA version
MODEL 221 with ENGINE 272.975 except CODE (494) USA version up to Model Year 8
MODEL 211, 219 with ENGINE 272.985 except CODE (494) USA version
MODEL 221 with ENGINE 273.922 except CODE (494) USA version up to Model Year 8
MODEL 164 with ENGINE 273.923 except CODE (494) USA version up to Model Year 8
MODEL 221 with ENGINE 273.924 except CODE (494) USA version up to Model Year 8
MODEL 211, 219 with ENGINE 273.960 except CODE (494) USA version
MODEL 216, 221 with ENGINE 273.961 except CODE (494) USA version up to Model Year 8
MODEL 211 with ENGINE 273.962 except CODE (494) USA version
MODEL 164, 251 with ENGINE 273.963 except CODE (494) USA version up to Model Year 8
MODEL 230 with ENGINE 273.965 except CODE (494) USA version up to Model Year 8
MODEL 209 with ENGINE 273.967 except CODE (494) USA version
MODEL 221 with ENGINE 273.968 except CODE (494) USA version up to Model Year 8
MODEL 209 with ENGINE 272.940 except CODE (494) USA version
MODEL 209 with ENGINE 272.960 except CODE (494) USA version
Shows model 171
Fig. 87: Locating Engine Diagnosis Indicator Lamp
Courtesy of MERCEDES-BENZ USA
Location
The engine diagnosis indicator lamp (engine symbol) is located in the instrument cluster.
Task
To indicate faults in the fuel injection system.
Function
The indicator lamp is actuated by the instrument cluster via a CAN message from the engine control unit. To
check the function it lights up with ignition ON and as of an engine speed of approx. 500 RPM for approx. 1 s.
If there is no fault, the indicator lamp goes out
COMPONENT DESCRIPTION FOR THE "CHECK ENGINE" INDICATOR LAMP - GF54.30-P-
5011V
MODEL 203 with ENGINE 272.920 with CODE (494) USA version up to Model Year 8
MODEL 211 with ENGINE 272.922 with CODE (494) USA version
MODEL 203 with ENGINE 272.940 with CODE (494) USA version up to Model Year 8
MODEL 203 with ENGINE 272.941 with CODE (494) USA version up to Model Year 8
MODEL 171 with ENGINE 272.942 with CODE (494) USA version up to Model Year 8
MODEL 211, 219 with ENGINE 272.943 with CODE (494) USA version
MODEL 211 with ENGINE 272.944 with CODE (494) USA version
MODEL 251 with ENGINE 272.945 with CODE (494) USA version up to Model Year 8
MODEL 221 with ENGINE 272.946 with CODE (494) USA version up to Model Year 8
MODEL 203 with ENGINE 272.960 with CODE (494) USA version up to Model Year 8
MODEL 171 with ENGINE 272.963 with CODE (494) USA version up to Model Year 8
MODEL 211, 219 with ENGINE 272.964 with CODE (494) USA version
MODEL 221 with ENGINE 272.965 with CODE (494) USA version up to Model Year 8
MODEL 230 with ENGINE 272.966 with CODE (494) USA version up to Model Year 8
MODEL 164, 251 with ENGINE 272.967 with CODE (494) USA version up to Model Year 8
MODEL 203 with ENGINE 272.970 with CODE (494) USA version up to Model Year 8
MODEL 211 with ENGINE 272.972 with CODE (494) USA version
MODEL 221 with ENGINE 272.975 with CODE (494) USA version up to Model Year 8
MODEL 221 with ENGINE 273.922 with CODE (494) USA version up to Model Year 8
MODEL 164 with ENGINE 273.923 with CODE (494) USA version up to Model Year 8
MODEL 221 with ENGINE 273.924 with CODE (494) USA version up to Model Year 8
MODEL 211, 219 with ENGINE 273.960 with CODE (494) USA version
MODEL 216, 221 with ENGINE 273.961 with CODE (494) USA version up to Model Year 8
MODEL 211 with ENGINE 273.962 with CODE (494) USA version
MODEL 164, 251 with ENGINE 273.963 with CODE (494) USA version up to Model Year 8
MODEL 230 with ENGINE 273.965 with CODE (494) USA version up to Model Year 8
MODEL 209 with ENGINE 273.967 with CODE (494) USA version
MODEL 221 with ENGINE 273.968 with CODE (494) USA version up to Model Year 8
MODEL 209 with ENGINE 272.940 with CODE (494) USA version
MODEL 209 with ENGINE 272.960 with CODE (494) USA version
Shows model 219
Fig. 88: Locating Check Engine MIL
Courtesy of MERCEDES-BENZ USA
Location
The "CHECK ENGINE" indicator lamp is located in the instrument cluster.
Task
To indicate faults in the fuel injection system
Function
The indicator lamp is actuated by the instrument cluster via a CAN message from the engine control unit. To
check the function it lights up with ignition ON and as of an engine speed of approx. 500 RPM for approx. 1 s.
If there is no fault, the indicator lamp goes out
COMPONENT DESCRIPTION FOR INSTRUMENT CLUSTER - GF54.30-P-6000LE
MODEL 216.3, 221.0 /1 (except, 221.095 /195) as of model year 2009 /YoM 08
Shown on model 221 up to 31.5.09
Fig. 89: Identifying Instrument Cluster Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 31.5.09 with code (610) Night View Assist
Fig. 90: Identifying Instrument Cluster Components With Night View Assist
Courtesy of MERCEDES-BENZ USA
Shown on model 221 as of 1.6.09
Fig. 91: Identifying Instrument Cluster Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221 up to 1.6.09 with code (610) Night View Assist
Fig. 92: Identifying Instrument Cluster Components - With Night View Assist
Courtesy of MERCEDES-BENZ USA
Location
The instrument cluster is located in the dashboard on the driver-side.
Task
The instrument cluster has the following tasks:
Reading in of signals
Evaluation of input factors
Actuation of components
Output of acoustic and information warnings
Output of signals
Reading in of signals
The instrument cluster reads in the signals via the following connection:
Central CAN (CAN F)
Central CAN
The signals are read in by the instrument cluster via the central CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
The central gateway control unit (N93) makes information from other control units on the central CAN
available to the instrument cluster. The central gateway control unit serves as an interface with the following
data bus systems:
Interior CAN (CAN B)
Diagnostic CAN (CAN D)
Chassis CAN (CAN E)
Front end CAN (CAN G)
Interior CAN
The central gateway control unit passes on signals provided on the interior CAN to the instrument cluster via
the central CAN. The functions resulting therefrom are described in the corresponding function descriptions
(see block diagram or function schematic).
Chassis CAN
The central gateway control unit relays the signals placed on the chassis CAN via the central CAN to the
instrument cluster. The functions resulting therefrom are described in the corresponding function descriptions
(see block diagram or function
Diagnostic CAN
The central gateway control unit passes on signals provided on the diagnosis CAN to the instrument cluster via
the central CAN. The functions resulting therefrom are described in the corresponding function descriptions
(see block diagram or function schematic).
schematic).
Front end CAN
The central gateway control unit relays the signals placed on the front end CAN via the central CAN to the
instrument cluster. The functions resulting therefrom are described in the corresponding function descriptions
(see block diagram or function schematic).
Evaluation of input factors
The integrated microprocessor evaluates the input factors read in. The appropriate components are then
actuated.
Actuation of components
The instrument cluster directly actuates all internal actuators (e.g. indicator and warning lamps, stepper motors
of displays, multifunction display) as well as the instrument illumination.
Output of acoustic and information warnings
The instrument cluster actuates the warning buzzer (A1h1) to issue acoustic and information warnings, which
are requested by the systems installed in the vehicle.
The "audible turn signal indicator" is acoustically realized by actuating the acoustic turn signal lights function
check (A1h2).
Output of signals
The output of signals is carried out over the following connection:
Central CAN
Chassis CAN
Central CAN
The signals are transmitted by the instrument cluster via the central CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Chassis CAN
The signals are sent by the instrument cluster via the chassis CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Wiring diagram for instrument cluster (IC) control unit Model 216 PE54.30-P-2101-97CAA
Model 221 PE54.30-P-2101-97SAA
INSTRUMENT CLUSTER, COMPONENT DESCRIPTION - GF54.30-P-6000LEH
MODEL 221.095/ 195
Shown without code (494) USA version
Fig. 93: Identifying Instrument Cluster Components (Without Code 494)
Courtesy of MERCEDES-BENZ USA
On vehicles with code (494) USA version the regenerative braking system indicator lamp is not shown by
the symbol but by the "RBS" text [regenerative braking system].
Location
The instrument cluster is located in the dashboard on the driver-side.
Task
The instrument cluster has the following tasks:
Reading in of signals
Evaluation of input factors
Actuating components
Output of acoustic and information warnings
Output of signals
Reading in of signals
The instrument cluster reads in input factors by means of the following connection:
Central CAN (CAN F)
Central CAN
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
The central gateway control unit (N93) makes information from other control units on the central CAN
available to the instrument cluster. The central gateway control unit serves as an interface with the following
data bus systems:
Interior CAN (CAN B)
Diagnostic CAN (CAN D)
Chassis CAN (CAN E)
Front end CAN (CAN G)
Interior CAN
The central gateway control unit passes on signals provided on the interior CAN to the instrument cluster via
the central CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
The signals are read in by the instrument cluster via the central CAN.
Diagnostic CAN
The central gateway control unit passes on signals provided on the diagnosis CAN to the instrument cluster via
the central CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Chassis CAN
The central gateway control unit relays the signals placed on the chassis CAN via the central CAN to the
instrument cluster.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Front end CAN
The central gateway control unit relays the signals placed on the front end CAN via the central CAN to the
instrument cluster.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Evaluation of input factors
The input factors that have been read in are evaluated by the integrated microprocessor and the relevant
components are then actuated.
Component actuation
The instrument cluster directly actuates all internal actuators (e.g. indicator and warning lamps, stepper motors
of displays, multifunction display) as well as the instrument illumination.
Output of acoustic and information warnings
The instrument cluster actuates the warning buzzer (A1h1) to issue acoustic and information warnings, which
are requested by the systems installed in the vehicle.
The "audible turn signal indicator" is realized by actuating the audible turn signal indicator (A1h2).
Output of signals
The output of signals is carried out over the following connection:
Central CAN
Chassis CAN
Central CAN
The signals are transmitted by the instrument cluster via the central CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Chassis CAN
The signals are sent by the instrument cluster via the chassis CAN. The functions resulting therefrom are
described in the corresponding function descriptions (see block diagram or function schematic).
Wiring diagram for instrument cluster (IC) control unit PE54.30-P-2101-97SAA
INSTRUMENT CLUSTER, COMPONENT DESCRIPTION - GF54.30-P-6000SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Shown on model 221 up to 31.12.05
Fig. 94: Locating Instrument Cluster
Courtesy of MERCEDES-BENZ USA
Location
The instrument cluster is located in the dashboard on the driver-side.
Task
The instrument cluster has the following tasks:
Receive the input signals from the central CAN for the various operating functions, displays and warning
messages
Determination of vehicle speed signal
Illumination of the multifunction display (A1p13) depending on:
Switch and controls illumination brightness control/display Night View Assist (S6/2r1) in the
cockpit switch group (S6/2)
Rain/light sensor (B38/2)
Right brightness sensor (A1b2)
Left brightness sensor (A1b3)
Output of messages in the multifunction display
Actuation of signal lamps
Provision of Night View Assist display
Output of acoustic signals
Actuation of instrument cluster/COMAND display additional fan (M4/13)
Acoustic signals
The acoustic warning and information signals are produced by a speaker (gong) and a warning buzzer (A1h1),
the turn signal knocking sound by the audible turn signal indicator (A1h2):
Turn signal ON (turn signal knocking sound)
Light warning (gong)
Parking brake reminder warning (gong)
Key reminder warning (gong)
Door warning (gong)
Seat belt reminder warning (warning buzzer)
Engine oil level warning (gong)
Warning messages (gong and warning buzzer)
Daytime running lamps ON with open door (gong)
Actuation of stepper motors
The following displays are driven by a stepper motor:
Engine coolant temperature display (A1p1)
Fuel level and reserve gage (A1p2)
Tachometer (A1p5)
Variable displays in the multifunction display
The following displays are shown in the multifunction display:
Outside temperature
Digital speedometer (ring speedo or band speedo)
Digital additional tachometer
Odometer
Trip odometer
Selected drive stage/transmission mode
Adjustment of air suspension/adaptive damping system (ADS)
Error messages with symbols (warning message)
Navigation
Audio
Trip computer (TRIP)
Telephone
Tire pressure monitor (TPM)
Engine oil level warning/engine oil level measurement
Configuration menu for vehicle settings defined by the user
Service processor
Workshop-relevant information
Backup camera setting
Parktronic display (front vehicle area)
Night Vision Assist display
Tow-away protection/interior protection
Only those systems fitted in the vehicle are displayed.
The instrument cluster requires the instrument cluster/ COMAND display additional fan for cooling. This is
fitted on the side of the air conditioning. The instrument cluster/ COMAND display additional fan has no
influence on the displays in the instrument cluster.
Shown on model 221 up to 31.8.06
Fig. 95: Identifying Instrument Cluster Components Location
Courtesy of MERCEDES-BENZ USA
COCKPIT CENTRAL DISPLAY, COMPONENT DESCRIPTION - GF54.30-P-6100SX
Location shown on left-hand drive vehicle model 221 up to 31.12.05
Fig. 96: Identifying Cockpit Central Display Components
Courtesy of MERCEDES-BENZ USA
The COMAND display is located centrally above the upper control panel control unit next to the instrument
cluster.
Task
The main task of the COMAND display is the uniform display of user-relevant operation/information windows
as well as the display of video picture information of the following systems:
Navigation, with code (527) COMAND APS with single DVD drive (with navigation), with code (494)
USA version or with code (498) Japan version
Audio (e.g. radio, audio CD or audio DVD, MP3 or auxiliary (AUX))
Telematics (e.g. telephone, SMS, address book), with code (386) Preinstallation for telephone "Handy",
UPCI system, with code (388) Telephone "Handy", UPCI system, with code (494) USA version or with
code (498) Japan version
Video (TV, DVD video or AUX)
The TV function is available as standard equipment on vehicles with code (498) Japan version otherwise
the TV function is available with code (863) Digital/analog TV tuner.
The DVD video function is available as standard equipment on vehicles except code (494) USA version.
Vehicle (e.g. locator lighting, rear roller blind)
The rear roller blind function is available as standard equipment on model 221.1 and available on model
221.0 with code (540) Electric rear window roller blind or with code (498) Japan version.
Set up shown on "Audio" menu item on model 221 up to 31.8.06
Fig. 97: Screen Display - Audio Menu
Courtesy of MERCEDES-BENZ USA
The COMAND display is a swiveling "8 -Thin Film Transistor (TFT) color screen" in 16:9 format with a
resolution of 800 x480 red, green and blue (RGB) pixels.
The "8 TFT color screen" enables a horizontal viewing angle of a maximum of ±80° and a vertical viewing
angle of a maximum of ±30°.
However, the quality of the display decreases as the viewing angle increases!
In addition 2 photosensors, for automatic brightness control and an electric motor for manual adjustment about
the vertical axis are integrated in the COMAND display.
Function
The displays and the menu display of the user-relevant operating/ information windows are conveyed from the
display and displayed there.
This is connected to the telematics CAN for control and diagnosis of the COMAND display.
The brightness is automatically controlled via the two photosensors integrated in the COMAND display. The
changeover between day and night design takes place via the COMAND controller unit. For this purpose the
COMAND controller unit reads in the Controller Area Network (data bus/CAN Bus) (CAN) messages of the
rain/light sensor (B38/2) via the central CAN from the central gateway control unit (N93). After evaluating the
CAN messages the COMAND controller unit transmits the corresponding signal to the COMAND display via
the LVDS connection.
The manual brightness control of the COMAND display and the adjustment of the COMAND display about the
vertical axis take place via the buttons of the COMAND display brightness control integrated in the cockpit
switch group (S6/2r2), COMAND display swivel left switch (S6/2s13) and the COMAND display swivel right
switch (S6/2s14). The COMAND display can be adjusted in the following 3 stages with the associated angles:
1 = -10°
2 = 0°
3 = +10°
The cockpit switch group is read by the upper control panel control unit and the resulting CAN messages are
transmitted to the interior CAN. The central gateway control unit reads in these CAN messages and passes them
on to the COMAND controller unit via the central CAN. The COMAND controller unit reads in these CAN
messages and passes these on to the COMAND display via the telematics CAN.
COMAND DISPLAY, COMPONENT DESCRIPTION - GF54.30-P-6110LE
MODEL 216, 221 except CODE (867) SPLITVIEW as of Model Year 2009 /YoM 08
Shown on model 221
Fig. 98: Locating COMAND Display
Courtesy of MERCEDES-BENZ USA
Location
The COMAND display is located in the center of the instrument panel.
Task
The COMAND display provides uniform display of user-relevant operation and information windows as well as
the display of video image information (with code (863) TV tuner digital/analog or code (498) Japan version).
The COMAND display also performs the following tasks:
Reading in of signals
Reading in of signals
Signals are read in via the following connections:
Telematics CAN (CAN A)
Low Voltage Differential Signal (LVDS) line
Telematics CAN
The COMAND display is a subscriber of telematics CAN.
The COMAND display reads in the signals.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
LVDS line
The COMAND display receives all information via the LVDS line for the display of corresponding data content
from the COMAND controller unit (A40/3).
Body
The COMAND display is a swiveling 8 -Thin Film Transistor (TFT color screen in 16:9 format with a
resolution of 800 x 480 pixels. In addition, two photosensors for automatic brightness control, and an electric
motor for manual adjustment about the vertical axis are integrated in the COMAND display.
Variants
Left-hand drive vehicle
Right-hand drive vehicle
Model 216 up to 31.5.09
Cockpit Management and Data System PE82.85-P-
Without code (498) Japan
(COMAND) control unit wiring diagram 2101-99CAA
version
Model 216 as of 1.6.09 Without PE82.85-P-
code (498) Japan version 2101-99CAE
Model 216 With code (529) PE82.85-P-
HIGH Class Japan 2101-99CAD
Model 221 up to 31.5.09
PE82.85-P-
Without code (498) Japan
2101-99SAA
version
Model 221 as of 1.6.09 Without PE82.85-P-
code (498) Japan version 2101-99SAE
Model 221 with code (529) PE82.85-P-
HIGH Class Japan 2101-99SAD
SPLITVIEW DISPLAY, COMPONENT DESCRIPTION - GF54.30-P-6120LE
MODEL 216 with CODE (867) SPLITVIEW as of Model Year 2010 /modification year 09
MODEL 221 with CODE (867) SPLITVIEW as of Model Year 2010 /modification year 09 model
refinement package
Shown on model 221
Fig. 99: Locating SPLITVIEW Display
Courtesy of MERCEDES-BENZ USA
Location
The SPLITVIEW display is located centrally in the instrument panel.
Task
The SPLITVIEW display serves the uniform presentation of user-relevant operating and information windows
as well as the presentation of video picture information.
Moreover, the SPLITVIEW display makes possible the presentation of two different views at the same time.
This function enables the driver and front passenger to access video picture information or vehicle system
information at the same time and independently of each other (dual viewing mode). The SPLITVIEW display is
equipped with an infrared transmitter/receiver which makes it possible to actuate infrared headphones. The
SPLITVIEW display for the front passenger is operated via a remote control. A uniform picture can be output
via a mono output mode.
Caused by the design of the SPLITVIEW display the visual range of the driver (1) and visual range of the front
passenger (2) is defined in a fixed manner, an insufficient picture quality is possible in the section area (3) of
the visual ranges.
In order to prevent the SPLITVIEW display from overheating it is air-cooled by an internal blower motor. The
temperature of the SPLITVIEW display is kept below T = 85 °C during operation. The temperature of the
SPLITVIEW display is kept below T = 95 °C when the vehicle is at a standstill. Cooling is controlled internally.
Fig. 100: Design Of SPLITVIEW Display Visual Range Of Driver And Front Passenger
Courtesy of MERCEDES-BENZ USA
In addition the SPLITVIEW display has the following tasks:
Reading in of signals
Reading in of signals
Signals are read in via the following connections:
Telematics CAN (CAN A)
Low Voltage Differential Signal (LVDS) line
Telematics CAN
The SPLITVIEW display is a subscriber on the telematics CAN. The signals are read in by the SPLITVIEW
display.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Body
The SPLITVIEW display is an 8 -Thin Film Transistor (TFT) color SPLITVIEW display in a 16:9 format with
a resolution of 800 x 480 pixels. In order to prevent damage to the SPLITVIEW display it is protected by a
tinted acrylic glass lens.
It is not possible to swivel the SPLITVIEW display.
Variants
Left-hand drive vehicle
Right-hand drive vehicle
The code (867) SPLITVIEW can be deactivated for vehicles
LVDS line
The SPLITVIEW display receives all the information for presenting the corresponding contents from the
COMAND controller unit (A40/3) via the low voltage differential signaling line.
with code (494) USA version ex-factory, because the function is not yet permitted in every region by various
legislators. It can be activated however, when legal, by the dealer.
Cockpit Management and Data System (COMAND) control unit Model PE82.85-P-2101-
wiring diagram 216 97CAE
Model PE82.85-P-2101-
221 97SAE
NIGHT VIEW ASSIST CONTROL UNIT, COMPONENT DESCRIPTION - GF54.30-P-6200LE
MODEL 216.3, 221.0 /1 with CODE (610) Night vision assist as of model year 2009 /YoM 08
Shown on model 221.0 up to 31.5.09
Fig. 101: Locating Night View Assist Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The Night View Assist control unit is located on the left on the A-pillar behind the paneling in the driver
footwell.
Task
The Night View Assist control unit performs the following tasks:
Reading in of sensors, pickups and signals
Evaluation of input factors
Output of signals
Actuating components
For vehicles up to 31.5.09, the Night View Assist control unit is a subscriber to the vehicle dynamics CAN
(CAN H).
For vehicles as of 1.6.09, the Night View Assist control unit is a subscriber to the chassis CAN (CAN E).
Reading in of sensors, pickups and signals
The input factors are read in via the following connections:
Low voltage differential signal (LVDS)
Vehicle dynamics CAN (up to 31.5.09)
Chassis CAN (as of 1.6.09)
LVDS
The Night View Assist control unit receives the pictures recorded by the Night View Assist camera (B84/2) via
the digital video interface (LVDS line).
Vehicle dynamics CAN (up to 31.5.09)
The Night View Assist control unit reads in the signals via the vehicle dynamics CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Chassis CAN (as of 1.6.09)
The Night View Assist control unit reads in the signals via the chassis CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
The following information is read in and processed:
Status of Night View Assist button (S1s9)
Status of low beam actuation (up to 31.5.11)
Data from rain/light sensor (B38/2)
Vehicle speed
Light source identification by the multifunction camera (A40/11) (as of 1.6.09)
Vehicle dynamics (as of 1.6.09 up to 31.5.11)
Status of adaptive high beams (as of 1.6.11)
Evaluation of input factors
The integrated microprocessor evaluates the information read in. The pictures taken by the Night View Assist
camera are processed accordingly. The information read in is also used for fault detection and system diagnosis.
Output of signals
to the instrument cluster.
The Night View Assist camera is controlled by the Night View Assist control unit via the control channel of the
digital video interface (LVDS line).
Actuation of components
The actuation of the components takes place via the following connections:
Vehicle dynamics CAN (up to 31.5.09)
Chassis CAN (as of 1.6.09)
Vehicle dynamics CAN (up to 31.5.09)
The Night View Assist control unit actuates the following components:
Left infrared emitter (E1e11)
Right infrared lamp (E2e11)
The Night View Assist control unit transmits the request via:
Vehicle dynamics CAN
ESP control unit (N47-5)
Chassis CAN
Central gateway control unit (N93)
Interior CAN (CAN B)
Chassis CAN (as of 1.6.09)
The Night View Assist control unit actuates the following components:
Left infrared lamp
Right infrared lamp
The Night View Assist control unit transmits the request via:
Chassis CAN
Central gateway control unit
Interior CAN
Front SAM control unit
Front SAM control unit with fuse and relay module (N10/1)
The corresponding signals are sent by the Night View Assist control unit via the vehicle dynamics CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
The corresponding signals are sent by the Night View Assist control unit via the chassis CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Wiring diagram, Night View Assist control unit Model 221 PE54.30-P-2103-97SAA
Model 216 PE54.30-P-2103-97CAA
NIGHT VISION ASSIST CONTROL UNIT, COMPONENT DESCRIPTION - GF54.30-P-6200SX
MODEL 221.0 /1, 216.3 with CODE (610) Night vision assist up to Model Year 8
Shown on model 221.0
Fig. 102: Locating Night View Assist Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The night view assist control unit is located on the left on the A-pillar behind the paneling in the driver footwell.
Tasks
To record information from the night view assist camera (B84/2)
Picture processing
Transmit the display picture to the instrument cluster (A1)
Fault detection and administration
Diagnosis
Function
The night view assist control unit is a subscriber to the vehicle dynamics CAN and receives the video pictures
of the night view assist camera via the digital video interface (Low-Voltage Differential Signaling) and
processes them.
After this the processed video picture is transmitted to the instrument cluster via a further digital interface.
Camera control is realized by the night view assist control unit via a control channel of the digital video
interface.
Discrete inputs
Terminal 87 F
Digital video interface to night view assist camera
Discrete outputs
Digital video interfaces to instrument cluster
NIGHT VISION ASSIST CAMERA, COMPONENT DESCRIPTION - GF54.30-P-6220SX
MODEL 221.0 /1, 216.3 with CODE (610) Night vision assist up to Model Year 8
Shown on model 221.0
Fig. 103: Locating Night Vision Assist Camera
Courtesy of MERCEDES-BENZ USA
Location
The night view assist camera is located on the right of the windshield in front of the inside rearview mirror unit
(A67).
Task
The night view assist camera has a high light sensitivity, it records the infrared-picture and transmits data via
the digital video interface (Low-Voltage Differential Signaling (LVDS)) to the Night View Assist control unit
(N101).
OVERVIEW OF SYSTEM COMPONENTS, SPEED LIMIT ASSIST - GF54.30-P-9990LE
MODEL 216.3 with CODE (513) Speed Limit Assist as of model year 2011 /YoM 10 model refinement
package
MODEL 221.0 /1 with CODE (513) Speed Limit Assist as of Model Year 2010 /modification year 09
model refinement package
A1
GF54.30-P-
Component description for instrument cluster Model 216.3, model 221 (except
6000LE
221.095/195)
GF54.30-P-
Model 221.095/195
6000LEH
Component description for COMAND controller GF82.85-P-
A40/3
unit 3136LE
A40/8 GF54.30-P-
COMAND display, component description
Without code (867) SPLITVIEW 6110LE
A40/10
GF54.30-P-
SPLITVIEW display, component description with code (867) SPLITVIEW as
6120LE
of 1.6.09
GF54.21-P-
Component description for multifunction camera A40/11
3300LE
Yaw rate sensor for lateral and longitudinal GF42.45-P-
B24/15
acceleration, component description 4810LE
N3/9 GF07.16-P-
Component description for CDI control unit
On model 221 with engine 629.9 6000OA
GF07.16-P-
On model 221 with engine 642.8
6000OHS
GF07.16-P-
On model 221 with engine 642.9
6000OHL
N3/10
Component description for ME-SFI [ME] control GF07.61-P-
On model 221 with engine 272
unit 6000MIS
(except 272.974)
On model 221 with engine GF07.61-P-
272.974 6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
On model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278
6000MMC
Component description for regenerative braking N30/6 GF42.22-P-
system control unit On model 221.095/195 1100LEH
N47-5 GF42.45-P-
Component description for ESP control unit
Without model 221.095/195 5118LE
Component description for steering column tube GF54.21-P-
N80
module 6050LE
Component description for central gateway control GF54.21-P-
N93
unit 4170LE
Limit Assist 0991LE
OVERVIEW OF SYSTEM COMPONENTS, ATTENTION ASSIST - GF54.30-P-9991LE
MODEL 216.3 as of model year 2011 /YoM 10 model refinement package
MODEL 221.0 /1 as of model year 2010 /YoM 09 model refinement package
Component description for
instrument cluster A1 GF54.30-P-
Model 216.3, model 221 6000LE
(except 221.095/195)
GF54.30-P-
Model 221.095/195
6000LEH
A40/3
Component description for With code (526) COMAND with single DVD drive GF82.85-P-
COMAND controller unit (without navigation) or code (527) COMAND APS with 3136LE
single DVD drive (with navigation system)
GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with navigation GF82.85-P-
system) 3136LEU
Component description for
N30/6 GF42.22-P-
regenerative braking system
On model 221.095/195 1100LEH
control unit
Component description for N47-5 GF42.45-P-
ESP control unit Model 216.3, 221 (except 221.095/195) 5118LE
Component description for
GF82.20-P-
overhead control panel control N70
5216LE
unit
EZS control unit, component GF80.57-P-
N73
description 6003LE
Component description for GF54.21-P-
N80
steering column tube module 6050LE
Component description for GF54.21-P-
N93
central gateway control unit 4170LE
Table of contents for function GF54.30-P-
description, attention assist 0992LE
OVERVIEW OF COCKPIT CENTRAL DISPLAY SYSTEM COMPONENTS, COMPONENT
DESCRIPTION - GF54.30-P-9993SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Front central operating unit, component description GF54.21-P-4500SX
Cockpit central display, component description GF54.30-P-6100SX
Table of contents for function description of cockpit central display GF54.30-P-0993SX
OVERVIEW OF SYSTEM COMPONENTS, NIGHT VIEW ASSIST - GF54.30-P-9995LE
MODEL 221.0 /1, 216.3 with CODE (610) Night vision assist as of model year 2009 /YoM 08
A1
GF54.30-P-
Component description for instrument cluster Model 216, model 221 (except
6000LE
221.095/195)
GF54.30-P-
Model 221.095/195
6000LEH
A40/11
GF54.21-P-
Component description for multifunction camera Model 221 as of 1.6.09, model
3300LE
216 as of 1.6.10
Component description for intelligent servo module A80 GF27.19-P-
for DIRECT SELECT Transmission 722.6 4020ACS
Transmission 722.9 (except GF27.19-P-
722.931/950) 4020AHS
GF27.19-P-
Transmission 722.931
4020AHT
GF27.19-P-
Transmission 722.950
4020LEH
Component description for yaw rate sensor for GF42.45-P-
B24/15
lateral and longitudinal acceleration 4810LE
Component description for Xenon headlamp control E1n1, E2n1 GF82.10-P-
unit As of 1.6.11 2114LE
N3/9 GF07.16-P-
Component description for CDI control unit
With engine 629 6000OA
GF07.16-P-
With engine 642.8
6000OHS
GF07.16-P-
On engine 642.9
6000OHL
GF07.16-P-
With engine 651
6000OLS
Component description for ME-SFI [ME] control N3/10 GF07.61-P-
unit With engine 156 6000MAS
With engine 272 (except GF07.61-P-
272.974) 6000MIS
GF07.61-P-
With engine 272.974
6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
With engine 276
6000MMB
GF07.61-P-
With engine 157, 278.
6000MMC
Component description for front SAM control unit GF54.21-P-
N10/1
with fuse and relay module 6070LE
Component description for regenerative braking N30/6 GF42.22-P-
system control unit On model 221.095/195 1100LEH
N47-5
GF42.45-P-
Component description for ESP control unit On model 216, 221 (except
5118LE
221.095/195)
Component description for overhead control panel GF82.20-P-
N70
control unit 5216LE
Upper control panel control unit, component GF54.21-P-
N72/1
description 6040LE
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for steering column tube GF54.21-P-
N80
module 6050LE
Component description for central gateway control GF54.21-P-
N93
unit 4170LE
Night View Assist control unit, component GF54.30-P-
N101
description 6200LE
Table of contents for function description, Night GF54.30-P-
View Assist 0995LE
OVERVIEW OF SYSTEM COMPONENTS, NIGHT VIEW ASSIST - GF54.30-P-9995SX
MODEL 221.0 /1, 216.3 with CODE (610) Night vision assist up to Model Year 8
A1 GF54.30-P-
Instrument cluster, component description
Model 221 6000SX
Intelligent servo module (ISM) component A80 GF27.19-P-
description Model 221 with transmission 722.6 4015SXA
GF27.19-P-
Model 221 with transmission 722.9
4015SX
GF54.21-P-
Rain/light sensor, component description B38/2
6000SX
Night vision assist camera, component GF54.30-P-
B84/2
description 6220SX
E1, E2 GF82.10-P-
Lamp unit, component description
Model 221 2017SX
GF42.45-P-
Wheel RPM sensor, component description L6/1, L6/2, L6/3 and L6/4
5134SX
Driver-side SAM control unit with fuse and GF54.21-P-
N10/1
relay module, component description 6010SX
GF42.45-P-
Description of components in ESP control unit N47-5
5118SX
N62/1
Component description for radar sensors control GF30.30-P-
Model 221 with engine 272, 273 and
unit 3301SX
code (233) Distronic Plus
Overhead control panel control unit, component GF82.20-P-
N70
description 5216SX
Upper control panel control module component GF54.21-P-
N72/1
description 6040SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
Night vision assist control unit, component GF54.30-P-
N101
description 6200SX
S1 GF82.10-P-
Rotary light switch, component description
Model 221 4106SX
Table of contents for function description, night GF54.30-P-
view assist 0995SX
OVERVIEW OF SYSTEM COMPONENTS, INSTRUMENT CLUSTER (IC) COMPONENT
DESCRIPTION - GF54.30-P-9996LE
MODEL 216.3, 221.0 /1 as of model year 2009 /YoM 08
Component description GF54.30-P-
A1
for instrument cluster 6000LE
Model 216.3, model 221 (except 221.095/195) GF54.30-P-
Model 221.095/195 6000LEH
STH control unit, A6n1 GF83.70-P-
component description With code (228) Stationary heater 4200LE
Component description
GF42.20-P-
for electric parking brake A13
5000LE
controller unit
A40/3
Component description
With code (526) COMAND with single DVD drive (without GF82.85-P-
for COMAND controller
navigation) or code (527) COMAND APS with single DVD 3136LE
unit
drive (with navigation system)
With code (529) HIGH Class Japan with code (498) Japan GF82.85-P-
version 3136LEJ
With code (530) COMAND APS USA (with navigation GF82.85-P-
system) 3136LEU
A40/11
On model 221 as of 1.6.09 or model 216 as of 1.9.10 with code
Component description GF54.21-P-
(238) Active Lane Keeping Assist or code (476) Automatic
for multifunction camera 3300LE
lane recognition or code (513) Speed Limit Assist or with code
(608) Adaptive Highbeam Assist
Component description
for front reversible A76, A76/1 GF91.40-P-
emergency tensioning Model 221 4020LE
retractor
Component description
for intelligent servo A80 GF27.19-P-
module for DIRECT With transmission 722.6 4020ACS
SELECT
GF27.19-P-
With transmission 722.9 (except 722.931/950)
4020AHS
GF27.19-P-
With transmission 722.931
4020AHT
GF27.19-P-
With transmission 722.950
4020LEH
A89
On model 216 up to 31.8.10 with engine 156, 273, 275 and
DTR controller unit, GF30.30-P-
code (219) Distronic (DTR) Model 221 up to 31.8.10 with
component description 3210LEA
engine 156, 272, 273, 275, 642, 629 and code (219) Distronic
(DTR)
On model 216 up to 31.8.10 with engine 156, 273, 275 and
code (233) DISTRONIC PLUS GF30.30-P-
Model 221 up to 31.8.10 with engine 156, 272, 273, 275, 642, 3210LE
629 and code (233) DISTRONIC PLUS
On model 216 as of 1.6.09 up to 31.8.10 with engine 156, 273,
275 and code (233) Distronic Plus GF30.30-P-
Model 221 as of 1.6.09 up to 31.8.10 with engine 156, 272, 3210LEB
273, 275, 642, 629 and code (233) Distronic Plus
On model 221 as of 1.6.09 up to 31.8.10 with engine 156, 272,
GF30.30-P-
273, 275, 629, 642 and code (239) Plus Light adaptive cruise
3210LEC
control
On model 216.3 as of 1.9.10 With code (233) DISTRONIC
PLUS with code (237) Active Blind Spot Assist Model 221
GF30.30-P-
(except 221.095/195) as of 1.9.10 with code (233)
3210LED
DISTRONIC PLUS or with code (237) Active Blind Spot
Assist or with code (239) Plus Light adaptive cruise control
E1n1, E2n1
Model 221 up to 31.5.09 with code (615) Bi-xenon headlamp
Component description
unit with integrated curve illumination or code (616) Xenon GF82.10-P-
for Xenon headlamp
headlamp unit with asymmetrical integrated curve illumination 2114LE
control unit
or
Model 216
Component description
GF91.60-P-
for restraint systems N2/7
4048LE
control unit
Component description
for Weight Sensing N2/13 MODEL 221 up to 31.8.08 with CODE (494) USA GF91.60-P-
System (WSS) control version 4046LEU
unit
Component description N3/9 GF07.16-P-
for CDI control unit On model 221 with engine 629.9 6000OA
GF07.16-P-
On model 221 with engine 642.8
6000OHS
GF07.16-P-
On model 221 with engine 642.9
6000OHL
Component description
N3/10 GF07.61-P-
for ME-SFI [ME] control
With engine 156 6000MAS
unit
GF07.61-P-
On model 221 with engine 272 (except 272.974)
6000MIS
GF07.61-P-
On model 221 with engine 272.974
6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
On model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278
6000MMC
Component description
for front SAM control unit GF54.21-P-
N10/1
with fuse and relay 6070LE
module
Component description
for rear SAM control unit GF54.21-P-
N10/2
with fuse and relay 6030LE
module
Component description
N15/3 GF27.60-P-
for electronic transmission
With transmission 722.6 5164ACS
control unit
Component description
N28/1 GF31.19-P-
for trailer recognition
For model 221 with code (550) Trailer hitch 4050LE
control unit
Component description
system control unit On model 221.095/195 1100LEH
Left front seat control
GF91.29-P-
unit, component N32/1
5230LE
description
Right front seat control
GF91.29-P-
unit, component N32/2
5240LE
description
Component description N47-5 GF42.45-P-
for ESP control unit Model 216.3, 221 (except 221.095/195) 5118LE
N51
AIRmatic with ADS On model 221 up to 31.5.09 without code (487) Active Body
GF32.22-P-
control unit, component Control (ABC), Model 221.1 with code (Z07) Highest
5108LE
description protection, Model 216.3 up to 31.5.09 with code (489)
AIRmatic (air suspension with continuous damper adjustment)
On model 221 as of 1.6.09 without code (487) Active Body
Control (ABC) and without code (Z07) Highest protection, on GF32.22-P-
model 216.3 as of 1.6.09 with code (489) AIRmatic (air 5108LEA
suspension with continuous damper adjustment))
N51/2
ABC control unit, On model 221 with code (487) Active Body Control (ABC), on GF32.50-P-
component description model 216.3 without code (489) AIRmatic (air suspension with 4501LE
continuous damper adjustment)
Component description N62
GF54.65-P-
for PARKTRONIC On model 221 up to 31.5.09 with code (220) PARKTRONIC,
5001LE
control unit on model 216 up to 31.8.10
On model 221 as of 1.6.09 with code (220) PARKTRONIC or
code (230) Exclusive parking assist on model 216 as of 1.9.10 GF54.65-P-
with code (220) PARKTRONIC or code (230) Exclusive 5001LEA
parking assist
Component description
GF30.30-P-
for radar sensors control N62/1 Up to 31.8.10 with code (233) DISTRONIC PLUS
3301LE
unit
Up to 31.8.10 with code (234) Blind Spot Assist, on model 221
(except 221.095/195) as of 1.9.10 with code (239) Plus Light GF30.30-P-
adaptive cruise control, on model 221.095/195 as of 1.9.10 3301LEB
with code (234) Blind Spot Assist
Model 221 up to 31.8.10 with code (239) Plus Light adaptive GF30.30-P-
cruise control 3301LEC
Video and radar sensor N62/2 On model 216.3, 221 (except 221.095 /195) as of 1.9.10
GF30.30-P-
system control unit, with code (233) DISTRONIC PLUS with code (237) Active
3304LE
component description Blind Spot Assist with code (238) Active Lane Keeping Assist
Component description GF72.29-P-
N69/1 Model 216
for left door control unit 4124LA
Component description N3/9 GF07.16-P-
for CDI control unit On model 221 with engine 629.9 6000OA
GF07.16-P-
On model 221 with engine 642.8
6000OHS
GF07.16-P-
On model 221 with engine 642.9
6000OHL
Component description
N3/10 GF07.61-P-
for ME-SFI [ME] control
With engine 156 6000MAS
unit
GF07.61-P-
On model 221 with engine 272 (except 272.974)
6000MIS
GF07.61-P-
On model 221 with engine 272.974
6000MEH
GF07.61-P-
With engine 273
6000MLS
GF07.61-P-
With engine 275
6000MOS
GF07.61-P-
On model 221 with engine 276
6000MMB
GF07.61-P-
On engine 157, 278
6000MMC
Component description
for front SAM control unit GF54.21-P-
N10/1
with fuse and relay 6070LE
module
Component description
for rear SAM control unit GF54.21-P-
N10/2
with fuse and relay 6030LE
module
Component description
N15/3 GF27.60-P-
for electronic transmission
With transmission 722.6 5164ACS
control unit
Component description
N28/1 GF31.19-P-
for trailer recognition
For model 221 with code (550) Trailer hitch 4050LE
control unit
Component description
N30/6 GF42.22-P-
for regenerative braking
On model 221.095/195 1100LEH
system control unit
Left front seat control
GF91.29-P-
unit, component N32/1
5230LE
description
Right front seat control
GF91.29-P-
unit, component N32/2
5240LE
description
Component description N47-5 GF42.45-P-
for ESP control unit Model 216.3, 221 (except 221.095/195) 5118LE
AIRmatic with ADS Body Control (ABC), Model 221.1 with code (Z07) Highest
GF32.22-P-
control unit, component protection, Model 216.3 up to 31.5.09 with code (489)
5108LE
description AIRmatic (air suspension with continuous damper adjustment)
On model 221 as of 1.6.09 without code (487) Active Body
Control (ABC) and without code (Z07) Highest protection, on GF32.22-P-
model 216.3 as of 1.6.09 with code (489) AIRmatic (air 5108LEA
suspension with continuous damper adjustment))
N51/2
ABC control unit, On model 221 with code (487) Active Body Control (ABC), on GF32.50-P-
component description model 216.3 without code (489) AIRmatic (air suspension with 4501LE
continuous damper adjustment)
Component description N62
GF54.65-P-
for PARKTRONIC On model 221 up to 31.5.09 with code (220) PARKTRONIC,
5001LE
control unit on model 216 up to 31.8.10
On model 221 as of 1.6.09 with code (220) PARKTRONIC or
code (230) Exclusive parking assist on model 216 as of 1.9.10 GF54.65-P-
with code (220) PARKTRONIC or code (230) Exclusive 5001LEA
parking assist
Component description
N62/1 GF30.30-P-
for radar sensors control
Up to 31.8.10 with code (233) DISTRONIC PLUS 3301LE
unit
Up to 31.8.10 with code (234) Blind Spot Assist, on model 221
(except 221.095/195) as of 1.9.10 with code (239) Plus Light GF30.30-P-
adaptive cruise control, on model 221.095/195 as of 1.9.10 3301LEB
with code (234) Blind Spot Assist
Model 221 up to 31.8.10 with code (239) Plus Light adaptive GF30.30-P-
cruise control 3301LEC
N62/2
Video and radar sensor
On model 216.3, 221 (except 221.095 /195) as of 1.9.10 with GF30.30-P-
system control unit,
code (233) DISTRONIC PLUS with code (237) Active Blind 3304LE
component description
Spot Assist with code (238) Active Lane Keeping Assist
Component description GF72.29-P-
N69/1 Model 216
for left door control unit 4124LA
Component description N69/2 GF72.29-P-
for right door control unit Model 216 4128LA
Component description
N69/1 GF72.29-P-
for left front door control
Model 221 4141LE
unit
Component description
N69/2 GF72.29-P-
for right front door control
Model 221 4142LE
unit
Rear door control unit, N69/3, N69/4 GF72.29-P-
component description On model 221 6020LE
Component description N69/5 GF80.61-P-
With CODE (889) Keyless Go 4204LE
unit
Component description
GF82.20-P-
for overhead control panel N70
5216LE
control unit
Upper control panel
GF54.21-P-
control unit, component N72/1
6040LE
description
EZS control unit, GF80.57-P-
N73
component description 6003LE
Component description
GF54.21-P-
for steering column tube N80
6050LE
module
Component description
GF54.10-P-
for battery management N82/2 On model 221.095/195
3012MEH
system control unit
Component description N88
GF40.15-P-
for TPM [RDK] control For code (494) USA version or code (475) Tire pressure
5123LE
unit monitor (Premium), Siemens up to 31.5.09
With code (475) Tire pressure monitor (Premium), Schrader GF40.15-P-
As of 1.6.09 5123LEA
Component description
GF54.21-P-
for central gateway N93
4170LE
control unit
Night View Assist control
GF54.30-P-
unit, component N101 with code (610) Night View Assist
6200LE
description
Component description
for Weight Sensing N110 MODEL 221 as of 1.9.08 with CODE (494) USA GF91.60-P-
System (WSS) control version Model 216 with code (494) USA version 4069LAU
unit
Component description
N123/4 GF82.95-P-
for emergency call system
With code (359) TELE AID emergency call system 3212LEU
control unit
Component description
Y3/8n4 GF27.60-P-
for fully integrated
With transmission 722.9 (except 722.931/950) 5165AHS
transmission control unit
GF27.60-P-
With transmission 722.931
5165AHT
GF27.60-P-
With transmission 722.950
5165LEH
Table of contents for
GF54.30-P-
function description of
0997LE
instrument cluster (IC)
OVERVIEW OF SYSTEM COMPONENTS, INSTRUMENT CLUSTER (KI) COMPONENT
DESCRIPTION - GF54.30-P-9996SX
MODEL 221.0 /1, 216.3 up to Model Year 8
Instrument cluster, component description GF54.30-P-6000SX
Table of contents, description of instrument cluster functions (IC) GF54.30-P-0997SX
FANFARE POSITION OF COMPONENTS - GF54.35-P-0001-01LE
Fig. 104: Locating Fanfare Components
Courtesy of MERCEDES-BENZ USA
FANFARE POSITION OF COMPONENTS - GF54.35-P-0001-01SX
15.03.07 The document has been updated to this date and will no longer be subject to revision.
Fig. 105: Locating Fanfare Components
Courtesy of MERCEDES-BENZ USA
FANFARE HORNS BLOCK DIAGRAM - GF54.35-P-0001-03LE
Fig. 106: Fanfare Horns Block Diagram
Courtesy of MERCEDES-BENZ USA
FANFARE HORNS BLOCK DIAGRAM - GF54.35-P-0001-03SX
15.03.07 The document has been updated to this date and will no longer be subject to revision.
Fig. 107: Fanfare Horns Block Diagram
Courtesy of MERCEDES-BENZ USA
FANFARE HORN SYSTEM, FUNCTION - GF54.35-P-0001LE
MODEL 221.0 /1, 216.3 as of Model Year 09 /Modification year 08
General function requirements
Circuit 15 On
The status of circuit 15 is transmitted by the EIS [EZS] control unit (N73) via the interior CAN.
Fanfare horns general
The left fanfare horn (H2) and right fanfare horn (H2/1) are the audible warning system on the vehicle.
Function sequence - operate fanfare horns
The operation of the fanfare horns is requested by pressing fanfare horns buttons (S110s5, S111s5). The status
of the fanfare horn buttons is read in by the steering column tube module (N80) via the steering LIN.
The steering column tube module transmits the request on further to the central gateway control unit (N93) via
the interior CAN. The central gateway control unit transmits the request to the front SAM control unit with fuse
and relay module via the interior CAN (N10/1).
The front SAM control unit actuates the fanfare horns relay (N10/1kF). As a result of this the fanfare horns
relay switches through the power supply (circuit 30) to the fanfare horns.
The signal tone sounds as long as one of the fanfare buttons is pressed.
GF54.35-P-0001-
Fanfare position of components
01LE
Model PE54.35-P-2051-
Electrical function schematic, fanfare horns
216 97CAA
Model PE54.35-P-2051-
221 97SAA
GF54.35-P-0001-
Fanfare horns block diagram
03LE
Front SAM control unit with fuse and relay module,
N10/1 GF54.21-P-6070LE
component description
Component description for the EZS control unit N73 GF80.57-P-6003LE
Steering column module, component description N80 GF54.21-P-6050LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
FANFARE HORN SYSTEM, FUNCTION - GF54.35-P-0001SX
MODEL 221.0 /1 up to Model Year 8
15.03.07 The document has been updated to this date and will no longer be subject to revision.
Fig. 108: Fanfare Horn Function Diagram
Courtesy of MERCEDES-BENZ USA
Function requirements:
Circuit 15 ON
Function
The pressing of the fanfare horn system button is read in by the steering column module via the steering LIN
and passed on to the central gateway control unit via the chassis CAN. The central gateway control unit passes
on the request to the front SAM control unit via the interior CAN.
The front SAM control unit actuates the fanfare horns via the fanfare horns relay.
The circuit status is transmitted by the EIS [EZS] control unit on the interior CAN.
GF54.35-P-0001-
Fanfare position of components
01SX
GF54.35-P-0001-
Fanfare horns block diagram
03SX
Driver-side SAM control module with fuse and relay module component
N10/1 GF54.21-P-6010SX
description
Electronic ignition/starter switch control unit (EIS) component description N73 GF80.57-P-6000SX
Steering column module component description N80 GF54.21-P-6050SX
Central gateway control unit, component description N93 GF54.21-P-4170SX
HVAC
Climate Control - Maintenance - S-Class (221)
MAINTENANCE
REPLACE COMBINATION FILTER - AP83.00-P-8384SX
MODEL 216
MODEL 221.0 /1
Fig. 1: Identifying Combination Filter Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Switch off ignition
Remove right cover below instrument
2
panel
Remove/install cover below instrument AR68.10-P-
panel (right) 1520SX
Unlock both sliders (1) in direction of Installation: Insert lugs (2a) of
3 arrow and remove cover (2) from air cover (2) into recesses (3a) of air
conditioner housing (3) conditioner housing (3).
Remove both combination filters (4) The combination filters (4) should
4 downward out of air conditioner housing never be cleaned; always fit new
(3) combination filters.
5 Install in the reverse order
ENGINE
Crank Assembly - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: CRANK ASSEMBLY - AH03.00-Z-9999AZ
MODEL all
Assignment of pistons to cylinder AH03.10-P-
ENGINE 639.939 in MODEL 454.0
bore 0001-02FG
Assignment of pistons to cylinder AH03.10-P-
ENGINE 134.9, 135.9 in MODEL 454.0
bore 0001-02FF
Assignment of pistons to cylinder AH03.10-P-
668.940 /941 /942
bore 0001-02GD
Assignment of pistons to cylinder AH03.10-P-
132.9 in MODEL 451.3 /4
bore 0001-02MCC
Assignment of pistons to cylinder AH03.10-P-
ENGINE 266.920 /940 /960 /980
bore 0001-02AK
Assignment of the piston to the AH03.10-P-
ENGINE 166.940 /960 /990 /995
cylinder bore 0001-02GF
AH03.20-P-
Bearing diagram for crankshaft ENGINE 266.920 /940 /960 /980
4351-01AK
AH03.20-P-
Bearing diagram of crankshaft ENGINE 271
4351-01TK
ENGINE 601.943, AH03.20-N-
Bearing diagram of crankshaft
602.980 /981 /982 /983 /984 /985 4351-01B
AH03.20-P-
Bearing diagram of crankshaft ENGINE 639.939 in MODEL 454.0
4351-01FG
AH03.20-P-
Bearing diagram of crankshaft ENGINE 601, 602, 603 (except, 602.98)
4351-01AW
AH03.20-N-
Bearing diagram of crankshaft ENGINE 111
4351-01A
AH03.20-P-
Bearing diagram of crankshaft ENGINE 640
4351-01AL
AH03.20-P-
Bearing diagram of crankshaft ENGINE 166, 668
4351-01GF
General information on assigning AH03.20-P-
ENGINE 112
balancing shaft to engine 1000-01AV
Installation notes for crankshaft AH03.20-P-
ENGINE 120
radial shaft seals 0001-01AO
Interference fit of crankshaft ENGINE 111 /, 601.943, AH03.20-P-
bearing cap 602.980 /981 /982 /983 /984 /985, 604, 605, 606 4351-02A
Interference fit of crankshaft AH03.20-P-
ENGINE 611, 612, 613...
bearing cap 4351-02C
Interference fit of crankshaft AH03.20-P-
ENGINE 272
bearing cap 4351-02VA
Interference fit of crankshaft AH03.20-P-
ENGINE 132.9 in MODEL 451.3 /4
bearing cap 4351-02MCC
Interference fit of crankshaft AH03.20-P-
ENGINE 166, 668
bearing cap 4351-02GF
Interference fit of crankshaft AH03.20-P-
ENGINE 640
bearing cap 4351-02AL
Interference fit of the crankshaft AH03.20-P-
ENGINE 639.939 in MODEL 454.0
bearing cap 4351-02FG
Precision fit of crankshaft AH03.20-P-
ENGINE 271
bearing cap 4351-02TK
Precision fit of crankshaft AH03.20-P-
ENGINE 273
bearing cap 4351-02SX
Precision fit of crankshaft AH03.20-P-
ENGINE 134.9, 135.9 in MODEL 454.0
bearing cap 4351-02FF
Precision fit of crankshaft AH03.20-P-
ENGINE 266.920 /940 /960 /980
bearing cap 4351-02AK
PRECISION FIT OF CRANKSHAFT BEARING CAP - AH03.20-P-4351-02SX
The crankshaft bearing caps are machined together with the crankcase and must not be interchanged.
The crankshaft bearing caps are fitted on the side in the crankcase and must be mounted in the correct
installation position. If the installation position is correct, the semicircle will point (3) in the direction of
travel (arrow).
The crankshaft bearing caps are numbered consecutively on the semicircles (3) beginning with the first
crankshaft bearing cap at the front.
Fig. 1: Identifying Crankshaft Bearing Cap & Semicircles
Courtesy of MERCEDES-BENZ USA
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: CRANK ASSEMBLY - AR03.00-Z-9156AB
ENGINE 156
Remove, install flywheel / ENGINE 156 in MODEL 164, 251 with AR03.30-P-
drive plate TRANSMISSION 722 8001GZS
Remove, install flywheel / ENGINE 156.983 in MODELS 211.077 /277, 219.377AR03.30-P-
drive plate ENGINE 156.982 in MODELS 209.377 /477 8001TMG
Remove, install ENGINE 156 in MODEL 216, 221 with AR03.30-P-
flywheel/drive plate TRANSMISSION 722 8001SMG
Remove/install belt AR03.30-P-
ENGINES 156 in MODEL 204, 212
pulley/vibration damper 1600CMG
Remove/install belt AR03.30-P-
ENGINES 156 in MODEL 164, 251
pulley/vibration damper 1600GZS
Remove/install belt AR03.30-P-
ENGINES 156 in MODEL 230.470
pulley/vibration damper 1600RMG
Remove/install belt AR03.30-P-
ENGINES 156 in MODEL 216, 221
pulley/vibration damper 1600SMG
Remove/install belt ENGINES 156.982 in MODEL 209.377 /477 ENGINES AR03.30-P-
pulley/vibration damper 156.983 in MODEL 211.077 /277, 219.377 1600TMG
AR03.20-P-
Remove/install crankshaft ENGINES 156.980 /981 /982 /983 /984 /985
4351AMG
Remove/install flywheel / AR03.30-P-
ENGINES 156 in MODEL 204, 212
drive plate 8001CMG
Remove/install flywheel / AR03.30-P-
ENGINE 156 in MODEL 230.470
drive plate 8001RMG
AR03.10-P-
Remove/install piston ENGINES 156
7021AMG
Remove/install retaining lock ENGINE 156 in MODEL 164, 251 with AR03.30-P-
for crankshaft / ring gear TRANSMISSION 722 5000GZS
Remove/install retaining lock ENGINE 156.982 in MODEL 209.377 with CODE (P98) AR03.30-P-
for crankshaft / ring gear Black Series 5000QBS
Remove/install retaining lock AR03.30-P-
ENGINE 156 in MODEL 204, 212
for crankshaft/ ring gear 5000CMG
Remove/install retaining lock AR03.30-P-
ENGINE 156 in MODEL 230.470
for crankshaft/ ring gear 5000RMG
Remove/install retaining lock ENGINE 156 in MODEL 216, 221 with AR03.30-P-
for crankshaft/ ring gear TRANSMISSION 722 5000SMG
Remove/install retaining lock AR03.30-P-
ENGINE 156...
for crankshaft/ ring gear 5000TMG
Replace front crankshaft AR03.20-P-
ENGINES 156 in MODEL 204, 212
radial sealing ring 3000CMG
Replace front crankshaft AR03.20-P-
ENGINE 156 in MODEL 164, 251
radial sealing ring 3000GZS
Replace front crankshaft AR03.20-P-
ENGINE 156 in MODEL 230.470
radial sealing ring 3000RMG
Replace front crankshaft AR03.20-P-
ENGINE 156 in MODEL 216, 221
radial sealing ring 3000SMG
Replace front crankshaft ENGINE 156.982 in MODEL 209.377 /477 ENGINE AR03.20-P-
radial sealing ring 156.983 in MODEL 211.077 /277, 219.377 3000TMG
Replace rear crankshaft radial AR03.20-P-
ENGINE 156 in MODEL 164, 251
seal 3063GZS
Replace rear crankshaft radial AR03.20-P-
ENGINES 156 in MODEL 204, 212
sealing ring 3063CMG
Replace rear crankshaft radial AR03.20-P-
ENGINE 156 in MODEL 230.470
sealing ring 3063RMG
Replace rear crankshaft radial AR03.20-P-
ENGINE 156 in MODEL 216, 221
sealing ring 3063SMG
Replacing rear crankshaft ENGINE 156.983 in MODELS 211.077 /277, 219.377 AR03.20-P-
radial seal ENGINE 156.982 in MODELS 209.377 /477 3063TMG
TESTING AND REPAIR WORK: PASSENGER CARS: CRANK ASSEMBLY - AR03.00-Z-9273AB
ENGINE 273
Remove, install flywheel / drive ENGINE 272 in MODEL 203, 209 ENGINE 273 in AR03.30-P-
plate MODEL 209 8001QB
Remove, install flywheel / drive AR03.30-P-
ENGINE 272, 273 in MODELS 211, 219
plate 8001TS
AR03.10-P-
Remove, install piston rings ENGINE 272, 273 Piston removed
7311VA
AR03.10-P-
Remove, install pistons ENGINE 272, 273 in MODEL 230
7021RX
Remove/install belt ENGINE 272 in MODEL 204 ENGINE 272, 273 in AR03.30-P-
pulley/vibration damper MODEL 207 1600CV
Remove/install belt AR03.30-P-
ENGINES 272, 273 in MODEL 212
pulley/vibration damper 1600EWS
Remove/install belt ENGINES 272, 273 in MODEL 164, 251 ENGINES AR03.30-P-
pulley/vibration damper 273 in MODEL 463 1600GZA
Remove/install belt AR03.30-P-
ENGINE 272, 273...
pulley/vibration damper 1600QB
Remove/install belt AR03.30-P-
ENGINES 272, 273 in MODEL 230
pulley/vibration damper 1600RX
Remove/install belt ENGINES 273 in MODEL 216 ENGINES 272, 273 AR03.30-P-
pulley/vibration damper in MODEL 221 1600SX
Remove/install belt AR03.30-P-
ENGINE 272, 273 in MODELS 211, 219
pulley/vibration damper 1600TS
ENGINES 272 in MODEL 204 ENGINES 272, 273 AR03.20-P-
Remove/install crankshaft
in MODEL 207 4351CV
AR03.20-P-
Remove/install crankshaft ENGINES 272, 273 in MODEL 212
4351EWS
AR03.20-P-
Remove/install crankshaft ENGINES 272, 273 in MODEL 164, 251
4351GZA
AR03.20-P-
Remove/install crankshaft ENGINE 272, 273...
4351QB
AR03.20-P-
Remove/install crankshaft ENGINES 272, 273 in MODEL 230
4351RX
AR03.20-P-
Remove/install crankshaft ENGINES 273 in MODEL 216, 221
4351SX
AR03.20-P-
Remove/install crankshaft ENGINE 272, 273...
4351TS
Remove/install flywheel / drive ENGINES 272 in MODEL 204 ENGINES 272, 273 AR03.30-P-
plate in MODEL 207 8001CV
Remove/install flywheel / drive AR03.30-P-
ENGINES 272, 273 in MODEL 212
plate 8001EW
Remove/install flywheel / drive AR03.30-P-
ENGINES 272, 273 in MODEL 164, 251
plate 8001GZA
Remove/install flywheel / drive ENGINE 273 in MODEL 216 ENGINE 272, 273 AR03.30-P-
plate (except 272.974) in MODEL 221 8001SX
Remove/install flywheel/drive AR03.30-P-
ENGINE 272, 273 in MODEL 230
plate 8001RX
ENGINES 272 in MODEL 204 ENGINES 272, 273 AR03.10-P-
Remove/install piston
in MODEL 207 7021CV
AR03.10-P-
Remove/install piston ENGINES 272, 273 in MODEL 212
7021EWS
AR03.10-P-
Remove/install piston ENGINES 272, 273 in MODEL 164, 251
7021GZA
AR03.10-P-
Remove/install piston ENGINE 272, 273...
7021QB
ENGINES 273 in MODEL 216 ENGINES 272, 273 AR03.10-P-
Remove/install piston
in MODEL 221 7021SX
ENGINES 272, 273 in MODEL 211, 219 with AR03.10-P-
Remove/install piston
TRANSMISSION 722.9 7021TS
Remove/install retaining lock for AR03.30-P-
ENGINE 272, 273, 276, 278...
crankshaft/ring gear 5000CV
Remove/install retaining lock for AR03.30-P-
ENGINES 272, 273 in MODEL 212
crankshaft/ring gear 5000EWS
Remove/install retaining lock for ENGINE 272, 273 (except 272.973) in MODEL AR03.30-P-
crankshaft/ring gear 164, 251 with TRANSMISSION 722.9 5000GZA
Remove/install retaining lock for AR03.30-P-
ENGINE 272, 273...
crankshaft/ring gear 5000QB
Remove/install retaining lock for AR03.30-P-
ENGINES 272, 273 in MODEL 230
crankshaft/ring gear 5000RX
ENGINES 157, 273, 278 in MODEL 216
Remove/install retaining lock for AR03.30-P-
ENGINES 157, 272, 273, 276, 278 (except 272.974)
crankshaft/ring gear 5000SX
in MODEL 221
Remove/install retaining lock for AR03.30-P-
ENGINES 272, 273 in MODEL 211, 219
crankshaft/ring gear 5000TS
Replace front crankshaft radial ENGINE 272 in MODEL 204 ENGINE 272, 273 in AR03.20-P-
sealing ring MODEL 207 3000CV
Replace front crankshaft radial AR03.20-P-
ENGINES 272, 273 in MODEL 212
sealing ring 3000EWS
Replace front crankshaft radial ENGINES 272, 273 in MODEL 164, 251 ENGINES AR03.20-P-
sealing ring 273 in MODEL 463 3000GZA
Replace front crankshaft radial AR03.20-P-
ENGINE 272, 273...
sealing ring 3000QB
Replace front crankshaft radial AR03.20-P-
ENGINE 272, 273 in MODEL 230
sealing ring 3000RX
Replace front crankshaft radial ENGINE 273 in MODEL 216 ENGINE 272, 273 in AR03.20-P-
sealing ring MODEL 221 3000SX
Replace front crankshaft radial AR03.20-P-
ENGINE 272, 273 in MODELS 211, 219
sealing ring 3000TS
sealing ring in MODEL 207 3063CV
Replace rear crankshaft radial AR03.20-P-
ENGINES 272, 273 in MODEL 212
sealing ring 3063EWS
Replace rear crankshaft radial AR03.20-P-
ENGINES 272, 273 in MODEL 164, 251
sealing ring 3063GZA
Replace rear crankshaft radial AR03.20-P-
ENGINE 272, 273...
sealing ring 3063QB
Replace rear crankshaft radial AR03.20-P-
ENGINES 272, 273 in MODEL 230
sealing ring 3063RX
Replace rear crankshaft radial ENGINES 273 in MODEL 216 ENGINES 272, 273 AR03.20-P-
sealing ring (except 272.974) in MODEL 221 3063SX
Replace rear crankshaft radial AR03.20-P-
ENGINES 272, 273 in MODEL 211, 219
sealing ring 3063TS
TESTING AND REPAIR WORK: PASSENGER CARS: CRANK ASSEMBLY - AR03.00-Z-9275AB
ENGINE 275
Measuring crankshaft and ENGINES 137.970, AR03.20-P-
remounting in bearings 275.950 /951 /953 /954/980 /981 /982 4355L
Remove/install belt ENGINES 137 in MODEL 215, 220 ENGINES 275 in AR03.30-P-
pulley/vibration damper MODEL 215, 216, 220, 221, 230 1600L
AR03.20-P-
Remove/install crankshaft ENGINES 275 in MODEL 215, 216, 220, 221
4351MC
AR03.20-P-
Remove/install crankshaft ENGINE 275 in MODEL 230
4351R
Remove/install flywheel / AR03.30-P-
ENGINE 275 in MODEL 215, 216, 220, 221
drive plate 8001MC
Remove/install flywheel / AR03.30-P-
ENGINE 275 in MODEL 230
drive plate 8001R
AR03.10-P-
Remove/install piston ENGINES 275
7021MC
Remove/install retaining lock AR03.30-P-
ENGINE 275 in MODEL 216, 221
for crankshaft /ring gear 5000SZ
Remove/install retaining lock AR03.30-P-
ENGINE 112, 113, 137, 275...
for crankshaft/ring gear 5000B
Replace front crankshaft radial AR03.20-P-
ENGINE 275
sealing ring 3000MC
Replace rear crankshaft radial AR03.20-P-
ENGINE 275 in MODEL 215, 216, 220, 221
seal 3063MC
Replace rear crankshaft radial AR03.20-P-
ENGINE 275 in MODEL 230
sealing ring 3063R
CHECK CONNECTING ROD BOLTS - AR03.10-P-6111-01L
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Engine 137,
Number Designation 275, 285
BE03.10-P-1001- Connecting rod Thread Ø M 7X1
03A bolts Shank length New mm 38
max. mm 38.4
1. Measure length (L).
If the length (L) of connecting rod bolts exceeds the maximum permissible dimension then the connecting rod
bolts must be replaced.
Fig. 2: Identifying Length Of Connecting Rod Bolt
Courtesy of MERCEDES-BENZ USA
CHECK CONNECTING ROD BOLTS - AR03.10-P-6111-01VA
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Number Designation Engine 272 Engine 273
BE03.10-P- Connecting rod Thread Ø M 8x1 8x1
1001-03A bolts Shank length New mm 39.5 39.5
max. mm 40.5 40.5
1. Measure length (L).
If the length (L) exceeds maximum permissible size, the connecting rod bolts must be replaced!
Fig. 3: Identifying Connecting Rod Bolt Length
Courtesy of MERCEDES-BENZ USA
TIGHTEN CONNECTING ROD BOLTS - AR03.10-P-6111-02AMG
ENGINE 156
MODIFICATION NOTES
3.2.12 Value modified: *BA03.10-P-1001-01Q
connecting rod bearing
cap on the connecting rod,
Stage 3
CONNECTING ROD
Number Designation Engine 156
BA03.10-P-1001- Connecting rod STAGE 1 Nm 10
01Q bearing cap on Stage 2 Nm 40
connecting rod Stage 3 Angle° 90
Do not use impact wrench or compressed air tool to screw in otherwise the threaded holes will be damaged.
Connecting rod bolts must be replaced.
The previously installed connecting rod bolts must not be used again otherwise loosening can occur and
associated engine damage can occur.
1. Lubricate the bolt thread and head contact surface with engine oil.
2. Tighten connecting rod bolts.
Observe the tightening specification and tightening torque.
If no angle tightener is available, continue turning the connecting rod bolts to the specified angle using a
socket wrench and locking handle. Do not use a flexi-rod torque wrench for tightening in order to avoid any
angle errors.
Fig. 4: Tightening Connecting Rod Bolts
Courtesy of MERCEDES-BENZ USA
Tightening specification Stages (per connecting rod)
1 Alternate tightening of connecting rod bolts Stage 1
2 Alternate further tightening of connecting rod Stage 2
bolts
3 Alternate tightening of connecting rod bolts as Stage 3
per tightening angle
4 Alternate loosening of connecting rod bolts Stage 4
5 Alternate tightening of connecting rod bolts Stage 5
6 Alternate further tightening of connecting rod Stage 6
bolts
7 Alternate tightening of connecting rod bolts as Stage 7
per tightening angle
TIGHTEN CONNECTING ROD BOLTS - AR03.10-P-6111-02L
ENGINE 137.970, 275
CONNECTING ROD
Number Designation Engine 137 Engine 275, 285
BA03.10-P- Connecting rod Stage 1 Nm 5 5
1001-01E bolt Stage 2 Nm 15 15
Stage 3 Angle° 90 90
1. Coat thread and head contact surfaces of bolt with engine oil.
2. Pretighten connecting rod bolts with torque (stage 1, stage 2).
If no torquing angle wrench is available, connecting rod screws can be torqued further by the specified angle
in a single operation using a wrench and tommy bar. Do not use a flexi-rod torque wrench for tightening in
order to avoid any angle errors.
Fig. 5: Tightening Connecting Rod Bolt
Courtesy of MERCEDES-BENZ USA
TIGHTEN CONNECTING ROD BOLTS - AR03.10-P-6111-02VA
ENGINE 272, 273
CONNECTING ROD
Number Designation Engine 272 Engine 273
Stage 1 Nm 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 20 25
Stage 3 Angle° 90 90
1. Lubricate the bolt thread and head contact surface with engine oil.
2. Tighten connecting rod bolts to step 1.
3. Tighten connecting rod bolts to step 2.
4. Tighten connecting rod bolts to step 3.
If no angle tightener is available, continue turning the connecting rod bolts to the specified angle using a
socket wrench and locking handle.
Do not use a flexi-rod torque wrench for tightening in order to avoid any angle errors.
Shown on engine 272
Fig. 6: Tightening Connecting Rod Bolts
Courtesy of MERCEDES-BENZ USA
INSTALL AND GAUGE CONNECTING ROD BEARINGS - AR03.10-P-6111-06L
ENGINE 137.970, 275
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Engine Engine
Number Designation Engine 137 275.95, 285.95 275.98, 285.98
BE03.20-P- Connecting Radial mm 0.017...0.052 0.026...0.059 0.019...0.048
1002-04E rod bearing measurement
play new
CONNECTING ROD
Number Designation Engine 137 Engine 275, 285
BA03.10-P- Connecting rod Stage 1 Nm 5 5
1001-01E bolt Stage 2 Nm 15 15
Stage 3 Angle° 90 90
1. Clean bearing points of connecting rod, connecting rod bearing caps and connecting rod bearing journals
with a chamois leather and.
Blow out oil galleries with compressed air in direction of oil flow.
Do not use any hard objects for cleaning.
2. The assignment of connecting rods to connecting rod bearing journals is indicated on the back of
connecting rod bearing shells by a colored dot.
Only the following color combinations of connecting rod bearing shells may be fitted to each other.
shells in connecting rod bearing cap in yellow
or
B. Upper connecting rod bearing shells of connecting rod in blue, lower connecting rod bearing shells
in connecting rod bearing cap in red
or
C. Upper connecting rod bearing shells of connecting rod in red, lower connecting rod bearing shells
in connecting rod bearing cap in blue
The sequence of the individual color combinations on the connecting rod bearing journals can be
selected at random.
3. Insert connecting rod bearing shell (7) into connecting rod (4) and connecting rod bearing cap.
Connecting rod bearing shells (7) with oil holes (arrow) must be fitted in the connecting rods,
otherwise the connecting rod bearings will not be lubricated. The anti-twist locks (8) of the connecting
rod bearing shells (7) must be located in the grooves (9) in the connecting rod (4) and the connecting rod
bearing cap.
4. Wet thread and head contact surfaces of bolt with engine oil.
5. Pretighten connecting rod bolts with torque (stage 1, stage 2).
Fig. 7: Identifying Connecting Rod Components
Courtesy of MERCEDES-BENZ USA
6. Tighten connecting rod bolts using an angle wrench to stage 3.
If no torquing angle wrench is available, connecting rod screws can be torqued further by the specified angle
in a single operation using a wrench and tommy bar. Do not use a flexi-rod torque wrench for tightening in
order to avoid any angle errors.
Fig. 8: Tightening Connecting Rod Bolts
Courtesy of MERCEDES-BENZ USA
INSTALL AND GAUGE CONNECTING ROD BEARINGS - AR03.10-P-6111-06VA
MODIFICATION NOTES
15.9.09 Value modified: Connecting rod bearing play Engine 156 *BE03.20-P-1002-04E
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 156 Engine 272
BE03.20-P-1002- Connecting rod bearing Radial measurement
mm 0.028...0.063 0.022...0.066
04E play new
Assignment of conrod bearings to conrod bearing journals on engine 272
Upper half Connecting Lower half Connecting rod bearing Connecting rod bearing play
rod cap (mm)
yellow yellow 0.026 - 0.066
blue red 0.026 - 0.066
red blue 0.026 - 0.066
1. Clean the bearing points of connecting rod, connecting rod bearing caps and connecting rod bearing
journals with a chamois leather.
Blow through oil ducts in direction of flow oil with compressed air. Never use hard objects for
cleaning.
2. The assignment of connecting rods to connecting rod bearing journals is indicated on the back of
connecting rod bearing shells by a colored dot.
Only the assigned color combinations of the conrod bearing shells (see table) may be installed
together. The sequence of the individual color combinations on the connecting rod bearing journals can
be selected at random.
3. Insert connecting rod bearing shells (1) into connecting rod and connecting rod bearing cap (2).
The anti-twist locks (3) of the conrod bearing shells (1) must be located in the slots (4) of the conrods
(2) and the conrod bearing caps.
Fig. 9: Identifying Connecting Rod Bearing Shells, Bearing Cap And Anti-Twist Locks
Courtesy of MERCEDES-BENZ USA
MOUNT CONNECTING ROD BEARING - AR03.10-P-6111-08SX
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 273
BE03.20-P-1002- Connecting rod Radial measurement mm 0.022...0.066
04E bearing play new
CONNECTING ROD
Number Designation Engine 273
BA03.10-P-1001- Connecting rod bolt Stage 1 Nm 5
01E Stage 2 Nm 25
Stage 3 Angle° 90
ASSIGNMENT OF CONNECTING ROD BEARING TO CONNECTING ROD JOURNAL FOR
ENGINE 273
Assignment of connecting rod bearing to connecting rod journal for engine 273
Upper half of connecting Lower half of connecting rod bearing Connecting rod bearing play
rod cap (mm)
yellow yellow 0.022...0.066
blue red 0.022...0.066
red blue 0.022...0.066
1. Clean bearing points on connecting rod, connecting rod bearing caps and connecting rod journals with a
chamois leather.
Blow through oil ducts in direction of flow oil with compressed air. Never use hard objects for
cleaning.
2. The assignment of connecting rods to connecting rod bearing journals is indicated on the back of
connecting rod bearing shells by a colored dot.
Only the assigned color combinations of the conrod bearing shells (see table) may be installed
together. The sequence of the individual color combinations on the connecting rod bearing journals can
be selected at random.
3. Insert connecting rod bearing shells (1) into connecting rod and connecting rod bearing cap (2).
The anti-twist locks (3) of the connecting rod bearing shells (1) must be located in the cutouts (4) of
the connecting rod (2) and the connecting rod bearing cap.
Fig. 10: Identifying Anti-Twist Locks Of Connecting Rod Bearing Shells And Cutouts Of
Connecting Rod
Courtesy of MERCEDES-BENZ USA
4. Install connecting rod bearing cap with connecting rod bearing shells (1).
5. Spread engine oil onto the thread and bolt head contact surface of the connecting rod bolts.
6. Screw in connecting rod bolts and tighten to step 1.
7. Tighten connecting rod bolts to step 2.
8. Tighten connecting rod bolts using an angle wrench to Stage 3.
If no torquing angle wrench is available, the connecting rod screws can be torqued further by the specified
angle in a single operation using a wrench and tommy bar.
Do not use a flexi-rod torque wrench for tightening in order to avoid any angle errors.
Fig. 11: Tightening Connecting Rod Bolt
Courtesy of MERCEDES-BENZ USA
REMOVING/INSTALLING OIL DEFLECTOR PLATE - AR03.10-P-7021-01SX
ENGINE 272, 273
OIL PUMP
Number Designation Engine 272 Engine 273
BA18.10-P-1006- Bolt for oil baffle on Nm 9 9
01B crankcase
Shown on engine 273
1. Unscrew bolts (1).
2. Remove oil baffle (2) from crankcase.
3. Install in the reverse sequence.
Fig. 12: Identifying Crankcase Oil Baffles And Bolts
Courtesy of MERCEDES-BENZ USA
ASSIGNING A STANDARD DIMENSION PISTON TO A CYLINDER BORE - AR03.10-P-7021-02L
ENGINE 137.970, 275
MODIFICATION NOTES
15.8.08 Note for determination of valid measurement for a cylinder bore - added Step 1
TEST SPECIFICATIONS FOR PISTONS
Number Designation Engine 137.970
BE03.10-P-1001- Piston dia. Ø Default mm 83.975 to 84.003
02E Auxiliary stage mm 84.025 to 84.053
BE03.10-P-1002- Piston clearance Default mm < or =0, 04
02E Auxiliary stage mm < or =0, 04
TEST SPECIFICATIONS FOR PISTONS
Engine
275.950/951/953/954, Engine 275.98,
Number Designation 285.950 285.98
BE03.10-P- Piston Ø Standard Step mm 81.970 to 82.008 82.563...82.575
1003-02F markings X
Step marking mm 82.020 to 82.058 82.613 to 82.625
BE03.10-P- Piston Default mm < or =0.04 -
1004-02F clearance
TEST SPECIFICATIONS FOR CYLINDER BORE
Engine
275.950/951/953/954,
Number Designation Engine 137.970 285.950
BE01.40-P- Cylinder dia. Standard mm 84.000 to 82.000 to 82.015
1001-01G marking X 84.015
Auxiliary stage mm 84.050 to 82.050 to 82.065
marking 84.065
TEST SPECIFICATIONS FOR CYLINDER BORE
Engine 275.98
Number Designation 285.98
BE01.40-P-1001- Cylinder dia. Standard marking X mm 82.600 to 82.615
01G Auxiliary stage mm 82.650 to 82.665
marking
1. Assign piston to the cylinder bore
Measurement values for the cylinder bore are only valid with a screwed on lower crankcase section.
The cylinder bore diameter is specified in two tolerances. The two tolerances of the cylinder bore diameters
are distinguished by the letters x and
This marking is located at the bottom right on the crankcase at the mount for the engine support.
The piston diameters result from the tolerances (standard, auxiliary stage) of the cylinder bore diameters and do
not have a marking of their own. If necessary, the piston diameter can be read off on the piston crown.
Fig. 13: Identifying Cylinder Bore Diameter Tolerance
Courtesy of MERCEDES-BENZ USA
No piston with a standard diameter should be installed in a cylinder bore with identification
Piston with standard diameter in cylinder bore with standard diameter (marking x)
Piston with auxiliary diameter in cylinder bore with auxiliary diameter (identification marking
ASSIGNING A STANDARD SIZE PISTON TO A CYLINDER BORE - AR03.10-P-7021-02VA
ENGINE 272, 273
MODIFICATION NOTES
23.4.10 Value modified: Piston diameter Engine 273.96/97 *BE03.10-P-1001-02D
TEST VALUES FOR CYLINDER BORE
Number Designation Engine 272.91/92/94/95 Engine 272.96/97/ 98/99
Stage X mm 88.000...88.015 92.900...92.915
BE01.40-P-1001-01I Cylinder dia. Stage mm 88.100...88.115 93.000...93.015
Repair size mm 88.250...88.265 93.150...93.165
TEST VALUES FOR CYLINDER BORE
Number Designation Engine 273.92 Engine 273.96/97
Stage X mm 92.900...92.915 98.000...98.015
BE01.40-P-1001-01I Cylinder dia. Stage mm 93.000...93.015 98.100...98.115
Repair size mm 93.150...93.165 98.250...98.265
TEST VALUES FOR PISTONS
Engine Engine 272.96/97/
Number Designation
272.91/92/94/95 98/99
Standard identification
mm 87.973...88.003 92.863...92.897
X
BE03.10-P-1001- Piston
Auxiliary size mm
02D diameter mm 88.073...88.103 92.963...92.997
marking
Repair size mm 88.223...88.253 93.113...93.147
Standard identification
mm 0.003...0.042 0.003...0.052
BE03.10-P-1002- Piston X
02D clearance Auxiliary size marking mm 0.003...0.042 0.003...0.052
Repair size mm 0.003...0.042 0.003...0.052
TEST VALUES FOR PISTONS
Number Designation Engine 273.92 Engine 273.96/97
Standard identification X mm 92.863...92.897 97.973...98.007
BE03.10-P-1001-02D Piston diameter Auxiliary size marking mm 92.963...92.997 98.073...98.107
Repair size mm 93.113...93.147 98.223...98.257
Standard identification X mm 0.003...0.052 0.007...0.042
BE03.10-P-1002-02D Piston clearance Auxiliary size marking mm 0.003...0.052 0.007...0.042
Repair size mm 0.003...0.052 0.007...0.042
1. Assign piston to the cylinder bore
Piston diameters are specified in two tolerances. The piston diameters are differentiated from each other by
the identification x or
Pistons marked with x must only be installed in cylinder bores marked with x.
Pistons marked with x must only be installed in cylinder bores marked with x.
Fig. 14: View Of Piston Identification Marks
Courtesy of MERCEDES-BENZ USA
Cylinder bore diameters are specified in two tolerances. The cylinder bore diameters are differentiated from
each other by the identification x or
Shown on engine 272
Fig. 15: View Of Cylinder Bore Identification Mark
REMOVE/INSTALL PISTON - AR03.10-P-7021AMG
ENGINES 156
Fig. 16: Identifying Piston Components
Courtesy of MERCEDES-BENZ USA
Fig. 17: Identifying Tensioning Strap
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
11.12.09 Value changed: connecting rod bearing cap on the connecting rod *BA03.10-P-1001-01Q
Value changed: connecting rod bearing cap on the connecting rod *BA03.10-P-1001-01Q
Removing
Align vehicle between columns of vehicle lift
slipping or toppling off the lifting support points specified by vehicle 0010-01A
platform. manufacturer.
Do not open cooling system unless coolant
Risk of injury to skin and eyes
temperature is below 90°C. Open cap slowly and
caused by scalding from contact
release the pressure. Do not pour coolant into AS20.00-Z-
with hot coolant spray. Risk of
beverage containers. 0001-01A
poisoning caused by swallowing
Wear protective gloves, protective clothing and
coolant.
safety glasses.
Risk of explosion caused by fuel
No fire, sparks, open flames or smoking. Only
igniting, risk of poisoning caused
pour fuels into suitable and appropriately AS47.00-Z-
by inhaling and swallowing fuel
marked containers. 0001-01A
and risk of injury to eyes and
Wear protective clothing when handling fuel.
skin caused by contact with fuel
Notes on self-locking nuts and AH00.00-N-
bolts 0001-01A
Remove engine with front axle AR01.10-P-
1.1 Model 164, 251
carrier 2500GZS
AR01.10-P-
Model 204
2400CMG
AR01.10-P-
Model 212
2400EMG
AR01.10-P-
Model 209
2400QMG
1.2 Remove engine
AR01.10-P-
Model 211, 219
2400TMG
AR01.10-P-
Model 216, 221
2400SMG
AR01.10-P-
Model 230
2400RMG
Detach engine from front axle AR01.10-P-
2 Model 164, 251
carrier 2510GZS
3 Detach transmission from engine
Mount engine onto assembly
4
stand
AR01.30-P-
Model 164, 251
5800GZS
AR01.30-P-
Model 204, 212
5800CMG
AR01.30-P-
5 Remove cylinder heads Model 209, 211, 219
5800TMG
AR01.30-P-
Model 216, 221
5800SMG
AR01.30-P-
Model 230
5800RMG
Model 164, 251 7555GZS
AR01.45-P-
Model 204, 212
7555CMG
AR01.45-P-
Model 209, 211, 219
6 Remove oil pan bottom section 7555TMG
AR01.45-P-
Model 216, 221
7555SMG
AR01.45-P-
Model 230
7555RMG
AR01.45-P-
Model 164, 251
7500GZS
AR01.45-P-
Model 204, 212
7500CMG
AR01.45-P-
Model 209
7500QMG
7 Detach oil pan
AR01.45-P-
Model 211, 219
7500TMG
AR01.45-P-
Model 216, 221
7500SMG
AR01.45-P-
Model 230
7500RMG
AR18.10-P-
Model 164, 251
6020GZS
AR18.10-P-
Model 204, 212
6020CMG
AR18.10-P-
8 Remove oil pump Model 209, 211, 219
6020TMG
AR18.10-P-
Model 216, 221
6020SMG
AR18.10-P-
Model 230
6020RMG
9 Remove engine support
Remove refrigerant compressor
or compressor from cylinder
AR18.40-P-
10 crankcase and disconnect
4123AMG
connector on oil temperature
sensor
Remove vacuum reservoir from On vehicles with vacuum reservoir at the
11
cylinder crankcase cylinder crankcase
Unscrew bolts from cylinder
12 crankcase lower section
(bedplate)
Mount the crankshaft bracket on
13 Crankshaft bracket Fig. 19
the crankshaft
connecting rod (2) and Connecting rod (2) and connecting rod
connecting rod bearing cap (1) at bearing cap (1) are cracked. They must not be
14
one side swapped or installed on wrong sides as the
dimensional accuracy would no longer be given.
Remove connecting rod bearing
15
cap (1)
Mark pistons (3) for the cylinder bores.
If pistons are used (3), the arrows indicating
Remove connecting rod (2) with the driving direction and the marking of the
16 pistons (3) from crankcase in the pistons (3) may no longer be visible because of
direction of cylinder head carbon deposits. For this reason, remove carbon
deposits from pistons (3). If arrows indicating
the driving direction on pistons (3) are no longer
recognizable then these must be newly marked.
Remove circlip (4) for piston pin Do not damage piston (3). Place a clean cloth
17
(5) underneath.
Press piston pin (5) out of piston
18
(3)
Install
19 Assign piston (3) to cylinder bore
Lubricate piston pin (5) and
20
connecting rod small end
Align piston (3) and connecting Install piston (3) with arrow in direction of
21
rod (2) travel.
Push piston pins (5) into pistons
22
(3)
Insert circlip (4) of piston pin (5) Do not damage piston (3). Place a clean cloth
23
in piston (3) underneath.
Lubricate cleaned parts (cylinder
bores, connecting rod journals,
24
connecting rod bearing shells and
piston (3))
Place tensioning strap (6) on Piston ring end gaps must be offset 120°.
25
piston (3) and tension it Tensioning strap Fig. 18
Pay attention to the arrow (in the direction of
travel) on the piston (3).
Install piston (3) in direction of Rotate crankshaft sufficiently that the
26
travel connecting rod when inserting piston (3) into
cylinder bore does not touch the connecting rod
journal!!
Anti-twist locks (8) for connecting rod
bearing shells (10) must be located in grooves
(9) of connecting rod (2) and connecting rod
and connecting rod bearing cap Connecting rod (2) and connecting rod
(1) bearing cap (1) are cracked. They must not be
27
swapped or installed on wrong sides as the
dimensional accuracy would no longer be given.
Tighten connecting rod bolts (7) according to
tightening specification.
The connecting rod bolts (7) must be AR03.10-P-
replaced. 6111-
The previously installed connecting rod bolts (7) 02AMG
28 Tighten connecting rod bolts (7)
must not be installed again otherwise loosening
can occur and associated engine damage can
occur.
*BA03.10-
P-1001-01Q
Turn crankshaft by hand and
29 check for unobstructed movement
of crank assembly
Remove crankshaft bracket from
30 Crankshaft bracket Fig. 19
crankshaft
Clean
Do not use any sharp-edged tools or abrasive AR01.00-P-
paper as this will damage the sealing surfaces. 0050-01A
Remove sealant on cylinder
*BR00.45-
31 crankcase and cylinder crankcase Loctite 7200
lower section (bedplate) Z-1038-04A
*BR00.45-
Cleaning spray, Loctite 7063 (150ml)
Z-1046-04A
AR03.20-P-
Install cylinder crankcase lower Replace bolts and tighten down according to 4351-
32
section (bedplate) tightening specification. 05AMG
*BA03.20-
P-1001-01J
*BA03.20-
P-1002-01J
Notes on application of sealant to AH01.40-P-
the cylinder crankcase lower 1000-
section (bedplate) 03AMG
Squeeze gun Fig. 20
*BR00.45-
Loctite sealant 5970
Z-1013-01A
AR03.20-P-
Model 164, 251
3063GZS
AR03.20-P-
33 Model 204, 212
3063CMG
AR03.20-P-
Model 209, 211, 219
sealing ring AR03.20-P-
Model 216, 221
3063SMG
AR03.20-P-
Model 230
3063RMG
On vehicles with vacuum reservoir at the
34 Install vacuum reservoir
cylinder crankcase
*BA22.10-
35 Mount engine support
P-1001-02A
Mount the refrigerant compressor AR18.40-P-
36
on the cylinder crankcase 4123AMG
AR18.10-P-
Model 164, 251
6020GZS
AR18.10-P-
Model 204, 212
6020CMG
AR18.10-P-
37 Install oil pump Model 209, 211, 219
6020TMG
AR18.10-P-
Model 216, 221
6020SMG
AR18.10-P-
Model 230
6020RMG
AR01.45-P-
Model 164, 251
7500GZS
AR01.45-P-
Model 204, 212
7500CMG
AR01.45-P-
Model 209
7500QMG
38 Fit oil pan
AR01.45-P-
Model 211, 219
7500TMG
AR01.45-P-
Model 216, 221
7500SMG
AR01.45-P-
Model 230
7500RMG
AR01.45-P-
Model 164, 251
7555GZS
AR01.45-P-
Model 204, 212
7555CMG
AR01.45-P-
39 Fit oil pan bottom section Model 209, 211, 219
7555TMG
AR01.45-P-
Model 216, 221
7555SMG
AR01.45-P-
Model 230
7555RMG
AR01.30-P-
Model 164, 251
5800GZS
Model 204, 212 5800CMG
AR01.30-P-
Model 209, 211, 219
5800TMG
40 Mount the cylinder heads AR01.30-P-
Model 216, 221
5800SMG
AR01.30-P-
Model 230
5800RMG
41 Attach transmission to engine
AR01.10-P-
42 Attach engine to front axle carrier Model 164, 251
2510GZS
Install engine with front axle AR01.10-P-
43.1 Model 164, 251
carrier 2500GZS
AR01.10-P-
Model 204
2400CMG
AR01.10-P-
Model 212
2400EMG
AR01.10-P-
Model 209
2400QMG
43.2 Install engine
AR01.10-P-
Model 211, 219
2400TMG
AR01.10-P-
Model 216, 221
2400SMG
AR01.10-P-
Model 230
2400RMG
Risk of accident caused by
vehicle starting off by itself when
Secure vehicle to prevent it from moving by
engine is running.Risk of injury
itself. AS00.00-Z-
caused by contusions and burns
Wear closed and snug-fitting work clothes. 0005-01A
during starting procedure or when
Do not touch hot or rotating parts.
working near the engine as it is
running
Conduct engine test run and
44
check engine for leaks
ENGINE SUPPORT (ENGINE SIDE)
Number Designation Engine 156
Stage 1 Nm 20
BA22.10-P-1001-02A Bolt, engine support to cylinder crankcase
Stage 2 Angle° 90
CRANKSHAFT BEARING CAP
Engine
Number Designation
156
Stage
Nm 20
1
Stage
Nm 32
2
Stage
Angle° 90
3
Stage
Angle° 90
4
Stage
loosen
5
M9
Stage
Nm 20
6
Stage
Nm 32
7
Stage
Angle° 90
8
Stage
Angle° 90
9
BA03.20-P- Crankshaft bearing cap bolt (lower section of crankcase/ Stage
Nm 20
1001-01J main bearing threaded connection) 1
Stage
Nm 40
2
Stage
Angle° 90
3
Stage
Angle° 90
4
Stage
M10 loosen
5
Stage
Nm 20
6
Stage
Nm 40
7
Stage
Angle° 90
8
Stage
Angle° 90
9
BA03.20-P- M6 Nm 8.5
Crankcase lower section on crankcase upper section
1002-01J M8 Nm 20
CONNECTING ROD
Number Designation Engine 156
STAGE 1 Nm 10
Stage 2 Nm 40
BA03.10-P-1001-01Q Connecting rod bearing cap on connecting rod Stage 3 Angle° 120
Stage 4 loosen
Stage 5 Angle° 10
Stage 6 Nm 40
Stage 7 Angle° 90
Fig. 18: Identifying Tensioning Strap (000 589 04 14 00)
Courtesy of MERCEDES-BENZ USA
Fig. 19: Identifying Crankshaft Bracket (156 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 20: Identifying Squeeze Gun (112 589 00 25 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-
Loctite sealant 5970 A 003 989 98 20
1013-01A
Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925
BR00.45-Z-
Loctite 7200 Munchen Germany Tel. +49 899268-0 Fax + 49 899101978
1038-04A
www.Loctite.de
BR00.45-Z- Cleaning spray,
A 001 986 71 71 10
1046-04A Loctite 7063 (150ml)
REMOVE/INSTALL PISTON - AR03.10-P-7021MC
ENGINES 275
Fig. 21: Identifying Piston Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Note for determination of valid measurement for a cylinder bore - Step AR03.10-P-7021-
15.8.08
added 1 02L
Removing
Removal of piston on the
left occurs (4b) analog to
removal of piston on the
right (4a)
Model 215, 220 except 220 with special protection
protection, code Z07 2400MC
1.1 Remove engine Model 220 with special protection version, code 979,
light armoring, code Z04 or top protection, code Z07
AR01.10-P-
Model 216, 221
Remove engine with 2500SZ
1.2
front axle carrier AR01.10-P-
Model 230
2500RC
AR27.10-P-
Model 216, 221
0500SZ
2 Remove transmission
AR27.10-P-
Model 230
0500RC
AR01.10-P-
Model 216, 221
Detach engine from front 2510SX
3
axle carrier AR01.10-P-
Model 230
2510RX
Mount engine onto
4
assembly stand
The right or the left cylinder head must be removed AR01.30-P-
5 Remove cylinder head depending on the piston (4a, 4b) which should be 5800M
removed.
AR01.45-P-
Model 215, 220
7500L
AR01.45-P-
6 Detach oil pan Model 216, 221
7500SZ
AR01.45-P-
Model 230
7500RA
Remove oil deflector
7
plate
Mark connecting rod (2) and connecting rod bearing
cap relative to each other so that, when installing, the
Remove connecting rod parts are not mixed up.
8
bearing cap (1) Connecting rod (2) and connecting rod bearing cap
are cracked. They must not be installed on the wrong
side as the accuracy of fit is no longer given.
Mark connecting rod
bearing shell and
9
connecting rod bearing
cap (1) to each other
Mark position of pistons
10 (4a, 4b) and cylinder liner Do not mix up the pistons, as this can lead to engine
damage.
relative to each other
Observe identification arrow on the piston crown. On
11 pistons (4a, 4b) which are used, the identification arrow
of the pistons may no longer be visible because of carbon
(2) with pistons (4a, 4b) from the piston. If the identification arrow is no longer
recognizable on the piston, the piston must be identified
again.
Mark connecting rod
bearing shell and Do not mix up the upper and lower connecting rod
12
connecting rod (2) to bearing shell as this can lead to engine damage.
each other
Remove the circlip (5) Use clean shop towels as a base so that the piston on
13
from the piston pin (6) the pistons (4a, 4b) are not damaged.
The connecting rod (2) is not marked so mark
connecting rod (2) and piston (4a, 4b) relative to each
14 Press out piston pin (6)
other so that connecting rod (2) can be reinstalled in its
original installation position with piston (4a, 4b).
Inspect connecting rods Connecting rods with blue discoloration as a result of
15 (2) for blue discoloration, bearing damage, with transverse scores and notches must
cross scores and notches be replaced as this can lead to engine damage
Install
AR03.10-P-
7021-02L
*BE03.10-
Assigning a standard P-1003-02F
16 dimension piston to a
cylinder bore *BE03.10-
P-1004-02F
*BE01.40-
P-1001-01G
Oil piston pin (6) and
17
connecting rod bush
Installation: When installing, ensure that connecting
Assemble piston (4a, 4b)
18 collar (broad side) (a) points in direction of crank web
and connecting rod (2)
when fitted.
Push in piston pin (6) by
19
hand
Insert circlip (5) for
piston pin (6) into the Use a clean shop towel as a base so that the piston is
20
groove on the piston (4a, not damaged.
4b)
Lubricate cleaned
cylinder bore, connecting
21 rod journals, connecting
rod bearing shells and
pistons (4a, 4b)
22 The piston ring end gap of piston ring 1 (upper ring)
Fit on tensioning strap (7) points to the front when the pistons (4a, 4b) are installed
tension end gaps are offset each by 120°.
Fig. 22
Install piston (4a, 4b)
with marking arrow In order to avoid causing damage during installation,
23 turn crankshaft until connecting rod (2) does not touch
pointing in direction of
front of vehicle connecting rod journal when inserting the piston.
AR03.10-P-
Check connecting rod 6111-01L
24
bolts (3) *BE03.10-
P-1001-03A
Insert connecting rod According to the attached markings. Do not mix up
bearing shell into top and bottom connecting rod bearing shells.
25 connecting rod (2) and The anti-twist locks of the connecting rod bearing
connecting rod bearing shells must be located in the slots of the connecting rods
cap (1) and in the slots of the connecting rod bearing caps.
Bolt connecting rod bearing cap and connecting rod AR03.10-P-
Install connecting rod (2) to each other with the markings (arrows) lined up. 6111-02L
26
bearing cap (1) *BA03.10-
P-1001-01E
*BA01.40-
27 Install oil deflector plate
P-1009-01C
AR01.45-P-
Model 215, 220
7500L
AR01.45-P-
28 Installing oil pan Model 216, 221
7500SZ
AR01.45-P-
Model 230
7500RA
AR01.30-P-
29 Install cylinder head
5800M
Detach engine from
30
engine assembly stand
AR01.10-P-
Model 216, 221
Install engine onto front 2510SX
31
axle carrier AR01.10-P-
Model 230
2510RX
AR27.10-P-
Model 216, 221
0500SZ
32 Mount transmission
AR27.10-P-
Model 230
0500RC
Model 215, 220 except 220 with special protection
version, code 979, light armoring, code Z04 or top
AR01.10-P-
33.1 Install engine protection, code Z07
2400MC
Model 220 with special protection version, code 979,
light armoring, code Z04 or top protection, code Z07
AR01.10-P-
Model 216, 221
Install engine with front 2500SZ
33.2
axle carrier AR01.10-P-
Model 230
2500RC
TEST SPECIFICATIONS FOR PISTONS
Engine 275.950/951/953/954, Engine 275.98,
Number Designation
285.950 285.98
Standard Step
BE03.10-P- mm 81.970...82.008 82.563...82.575
Piston Ø markings X
1003-02F
Step marking mm 82.020...82.058 82.613...82.625
BE03.10-P- Piston
Default mm 0.04 -
1004-02F clearance
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Number Designation Engine 137, 275, 285
Thread diameter M 7X1
BE03.10-P-1001-03A Connecting rod bolts Shank length New mm 38
max. mm 38.4
TEST SPECIFICATIONS FOR CYLINDER BORE
Engine 275.950/951/953/954, Engine 275.98
Number Designation
285.950 285.98
Standard marking
mm 82.000...82.015 82.600...82.615
BE01.40-P- Cylinder X
1001-01G dia. Auxiliary stage
mm 82.050...82.065 82.650...82.665
marking
CRANKCASE, TIMING CASE COVER, END COVER
Number Designation Engine 137 Engine 275, 285
BA01.40-P-1009-01C Bolt, oil baffle to lower crankcase section Nm 8 8
CONNECTING ROD
Number Designation Engine 275, 285
Stage 1 Nm 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 15
Stage 3 Angle° 90
Fig. 22: Identifying Tensioning Strap (000 589 04 14 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL PISTON - AR03.10-P-7021SX
ENGINES 273 in MODEL 216
ENGINES 272, 273 in MODEL 221
Fig. 23: Identifying Piston Components
Courtesy of MERCEDES-BENZ USA
Fig. 24: Identifying Tensioning Strap
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
23.4.10 Value modified: Piston Ø Engine 273.96/97 *BE03.10-P-1001-02D
Removing
Remove engine with AR01.10-P-
1 Vehicles without 4MATIC
front axle carrier 2500SX
AR01.10-P-
Vehicles with 4MATIC
2500SW
Detach engine from AR01.10-P-
2 Vehicles without 4MATIC
front axle carrier 2510SX
AR01.10-P-
Vehicles with 4MATIC
2510TW
Detach transmission AR27.10-P-
3 Vehicles without 4MATIC
from engine 0500SX
AR27.10-P-
Vehicles with 4MATIC
0500SYZ
Mount engine onto
4
assembly stand
AR01.45-P-
5 Detach oil pan Vehicles with engine 272
7500SY
AR01.45-P-
Vehicles with engine 273 without 4MATIC
7500SX
AR01.45-P-
Vehicles with engine 273 and 4MATIC
7500SW
Remove oil baffle from AR03.10-P-
6
cylinder crankcase 7021-01SX
AR01.30-P-
7 Remove cylinder heads Right cylinder head
5800SY
AR01.30-P-
Left cylinder head
5800SX
Place markings (11) on
Connecting rod must be installed in the same position
8 connecting rod (2) and
and in the same direction.
cap (1) at one side
Remove connecting rod
9
bearing cap (1)
If pistons are used (3), the arrows indicating the driving
direction and the marking of the pistons (3) may no longer
Remove connecting rod
be visible because of carbon deposits. For this reason,
(2) with pistons (3)
10 from crankcase in the remove carbon deposits from pistons (3). If arrows
indicating the driving direction on pistons (3) are no longer
direction of cylinder
recognizable then these must be newly marked. The
head
pistons (3) be installed in the same position and in the
same direction.
Remove circlip (4) for Do not damage piston (3). Place a clean cloth
11
piston pin (5) underneath.
Press the piston pin (5)
12
out of piston (3)
Install
Assign piston (3) to AR03.10-P-
13
cylinder bore 7021-02VA
*BE01.40-
Cylinder dia.
P-1001-01I
*BE03.10-
Piston Ø
P-1001-02D
*BE03.10-
Piston clearance
P-1002-02D
Lubricate piston pin (5)
14 and connecting rod
small end
Align piston (3) and
15 Install piston (3) with arrow in direction of travel.
connecting rod (2)
Press piston pin (5) by
16
hand into piston (3)
Insert circlip (4) of
Do not damage piston (3). Place a clean cloth
17 piston pin (5) into
underneath.
groove on piston (3)
Oil cleaned parts
(cylinder bores,
connecting rod bearing
18
journals, connecting rod
bearing shells (10) and
piston (3))
Place tensioning strap
19 (6) on piston (3) and Piston ring end gaps must be offset 120°.
tension it
Fig. 25
Install piston (3) in
20 Observe arrow (in direction of travel) on piston (3).
direction of travel
Rotate crankshaft so that connecting rod (2) is not
touching connecting rod journal when inserting the piston
(3) into cylinder bore!
Check connecting rod AR03.10-P-
21
bolts (7) 6111-01VA
*BE03.10-
Connecting rod bolts
P-1001-03A
Install connecting rod
AR03.10-P-
22 bearings and connecting Engine 272
6111-06VA
rod bearing cap (1)
*BE03.20-
Connecting rod bearing play
P-1002-04E
AR03.10-P-
Engine 273
6111-08SX
*BE03.20-
Connecting rod bearing play
P-1002-04E
*BA03.10-
P-1001-01E
Anti-twist locks (8) for connecting rod bearing shells
(10) must be located in grooves (9) of connecting rod (2)
and connecting rod bearing cap (1).
Connecting rods have been cracked during
manufacture. The connecting rod bearing caps (1) are not
interchangeable and cannot be fitted laterally reversed.
Tighten connecting rod AR03.10-P-
23
bolts (7) 6111-02VA
*BA03.10-
P-1001-01E
Turn crankshaft by
hand and check for
24
unobstructed movement
of crank assembly
Install oil deflector AR03.10-P-
25
plate 7021-01SX
*BA18.10-
P-1006-01B
AR01.45-P-
26 Installing oil pan Vehicles with engine 272
7500SY
AR01.45-P-
Vehicles with engine 273 without 4MATIC
7500SX
AR01.45-P-
Vehicles with engine 273 and 4MATIC
7500SW
27 Install cylinder heads Right cylinder head 5800SY
AR01.30-P-
Left cylinder head
5800SX
Detach engine from
28
engine assembly stand
Attach transmission to AR27.10-P-
29 Vehicles without 4MATIC
engine 0500SX
AR27.10-P-
Vehicles with 4MATIC
0500SYZ
Fit engine to front axle AR01.10-P-
30 Vehicles with 4MATIC
carrier 2510SX
AR01.10-P-
Vehicles without 4MATIC
2510TW
Install engine with front AR01.10-P-
31 Vehicles without 4MATIC
axle carrier 2500SX
AR01.10-P-
Vehicles with 4MATIC
2500SW
TEST SPECIFICATIONS FOR CYLINDER BORE
Engine Engine
Number Designation 272.91/92/94/95 272.96/97/98/99
BE01.40-P- Cylinder dia. Stage X mm 88.000...88.015 92.900...92.915
1001-01I Stage mm 88.100...88.115 93.000...93.015
Repair stage mm 88.250...88.265 93.150...93.165
TEST SPECIFICATIONS FOR CYLINDER BORE
Number Designation Engine 273.92 Engine 273.96/97
BE01.40-P- Cylinder dia. Stage X mm 92.900...92.915 98.000...98.015
1001-01I Stage mm 93.000...93.015 98.100...98.115
Repair stage mm 93.150...93.165 98.250...98.265
TEST SPECIFICATIONS FOR PISTONS
Engine Engine
Number Designation 272.91/92/94/95 272.96/97/98/99 Engine 273.92
BE03.10-P- Piston Ø Standard mm mm 87.973...88.003 92.863...92.897 92.863...92.897
1001-02D identification X
Auxiliary stage mm 88.073...88.103 92.963...92.997 92.963...92.997
marking
Repair stage mm 88.223...88.253 93.113...93.147 93.113...93.147
BE03.10-P- Piston Standard mm mm 0.003...0.042 0.003...0.052 0.003...0.052
1002-02D clearance identification X
Auxiliary stage mm 0.003...0.042 0.003...0.052 0.003...0.052
marking
Repair stage mm 0.003...0.042 0.003...0.052 0.003...0.052
TEST SPECIFICATIONS FOR PISTONS
Number Designation Engine 273.96/97
BE03.10-P-1001- Piston Ø Standard mm identification X mm 97.973...98.007
02D Auxiliary stage marking mm 98.073...98.107
Repair stage mm 98.223...98.257
BE03.10-P-1002- Piston clearance Standard identification X mm 0.007 to 0.042
02D Auxiliary stage marking mm 0.007 to 0.042
Repair stage mm 0.007 to 0.042
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Number Designation Engine 272 Engine 273
BE03.10-P- Connecting rod Thread dia. M 8x1 8x1
1001-03A bolts Shank length New mm 39.5 39.5
max. mm 40.5 40.5
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 272 Engine 273
BE03.20-P-1002- Connecting rod Radial measurement mm 0.022...0.066 0.022...0.066
04E bearing play new
CONNECTING ROD
Number Designation Engine 272 Engine 273
BA03.10-P-1001- Connecting rod bolt Stage 1 Nm 5 5
01E Stage 2 Nm 20 25
Stage 3 Angle° 90 90
OIL PUMP
Number Designation Engine 272 Engine 273
BA18.10-P-1006- Bolt, oil baffle to crankcase Nm 9 9
01B
Fig. 25: Identifying Tensioning Strap (000 589 04 14 00)
Courtesy of MERCEDES-BENZ USA
MEASURE VERTICAL CLEARANCE OF PISTON RINGS - AR03.10-P-7311-01VA
CHECK VALUES FOR PISTON RINGS
Engine Engine
Number Designation 272.91/92/94/95 272.96/97/98/99
BE03.10-P- Piston ring vertical Groove 1 mm 0.03...0.08 0.02 to 0.07
1001-05D clearance Groove 2 mm 0.02 to 0.06 0.015 to 0.05
Groove 3 mm - -
CHECK VALUES FOR PISTON RINGS
Engine
Number Designation Engine 273.92 273.96/97
BE03.10-P-1001- Piston ring vertical Groove 1 mm 0.02 to 0.07 0.02 to 0.07
05D clearance Groove 2 mm 0.015 to 0.05 0.002 to 0.06
Groove 3 mm - -
1. Measure vertical clearance between compression ring and mounting groove in piston with a feeler gauge
for the compression ring concerned; replace compression ring or piston if necessary.
The vertical clearance of the oil scraper ring cannot be measured because of its three-part structure. The oil
scraper ring must be replaced along with the compression rings.
Fig. 26: Measuring Vertical Clearance Between Compression Ring And Mounting Groove Of Piston
Courtesy of MERCEDES-BENZ USA
MEASURE PISTON RING END GAP - AR03.10-P-7311-02VA
CHECK VALUES FOR PISTON RINGS
Engine Engine
Number Designation 272.91/92/94/95 272.96/97/98/99
BE03.10-P-1002- Piston ring end Groove 1 mm 0.2 to 0.35 0.2 to 0.35
05D gap Groove 2 mm 0.3...0.5 0.3...0.5
Groove 3 mm 0.2 to 0.9 0.2 to 0.9
CHECK VALUES FOR PISTON RINGS
Engine
Number Designation Engine 273.92 273.96/97
BE03.10-P-1002- Piston ring end gap Groove 1 mm 0.2 to 0.35 0.2 to 0.35
05D Groove 2 mm 0.3...0.5 0.3...0.5
Groove 3 mm 0.2 to 0.9 0.2 to 0.9
1. Clean the cylinder barrel.
2. Insert both compression rings one after the other above running surface in the cylinder bore, and measure
end gap with a feeler gauge; replace piston rings if necessary.
The end gap of the oil scraper ring cannot be measured because of its three-part structure. The oil scraper
ring must be replaced along with the compression rings.
Fig. 27: Measuring Piston Ring End Gap
Courtesy of MERCEDES-BENZ USA
REMOVE, INSTALL PISTON RINGS - AR03.10-P-7311VA
ENGINE 272, 273
Piston removed
Fig. 28: Removing/Installing Piston Ring
Courtesy of MERCEDES-BENZ USA
Removing
Using pliers, remove
1 compression rings (1, 2) Pliers Fig. 29
from piston (4)
Remove oil scraper ring (3) The oil scraper ring (3) is in three parts, and must
2
from piston (4) be removed by hand.
Install
Measure the width of the *BE03.10-P-
3
compression rings (1, 2) 1003-05D
Measure the end gap of AR03.10-P-
4
compression rings (1, 2) 7311-02VA
*BE03.10-P-
1002-05D
Using the pliers, fit the Note the installation position of compression
5 compression rings (1, 2) to rings (1, 2). The "Top" marking or manufacturer's
piston (4) designation must face towards the piston crown (5).
Pliers
Measure the vertical
AR03.10-P-
6 clearance of compression
7311-01VA
rings (1, 2)
*BE03.10-P-
1001-05D
Fit the oil scraper ring (3)
7
by hand
TEST VALUES FOR PISTON RINGS
Engine Engine
Number Designation 272.91/92/94/95 272.96/97/ 98/99
BE03.10-P-1001- Piston ring Groove 1 mm 0.03...0.08 0.02 to 0.07
05D vertical Groove 2 mm 0.02...0.06 0.015 to 0.05
clearance Groove 3 mm - -
BE03.10-P-1002- Piston ring Groove 1 mm 0.2 to 0.35 0.2 to 0.35
05D end gap Groove 2 mm 0.3...0.5 0.3...0.5
Groove 3 mm 0.2...0.9 0.2...0.9
BE03.10-P-1003- Dimension Plain compression ring mm 88.0x1.5x3.1 92.9x1.5x3.1
05D Taper-faced hook scraper mm 88.0x1.75x3.5 92.9x1.75x3.7
ring
Oil scraper ring mm 88.0x2.5x3.03 92.9x2.5x3.03
TEST VALUES FOR PISTON RINGS
Number Designation Engine 273.92 Engine 273.96/97
BE03.10-P- Piston ring Groove 1 mm 0.02 to 0.07 0.02 to 0.07
1001-05D vertical clearance Groove 2 mm 0.015 to 0.05 0.002 to 0.06
Groove 3 mm - -
BE03.10-P- Piston ring end Groove 1 mm 0.2 to 0.35 0.2 to 0.35
1002-05D gap Groove 2 mm 0.3...0.5 0.3...0.5
Groove 3 mm 0.2...0.9 0.2...0.9
BE03.10-P- Dimension Plain compression ring mm 92.9x1.5x3.1 98.0x1.2x3.1
1003-05D Taper-faced hook scraper mm 92.9x1.75x3.7 98.0x1.5x3.7
ring
Oil scraper ring mm 92.9x2.5x3.03 98.0x2.5x3.03
Fig. 29: Identifying Pliers (000 589 51 37 00)
Courtesy of MERCEDES-BENZ USA
INSTALL FRONT CRANKSHAFT RADIAL SEAL - AR03.20-P-3000-01B
Fig. 30: Identifying Sleeve (119 589 01 14 00)
Courtesy of MERCEDES-BENZ USA
1. Deburr edge of mounting bore for crankshaft radial sealing ring at timing case cover.
2. Push the crankshaft radial sealing ring onto the side (a) of the sleeve (2).
Circumference and sealing lip of crankshaft radial seal as well as the mating contact surface on the
vibration damper must be free of oil and grease.
Fig. 31: Identifying Crankshaft Radial Sealing Ring Side Of Sleeve
Courtesy of MERCEDES-BENZ USA
3. Align groove of sleeve (2) to the Woodruff key of the crankshaft.
Turn to ensure that the slot in the sleeve (2) is aligned with the Woodruff key in the crankshaft.
4. Push sleeve (2) onto crankshaft and press in crankshaft radial sealing about 2 mm.
If necessary, knock in sleeve (2) with light blows from a hammer until it is possible to insert
the central bolt (3).
5. Draw in sleeve (2) with central bolt (3) as far as the stop.
The crankshaft radial sealing ring must be positioned at right angles to the crank journal otherwise
proper sealing is not assured.
Fig. 32: Identifying Sleeve And Central Bolt
Courtesy of MERCEDES-BENZ USA
Shown on engine 112
Repair size 1 is identified by a 3 mm wide shoulder on the contact surface.
7. Turn sleeve (2) and push onto the crankshaft with side of repair size 1 (b).
Turn to ensure that the slot in the sleeve (2) is aligned with the Woodruff key in the crankshaft.
8. Draw in sleeve (2) with central bolt (3) as far as the stop.
9. Detach sleeve (2).
Shown on engine 112
Fig. 33: Identifying Sleeve With Central Bolt - Engine 112
10. Check installation location of the crankshaft radial sealing ring (1) to the crankpin (4).
The crankshaft radial sealing ring (1) must be positioned at right angles to the crank journal (4)
otherwise proper sealing is not assured.
The installation depth (B) of the crankshaft radial sealing ring (1) is preset through the sleeve
(2) and must not be altered subsequently.
Shown on engine 112
Fig. 34: Identifying Depth Of Crankshaft Radial Sealing Ring
Courtesy of MERCEDES-BENZ USA
REPLACE FRONT CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3000MC
ENGINE 275
Fig. 35: Identifying Belt Pulley/Vibration Damper, Crankshaft Radial Seal And Poly-V Belt
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
support points specified by vehicle
manufacturer.
AR01.10-P-
Engine 275.95
2405LA
1 Remove engine cover (1) front section
AR01.10-P-
Engine 275.98
2405IM
Model 215, 220 except 215.379,
AR20.40-P-
220.179
6800AC
Model 230
AR20.40-P-
Model 215.379, 220.179
2 Remove fan shroud 6800IM
Model 216, 221 except 216.379, AR20.40-P-
221.179 6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
3 Attach guard plate for radiator / condenser
WF58.50-P-
Radiator guard plate/ condenser
0110-01A
AR13.22-P-
Model 215, 220, 230
1202L
4 Remove poly-V belt (2)
AR13.20-P-
Model 216, 221
0001SZ
AR03.30-P-
5 Remove belt pulley/vibration damper (3)
1600L
Do not damage crankshaft and
mounting hole for crankshaft AR03.20-P-
6 Remove crankshaft radial sealing ring (4) radial seal (4). Use a clean cloth as 3000-01B
a base.
Fig. 30
7 Install in the reverse order
Risk of accident caused by vehicle starting off Secure vehicle to prevent it from
by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting work
0005-01A
starting procedure or when working near the clothes.
engine as it is running Do not touch hot or rotating parts.
Determine oil leakage after
spraying the cleaned and dried
8 Check for leaks with engine running
surrounding area with MB contrast
spray.
*BR00.45-
Crack detector
Z-1001-03A
Fig. 36: Identifying Sleeve (119 589 01 14 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-03A Crack detector A 000 989 03 59
REPLACE FRONT CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3000SMG
ENGINE 156 in MODEL 216, 221
Fig. 37: Locating Crankshaft Radial Seal
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of death caused by vehicle slipping or Align vehicle between columns of AS00.00-Z-
toppling off the lifting platform. vehicle lift and position four support 0010-01A
specified by vehicle manufacturer.
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk lids, clear of moving parts. 0011-01A
tailgates or sliding roof.
1 Open engine hood
2 Remove left and right intake air duct
Do not tilt front engine cover,
3 Remove front engine cover but lift upwards vertically otherwise
retaining lugs can break off.
AR20.40-P-
4 Remove electric fan
5000SMG
5 Attach guard plate for radiator / condenser
WF58.50-P-
Guard plate for radiator / condenser
0110-01A
AR13.22-P-
6 Remove poly-V belt
1202SMG
AR03.30-P-
7 Remove belt pulley/vibration damper
1600SMG
Do not damage crankshaft and
mounting hole for crankshaft radial
seal. Use a clean cloth as a base.
Use a screwdriver to press out
8 Remove crankshaft radial sealing ring (4) crankshaft radial sealing ring (4)
Installation: install crankshaft AR03.20-P-
radial sealing ring (4) with sleeve. 3000-01B
Sleeve Fig. 30
9 Install in the reverse order
Vehicle must be horizontal and
standing on its wheels. Measuring
errors can occur if this requirement
10 Check engine oil level and correct if required. is not observed.
Insert dipstick fully in dipstick
guide tube and leave for at least 3
seconds.
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running.Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting work
0005-01A
starting procedure or when working near the clothes.
engine as it is running Do not touch hot or rotating parts.
In the event of oil loss determine
and eliminate cause, otherwise
malfunctions, transmission damage,
may occur.
Determine oil leakage after
Conduct engine test run and check the engine spraying the cleaned and dried *BR00.45-
11
for oil leaks surrounding area with MB contrast Z-1001-03A
spray.
MB contrast spray
Fig. 38: Identifying Sleeve (119 589 01 14 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1001-03A MB contrast spray 000 989 03 59
REPLACE FRONT CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3000SX
ENGINE 273 in MODEL 216
ENGINE 272, 273 in MODEL 221
Fig. 39: Identifying Belt Pulley/Vibration Damper And Crankshaft Radial Seal
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove belt AR03.30-P-1600SX
pulley/vibration damper
(2)
2 Press out crankshaft radial Do not damage
sealing ring (5) from the crankshaft and mounting
mounting bore using a bore. Use a clean rag as a
screwdriver base while pressing out;
otherwise there can be
leakage.
Installation: Install AR03.20-P-3000-01B
front crankshaft radial
sealing ring (5).
Fig. 30
Checking
3 Check contact surface of The belt
crankshaft radial sealing pulley/vibration damper
ring (5) at hub of belt (2) must be replaced if
pulley/vibration damper there are score marks and
(2) galling.
4 Install in the reverse order
5 Check engine oil level;
correct if necessary
Engine oil and filter AP18.00-P-0101SX
change
Risk of accident caused Secure vehicle to prevent AS00.00-Z-0005-01A
by vehicle starting off by it from moving by itself.
itself when engine is Wear closed and snug-
running. Risk of injury fitting work clothes. Do
caused by contusions and not touch hot or rotating
burns during starting parts.
procedure or when
working near the engine
as it is running
6 Carry out an engine test
run and check engine for
leaks
Fig. 40: Identifying Sleeve (119 589 01 14 00)
Courtesy of MERCEDES-BENZ USA
INSTALLING REAR CRANKSHAFT RADIAL SEAL - AR03.20-P-3063-01AMG
Engine 156
Fig. 41: Identifying Installation Tool (111 589 08 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 42: Identifying Installation Tool, Shim, Bore And Bore Holes
Courtesy of MERCEDES-BENZ USA
Fig. 43: Identifying Installation Tool, Bore And Bore Holes
Courtesy of MERCEDES-BENZ USA
Fig. 44: Identifying Bore And Center-Punch Bore
Courtesy of MERCEDES-BENZ USA
1.1 For an installation tool (111) without bore (111B): Place shim (3s ) as a template and align
bore holes (3s S) to bore holes (111S) to have one above the other.
2.1 For an installation tool (111) without bore (111B): Select template bore hole (3B) and center-
punch bore (111B), remove shim (3s ).
3.1 For an installation tool (111) without bore (111B): Fix to bore (111B) with the diameter of the
template bore hole (3B).
Fig. 45: Identifying Crankshaft Radial Seal, Press-In Bushing Screw, Crankshaft Flange And
Press-In Sleeve
Courtesy of MERCEDES-BENZ USA
4 Check edge for mounting hole on engine for ridging; deburr if necessary.
5 Lightly wet sealing lip and outer flank of crankshaft radial sealing ring (1) with oil.
6 Carefully push crankshaft radial sealing ring (1) onto crankshaft flange (3) contact surface and push
lightly into mounting hole.
7 Screw guide sleeve 03 (111F) for installation tool onto crankshaft flange (3).
8 Place press-in bushing (111) of installation tool onto crankshaft radial sealing ring (1) and screw
onto guide sleeve 03 (111F).
9 Press in crankshaft radial sealing ring (1) by turning press-in bushing screw (2) in mounting hole.
10 Loosen press-in bushing screw (2).
Check for correct installation position of crankshaft radial sealing ring (1) in the process.
A wrong installation position leads to leakage.
The protrusion of the edge of the mounting hole to crankshaft radial sealing ring (1) must be about 1
mm.
11.1 If the protrusion of the edge of the mounting hole to crankshaft radial sealing ring (1) is less than 1
mm: proceed with pressing in procedure.
12 Detach the mounting tool.
INSTALLING REAR CRANKSHAFT RADIAL SEAL - AR03.20-P-3063-01B
Fig. 46: Identifying Installation Tool (111 589 08 43 00)
Courtesy of MERCEDES-BENZ USA
1. Deburr edge of mounting hole around entire circumference for rear crankshaft radial sealing ring (4) and
clean mounting hole (arrow).
2. Fit internal component (1) of installation tool to crankshaft.
Fig. 47: Identifying Internal Component Of Installation Tool On Crankshaft
Courtesy of MERCEDES-BENZ USA
3. Carefully push rear crankshaft radial sealing ring (4) over the internal component (1) of the
installation tool and the crankshaft journal.
Ensure that the sealing lip (6) of the rear crankshaft radial sealing ring (4) is not damaged or
compressed.
Circumference (5) and sealing lip (6) of the rear crankshaft radial sealing ring (4) as well as the mating
contact surface on the crankshaft must be free of oil and grease.
Fig. 48: Identifying Rear Crankshaft Radial Sealing Ring
Courtesy of MERCEDES-BENZ USA
4. Position the outer part (2) of the mounting tool.
Use outer part (2) with chamfer.
5. Screw in bolt (3) until a resistance is felt.
6. Detach the mounting tool.
Fig. 49: Identifying Outer Part Of Mounting Tool And Bolt
Courtesy of MERCEDES-BENZ USA
7. Check installation location of the crankshaft rear radial sealing ring (4).
The rear crankshaft radial sealing ring (4) must be positioned at right angles to the crankshaft (7) otherwise
proper sealing is not assured.
The clearance between the edge of the end cover (8) and the rear crankshaft radial sealing ring (4) must be
approx. 1 mm (dimension a) around the entire circumference.
Fig. 50: Identifying Crankshaft Rear Radial Sealing Ring And End Cover
Courtesy of MERCEDES-BENZ USA
INSTALLING REAR CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3063-01SX
ENGINE 273
MODIFICATION NOTES
15.2.10 Diameter of the crankshaft flange altered - added BT03.20-P-0003-01A
CRANKCASE, TIMING CASE COVER, END COVER
Number Designation Engine 273
BA01.40-P-1003-01T Bolt, end cover to crankcase or oil pan Nm 9
Fig. 51: Identifying Insertion Tool (271 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 52: Identifying Insertion Tool (273 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 53: Identifying Squeeze Gun (112 589 00 25 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
Adolf Wurth GmbH & Co. KG
Reinhold-Wurth-Str. 12-17
74653 Kunzelsau-Gaisbach
BR00.45-Z-1028-04A Cleaner from package Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
BR00.45-Z-1038-04A Loctite 7200 Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
The crankshaft radial sealing ring (1) is vulcanized into the end cover (2) and can only, therefore, be
replaced together with the end cover (2). Do not reuse the end cover (2) with the rear crankshaft radial sealing
ring (1) after removal.
The crankshaft radial sealing ring (1) has a protective lip (1s) in addition to the sealing lip (1d). The sealing lip
(1d), protective lip (1s) and contact surface (3a) at the crankshaft flange (3) must not be lubricated for
assembly!
Fig. 54: Identifying Crankshaft Radial Sealing Ring, End Cover And Sealing Lip
Courtesy of MERCEDES-BENZ USA
1. Clean and degrease crankcase (4) and oil pan in the area of the applied sealant as well as contact
surface (3a) on the flange (3).
2. Clean and degrease sealing surface of new end cover (2).
3. Apply sealant with the squeeze gun in the form of a bead (A) with a height and width of 2.0 mm
(±0.5) mm to crankcase (4) and oil pan.
Use exclusively approved sealants. Do not spread bead (A). Mount end cover (2) within 5 minutes
after applying sealant.
The contact surface (3a) must not be cleaned using abrasive paper since this would damage the surface
of the crankshaft. crankshaft.
Fig. 55: Identifying Sealant Application Area Of Crankcase
Courtesy of MERCEDES-BENZ USA
4. Mount end cover (2) with crankshaft radial sealing ring (1) on insertion tool (6).
Make sure that the protective lip (1s) faces towards the side applying the force and the sealing lip (1d)
faces in the direction of the crankcase. Leakage could occur otherwise at rear crankshaft radial sealing
ring (1).
The crankshaft radial sealing ring (1) can only be mounted on the insertion tool (6), if
insertion tool (6) is fitted together with insertion tool (7).
Special tool:
Insertion tool 271 589 00 43 00
Engine 273.92 up to engine end no. 300193, 273.96 /97 up to engine end no. 300345.
Insertion tool 273 589 00 43 00
Engine 273.92 as of engine end no. 300194, 273.96 /97 as of engine end no. 300346.
Fig. 56: Identifying Crankshaft Radial Sealing Ring On Insertion Tools
Courtesy of MERCEDES-BENZ USA
5. Separate insertion tool (7) from insertion tool (6).
6. Mount end cover (2) with crankshaft radial shaft sealing ring (1) and insertion tool (6) onto
contact surface (3a) on crankshaft flange (3).
Fig. 57: Identifying Crankshaft Radial Sealing Ring And Insertion Tools
Courtesy of MERCEDES-BENZ USA
7. Tighten bolts (2a) gradually in crosswise pattern, then tighten the bolts (2b) - observe tightening torque.
8. Detach insertion tool (6) from crankshaft flange (3).
Fig. 58: Checking Position Of Sealing Lip
Courtesy of MERCEDES-BENZ USA
9. Carefully lift protective lip (1s) and check the correct 10 installation position of sealing lip (1d).
A wrong installation position leads to leakage.
The sealing lip (1d) must point towards crankcase (4) all around its circumference.
10. Check for correct installation position of the protective lip (1s).
An incorrect installation position leads to premature wear of crankshaft radial sealing ring (1).
The protective lip (1s) must point towards transmission housing around its entire circumference.
REPLACE REAR CRANKSHAFT RADIAL SEAL - AR03.20-P-3063MC
ENGINE 275 in MODEL 215, 216, 220, 221
Fig. 59: Identifying Crankshaft Radial Seal, Drive Plate And End Cover
Courtesy of MERCEDES-BENZ USA
Remove/install
AR27.10-P-
Model 215, 220
Remove automatic 0500I
1
transmission AR27.10-P-
Model 216, 221
0500SZ
AR03.30-P-
2 Remove drive plate (1)
8001MC
Remove the end cover AR01.40-P-
3
(2) 8913MC
The rear crankshaft radial sealing ring (3) must
taken off.
Remove rear crankshaft Installation: First install end cover (2) and then
4
radial seal (3) install crankshaft radial sealing ring (3):?
AR03.20-P-
Install crankshaft radial seal
3063-01B
Install in the reverse
5 Before installing transmission, inspect for oil leaks
order
REPLACE REAR CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3063SMG
ENGINE 156 in MODEL 216, 221
Fig. 60: Identifying Crankshaft Radial Sealing Ring Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
support points specified by
vehicle manufacturer.
AH00.00-N-
Notes on self-locking nuts and bolts All models
0001-01A
1 Raise vehicle with lifting platform
2 Remove automatic transmission 0500SX
Clean and degrease sealing
Install retaining lock for crankshaft/starter ring surfaces on crankshaft radial AR03.30-P-
3
gear sealing ring (1) and mounting 5000SMG
hole.
*BA03.30-P-
4 Remove bolts (4) from drive plate (2)
1002-01Q
Do not damage sealing AR03.20-P-
Remove crankshaft radial sealing ring (1) surfaces on crankshaft radial 3063-
5 sealing ring (1) and crankshaft (3). 01AMG
using a suitable tool.
Installation tool Fig. 41
6 Install in the reverse order
Risk of accident caused by vehicle starting off Secure vehicle to prevent it from
by itself when engine is running. Risk of injury moving by itself.
AS00.00-Z-
caused by contusions and burns during starting Wear closed and snug-fitting work
0005-01A
procedure or when working near the engine as clothes.
it is running Do not touch hot or rotating parts.
Conduct engine test run and check engine for
7
leaks
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 156
Stage 1 Nm 20
BA03.30-P-1002-01Q Bolt, starter ring gear/drive plate to crankshaft Stage 2 Nm 45
Stage 3 Angle° 90
Fig. 61: Identifying Installation Tool (111 589 08 43 00)
Courtesy of MERCEDES-BENZ USA
REPLACE REAR CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3063SX
ENGINES 273 in MODEL 216
ENGINES 272, 273 (except 272.974) in MODEL 221
Shown on engine 273.961
Fig. 62: Identifying Rear Crankshaft Radial Sealing Ring Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
10.3.10 Diameter of the crankshaft flange altered - added BT03.20-P-0003-01A
Removing
AR03.30-P-
1 Remove driven plate
8001SX
Clean
Clean crankcase (2) and oil pan (3) in area of *BR00.45-Z-
2 Cleaner from package
the end cover (4) 1028-04A
3 Remove bolts (4a, 4b)
Do not hit tool for prying off
between end cover (4) and crankcase
(2); the sealing surface will be
Pry off end cover (4) with crankshaft radial damaged.
4
sealing ring (5) from crankcase (2) Fit tool for prying off onto side
recess clearances of end cover (4). If
required heat up sealant with hot air
gun.
5 Remove end cover (4)
Clean
Do not use any sharp-edged tools AR01.00-P-
or abrasive paper as this will damage 0050-01A
*BR00.45-Z-
Loctite 7200
1038-04A
6 Clean sealing surfaces for end cover (4)
Cleaning spray, Loctite 7063 *BR00.45-Z-
(150ml) 1046-04A
Install
It is essential to observe notes
Install end cover (4) with crankshaft radial concerning applying sealant and the
7
sealing ring (5) correct installation position of lips of
the crankshaft radial sealing ring (5).
Engine 273.92# ## as of 300194, BT03.20-P-
273.96# /97# ## as of 300346 0003-01A
AR03.20-P-
Engine 272
3063-01VA
AR03.20-P-
Engine 273
3063-01SX
*BA01.40-P-
Engine 272 1004-01G
*BA01.40-P-
Engine 273 1003-01T
Insertion tool (engine 272,
Diameter of the crankshaft flange altered 273.92 up to engine end no. 300193,
273.96 /97 up to engine end no. Fig. 51
300345 with crankshaft flange Ø =
93 mm)
Insertion tool (engine 273.92
as of engine end no. 300194,
273.96 /97 as of engine end no. Fig. 52
300346 with crankshaft flange Ø =
96 mm)
Squeeze gun Fig. 20
*BR00.45-Z-
Loctite 5970 sealant
1013-01A
AR03.30-P-
8 Install drive plate
8001SX
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns Wear closed and snug-fitting work
0005-01A
during starting procedure or when working clothes. Do not touch hot or rotating
near the engine as it is running parts.
Carry out an engine test run and check
9
engine for leaks
CRANKCASE, TIMING CASE COVER, END COVER
Number Designation Engine 272
BA01.40-P-1004-01G Bolt, end cover to crankcase or oil pan Nm 8
CRANKCASE, TIMING CASE COVER, END COVER
Number Designation Engine 273
BA01.40-P-1003-01T Bolt, end cover to crankcase or oil pan Nm 9
Fig. 63: Identifying Insertion Tool (271 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 64: Identifying Insertion Tool (273 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 65: Identifying Squeeze Gun (112 589 00 25 00)
Courtesy of MERCEDES-BENZ USA
Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
Adolf Wurth GmbH & Co. KG
Reinhold-Wurth-Str. 12-17
74653 Kunzelsau-Gaisbach
BR00.45-Z-1028-04A Cleaner from package Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
BR00.45-Z-1038-04A Loctite 7200 Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-1046-04A Cleaning spray, Loctite 7063 (150ml) A 001 986 71 71 10
DETERMINE CRANKSHAFT BEARING AXIAL PLAY - AR03.20-P-4291-03SX
ENGINE 273
MODIFICATION NOTES
18.2.08 SWZ (136 589 04 21 00) removed and replaced by SWZ (363 589 02 21 00)
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 273
BE03.20-P-1001- Main bearing play Radial measurement new mm 0.022...0.046
04E Axial measurement when new mm 0.100 to 0.266
Fig. 66: Identifying Dial Indicator (001 589 32 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 67: Identifying Extension (366 589 00 21 05)
Courtesy of MERCEDES-BENZ USA
Fig. 68: Identifying Dial Indicator Holder (363 589 02 21 00)
Courtesy of MERCEDES-BENZ USA
Only the one washer disc thickness is used.
1. Install dial indicator (2) with dial indicator holder (1)
2. Using a suitable tool, press the crankshaft axially on one side up to the attachment and hold it.
3. Set scale of dial gage (2) to zero.
4. Using a suitable tool, press the crankshaft axially on the other side up to the attachment and hold it.
5. Read off measurement value at dial indicator (2).
The measured value corresponds to the axial play of the crankshaft.
Fig. 69: Measuring Crankshaft Axial Play
Courtesy of MERCEDES-BENZ USA
INSTALL/GAUGE CRANKSHAFT BEARINGS - AR03.20-P-4341-01AMG
ENGINE 156, 159
MODIFICATION NOTES
14.9.09 Value changed: Main bearing play, radial - new value *BE03.20-P-1001-04E
Value changed: Main bearing play, axial - new value *BE03.20-P-1001-04E
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 156 Engine 159
Radial measurement new mm 0.022 to 0.041 0.020 to 0.042
BE03.20-P-1001-04E Main bearing play
Axial measurement when new mm 0.15 to 0.316 0.15 to 0.316
INSPECTION DATA OF CRANKSHAFT MAIN BEARING SHELLS
Engine Engine
Number Designation
156 159
Replacement part additional
Main bearing shells standard number colored marking blue 52 52
BE03.20-P- dimension for crankcase and (b)=1
1001-03J bearing cap(s)
ø 67, 950/67, 966 mm 2.255 to 2.265 to
Bearing shell thickness mm
2.259 2.269
Replacement part additional
Main bearing shells standard number colored marking yellow 54 54
BE03.20-P- dimension for crankcase and (y)=2
1002-03J bearing cap(s)
ø 67, 950/67, 966 mm 2.259 to 2.269 to
Bearing shell thickness mm
2.263 2.273
Replacement part additional
BE03.20-P- Main bearing shells standard number colored marking red (r) 56 56
1003-03J dimension for crankcase and =3
ø 67, 950/67, 966 mm 2.263 to 2.273 to
Bearing shell thickness mm
2.267 2.277
Replacement part additional
Main bearing shell standard number (color coding green (g) 59 59
BE03.20-P- =4
dimension for bearing cap
1004-03J
ø 67, 950/67, 966 mm 2.267 to 2.277 to
Bearing shell thickness mm
2.271 2.281
CHECK VALUES FOR CRANKSHAFT
Number Designation Engine 156 Engine 159
67.950 to 67.950 to
Nominal dia. mm
67.965 67.965
1st repair 67.962 to 67.962 to
Blue (B) mm
stage 67.965 67.965
BE03.20-P-1001- Repair stage Yellow 67.958 to 67.958 to
Crankshaft journal dia. mm
02I 2 (y) 67.962 67.962
Repair stage 67.954 to 67.954 to
Red (R) mm
3 67.958 67.958
Repair stage 67.950 to 67.950 to
Green (g) mm
4 67.954 67.954
27.900 to 27.900 to
Marking N/0 mm
BE03.20-P-1002- Crankshaft journal width at fit 29.933 29.933
02I bearing 28.000 to
Marking N1/1 mm -
28.033
CRANKSHAFT BEARING CAP
Engine
Number Designation
156
Stage
Nm 20
1
Stage
Nm 32
2
Stage
Angle° 90
3
Stage
Angle° 90
4
M9
Stage
Releasing
5
Stage
Nm 20
6
Stage
Nm 32
7
Stage
Angle° 90
8
Stage
Angle° 90
9
Stage
Nm 20
1
Stage
Nm 40
2
Stage
Angle° 90
3
Stage
Angle° 90
BA03.20-P- Crankshaft bearing cap bolt (lower section of crankcase/ 4
1001-01J main bearing threaded connection) Stage
M10 Releasing
5
Stage
Nm 20
6
Stage
Nm 40
7
Stage
Angle° 90
8
Stage
Angle° 90
9
BA03.20-P- M6 Nm 8.5
Crankcase lower section on crankcase upper section
1002-01J M8 Nm 20
CRANKSHAFT BEARING CAP
Number Designation Engine 159
BA03.20-P- Crankshaft M9 Stage 1 Nm 20
1001-01L bearing cap bolt Stage 2 Nm 32
(lower section of Stage 3 Angle° 90
crankcase/main
Stage 4 Angle° 90
bearing threaded
connection) Stage 5 Releasing
Stage 6 Nm 20
Stage 7 Nm 32
Stage 8 Angle° 90
Stage 9 Angle° 90
M10 Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 Angle° 90
Stage 4 Angle° 90
Stage 5 Releasing
Stage 6 Nm 20
Stage 7 Nm 40
Stage 8 Angle° 90
Stage 9 Angle° 90
BA03.20-P- Crankcase lower M6x40 1st stage Nm 10
1002-01L section on M8x30 Stage 2 Angle° 90
crankcase upper M8x40 Stage 3 Angle° 10
section
M8x65 Stage 1 Nm 10
Stage 2 Angle° 180
Stage 3 Angle° 10
1. Blow out oil ducts with compressed air.
2. Clean bearing points in cylinder crankcase upper section, main bearing cap or cylinder crankcase lower
section and main bearing journal on crankshaft with chamois leather.
If a bearing damage has occurred, it may be necessary to remove any swarf from the connecting rod
bores, oil ducts on the crankshaft as well as the crankcase! Do not use any hard objects for cleaning.
Assignment of the upper bearing shell halves to the basic journal of the crankshaft occurs via color
markings on the rear side of the upper bearing shell halves and numbers on the upper cylinder crankcase
(see picture).
Only the assigned letter and number combinations should be fitted together.
Fig. 70: View Of Upper Cylinder Crankcase
Courtesy of MERCEDES-BENZ USA
Example: assignment of the upper bearing shells halves
Assignment of the upper bearing shell halves takes place from the power take-off to the control side of
the engine.
Fig. 71: Identifying Crankcase Top Section And Cylinder Crankcase Lower Section
Courtesy of MERCEDES-BENZ USA
First number "1": A bearing shell halve with the color coding blue must be inserted in the bearing
cap '1'.
Second number "2": A bearing shell halve with the color coding yellow must be inserted in the
bearing cap '2'.
Third number "2": A bearing shell halve with the color coding yellow must be inserted in the
bearing cap '3'.
Fourth number "2": A bearing shell halve with the color coding yellow must be inserted in the
bearing cap '4'.
Fifth number "1": A bearing shell halve with the color coding blue must be inserted in the bearing
cap '5'.
The bottom halves of the bearing shells (15) are assigned to the basic journal of the crankshaft by
means of the first letter of the respective color.
The color coding of the bottom halves of the bearing shells is located at the rear of the lower bearing shell
halves.
The initial letters of the particular colors are engraved on the journal of the crankshaft (15).
When installing the lower bearing shell halves the order of the colors engraved on the journal of the
crankshaft (15) must be observed.
Example: Assignment of the upper bearing shells halves
Y = YELLOW
R = RED
Y = YELLOW
R = RED
Y = YELLOW
Fig. 72: Identifying Crankcase Top Section, Crankshaft And Intermediate Gear Bearing
Sleeve
Courtesy of MERCEDES-BENZ USA
3. Insert upper bearing shell halves (1) with the oil holes (2) and the oil grooves (3) in the cylinder
crankcase upper section (7).
Ensure that the anti-twist locks (4) on the upper crankshaft bearing shell halves (1) are seated in the
cutouts of the cylinder crankcase upper section (7)
4. Insert lower bearing shell halves into bearing cap or cylinder crankcase lower section (8).
Ensure that the anti-twist locks on the lower bearing shell halves are seated in the recesses for the
bearing cap or the cylinder crankcase lower section (8).
Fig. 73: Identifying Cylinder Crankcase Upper Section Components
Courtesy of MERCEDES-BENZ USA
5. Insert crankcase (15) into cylinder crankcase upper section (7).
6. Install upper thrust plates.
The oil grooves on the thrust plates must point to the crank webs.
7.1 Engine 156: Install bearing cap according to marking.
Installation: When installing the fitted bearing cap firmly hold both thrust plates. The anti-twist locks
on the thrust plates must sit in the slots on the fitted bearing cap. The oil grooves on the thrust plates must
point to the crank webs.
7.2 Engine 159: Install cylinder crankcase lower section (8)
Installation: When installing cylinder crankcase lower section (8), hold both thrust plates. The anti-
twist locks on the thrust plates should be seated in the grooves. The oil grooves on the thrust plates must
point to the crank webs.
8 Moisten bolts on bearing cap or cylinder crankcase bottom section (8) on thread and bolt head contact
surface with oil.
9 Tighten bolts according to tightening procedure.
Observe torque and tightening angle of bolts.
10 Turn crankshaft (15) to check for unobstructed movement.
TIGHTENING PROCEDURE FOR CRANKSHAFT BEARING CAPS - AR03.20-P-4351-02SX
ENGINE 273
CRANKSHAFT BEARING CAP
Number Designation Engine 273
BA03.20-P-1001- Bolt for crankshaft bearing cap M8 Stage 1 Nm 20
01D Stage 2 Angle° 90
BA03.20-P-1002- Side crankshaft bearing cap bolt M8 Stage 1 Nm 20
01D Stage 2 Angle° 90
BA03.20-P-1003- Bolt for crankshaft bearing cap M10 Stage 1 Nm 5
01D Stage 2 Nm 30
Stage 3 Angle° 90
Lubricate bolts (1 to 30) of crankshaft bearing cap and the crankshaft fitted bearing cap on thread and bolt
head contact surface.
1. Tighten bolts (1 to 30) in the numbering sequence.
The arrow indicates the direction of travel.
If no torquing angle wrench is available at the final tightening stage, the bolts can be turned further
using a socket wrench and locking handle all in a single operation. Do not use a flexi-rod torque wrench
for tightening in order to avoid any angle errors.
To loosen the bolts (1 to 30), proceed in reverse order.
Fig. 74: Identifying Crankshaft Bearing Cap Bolt Tightening Sequence
Courtesy of MERCEDES-BENZ USA
TIGHTENING PROCEDURE FOR CRANKCASE BOTTOM SECTION - AR03.20-P-4351-05AMG
ENGINE 156
CRANKSHAFT BEARING CAP
Number Designation Engine 156
BA03.20-P- Crankshaft bearing cap bolt M9 Stage 1 Nm 20
1001-01J (lower section of crankcase/ Stage 2 Nm 32
main bearing threaded Stage 3 Angle° 90
connection)
Stage 4 Angle° 90
Stage 5 Releasing
Stage 6 Nm 20
Stage 7 Nm 32
Stage 8 Angle° 90
Stage 9 Angle° 90
M10 Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 Angle° 90
Stage 4 Angle° 90
Stage 5 Releasing
Stage 6 Nm 20
Stage 7 Nm 40
Stage 8 Angle° 90
Stage 9 Angle° 90
1. Oil bolts of bearing caps on threads and bolt head contact surfaces.
Always replace bolts.
2. Tighten bolts of bearing caps.
Observe tightening specification and tightening torque.
If an angle tightener is not available, continue turning bolts with a socket wrench and breaker bar by the
specified angle in one pull. Do not use a flexi-rod torque wrench for tightening in order to avoid any angle
errors.
Tightening procedure for lower crankcase section
Fig. 75: Identifying Bearing Caps Tightening Sequence
Courtesy of MERCEDES-BENZ USA
Tightening specification Stage (per bolt)
1 Alternate pre-tightening of bolts Stage 1
2 Alternate continued tightening of bolts Stage 2
3 Alternate angle of rotation tightening of Stage 3
bolts
4 Alternate angle of rotation tightening of Stage 4
bolts
5 Alternate loosening of bolts Stage 5
6 Alternate pre-tightening of bolts Stage 6
7 Alternate continued tightening of bolts Stage 7
8 Alternate angle of rotation tightening of Stage 8
bolts
9 Alternate angle of rotation tightening of Stage 9
bolts
TIGHTENING PROCEDURE FOR CRANKCASE BOTTOM SECTION - AR03.20-P-4351-05L
ENGINE 137.970, 275
CRANKCASE, TIMING CASE COVER, END COVER
Engine 275,
Number Designation Engine 137 285
BA01.40-P- Bolt, crankcase bottom 1-14 M10 Stage 1 Nm 40 40
1008-01C section to top part Stage 2 Angle° 90 90
15-28 M8 Stage 1 Nm 12 12
Stage 2 Angle° 90 90
Stage 3 Angle° 90 90
29-54 M6 Stage 1 Nm 8 8
Stage 2 Angle° - -
55-61 M8 Stage 1 Nm 20 20
Stage 2 Angle° - -
See - -
picture
Fig. 76: Bolt Assignment Of Crankcase Bottom Section
Courtesy of MERCEDES-BENZ USA
Bolt assignment
Attach bolts by hand and tighten slightly e.g. with a battery-operated screwdriver
Inner and center threaded connection:
1. Tighten bolts 1 to 14 according to tightening stage 1, starting with bolt 1.
2. Drive in dowel pins.
3. Tighten bolts 15 to 28 according to tightening stage 1, starting with bolt 15.
4. Tighten bolts 1 to 14 according to tightening stage 2, starting with bolt 1.
5. Tighten bolts 15 to 28 according to tightening stage 2, starting with bolt 15.
6. Tighten bolts 15 to 28 according to tightening stage 3, starting with bolt 15.
External threaded connection:
7. Tighten bolts 29 to 35 starting with bolt 29.
8. Tighten bolts 36 to 39 starting with bolt 36.
9. Tighten bolts 40 to 54 starting with bolt 40.
10. Tighten bolts 55 and 56, starting with bolt 55
11. Tighten bolts 57 and 61, starting with bolt 57
REMOVE/INSTALL CRANKSHAFT - AR03.20-P-4351AMG
ENGINES 156.980 /981 /982 /983 /984 /985
Fig. 77: Identifying Crankshaft Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 78: Identifying Crankshaft Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of vehicle
Risk of death caused by vehicle
lift and position four support plates at AS00.00-Z-
slipping or toppling off of the lifting
vehicle lift support points specified by 0010-01A
platform.
vehicle manufacturer.
Do not open cooling system unless coolant
caused by scalding from contact with and release the pressure. Do not pour coolant
hot coolant spray. Risk of poisoning into beverage containers. AS20.00-Z-
caused by swallowing coolant. Wear protective gloves, protective clothing 0001-01A
and safety glasses.
Risk of explosion caused by fuel No fire, sparks, open flames or smoking.
igniting, risk of poisoning caused by Pour fuels only into suitable and
AS47.00-Z-
inhaling and swallowing fuel and appropriately marked containers.
0001-01A
risk of injury to eyes and skin Wear protective clothing when handling
caused by contact with fuel fuel.
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
Remove engine with front axle AR01.10-P-
1.1 Model 164, 251
carrier 2500GZS
AR01.10-P-
Model 204
2400CMG
AR01.10-P-
Model 209
2400QMG
AR01.10-P-
1.2 Remove engine Model 211, 219
2400TMG
AR01.10-P-
Model 216, 221
2400SMG
AR01.10-P-
Model 230
2400RMG
AR01.10-P-
2 Detach engine from front axle carrier Model 164, 251
2510GZS
3 Detach transmission from engine
Remove oil lines from automatic
4
transmission at oil pan
5 Mount engine onto assembly stand
Only if it is not possible to crank engine
due to high compression.
AR15.12-P-
Model 164, 251
1010GZS
AR15.12-P-
Model 204
1010CMG
6 Remove spark plugs
AR15.12-P-
Model 209, 211, 219
1010TMG
AR15.12-P-
Model 216, 221
1010SMG
AR15.12-P-
Model 230
1010RMG
Turn engine at crankshaft (5) in
AR05.20-P-
direction of engine rotation to a 40° Rotate engine at crankshaft (5) in running
7 6010-
crank angle after ignition TDC and direction until the 40° marking on pulley/
01AMG
on timing case.
AR01.40-P-
8 Remove timing case cover Do not damage cylinder head gaskets. 8000AMG
AR03.30-P-
Model 164, 251
8001GZS
AR03.30-P-
Model 204
8001CMG
AR03.30-P-
9 Remove flywheel/drive plate Model 209, 211, 219
8001TMG
AR03.30-P-
Model 216, 221
8001SMG
AR03.30-P-
Model 230
8001RMG
AR18.10-P-
Model 164, 251
6020GZS
AR18.10-P-
Model 204
6020CMG
AR18.10-P-
10 Remove oil pump Model 209, 211, 219
6020TMG
AR18.10-P-
Model 216, 221
6020SMG
AR18.10-P-
Model 230
6020RMG
11 Remove oil pump chain (6)
Remove vacuum reservoir (7) at On vehicles with vacuum reservoir (7) at
12
crankcase top section (11) cylinder crankcase upper section (11).
13 Detach both engine supports (12)
Installation: Lubricate bearing shells and
Loosen bolts (14, 15) from crankcase
check for unobstructed movement of
14 bottom section (13) in reverse order
crankshaft (5) by turning.
of tightening procedure
Installation: Install new bolts.
AR03.20-P-
Tightening procedure for cylinder crankcase
4351-
lower section (13)
05AMG
*BA03.20-
P-1001-01J
*BA03.20-
P-1002-01J
AH01.40-P-
Information on application of sealant
Installation 1000-
to crankcase bottom section
03AMG
Squeeze gun Fig. 20
*BR00.45-
Loctite 5970 sealant
Z-1013-01A
Clean
Do not use any sharp-edged tools or AR01.00-P-
abrasive paper as this will damage the 0050-01A
sealing surfaces.
15 Remove sealant *BR00.45-
Loctite 7200
Z-1038-04A
*BR00.45-
Loctite 7063 cleaning spray (150 ml)
Z-1046-04A
The connecting rods (1) are cracked
Place match marks for connecting
during production. The connecting rod
16 rod (1) and connecting rod bearing
cap (2) (arrow) bearing caps (2) are not interchangeable and
must not be installed in the wrong direction.
Assign connecting rod bearing cap (2)
and lower connecting rod bearing shells (3)
to each other. Mark connecting rod (1) and
upper connecting rod bearing shells (4)
relative to each other. While rotating the
crankshaft (5) ensure that connecting rods
(1) do not tilt.
Installation: Lubricate bearing shells and
check for unobstructed movement of
crankshaft (5) by turning.
Installation: Install connecting rod AR03.10-P-
Remove connecting rod bearing cap bearing, measure. 6111-06VA
17
(2) Installation: Tighten connecting rod
bolts according to the tightening
specification.
AR03.10-P-
Connecting rod bolts must be replaced. 6111-
The previously installed connecting rod bolts 02AMG
must not be installed again otherwise
loosening can occur and associated engine
damage can occur.
*BE03.20-
Connecting rod bearing play
P-1002-04E
*BA03.10-
P-1001-01Q
AR03.20-P-
The installation takes place before
Remove rear crankshaft radial 3063-
18 mounting flywheel/drive plate.
sealing ring 01AMG
Installation tool Fig. 41
Take out upper crankshaft-bearing shells
(8) and thrust plates (9) from cylinder
crankcase upper section (11). Mark thrust
plates (9) relative to crankshaft fitted
bearing. Note bearing clearance.
Installation: Check upper crankshaft AR03.20-P-
bearing shells (8) and bottom crankshaft 4341-
bearing shell (10) for wear. 01AMG
*BE03.20-
Main bearing play
P-1001-04E
Main bearing shells standard dimension for
*BE03.20-
crankcase and bearing cap(s) ø 67, 950/67,
P-1001-03J
966 mm
Main bearing shells standard dimension for
*BE03.20-
crankcase and bearing cap(s) ø 67, 950/67,
P-1002-03J
966 mm
Main bearing shells standard dimension for
Remove crankshaft (5) from cylinder *BE03.20-
19 crankcase and bearing cap(s) ø 67, 950/67,
crankcase upper section (11) P-1003-03J
966 mm
Main bearing shells standard dimension for
*BE03.20-
crankcase and bearing cap(s) ø 67, 950/67,
P-1004-03J
966 mm
*BE03.20-
Crankshaft journal dia.
P-1001-02I
*BE03.20-
Crankshaft journal width at fit bearing
P-1002-02I
*BA03.20-
P-1001-01J
*BA03.20-
P-1002-01J
20 Install in the reverse order
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving by
running. Risk of injury caused by itself. AS00.00-Z-
contusions and burns during starting Wear closed and snug-fitting work clothes. 0005-01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
Conduct engine test run and check
21
engine for leaks
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 156
Radial measurement new mm 0.022 to 0.041
BE03.20-P-1001-04E Main bearing play
Axial measurement when new mm 0.15 to 0.316
BE03.20-P-1002-04E Connecting rod bearing play Radial measurement new mm 0.028 to 0.063
INSPECTION DATA OF CRANKSHAFT MAIN BEARING SHELLS
Number Designation Engine 156
BE03.20-P-1001- Main bearing shells Replacement part additional 52
03J standard dimension number colored marking blue
for crankcase and (b)=1
bearing cap(s) ø 67, Bearing shell thickness mm 2.255 to 2.259
950/67, 966 mm
BE03.20-P-1002- Main bearing shells Replacement part additional 54
03J standard dimension number colored marking yellow
for crankcase and (y)=2
bearing cap(s) ø 67,
950/67, 966 mm Bearing shell thickness mm 2.259 to 2.263
BE03.20-P-1003- Main bearing shells Replacement part additional 56
03J standard dimension number colored marking red (r)
for crankcase and =3
bearing cap(s) ø 67,
950/67, 966 mm Bearing shell thickness mm 2.263 to 2.267
BE03.20-P-1004- Main bearing shell Replacement part additional 59
03J standard dimension number (color coding green (g)
for bearing cap ø 67, =4
950/67, 966 mm Bearing shell thickness mm 2.267 to 2.271
TEST SPECIFICATIONS FOR CRANKSHAFT
Number Designation Engine 156
67.950 to
Nominal dia. mm
67.965
1st repair 67.962 to
Blue (B) mm
stage 67.965
BE03.20-P-1001- Yellow 67.958 to
Crankshaft journal dia. Repair stage 2 mm
02I (y) 67.962
67.954 to
Repair stage 3 Red (R) mm
67.958
67.950 to
Repair stage 4 Green (g) mm
67.954
27.900 to
Marking N/0 mm
BE03.20-P-1002- Crankshaft journal width at fit 29.933
02I bearing 28.000 to
Marking N1/1 mm
28.033
CRANKSHAFT BEARING CAP
Engine
Number Designation
156
Stage
Nm 20
1
Stage
Nm 32
2
Angle° 90
3
Stage
Angle° 90
4
Stage
Releasing
5
Stage
Nm 20
M9 6
Stage
Nm 32
7
Stage
Angle° 90
8
Stage
Angle° 90
9
Stage
Nm 20
1
BA03.20-P- Crankshaft bearing cap bolt (lower section of crankcase/
1001-01J main bearing threaded connection) Stage
Nm 40
2
Stage
Angle° 90
3
Stage
Angle° 90
4
Stage
M10 Releasing
5
Stage
Nm 20
6
Stage
Nm 40
7
Stage
Angle° 90
8
Stage
Angle° 90
9
BA03.20-P- M6 Nm 8.5
Crankcase lower section on crankcase upper section
1002-01J M8 Nm 20
CONNECTING ROD
Number Designation Engine 156
STAGE 1 Nm 10
Stage 2 Nm 40
Stage 3 Angle° 120
BA03.10-P-1001-01Q Connecting rod bearing cap on connecting rod Stage 4 Releasing
Stage 5 Angle° 10
Stage 6 Nm 40
Stage 7 Angle° 90
Fig. 79: Identifying Installation Tool (111 589 08 43 00)
Courtesy of MERCEDES-BENZ USA
Fig. 80: Identifying Squeeze Gun (112 589 00 25 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-
Loctite 5970 sealant A 003 989 98 20
1013-01A
Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925
BR00.45-Z-
Loctite 7200 Munchen Germany Tel. +49 899268-0 Fax + 49 899101978
1038-04A
www.Loctite.de
BR00.45-Z- Loctite 7063 cleaning
A 001 986 71 71 10
1046-04A spray (150 ml)
REMOVE/INSTALL CRANKSHAFT - AR03.20-P-4351MC
ENGINES 275 in MODEL 215, 216, 220, 221
Fig. 81: Identifying Crankshaft Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
28.5.08 Clean sealing surfaces - added Step 19
Removing
Model 215, 220 except 220 with special protection
version, code 979, light armoring, code Z04 or top
AR01.10-P-
1.1 Remove engine protection, code Z07
2400MC
Model 220 with special protection version, code 979,
light armoring, code Z04 or top protection, code Z07
Remove engine with front AR01.10-P-
1.2 Model 216, 221
axle carrier 2500SZ
AR27.10-P-
2 Remove transmission Model 216, 221
0500SZ
Detach engine from front AR01.10-P-
3 Model 216, 221
axle carrier 2510SX
Mount engine onto
4
assembly stand
AR01.40-P-
5 Remove end cover
8913MC
AR01.40-P-
6 Remove timing case cover
8000M
AR01.45-P-
Model 215, 220
7500L
7 Remove oil pan
AR01.45-P-
Model 216, 221
7500SZ
8 Remove oil deflector plate
AR18.10-P-
9 Remove oil pump
6020L
Loosen bolts (7, 8, 9) in reverse order of tightening
procedure:?
AR03.20-P-
Remove bolts (M10) (7), Tightening procedure for crankcase bottom section 4351-05L
bolts (M8) (8), bolts (M6)
10 Observe dowel pins when prying off. If lower
(9) and pry off crankcase
bottom section (1) crankcase section (1) cannot be pried off:?
Fig. 82
Remove dowel pins
Fig. 83
Place match marks on
crankshaft bearing shells in
lower crankcase section
11
(without oil hole) (6) and
on crankshaft bearings in
lower crankcase section (1)
Place match marks on
12 connecting rod and
connecting rod bearing cap
Remove connecting rod While turning crankshaft (2) ensure that connecting
13
bearing caps rods do not get jammed.
Mark connecting rod
bearing shell and Do not mix up top and bottom connecting rod
14
connecting rod bearing cap bearing shells.
to each other
Mark connecting rod
bearing shell and Do not mix up top and bottom connecting rod
15
connecting rod to each bearing shells.
other
Take crankshaft (2) out of
16
crankcase top section (3)
Place match marks on
crankshaft bearing shells in
upper crankcase section
17
(with oil hole) (4) and on
crankshaft bearings in
upper crankcase section (3)
Install
Lubricate crankshaft bearing shells in upper
crankcase section (with oil hole) (4) before installing
crankshaft (2). The oil grooves in the thrust washers
(thrust bearing) (5/1) and thrust washers (thrust
bearing) (5/2) must point towards thrust collars of the
18 Insert crankshaft (2) crankshaft (2). Thrust washers (thrust bearing) (5/1)
and thrust washers (thrust bearing) (5/2) are each fitted
with a retaining lug as an anti-twist lock.
Observe crankshaft bearing shell assignment:?
AR03.20-P-
Assign crankshaft bearing shells.
4360-01L
Clean
Do not use any sharp-edged tools or abrasive paper AR01.00-P-
Clean sealing surfaces on as this will damage the sealing surfaces. 0050-01A
lower crankcase section (1) *BR00.45-
19 Loctite 7200
and upper crankcase Z-1038-04A
section (3) *BR00.45-
Loctite 7063 cleaning spray (150 ml)
Z-1046-04A
Lubricate bolts for the lower crankcase section (1)
Install lower crankcase
20 on thread and bolt head contact surface.
section (1)
Observe sealant flow and tightening procedure:?
Notes on application of sealant to crankcase bottom AH01.40-
section P-1000-03A
Fig. 20
*BR00.45-
Loctite 5970 sealant
Z-1013-01A
AR03.20-P-
Tightening procedure for crankcase bottom section
4351-05L
*BA01.40-
P-1008-01C
21 Crank crankshaft (2) To check for unobstructed movement.
Check axial play of AR03.20-P-
22
crankshaft (2) 4355-02L
AR03.10-P-
23 Check connecting rod bolts
6111-01L
The anti-twist locks of connecting rod bearing shells
must be located in slots of connecting rods and of
Fit connecting rod bearing
connecting rod bearing caps. AR03.10-P-
24 and mount connecting rod
bearing cap The connecting rod and connecting rod bearing cap 6111-06L
are broken. They must not be installed on wrong side
since the accuracy of fit would no longer be given.
AR03.10-P-
Tighten connecting rod 6111-02L
25
bolts
P-1001-01E
26 Crank crankshaft (2) to check for unobstructed movement.
AR18.10-P-
27 Install oil pump
6020L
*BA01.40-
28 Install oil deflector plate
P-1009-01C
AR01.45-P-
Model 215, 220
7500L
29 Installing oil pan
AR01.45-P-
Model 216, 221
7500SZ
Replace the O-rings and radial sealing ring.
The sealing lip of radial sealing ring and its mating AR01.40-P-
30 Install timing case cover surface must not be oiled or greased. 8000M
Pay attention to fitted sleeves when pressing on end
cover!
Replace radial sealing ring.
The sealing lip of radial sealing ring and its mating
AR01.40-P-
31 Install end cover surface must not be oiled or greased.
8913MC
Pay attention to the fitted sleeves when pressing on the
end cover.
Detach engine from engine
32
assembly stand
Install engine onto front AR01.10-P-
33 Model 216, 221
axle carrier 2510SX
AR27.10-P-
34 Attach transmission Model 216, 221
0500SZ
Model 215, 220 except 220 with special protection
version, code 979, light armoring, code Z04 or top
AR01.10-P-
35.1 Install engine protection, code Z07
2400MC
Model 220 with special protection version, code 979,
light armoring, code Z04 or top protection, code Z07
Install engine with front AR01.10-P-
35.2 Model 216, 221
axle carrier 2500SZ
CRANKCASE, TIMING CASE COVER, END COVER
Engine 275,
Number Designation Engine 137 285
BA01.40-P- Bolt, 1-14 M10 Stage 1 Nm 40 40
1008-01C crankcase Stage 2 Angle° 90 90
bottom 15-28 M8 Stage 1 Nm 12 12
section to top
Stage 2 Angle° 90 90
part
Stage 3 Angle° 90 90
29-54 M6 Stage 1 Nm 8 8
Stage 2 Angle° - -
55-61 M8 Stage 1 Nm 20 20
Stage 2 Angle° - -
See picture - -
BA01.40-P- Bolt, oil baffle to lower crankcase section Nm 8 8
1009-01C
CONNECTING ROD
Number Designation Engine 275, 285
Stage 1 Nm 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 15
Stage 3 Angle° 90
Fig. 82: Identifying Threaded Stud (116 589 01 34 00)
Courtesy of MERCEDES-BENZ USA
Fig. 83: Identifying Impact Extractor (116 589 20 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 84: Identifying Squeeze Gun (112 589 00 25 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
BR00.45-Z-1038-04A Loctite 7200 Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
REMOVE/INSTALL CRANKSHAFT - AR03.20-P-4351SX
ENGINES 273 in MODEL 216, 221
Fig. 85: Identifying Crankshaft Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 86: Identifying Crankshaft Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Step
26.11.07 Installation note on install new chain tensioner, added
42
Special tool (136 589 04 21 00) removed and replaced by special AR03.20-P-4291-
18.2.08
tool (363 589 02 21 00) 03SX
REMOVING
Removing
1 Drain engine oil
AP18.00-P-
Engine oil and filter change
0101SX
Remove engine with front axle AR01.10-P-
2 Vehicles without 4MATIC
carrier 2500SX
AR01.10-P-
Vehicles with 4MATIC
2500SW
Detach engine from front axle AR01.10-P-
3 Vehicles without 4MATIC
carrier 2510SX
AR01.10-P-
Vehicles with 4MATIC
2510TW
Remove automatic AR27.10-P-
4 Vehicles without 4MATIC
transmission from engine 0500SX
AR27.10-P-
Vehicles with 4MATIC
0500SYZ
Mount engine onto assembly
5
stand
Remove front cover at left AR01.30-P-
6
cylinder head 5700SX
Remove the right cylinder AR01.20-P-
7
head cover 5014SY
Rotate engine at crankshaft (7)
in direction of rotation of
AR05.20-P-
8 engine to a 40° crank angle
6010-01VB
after ignition TDC and check
basic position of camshaft
AR03.30-P-
9 Remove driven plate
8001SX
Remove oil pan bottom AR01.45-P-
10 Vehicles without 4MATIC
section 7555SX
AR01.45-P-
Vehicles with 4MATIC
7555SW
AR01.45-P-
11 Detach oil pan Vehicles without 4MATIC
7500SX
AR01.45-P-
Vehicles with 4MATIC
7500SW
Remove rear crankshaft radial AR03.20-P-
12
sealing ring 3063SX
AR18.10-P-
13 Remove oil pump
6020SX
Remove oil baffle from AR03.10-P-
14
cylinder crankcase 7021-01SX
AR15.40-P-
15 Remove alternator
5032SX
AR05.10-P-
16 Remove chain tensioner
7800SX
AR01.40-P-
17 Remove timing case cover Do not damage cylinder head gaskets. 8000SX
18 Remove oil pump chain (12)
Remove camshaft adjuster AR05.20-P-
19
(13) on right cylinder head 7201SX
Detach timing chain drive gear
20 Secure key (15).
(14) from crankshaft (7)
Mark connecting rods (1) and Connecting rod (1) and connecting rod bearing
connecting rod bearing caps cap (2) are cracked. They must not be swapped or
21
(2) on one side relative to each installed on wrong sides as the dimensional
other accuracy would no longer be given.
Mark connecting rod bearing cap (2) and lower
Remove connecting rod connecting rod bearing shells (3) relative to each
bearing cap (2) and lower other. Mark connecting rods (1) and connecting rod
22
connecting rod bearing shells bearing caps (4) relative to each other. While
(3) rotating crankshaft (7) ensure that connecting rods
(1) do not get caught.
Loosen crankshaft bearing cap
(5) bolts and crankshaft fitted AR03.20-P-
23
bearing cap (6) in reverse 4351-02SX
order of tightening procedure
Carefully pry out crankshaft bearing cap (5) and
crankshaft fitted bearing cap (6). Mark the lower
Remove crankshaft bearing crankshaft bearing shells (9) relative to their
24 cap (5) and crankshaft fitted respective crankshaft bearing caps (5) and
bearing cap (6) crankshaft fitted bearing caps (6). Mark lower
thrust plates (11) relative to crankshaft fitted
bearing cap (6).
Remove crankshaft (7) from
25
crankcase
Remove upper crankshaft
bearing shells (8) and upper Mark upper crankshaft bearing shells (8) and
26 upper thrust washers (10) from crankcase relative
thrust washers (10) from
crankcase to crankshaft fitted bearing.
Install
Lubricate upper crankshaft
When replacing the crankshaft bearing shells (8,
27 bearing shells (8) and insert
9) or the crankshaft (7): ?
them into crankcase
AR03.20-P-
Assign crankshaft bearing shells.
4360-01SX
Main bearing play P-1001-04E
Lubricate crankshaft journals
28 and insert crankshaft (7) in
crankcase
Lubricate upper thrust plate
Oil grooves in the upper thrust plates (10) must
29 (10) and insert in crankshaft
point toward the thrust collars of the crankshaft (7).
fitted bearing in crankcase
Lubricate lower crankshaft
bearing shells (9) and lower
thrust plates (11) and insert in When replacing the crankshaft bearing shells (8,
30
crankshaft bearing cap (5) and 9) or the crankshaft (7): ?
crankshaft fitted bearing cap
(6)
AR03.20-P-
Assign crankshaft bearing shells.
4360-01SX
*BE03.20-
Main bearing play
P-1001-04E
Insert crankshaft bearing cap The crankshaft bearing caps (5) and fitted
31 (5) and crankshaft fitted bearing caps (6) are numbered consecutively. Pay
bearing cap (6) attention to fit: ?
AH03.20-P-
Fit of crankshaft bearing cap
4351-02SX
Insert and tighten bolts for
crankshaft bearing caps (5) Bolts must be replaced with new ones,
32 otherwise there is risk of breakage. Tighten bolts
and for crankshaft fitted
according to tightening scheme: ?
bearing cap (6)
AR03.20-P-
Tightening procedure for crankshaft bearing caps
4351-02SX
*BA03.20-
P-1001-01D
*BA03.20-
P-1002-01D
*BA03.20-
P-1003-01D
Rotate crankshaft (7) and
33 check for unobstructed
movement
Determine crankshaft bearing AR03.20-P-
34
axial play 4291-03SX
Fig. 66
Fig. 67
Fig. 68
*BE03.20-
Main bearing play
P-1001-04E
AR03.10-P-
35 Check connecting rod bolts
6111-01VA
*BE03.10-
Connecting rod bolts
P-1001-03A
Connecting rod (1) and connecting rod bearing
cap (2) are cracked. They must not be swapped or AR03.10-P-
36 Mount connecting rod bearing
installed on wrong sides as the dimensional 6111-08SX
accuracy would no longer be given.
*BE03.20-
Connecting rod bearing play
P-1002-04E
*BA03.10-
P-1001-01E
Rotate crankshaft (7) and
37 check for unobstructed
movement
Slide timing chain drive gear
38 Observe key (15).
(14) onto crankshaft (7)
Install camshaft adjuster (13) Check engine timing at a 40° crank angle after
on right cylinder head while ignition TDC. At 40° crank angle after ignition AR05.20-P-
39
adjusting basic positions of TDC, fitting key (15) aligns with the marking (16) 7201SX
camshaft on the cylinder crankcase.
lay oil pump chain (12) on
40
drive gear
AR01.40-P-
41 Install timing case cover
8000SX
Replace chain tensioner . The previously
installed chain tensioner must not be reinstalled
42 Install chain tensioner because, during removal, its pressure pin is pressed AR05.10-P-
into the end position. The thrust pin latch prevents 7800SX
this return stroke. This would overstretch the
timing chain on reinstalling.
Mount oil baffle on cylinder AR03.10-P-
43
crankcase 7021-01SX
*BA18.10-
P-1006-01B
AR18.10-P-
44 Install oil pump
6020SX
Installing rear crankshaft Replace rear crankshaft radial sealing ring with AR03.20-P-
45
radial sealing ring new one to ensure that there are no leaks. 3063SX
AR01.45-P-
46 Install oil pan Vehicles without 4MATIC
7500SX
AR01.45-P-
Vehicles with 4MATIC
7500SW
47 Install oil pan bottom section Vehicles without 4MATIC
7555SX
AR01.45-P-
Vehicles with 4MATIC
7555SW
AR15.40-P-
48 Install alternator
5032SX
AR01.20-P-
49 Fit right cylinder head cover
5014SY
Install front cover on left AR01.30-P-
50
cylinder head 5700SX
AR03.30-P-
51 Install drive plate
8001SX
Mount automatic transmission AR27.10-P-
52 Vehicles without 4MATIC
to engine 0500SX
AR27.10-P-
Vehicles with 4MATIC
0500SYZ
Install engine onto front axle AR01.10-P-
53 Vehicles without 4MATIC
carrier 2510SX
AR01.10-P-
Vehicles with 4MATIC
2510TW
Install engine with front axle AR01.10-P-
54 Vehicles without 4MATIC
carrier 2500SX
AR01.10-P-
Vehicles with 4MATIC
2500SW
55 Pour in engine oil
AP18.00-P-
Engine oil and filter change
0101SX
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 273
BE03.20-P-1001- Main bearing play Radial measurement new mm 0.022...0.046
04E Axial measurement when mm 0.100 to 0.266
new
BE03.20-P-1002- Connecting rod bearing Radial measurement new mm 0.022...0.066
04E play
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Number Designation Engine 273
BE03.10-P-1001-03A Connecting rod bolts Thread dia. M 8x1
Shank length New mm 39.5
max. mm 40.5
CRANKSHAFT BEARING CAP
Number Designation Engine 273
BA03.20-P-1001- Bolt for crankshaft bearing cap M8 Stage 1 Nm 20
01D
Stage 2 °Angle 90
BA03.20-P-1002- Side crankshaft bearing cap bolt M8 Stage 1 Nm 20
01D
Stage 2 °Angle 90
BA03.20-P-1003- Bolt for crankshaft bearing cap M10 Stage 1 Nm 5
01D
Stage 2 Nm 30
Stage 3 °Angle 90
CONNECTING ROD
Number Designation Engine 273
BA03.10-P-1001- Connecting rod bolt Stage 1 Nm 5
01E
Stage 2 Nm 25
Stage 3 °Angle 90
OIL PUMP
Number Designation Engine 273
BA18.10-P-1006-01B Bolt, oil baffle to crankcase Nm 9
Fig. 87: Identifying Dial Indicator (001 589 32 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 88: Identifying Extension (366 589 00 21 05)
Courtesy of MERCEDES-BENZ USA
Fig. 89: Identifying Dial Indicator Holder (363 589 02 21 00)
Courtesy of MERCEDES-BENZ USA
MOUNT CRANKSHAFT RADIALLY IN BEARINGS - AR03.20-P-4355-01L
ENGINE 137 ENGINE 275
TEST AND ADJUSTMENT VALUES
Number Designation Engine 137
BE01.40-P- Crankshaft bearing Basic bore Ø mm 68.500 to 68.519
1001-02G Code number 52 1st stage blue mm 68.500 to 68.506
Code number 54 2nd stage mm 68.506 to 68.513
yellow
Code number 56 3rd stage red mm 68.513 to 68.519
Basic bore width at fit bearing mm 17.073 to 18.00
Permissible out-of-roundness and conicity of mm 0.02
basic bore
TEST AND ADJUSTMENT VALUES
Engine 275,
Number Designation 285
BE01.40-P- Crankshaft Basic bore Ø mm 68.500 to
1001-02G bearing 68.519
Code number 52 1st stage blue mm 68.500 to
68.506
Code number 54 2nd stage mm 68.506 to
yellow 68.513
Code number 56 3rd stage red mm 68.513 to
68.519
Basic bore width at fit bearing mm 19.967 to 20.00
Permissible out-of-roundness and conicity of mm 0.02
basic bore
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS
Engine
275.950/951/953/954,
Number Designation Engine 137 285.950
BE03.20-P- Main bearing shells Replacement part 52 52
1001-03E standard size for additional number (color
upper crankcase coding blue)
section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.252 to 2.257 2.255 to 2.262
bore dia. 68.5 mm
BE03.20-P- Main bearing shells Replacement part 54 54
1002-03E standard size for additional number
upper crankcase (color coding yellow)
section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.257 to 2.262 2.260 to 2.267
bore dia. 68.5 mm
BE03.20-P- Main bearing shells Replacement part 56 56
1003-03E standard size for additional number
upper crankcase (color coding red)
section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.262 to 2.267 2.265 to 2.272
bore dia. 68.5 mm
BE03.20-P- Main bearing shells Replacement part 57 57
1004-03E standard size for additional number
crankcase bottom (color coding white)
section main bearing
bore dia. 68.5 mm Bearing shell thickness mm 2.267 to 2.272 2.270 to 2.277
BE03.20-P- Main bearing shells Replacement part 58 58
1005-03E standard size for additional number
crankcase bottom (color coding purple)
section main bearing
bore dia. 68.5 mm Bearing shell thickness mm 2.272 to 2.277 2.275 to 2.282
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS
Engines
275.980/981
Number Designation 982/983/, 285.980
BE03.20-P-1001- Main bearing shells Replacement part additional 52
03E standard size for upper number (color coding blue)
crankcase bottom section Bearing shell thickness mm 2.252 to 2.257
main bearing bore dia.
68.5 mm
BE03.20-P-1002- Main bearing shells Replacement part additional 54
03E standard size for upper number (color coding
crankcase section and yellow)
crankcase bottom section
main bearing bore dia.
Bearing shell thickness mm 2.257 to 2.262
68.5 mm
BE03.20-P-1003- Main bearing shells Replacement part additional 56
03E standard size for upper number (color coding red)
crankcase section and
crankcase bottom section
main bearing bore dia. Bearing shell thickness mm 2.262 to 2.267
68.5 mm
BE03.20-P-1004- Main bearing shells Replacement part additional 57
03E standard size for number (color coding
crankcase bottom section white)
main bearing bore dia.
68.5 mm Bearing shell thickness mm 2.267 to 2.272
BE03.20-P-1005- Main bearing shells Replacement part additional 58
03E standard size for number (color coding
crankcase bottom section purple)
main bearing bore dia.
68.5 mm Bearing shell thickness mm 2.272 to 2.277
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Engines Engines
275.95, 275.98,
Number Designation Engine 137 285.95 285.98
BE03.20-P- Main Radial measurement new mm 0.028 to 0.052 0.022 to 0.047 0.018 to 0.058
1001-04E bearing play Axial measurement when mm 0.10 to 0.260 0.100 to 0.254 0.100 to 0.254
new
CRANKCASE, TIMING CASE COVER, END COVER
Engine 275,
Number Designation Engine 137 285
BA01.40-P- Bolt, crankcase bottom 1-14 M10 Stage 1 Nm 40 40
1008-01C section to top part Stage 2 Angle° 90 90
15-28 M8 Stage 1 Nm 12 12
Stage 2 Angle° 90 90
Stage 3 Angle° 90 90
29-54 M6 Stage 1 Nm 8 8
Stage 2 Angle° - -
55-61 M8 Stage 1 Nm 20 20
Stage 2 Angle° - -
See picture - -
Fig. 90: Identifying Dial Indicator (001 589 53 21 00)
Courtesy of MERCEDES-BENZ USA
1. Mount lower crankcase section (1).
Fig. 91: Identifying Lower Crankcase Section
Courtesy of MERCEDES-BENZ USA
Measurement without bearing shells for determining thickness of bearing shell
2.1 Measure crankshaft bearing bore in direction A, B and C at two levels (out-of-roundness).
Fig. 92: Identifying Crankshaft Bearing Bore Measuring Directions
Courtesy of MERCEDES-BENZ USA
Fig. 93: Measuring Crankshaft Bearing Bore
Courtesy of MERCEDES-BENZ USA
Measurement with bearing shells for determining radial bearing clearance
2.2 Measure crankshaft bearing bore in direction A, B and C at two levels (out-of-roundness).
3.1 Measure crankshaft bearing bore, without bearing shells, in direction A, note measurement, example:
68.51 mm.
3.2 Measure crankshaft bearing bore, without bearing shells, in direction A, note measurement, example:
64 mm.
Fig. 94: Identifying Crankshaft Bearing Bore Measuring Directions
Courtesy of MERCEDES-BENZ USA
Fig. 95: Measuring Crankshaft Bearing Bore
Courtesy of MERCEDES-BENZ USA
4 Detach lower crankcase section (1).
5 Measure crankshaft bearing journal dia. example: 63.95 mm
6.1 Determine bearing shell thickness
Example:
Bearing bore dia. 68.51 mm
Crankshaft journal dia. -63.95 mm
4. 56 mm
Radial bearing play: dia. -0.04 mm
Check values --> table "crankshaft bearing play"
4.52 mm : 2
Bearing shell thickness 2.26 mm
6.2 Determine radial bearing clearance
Example:
Bearing bore dia. 64.00 mm
Crankshaft journal dia. -63.95 mm
Radial bearing play: 0.05 mm
Fig. 96: Measuring Bearing Shell Thickness
Courtesy of MERCEDES-BENZ USA
7 Assign bearing shells (only for standard dimension crankshaft)
Example:
Bearing shell thickness 2.26 mm --> chart "test values of crankshaft bearing shells"
Upper bearing shell "yellow"
Lower bearing shell "yellow"
If the thickness of the bearing shell differs, install thicker bearing shell in lower crankcase section (1).
MOUNT CRANKSHAFT AXIALLY - AR03.20-P-4355-02L
ENGINE 137.970, 275
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE
Engines Engines
Number Designation Engine 137 275.95, 285.95 275.98, 285.98
BE03.20-P-1001- Main bearing radial when mm 0.028...0.052 0.022...0.047 0.018...0.058
04E play new
axial when mm 0.10...0.260 0.100...0.254 0.100...0.254
new
Fig. 97: Identifying Dial Indicator (001 589 53 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 98: Identifying Dial Indicator Holder (363 589 02 21 00)
Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1001-12A Quick calipers for internal measurements
WH58.30-Z-1012-12A Setting gage for micrometer
1. Note width of fitted bearing (5th main bearing) at upper crankcase section and note value.
2. Measure width of fitted bearing at crankshaft, note.
3. Determine thickness of thrust washer.
Fig. 99: Measuring Crankshaft Bearing Width
Courtesy of MERCEDES-BENZ USA
4. Insert thrust plates (5).
The oil grooves (arrows) must be pointing toward the contact surface of the crankshaft and be oiled.
Fig. 100: Locating Thrust Plate Oil Grooves
Courtesy of MERCEDES-BENZ USA
5. Measure axial bearing play, adjust if necessary.
Fig. 101: Measuring Axial Bearing Play
Courtesy of MERCEDES-BENZ USA
MEASURING CRANKSHAFT AND REMOUNTING IN BEARINGS - AR03.20-P-4355L
ENGINES 137.970, 275.950 /951 /953 /954 /980 /981 /982
Fig. 102: Identifying Crankshaft Bearings
Courtesy of MERCEDES-BENZ USA
Removing
The oil grooves (arrows) in the
thrust washers (thrust bearing) 5th
main bearing = fitted bearing (5)
must point towards the thrust collar
of the crankshaft
AR03.20-P-
Engine 137
4351L
AR03.20-
1 Remove the crankshaft (2) Engine 275.950 /953 /980 /982
P-4351MC
AR03.20-P-
Engine 275.951/ 954/ 981
4351R
After bearing damage has occurred, remove
any swarf which is present in the connecting
2 Clean engine parts rod bores and in the crankshaft and crank case
oil galleries:?
Clean main oil gallery
Checking
After a bearing damage has occurred:?
Connecting rods which overheated due to
3 Inspect connecting rod bearing damage (blue discoloration), must be
replaced.
cross scores and notches.
4 Check crankshaft (2) If there is damage to the crankshaft (2):?
Install new crankshaft.
AR03.20-
P-4355-
01L
A radial mounting of the main bearings in
Mount crankshaft (2) radially in case of standard dimension crankshafts is
5
bearings possible by assigning crankshaft bearing
shells marked in colors.?
AR03.20-
Assign crankshaft bearing shells. P-4360-
01L
AR03.20-
6 Mount crankshaft (2) axially P-4355-
02L
Installing
AR03.20-P-
Engine 137
4351L
AR03.20-
7 Install crankshaft (2) Engine 275.950 /953 /980 /982
P-4351MC
AR03.20-P-
Engine 275.951/ 954/ 981
4351R
ASSIGN CRANKSHAFT BEARING SHELLS - AR03.20-P-4360-01L
TEST SPECIFICATIONS FOR CRANKSHAFT MAIN BEARING SHELLS
Engine
275.950/951/953/954,
Number Designation Engine 137 285.950
BE03.20-P- Main bearing shells Replacement part 52 52
1001-03E standard size for additional number (color
upper crankcase coding blue)
section and
crankcase bottom
section main
bearing bore dia. Bearing shell thickness mm 2.252 to 2.257 2.255 to 2.262
68.5 mm
BE03.20-P- Main bearing shells Replacement part additional 54 54
1002-03E standard size for number (color coding yellow)
upper crankcase
section and
crankcase bottom
section main Bearing shell thickness mm 2.257 to 2.262 2.260 to 2.267
bearing bore dia.
68.5 mm
BE03.20-P- Main bearing shells Replacement part additional 56 56
1003-03E standard size for number (color coding red)
upper crankcase
section and
crankcase bottom
section main Bearing shell thickness mm 2.262 to 2.267 2.265 to 2.272
bearing bore dia.
68.5 mm
BE03.20-P- Main bearing shells Replacement part additional 57 57
1004-03E standard size for number (color coding white)
crankcase bottom
section main
bearing bore dia. Bearing shell thickness mm 2.267 to 2.272 2.270 to 2.277
68.5 mm
BE03.20-P- Main bearing shells Replacement part additional 58 58
1005-03E standard size for number (color coding purple)
crankcase bottom
section main
bearing bore dia. Bearing shell thickness mm 2.272 to 2.277 2.275 to 2.282
68.5 mm
TEST SPECIFICATIONS FOR CRANKSHAFT MAIN BEARING SHELLS
Engine 275.980/981
Number Designation 982/983/, 285.980
BE03.20-P-1001- Main bearing shells Replacement part additional number 52
03E standard size for upper (color coding blue)
crankcase section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.252 to 2.257
bore dia. 68.5 mm
BE03.20-P-1002- Main bearing shells Replacement part additional number 54
03E standard size for upper (color coding yellow)
crankcase section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.257 to 2.262
bore dia. 68.5 mm
BE03.20-P-1003- Main bearing shells Replacement part additional number 56
03E standard size for upper (color coding red)
crankcase section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.262 to 2.267
bore dia. 68.5 mm
BE03.20-P-1004- Main bearing shells Replacement part additional number 57
03E standard size for (color coding white)
crankcase bottom
section main bearing Bearing shell thickness mm 2.267 to 2.272
bore dia. 68.5 mm
BE03.20-P-1005- Main bearing shells Replacement part additional number 58
03E standard size for (color coding purple)
crankcase bottom
section main bearing Bearing shell thickness mm 2.272 to 2.277
bore dia. 68.5 mm
1. Assign bearing shells to upper crankcase section
The bearing shells are marked on the side in color.
The upper crankcase section carried letters, which correspond to the sequence of the bearing shells (1, 2,
3, 4, 5, 6, 7) in the upper crankcase section. The bearing shells should be selected according to the letter
sequence (only shown in picture with "b"). Letters "g" and "r" may also be used. The following letters
require the following wheel offset code numbers of bearing shells (upper section):
b (blue) = wheel offset code number 52
g (yellow) = wheel offset code number 54
r (red) = wheel offset code number 56
Shown on engine 137
Fig. 103: Identifying Bearing Shells & Markings
Courtesy of MERCEDES-BENZ USA
2. Assign bearing shells to lower crankcase section
The bearing shells are marked on the side in color. Letters for assigning the bearing shells to the bottom part
of the crankcase are included on the crankshaft journal. Select the bearing shells to match the letters.
Shown on engine 137
Fig. 104: Identifying Bearing Shells Of Lower Crankcase Section
Courtesy of MERCEDES-BENZ USA
ASSIGN CRANKSHAFT BEARING SHELLS - AR03.20-P-4360-01SX
ENGINE 273
INSPECTION DATA FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 273
BE03.20-P-1001- Main bearing play radial when new mm 0.022...0.046
04E
axial when new mm 0.100...0.266
ASSIGNMENT OF CRANKSHAFT BEARING SHELL UPPER HALVES (CRANKCASE)
Assignment of crankshaft bearing shell upper halves (crankcase)
Diameter of crankshaft bearing Number on Color coding for Crankshaft bearing
hole in crankcase crankcase bearing shell play (mm)
68.500...68.506 1 blue 0.022...0.046
above 68.506...68.513 2 yellow 0.022...0.046
above 68.513...68.519 3 red 0.022...0.046
ASSIGNMENT OF CRANKSHAFT BEARING SHELL LOWER HALVES (BEARING CAP)
Assignment of crankshaft bearing shell lower halves (bearing cap)
Diameter of crankshaft Laser labeling on front Color marking for Crankshaft bearing
journal crankshaft journal bearing shell play (mm)
63.945...63.949 v purple 0.022...0.046
above 63.949...63.953 w white 0.022...0.046
above 63.953...63.957 r red 0.022...0.046
above 63.957...63.961 g yellow 0.022...0.046
above 63.961...63.965 b blue 0.022...0.046
1. Clean crankshaft bearing points in crankcase, crankshaft bearing cap and crankshaft journal for crankshaft
with a chamois leather.
The top crankshaft bearing shells are assigned to the crankcase by means of color codings (on the
reverse side of the crankshaft bearing shells) and numbers which are stamped on the crankcase (see
arrows).
Only assigned color and numerical combinations (see table) may be fitted together.
If a bearing damage has occurred, it may be necessary to remove any swarf from the connecting rod
bores, the crankshaft and crankcase oil galleries as well as the crankcase!
Do not use any hard objects for cleaning.
Blow through oil galleries in direction of flow oil with compressed air.
Fig. 105: Locating Numbers Stamped On Crankcase
Courtesy of MERCEDES-BENZ USA
Assignment of the bottom crankshaft bearing shells to the crankshaft journal is by means of letters
(initial letter of the particular color).
The initial letters of the particular colors are engraved on the front journal of the crankshaft (arrow).
The color coding on the lower crankshaft bearing shell is located on its rear side.
When installing the crankshaft bearing shells, it is important to keep to the order of the colors
which is engraved on the crankshaft journal!
Fig. 106: Identifying Color Coding On Lower Crankshaft
Courtesy of MERCEDES-BENZ USA
Example:
Arrow identifies direction of travel.
First letter "b ": A crankshaft bearing shell with the color coding blue must be inserted in the
crankshaft bearing cap (1).
Second letter "g ": A crankshaft bearing shell with the color coding yellow must be inserted in the
crankshaft bearing cap (2).
Third letter "r ": A crankshaft bearing shell with the color coding red must be inserted in the
crankshaft bearing cap (3).
Fourth letter "w ": A crankshaft bearing shell with the color coding white must be inserted in the
crankshaft bearing cap (4).
Fifth letter "r ": A crankshaft bearing shell with the color coding red must be inserted in the
crankshaft bearing cap (5).
Fig. 107: Identifying Crankshaft Bearing Caps
Courtesy of MERCEDES-BENZ USA
2. Lubricate top crankshaft bearing shells (1) with the oil holes (2) and the oil grooves (3) and insert in the
crankcase.
When doing this ensure that the anti-twist locks (4) for the bearing shell halves (1) are located in the
recesses of the crankcase.
3. Lubricate lower crankshaft bearing shell (7) and insert in the crankshaft bearing cap (6).
When doing this, ensure that the anti-twist locks (5) of the bottom bearing shell halves (7) are located
in the recesses of the crankshaft bearing cap (6).
Halves
Courtesy of MERCEDES-BENZ USA
4. Lay crankshaft (7) in the crankcase.
5. Lubricate upper thrust plate (8) and install.
There is only one fitted bearing width therefore only one washer disc thickness is used.
The oil grooves of the thrust washers (8) must point toward the crankshaft webs (10).
Fig. 109: Identifying Upper Thrust Plate And Crankshaft Web
Courtesy of MERCEDES-BENZ USA
6. Install the crankshaft bearing cap (2) as per its identification.
When installing the fit bearing cap (3) hold both thrust plates (8) tight. The anti-twist locks (11) of the lower
thrust plates (8) must be located in the slots (12) of the fit bearing cap (3).
The oil grooves (9) of the lower thrust plates (8) must point toward the crank webs (10).
Fig. 110: Identifying Crankshaft Bearing Cap, Crank Webs And Oil Grooves Of Lower Thrust Plates
Courtesy of MERCEDES-BENZ USA
INSPECTING BELT PULLEY / VIBRATION DAMPER FOR AXIAL AND RADIAL RUNOUT -
AR03.30-P-1600-01B
ENGINE 112, 113, 137, 275, 285, 112.945, 113.962 /982
BELT PULLEY/VIBRATION DAMPER
Engine 112, Engine Engine
Number Designation 113.94/96/98 113.990/991 113.992
BE03.30-P- Permissible difference Radial runout mm 0.5 0.4 0.4
1001-02A at vibration damper Lateral trueness mm 0.3 0.4 0.2
BELT PULLEY/VIBRATION DAMPER
Number Designation Engine 271 Engine 275, 285
BE03.30-P-1001- Permissible difference Radial runout mm 0.3 -
02C at vibration damper Lateral trueness mm 0.3 0.3
Courtesy of MERCEDES-BENZ USA
Fig. 112: Identifying Dial Indicator Holder (363 589 02 21 00)
Courtesy of MERCEDES-BENZ USA
1. Bolt dial gage holder (03) onto timing case cover.
2. Insert dial gage (04 ) into dial indicator holder (03).
3. Check lateral trueness
Position tracer pin (05) of dial gage (04) at measuring point (B).
4. Rotate belt pulley/ vibration damper (62) by hand, inspect lateral trueness.
Fig. 113: Checking Lateral Trueness
Courtesy of MERCEDES-BENZ USA
5. Inspect concentricity
Position tracer pin (05) of dial gage (04) at measuring point (A).
6. Rotate belt pulley/ vibration damper (62) by hand, inspect concentricity.
REMOVE/INSTALL BELT PULLEY/VIBRATION DAMPER - AR03.30-P-1600L
ENGINES 137 in MODEL 215, 220
ENGINES 275 in MODEL 215, 216, 220, 221, 230
Shown on engine 137
Fig. 114: Identifying Belt Pulley/Vibration Damper Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Model 215, 220 except 215.379, 220.179
AR20.40-P-
Model 230 without code (P99) Special model "AMG Black
6800AC
Series"
AR20.40-P-
Remove fan shroud Model 215.379, 220.179 6800IM
1.1
(1)
AR20.40-P-
Model 216, 221 except 216.379, 221.179
6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
Model 230 with code (P99) Special model "AMG Black AR20.40-P-
1.2 Remove fan unit
Series" 5050RBS
AR13.22-P-
Model 215, 220, 230
Remove poly-V belt 1202L
2
(2) AR13.20-P-
Model 216, 221
0001SZ
In order to avoid damage to starter ring gear, the center
bolt (3) must not be counterheld at starter ring gear (with
Remove center bolt retaining lock) for disassembly. Using a high torque,
3
(3) counterhold with the counterholder on the spokes of the belt
pulley/ vibration damper (4).
For better disassembly use the extension.
WF58.50-P-
Extension for counterholder
0330-02A
Installation: Replace center bolt (3).
*BA03.30-P-
Engine 137 1001-01D
*BA03.30-P-
Engine 275
1001-01I
Fig. 115
Installation: The installation position is given by feather
key.
Inspect running surface of hub for signs of wear; if lateral
trueness is not correct:?
AR03.30-P-
Remove belt Check belt pulley/vibration damper (4) for lateral trueness.
1600-01B
4 pulley/vibration *BE03.30-P-
damper (4) Engine 137
1001-02A
*BE03.30-P-
Engine 275
1001-02C
Fig. 116
Fig. 68
Install in the reverse
5
order
BELT PULLEY/VIBRATION DAMPER
Number Designation Engine 275, 285
Radial runout mm -
BE03.30-P-1001-02C Permissible difference at vibration damper
Lateral trueness mm 0.3
BELT PULLEY/VIBRATION DAMPER
Number Designation Engine 137
Radial runout mm -
BE03.30-P-1001-02A Permissible difference at vibration damper
Lateral trueness mm 0.3
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 137
Stage 1 Nm 200
BA03.30-P-1001-01D Central bolt to vibration damper
Stage 2 Angle° 90
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 275, 285
Stage 1 Nm 275
BA03.30-P-1001-01I Central bolt, belt pulley to crankshaft
Stage 2 Angle° 90
Fig. 115: Identifying Counterholder (112 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 116: Identifying Dial Indicator (001 589 53 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 117: Identifying Dial Indicator Holder (363 589 02 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL BELT PULLEY/VIBRATION DAMPER - AR03.30-P-1600SMG
ENGINES 156 in MODEL 216, 221
Fig. 118: Identifying Belt Pulley/Vibration Damper Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
6.8.09 Value changed: vibration damper on crankshaft, 1st stage *BA03.30-P-1001-01Q
Value changed: vibration damper on crankshaft, 2nd stage *BA03.30-P-1001-01Q
Remove/install
Align vehicle between columns of
Risk of death caused by vehicle slipping or vehicle lift and position four support AS00.00-Z-
toppling off of the lifting platform. plates at vehicle lift support points 0010-01A
specified by vehicle manufacturer.
Do not tilt front engine cover, but
1 Remove front engine cover lift upwards vertically otherwise the
retaining lugs can break off.
AR20.40-P-
2 Remove electric fan
5000SMG
AR13.22-P-
3 Remove poly-V belt (3)
1202SMG
Installation: The center bolt (2)
should always be replaced.
Installation: Make two markings
on counterholder (4) to aid applying
tightening angle.
4 Remove center bolt (2) Use extension.
*BA03.30-
P-1001-01Q
Torque wrench Fig. 119
Counterholder Fig. 115
Installation: The groove on belt
Detach belt pulley/vibration damper (1) from pulley/ vibration damper (1) must
5
crankshaft engage in feather key of the
crankshaft.
Checking
Check for scoring and galling; if
Check tread on crankshaft radial sealing ring necessary: ?
6
at hub of belt pulley/vibration damper (1) Replace belt pulley/vibration damper
(1).
Only when replacing belt
7 Replace front crankshaft radial sealing ring pulley/vibration damper (1) or in the AR03.20-P-
event of a leak at crankshaft radial 3000SMG
sealing ring.
8 Install in the reverse order
Check engine oil level and replenish oil if
9
necessary
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns Wear closed and snug-fitting work
0005-01A
during starting procedure or when working clothes.
near the engine as it is running Do not touch hot or rotating parts.
In the event of oil loss determine
and eliminate cause, otherwise
Conduct engine test run and check engine for
10 malfunctions, transmission damage,
leaks
and serious environmental pollution
may occur.
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 156
Stage 1 Nm 250
Stage 2 Releasing
BA03.30-P-1001-01Q Vibration damper on crankshaft
Stage 3 Nm 200
Stage 4 Angle° 180
Fig. 119: Identifying Torque Wrench (000 589 10 99 01)
Courtesy of MERCEDES-BENZ USA
Fig. 120: Identifying Counterholder (112 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL BELT PULLEY/VIBRATION DAMPER - AR03.30-P-1600SX
ENGINES 273 in MODEL 216
ENGINES 272, 273 in MODEL 221
Fig. 121: Identifying Belt Pulley/Vibration Damper Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Switch off ignition
Remove engine intake air duct and front AR09.10-P-
2 See Remove air filter housing.
engine cover 1150SX
AR13.20-P-
3.1 Remove poly-V belt Except model 221.095 /195
0001SX
AR13.22-P-
3.2 Remove both V-belts Model 221.095 / 195
1202SXH
Place engine at center bolt (3) for
4
crankshaft at TDC
Install retaining lock for crankshaft/starter AR03.30-P-
5 Except model 221.095 /195
ring gear 5000SX
6.1 Remove center bolt (3) Except model 221.095 /195
Installation: Replace center bolt
(3).
*BA03.30-
P-1001-01M
Remove center bolt (3); to do this
6.2 counterhold belt pulley/vibration damper Model 221.095 / 195
(2) with a counterholder
Installation: Replace center bolt
(3).
Fig. 123
pulley
Vehicles a twin-belt pulley Fig. 122
Installation: Place belt
pulley/vibration damper (2) on
Detach belt pulley/vibration damper (2) crankshaft and rotate to ensure that
7
from crankshaft groove of belt pulley/vibration damper
(2) is engaged in feather key (4) of
crankshaft.
Checking
Check contact surface of crankshaft radial Check for scoring and galling, if
8 sealing ring (5) at hub of belt necessary, replace belt pulley/vibration
pulley/vibration damper (2) damper (2).
When replacing belt pulley /vibration
AR03.20-P-
9 Replace front crankshaft radial seal (5) damper (2) or in the event of leaks on
3000SX
crankshaft radial sealing ring (5).
10 Install in the reverse order
Checking
Risk of accident caused by vehicle
Secure vehicle to prevent it from
starting off by itself when engine is
moving by itself.
running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-fitting work
contusions and burns during starting 0005-01A
clothes.
procedure or when working near the
Do not touch hot or rotating parts.
engine as it is running
Conduct engine test run and check engine
11
for leaks
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 272 Engine 273
Stage 1 Nm 200 200
BA03.30-P-1001-01M Center bolt for belt pulley on crankshaft
Stage 2 Angle° 90 90
Fig. 122: Identifying Counterholder (272 589 00 07 00)
Courtesy of MERCEDES-BENZ USA
Fig. 123: Identifying Counterholder (272 589 01 07 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL RETAINING LOCK FOR CRANKSHAFT/RING GEAR - AR03.30-P-5000SMG
ENGINE 156 in MODEL 216, 221 with TRANSMISSION 722
Fig. 124: Identifying Retaining Lock
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
lifting platform and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at lifting platform
toppling off the lifting platform. 0010-01A
support points specified by vehicle
manufacturer.
Risk of injury caused by moving parts Keep all body parts and limbs away
AS00.00-Z-
that can pinch, crush or, in extreme cases from moving mechanical
0009-01A
even sever extremities. components.
1 On vehicles with code 889,
(transmitter key). start/stop button repeatedly until
ignition is switched off
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant gloves,
caused by swallowing battery acid. Risk of AS54.10-Z-
clothing and glasses. Only pour
injury caused by burns to skin and eyes 0001-01A
battery acid into suitable and
from battery acid or when handling damaged
appropriately marked containers.
lead-acid batteries
Insulate clamping device of
ground line in order to prevent AR54.10-
2 Disconnect ground line from battery
inadvertent contact with ground point P-0003SX
of battery.
AH54.10-
Notes on battery All models P-0001-
01A
AR00.60-
3 Raise vehicle with lifting platform
P-1000SX
AR15.30-
4 Remove starter P-
7100SMG
Slide retaining lock into starter
opening (see arrow) and allow to
latch into ring gear. If required,
5 Insert retaining lock (1) into starter opening continue turning engine at center bolt
on the crankshaft in direction of
rotation of the engine.
Retaining lock Fig. 125
6 Install in the reverse order
7 Perform basic programming
Fig. 125: Identifying Retaining Lock (112 589 03 40 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL RETAINING LOCK FOR CRANKSHAFT/RING GEAR - AR03.30-P-5000SX
ENGINES 157, 273, 278 in MODEL 216
ENGINES 157, 272, 273, 276, 278 (except 272.974) in MODEL 221
Shown on vehicle without 4-MATIC
Fig. 126: Identifying Retaining Lock, Nut And Cover
Courtesy of MERCEDES-BENZ USA
Installing, removing
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off of the
support points specified by vehicle 0010-01A
lifting platform.
manufacturer.
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and AS00.00-Z-
caused by handling hot or
safety glasses, if necessary. 0002-01A
glowing objects.
Remove shield above the front
1 Vehicles with 4MATIC
axle transmission drive shaft
*BA33.30-P-
1009-03G
For vehicles with 4-MATIC the cover (2) is
Unscrew nuts (1) and remove on the right engine side of the vehicle and for
2
bolts from transmission bell vehicles without 4-MATIC the cover (2) is on
the left engine side (see picture).
*BA27.40-P-
1001-01E
Remove cover (2) from
3
crankcase
Checking
rotating engine at the center bolt for crankshaft
Check splines of ring gear for
4 in its direction of rotation. Replace clutch plate
drive plate
if necessary: ?
AR03.30-P-
Engine 272, 273
8001SX
AR03.30-P-
Engine 157, 276, 278
8001MM
Fig. 127
Risk of injury caused by
No parts of the body or limbs should be within
moving parts that can pinch, AS00.00-Z-
the operating range of the mechanism when
crush or, in extreme cases, even 0009-01A
moving components.
sever extremities
If required, rotate engine further at center
Insert retaining lock (01) into bolt for crankshaft in engine's direction of
5
access opening rotation until the retaining lock (01) snaps into
place.
Fig. 125
6 Remove in the reverse order
HOUSING
Transmission 722.9 in Model 216,
Number Designation
221
BA27.40-P-1001- Bolt, automatic transmission to
Nm 39
01E crankcase
FRONT AXLE TRANSMISSION
Number Designation Model 216 Model 221
BA33.30-P-1009-03G Collar bolt, shield to shield bracket Nm 8 8
Fig. 127: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 128: Identifying Retaining Lock (112 589 03 40 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL RETAINING LOCK FOR CRANKSHAFT / RING GEAR - AR03.30-P-5000SZ
ENGINE 275 in MODEL 216, 221
Fig. 129: Removing/Installing Retaining Lock For Crankshaft/Ring Gear
Courtesy of MERCEDES-BENZ USA
Install/remove
AR15.30-P-
1 Remove starter
7100SZ
Slide retaining lock (1) into starter opening and
Insert allow to latch in starter ring gear; crank engine at crankshaft
2 in direction of rotation if necessary.
retaining lock (1)
Fig. 130
Remove in the
3
reverse order
Fig. 130: Identifying Retaining Lock (285 589 02 40 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL FLYWHEEL / DRIVE PLATE - AR03.30-P-8001MC
ENGINE 275 in MODEL 215, 216, 220, 221
Fig. 131: Identifying Clutch Plate, Screw And Washer
Courtesy of MERCEDES-BENZ USA
Remove/install
AR27.10-P-
Model 215, 220
Remove automatic 0500I
1
transmission AR27.10-P-
Model 216, 221
0500SZ
AR03.30-P-
Model 215, 220
2 Install retaining lock 5000B
Model 216, 221 5000SZ
Installation: replace bolts (2), as if they are used
again, the connection may not be tight or the bolts may
Remove bolts (2) from
3 shear off.
drive plate (1)
*BA03.30-P-
1003-01I
4 Remove washer (3)
Remove drive plate (1) Installation: The cylindrical pin (arrow) determines
5
with starter ring gear the installation position.
Install in the reverse
6
order
If a new drive plate (1) is installed, perform
initialization in the ME-SFI [ME] control unit with
7 Carry out initialization STAR DIAGNOSIS in the menu point "Control unit
adaptation".
STAR DIAGNOSIS Compact diagnosis system for
passenger cars
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 275, 285
BA03.30-P-1003- Bolt, flywheel or two-mass Stage 1 Nm 45
01I flywheel/drive plate to crankshaft Stage 2 Angle° 90
REMOVE/INSTALL FLYWHEEL / DRIVE PLATE - AR03.30-P-8001MM
ENGINE 157, 278 in MODEL 216, 221
Shown on engine 278
Fig. 132: Identifying Drive Plate Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove transmission Model 216 except 216.39 AR27.10-P-0500SX
with torque converter Model 221 except
221.08/094/18/194
Model 221.08/18 AR27.10-P-0500SYZ
Model 216.39
Model 221.094/194
2 Install retaining lock for AR03.30-P-5000SX
crankshaft/starter ring
3 Remove bolts (1a) from Do not use an impact AR03.30-P-8001-02MM
drive plate (1) wrench/driver or
compressed air tool in order
to unscrew and screw in the
bolts (1), otherwise the
threads in the crankshaft
will be damaged
Installation: Replace bolts *BA03.30-P-1002-01M
(1a)
4 Remove drive plate (1) Installation: The cylinder
from crankshaft flange pin (2) determines the
installation location of
drive plate (1)
Checking
5 Check threaded union (3) In case of damaged or loose
in the drive plate (1) threaded unions (3), drive
plate (1) must be replaced.
6 Install in the reverse
order
7 Carry out first Only when replacing AD00.00-P-2000-04A
initialization and then
sensor rotor adaptation Menu Guidance:
using STAR *Engine control Module
DIAGNOSIS *Adaptations
*Learning processes
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 157 Engine 276 Engine 278
BA03.30-P- Bolt, starter ring gear/ Stage 1 Nm 20 20 20
1002-01M drive plate to crankshaft Stage 2 Nm 45 45 45
Stage 3 Angle° 90 90 90
REMOVE/INSTALL FLYWHEEL /CLUTCH PLATE - AR03.30-P-8001-02MM
ENGINE 157
Fig. 133: Identifying Flywheel/Clutch Plate Components
Courtesy of MERCEDES-BENZ USA
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 157
BA03.30-P-1002- Screw/bolt, starter Stage 1 Nm 20
01M ring gear/ drive Stage 2 Nm 45
plate to crankshaft Stage 3 Angle° 90
Fig. 134: Identifying Retaining Lock (112 589 03 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 135: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Detaching
Do not use any impact wrench/driver or compressed air tool to screw bolts (1 to 8) in and out. The
thread in the crankshaft (10) can get damaged otherwise.
1 Insert retaining lock for starter ring gear and block engine. If necessary rotate
engine at center bolt of crankshaft (10) until the retaining lock latches correctly in
the starter ring gear.
2 Loosen screw/bolts (1 to 8) as per figure in the numerical sequence.
3 Remove retaining lock
4 Remove screw/bolts (1 to 8) and front perforated plate (11v)
5 Remove drive plate (12)
6 Remove rear perforated plate (11h)
Checking
7 Check drive plate (12) for damage.
In case of damaged or loose threaded unions (13), drive plate (12) must be
replaced.
8 Check positioning pin (9) on crankshaft (10) and replace if necessary.
Attaching
Bolts (1 to 8) as well as the front and rear perforated plate (11h, 11v) must be replaced after each
disassembly.
Faulty installation or
swapping of the
perforated plates
(11h, 11y) leads to
engine and
transmission
damage!
9 Position rear perforated plate (11h) on the crankshaft (10).
The rear perforated plate (11h) has a disc thickness of 2mm.
10 Position drive plate (12) on the crankshaft (10).
11 Position front perforated plate (11h) on the crankshaft (10).
The front perforated plate (11h) has a disc thickness of 3.5mm
12 Screw in bolts (1 to 8) by hand and tighten finger-tight. Tightening of screw/bolts
(1 to 8) must take place in four stages according to the numerical sequence shown
in the figure.
13 Insert retaining lock for starter ring gear and block engine. If necessary rotate
engine at center bolt of crankshaft (10) until the retaining lock latches correctly in
the starter ring gear.
14 Tighten screw/bolts (1 to 8) as per figure in the numerical sequence to stage 1.
Observe correct sequence.
15 Tighten screw/bolts (1 to 8) as per figure in the numerical sequence to stage 2.
Observe correct sequence.
16 Tighten screw/bolt (1 to 8) as per figure in the numerical sequence to stage 3. Only
on vehicle with gasoline engine. Observe correct sequence.
17 Remove retaining lock
REMOVE/INSTALL FLYWHEEL/DRIVE PLATE - AR03.30-P-8001SMG
ENGINE 156 in MODEL 216, 221 with TRANSMISSION 722
Fig. 136: Identifying Drive Plate, Flex Plate, Straight Pin And Bolts
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off the lifting
support points specified by vehicle 0010-01A
platform.
manufacturer.
AR27.10-P-
1 Remove automatic transmission
0500SX
Install retaining lock for AR03.30-P-
2
crankshaft (5) and starter ring gear 5000SMG
Installation: Replace bolts (3) since, if
they are used again, the connection may not
Remove bolts (3) from drive plate
3 be tight or the bolts may shear off.
(1)
*BA03.30-P-
1002-01Q
Installation: The flex plate (2) must be
installed back into the same position as
4 Remove flex plate (2)
bulging caused by the bolts may generate an
incorrect torque.
5 Remove drive plate (1) Installation: The straight pin (4)
determines the installation position.
6 Install in the reverse order
If a new drive plate (1) is installed,
7 Carry out initialization perform initialization in the ME control unit
"Control unit adaptation".
Connect STAR DIAGNOSIS and
AD00.00-P-
read out fault memory STAR
2000-04A
DIAGNOSIS diagnosis system
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 156
Stage 1 Nm 20
BA03.30-P-1002-01Q Bolt, starter ring gear/drive plate to crankshaft Stage 2 Nm 45
Stage 3 Angle° 90
REMOVE/INSTALL FLYWHEEL / DRIVE PLATE - AR03.30-P-8001SX
ENGINE 273 in MODEL 216
ENGINE 272, 273 (except 272.974) in MODEL 221
Fig. 137: Identifying Clutch Plate, Cylinder Pin, Threaded Tool And Screws
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove automatic Vehicles without 4MATIC AR27.10-P-0500SX
transmission together with
torque converter Vehicles with 4MATIC AR27.10-P-0500SYZ
2 Install retaining lock for AR03.30-P-5000SX
crankshaft/starter ring
gear
3 Remove bolts (1a) from Installation:
drive plate (1) tightening angle wrench is
available, the bolts can be
torqued further by the
specified angle in a single
operation using a wrench
and tommy lever (1a).
To avoid any angle errors,
a bending rod torque
wrench must not be used
for tightening according to
angle degrees. This
falsifies the tightening
torque.
*BA03.30-P-1002-01M
4 Remove drive plate (1) Installation: The
from crankshaft flange cylinder pin (2)
determines the installation
location of drive plate (1).
Checking
5 Check threaded union (3) In case of damaged or
in the drive plate (1) loose threaded unions (3),
drive plate (1) must be
replaced.
6 Install in the reverse order
7 Carry out first Only when replacing.
initialization and then
sensor rotor adaptation
using STAR DIAGNOSIS
Menu guidance:
Engine control
module
Adaptations
Learning processes
Connect STAR AD00.00-P-2000-04A
DIAGNOSIS and read out
fault memory
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 272 Engine 273
BA03.30-P- Bolt, starter ring gear/drive Stage 1 Nm 20 20
1002-01M plate to crankshaft Stage 2 Nm 45 45
Stage 3 Angle° 90 90
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: CRANK ASSEMBLY - BA03.00-Z-9999AZ
MODEL all
BA03.20-P-
Balance shaft ENGINE 651
1000-02H
BA03.20-P-
Balance shaft ENGINE 155
1000-02G
BA03.20-P-
Balance shaft ENGINE 628.960 /961 /962 /963, 629
1000-02B
BA03.20-P-
Balance shaft ENGINE 271
1000-02C
BA03.20-P-
Balancing shaft ENGINE 112 / /, 272
1000-02A
BA03.20-P-
Balancing shaft ENGINE 642 /
1000-02D
BA03.10-P-
Connecting rod ENGINE 611, 612, 613, 628, 629
1000-01I
BA03.10-P-
Connecting rod ENGINE 646, 647, 648
1000-01P
BA03.10-P-
Connecting rod ENGINE 642
1000-01L
BA03.10-P-
Connecting rods ENGINE 601, 602 /, 603 / (except, 602.98 /98)
1000-01C
BA03.10-P-
Connecting rods ENGINE 651
1000-01R
BA03.10-P-
Connecting rods ENGINE 640
1000-01M
BA03.10-P-
Connecting rods ENGINE 266
1000-01J
BA03.10-P-
Connecting rods ENGINE 111
1000-01H
ENGINE 112 / /, 113 /, 137, 157, 271, 272, 273 /, BA03.10-P-
Connecting rods
275, 285, 276, 278 1000-01E
BA03.10-P-
Connecting rods ENGINE 156, 159
1000-01Q
BA03.10-P-
Connecting rods ENGINE 103 /, 104 /, 120
1000-01A
BA03.10-P-
Connecting rods ENGINE 604, 605, 606 /
1000-01B
BA03.10-P-
Connecting rods ENGINE 668.914 /940 /941 /942
1000-01G
BA03.10-P-
Connecting rods ENGINE 119
1000-01D
BA03.10-P-
Connecting rods ENGINE 166.940 /960 /961 /990 /991 /995
1000-01F
ENGINE 111, 601 /943, BA03.20-N-
Crankshaft
602.980 /982 /983 /984 /985 1000-01A
BA03.20-P-
Crankshaft ENGINE 640
1000-01F
BA03.20-P-
Crankshaft ENGINE 651
1000-01K
ENGINE 601, 602, 603, 604, 605, 606, 611, 612, BA03.20-P-
Crankshaft
613, 646, 647, 648... 1000-01A
BA03.20-P-
Crankshaft ENGINE 119, 120
1000-01C
BA03.20-P-
Crankshaft ENGINE 112 / /, 113 /, 157, 272, 273 /, 276, 278
1000-01D
BA03.20-P-
Crankshaft ENGINE 103 /, 104 /, 111, 271
1000-01B
BA03.20-P-
Crankshaft ENGINE 642 /
1000-01E
BA03.20-P-
Crankshaft ENGINE 156
1000-01J
BA03.20-P-
Crankshaft ENGINE 159
1000-01L
ENGINE 111, 601 /943, BA03.10-N-
diameters
602.980 /982 /983 /984 /985 1000-01A
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 651
damper, starter ring gear 1000-01R
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 668.914 /940 /941 /942
damper, starter ring gear 1000-01F
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 646.8 /951 /961 /962 /963 /966, 647, 648
damper, starter ring gear 1000-01H
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 103 /, 104 /, 111
damper, starter ring gear 1000-01B
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 157, 272, 273 /, 276, 278
damper, starter ring gear 1000-01M
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 112 / /, 113 /, 137, 155
damper, starter ring gear 1000-01D
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 166.940 /960 /961 /990 /991 /995
damper, starter ring gear 1000-01E
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 628.960 /961 /962 /963, 629, 642 /
damper, starter ring gear 1000-01G
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 156, 159
damper, starter ring gear 1000-01Q
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 119, 120
damper, starter ring gear 1000-01C
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 640
damper, starter ring gear 1000-01O
Flywheel, driven plate, vibration ENGINE 601, 602, 603, 604, 605, 606, 611, 612, BA03.30-P-
damper, starter ring gear 613, 647... 1000-01A
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 271, 275, 285
damper, starter ring gear 1000-01I
Flywheel, driven plate, vibration BA03.30-P-
ENGINE 266
damper, starter ring gear 1000-01N
BA03.20-P-
Lanchester balancer ENGINE 640, 646.8 /961 /962 /963 /966
1000-03A
CONNECTING RODS - BA03.10-P-1000-01E
Engine 112, 113, 137, 157, 271, 272, 273, 275, 276, 278, 285
CONNECTING ROD
Number Designation Engines 112, 113 Engine 137 Engine 157
Stage 1 Nm 5 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 25 15 25
Stage 3 Angle° 90 90 90
CONNECTING ROD
Number Designation Engine 271 Engine 272
Stage 1 Nm 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 15 20
Stage 3 Angle° 90 90
CONNECTING ROD
Number Designation Engine 273 Engine 275, 285
Stage 1 Nm 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 25 15
Stage 3 Angle° 90 90
CONNECTING ROD
Number Designation Engine 276 Engine 278
Stage 1 Nm 5 5
BA03.10-P-1001-01E Connecting rod bolt Stage 2 Nm 25 25
Stage 3 Angle° 90 90
CONNECTING RODS - BA03.10-P-1000-01Q
Engine 156, 159
MODIFICATION NOTES
11.12.09 Value changed: connecting rod bearing cap on the connecting rod
Value changed: connecting rod bearing cap on the connecting rod
CONNECTING ROD
Engine Engine
Number Designation
156 159
STAGE
Nm 10 10
1
Stage 2 Nm 40 40
BA03.10-P-1001- Connecting rod bearing cap on connecting Stage 3 Angle° 120 120
01Q rod Stage 4 Releasing Releasing
Stage 5 Angle° 10 10
Stage 6 Nm 40 40
Stage 7 Angle° 90 90
CRANKSHAFT - BA03.20-P-1000-01D
Engine 112, 113, 157, 272, 273, 276, 278
MODIFICATION NOTES
10.2.10 Value changed: side crankshaft bearing cap bolt, stage 1 Engine 272
Value changed: side crankshaft bearing cap bolt, stage 2 Engine 272
CRANKSHAFT BEARING CAP
Engines 112, Engine Engine
Number Designation
113 157 272
Stage
Nm 20 20 20
BA03.20-P-1001- Bolt for crankshaft bearing 1
M8
01D cap Stage
Angle° 90 90 90
2
Stage
Nm 30 20 20
BA03.20-P-1002- Side crankshaft bearing 1
M8
01D cap bolt Stage
Angle° - 90 90
2
Stage
Nm 5 5 5
1
Stage
Nm 30 30 30
BA03.20-P-1003- Bolt for crankshaft bearing 2
M10
01D cap Stage
Angle° 90 90 90
3
CRANKSHAFT BEARING CAP
Engine Engine Engine
Number Designation
273 276 278
Stage
Nm 20 20 20
BA03.20-P-1001- Bolt for crankshaft bearing 1
M8
01D cap Stage
Angle° 90 90 90
2
Stage
Nm 20 20 20
BA03.20-P-1002- Side crankshaft bearing cap 1
M8
01D bolt Stage
Angle° 90 90 90
2
Stage
Nm 5 5 5
1
BA03.20-P-1003- Bolt for crankshaft bearing Stage
M10 Nm 30 30 30
01D cap 2
Stage
Angle° 90 90 90
3
CRANKSHAFT - BA03.20-P-1000-01J
Engine 156
CRANKSHAFT BEARING CAP
Engine
Number Designation
156
Stage
Nm 20
1
Stage
Nm 32
2
Stage
Angle° 90
3
Stage
M9 4 Angle° 90
Stage
Releasing
5
Stage
Nm 20
6
Stage
Nm 32
7
Stage
Angle° 90
8
Stage
Angle° 90
9
Stage
Nm 20
1
Stage
Nm 40
2
Stage
Angle° 90
3
BA03.20-P- Crankshaft bearing cap bolt (lower section of crankcase/ Stage
Angle° 90
1001-01J main bearing threaded connection) 4
Stage
M10 Releasing
5
Stage
Nm 20
6
Stage
Nm 40
7
Stage
Angle° 90
8
Stage
Angle° 90
9
BA03.20-P- M6 Nm 8.5
Crankcase lower section on crankcase upper section
1002-01J M8 Nm 20
BA03.20-P-
Bearing bolt to crankcase at front for chain drive Nm 20
1003-01J
BA03.20-P-
Axle journal on crankcase at the front for chain drive Nm 30
1004-01J
BA03.20-P- Fastening for cover plate for oil thermostat on crankcase
M6 Nm 8.5
1005-01J top section
BA03.20-P-
Oil line (oil radiator) with bracket M8 Nm 20
1006-01J
BA03.20-P-
Knock sensor shield M8 Nm 20
1007-01J
BA03.20-P- Bolt for oil dipstick guide tube on camshaft adjuster
M6 Nm 8.5
1008-01J cover
BA03.20-P-
Drain screw for coolant Nm 15
1009-01J
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR - BA03.30-P-1000-
01I
ENGINE 271, 275, 285
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Engine Engines 275,
Number Designation
271 285
1st
Nm 200 275
BA03.30-P- stage
Central bolt of belt pulley to crankshaft
1001-01I 2nd
Angle° 90 90
stage
BA03.30-P-
Bolt of retaining lock to oil pan Nm 10 -
1002-01I
1st
Nm 45 45
BA03.30-P- Bolt for flywheel or two-mass flywheel / stage
1003-01I driven plate to crankshaft 2nd
Angle° 90 90
stage
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR - BA03.30-P-1000-
01M
Engines 157, 272, 273, 276, 278
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Engine Engine Engine Engine
Number Designation
157 272 273 276
Stage
Nm 200 200 200 200
BA03.30-P- Center bolt for belt pulley on 1
1001-01M crankshaft Stage
Angle° 180 90 90 180
2
Stage
Nm 20 20 20 20
1
BA03.30-P- Bolt, starter ring gear/drive plate to Stage
Nm 45 45 45 45
1002-01M crankshaft 2
Stage
Angle° 90 90 90 90
3
Stage
Nm - 45 45 -
BA03.30-P- Bolt, flywheel or two-mass 1
1003-01M flywheel / drive plate to crankshaft Stage
Angle° - 90 90 -
2
Stage
Nm - 20 - -
1
BA03.30-P- Bolt, starter ring gear/starter- Stage
Nm - 45 - -
1004-01M alternator to crankshaft 2
Stage
Angle° - 90 - -
3
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Engine
Number Designation
278
Stage
Nm 200
BA03.30-P-1001- 1
Center bolt for belt pulley on crankshaft
01M Stage
Angle° 180
2
Stage
Nm 20
1
BA03.30-P-1002- Stage
Bolt, starter ring gear/drive plate to crankshaft Nm 45
01M 2
Stage
Angle° 90
3
Stage
Nm -
BA03.30-P-1003- Bolt, flywheel or two-mass flywheel / drive plate to 1
01M crankshaft Stage
Angle° -
2
Stage
Nm -
1
BA03.30-P-1004- Stage
Bolt, starter ring gear/starter-alternator to crankshaft Nm -
01M 2
Stage
Angle° -
3
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR - BA03.30-P-1000-
01Q
Engine 156, 159
MODIFICATION NOTES
6.8.09 Value changed: Vibration damper on crankshaft, 1st stage Engine 156
Value changed: Vibration damper on crankshaft, 2nd stage Engine 156
6.8.09 Value changed: Vibration damper on crankshaft, 1st stage Engine 156
Value changed: Vibration damper on crankshaft, 2nd stage Engine 156
6.8.09 Value changed: Vibration damper on crankshaft, 1st stage Engine 156
Value changed: Vibration damper on crankshaft, 2nd stage Engine 156
6.8.09 Value changed: Vibration damper on crankshaft, 1st stage Engine 156
Value changed: Vibration damper on crankshaft, 2nd stage Engine 156
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Engine Engine
Number Designation
156 159
Stage
Nm 250 250
1
Stage
Releasing Releasing
2
BA03.30-P-1001- Stage
Vibration damper on crankshaft Nm 200 200
01Q 3
Stage
Angle° 180 180
4
Stage
Nm 20 20
1
BA03.30-P-1002- Bolt, starter ring gear/drive plate to Stage
Nm 45 45
01Q crankshaft 2
Stage
Angle° 90 90
3
BA03.30-P-1003-
Guide wheel on crankcase M10 Nm 58 55
01Q
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: CRANK ASSEMBLY - BE03.00-Z-
9999AZ
MODEL all
Belt pulley / BE03
vibration ENGINE 642 / P-100
damper 02D
Belt BE03
pulley/vibration ENGINE 120 P-100
damper 02B
Belt BE03
pulley/vibration ENGINE 271, 275, 285 P-10
damper 02C
Belt BE03
pulley/vibration ENGINE 111, 112 /, 113 /, 137, 155.980 P-100
damper 02A
BE03
Check values
ENGINE 120 P-100
for a crankshaft
02B
BE03
Check values
ENGINE 651 P-100
for a crankshaft
02H
Check values BE03
for connecting ENGINE 112, 113, 155... P-100
rod 01D
for connecting P-100
ENGINE 137.970
rod 01E
Check values BE03
for connecting ENGINE 601.943, 602.980 /982 /983 /984 /985 N-10
rod 01D
Check values BE03
for connecting ENGINE 601, 602, 603, 604, 605, 606, 611, 612, 613, 628, 646, 647, 648... P-100
rod 01C
Check values BE03
for connecting ENGINE 103 /, 104 /, 119, 120 P-100
rod bolts 03B
Check values
BE03
for crankshaft
ENGINE 604, 605, 606, 611, 612, 613, 646, 647, 648... P-100
main bearing
03A
shells
BE03
Check values ENGINE
P-100
for piston rings 271.8 /910 /911 /921 /940 /941 /942 /944 /946 /948 /950 /952 /954 /955 /956 /957
05C
BE03
Check values
ENGINE 646.951 /8 /961 /962 /963 /966, 647, 648 P-100
for piston rings
05J
BE03
Check values
ENGINE 157, 272.91 /92 /94 /95 /96 /97 /98 /99, 273.92 /96 /97 /96, 276, 278 P-10
for piston rings
05D
BE03
Check values
ENGINE 651 P-100
for piston rings
05K
BE03
Check values
ENGINE 112, 113, 137, 155, 275, 285... P-10
for piston rings
05B
BE03
Check values
ENGINE 112, 113, 155, 272, 273... P-10
for pistons
02D
BE03
Crankshaft test
ENGINE 111, 112.951 /976, 166.940 /960 /990, 668.940 /941 /942 P-100
data
02A
BE03
Crankshaft test
ENGINE 601, 602 /, 603 / (except, 602.98 /98) P-100
data
02C
BE03
Crankshaft test
ENGINE 640 P-100
data
02F
BE03
Crankshaft test
ENGINE 604, 605, 606 /, 611, 612.961 /962 /963 /990, 613 P-100
data
02D
BE03
Crankshaft test
ENGINE 601.943, 602.980 /981 /982 /983 /984 /985 N-10
data
02D
BE03
Flywheel ENGINE 601, 603 / P-100
03C
BE03
Flywheel ENGINE 103 /, 104 /, 111 P-100
03B
BE03
Flywheel ENGINE 601, 602 /, 604, 605, 606 / P-100
03A
BE03
Flywheel,
ENGINE 103 /, 104 /, 119, 120 P-100
driven plate
01B
BE03
Flywheel,
ENGINE 111, 271, 604, 605, 606, 611.96 /981 /983 /987, 612.981 /96 /99, 613 P-100
driven plate
01A
BE03
Flywheel,
ENGINE 601, 602 /, 603 / (except, 602.98 /98) P-100
driven plate
01C
Inspection data
BE03
of bolts for
ENGINE 601, 602 /982 /983 N-10
crankshaft
01B
bearing caps
Inspection data
BE03
of bolts of
ENGINE 640 P-100
crankshaft
01E
bearing caps
Inspection data
BE03
of bolts of
ENGINE 642 P-100
crankshaft
01D
bearing caps
Inspection data BE03
of connecting ENGINE 111, 166, 668... P-100
rod 01A
Inspection data BE03
of connecting ENGINE 120 P-100
rod 01B
Inspection data BE03
of connecting ENGINE 640 P-100
rod 01F
BE03
Inspection data
ENGINE 640 P-100
of conrod bolts
03G
BE03
Inspection data
ENGINE 166.940 /960 /961 /990 /991 /995 P-100
of conrod bolts
03E
Inspection data
BE03
of crankshaft
ENGINE 651 P-100
bearing cap
01F
bolts
Inspection data
BE03
of crankshaft
ENGINE 137, 275, 285 P-10
bearing cap
01C
bolts
Inspection data
BE03
of crankshaft
ENGINE 640 P-100
bearing
04F
clearance
Inspection data BE03
of crankshaft ENGINE 111, 166.940 /960 /990, 668.940 /941 /942 P-100
bearing play 04D
Inspection data
BE03
of crankshaft
ENGINE 628.960 /961 /962 /963, 629, 642 P-100
main bearing
03D
shells
Inspection data
BE03
of crankshaft
ENGINE 157, 276, 278 P-100
main bearing
03K
shells
Inspection data
BE03
of crankshaft
ENGINE 640 P-100
main bearing
03H
shells
Inspection data
BE03
of crankshaft
ENGINE 612.967 in MODEL 209 P-100
main bearing
03F
shells
BE03
Inspection data
ENGINE 640 P-100
of piston rings
05I
BE03
Inspection data
ENGINE 266.920 /940 /960 /980 P-100
of piston rings
05F
BE03
Lanchester
ENGINE 640, 646.961 /962 /963 /966 /8 P-100
balancer
05A
Starter ring BE03
ENGINE 602 /, 604, 605, 606 /, 611, 612.961 /962 /963 /965 /966 /967 /990
gear
04A
BE03
Starter ring
ENGINE 120 P-100
gear
04B
BE03
TDC sensor
ENGINE 604, 605, 606 / P-100
bracket
01A
Test BE03
dimensions for ENGINE 601.943, 602.980 /982 /983 /984 /985 N-10
pistons 02E
Test
BE03
specifications
ENGINE 651 P-100
for a
01H
connecting rod
Test
BE03
specifications
ENGINE 111, 112, 113, 137, 157, 271, 272, 273, 275, 276, 278, 285, 604, 605, 606... P-10
for connecting
03A
rod bolts
Test
BE03
specifications
ENGINE 651 P-100
for connecting
03I
rod bolts
Test BE03
specifications ENGINE 156, 159 P-10
for crankshaft 02I
Test BE03
specifications ENGINE 157, 276, 278 P-100
for crankshaft 02J
Test
specifications BE03
for crankshaft ENGINE 112, 113, 137, 155, 156, 159, 271, 272, 273, 275, 285... P-10
bearing 04E
clearance
Test
specifications BE03
for crankshaft ENGINE 604, 605, 606, 611, 612, 613, 628, 629, 642, 646, 647, 648, 651... P-100
bearing 04A
clearance
Test
specifications BE03
for crankshaft ENGINE 156, 159 P-10
main bearing 03J
shells
Test
for crankshaft P-100
main bearing ENGINE 651 03I
shells
Test
specifications BE03
for crankshaft ENGINE 601, 602, 603 P-100
main bearing 03B
shells
Test
specifications BE03
for crankshaft ENGINE 137, 275.950 /951 /953 /954 /980 /981 /982 /983, 285.950 /980 P-10
main bearing 03E
shells
Test BE03
specifications ENGINE 651 P-100
for pistons 02J
Test BE03
specifications ENGINE 646.951 /8 /961 /962 /963 /966, 647, 648 P-100
for pistons 02I
Test BE03
specifications ENGINE 271, 275, 285... P-10
for pistons 02F
BE03
Test values for
ENGINE 629, 642 / P-100
connecting rod
01G
Test values for BE03
connecting rod ENGINE 601, 602 /, 603 / (except, 602.98 /98) P-100
bolts 03C
BE03
Test values for
ENGINE 611, 612, 613, 628, 629, 642, 646, 647, 648, 668... P-100
conrod bolts
03D
BE03
Test values for
ENGINE 629, 642, 646 P-100
crankshaft
02E
Test values for
BE03
crankshaft
ENGINE 111, 604, 605, 606, 611, 612, 613, 628, 646, 647, 648... P-100
bearing cap
01A
bolts
Test values for
BE03
crankshaft
ENGINE 601, 602, 603 P-100
bearing cap
01B
bolts
Test values for BE03
crankshaft ENGINE 120 P-100
bearing play 04B
Test values for BE03
crankshaft ENGINE 601.943, 602.980 /981 /982 /983 /984 /985 N-10
bearing play 04A
Test values for BE03
crankshaft ENGINE 601, 602 /, 603 / (except, 602.982) P-100
bearing play 04C
Test values for
BE03
crankshaft
ENGINE 111 P-100
main bearing
03C
shells
Test values for
BE03
crankshaft
ENGINE 601.943, 602.980 /981 /982 /983 /984 /985 N-10
main bearing
03A
shells
BE03
Test values for
ENGINE 120 P-100
piston rings
05A
BE03
Test values for
ENGINE 642 P-100
piston rings
05E
BE03
Test values for ENGINE
P-100
pistons 111.920 /921 /940 /941 /942 /943 /944 /945 /946 /947 /960 /961 /970 /973 /974 /975 /977
02A
BE03
Test values for
ENGINE 642 P-100
pistons
02G
BE03
Test values for
ENGINE 120 with CODE (473) Engine mit niederer Verdichtung P-100
pistons
02C
BE03
Test values for
ENGINE 137.970 P-100
pistons
02E
BE03
Test values for
ENGINE 640 P-100
pistons
02H
BE03
Test values for
ENGINE 601, 602, 603, 604, 605, 606, 611, 612, 613, 628, 629, 642... P-100
pistons
02B
CHECK VALUES FOR PISTONS - BE03.10-P-1000-02D
Engines 112, 113, 155, 272, 273
MODIFICATION NOTES
23.4.10 Value modified: Piston diameter Engine 273.96/97
CHECK VALUES FOR PISTONS
Engines
Number Designation 112.910/911 Engine 112.912 Engine 112.913
BE03.10-P- Piston Standard mm 83.175...83.195 83.175...83.195 89.875...89.895
1001-02D diameter identification X
Auxiliary mm mm 83.225...83.245 83.225...83.245 89.922...89.952
identification
Repair size mm 83.425...83.445 83.425...83.445 90.125...90.145
BE03.10-P- Piston Standard mm < or =0.040 < or =0.040 < or =0.043
1002-02D clearance identification X
Auxiliary mm < or =0.040 < or =0.040 < or =0.043
Repair size mm < or =0.040 < or =0.040 < or =0.043
CHECK VALUES FOR PISTONS
Engine
113.960/
961/962961/
962/ 963/
964/965965/
967/ 967/
Engines 968/971980/
Engines 112.946/ 981/ 980/
112.920/921/940 /941/942/943/944/945, 946/947/ 981/982984/
Number Designation 113.940/941/942/944 949/960 990/ 984
BE03.10- Piston Standard mm 89.872...89.902 89.872...89.902 96.972...97.000
P-1001- diameter identification
02D X
Auxiliary mm 89.872...89.902 89.872...89.902 97.022...97.050
Repair size mm 90.122...90.152 90.122...90.152 97.222...97.250
BE03.10- Piston Standard mm < or =0.043 < or =0.043 < or =0.043
P-1002- clearance identification
02D X
Auxiliary mm < or =0.043 < or =0.043 < or =0.043
Repair size mm < or =0.043 < or =0.043 < or =0.043
CHECK VALUES FOR PISTONS
Engine
112.960/960/961 Engines Engine
Number Designation 961 AMG 113.987/988/989/990/991/992/993/995 155
BE03.10- Piston Standard mm 89.875...89.895 96.975...96.995 -
P-1001- diameter identification
02D X
Auxiliary mm 89.925...89.945 97.025...97.045 -
Repair size mm 90.125...90.145 97.225...97.245 -
BE03.10- Piston Standard mm < or =0.04 0.005...0.040 -
P-1002- clearance identification
02D X
Auxiliary mm < or =0.04 0.005...0.040 -
identification
Repair size mm < or =0.04 0.005...0.040 -
CHECK VALUES FOR PISTONS
Engine Engine
Number Designation 272.91/92/94/95 272.96/97/ 98/99 Engine 273.92
BE03.10- Piston Standard mm 87.973...88.003 92.863...92.897 92.863...92.897
P-1001- diameter identification X
02D Auxiliary mm 88.073...88.103 92.963...92.997 92.963...92.997
Repair size mm 88.223...88.253 93.113...93.147 93.113...93.147
BE03.10- Piston Standard mm 0.003...0.042 0.003...0.052 0.003...0.052
P-1002- clearance identification X
02D Auxiliary mm 0.003...0.042 0.003...0.052 0.003...0.052
Repair size mm 0.003...0.042 0.003...0.052 0.003...0.052
CHECK VALUES FOR PISTONS
Number Designation Engine 273.96/97
Standard identification X mm 97.973...98.007
BE03.10-P-1001-02D Piston diameter Auxiliary mm 98.073...98.107
Repair size mm 98.223...98.257
Standard identification X mm 0.007...0.042
BE03.10-P-1002-02D Piston clearance Auxiliary mm 0.007...0.042
Repair size mm 0.007...0.042
TEST SPECIFICATIONS FOR PISTONS - BE03.10-P-1000-02F
Engine 271, 275, 285
MODIFICATION NOTES
21.10.05 Piston dia. Engine 275, 285
8.11.05 Piston projects or stands back Engine 271
TEST SPECIFICATIONS FOR PISTONS
En
Engine Engine 275
Number Designation 271.910/911/921/940/941/944/946/948/950/952/954/955/956/957 271.942 285
BE03.10- Piston mm 0.055...-0.255 0.080...- -
P-1001- projects 0.280
02F or stands
back
BE03.10- Piston Standard mm 81.946 to 81.964 81.946 81.
P-1003- dia. Step to
02F markings 81.964
X
Step mm 81.996 to 82.014 - 82.
marking
BE03.10- Piston Default mm - - >o
P-1004- clearance
02F
TEST SPECIFICATIONS FOR PISTONS
Engine Engine 275.98,
Number Designation 271.820 Engine 271.860 285.98
BE03.10-P- Piston projects mm 0.52 to 0.90 -0.18...0.20 -
1001-02F or stands back
BE03.10-P- Piston dia. Standard Step mm 81.946 to 81.946 to 81.964 82.563...82.575
1003-02F markings X 81.964
Step marking mm 81.996 to 81.996 to 82.014 82.613 to 82.625
82.014
BE03.10-P- Piston clearance Default mm - - -
1004-02F
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS - BE03.10-P-1000-03A
Engine 111, 112, 113, 137, 157, 271, 272, 273, 275, 276, 278, 285, 604, 605, 606
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Engine 112 except 112.951/976,
Engine Engine
Number Designation 111 113.94/96/971/980/981/982/984/986
BE03.10- Connecting Thread M 9X1 8X1
P-1001- rod bolts diameter
03A Shank New mm 51.7 to 47
length 52.3
max. mm 52.9 47.6
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Number Designation 112.951/976 113.987/988/989/990/991/993
BE03.10-P- Connecting rod Thread M 8X1 8X1
1001-03A bolts diameter
Shank length New mm 46.7 to 47.3 41.7 to 42.3
max. mm 47.6 42.5
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Engine Engine 137,
Number Designation 113.992/995 275, 285
BE03.10-P-1001- Connecting rod Thread diameter M 8X1 7X1
03A bolts Shank length New mm 42 38
max. mm 42.6 38.4
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Number Designation Engine 271 Engine 272
BE03.10-P-1001- Connecting rod Thread diameter M 7X1 8X1
03A bolts Shank length New mm 38 39.5
max. mm 38.4 40.5
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Number Designation Engine 273 Engine 276
BE03.10-P-1001- Connecting rod bolts Thread diameter M 8X1 8X1
03A Shank length New mm 39.5 42.5
max. mm 40.5 42.8
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS
Engines 157, Engine 604,
Number Designation 278 605, 606
BE03.10-P-1001- Connecting rod Thread diameter M 8X1 9X1
03A bolts Shank length New mm 42.5 51.7 to 52.3
max. mm 42.8 52.9
CHECK VALUES FOR PISTON RINGS - BE03.10-P-1000-05B
Engines 112, 113, 137, 155, 275, 285
CHECK VALUES FOR PISTON RINGS
Engines
Engine Engine
Number Designation 112.920/921/922/923/940/941/942/943/9
112.910/911/912 112.913
engine 113.940/941/942/943
BE03.10- Piston ring Groove 1 mm 0.012...0.060 0.033...0.075 0.012...0.060
P-1001- vertical
05B clearance Groove 2 mm 0.010...0.030 0.015...0.05 0.010...0.030
BE03.10-
Piston ring Groove 1 mm 0.200...0.350 0.200...0.350 0.200...0.350
P-1002-
end gap Groove 2 mm 0.200...0.400 0.200...0.400 0.200...0.400
05B
Plain
compression mm 83.2x1.5x3.1 89.9x1.5x3.1 89.9x1.5x3.1
BE03.10- ring
P-1003- Dimension
05B Taper-faced
hook mm 83.2x3.5x3.5 89.9x1.75x3.5 89.9x3.5x3.5
scraper ring
CHECK VALUES FOR PISTON RINGS
ENGINE Engine Engine
Number Designation
112.951 112.949 112.976
BE03.10-P- Piston ring Groove 1 mm 0.03...0.075 0.028...0.070 0.033...0.070
1001-05B vertical clearance Groove 2 mm 0.015...0.05 0.015...0.05 0.01...0.04
BE03.10-P- Piston ring end Groove 1 mm 0.200...0.350 0.200...0.350 0.20...0.35
1002-05B gap Groove 2 mm 0.200...0.400 0.200...0.400 0.2...0.4
Plain compression
mm 89.9x1.5x3.05 89.9x1.5x3.1 97.00x1.5x3.3
BE03.10-P- ring
Dimension
1003-05B Taper-faced hook
mm 89.9x1.75x3.5 89.9x1.75x3.5 97.00x1.75x3.5
scraper ring
CHECK VALUES FOR PISTON RINGS
Engine
Engines Engines
Number Designation 112.960/960/961
113.944/980/981/982/984 113.960/961/962/963/964/965
961 AMG
BE03.10- Piston ring Groove 1 mm 0.010...0.040 0.012...0.060 0.012...0.060
P-1001- vertical
05B clearance Groove 2 mm 0.005...0.020 0.010...0.030 0.010...0.030
BE03.10-
Piston ring Groove 1 mm 0.200...0.350 0.200...0.350 0.200...0.350
P-1002-
end gap Groove 2 mm 0.200...0.400 0.200...0.400 0.200...0.400
05B
Plain
compression mm 89.9x1.5 3.05 97.0x1.2 3.5 97.0x1.5 3.1
BE03.10- ring
P-1003- Dimension
05B Taper-faced
hook mm 89.9x1.5x3.5 97.0x1.5x4.0 97.0x3.5 3.5
scraper ring
CHECK VALUES FOR PISTON RINGS
Engine Engines Engine
Number Designation
113.967 113.987/988/989 113.990/991/992/995
BE03.10-P- Piston ring Groove 1 mm 0.033...0.070 0.020...0.065 0.020...0.065
1001-05B
clearance Groove 2 mm 0.01...0.04 0.015...0.045 0.015...0.050
BE03.10-P- Piston ring Groove 1 mm 0.200...0.350 0.200...0.350 0.200...0.350
1002-05B end gap Groove 2 mm 0.200...0.400 0.200...0.400 0.200...0.400
Plain
compression mm 97.0x1.5x3.3 97.0x1.2x3.5 97.0x1.2x3.5
BE03.10-P- ring
Dimension
1003-05B Taper-faced
hook scraper mm 97.0x1.75x3.5 97.0x1.5x4 97.0x1.75x3.5
ring
CHECK VALUES FOR PISTON RINGS
Engine
Number Designation Engine 137
155
BE03.10-P-1001- Piston ring vertical Groove 1 mm - 0.012...0.060
05B clearance Groove 2 mm - 0.010...0.030
BE03.10-P-1002- Groove 1 mm - 0.250...0.350
Piston ring end gap
05B Groove 2 mm - 0.250...0.500
Plain compression ring mm - 84.0x1.2x3.1
BE03.10-P-1003-
Dimension Taper-faced hook scraper
05B mm - 84.0x1.5x3.5
ring
CHECK VALUES FOR PISTON RINGS
Engines 275.95, Engines 275.98,
Number Designation
285.95 285.98
BE03.10-P- Piston ring verticalGroove 1 mm 0.03...0.08 0.03...0.07
1001-05B clearance Groove 2 mm 0.015...0.055 0.03...0.07
BE03.10-P- Groove 1 mm 0.200...0.400 0.20...0.35
Piston ring end gap
1002-05B Groove 2 mm 0.200...0.400 0.35...0.55
Plain compression
mm 82.0x1.2x2.9 82.6x1.2x2.9
BE03.10-P- ring
Dimension
1003-05B Taper-faced hook
mm 82.0x1.5x3.4 82.6x1.0x3.1
scraper ring
CHECK VALUES FOR PISTON RINGS - BE03.10-P-1000-05D
Engine 157, 272, 273, 276, 278
MODIFICATION NOTES
Piston ring vertical clearance Dimensions of plain compression ring, taper- Engines 272.967,
25.1.06
faced hook scraper ring, oil scraper ring 273.96
CHECK VALUES FOR PISTON RINGS
Engine Engine
Number Designation
272.91/92/94/95 272.96/97/98/99
Groove 1 mm 0.03...0.08 0.02 to 0.07
BE03.10-P- Piston ring vertical
Groove 2 mm 0.02 to 0.06 0.015 to 0.05
1001-05D clearance
Groove 3 mm - -
Groove 1 mm 0.2 to 0.35 0.2 to 0.35
BE03.10-P-
Piston ring end gap Groove 2 mm 0.3...0.5 0.3...0.5
1002-05D
Groove 3 mm 0.2 to 0.9 0.2 to 0.9
Plain compression
mm 88.0X1.5X3.1 92.9X1.5X3.1
ring
BE03.10-P-
Dimension Taper-faced hook
1003-05D mm 88.0X1.75X3.5 92.9X1.75X3.7
scraper ring
Oil scraper ring mm 88.0X2.5X3.03 92.9X2.5X3.03
CHECK VALUES FOR PISTON RINGS
Engine
Number Designation Engine 273.92
273.96/97
Groove 1 mm 0.02 to 0.07 0.02 to 0.07
BE03.10-P-1001- Piston ring vertical
Groove 2 mm 0.015 to 0.05 0.002 to 0.06
05D clearance
Groove 3 mm - -
Groove 1 mm 0.2 to 0.35 0.2 to 0.35
BE03.10-P-1002-
Piston ring end gap Groove 2 mm 0.3...0.5 0.3...0.5
05D
Groove 3 mm 0.2 to 0.9 0.2 to 0.9
Plain compression ring mm 92.9X1.5X3.1 98.0X1.2X3.1
BE03.10-P-1003- Taper-faced hook
Dimension mm 92.9X1.75X3.7 98.0X1.5X3.7
05D scraper ring
Oil scraper ring mm 92.9X2.5X3.03 98.0X2.5X3.03
CHECK VALUES FOR PISTON RINGS
Number Designation Engine 157 Engine 276 Engine 278
0.025 to
Groove 1 mm 0.05 to 0.08 0.03...0.08
0.075
BE03.10-P- Piston ring vertical
0.015 to 0.015 to
1001-05D clearance Groove 2 mm 0.015 to 0.06
0.05 0.055
Groove 3 mm - - -
Groove 1 mm 0.15 to 0.3 0.2 to 0.3 0.15 to 0.3
BE03.10-P-
Piston ring end gap Groove 2 mm 0.4 to 0.6 0.4 to 0.6 0.4 to 0.6
1002-05D
Groove 3 mm 0.25 to 0.5 0.2 to 0.7 0.2 to 0.7
Plain compression
BE03.10-P- mm 98X1.2X3.3 92.9X1.2X3.1 92.9X1.2X3.1
Dimension ring
1003-05D
mm 98X1.5X4 92.9X1.5X3.7 92.9X1.5X3.7
scraper ring
Oil scraper ring mm 98X2X2.8 92.9X2X2.65 92.9X2X2.65
INSPECTION DATA OF CRANKSHAFT BEARING CAP BOLTS - BE03.20-P-1000-01C
Engine 137, 275, 285
INSPECTION DATA OF CRANKSHAFT BEARING CAP BOLTS
Number Designation Engine 137, 275, 285
Thread diameter M 10
BE03.20-P-1001-01C Crankshaft bearing cap bolts Length (L) when new mm 117, 7...118, 3
max. length (L) mm 119
Thread diameter M8
BE03.20-P-1002-01C Crankshaft bearing cap bolts Length (L) when new mm 111, 7...112, 3
max. length (L) mm 113, 5
TEST SPECIFICATIONS FOR CRANKSHAFT - BE03.20-P-1000-02I
Engine 156, 159
TEST SPECIFICATIONS FOR CRANKSHAFT
Number Designation Engine 156 Engine 159
Nominal 67.950 to 67.950 to
mm
dia. 67.965 67.965
Repair stage 67.962 to 67.962 to
Blue (B) mm
1 67.965 67.965
BE03.20-P-1001- Repair stage Yellow 67.958 to 67.958 to
Crankshaft journal dia. mm
02I 2 (y) 67.962 67.962
Repair stage 67.954 to 67.954 to
Red (R) mm
3 67.958 67.958
Repair stage 67.950 to 67.950 to
Green (g) mm
4 67.954 67.954
27.900 to 27.900 to
Marking N/0 mm
BE03.20-P-1002- Crankshaft journal width at fit 29.933 29.933
02I bearing 28.000 to
Marking N1/1 mm -
28.033
TEST SPECIFICATIONS FOR CRANKSHAFT MAIN BEARING SHELLS - BE03.20-P-1000-03E
Engine 137, 275, 285
TEST SPECIFICATIONS FOR CRANKSHAFT MAIN BEARING SHELLS
Engine
Number Designation Engine 137 285.950
BE03.20-P- Main bearing shells Replacement part 52 52
1001-03E standard size for additional number
upper crankcase (color coding blue)
section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.252 to 2.257 2.255 to 2.262
bore Ø 68.5 mm
BE03.20-P- Main bearing shells Replacement part 54 54
1002-03E standard size for additional number
upper crankcase (color coding yellow)
section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.257 to 2.262 2.260 to 2.267
bore Ø 68.5 mm
BE03.20-P- Main bearing shells Replacement part 56 56
1003-03E standard size for additional number
upper crankcase (color coding red)
section and
crankcase bottom
section main bearing Bearing shell thickness mm 2.262 to 2.267 2.265 to 2.272
bore Ø 68.5 mm
BE03.20-P- Main bearing shells Replacement part 57 57
1004-03E standard size for additional number
crankcase bottom (color coding white)
section main bearing
bore Ø 68.5 mm Bearing shell thickness mm 2.267 to 2.272 2.270 to 2.277
BE03.20-P- Main bearing shells Replacement part 58 58
1005-03E standard size for additional number
crankcase bottom (color coding purple)
section main bearing
bore Ø 68.5 mm Bearing shell thickness mm 2.272 to 2.277 2.275 to 2.282
TEST SPECIFICATIONS FOR CRANKSHAFT MAIN BEARING SHELLS
Engines
275.980/981
Number Designation 982/983/, 285.980
BE03.20-P- Main bearing shells standard Replacement part additional 52
1001-03E size for upper crankcase number (color coding blue)
section and crankcase bottom
section main bearing bore Ø Bearing shell thickness mm 2.252 to 2.257
68.5 mm
BE03.20-P- Main bearing shells standard Replacement part additional 54
1002-03E size for upper crankcase number (color coding yellow)
section and crankcase bottom
section main bearing bore Ø
68.5 mm Bearing shell thickness mm 2.257 to 2.262
BE03.20-P- Main bearing shells standard Replacement part additional 56
1003-03E size for upper crankcase number (color coding red)
section and crankcase bottom
section main bearing bore Ø Bearing shell thickness mm 2.262 to 2.267
68.5 mm
BE03.20-P- Main bearing shells standard Replacement part additional 57
1004-03E size for crankcase bottom number (color coding white)
section main bearing bore Ø
68.5 mm Bearing shell thickness mm 2.267 to 2.272
BE03.20-P- Main bearing shells standard Replacement part additional 58
1005-03E size for crankcase bottom number (color coding purple)
section main bearing bore Ø
68.5 mm Bearing shell thickness mm 2.272 to 2.277
TEST SPECIFICATIONS FOR CRANKSHAFT MAIN BEARING SHELLS - BE03.20-P-1000-03J
Engine 156, 159
TEST SPECIFICATIONS FOR CRANKSHAFT MAIN BEARING SHELLS
Number Designation Engine 156 Engine 159
BE03.20-P- Main bearing shells Replacement part 52 52
1001-03J standard dimension additional number colored
for crankcase and marking blue (b)=1
bearing cap(s) ø 67,
950/67, 966 mm Bearing shell thickness mm 2.255 to 2.259 2.265 to 2.269
BE03.20-P- Main bearing shells Replacement part 54 54
1002-03J standard dimension additional number colored
for crankcase and marking yellow (y)=2
bearing cap(s) ø 67,
950/67, 966 mm Bearing shell thickness mm 2.259 to 2.263 2.269 to 2.273
BE03.20-P- Main bearing shells Replacement part 56 56
1003-03J standard dimension additional number colored
for crankcase and marking red (r)=3
bearing cap(s) ø 67,
950/67, 966 mm Bearing shell thickness mm 2.263 to 2.267 2.273 to 2.277
BE03.20-P- Main bearing shell Replacement part 59 59
1004-03J standard dimension additional number (color
for bearing cap ø 67, coding green (g)=4
950/67, 966 mm Bearing shell thickness mm 2.267 to 2.271 2.277 to 2.281
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE - BE03.20-P-1000-04E
Engine 112, 113, 137, 155, 156, 159, 271, 272, 273, 275, 285
MODIFICATION NOTES
14.9.09 Value changed: Main bearing play, radial - new value Engine 156
Value changed: Main bearing play, axial - new value Engine 156
Value changed: Connecting rod bearing play Engine 156
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Engine 112 except 112.951/976, Engine
Number Designation
113.940/941/942/943/944/948/960/961/963/964/965/966/967/968/971/9
Radial
measurement mm 0.026 to 0.050
BE03.20- Main new
P-1001- bearing
04E play Axial
measurement mm
when new
BE03.20- Connecting Radial
P-1002- rod bearing measurement mm 0.022 to 0.067
04E play new
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Engine Engine
Number Designation
113.987/988/989/990/991/993 113.992/995
Radial
mm 0.026 to 0.050 0.026 to 0.050
BE03.20-P- Main bearing measurement new
1001-04E play Axial measurement
mm 0.10 to 0.266 0.10 to 0.266
when new
BE03.20-P- Connecting rod Radial
mm 0.022 to 0.067 0.022 to 0.067
1002-04E bearing measurement new
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Engine
Number Designation Engine 156 Engine 159
155
Radial measurement 0.022 to 0.020 to
mm -
BE03.20-P- new 0.041 0.042
Main bearing play
1001-04E Axial measurement 0.15 to 0.15 to
mm -
when new 0.316 0.316
BE03.20-P- Connecting rod Radial measurement 0.028 to 0.028 to
mm -
1002-04E bearing play new 0.063 0.063
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Number Designation Engine 271 Engine 272 Engine 273
Radial measurement 0.021 to 0.022 to 0.022 to
mm
new 0.045 0.046 0.046
1001-04E Axial measurement 0.10 to 0.100 to 0.100 to
Main bearing play mm
when new 0.30 0.266 0.266
BE03.20-P- Connecting rod Radial measurement 0.022 to 0.022 to
mm -
1002-04E bearing play new 0.066 0.066
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE
Engine Engine Engine
Number Designation
137 275.95, 285.95 275.98, 285.98
Radial measurement 0.028 to
mm 0.022 to 0.047 0.018 to 0.058
BE03.20-P- new 0.052
Main bearing play
1001-04E Axial measurement 0.10 to
mm 0.100 to 0.254 0.100 to 0.254
when new 0.260
BE03.20-P- Connecting rod Radial measurement 0.017 to
mm 0.026 to 0.059 0.019 to 0.048
1002-04E bearing play new 0.052
BELT PULLEY/VIBRATION DAMPER - BE03.30-P-1000-02C
Engine 271, 275, 285
BELT PULLEY/VIBRATION DAMPER
Engine Engine 275,
Number Designation
271 285
Radial
BE03.30-P-1001- Permissible deviation at vibration mm 0, 3 -
runout
02C damper
Axial runout mm 0, 3 0, 3
COMPONENT MODIFICATIONS
DIAMETER OF THE CRANKSHAFT FLANGE ALTERED - BT03.20-P-0003-01A
ENGINES 273.92# ## as of 300194, 273.96# /97# ## as of 300346
Courtesy of MERCEDES-BENZ USA
Altered crankshaft flange diameter
As of engine production date 06/10/08 crankshafts were installed whose crankshaft flange (3) had a diameter of
96 mm (it was previously a diameter of 93 mm).
During assembly of the end cover (2) (with a vulcanized crankshaft radial sealing ring (1)), it is therefore
necessary to use the insertion tool as mentioned.
Fig. 139: Identifying Crankshaft Radial Seal, End Cover And Crankshaft Flange
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS
611 589 01 40 00 RETAINER DEVICE - WS03.00-N-3102B
FG 03/05/Set B
ENGINES 612, 611, 612, 647, 611, 612, 613, 629, 646, 647, 648, 611, 646
Use:
Holding device for pulling in the timing chain. Hold timing chain meshed with camshaft sprocket.
Fig. 140: Identifying Retainer Device (611 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
000 589 04 14 00 TENSIONING STRAP - WS03.00-P-0001C
FG 03/Set C
ENGINES all
Use:
Tensioning strap 60 - 125 ømm dia. for compressing piston rings
Fig. 141: Identifying Tensioning Strap (000 589 04 14 00)
Courtesy of MERCEDES-BENZ USA
000 589 20 21 00 HARDNESS TESTER - WS03.00-P-0002C
FG 03/Set C
ENGINE all
Further use FG 00 WS00.00-N-3047Z
FG 03/Set B WS03.00-N-0002B
Use:
Hardness tester (SKLEROGRAF) for testing hardness in Shore, Brinell, or Rockwell on the basis of rebound.
(Test does not leave any traces on hardened workpieces).
Fig. 142: Identifying Hardness Tester (000 589 20 21 00)
Courtesy of MERCEDES-BENZ USA
000 589 51 37 00 PLIERS - WS03.00-P-0005C
FG 03/Set C
ENGINE all
Use:
Pliers for expanding piston rings
Fig. 143: Expanding Piston Rings
Courtesy of MERCEDES-BENZ USA
Fig. 144: Identifying Pliers (000 589 51 37 00)
Courtesy of MERCEDES-BENZ USA
001 589 65 09 00 SOCKET - WS03.00-P-0006B
FG 03/01/05/27 Set B
ENGINE all
Further use FG 07/Set A WS07.00-P-0006A
Use:
Bihexagonal socket, 27 mm, 1/2" square drive for loosening and tightening the center bolt on the crankshaft.
Fig. 145: Identifying Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
001 589 32 21 00 DIAL GAGE - WS03.00-P-0007B
FG 01/03/Set B
ENGINE 601.943, 602.980 /982 /983 /984 /985, 612.965, 112, 113, 271, 272, 642, 646, 651, 272, 273
Use:
Dial indicator, stroke 1 mm, scale value 0.001 mm, for measuring crankshaft radial and axial bearing clearance
and cylinder bores.
Fig. 146: Identifying Dial Gage (001 589 32 21 00)
Courtesy of MERCEDES-BENZ USA
111 589 08 43 00 INSTALLATION TOOL - WS03.00-P-0016B
FG 03/Set B
ENGINE 102.92 /93 /96 /98 /99, 111 /979, 112, 113, 137, 156, 159, 272, 275, 285, 601 /943,
602.91 /93 /94 /96 /980 /983, 603.91/93 /97, 604, 605, 606, 628.962, 629
MODIFICATION NOTES
18.8.93 Replacement for: 601 589 03 43 00
Part 111 589 08 43 03 Insertion sleeve FG 03/Set B WS03.00-P-0016-01B
Use:
Installation tool for pressing in the rear crankshaft radial seal into the normal position, and into a position
offset 3 mm to the inside with part 3 if the crankshaft is worn.
Fig. 147: Identifying Installation Tool (111 589 08 43 00)
Courtesy of MERCEDES-BENZ USA
119 589 01 14 00 SLEEVE - WS03.00-P-0022B
FG 03/05/Set B
ENGINE 112, 113, 119, 120, 137, 156, 157, 159, 272, 273, 275, 276, 278
Use:
Sleeve to press in front crankshaft radial sealing ring.
Fig. 148: Identifying Sleeve (119 589 01 14 00)
Courtesy of MERCEDES-BENZ USA
602 589 00 40 00 RETAINING LOCK - WS03.00-P-0028B
FG 01/03/05/27/ Set B
ENGINES 102.92 /93 /96 /97 /98 /99, 111, 271, 601, 602.91 /93 /94 /96 /983, 603.91 /93 /96 /97, 604, 605,
606, 611 /980, 612 /965 /966, 613, 646, 647, 648
Use:
Retaining lock for crankshaft via starter ring gear (fixing in starter hole).
Fig. 149: Identifying Retaining Lock (602 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
112 589 03 40 00 RETAINING LOCK - WS03.00-P-0037B
FG 01/03/05/27/ Set B
ENGINE 112, 113, 137, 155, 156, 157, 272 /979, 273, 276, 278, 629, 642
Use:
Retaining lock for holding crankshaft via ring gear for flywheel or clutch plate.
Fig. 150: Identifying Retaining Lock (112 589 03 40 00)
Courtesy of MERCEDES-BENZ USA
112 589 00 40 00 COUNTERHOLDER - WS03.00-P-0038B
FG 01/03/Set B
ENGINE 112, 113, 137, 155, 156, 159, 275, 285
Separate part 112 589 00 40 01 Set of sleeves FG03/Set B WS03.00-P-0038-01B
Use:
Counterholder for vibration damper for loosening and tightening the center bolt.
Grip extension with commercially available threaded pipe e.g. 3/4" DIN 2441
Diameter 26.9 x 3.25 mm, length 1000 mm.
Fig. 151: Identifying Counterholder (112 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
611 589 00 14 00 INSERTION TOOL - WS03.00-P-0042B
FG 03/Set B
ENGINE 112, 113, 137, 156, 159, 601, 602, 603, 604, 605, 606, 611 /980, 612, 613, 612.965 /966, 629, 642 /,
646, 647 /981, 648
MODIFICATION NOTES
7.10.97 Replacement for 606 589 00 14 00 FG 03/Set B C WS03.00-P-0035C
Use:
Insertion tool for front crankshaft radial sealing ring.
Fig. 152: Identifying Insertion Tool (611 589 00 14 00)
Courtesy of MERCEDES-BENZ USA
366 589 00 21 05 EXTENSION - WS03.00-P-0086-01A
FG03/Set A
ENGINE 112, 113, 272, 273
Further use FG35/Set A WS35.00-N-3111-05A
Use:
Extension for dial indicator.
Fig. 153: Identifying Extension (366 589 00 21 05)
Courtesy of MERCEDES-BENZ USA
285 589 02 40 00 RETAINING LOCK - WS03.00-P-0089B
FG 03/Set B
ENGINES 275, 285
Use:
Retaining lock for holding the crankshaft over the starter gearwheel.
Fig. 154: Identifying Retaining Lock (285 589 02 40 00)
Courtesy of MERCEDES-BENZ USA
272 589 00 14 00 INSERTION TOOL - WS03.00-P-0090B
FG 03/Set B
ENGINE 271, 272, 273
Use:
Insertion tool for front crankshaft radial shaft sealing ring.
NOTE: Replacement for W271 589 01 15 00
Fig. 155: Identifying Insertion Tool (272 589 00 14 00)
Courtesy of MERCEDES-BENZ USA
156 589 00 40 00 CRANKSHAFT BRACKET - WS03.00-P-0101B
FG 03/Set B
ENGINE 156, 159
Use:
Bracket for securing crankshaft and thrust bearing.
Fig. 156: Identifying Crankshaft Bracket (156 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
112 589 07 40 00 COUNTERHOLDER - WS03.00-P-0102B
FG 03/Set B
ENGINE 112, 113, 271, 272 /, 273, 640, 642 /, 646 /
Use:
Counterholder for fixing in place and unfastening the belt pulley on the air conditioner compressor.
NOTE: Partially in combination with 112 589 02 09 00 socket
Fig. 157: Identifying Counterholder (112 589 07 40 00)
Courtesy of MERCEDES-BENZ USA
112 589 02 09 00 SOCKET - WS03.00-P-0109B
FG 03/Set B
ENGINE 112, 113, 271, 272, 273
Use:
Socket wrench to loosen belt pulley on the air conditioner compressor, e.g. in combination with 112 589 07 40
00 counterholder.
Fig. 158: Identifying Socket (112 589 02 09 00)
Courtesy of MERCEDES-BENZ USA
651 589 02 63 00 ASSEMBLY TOOL - WS03.00-P-0111C
FG 03/05/18/Set C
ENGINE 651
Use:
Fixing the balance shaft for mounting the drive gears.
Fig. 159: Identifying Assembly Tool (651 589 02 63 00)
Courtesy of MERCEDES-BENZ USA
651 589 00 40 00 COUNTERHOLDER - WS03.00-P-0114B
FG 01/03/05/07/18/25/27/Set B
ENGINE 651
Use:
For loosening and tightening the mounting bolts on the vibration damper. The counterholder can also be used to
turn the engine.
Fig. 160: Identifying Counterholder (651 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS: PASSENGER CARS: CRANK ASSEMBLY - WS03.00-Z-9999AZ
MODEL all
000 589 04 14 00 Tensioning strap FG 03/Set C WS03.00-P-0001C
000 589 20 21 00 Hardness tester FG 03/Set C WS03.00-P-0002C
FG 00/03/05/26/27/ 28/33/43/46/Set
000 589 28 33 00 Puller dia. 28-37 mm WS00.00-N-3026Z
B
FG 00/03/05/26/27/ 28/33/43/46/Set
000 589 33 33 00 Counter stay WS00.00-N-0051Z
B
000 589 51 37 00 Pliers FG 03/Set C WS03.00-P-0005C
000 589 65 33 00 Puller FG 00/03/27/33 WS00.00-P-0007Z
001 589 32 21 00 Dial gage FG 01/03/Set B WS03.00-P-0007B
001 589 65 09 00 Socket FG 03/01/05/27Set B WS03.00-P-0006B
001 589 78 21 00 Compression tester FG 01/03/05/set A WS01.00-N-0006A
102 589 00 33 00 Puller FG 03/Set B WS03.00-P-0009B
102 589 01 14 00 Sleeve FG 03/Set B WS03.00-P-0010B
102 589 01 40 00 Retaining lock FG 03/Set B WS03.00-P-0011B
102 589 05 33 00 Puller FG 03/Set C WS03.00-P-0012C
103 589 00 33 00 Puller FG 03/Set B WS03.00-P-0013B
110 589 00 40 00 Retaining lock FG 03/Set C WS03.00-P-0014C
110 589 07 61 00 Sleeve FG 03/Set B WS03.00-P-0015B
111 589 08 43 00 Installation tool FG 03/Set B WS03.00-P-0016B
WS03.00-P-0016-
111 589 08 43 03 Press-in sleeve FG 03/Set B
01B
112 589 00 40 00 Counterholder FG 01/03/Set B WS03.00-P-0038B
WS03.00-P-0038-
112 589 00 40 01 Set of sleeves FG03FG 03/Set B
01B
112 589 00 40 01 Set of sleeves FG03FG 03/Set B 01B
112 589 02 09 00 Socket FG 03/Set B WS03.00-P-0109B
112 589 03 40 00 Retaining lock FG 01/03/05/27/ Set B WS03.00-P-0037B
112 589 07 40 00 Counterholder FG 03/Set B WS03.00-P-0102B
116 589 01 40 00 Retaining lock FG 03/Set C WS03.00-P-0017C
116 589 01 62 00 Removal and installation FG 42/01/03/26/27/28/ 29/33/35/ Set
WS42.00-P-0017B
tool B
116 589 17 21 00 Gauge pin FG 03/Set C WS03.00-P-0019C
116 589 20 33 00 Impact extractor FG 05/01/03/07/ Set B WS05.00-P-0089B
117 589 00 43 00 Installation tool FG 03/Set B WS03.00-P-0020B
119 589 00 21 00 Locating tool FG 03/Set C WS03.00-P-0021C
119 589 01 14 00 Sleeve FG 03/05/Set B WS03.00-P-0022B
123 589 09 63 00 Measuring extension FG 03/Set C WS03.00-P-0023C
130 589 00 61 00 Sleeve FG 03/Set B WS03.00-P-0024B
156 589 00 40 00 Crankshaft bracket FG 03/Set B WS03.00-P-0101B
159 589 00 40 00 Retaining lock FG 01/03/05/Set B WS01.00-P-0154B
166 589 00 14 00 Assembly sleeve FG 03/Set B WS03.00-P-0041B
166 589 00 40 00 Retaining lock FG 03/Set B WS03.00-P-0039B
166 589 01 40 00 Retaining lock FG 03/Set B WS03.00-P-0040B
199 589 02 15 00 Drift FG 03/Set B WS03.00-P-0115B
WS35.00-P-0171-
220 589 01 43 12 Threaded spindle FG35 03/Set B
01B
230 589 00 40 00 Counterholder FG 03/Set B WS03.00-P-0068B
266 589 01 40 00 Retaining lock FG 03/Set B WS03.00-P-0096B
270 589 00 40 00 Retaining lock FG 01/03/05/Set B WS01.00-P-0160B
271 589 00 01 00 Open-end wrench FG 01/03/18/Set C WS01.00-P-0063C
271 589 00 15 00 Drift FG 03/05/Set C WS03.00-P-0069C
271 589 00 40 00 Counterholder FG 03/Set B WS03.00-P-0071B
271 589 00 43 00 Installation tool FG 01/03/Set B WS01.00-P-0120B
271 589 01 01 00 Open wrench FG 01/03/18/Set C WS01.00-P-0149C
271 589 01 15 00 Drift FG 03/Set C WS03.00-P-0070C
271 589 02 63 00 Assembly inserts FG 03/05/Set C WS05.00-P-0216C
271 589 03 40 00 Counterholder FG 03/Set B WS03.00-P-0119B
271 589 09 63 00 Assembly element FG 03/05/Set B WS05.00-P-0228B
272 589 00 07 00 Counterholder FG 03/Set B WS03.00-P-0116B
272 589 00 14 00 Insertion tool FG 03/Set B WS03.00-P-0090B
272 589 01 07 00 Counterholder FG 03/Set B WS03.00-P-0118B
272 589 02 07 00 Counterholder FG 03/Set B WS03.00-P-0123B
273 589 00 43 00 Insertion tool FG 01/03/Set B WS01.00-P-0152B
285 589 02 40 00 Retaining lock FG 03/Set B WS03.00-P-0089B
366 589 00 21 05 Extension FG03/Set A 01A
601 589 02 40 00 Retaining lock FG 03/Set B WS03.00-P-0025B
601 589 03 14 00 Sleeve FG 03/Set B WS03.00-N-0026B
601 589 07 21 00 Measuring device FG 03/Set C WS03.00-P-0027C
602 589 00 40 00 Retaining lock FG 01/03/05/27 / Set B WS03.00-P-0028B
602 589 00 98 00 Case FG 03/05/18/Set C WS05.00-P-0158C
602 589 04 63 00 Thrust spindle FG 03/05/Set C WS05.00-P-0160C
WS05.00-P-0160-
602 589 04 63 01 Pressure pins FG 03/05/Set C
01C
603 589 01 21 00 Locating tool FG 03/Set C WS03.00-P-0029C
606 589 00 14 00 Shell FG 03/Set C WS03.00-P-0035C
606 589 03 15 00 Installation tool FG 03/Set C WS03.00-P-0036C
WS03.00-P-0036-
606 589 03 15 01 Drift FG03/Set C
01C
611 589 00 14 00 Insertion tool FG 03/Set B WS03.00-P-0042B
611 589 00 40 00 Counterholder FG 01/03/20/46/ Set B WS20.00-N-3032B
611 589 01 14 00 Assembly sleeve FG 03/01/Set B WS03.00-P-0043B
611 589 01 40 00 Retainer device FG 03/05/Set B WS03.00-N-3102B
613 589 00 33 00 Puller FG 03/Set B WS03.00-P-0044B
615 589 01 33 00 Puller FG 03/Set C WS03.00-P-0030C
617 589 00 14 00 Sleeve FG 03/Set B WS03.00-P-0031B
617 589 00 16 00 Square drive FG 03/Set B WS03.00-P-0032B
628 589 00 40 00 Retaining lock FG 03/Set B WS03.00-P-0045B
628 589 01 40 00 Counterholder FG 03/Set B WS03.00-P-0046B
628 589 02 40 00 Counterholder FG 03/Set B WS03.00-P-0047B
629 589 00 21 00 Fastening tool FG 03/Set B WS03.00-P-0095B
629 589 01 63 00 Engine turning device FG 01/03/05/27/ Set B WS01.00-P-0137B
629 589 02 63 00 Engine turning device FG 01/03/05/27/ Set B WS01.00-P-0142B
640 589 00 21 00 Alignment tool FG 03/Set C WS03.00-P-0110C
WS03.00-P-0110-
640 589 00 21 01 Alignment tool FG03/Set C
01C
642 589 00 14 00 Centering sleeve FG 01/03/Set B WS03.00-P-0094B
646 589 00 21 00 Adjustment tool FG 03/Set C WS03.00-P-0083C
651 589 00 40 00 Counterholder FG 01/03/05/07/18/ 25/27/Set B WS03.00-P-0114B
651 589 00 43 00 Extraction and insertion
FG 03/Set C WS03.00-P-0120C
tool
651 589 00 61 00 Insertion tool FG 01/03/Set B WS03.00-P-0112B
651 589 01 40 00 Tie-down set FG 03/05/Set C WS05.00-P-0262C
651 589 01 61 00 Insertion tool FG 03/Set B WS03.00-P-0113B
651 589 02 40 00 Retaining lock FG 01/03/05/Set B WS01.00-P-0084B
651 589 02 63 00 Assembly tool FG 03/05/18/Set C WS03.00-P-0111C
ACCESSORIES & BODY, CAB
Detachable Body Components - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: DETACHABLE BODY COMPONENTS, EXTERIOR
FLAPS - AH88.00-Z-9999AZ
MODEL all
General information on repair to detachable MODEL 124, 129, 140, 168, 202, AH88.00-P-1000-
plastic components 208, 210, 414 01A
General notes on filling detachable body AH88.00-P-1000-
MODEL 450.418
components 02CR
AH88.50-P-0002-
General notes on repairing tubular frame MODEL 171.4, 172.4
01V
MODEL 129, 202, 203, 208, 210, AH88.50-P-0001-
Notes on electric trunk lid emergency release
215, 220... 01A
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: DETACHABLE BODY COMPONENTS,
EXTERIOR FLAPS - AR88.00-Z-9221AA
MODEL 221
AR88.40-P-
Adjust engine hood MODEL 216, 221
3020SX
AR88.50-P-
Adjust trunk lid MODEL 216, 221
5200SX
AR88.20-P-
Disassemble/assemble front bumper MODEL 221.0/ 1
2050SX
AR88.70-P-
Disassemble/assemble outside mirror MODEL 216, 221...
9030TX
AR88.20-P-
Disassemble/assemble rear bumper MODEL 221.0 /1
2100SX
AR88.70-P-
Remove/install complete outside mirror MODEL 204, 207, 212, 216, 221
9000CW
MODEL 221.1 with CODE (Z07) Top AR88.70-P-
Remove/install complete outside mirror
protection with hydraulic power windows 9000SXS
AR88.40-P-
Remove/install engine hood MODEL 216, 221
3000SX
Remove/install engine hood catch MODEL 216, 221
3200SX
MODEL 216 up to model year 2011 MODEL AR88.20-P-
Remove/install front bumper
221 2000SX
AR88.10-P-
Remove/install front fenders MODEL 216, 221
1000SX
Remove/install gas-operated strut on AR88.40-P-
MODEL 216, 221
engine hood 3010SX
AR88.70-P-
Remove/install glass adjustment drive MODEL 216, 219, 221
9060TX
AR88.40-P-
Remove/install hood hinge MODEL 216, 221
3060SX
Remove/install hydraulic pump for trunk MODEL 216.3, 221.0 /1 with code (881) AR88.50-P-
lid remote control Remote trunk closing (RTC [HDFS]) 5070SX
Remove/install interior ventilation flap MODEL 221.1 with CODE (Z07) Top AR88.10-P-
in rear fender protection with emergency fresh air system 1110SXS
Remove/install longitudinal member MODEL 221.0 MODEL 221.1 except CODE AR88.80-P-
paneling (Z07) Top protection 6000SX
Remove/install longitudinal member MODEL 221.1 with CODE (Z07) Top AR88.80-P-
paneling protection 6000SXS
AR88.40-P-
Remove/install Mercedes star MODEL 221.0/ 1
4050SX
MODEL 211.0 /2 /6 as of 1.6.06, 219, 216, AR88.70-P-
Remove/install mirror lens
221 9020TX
MODEL 221.1 with CODE (Z07) Top AR88.80-P-
Remove/install outer door sill molding
protection 1001SXS
Remove/install outside mirror fold-back AR88.70-P-
MODEL 216, 219, 221...
motor 9070TX
AR88.70-P-
Remove/install outside mirror trim MODEL 204, 207, 212, 216, 218, 221, 246...
9040CY
AR88.70-P-
Remove/install outside mirror trim MODEL 216, 219, 221...
9040TX
Remove/install pull cable for engine MODEL 221.0 /1 Engine hood cable front AR88.40-P-
hood section 3100SX
AR88.20-P-
Remove/install rear bumper MODEL 221.0/ 1
2200SX
MODEL 221.1 with CODE (Z07) Top AR88.20-P-
Remove/install rear bumper
protection 2200SXS
Remove/install remote trunk closing MODEL 216.3, 221.0 /1 with CODE (881) AR88.50-P-
control unit Remote trunk closing (RTC [HDFS]) 5300SX
AR88.30-P-
Remove/install spare tire well MODEL 204.3, 221, 216
1000SX
MODEL 221.0 /1 up to 31.5.09 except CODE AR88.85-P-
Remove/install taillamp trim panel
(800) Model year 2010 9814SX
Remove/install tank recess MODEL 216, 221 2000SX
AR88.50-P-
Remove/install trunk lid MODEL 216, 221
5000SX
AR88.50-P-
Remove/install trunk lid lock cylinder MODEL 216, 221
5061SX
Remove/install trunk lid opening angle MODEL 216.3, 221.0 /1 with code (881) AR88.50-P-
detection sensor Remote trunk closing (RTC [HDFS]) 5065SX
REMOVE/INSTALL FRONT FENDERS - AR88.10-P-1000SX
MODEL 216, 221
Shown on model 221
Fig. 1: Identifying Front Fender Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove left and right front inner fender
AR88.80-P-
Model 216
6000SC
Model 221 without code (Z07) AR88.80-P-
Loosen longitudinal member paneling until Top protection 6000SX
2 nuts (6) are accessible, then unscrew nuts
(6) Model 221 with CODE (Z07)
Highest protection AR88.80-P-
On model 221 it is not 6000SXS
necessary to remove the rear door.
Pull insulation (2) to side and unscrew bolts
3
(4)
Unscrew bolt (8) and remove terminal strip
4
(9)
5 Remove cover (11) from front fender (1)
6 Remove bolts (10)
Installation: Check gaps on
front fender (1), adjust if
necessary.
Model 216
AR60.00-P-
Gap dimensions on hoods, doors
0700-01SC
and lids
*BE60.00-P-
1001-01T
*BE60.00-P-
7 Remove front fender (1) 1002-01T
Fig. 2
Model 221
AR60.00-P-
Gap dimensions on hoods, doors
0700-01SX
and lids
*BE60.00-P-
1001-01R
*BE60.00-P-
1002-01R
Fig. 2
8 Install in the reverse order
CHECK VALUES FOR GAPS
Model 216 up to Model 216 as of
Number Designation
model year 2011 model year 2011
Engine hood to Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
fender "A"
Engine hood to Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
headlamp "B"
Engine hood to A- Dimension
mm 4.0 (±0.5) 4.0 (±0.5)
pillar "D"
BE60.00-P- Gap Radiator Dimension
mm 5.0 (±1.0) 2.0 (±1.0)
1001-01T dimension grille/bumper "C"
Engine hood to Dimension
mm 5.0 (±1.0) 5.0 (±1.0)
bumper "P"
Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
Bumper to "Q"
headlamp AR60.00-P-0700- AR60.00-P-0700-
See picture
01SC 01S C
Front door to Dimension
mm 4.0 (±0.5) 4.0 (±0.5)
fender "E"
Front door to rear Dimension
mm 4.0 (±0.5) 4.0 (±0.5)
fender "F"
Front fender to A- Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
BE60.00-P- Gap pillar "G"
1002-01T dimension Front fender to Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
headlamp "H"
AR60.00-P-0700- AR60.00-P-0700-
See picture
01SC 01S C
CHECK VALUES FOR GAPS
Number Designation Model 221
Dimension
Engine hood to fender mm 3.5 (±0.5)
"A"
Dimension
Engine hood to headlamp mm 3.5 (±0.5)
"B"
Dimension
Radiator grille/bumper mm 5 (±1)
"C"
BE60.00-P-1001- Gap Dimension
Engine hood to bumper mm 5 (±1.5)
01R dimension "P"
Dimension
Bumper to headlamp mm 3.5 (±0.5)
"Q"
Dimension
mm 3.5 (±0.5)
"R"
Bumper to fender
AR60.00-P-0700-
See picture
01SX
Dimension
Front door to A-pillar mm 4.5 (±0.5)
"D"
Dimension
Front door to fender mm 4 (±0.5)
"E"
Dimension
Front door to rear door mm 4.5 (±0.5)
"F"
Trim strip at front door to roof Dimension
mm 4.5 (±0.5)
BE60.00-P-1002- Gap frame "G"
01R dimension Trim strip at rear door to roof Dimension
mm 4.5 (±0.5)
frame "H"
Rear door to side section, Dimension
mm 4.5 (±0.5)
bottom "I"
Dimension
mm 4.5 (±0.5)
Front door cover to rear door "S"
cover AR60.00-P-0700-
See picture
01SX
Fig. 2: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL INTERIOR VENTILATION FLAP IN REAR FENDER - AR88.10-P-1110SXS
MODEL 221.1 with CODE (Z07) Top protection with emergency fresh air system
Fig. 3: Identifying Rear Fender Interior Ventilation Flap Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR88.20-P-
1 Remove rear bumper (1)
2200SXS
Disconnect left and right electrical
2
connector (2).
3 Unclip vent flap (3).
Remove left exhaust flap motor (M90/1)
4.1 When replacing vent flap (3).
and right exhaust flap motor (M90/2).
5 Install in the reverse order
6.1 Perform system check. After replacing left exhaust flap motor
Check emergency fresh air system. (M90/2) 8654SX
LOOSEN FRONT BUMPER AND FASTEN - AR88.20-P-2000-01SX
Fig. 4: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
1.1 Unscrew bolts (9), unclip radiator paneling (10) (arrows) and remove radiator paneling (10).
Only on model 216.
Fig. 5: Locating Radiator Paneling Clips
Courtesy of MERCEDES-BENZ USA
2.1 Remove expansion clips (11) and unclip cover (12) next to left lamp unit and right lamp unit (arrows).
Only on model 216.
Fig. 6: Locating Lamp Unit Cover Clips
Courtesy of MERCEDES-BENZ USA
Fig. 7: Identifying Front Lamp Components
Courtesy of MERCEDES-BENZ USA
Work sequence is shown for removal of left front lamp unit on model 221 as an example.
3 Unscrew bolt (3) on clamping strip (4) and remove clamping strip (4).
4.1 Unclip air inlet grate (2).
Only on model 221.
5 Unscrew nut (6).
6 Unscrew bolts (7) at top on front bumper (1).
7 Attach adhesive tape (8), as illustrated, to front bumper (1) and front fender.
The adhesive tape (8) serves to protect the front bumper (1) and front fender.
8.1 Lift front fender in area of left front lamp unit with assembly wedge until retaining clip on
front bumper (1) is exposed.
Do not damage front fender.
Only on model 216.
9 Pull front bumper (1) forward far enough to remove left front lamp unit.
Carefully pull front bumper (1) forward, otherwise, the front bumper (1) or front fender can be
damaged.
Installation: Ensure that front bumper (1) is seated properly in mount (5).
10 Fasten in reverse order
REMOVE/INSTALL FRONT BUMPER - AR88.20-P-2000SX
MODEL 216 up to model year 2011
MODEL 221
Shown on model 221
Fig. 8: Identifying Front Bumper Components (Model 221)
Courtesy of MERCEDES-BENZ USA
Model 216 only
Fig. 9: Locating Radiator Grille And Bolts (Model 216)
Courtesy of MERCEDES-BENZ USA
Fig. 10: Identifying Expansion Clip And Cover (Model 216)
Courtesy of MERCEDES-BENZ USA
Fig. 11: Identifying Front Bumper And Screw (Model 221)
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between the columns of the
Risk of death caused by vehicle
lifting platform and position the four support AS00.00-Z-
slipping or toppling off of the lifting
plates at the lifting platform support points 0010-01A
platform.
specified by the vehicle manufacturer.
1 Lift vehicle on lifting platform.
Remove fender liner front section
2
from left fender and right fender
3.1 Unclip air inlet grate (6) Model 221 only
Unscrew nuts (7) at bottom of front
4
bumper (1)
Unclip outside temperature indicator
5
temperature sensor (B14)
Disconnect PTS, front bumper On model 221 with code (220) Parktronic
6.1
connector (X26/27) system (PTS), model 216
6.2 connector, front bumper (X172/1) with code (229) Park assistant
Disconnect electrical connector (5)
7 from left front fog lamp (E5/1) and
right front fog lamp (E5/2)
Unscrew bolt (2) on left and right
clamping strip (3) and pivot left and
8
right clamping strip (3) toward
inside and remove
Unscrew bolts (9) and unclip
9.1 Model 216 only
radiator paneling (10) (arrows)
Remove expansion clips (11) and
10.1 Model 216 only
unclip cover (12) (arrows)
11 Unscrew bolt (8)
Lift left and right front fender in area Model 216 only
of lamp unit with assembly wedge
12.1
until retaining clip on front bumper
Fig. 4
(1) is exposed
Installation: Check gaps on front
bumper (1), adjust if necessary.
Model 216 AR60.00-P-
Gap dimensions on hoods, doors and lids 0700-01SC
*BE60.00-P-
1001-01T
13 Remove front bumper (1)
Fig. 2
Model 221 AR60.00-P-
Gap dimensions on hoods, doors and lids 0700-01SX
*BE60.00-P-
Model 221
1001-01R
Fig. 2
14 Install in the reverse order
Check adjustment for left front fog
15 lamp (E5/1) and right front fog lamp
(E5/2), correct if necessary
CHECK VALUES FOR GAPS
Model 216 up to Model 216 as of
Number Designation
model year 2011 model year 2011
Engine hood to Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
fender "A"
Engine hood to Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
headlamp "B"
Engine hood to A- Dimension
mm 4.0 (±0.5) 4.0 (±0.5)
pillar "D"
1001-01T dimension grille/bumper "C" mm 5.0 (±1.0) 2.0 (±1.0)
Engine hood to Dimension
mm 5.0 (±1.0) 5.0 (±1.0)
bumper "P"
Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
Bumper to "Q"
headlamp AR60.00-P-0700- AR60.00-P-0700-
See picture
01SC 01SC
CHECK VALUES FOR GAPS
Number Designation Model 221
Dimension
Engine hood to fender mm 3.5 (±0.5)
"A"
Engine hood to Dimension
mm 3.5 (±0.5)
headlamp "B"
Dimension
Radiator grille/bumper mm 5 (±1)
"C"
BE60.00-P-1001- Gap
Engine hood to bumper Dimension "P" mm 5 (±1.5)
01R dimension
Dimension
Bumper to headlamp mm 3.5 (±0.5)
"Q"
Dimension
mm 3.5 (±0.5)
"R"
Bumper to fender
AR60.00-P-0700-
See picture
01SX
Fig. 12: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 13: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE FRONT BUMPER - AR88.20-P-2050SX
MODEL 221.0/ 1
Shown on vehicle with code (220)
Parktronic system (PTS) and code (600)
Headlamp cleaning system
Fig. 14: Identifying Front Bumper Components - With Code 220 (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on vehicle with code (220)
Parktronic system (PTS) and code (600)
Headlamp cleaning system
Fig. 15: Identifying Front Bumper Components - With Code 220 (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Vehicles with code (229) Park Assist
Fig. 16: Identifying Front Bumper Components - With Code 229
Courtesy of MERCEDES-BENZ USA
Disassemble/assemble
AR88.20-P-
1 Remove front bumper (1).
2000SX
2 Remove license plate.
3 Remove license plate molding (4)
4 Install tow eye cover (3)
Remove left and right outer impact absorber
5
(5)
Remove left front fog lamp (E5/1) and right
6
front fog lamp (E5/2)
Remove support (6), center inner section (7)
7
and basic carrier (10)
Expose wiring harness (11) and remove front
On vehicles with code (220)
bumper PTS connector (X26/27) or radar
8.1 Parktronic system (PTS) or code
sensors/FFS connector, front bumper
(229) Park Assist
(X172/1)
Remove center impact absorber (8) and
9
bottom impact absorber (9)
Remove front PTS ultrasonic sensors (B8/1, On vehicles with code (220)
10.1 Parktronic system (PTS)
B8/2, B8/3, B8/4, B8/5 and B8/6)
Installation: Ensure that sealing
Information on preventing damage to rings of PTS ultrasonic sensors AH54.00-P-
electronic components due to electrostatic (B8/1, B8/2, B8/3, B8/4, B8/5 and 0001-01A
discharge B8/6) are seated correctly.
Remove radar sensors (A86/1b1, A86/1b2,
11.1 A86/1b3 and A86/1b4) with corresponding
bracket (12). On vehicles with code (229) Park
Information on preventing damage to Assist
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
On vehicles with code (600)
12.1 Remove flap (2)
Headlamp cleaning system
13 Assemble in reverse order
DISASSEMBLE/ASSEMBLE REAR BUMPER - AR88.20-P-2100SX
MODEL 221.0 /1
Shown with code (220) Parktronic system (PTS) and code (889) Keyless Go
Fig. 17: Identifying Rear Bumper Components - With Code 220 Parktronic System
Courtesy of MERCEDES-BENZ USA
Shown with code (229) Park assistant and code (889) Keyless Go
Fig. 18: Identifying Rear Bumper Components - With Code 229 Parktronic System
Courtesy of MERCEDES-BENZ USA
Disassemble/assemble
Notes on avoiding damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
Vehicles without code (Z07) Top AR88.20-P-
protection 2200SX
1 Remove rear bumper (1)
Vehicles with code (Z07) Top AR88.20-P-
protection 2200SXS
Only with code (220) Parktronic
system (PTS)
Remove rear PTS ultrasonic sensor (B8/7, Installation: Ensure that sealing
2.1
B8/8, B8/9 and B8/10) rings on rear PTS ultrasonic sensors
(B8/7, B8/8, B8/9 and B8/10) are
seated correctly.
Remove right inner radar sensor, rear
3.1 bumper (A86/2b2) and left inner radar Only with code (229) Park assistant
sensor, rear bumper (A86/2b3)
Unclip rear bumper Keyless Go antenna
4.1 (A2/99) and disconnect electrical Only with code (889) Keyless Go
connector
5 Remove towing eye cover (3)
Only with code (220) Parktronic
6.1 Expose wiring harness (4) and remove system (PTS) or code (229) Park
assistant or code (889) Keyless Go
7 Remove bracket (2)
Installation: Check clips (7),
8 Remove clips (7)
replace if necessary
Remove left and right inner section (6)
9
with mounting rail (5).
Unclip mounting rail (5) from left and
10
right inner section (6).
11 Assemble in the reverse order
REMOVE/INSTALL REAR BUMPER - AR88.20-P-2200SX
MODEL 221.0/ 1
Fig. 19: Identifying Rear Bumper Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 20: Identifying Rear Bumper Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 21: Identifying Rear Bumper Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage
AH54.00-P-
to electronic components due to
0001-01A
electrostatic discharge
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off of the
support points specified by vehicle 0010-01A
lifting platform.
manufacturer.
1 Lift vehicle on lifting platform.
2 Remove trunk floor paneling (8)
Do not bend hinge lever passage frame
See: ?
Loosen left and right side paneling
3 AR68.30-P-
in trunk (10) and connect Remove paneling in trunk
4600SX
Disconnect electrical connector
4
from wiring harness (7)
Remover mount (4) and mount (12)
5 Do not disconnect connectors
and lay down to side
Unscrew bolts (3) in left and right
6
rear fender
Unscrew nuts (2) inside of rear
7
center section
Unscrew bolts (13) at bottom of
8
rear bumper (1).
Loosen left and right rear fender
9 paneling (15) with mounting wedge Mounting wedge Fig. 4
until bolt (14) is accessible.
10 Remove bolts (14)
Remove expansion clip (16) from
11 rear fender paneling (15) on left
and right
Installation: Guide hose (18) into
12 Remove rear bumper (1)
bracket on rear bumper (1).
Guide wiring harness (7) through
13
opening in rear center section.
14 Install in the reverse order
See: ?
AR60.00-P-
Gap dimensions on hoods, doors and lids
Check gaps on rear bumper (1), 0700-01SX
15
adjust if necessary *BE60.00-P-
Trunk lift to bumper, dimension "L"
1003-01R
Feeler gauge Fig. 2
CHECK VALUES FOR GAPS
Number Designation Model 221
Dimension
Trunk lid to rear fender, top mm 4 (±0.5)
"J"
Dimension
Trunk lid to rear lamp unit mm 4 (±0.5)
"K"
BE60.00-P-1003- Gap Dimension
01R dimension Trunk lid to bumper mm 5.5 (±1.5)
"L"
Dimension
Rear fender to rear lamp unit mm 2.5 (±0.5)
"M"
mm 4 (±0.5)
"N"
Trunk lid license plate panel to
rear lamp unit AR60.00-P-0700-
See picture
01SX
Fig. 22: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 23: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REAR BUMPER - AR88.20-P-2200SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 24: Identifying Rear Bumper Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 25: Identifying Rear Bumper Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 26: Identifying Rear Bumper Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Shown on right side of vehicle.
Fig. 27: Identifying Rear Bumper Components (Right Side)
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove trunk floor paneling as
AR68.30-P-
1 well as left and right side
4600SXS
paneling in trunk.
Disconnect PTS, rear bumper
2.1 On vehicles without code (229) Park Assist
connector (X35/28)
Disconnect radar sensors/FFS
2.2 connector, rear bumper
(X172/2) On vehicles with code (229) Park Assist
electronic components due to AH54.00-P-
electrostatic discharge 0001-01A
On vehicles with code (218) Backup camera or
Loosen bolt (3) and nuts (4),
Code (390 to 396) Linguatronic or
3.1 remove bracket (2) and lay
Code (529) HIGH Class Japan or
down to side.
Code (813) Voice control system (VCS)
Unscrew bolts (5), loosen nut
4 (7), remove bracket (6) and lay
down to side.
Unscrew bolts (10) on both
5
sides of vehicle.
Unscrew left and right nut (9)
6
inside of rear center section.
Risk of death caused by
vehicle slipping or toppling off Align vehicle between lifting platform columns
of the lifting platform. and position the four support plates at the lifting AS00.00-Z-
platform support points specified by vehicle 0010-01A
Raise vehicle with lifting manufacturer.
7
platform
Unscrew bolts (13) at bottom of
8
rear bumper (1).
Loosen left and right rear fender
9 paneling (15) until bolt (14) is Fig. 4
accessible.
10 Remove bolts (14)
Remove expansion clip (16)
11 from left and right rear fender
paneling (15).
Installation: Ensure that rear bumper (1) is
seated correctly in left and right guides (17).
Install hose (18) in bracket on rear bumper (1) on
right side of vehicle.
Check gaps on rear bumper (1), adjust if
Remove rear bumper (1) with necessary
12
aid of helper AR60.00-P-
Gap dimensions on hoods, doors and lids
0700-01SX
*BE60.00-P-
1003-01R
Fig. 2
Guide electrical wiring harness
Installation: Ensure that grommet is seated
13 (8) through opening into rear
center section. correctly in rear center section.
AR88.20-P-
14.1 Disassemble rear bumper (1) When replacing rear bumper (1).
2100SX
15 Install in the reverse order
CHECK VALUES FOR GAPS
Number Designation Model 221
Trunk lid to rear fender,
Dimension "J" mm 4 (±0.5)
top
Trunk lid to taillamp Dimension "K" mm 4 (±0.5)
Trunk lid to bumper Dimension "L" mm 5.5 (±1.5)
BE60.00-P-1003- Gap
01R dimension Dimension
Rear fender to taillamp mm 2.5 (±0.5)
"M"
Dimension "N" mm 4 (±0.5)
Trunk lid cover to
taillamp AR60.00-P-0700-
See picture
01SX
Fig. 28: Identifying Assembly Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 29: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
PREPARE BODY FLANGE FOR GLUING IN SPARE TIRE WELL - AR88.30-P-1000-03SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1049-02A Repair kit, installing window, 2-component adhesive A 168 670 00 93
A maximum of 2 mm of adhesive residue may be left. Pull off loose adhesive material (remaining
pieces which are not completely cut off).
2. Clean painted bonding surface on spare tire well body flange with cleaner from repair set (BETACLEAN
3300) from 2-component glue set and rub dry with rag.
3. If glue on spare tire well body flange is damaged or defective, apply paint glass primer (BETAPRIME
5061) from 2-component glue set in area to be glued.
Allow primer to air-dry for a minimum of 10 minutes.
4. Repair paint damages on spare tire well body flange not covered by glue with primer stick
In order to prevent adhesion faults when gluing in the spare tire well, the bonding surface of the body
flange must be free of dust, oil, grease, wax and other cohesive components or dirt particles.
If sheet metal parts are replaced in the area of the spare tire well, treat gluing area of spare tire well
with paint/glass primer (BETAPRIME 5061).
PREPARE GLUE CARTRIDGE - AR88.30-P-1000-05SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1049-02A Repair kit, installing window, 2-component adhesive A 168 670 00 93
1. Remove both cartridges from repair kit
Always process cartridges together.
2. Remove retainer (1) from cartridges.
3. Screw on application nozzle.
4. Insert cartridges into Betapower II (2-component electric cartridge gun) .
The 2-component glue set includes plastic primer (BETAPRIME 5404) and paint/glass primer
(BETAPRIME 5061). Use both primers to glue in the spare tire well.
Fig. 30: Removing Retainer From Cartridges
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL SPARE TIRE WELL - AR88.30-P-1000SX
MODEL 204.3, 221, 216
Shown on model 221
Fig. 31: Identifying Spare Tire Well Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 32: Identifying Spare Tire Well Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on model 221 with code (487)
Active Body Control (ABC)
Fig. 33: Identifying Spare Wheel Well & Holes
Courtesy of MERCEDES-BENZ USA
Removing
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off of the lifting
support points specified by vehicle 0010-01A
platform.
manufacturer.
when inserting blade in the Always interrupt air supply or power supply
AS67.00-Z-
multicutter and by glass splinters before inserting or removing blade.
0001-01A
when cutting out bonded windows Wear protective gloves and safety glasses.
AR68.30-P-
Model 204.0/3
4600CW
1 Remove trim in trunk
Model 216 AR68.30-P-
Model 221 without code (Z07) Top protection 4600SX
Model 221 with CODE (Z07) Highest AR68.30-P-
protection 4600SXS
2.1 Remove tool box (2) On vehicles with Tirefit
Code (669) Spare wheel on steel rim
2.2 Remove spare tire Code (690) Compact spare tire as emergency
wheel
Remove sound deadening mat (3)
3
from spare tire well (1)
Two-post lifting platform, 2.5 - 3.5 t
4 Lift vehicle on vehicle lift.
electrohydraulic gotis://H_00.1_01.1
Remove bolts (4) from cover panel
5
(12) on spare tire well (1) at bottom
6 Remove cover panel (12)
AR32.50-P-
7 Remove rear axle pressure reservoir With code (487) Active Body Control (ABC)
0011SX
Drill hole (5) next to body flange
8 (9) for inserting body saw (6) into drill gotis://K_58.1_04.0
spare tire well (1)
Saw as close as possible to body flange
Saw out spare tire well (1) parallel (9).
9
to body flange (9) Avoid damaging paint.
Body jig saw gotis://K_58.1_01.0
Cut out remains of the spare tire Cutting blade
10 Fig. 34
well (7) Multicutter
Two-post lifting platform, 2.5 - 3.5 t
11 Lower vehicle on lifting platform
electrohydraulic gotis://H_00.1_01.1
Install
With Active Body Control (ABC), code 487
Drill dia. 7 mm holes (10) for rear
12 In marked areas of spare tire well (1).
axle pressure reservoir
drill gotis://K_58.1_04.0
Code (487) Active Body Control (ABC)
In marked areas of spare tire well (1).
drill gotis://K_58.1_04.0
Cut out dia. 38 mm hole (11) for
13 Keyhole saw holder, dia. 32 - 152 mm
rear axle pressure reservoir
HSS bimetal keyhole saw, dia. 38 mm
(without mounting shaft and without drill
bits)
Cut off remaining glue (8) with scraper.
AR88.30-P-
Scraper
Prepare body flange (9) for gluing 1000-03SX
14 Replacement blade for scraper
in spare tire well (1)
Repair kit, installing window, 2-component *BR00.45-Z-
adhesive 1049-02A
Use cleaning set and plastic primer
BETAPRIME 5404 included in 2-component
adhesive set.
Clean gluing flange on spare tire
15 Observe flash-off time for BETAPRIME
well (1) and prime
5404 plastic primer.
Repair kit, installing window, 2-component *BR00.45-Z-
adhesive 1049-02A
Repair paint damage on body flange
16
(9) with primer stick
AR88.30-P-
Model 216, 221
1000-05SX
Model 204.3
AR67.10-P-
17 Prepare adhesive cartridge Betapower II (2-component electric
1000-07CW
cartridge gun)
Repair kit, installing window, 2-component *BR00.45-Z-
adhesive 1049-02A
Width of glue bead approx. 8 mm, height
approx. 13 mm.
Apply adhesive on gluing flange at Betapower II (2-component electric
18
new spare tire well (1) cartridge gun)
Repair kit, installing window, 2-component *BR00.45-Z-
adhesive 1049-02A
Install spare wheel well (1) within 10
Insert spare tire well (1) into body
19 minutes. Otherwise the adhesive force of the
opening.
glue starts to decrease.
Center spare tire well (1) and press
20 on by slightly knocking with plastic
hammer all the way around.
Insert sound deadening mat (3) into
21
spare tire well (1)
Two-post lifting platform 2.5-3.5 t, electro-
22 Lift vehicle on vehicle lift.
hydraulic gotis://H_00.1_01.1
Tighten cover panel (12) to spare
23
tire well (1) at bottom with bolts (4)
AR32.50-P-
24 Install rear axle pressure reservoir Code (487) Active Body Control (ABC)
0011SX
Two-post lifting platform 2.5-3.5 t, electro-
25 Lower vehicle on lifting platform
hydraulic gotis://H_00.1_01.1
Code (690) Compact spare tire as emergency
26.1 Install spare tire
wheel
26.2 Insert tool box (2) On vehicles with Tirefit.
AR68.30-P-
Model 204.0/3
4600CW
Model 216 AR68.30-P-
27 Remove trim in trunk
Model 221 without code (Z07) Top protection 4600SX
Model 221 with CODE (Z07) Highest AR68.30-P-
protection 4600SXS
Fig. 34: Identifying Cutting Blade (124 589 21 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1049-02A Repair kit, installing window, 2-component adhesive A 168 670 00 93
REMOVE/INSTALL ENGINE HOOD - AR88.40-P-3000SX
MODEL 216, 221
Illustrated on model 221
Fig. 35: Identifying Engine Hood Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being pinched
or crushed when removing, installing or Keep body parts and limbs well AS00.00-Z-
aligning hoods, doors, trunk lids, tailgates or clear of moving parts. 0011-01A
sliding roof.
Remove clips (3) and lift sound deadening mat
1
(2) at bottom
2 Remove expansion clips (7)
Unscrew nuts (6) from bottom engine hood
3
cover (5)
Unclip lower engine hood cover (5) and put
4 down in engine compartment with lines still
attached
Unclip AAC sun sensors (4 in total) (B32/2),
5 expose wiring harness (8) and lay down in
engine compartment
Use an assistant to secure the
engine hood (1).
Unscrew nut (9) on left and right engine hood Installation: Repair paint
6
hinge (10) and remove engine hood (1). damage on nuts (9) whit
corresponding touch-up paint
pen.
7 Install in the reverse order
8 Adjust engine hood (1)
3020SX
Check windshield washer system for proper
9 function, adjust windshield washer nozzles if
necessary.
Windshield wipers, windshield washer system AP82.30-P-
and headlamp cleaning system - function check 8252SX
REMOVE/INSTALL GAS-OPERATED STRUT ON ENGINE HOOD - AR88.40-P-3010SX
MODEL 216, 221
Shown on model 221 on left side of vehicle with front fender removed
Fig. 36: Identifying Gas-Operated Strut And Retainer
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between the columns of the
Risk of death caused by vehicle
lifting platform and position the four support AS00.00-Z-
slipping or toppling off of the lifting
plates at the lifting platform support points 0010-01A
platform.
specified by the vehicle manufacturer.
1 Raise vehicle with lifting platform
Remove rear section of fender liner on
2
left or right front fender
Risk of injury caused by body parts
Only remove and install gas-operated struts
being pinched or crushed when
when they are not under tension and when
working on gas-operated struts under
the components are properly secured.
tension AS00.00-Z-
Lift retainers (2) at top and bottom of 0012-01A
gas-operated strut (1) with suitable Do not remove retainers (2), otherwise
3 tension of the retainers (2) is no longer
screwdriver and remove gas-operated
strut (1) from mounts ensured
4 Install in the reverse order
ADJUST ENGINE HOOD - AR88.40-P-3020SX
MODEL 216, 221
Shown on model 221 on left side of vehicle with front fender removed
Fig. 37: Identifying Engine Hood Components
Courtesy of MERCEDES-BENZ USA
Risk of injury caused by fingers being pinched
Keep body parts and limbs well clear AS00.00-Z-
or crushed when removing, installing or aligning
of moving parts. 0011-01A
hoods, doors, trunk lids, liftgates or sliding roof
AR88.40-P-
1 Remove both engine hood lock top sections (2)
3200SX
Adjust in longitudinal and transverse direction
Adjust engine hood (1) so that
the gap between the engine hood (1)
and the front fender is not wedge-
shaped.
Model 216
AR60.00-P-
Gap dimensions on hoods, doors and
0700-01SC
lids
Loosen bolts (7), nuts (6) or bolts (9) on left and *BE60.00-P-
2 right engine hood hinge and adjust engine hood 1001-01T
(1) in longitudinal and lateral direction
Fig. 2
Model 221
AR60.00-P-
Gap dimensions on hoods, doors and
0700-01SX
lids
*BE60.00-P-
1001-01R
Fig. 2
Tighten bolts (7) only after
correct height adjustment.
1003-01M
3 Tighten bolts (7), nuts (6) or bolts (9). *BA88.40-P-
1004-01M
Adjust height
4 Slightly screw in left and right height stop (8)
Loosen bolts (7) and adjust engine hood (1) so
5 that height in the rear area is flush with front
fenders.
*BA88.40-P-
6 Tighten bolts (7)
1003-01M
AR88.40-P-
7 Install both upper engine hood catches (2).
3200SX
Adjust engine hood (1) using bolt (4) on both
8 engine hood catch upper sections (2) so that
height is flush with front fenders in front area
Adjust left and right height stop (8) so that a strip
of paper can be pulled through between the height The height stop (8) serves to
9 stop (8) and the corresponding counterelement on protect the engine hood (1) from
the engine hood hinge when the engine hood (1) fluttering in the rear area.
is closed.
Adjust stop buffers (5, 10) so that a strip of paper
The stop buffers (5, 10) serve to
can be pulled through between the stops buffers
10 protect the engine hood (1) from
(5, 10) and engine hood (1) when the engine hood
fluttering in the front area.
(1) is closed
From a height of 100 to 130 mm
(measured from tip of fender), the
engine hood (1) should drop by itself
into the lower engine hood catches
Check whether engine hood (1) closes properly
11 and lock.
and is tensioned, adjust if necessary.
The closed engine hood (1) should
not have play in the area of the upper
engine hood catches (2), i.e. should
have only slight tension
Check whether engine hood catch lower section s Pull engine hood (1) upward
13
are locked with a jerk,
Release engine hood (1) and check whether
14 retaining hood on upper frame cross member is
arrested.
15 Repair paint damage
CHECK VALUES FOR GAPS
Model 216 up to Model 216 as of
Number Designation
model year 2011 model year 2011
mm 3.5 (±0.5) 3.5 (±0.5)
fender "A"
Engine hood to Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
headlamp "B"
Engine hood to A- Dimension
mm 4.0 (±0.5) 4.0 (±0.5)
pillar "D"
Radiator Dimension
BE60.00-P- Gap mm 5.0 (±1.0) 2.0 (±1.0)
grille/bumper "C"
1001-01T dimension
Engine hood to Dimension
mm 5.0 (±1.0) 5.0 (±1.0)
bumper "P"
Dimension
mm 3.5 (±0.5) 3.5 (±0.5)
Bumper to "Q"
headlamp AR60.00-P-0700- AR60.00-P-0700-
See picture
01SC 01SC
CHECK VALUES FOR GAPS
Number Designation Model 221
Dimension
Engine hood to fender mm 3.5 (±0.5)
"A"
Engine hood to Dimension
mm 3.5 (±0.5)
headlamp "B"
Dimension
Radiator grille/bumper mm 5 (±1)
"C"
BE60.00-P-1001- Gap
Engine hood to bumper Dimension "P" mm 5 (±1.5)
01R dimension
Dimension
Bumper to headlamp mm 3.5 (±0.5)
"Q"
Dimension
mm 3.5 (±0.5)
"R"
Bumper to fender
AR60.00-P-0700-
See picture
01SX
ENGINE HOOD
Number Designation Model 216 Model 221
BA88.40-P-1003-01M Bolt/nut, engine hood to engine hood hinge Nm 8 8
BA88.40-P-1004-01M Screw for engine hood hinge on body Nm 10 10
Fig. 38: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL HOOD HINGE - AR88.40-P-3060SX
MODEL 216, 221
Illustrated on model 221
Fig. 39: Identifying Hood Hinge Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear AS00.00-Z-
installing or aligning hoods, doors, trunk of moving parts. 0011-01A
lids, tailgates or sliding roof.
1.1 Remove engine hood (1) hood hinge (3). 3000SX
When removing left or right engine
1.2 Support engine hood (1)
hood hinge (3).
Loosen left and right front fender in upper AR88.10-P-
2
and rear area and pivot toward outside. 1000SX
Only remove and install gas-operated
Risk of injury caused by body parts being
struts when they are not under
pinched or crushed when working on gas-
tension and when the components are
operated struts under tension AS00.00-Z-
properly secured.
0012-01A
Lift retainer (5) with suitable screwdriver Do not remove retainer (5),
3 and remove gas-operated strut (6) from hood otherwise the tension of the retainer
hinge (3). (5) is no longer ensured.
When removing left engine hood
4.1 Unclip bracket (7) with wiring harness.
hinge (3).
When removing left or right engine
hood hinge (3).
Unscrew bolts (2) from left and right engine Aid of helper required.
5.1
hood hinge (3). Installation: Do not tighten bolts
(2); they are tightened after adjusting
the engine hood.
Installation: Do not tighten bolts
Unscrew bolts (4) from left and right engine
6 (4); they are tightened after adjusting
hood hinge (3).
the engine hood.
7 Remove left and right hood hinges (3)
8 Install in the reverse order
AR88.40-P-
9 Adjust engine hood (1)
3020SX
REMOVE/INSTALL PULL CABLE FOR ENGINE HOOD - AR88.40-P-3100SX
MODEL 221.0 /1
Engine hood cable front section
Fig. 40: Identifying Engine Hood Pull Cable Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR88.40-P-
1 Remove engine hood catch lower section (6)
3200SX
Disconnect weather-stripping (1) in area of radiator
2
crossmember (8)
Open splitter (3) and unhook engine hood cable rear
3
section (4)
4 Remove radiator bracket (7) on left and right
Unscrew bolts (5) and remove radiator crossmember Rechargeable *WH58.30-Z-
5
(8) drill/screwdriver 1007-20A
Unclip engine hood cable front section (2) from clip
6
on radiator crossmember (8) and remove
7 Install in the reverse order
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1007-20A Cordless drill/driver
REMOVE/INSTALL ENGINE HOOD CATCH - AR88.40-P-3200SX
MODEL 216, 221
Illustrated on model 221
Fig. 41: Identifying Engine Hood Catch Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221 with code (551) Anti-theft alarm (ATA)
Fig. 42: Identifying Engine Hood Catch Components (With Anti-Theft Alarm)
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being pinched or Keep body parts and AS00.00-Z-
0011-01A
doors, trunk lids, tailgates or sliding roof. moving parts.
Unscrew nuts (3) and remove engine hood catch upper
1
section (2).
Unscrew bolts (4) on engine hood catch lower section
2
(5)
Remove engine hood catch lower section (5) upward
3 out of radiator crossmember and unhook engine hood
cable (6)
On vehicles with code
Remove ATA [EDW] hood switch (S62) on right
4.1 (551) Anti-theft alarm
engine hood catch lower section (5)
system ATA [EDW]
5 Remove engine hood catch lower section (5)
6 Install in the reverse order
AR88.40-P-
7 Check engine hood adjustment, adjust if necessary.
3020SX
REMOVE/INSTALL MERCEDES STAR - AR88.40-P-4050SX
MODEL 221.0/ 1
Fig. 43: Identifying Mercedes Star And Spring Bracket
Courtesy of MERCEDES-BENZ USA
Remove/install
Turn spring bracket (2) 90° to left with Fig.
1
assembly tool 44
Remove Mercedes star (1) upward from Carefully remove Mercedes star (1);
2
engine hood danger of paint damage.
3 Install in the reverse order
Fig. 44: Identifying Assembly Tool (202 589 11 63 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TRUNK LID - AR88.50-P-5000SX
MODEL 216, 221
Shown on model 221
Fig. 45: Identifying Trunk Lid Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing , Keep body parts and limbs well clear AS00.00-Z-
installing or aligning hoods, doors, trunk of moving parts. 0011-01A
lids, tailgates or sliding roof.
1 Take off cover (6)
Remove hazard warning triangle (5) and
2
bracket (4)
3 Detach umbrella holder (3)
4 Detach hinge bracket trim pieces (2)
5 Detach trunk lid trim (7)
Disconnect electrical connectors on wiring
harness (8) in trunk lid (1) and remove
6
wiring harness (8) from trunk lid (1) and
lay down to side.
Installation: Screw in bolts (9)
only until trunk lid (1) can still be
7 Unscrew bolts (9) on hinge levers
moved. These bolts (9) can be
tightened after adjusting trunk lid (1).
Remove trunk lid (1) out of the hinge levers
8
upwards
9 Install in the reverse order
AR88.50-P-
10 Adjust trunk lid (1)
5200SX
REMOVE/INSTALL TRUNK LID LOCK CYLINDER - AR88.50-P-5061SX
MODEL 216, 221
Shown on model 221
Fig. 46: Identifying Trunk Lid Lock Cylinder Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear AS00.00-Z-
installing or aligning hoods, doors, trunk lids, of moving parts. 0011-01A
tailgates or sliding roof.
1 Remove cover (6)
Remove hazard warning triangle (5) and
2
bracket (4).
3 Remove umbrella holder (3).
4 Remove hinge bracket trim pieces (2).
5 Remove trunk lid paneling (7)
6 Unclip covering (9)
The opening in the lock housing
with emergency key (12) corresponding removal hole in the
7
lock cylinder housing.
Loosen retaining tab (13) by
Insert 1.5 mm WAF Allen wrench (11) into pressing in the 1.5 mm WAF Allen
opening on lock housing (10) and pull lock wrench (11).
8
cylinder (8) with emergency key (12) out of Installation: Press lock cylinder
lock cylinder housing. (8) against the spring located in the
lock cylinder housing when locking.
9 Install in the reverse order
REMOVE/INSTALL TRUNK LID OPENING ANGLE DETECTION SENSOR - AR88.50-P-5065SX
MODEL 216.3, 221.0 /1 with code (881) Remote trunk closing (RTC [HDFS])
Illustrated on model 221
Fig. 47: Identifying Trunk Lid Opening Angle Detection Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers
being pinched or crushed when AS00.00-
Keep body parts and limbs well clear of
removing, installing or aligning Z-0011-
moving parts.
hoods, doors, trunk lids, tailgates or 01A
sliding roof.
Notes on avoiding damage to AH54.00-
electronic components due to P-0001-
electrostatic discharge 01A
Installation: When replacing the trunk lid
position sensor (B24/16), install right side
sensor for new trunk lid position sensor
(B24/16) and normalizing remote trunk
closing.
1 Remove right side paneling in trunk AR68.30-
Vehicles without code (Z07) Top protection
P-4600SX
AR68.30-
Vehicles with code (Z07) Top protection
P-4600SXS
Installation: When replacing trunk lid
Disconnect trunk lid position
2 position sensor (B24/16) do not yet connect
sensor connector (B24/16x1)
trunk lid position sensor connector (B24/16x1).
Expose electric wiring harness (4)
3 on trunk lid position sensor
(B24/16)
Press ball socket (8) off of hinge
4 lever (7) and ball socket (2) off of
rear fender
5 Remove hydraulic cylinder (1).
Unscrew bolt (6) and remove trunk Installation: Install trunk lid position
lid position sensor (B24/16) sensor (B24/16) first on hydraulic cylinder (1)
6
together with electric wiring and then connect trunk lid position sensor
harness (4). connector (B24/16x1).
7 Install in the reverse order
Only when replacing trunk lid position sensor
(B24/16).
To synchronize the sensor, first connect the
Synchronize sensor to trunk lid wiring harness supplied to the trunk lid
8.1 position sensor (B24/16) and then to the trunk
position sensor (B24/16)
lid position sensor connector (B24/16x1).
Ensure that the trunk lid is manually opened
and closed rapidly and without intermediate
stop.
If sensor synchronization is not successful, the
operation can be repeated as frequently as
required.
Sensor synchronization:
Move trunk lid by hand once up to upper stop, AD00.00-
Connect STAR DIAGNOSIS and then close by hand and press into trunk lid
P-2000-
read out fault memory lock. 04A
Open trunk lid, remove intermediate connector
and directly reconnect trunk lid position sensor
connector (B24/16x1).
Erase error message "Sensor error" now
present with STAR DIAGNOSIS.
9.1 Denormalize remote trunk closing Only when replacing trunk lid position sensor
normalize remote trunk closing Normalize remote trunk closing: Open
trunk lid by actuating trunk lid handle; trunk lid
AD00.00-
Connect STAR DIAGNOSIS and opens automatically. Wait until TLC hydraulic
P-2000-
read out fault memory pump switches off, then close trunk lid by
04A
actuating TLC button.
REMOVE/INSTALL HYDRAULIC PUMP FOR TRUNK LID REMOTE CONTROL - AR88.50-P-
5070SX
MODEL 216.3, 221.0 /1 with code (881) Remote trunk closing (RTC [HDFS])
Illustrated on model 221
Fig. 48: Identifying Trunk Lid Remote Control Hydraulic Pump Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being pinched or crushed Keep body parts
AS00.00-Z-
when removing, installing or aligning hoods, doors, trunk and limbs well clear
0011-01A
lids, tailgates or sliding roof. of moving parts.
Notes on avoiding damage to electronic components due to AH54.00-P-
electrostatic discharge 0001-01A
Vehicles without
AR68.30-P-
code (Z07) Top
4600SX
protection
1 Remove right side paneling in trunk
Vehicles with code
AR68.30-P-
(Z07) Top
4600SXS
protection
2 Disconnect HDS hydraulic pump connector (M51x1)
3 Disconnect trunk lid position sensor connector (B24/16x1)
4 Expose hydraulic line (4).
Remove protective cap (6) together with TLC hydraulic
5
pump (M51) from bracket.
Press ball socket (8) off of hinge lever (7) and ball socket (2)
6
off of rear fender
Remove hydraulic cylinder (1) together with hydraulic line
7
(4) and lay down to side.
8 Remove TLC hydraulic pump (M51) from protective cap (6).
Remove TLC hydraulic pump (M51) together with hydraulic
9
line (4) and hydraulic cylinder (1).
10 Install in the reverse order
Denormalize remote trunk closing with STAR DIAGNOSIS,
then normalize remote trunk closing
Normalize remote trunk closing: Open trunk lid by Only when
11.1
actuating trunk lid handle; trunk lid opens automatically. replacing HDS
Wait until TLC hydraulic pump (M51) switches off, then hydraulic pump
close trunk lid by actuating TLC button. (M51).
AD00.00-P-
Connect STAR DIAGNOSIS and read out fault memory
2000-04A
ADJUST TRUNK LID - AR88.50-P-5200SX
MODEL 216, 221
Shown on model 221
Fig. 49: Identifying Trunk Lid Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
17.5.06 Repair method and entire adjustment procedure modified
Removing
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear of AS00.00-Z-
installing or aligning hoods, doors, trunk moving parts. 0011-01A
lids, liftgates or sliding roof
Vehicles without code (Z07) Top AR68.30-P-
Remove trim from rear end center protection 4600SX
1
assembly AR68.30-P-
Vehicles with code (Z07) Top protection
4600SXS
Unscrew bolts (10) and remove locking
2
eye (11)
Remove left and right hinge bracket trim
3
pieces (2)
Adjust in longitudinal direction
Lift trunk lid paneling (7) at side on left
4 hinge lever and right hinge lever and
loosen bolts (9)
Model 216 AR60.00-P-
Gap dimensions on hoods, doors and lids 0700-01SC
*BE60.00-P-
1003-01T
Adjust trunk lid (1) in longitudinal Fig. 2
5
direction Model 221 AR60.00-P-
Gap dimensions on hoods, doors and lids 0700-01SX
*BE60.00-P-
1003-01R
Fig. 2
Tighten bolts (9) on left hinge lever and
6
right hinge lever
Adjust lateral direction and height
7 Screw in stops (8)
Install locking eye (11) and adjust so that
Center locking eye (11) with catch
8 height of trunk lid (1) matches height of
on trunk lid lock.
rear fender
9 Tighten bolts (10) for locking eye (11)
Remove stops (8) until the chalk on
the contact surfaces on the rear center
Mark contact surface of stops (8) with section and the two rear fenders are
10
chalk and adjust stops (8) visible when the trunk lid (1) is closed.
Do not slam the trunk lid (1), instead,
push slowly into lock by hand.
Install
Vehicles without code (Z07) Top AR68.30-P-
protection 4600SX
11 Install rear center section paneling
AR68.30-P-
Vehicles with code (Z07) Top protection
4600SXS
12 Install hinge bracket trim pieces (2)
On vehicles with code (218) Backup AR54.65-P-
13.1 Calibrate backup camera
camera 0022SX
CHECK VALUES FOR GAPS
Model 216 up to Model 216 as of
Number Designation
model year 2011 model year 2011
Trunk lid to rear Dimension
mm 3.5 (±0.8) 3.5 (±0.8)
fender, top "J"
Trunk lid to rear Dimension
mm 3.5 (±0.8) 3.5 (±0.8)
lamp unit "K"
BE60.00-P- Gap Trunk lid to Dimension
mm 5, 5 (±1.5) 5, 5 (±1.5)
1003-01T dimension bumper "L"
Rear fender to Dimension
mm 2.5 (±0.5) 2.5 (±0.5)
rear lamp unit "M"
AR60.00-P-0700- AR60.00-P-0700-
See picture
01SC 01SC
CHECK VALUES FOR GAPS
Number Designation Model 221
Dimension
Trunk lid to rear fender, top mm 4 (±0.5)
"J"
Dimension
Trunk lid to rear lamp unit mm 4 (±0.5)
"K"
Dimension
Trunk lid to bumper mm 5, 5 (±1.5)
BE60.00-P-1003- Gap "L"
01R dimension Dimension
Rear fender to rear lamp unit mm 2.5 (±0.5)
"M"
Dimension
mm 4 (±0.5)
Trunk lid license plate panel to "N"
rear lamp unit AR60.00-P-0700-
See picture
01SX
Fig. 50: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REMOTE TRUNK CLOSING CONTROL UNIT - AR88.50-P-5300SX
MODEL 216.3, 221.0 /1 with CODE (881) Remote trunk closing (RTC [HDFS])
Illustrated on model 221 before YoM 2008/1
Fig. 51: Identifying Remote Trunk Closing Control Unit Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
18.3.09 Checking HDS control module for current flashware Step 8
Remove/install
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear of AS00.00-Z-
removing, installing or aligning hoods,
moving parts. 0011-01A
doors, trunk lids, liftgates or sliding
roof
electronic components due to 0001-01A
electrostatic discharge
AR68.30-P-
1 Remove spare tire well paneling On model 216
4600SX
Vehicles without code (Z07) Top AR68.30-P-
Loosen right side paneling in trunk (3) protection 4600SX
2 and pivot to side until TLC control unit
(N121) is accessible AR68.30-P-
Vehicles with code (Z07) Top protection
4600SXS
3 Separate electrical connectors (4) As of YoM 2008/1, disconnect all 4
connectors
Unclip catch hook (5) and remove Installation: Ensure that guides (6) are
4
TLC control unit (N121) seated correctly in bracket.
Remove cover on fuse and relay Only when replacing TLC control unit
5 module from rear SAM control module (N121) on model 221 up to vehicle
with fuse and relay module identification end number 026743.
Only when replacing TLC control unit
(N121) on model 221 up to vehicle
Change fuse assignment for TLC identification end number 026743. AR54.15-P-
control unit (N121) on rear SAM Leave ground line on starter battery 1255-08SX
6 and on-board electrical system battery
control unit with fuse and relay
module connected.
Fig. 52
Fig. 53
7 Install in the reverse order
Check HDS control unit (N121) for
8
current flashware Only when replacing TLC control unit
Connect STAR DIAGNOSIS and read (N121). AD00.00-P-
out fault memory 2000-04A
Only when replacing TLC control unit
(N121).
Open trunk lid by actuating trunk lid
9 Normalize remote trunk closing handle. The trunk lid then opens
automatically. Wait until TLC hydraulic
pump switches off, then close trunk lid by
actuating TLC button.
Fig. 52: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Courtesy of MERCEDES-BENZ USA
Fig. 53: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TANK RECESS - AR88.60-P-2000SX
Shown on model 221
Fig. 54: Identifying Tank Recess Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Lift rear vehicle with floor jack. AR00.60-P-
Model 221
1000SX
Loosen fender liner from rear fender and
2 rear bumper below tank recess (1) with Fig. 4
assembly wedge.
3 Remove hose from tank recess draining (6).
Release fuel filler flap (4) with suitable tool
4
(arrow) and remove.
5 Remove expansion clip (5).
Remove protective cap (2) and unclip
6.1 Model 221 only
parking brake release cable.
7 Turn lock (3) approx. 90° clockwise.
8 Remove bolts (7)
Carefully install tank recess
sealing lip (1) over tank flap to
Coat sealing lip on tank recess (1) with
9 prevent tearing.
lubricant and install over tank flap.
*BR00.45-Z-
Antifriction agent
1010-06A
10 Remove tank recess (1).
11 Install in the reverse order
Fig. 55: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL COMPLETE OUTSIDE MIRROR - AR88.70-P-9000CW
MODEL 204, 207, 212, 216, 221
Shown on driver side on model 204 up to model year 2011
Fig. 56: Identifying Outside Mirror Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Unclip left and right mirror triangle paneling (1) and allow Mounting Fig.
1
electrical line (6) to hang down wedge 4
In model 204, 216,
2 Remove rear soundproofing from cover on mirror triangle (1)
221
Unclip window frame paneling in area of threaded connection on
3 On model 204.9
left outside mirror (M21/1) or right outside mirror (M21/2)
Mounting Fig.
4 Unclip cover (2) from door lining (3) and remove
wedge 4
5 Disconnect electrical connectors (4)
6 Remove omega clip (7) On model 204, 212
Protection door lining (3) in area of bolts (5) against damage with
7 In case of model 207
adhesive tape
Remove bolts (5) and remove left outside mirror (M21/1) or right Prevent screws
8
outside mirror (M21/2) (5) from falling.
9 Install in the reverse order
Fig. 57: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL COMPLETE OUTSIDE MIRROR - AR88.70-P-9000SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 58: Identifying Outside Mirror Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Completely lower crank window in left or right front
1
door
AR72.10-P-
2 Remove inner door panel on front door
0104SXS
Installation: Clean
bonding surface and glue on
window guide seal (1).
The bonding surface must be
Loosen window guide seal (1) on mirror triangle absolutely free of dust and
3 grease.
armor plate (3)
*BR00.45-Z-
Pure benzine/benzine
1048-04A
*BR00.45-Z-
MB special adhesive
1002-02A
Unscrew bolts (2) and remove mirror triangle armor *BA72.10-P-
4
plate (3) 1009-01R
*BA72.10-P-
5 Unscrew bolts (4) and remove armor plate (5)
1008-01R
*BA72.10-P-
6 Unscrew hidden bolts (arrows)
1010-01R
outside mirror (M21/1) or right electrically
7 adjustable and heated outside mirror (M21/2) and
guide electrical wiring harness through front door
8 Install in the reverse order
FRONT DOOR
Model 221 with code
Number Designation
Z07/Z07+Z19
BA72.10-P-1008- Bolt, small mirror triangle armor plate to
Nm 8
01R front door
BA72.10-P-1009- Bolt, mirror triangle armor plate on front
Nm 37
01R door
BA72.10-P-1010-
Bolt, mirror on front door Nm 3
01R
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-
Adhesive Terokal 2444 A 000 989 92 71
1002-02A
Otto Fischar GmbH &
Co. KG
Kaiserstrasse 221
BR00.45-Z- Pure benzine/benzine 100/140 (free of aromatic compounds), 66133 Saarbrucken
1048-04A 5-liter metal canister, article no.: 17042 Germany
Tel +49 681 98217-0
Fax:+49 681 98217-99
www.fischar.de
REMOVE/INSTALL MIRROR LENS - AR88.70-P-9020TX
MODEL 211.0 /2 /6 as of 1.6.06, 219, 216, 221
Shown on model 219
Fig. 59: Identifying Mirror Lens Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury Skin, eye and respiratory
system irritation may occur through contact Wear protective gloves and safety AS60.00-Z-
or inhalation of substances contained in the glasses. 0008-01R
mirror lens.
1 Tilt mirror lens (1) out upward
Press mirror glass (1) off of mirror glass Installation: Clip mirror lens (1)
2 into glass adjustment drive from Fig. 4
adjustment drive with mounting wedge (2)
bottom upward. Ensure that catch hook
(3) arrests completely.
Disconnect electrical connectors and
3
remove mirror lens (1)
4 Install in the reverse order
Fig. 60: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
DISASSEMBLE/ASSEMBLE OUTSIDE MIRROR - AR88.70-P-9030TX
MODEL 216 as of 1.6.09
MODEL 216 with CODE (800) Model year 2010
MODEL 221 as of 1.6.09
MODEL 221 with CODE (800) Model year 2010
Fig. 61: Identifying Outside Mirror Components (1 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 62: Identifying Outside Mirror Components (2 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 63: Identifying Outside Mirror Components (3 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 64: Identifying Outside Mirror Components (4 Of 4)
Courtesy of MERCEDES-BENZ USA
Disassemble
Remove/install outside Assemble new outside mirror from individual AR88.70-P-
1
rearview mirror parts. 9000CW
Remove covering on outside AR88.70-P-
2
rearview mirror 9040CY
Assemble
Install foam rubber (1) on
3
cast iron bearing (2)
Insert cast iron bearing (2)
4
into cover (3) and arrest
Install seal (4) on cover (3)
5
and arrest
Grease contact surface
*BR00.45-Z-
6 between cast iron bearing (2)
1085-06A
and base plate (7).
Observe marking (arrow) on folding mechanism
(6) to base plate (7), do not change position.
7 Remove transport retainer (5) If the base plate (7), pin (8) or spring (9) should
fall out of the folding mechanism (6), first insert
spring (9), then pin (8) and then base plate (7) into
the folding mechanism (6).
Grease contact surface
*BR00.45-Z-
8 between cast iron bearing (2)
1085-06A
and base plate (7)
Manually secure assembled cover (3) with
Install cover (3) on folding folding mechanism (6) against falling apart until it
9
mechanism (6) is firmly connected together by the gripping disk
(13).
Insert sleeve (10) into cast
10
iron bearing (2)
Install spring (11) above
11
sleeve (10)
Install base (12) on spring
12 Observe positioning (arrow).
(11)
Install gripping disk (13) on
13
base (12)
Position counterplate (14) on
14 cast iron bearing (2) from Fig. 65
bottom
Screw thrust piece (15) into
15 counterplate (14) with bolt Fig. 65
(16) and nut (17)
This pushes the gripping disk (13) onto the
16 Screw nut (17) fully down
sleeve (10)
Guide electric wiring harness Press electrical wiring harness (18) on folding
17
(18) through sleeve (10) mechanism (6) into bracket (arrows).
Guide electrical wiring
18 harness (18) through cast
iron bearing (2)
Moisten wiring harness
*BR00.45-Z-
19 passage on rubber grommet
1010-06A
(19) with lubricant
Guide electrical wiring
Guide carefully to prevent rubber grommet (19)
20 harness (18) through rubber
from being damaged by coupling housing (20, 22).
grommet (19)
Clip white coupling housing
21 (20) to long wiring harness
tieout (21)
Clip black coupling housing
22 (22) to short wiring harness
tieout (23)
Insert foam rubber (24) into
23
cast iron bearing (2)
Install rubber grommet (19)
24 on cast iron bearing (2) in
correct position
Press gripping disk (25) to
25 cast iron bearing (2) with SW
10 socket wrench
26 Clip cap (26) into cover (3)
Install outside rearview AR88.70-P-
27
mirror molding 9040CY
Fig. 65: Identifying Compressing Tool (001 589 00 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
BR00.45-Z-1085-06A Special grease lubricant A 000 989 38 60
REMOVE/INSTALL OUTSIDE MIRROR TRIM - AR88.70-P-9040CY
MODEL 204.0## /2## #A as of 213187
MODEL 204.0## /2## #F as of 231783
MODEL 204.0## /2## #R as of 048423
MODEL 207.### ## as of 032555
MODEL 216 as of 1.6.09
MODEL 221 as of 1.6.09
MODEL 216, 221 with CODE (800) Model year 2010
MODEL 204.3 /9, 212, 218, 246
Illustrated on model 204.9
Fig. 66: Identifying Outside Mirror Trim Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR88.70-P-
Model 204, 207, 212, 218
9020CW
Remove mirror glass on left and AR88.70-P-
1 Model 216, 221
right outside mirror 9020TX
AR88.70-P-
Model 246
9020NKB
Lift catch hook (arrow) and remove
2 upper paneling (1) upward in
direction of arrow
3 Remove screws/bolts (3)
4 Unlock catch hook (arrow B)
Unlock catch hook (arrow C) and The outside mirror ambient lamp is
retaining bracket (arrow D) and integrated into the bottom paneling (2) which
5
remove lower paneling (2) must be pulled out of the frame before
downward removing the bottom paneling (2).
6 Install in the reverse order
REMOVE/INSTALL OUTSIDE MIRROR TRIM - AR88.70-P-9040TX
MODEL 216 up to 31.5.09 except CODE (800) Model year 2010
MODEL 219
MODEL 221 up to 31.5.09 except CODE (800) Model year 2010
Illustrated on model 219
Fig. 67: Identifying Outside Mirror Trim Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR88.70-P-
1 Remove glass adjustment drive
9060TX
2 Remove bolts (2) and remove frame (1)
3 Disconnect electrical connector (3)
4 Unscrew bolt (4)
5 Pivot outside mirror paneling (5) downward (arrow)
Unclip left outside mirror ambient lamp (M21/1e1) or right outside mirror
6
ambient lamp (M21/2e1)
Pull bulb with frame out of left outside mirror ambient lamp ((M21/1e1) or
7
right outside mirror ambient lamp (M21/2e1)
8 Expose wiring harness (7)
9 Guide outside mirror paneling (5) over carrier (6) and remove
10 Install in the reverse order
REMOVE/INSTALL GLASS ADJUSTMENT DRIVE - AR88.70-P-9060TX
MODEL 216, 219, 221
Shown on model 219
Fig. 68: Identifying Glass Adjustment Drive Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR88.70-P-
1 Remove mirror glass
9020TX
2 Remove bolts (1)
Remove mirror up/down adjustment motor (M21/1m1) and mirror in/out
3 adjustment motor (M21/1m2) or mirror up/down adjustment motor (M21/2m1)
and mirror in/ out adjustment motor (M21/2m2)
4 Disconnect electrical connector (2)
5 Install in the reverse order
REMOVE/INSTALL OUTSIDE MIRROR FOLD-BACK MOTOR - AR88.70-P-9070TX
MODEL 216 up to 31.5.09 with CODE (500) Folding left/right outside mirrors except CODE (800) Model
year 2010
MODEL 219 with CODE (500) Fold left/right outside mirrors
MODEL 221 up to 31.5.09 with CODE (500) Folding left/right outside mirrors except CODE (800) Model
year 2010
Shown on model 219
Fig. 69: Identifying Outside Mirror Fold-Back Motor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR88.70-P-
1 Remove covering on outside rearview mirror
9040TX
2 Disconnect electrical connector (2)
*BA88.70-P-
3 Unscrew bolt (3) and remove carrier (1)
1002-01B
Unscrew bolts (4) and remove power folding mirror motor (M21/1m3)
4
or power folding mirror motor (M21/2m3)
5 Install in the reverse order
OUTSIDE MIRRORS
Number Designation Model 216 Model 219 Model 221
BA88.70-P-1002-01B Bolt, motor of fold-in mirror to mirror base Nm 11 11 11
REMOVE/INSTALL OUTER DOOR SILL MOLDING - AR88.80-P-1001SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 70: Identifying Outer Door Sill Molding Components
Courtesy of MERCEDES-BENZ USA
Removal
1 Open front door and rear door.
2 Unscrew bolt (3) with suitable puller.
Press front door sill molding (1) and rear door sill
3 Fig. 71
molding (2) off of longitudinal member.
Install
The bonding surfaces must be
absolutely free of grease and dust,
otherwise the adhesive force of the
Clean assembly area for front door sill molding (1) *BR00.45-
4 front door sill molding (1) and rear
and rear door sill molding (2). Z-1048-04A
door sill molding (2) is not ensured.
Remove glue residues by hand to
the extend possible.
Remove protective foils (4) from new front door
5
sill molding (1) and rear door sill molding (2).
Move front door sill molding (1) and rear door sill
molding (2) to position above longitudinal
member, lower uniformly, install pilot stud in
6
assembly holes and lay front door sill molding (1)
and rear door sill molding (2) down on
longitudinal member.
Press on firmly front door sill molding (1) and rear
7 door sill molding (2) uniformly from center toward
outside.
8 Tighten bolt (3) with suitable puller.
Fig. 71: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Otto Fischar GmbH &
Co. KG
Kaiserstrasse 221
BR00.45-Z- Pure benzine/benzine 100/140 (free of aromatic compounds), 66133 Saarbrucken
1048-04A 5-liter metal canister, article no.: 17042 Germany
Tel +49 681 98217-0
Fax:+49 681 98217-99
www.fischar.de
REMOVE/INSTALL LONGITUDINAL MEMBER PANELING - AR88.80-P-6000SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on left side of vehicle
Fig. 72: Identifying Longitudinal Member Paneling Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on left longitudinal member paneling
Fig. 73: Identifying Longitudinal Member Paneling Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
AR72.12-P-
1 Remove left or right rear door.
0600SX
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off of the
support points specified by vehicle 0010-01A
lifting platform.
Raise vehicle with lifting
2
platform
Remove underfloor paneling in
3 area of longitudinal member
paneling (3)
Remove longitudinal member
4 paneling (3) at bottom on
longitudinal member
Remove expansion clip (4) from
5
front fender liner (1)
Installation: Ensure that longitudinal
member paneling (3) is properly seated at all
Unclip longitudinal member attachment points on longitudinal member to
6 paneling (3), starting at front prevent paint damage.
fender (2) Installation: Insert clip (7) into grommet
(6).
Fig. 4
Remove clips (5) on longitudinal
Installation: Ensure that gasket (8) is
7 member and attach to
longitudinal member paneling (3) properly seated.
8 Install in the reverse order
Fig. 74: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL LONGITUDINAL MEMBER PANELING - AR88.80-P-6000SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 75: Identifying Longitudinal Member Paneling Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 76: Identifying Longitudinal Member Paneling Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
AR72.12-P-
1 Remove left and right rear door.
0600SXS
2 Remove underfloor protection
member paneling (3). 1000SXS
Unscrew nuts (9) and loosen
3 longitudinal member paneling (3)
at bottom of longitudinal member.
Remove expansion clip (4) from
4
front fender liner (1)
Installation: Ensure that longitudinal
member paneling (3) is properly seated at all
Unclip longitudinal member attachment points on longitudinal member to
5 paneling (3), starting at front prevent paint damage.
fender (2) Installation: Insert clip (7) into grommet
(6).
Fig. 4
Remove clips (5) on longitudinal
6 member and attach to longitudinal Installation: Ensure that sealing rings (8)
are seated correctly.
member paneling (3)
7 Install in the reverse order
Fig. 77: Identifying Assembly Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TAILLAMP TRIM PANEL - AR88.85-P-9814SX
MODEL 221.0 /1 up to 31.5.09 except CODE (800) Model year 2010
Illustrated on left taillamp
Fig. 78: Identifying Taillamps And Trim Strips
Courtesy of MERCEDES-BENZ USA
Removing
Remove left taillamp (E3) or right AR82.10-P-
1
taillamp (E4) 4905SX
Remove trim panels (1, 2) or trim The trim panels (1, 2) or trim panels (3,
2
panels (3, 4) 4) are glued and will be thereby damaged.
Install
The surfaces to be glued must be free of
grease and dust, otherwise the adhesive force
Clean assembly points for trim *BR00.45-Z-
3 of the components is not ensured.
panels (1, 3) on trim panels (2, 4) 1048-04A
Remove glue residues by hand to the
extend possible.
Glue trim panels (1, 2) or trim
4
panels (3, 4) to one another.
The surfaces to be glued must be free of
Clean assembly points for trim grease and dust, otherwise the adhesive force
*BR00.45-Z-
5 panels (2, 4) on left taillamp (E3) or of the components is not ensured.
1048-04A
right taillamp (E4) Remove glue residues by hand to the
extend possible.
Press trim panels (1, 2) or trim panels (3,
Press trim panels (1, 2) or trim 4) from center toward outside.
6 panels (3, 4) to left taillamp (E3) or
Fig. 79
right taillamp (E4)
Fig. 80
Install left taillamp (E3) or right AR82.10-P-
7
taillamp (E4) 4905SX
Guide roller from center toward outside
Press trim panels (1, 2) or trim with sufficient force. Do not slip off, danger
8 panels (3, 4) to left taillamp (E3) or of damaging paint.
right taillamp (E4) with roller
Fig. 79
Fig. 80
Fig. 79: Identifying Roller (168 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 80: Identifying Protective Covering (221 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Otto Fischar GmbH &
Co. KG
Kaiserstrasse 221
BR00.45-Z- Pure benzine/benzine 100/140 (free of aromatic compounds), 66133 Saarbrucken
1048-04A 5-liter metal canister, article no.: 17042 Germany
Tel +49 681 98217-0
Fax:+49 681 98217-99
www.fischar.de
SAFETY PRECAUTIONS
RISK OF INJURY CAUSED BY TEARING OF THE CUTTING WIRE - AS88.00-Z-0001-01A
Wear safety glasses.
Risk of injury
When cutting out detachable parts with the cutting wire, injuries to the eyes may occur caused by tearing of the
wire.
Safety instructions/precautions
Wear safety glasses when cutting out.
SAFETY INFORMATION: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - AS88.00-Z-
9999ZZ
MODEL all
Risk of injury caused by pinching and crushing when opening and MODEL AS88.40-Z-0001-
closing engine hood 949 01A
AS88.00-Z-0001-
Risk of injury caused by tearing of the cutting wire MODEL all
01A
RETROFITTING & CONVERSION
CONVERTING FRONT BUMPER - AZ88.00-P-0001-02SX
Model 221 up to 31.5.09
Check components removed from standard bumper before assembly and replace if damaged.
Pay attention to paint damage.
Vehicles with headlamp cleaning system, code 600
1. Install HCS cover (8) with HCS spring (9) in front bumper paneling (1).
Fig. 81: Identifying HCS Cover, HCS Spring & Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
Vehicles with Park assist, code 229
2. Insert front short range radar sensor (A86/1) into inner sensor unit bracket (12) and outer sensor unit
bracket (13) and secure with expansion rivets (14) each.
Fig. 82: Inserting Front Short Range Radar Sensor Into Brackets
Courtesy of MERCEDES-BENZ USA
3. Insert front short range radar sensor (A86/1) into front bumper paneling (1) and fasten with three
expansion rivets each.
Fig. 83: Identifying Front Short Range Radar Sensors And Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
4. Insert center lower impact absorber (2) into front bumper paneling (1).
Fig. 84: Identifying Center Lower Impact Absorber And Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
5. Insert center impact absorber (7) into front bumper paneling (1).
Fig. 85: Identifying Center Impact Absorber And Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
Fig. 86: Identifying PTS Wiring Harness, Center Impact Absorber & Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
Vehicles with Parktronic system (PTS) code 220
6. Insert PTS wiring harness (10) into front bumper paneling (1) and fasten to indicated retaining points in
center impact absorber (7) and front bumper paneling (1).
bumper paneling (1).
7. Fasten right front bumper PTS connector (X26/27) in front bumper paneling (1).
8. Connect left outer front PTS ultrasonic sensor (B8/1), center left front PTS ultrasonic sensor (B8/2), inner
left front PTS ultrasonic sensor (B8/3), inner right front PTS ultrasonic sensor (B8/4), center right front
PTS ultrasonic sensor (B8/5) and outer right front PTS ultrasonic sensor (B8/6) to PTS wiring harness
(10) and install in brackets of front bumper paneling (1).
Check decoupling rings before inserting front PTS ultrasonic sensors, replace if damaged.
The PTS ultrasonic sensors should arrest properly in bracket. Installation position is specified.
Vehicles with Park assist, code 229
9. Insert Park assist wiring harness (15) into front bumper paneling (1) and fasten to indicated retaining
points in center impact absorber (7) and front bumper paneling (1).
Routing path and installation position are indicated.
10. Connect Park assist wiring harness (15) to front short range radar sensor units (A86/1).
Fig. 87: Routing Park Assist Wiring Harness
Courtesy of MERCEDES-BENZ USA
11. Insert inner center section (18) into front bumper paneling (1) and arrest on center air passage.
Ensure that inner center section (18) is arrested correctly to guarantee proper function.
Fig. 88: Identifying Inner Center Section & Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
12. Insert fitted sleeves (19) on inner center section (18) on right and left into mounting holes in front bumper
paneling (1) (see arrow).
Fig. 89: Identifying Fitted Sleeves, Inner Center Section & Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
13. Insert center support (17) into front bumper paneling (1) and arrest.
Ensure that center support (17) is arrested correctly to guarantee proper function.
Fig. 90: Inserting Center Support Into Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
Fig. 91: Inserting Bottom Basic Carrier Into Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
14. Insert bottom basic carrier (16) into front bumper paneling (1) and arrest at bottom edge as well as on
right and left on inside of front bumper paneling (1).
Ensure that bottom basic carrier (16) is arrested correctly to guarantee proper function.
Fig. 92: Locating Basic Carrier Expansion Rivets
Courtesy of MERCEDES-BENZ USA
15. Fasten basic carrier (16) in area of struts on center air passage with three expansion rivets (see arrows).
16. Install left air inlet grate (5) and right air inlet grate (6) on assembly lugs in front bumper paneling (1) and
fasten with eight clips (4) each.
Fig. 93: Installing Air Inlet Grates
Courtesy of MERCEDES-BENZ USA
17. Insert left front fog lamp (E5/1) and right front fog lamp (E5/2) in left air inlet grate (5) and right air inlet
grate (6) and fasten with three sheet metal screws (22) each.
Fig. 94: Inserting Front Fog Lamps
Courtesy of MERCEDES-BENZ USA
18. Insert wheel well cover (3) into front bumper paneling (1) and fasten with two clips (4) each.
Fig. 95: Inserting Wheel Well Cover Into Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
19. Insert right impact absorber (20) and left impact absorber (21) into front bumper paneling (1) and arrest
(see arrows).
Insert right impact absorber (20) and left impact absorber (21) below center impact absorber (7) and
arrest in outer brackets (see arrows).
Fig. 96: Inserting Impact Absorbers
Courtesy of MERCEDES-BENZ USA
20. Hook check strap (24) into tow eye cover (23) and front bumper paneling (1) and insert tow eye cover
(23).
Fig. 97: Identifying Check Strap, Tow Eye Cover And Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
21. Position license plate frame (25) outside of front bumper paneling (1) and prepare for assembly.
Use license plate frame (25) as template for marking holes. The distance (a) between the center and
the outer edges of the license plate frame (25) should be equal (use center strut in center air passage as
orientation aid). Align license plate frame (25) along contour of front bumper paneling (1) (see arrows).
22. Drill four holes for installation license plate frame (25) and fasten license plate frame (25) to front
bumper paneling (1) using four bolts.
Tighten bolts only with screwdriver.
Fig. 98: Identifying Distance Between Center And Outer Edges Of License Plate Frame
Courtesy of MERCEDES-BENZ USA
After installing front bumper paneling.
23. Insert center air inlet grate (26) into front bumper paneling (1).
Fig. 99: Identifying Center Air Inlet Grate & Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
CONVERTING FRONT BUMPER - AZ88.00-P-0001-02SXA
Model 221 as of 1.6.09
Check components removed from standard bumper before assembly and replace if damaged.
Pay attention to paint damage.
front bumper paneling (1).
Paint HCS cover (3) and towing eye cover (4) in installed state to ensure uniform appearance of all component
finishes.
Fig. 100: Identifying Front Reinforcements, HCS Cover And Towing Eye Cover
Courtesy of MERCEDES-BENZ USA
1. Insert center vent grille (5) into front bumper paneling (1) and arrest.
the center vent grille (5) should arrest properly in the front bumper paneling (1).
Fig. 101: Identifying Center Vent Grille & Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
2. Insert bottom front reinforcement (6) into front bumper paneling (1), arrest and secure on right and left
with one clip (8) each.
The bottom front reinforcement (6) should arrest properly in the front bumper paneling (1).
Fig. 102: Identifying Bottom Front Reinforcement, Front Bumper Paneling & Clips
Courtesy of MERCEDES-BENZ USA
3. Insert right and left wheel arch cover (7) into front bumper paneling (1), arrest and secure with 2 clips (8)
and one clip (9) each.
Slightly lift front right and left reinforcements (2) to insert right and left wheel arch cover (7).
Fig. 103: Inserting Wheel Arch Covers
Courtesy of MERCEDES-BENZ USA
Vehicles with front fog lamp and daytime running light
4. Install lamp units (11) in right and left air inlet grate (10).
6 to 10 PTK 50x20 bolts are installed depending on equipment. Tightening torque for PTK 50x20
bolts is 2.5 Nm ±0.25 Nm.
5. Insert right and left air inlet grate (10) with installed lamp units (11) from rear into front bumper paneling
(1), arrest and secure with 4 clips each.
Fig. 104: Identifying Lamp Units, Air Inlet Grates & Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
Vehicles with LED daytime running lights
6. Insert right and left air inlet grate (10) into front bumper paneling (1), arrest and secure with 4 clips (8)
each.
Fig. 105: Identifying Air Inlet Grates, Front Bumper Paneling & Clips
Courtesy of MERCEDES-BENZ USA
Vehicles with LED daytime running lights
7. Insert LED lamps (18) from rear into right and left air inlet grate (10) and screw with three PTK 50 20
(19) bolts each.
Tightening torque for PTK 50 x20 (19) bolts is 2.5 Nm. Always maintain tightening sequence (A, B,
C).
Fig. 106: Identifying LED Lamps, Air Inlet Grates & Bolts
Courtesy of MERCEDES-BENZ USA
Vehicles with parking package consisting of reversing camera and PARKTRONIC including
parking guidance
8. Install front short range radar sensor units (A86/1) on right and left into sensor unit bracket (12) and
arrest.
short range radar sensor units (A86/1) should arrest correctly in the sensor unit brackets (12).
Fig. 107: Identifying Front Short Range Radar Sensor Units, Sensor Unit Brackets And Front
Reinforcements
Courtesy of MERCEDES-BENZ USA
Vehicles with parking package consisting of reversing camera and PARKTRONIC including
parking guidance
9. Insert wiring harness (13) into front bumper paneling (1) and fix in place in retaining points present.
Routing path and installation position are indicated.
Fig. 108: Identifying Wiring Harness Connections
Courtesy of MERCEDES-BENZ USA
Vehicles with parking package consisting of reversing camera and PARKTRONIC including
parking guidance
10. Connect left outer front PTS ultrasonic sensor (B8/1), center left front PTS ultrasonic sensor (B8/2), inner
left front PTS ultrasonic sensor (B8/3), inner right front PTS ultrasonic sensor (B8/4), center right front
PTS ultrasonic sensor (B8/5) and outer right front PTS ultrasonic sensor (B8/6) to PTS wiring harness
(13) and install in brackets of front bumper paneling (1).
Check decoupling rings before inserting front PTS ultrasonic sensors, replace if damaged.
The PTS ultrasonic sensors should arrest properly in bracket. Installation position is specified.
parking guidance
11. Connect wiring harness (13) to front short range radar sensor units (A86/1) on right and left.
12. Install center impact absorber (14) in front bumper paneling (1).
Vehicles with parking package consisting of reversing camera and PARKTRONIC including
parking guidance
13. Route wiring harness (13) into center impact absorber (14) and fix in place.
The routing path and the installation position are predefined in the center impact absorber (14).
Fig. 109: Routing Wiring Harness
Courtesy of MERCEDES-BENZ USA
14. Slide right and left impact absorber (15) in center below center impact absorber (14) and arrest in right
and left front reinforcements (2).
The right and left impact absorber (15) should arrest properly in the front right and left
reinforcements (2).
Fig. 110: Identifying Impact Absorbers And Front Reinforcements
Courtesy of MERCEDES-BENZ USA
15. Fasten front bumper PTS connector (X26/27) in right front reinforcement (2).
Fig. 111: Identifying Front Bumper PTS Connector And Right Front Reinforcement
Courtesy of MERCEDES-BENZ USA
16. Insert center front support (16) into front bumper paneling (1) and arrest.
The center front support (16) should arrest properly in the front bumper paneling (1).
The fitting sleeves (17) should arrest properly at top in the right and left front reinforcements (2) (see
arrows).
Fig. 112: Identifying Fitting Sleeves, Center Front Support And Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
17. Position license plate frame (25) outside of front bumper paneling (1) and prepare for assembly.
Use license plate frame (25) as template for marking holes. The distance (a) between the center and
the outer edges of the license plate frame (25) should be equal. Align license plate frame (25) along
contour of front bumper paneling (1).
Fig. 113: Identifying Distance Between Center And Outer Edges Of License Plate Frame
Courtesy of MERCEDES-BENZ USA
18. Drill four holes for installing license plate frame (25).
19. Fasten license plate frame (25) to front bumper paneling (1) with the 4 bolts included.
Select hole diameter so that the insert nuts included are seated tightly in the front bumper paneling
(1).
Tighten bolts only with screwdriver.
20. Slide trims on LED lamps (20) from front to LED lamps (18) and arrest.
The trims on the LED lamps (20) should arrest properly on the LED lamps (18) and in the right and
left air inlet grates (10).
Fig. 114: Identifying LED Lamps, Air Inlet Grates & Trim
Courtesy of MERCEDES-BENZ USA
CONVERTING REAR BUMPER - AZ88.00-P-0001-03SX
Model 221 up to 31.5.09
Check components removed from standard bumper before assembly and replace if damaged.
Pay attention to paint damage.
1. Insert bottom section paneling (2) into rear bumper paneling (1) and arrest.
Fig. 115: Identifying Bottom Section Paneling And Rear Bumper Paneling
Courtesy of MERCEDES-BENZ USA
2. Check whether bottom section paneling (2) is arrested correctly on inside of rear bumper paneling (1), if
necessary press in again (see arrows).
Fig. 116: Identifying Bottom Section And Rear Bumper Paneling
Courtesy of MERCEDES-BENZ USA
3. Clean contact surface (22) for bottom section covering on bottom section paneling (2).
The area to be glued on the bottom section paneling (2) must be free of dust and grease. For cleaning
use mixture of IPA (Isopropanol alcohol) and water with a ratio of 50 : 50.
Fig. 117: Identifying Contact Surface Of Bottom Section Covering On Bottom Section Paneling
Courtesy of MERCEDES-BENZ USA
4. Remove covering foil from bonding surface on bottom section covering (3) over a length of 300 mm (a).
This measure facilitates positioning and aligning the bottom section covering (3) on the bottom
section paneling.
Fig. 118: Removing Covering Foil From Bottom Section Covering
Courtesy of MERCEDES-BENZ USA
5. Install bottom section covering (3) on bottom section paneling (2) and align along end pipe cutouts (see
arrows).
Fig. 119: Identifying Bottom Section Covering & Paneling
Courtesy of MERCEDES-BENZ USA
6. Remove remaining covering foil from bonding surfaces and press bottom section covering (3) firmly to
bottom section paneling (2).
Work from inside toward outside. First remove and glue right side (A), then left side (B).
When gluing covering, ensure that the distances between the covering and paneling are uniform (see
arrows).
Fig. 120: Locating Distance Between Covering And Paneling
Courtesy of MERCEDES-BENZ USA
7. Install sealing washer (4) on mounting plates (5) (two each).
Fig. 121: Identifying Sealing Washer & Mounting Plates
Courtesy of MERCEDES-BENZ USA
8. Insert left bottom paneling bracket (6) and right bottom paneling bracket (7) into rear bumper paneling (1)
and fasten with blind rivet (see arrow, lower illustration).
The dowel pins of the bracket should be seated correctly in the fitted holes of the rear bumper
paneling (1) (coded by various diameter, see arrow, upper illustration).
The blind rivets of the two brackets simultaneously connect the inner reinforcement of the rear
bumper paneling (1) to the bottom section paneling (2). For this purpose, an additional blind rivet is
installed in the center (see arrow, lower illustration).
Fig. 122: Identifying Bottom Paneling Brackets
Courtesy of MERCEDES-BENZ USA
9. Insert rear reinforcement (11) into rear side guide (9) and arrest.
Fig. 123: Identifying Rear Reinforcement & Rear Side Guide
Courtesy of MERCEDES-BENZ USA
Fig. 124: Identifying Rear Side Guide, Rear Reinforcement & Rear Wheel Well Cover
Courtesy of MERCEDES-BENZ USA
10. Insert rear side guide (9) (with rear reinforcement (11)) and rear wheel well cover (14) into rear bumper
paneling (1) and fasten with five expansion rivets (12) each and one clip (13).
Fasten rear wheel well cover (14) at bottom with front expansion rivet of rear side guide (9).
11. Hook check strap (15) into rear bumper paneling (1) and tow eye cover (16).
12. Insert tow eye cover (16) into rear bumper paneling (1).
Arrest tow eye cover (16) correctly.
Fig. 125: Identifying Check Strap, Bumper Paneling And Tow Eye Cover
Courtesy of MERCEDES-BENZ USA
Vehicles with Park assist, code 229
13. Insert rear bracket (17) into rear bumper paneling (1) and fasten with four expansion rivets (12) each.
Insert rear short range radar sensor unit into rear bracket (17) and secure with two expansion rivets
each.
Fig. 126: Identifying Rear Bracket, Rear Bumper Paneling And Expansion Rivets
Courtesy of MERCEDES-BENZ USA
Vehicles with Park assist, code 229
14. Insert Park assist wiring harness (19) into rear bumper paneling (1) and fasten to indicated brackets as
illustrated.
Illustration shows version with two rear short range radar sensors (A86/2).
Fig. 127: Identifying Rear Short Range Radar Sensors, Park Assist Wiring Harness And Rear
Bumper Paneling
Courtesy of MERCEDES-BENZ USA
Vehicles with Park assist, code 229
15. Insert rear short range radar sensors (A86/2) into sensor unit bracket and secure with two expansion rivets
each.
16. Connect Park assist wiring harness (19) to rear short range radar sensors (A86/2).
17. Insert sensor unit bracket with rear short range radar sensors (A86/2) into rear bumper paneling (1) and
fasten with two expansion rivets each (see arrows).
Fig. 128: Connecting Park Assist Wiring Harness
Courtesy of MERCEDES-BENZ USA
Vehicles with Parktronic system (PTS) code 220
18. Insert PTS wiring harness (20) into rear bumper paneling (1) and fasten to indicated brackets as
illustrated.
19. Connect rear PTS ultrasonic sensor (21) to PTS wiring harness (20) and insert into rear bumper paneling
(1).
Fig. 129: Routing PTS Wiring Harness Of Rear Bumper Paneling
Courtesy of MERCEDES-BENZ USA
Check decoupling rings before inserting rear PTS ultrasonic sensors, replace if damaged.
The rear PTS ultrasonic sensors should arrest properly in bracket. Installation position is specified.
CONVERTING REAR BUMPER - AZ88.00-P-0001-03SXA
Model 221 as of 1.6.09
Check components removed from standard bumper before assembly and replace if damaged.
The inner support (2) and towing eye cover (3) are preinstalled in the front bumper paneling (1).
Paint towing eye cover (3) in installed state to ensure uniform appearance of all component finishes.
Fig. 130: Identifying Towing Eye Cover And Inner Support On Front Bumper Paneling
Courtesy of MERCEDES-BENZ USA
1. Install sealing washers (4) on right and left into mounting plates (5) (2 each).
Fig. 131: Identifying Sealing Washer & Mounting Plates
Courtesy of MERCEDES-BENZ USA
2. Install mounts (6) for right and left exhaust screens on inner support (2) (4 each).
Fig. 132: Identifying Exhaust Screen Mounts
Courtesy of MERCEDES-BENZ USA
3. Insert rear brackets (7) for right and left exhaust screens into inner support (2), arrest and fasten with 2
expansion rivets (13) each.
The rear brackets (7) should arrest properly in the inner support (2).
Fig. 133: Identifying Rear Brackets, Inner Support & Expansion Rivets
Courtesy of MERCEDES-BENZ USA
4. Insert right and left shielding bracket (8) into rear bumper paneling (1), arrest and fasten with 3 clips (9)
each and one expansion rivet (10).
The right and left shielding brackets (8) should arrest properly in the rear bumper paneling (1).
5. Install adapter (14) on right and left on right and left shield bracket (8).
Fig. 134: Identifying Shielding Bracket Components
Courtesy of MERCEDES-BENZ USA
6. Insert NBR bracket adapters (11) into rear bumper paneling (1) and secure with 2 clips (9) each.
Fig. 135: Identifying NBR Bracket Adapter, Rear Bumper Paneling & Clips
Courtesy of MERCEDES-BENZ USA
7. Insert wheel arch covers (12) on right and left into rear bumper paneling (1) and secure with 3 clips (9)
each.
Fig. 136: Identifying Wheel Arch Covers, Rear Bumper Paneling & Clips
Courtesy of MERCEDES-BENZ USA
8. Insert lateral supports (15) with sheet metal rails (16) on right and left into rear bumper paneling (1) and
fasten
Install lateral supports (15) with retaining lug (see arrow) into guide on rear bumper paneling (1).
Fasten lateral supports (15) and sheet metal rails (16) at top with 3 expansion rivets (18) each on
rear bumper paneling (1).
Fasten lateral supports (15) with 2 clips (9) each on rear bumper paneling (1).
Fig. 137: Installing Lateral Supports
Courtesy of MERCEDES-BENZ USA
Vehicles with parking package consisting of reversing camera and PARKTRONIC including
parking guidance
9. Position NBR mount (19) on right and left on sheet metal rails (16) and NBR mount adapter (11) and
fasten with one clip(17) each and 2 expansion rivets (18).
10. Insert rear short range radar sensor units (A86/2) on right and left into NBR mounts (19) and arrest.
The rear short range radar sensor units (A86/2) should arrest properly in the NBR mounts (19).
Fig. 138: Inserting Rear Short Range Radar Sensor Units
Courtesy of MERCEDES-BENZ USA
Vehicles with parking package consisting of reversing camera and PARKTRONIC including
parking guidance
11. Insert wiring harness (20) into rear bumper paneling (1) and fix in place in attachment points present.
Routing path and installation position are indicated.
Fig. 139: Identifying Rear Bumper Paneling Wiring Harness Connections
Courtesy of MERCEDES-BENZ USA
Vehicles with parking package consisting of reversing camera and PARKTRONIC including
parking guidance
12. Connect outer left rear PTS ultrasonic sensors (B8/10), inner left rear PTS ultrasonic sensors (B8/9), inner
right rear PTS ultrasonic sensors (B8/8) and outer right rear PTS ultrasonic sensors (B8/7) to wiring
harness (20) and install in brackets on rear bumper paneling (1).
Check decoupling rings before inserting rear PTS ultrasonic sensors, replace if damaged.
The PTS ultrasonic sensors should arrest properly in bracket. Installation position is specified.
Vehicles with parking package consisting of reversing camera and PARKTRONIC including
parking guidance
13. Connect wiring harness (20) to rear short range radar sensor units (A86/2) on right and left.
14. Install paneling cover lower section (23) on paneling lower section (22) and arrest.
The paneling cover lower section (23) should be arrested correctly in the paneling lower section (22).
15. Install lower section paneling (22) from outside on rear bumper paneling (1), arrest and fasten with one
expansion rivet (24) each on inner support (2).
The lower section of the paneling (22) should arrest correctly in the rear bumper paneling (1).
Fig. 140: Identifying Rear Bumper Paneling, Inner support & Cover
Courtesy of MERCEDES-BENZ USA
16. Insert exhaust screens (25) on right and left into paneling lower section (22).
17. Position lugs on mounts (6) and fasten exhaust screens (25) on inner support (2) with two bolts (26) each.
Align exhaust screens (25) before tightening. Ensure that the gap dimension (a) between the exhaust
screens (25) and the paneling lower section (22) is equal, if necessary loosen bolts (26) again and align
exhaust screens (25) again.
Tightening torque for bolts (26) is 5 Nm ±0.5 Nm.
Fig. 141: Identifying Exhaust Screens, Support, Bolts & Paneling
Courtesy of MERCEDES-BENZ USA
CONVERT SIDE PANELING - AZ88.00-P-0001-04SX
Model 221
Fig. 142: Identifying Side Paneling Components
Courtesy of MERCEDES-BENZ USA
Check mounting materials removed from standard part before assembly and replace if damaged.
Observe paint damage.
1. Install front bottom bracket (2), center bottom bracket (3) and rear bottom bracket (4) into longitudinal
member paneling (1).
Ensure that the brackets are arrested correctly at bottom in the longitudinal member paneling (1).
Insert rear bracket (5) correctly into longitudinal member paneling (1) (see arrow in lower left
illustration) and ensure that it is seated correctly in the arresting hole (see arrow in lower right
illustration).
Fig. 143: Identifying Rear Bracket, Longitudinal Member Paneling & Expansion Rivet
Courtesy of MERCEDES-BENZ USA
3. Insert clips (7) into longitudinal member paneling (1).
Use new clips (7) to ensure that the longitudinal member paneling (1) is seated securely.
Fig. 144: Identifying Clips & Longitudinal Member Paneling
Courtesy of MERCEDES-BENZ USA
RETROFIT AMG TRIM PARTS - AZ88.00-P-0001SX
MODEL 221
MODEL 221.176 except CODE (808) Model year 2008
MODEL 221.176 with CODE (808) Model year 2008 only in combination with AMG 4-pipe exhaust
system
The trim parts in the accessories and replacement part scope of delivery are primed and sho
match the color of the car before installation.
After conversion, have proper installation confirmed by authorized workshop on form shee
EU Type Approval". The form sheet is to be kept in the vehicle and to be handed over to th
persons, if required.
Model
Body kit,
221.022 /028 /054 /056 /070 /071/080 /084 /086 /087 /122 /128 /154 /156/170 /171 /176 /1
certificate
* only for Germany.
Remove
Disassemble Model 221.0 / 1
1 front Remove parts required for conversion, e.g. outer impact absorbers, wiring harnesses an
bumper Parktronic system or park assist) from standard bumper.
Model 221.0 / 1
Disassemble
2 Remove parts required for conversion, e.g. wiring harnesses, sensors or antennas (for P
rear bumper
system, park assist keyless go) from standard bumper.
Remove Type 221.0
longitudinal Model 221.1 except CODE (Z07) Top protection
3
member
Remove mounting parts from stock part.
paneling
Install
Model 221 up to 31.5.09
Modify
4 front
bumper Model 221 as of 1.6.09
The license plate cover is not included. It must be ordered according to the national ve
Install front
5 Model 221
bumper
Model 221 up to 31.5.09
On model 221 up to 31.5.09 the paneling lower section is not included. It must be orde
Modify rear exhaust pipe version.
6
bumper Model 221 as of 1.6.09
On model 221 as of 1.6.09 the exhaust screens are not included They must be ordered
engine version. It is necessary to replace the standard rear mufflers (see parts ordering note
Install rear
7 Model 221.0 / 1
bumper
Converting
8 side
paneling
Install
longitudinal Type 221.0
9
member Model 221.1 except CODE (Z07) Top protection
paneling
PARTS ORDERING NOTES
Part no. Designation Quantity
For all vehicles:
B6 603
Complete side paneling set W221 1
6193
B6 603
Complete side paneling set V221 1
6194
For vehicles up to 31.5.09:
B6 603
Front bumper 1
6191
B6 603
Front bumper (with PTS) 1
6192
A221 817
ECE cover (order according to national version) 1
00 78
A221 817
Switzerland cover (order according to national version) 1
01 78
A221 817
Italy cover (order according to national version) 1
02 78
A221 817
Japan cover (order according to national version) 1
03 78
A221 817
USA cover (order according to national version) 1
04 78
B6 603 Rear bumper, complete, all W/V 221 except S600 (only in combination with
1
6195 AMG single pipe extension retrofit)
B6 603 Rear bumper, complete (with PTS) all W/V 221 except S600 (only in
1
6196 combination with AMG single pipe extension retrofit)
A221 885
Paneling bottom section for B6 603 6195 and 6196 (not included) 1
02 25
B6 603 Rear bumper, complete, all V 221 with engine M275 (only to fit rear mufflers
1
6197 up to model year 2008)
B6 603 Rear bumper, complete (with PTS) all V 221 with engine M275 (only to fit
1
6198 rear mufflers up to model year 2008)
A221 885
Paneling bottom section for B6 603 6197 and 6198 (not included) 1
04 25
B6 603
Rear bumper, complete, all W/V 221 (non-visible end pipes) 1
6199
B6 603
Rear bumper, complete (with PTS) all W/V 221 (non-visible end pipes) 1
6200
A221 885
Paneling bottom section for B6 603 6199 and 6200 (not included) 1
09 25
B6 603
Rear bumper, complete for AMG 4-pipe exhaust system 1
6201
B6 603
Rear bumper, complete (with PTS) for AMG 4-pipe exhaust system 1
6202
A221 885
Paneling bottom section for B6 603 6201 and 6202 (not included) 1
06 25
For vehicles as of 1.6.09:
B6 603
Front bumper 1
6525
B6 603 Front bumper (with parking package consisting of reversing camera and
1
6526 PARKTRONIC including parking guidance)
B6 603
Front bumper (with LED) 1
6527
B6 603 Front bumper (with LED and parking package consisting of reversing camera
1
6528 and PARKTRONIC including parking guidance)
A221 817
ECE cover (order according to national version) 1
10 78
A221 817
Switzerland cover (order according to national version) 1
11 78
A221 817
Italy cover (order according to national version) 1
12 78
A221 817
Japan cover (order according to national version) 1
13 78
A221 817
USA cover (order according to national version) 1
14 78
B6 603
Rear bumper 1
6529
B6 603 Rear bumper (with parking package consisting of reversing camera and
1
6530 PARKTRONIC including parking guidance)
A221 490
Left exhaust screen (vehicles with V6/V8 diesel and gasoline engine; not included) 1
29 27
A221 490 Right exhaust screen (vehicles with V6/V8 diesel and gasoline engine; not
1
30 27 included)
A221 490
Left exhaust screen (vehicles with V12 engine; not included) 1
31 27
A221 490
Right exhaust screen (vehicles with V12 engine; not included) 1
32 27
A221 490
Left exhaust rear muffler (vehicles with V6 gasoline engine; not included) 1
89 35
A221 490
Right exhaust rear muffler (vehicles with V6 gasoline engine; not included) 1
91 35
A000 995
Clamp (vehicles with V6/V8 diesel and gasoline engine; not included) 1
45 35
A221 490
Left exhaust rear muffler (vehicles with V8 gasoline engine; not included) 1
93 35
A221 490
Right exhaust rear muffler (vehicles with V8 gasoline engine; not included) 1
95 35
A221 490
Left exhaust line (vehicles with V6/V8 diesel engine; not included) 1
03 59
A221 490
Right exhaust line (vehicles with V6/V8 diesel engine; not included) 1
04 59
PAINT FRONT MUD GUARDS - AZ88.30-P-0003-01SX
Risk of explosion caused No smoking! No open AS98.00-Z-0002-01A
by paint vapors igniting. flames! Use respiratory
Risk of poisoning caused protection, protective
by inhaling paint vapors. clothing, gloves, safety
goggles and skin cream.
Ensure that the area is
well ventilated.
Use only paint materials and paint systems approved by DC.
1. Mask cross-hatch pattern (A) on contour edge of front mud guards (1), according to figure.
Ensure that no paint or paint fog gets onto the cross-hatch pattern (A) of the front mud guards (1).
2. Pretreat front mud guards (1) according to DC painting guidelines and paint outside of front mud guards
(1) to match vehicle color.
Outside of new front mud guards (1) is already primed transparently.
3. Remove masking tape from front mud guards (1) when the paint is cured.
Fig. 145: Identifying Cross-Hatch Pattern Of Front Mud Guard
Courtesy of MERCEDES-BENZ USA
PAINT REAR MUD GUARDS - AZ88.30-P-0003-02SX
Use only paint and paint system approved by Daimler AG.
1. Mask cross-hatch pattern (A) on contour edge of rear mud guards (2), according to figure.
Ensure that no paint or paint fog gets onto the cross-hatch pattern (A) of the rear mud guards (2).
2. Pretreat rear mud guards (2) according to Daimler AG painting guidelines and paint outside of rear mud
guards (2) to match vehicle color.
Outside of new rear mud guards (2) is already primed transparently
3. Remove masking tape from rear mud guards (2) when the paint is cured.
Fig. 146: Identifying Cross-Hatch Pattern Of Rear Mud Guard
Courtesy of MERCEDES-BENZ USA
RETROFIT FRONT MUD GUARDS - AZ88.30-P-0003-03SX
Risk of explosion from Protect cans from direct AS00.00-Z-0015-01A
pressurized spray cans sunlight and temperatures
above 50 °C
Risk of explosion and Never spray anticorrosion AS97.00-Z-0001-01A
poisoning caused by agents on flames or
solvent vapors and gasses. glowing hot objects and
Injury hazard to skin keep them well away from
and eyes when working all potential sources of
on corrosion protection ignition. Use them only in
agents. well-ventilated rooms;
wear respiratory
protection.
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
BR00.45-Z-1003-05A Cavity preservation, solvent-free (1 l container) A 000 986 72 70 05
Fig. 147: Identifying Front Mud Guard Components
Courtesy of MERCEDES-BENZ USA
1. Remove protective foil (3) on adhesive strips on front mud guards (1) at corners, as shown in figure, and
position so that the ends of the protective foil (3) extend beyond the outer edge of the front mud guards
(1).
2. Protect inner front fender edge against corrosion in area of clips (5) on front mud guards (1) with wax
preservation agent
3. Clean front fender in area of front mud guards (1) with specified cleaning agent.
Front fender must be dry, free of dust and grease in area of front mud guards (1).
4. Position front mud guards (1) on front fender, as shown in figure, and fasten with clips (5).
The clips (5) for the front mud guards (1) have a barb on one side only and must be installed with the
barb side toward the front mud guards (1).
5. Drill hole with dia. (A) at position defined by front mud guards in inner fender and fasten front mud
guards (1) to inner fender with expansion rivet (6).
Ensure that no other components are damaged when drilling hole with dia. (A).
Fig. 148: Installing Front Mud Guards
Courtesy of MERCEDES-BENZ USA
6. Drill hole with dia. (A) at position defined by front mud guards (1) in underbody paneling and fasten
front mud guards (1) to underbody paneling with expansion rivets (6).
Ensure that no other components are damaged when drilling hole with dia. (A).
7. Remove entire protective foil (3) from adhesive strips on front mud guards (1) and uniformly press
adhesive strips against front fender
8. Protect inner front fender edge against corrosion in area of clips on front mud guards (1) with wax
preservation agent.
RETROFIT REAR MUD GUARDS - AZ88.30-P-0003-04SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
Fig. 149: Identifying Rear Mud Guard Components
Courtesy of MERCEDES-BENZ USA
1. Loosen protective foil (4) on adhesive strips on rear mud guards (2) from corners, as shown in figure, and
position so that the ends of the protective foil (4) extend beyond the outer edge of the rear mud guards (2)
2. Clean rear bumper in area of rear mud guards (2) with cleaning agent specified.
Rear bumper must be dry, free of dust and grease in the area of the rear mud guards (2).
3. Position rear mud guards (2) on rear fender as shown in figure and fasten with clips (8).
A barb is present on the clips (8) for the rear mud guards (2) on both sides.
4. Drill Ø 6.5 mm hole in wheel well paneling at position (A) defined by rear mud guard (2).
Cordless drill/driver gotis://G_58.0_01.1
Ensure that, when drilling, other components are not damaged.
5. Fasten inner mud guard (2) with expansion rivet (6) to wheel well paneling and secure expansion rivet (6)
with tooth lock washer (7) on wheel well paneling.
Fig. 150: Installing Rear Mud Guards
Courtesy of MERCEDES-BENZ USA
6. Drill Ø 6.5 mm hole in rear bumper at position (A) defined by rear mud guard (2).
Cordless drill/driver gotis://G_58.0_01.1
Ensure that, when drilling, other components are not damaged.
7. Fasten rear mud guard (2) to rear bumper with expansion rivet (6).
8. Remove entire protective foil (4) from adhesive strips on rear mud guards (2) and uniformly press
adhesive strips against rear bumper (2)
RETROFIT MUD GUARDS - AZ88.30-P-0003SX
MODEL 221.0 /1 except CODE (772) AMG styling package - front spoiler, side skirts and rear apron
except CODE (990) AMG vehicles
Fig. 151: Identifying Mud Guards
Courtesy of MERCEDES-BENZ USA
Remove
Align vehicle between the columns of the lifting
Risk of death caused by
platform and position the four support plates at the AS00.00-Z-
vehicle slipping or toppling
lifting platform support points specified by the vehicle 0010-01A
off of the lifting platform.
manufacturer.
1 Remove wheels
AP40.10-P-
4050SX
Socket wrench.
Electric or compressed air impact wrench Fig. 152
http://gotis.aftersales.mercedes-benz.com
Install
Risk of explosion caused by
No smoking! No open flames! Use respiratory
paint vapors igniting. Risk of AS98.00-Z-
protection, protective clothing, gloves, safety goggles
poisoning caused by 0002-01A
and skin cream. Ensure that the area is well ventilated.
inhaling paint vapors.
AZ88.30-P-
2 Paint front mud guards
0003-01SX
Risk of explosion caused by
No smoking! No open flames! Use respiratory
paint vapors igniting. Risk of AS98.00-Z-
protection, protective clothing, gloves, safety goggles
poisoning caused by 0002-01A
and skin cream. Ensure that the area is well ventilated.
inhaling paint vapors.
3 Paint rear mud guards
0003-02SX
Risk of explosion from Protect cans from direct sunlight and temperatures AS00.00-Z-
pressurized spray cans above 50 °C 0015-01A
Risk of explosion and
poisoning caused by solvent Never spray anticorrosion agents on flames or
vapors and gasses. Injury glowing hot objects and keep them well away from all AS97.00-Z-
hazard to skin and eyes potential sources of ignition. Use them only in well- 0001-01A
when working on corrosion ventilated rooms; wear respiratory protection.
protection agents.
AZ88.30-P-
4 Retrofit front mud guards
0003-03SX
*BR00.45-
Preservation agent
Z-1003-05A
*BR00.45-
Window cleaning agent.
Z-1025-04A
AZ88.30-P-
0003-04SX
5 Retrofit rear mud guards
*BR00.45-
Window cleaning agent.
Z-1025-04A
6 Fit wheels Observe tightening sequence.
AP40.10-P-
4050SX
*BA40.10-
Bolt, disk wheel to wheel hub or flange P-1001-01L
Socket wrench.
Electric or compressed air impact wrench Fig. 152
http://gotis.aftersales.mercedes-benz.com
WHEELS
Number Designation Model 221
BA40.10-P-1001-01L Bolt, disk wheel to wheel hub or flange Nm 150
Fig. 152: Identifying Socket Wrench (230 589 01 09 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
BR00.45-Z-1003-05A Cavity preservation, solvent-free (1 l container) A 000 986 72 70 05
PARTS ORDERING NOTES
Part no. Designation Quantity
B6 652 82 32 Front mud guards set 1
B6 652 82 33 Rear mud guards set 1
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: DETACHABLE BODY COMPONENTS,
EXTERIOR FLAPS - BA88.00-Z-9999AZ
MODEL all
MODEL 168, 170, 202, 203, 208.3 /4, 209, 210, BA88.20-P-1000-
Bumper
215, 220, 230 01A
BA88.20-P-1000-
Bumper MODEL 169, 245
01C
BA88.20-P-
Bumper MODEL 219, 221
1000-01D
BA88.20-P-1000-
Bumper MODEL 251
01F
BA88.20-P-1000-
Bumper MODEL 163
01B
BA88.20-P-1000-
Bumper MODEL 197
01H
BA88.20-P-1000-
Bumper MODEL 164.1 /8, 166
01E
BA88.80-P-1000-
Cover strips MODEL 219
01A
Detachable body components, BA88.30-P-1000-
MODEL 164.1 /8
underride guard 01D
Detachable body components, BA88.30-P-1000-
MODEL 163
underride guard 01A
MODEL 170, 171, 172, 202, 203, 208.3 /4, 209, BA88.40-P-1000-
Engine hood
211, 210 01A
BA88.40-P-1000-
Engine hood MODEL 219
01J
BA88.40-P-1000-
Engine hood MODEL 251
01L
BA88.40-P-1000-
Engine hood MODEL 199, 215, 220, 230, 461, 463
01D
BA88.40-P-1000-
Engine hood MODEL 163
01C
BA88.40-P-1000-
Engine hood MODEL 168, 414.700
01B
BA88.40-P-1000-
Engine hood MODEL 164.1 /8, 166
01K
BA88.40-P-1000-
Engine hood MODEL 204, 207, 212, 218
01N
BA88.40-P-1000-
Engine hood MODEL 197
01O
BA88.40-P-1000-
Engine hood MODEL 169, 245, 246
01I
BA88.40-P-1000-
Engine hood MODEL 240.078 /079/178
01E
BA88.40-P-
Engine hood MODEL 216, 221
1000-01M
BA88.70-P-
Exterior rearview mirrors MODEL 221
1000-01C
BA88.70-P-1000-
Exterior rearview mirrors MODEL 197
01F
BA88.70-P-1000-
Exterior rearview mirrors MODEL 209
01E
BA88.70-P-1000-
Exterior rearview mirrors MODEL 171, 172, 211, 230
01A
BA88.10-P-1000-
Fender MODEL 163
01A
BA88.10-P-1000-
Fenders MODEL 171, 210, 211, 220, 230, 240
01B
BA88.10-P-1000-
Fenders MODEL 169, 245, 246
01C
BA88.10-P-1000-
Fenders MODEL 197
01H
BA88.10-P-
Fenders MODEL 216, 219, 221
1000-01D
BA88.10-P-1000-
Fenders MODEL 251
01F
BA88.10-P-1000-
Fenders MODEL 204, 207, 212, 218
01G
BA88.10-P-1000-
Fenders MODEL 164.1 /8, 166
01E
BA88.60-P-1000-
Outside flaps MODEL 219.3
01C
BA88.60-P-1000-
Outside flaps MODEL 169, 245
01B
BA88.60-P-1000-
Outside flaps MODEL 207.4, 208.4, 209.4
01A
BA88.70-P-
Outside mirrors MODEL 216, 219, 221
1000-01B
BA88.50-P-1000-
Trunk lid MODEL 204, 207, 212, 218.3
01E
BA88.50-P-1000-
Trunk lid MODEL 197
01F
BA88.50-P-
Trunk lid MODEL 216, 219, 221
1000-01D
TYP 170, 171, 172, 199, 202, 203, 208.3 /4, 209, BA88.50-P-1000-
Trunk lid
210, 211, 215, 220, 230 01A
BA88.50-P-1000-
Trunk lid MODEL 240
01B
FENDERS - BA88.10-P-1000-01D
Model 216, 219, 221
FENDER
Number Designation Model 216 Model 219 Model 221
BA88.10-P-1001- Nut/bolt fender to body Nm 8 10 10
01D
BUMPER - BA88.20-P-1000-01D
Model 219, 221
BUMPER
Number Designation Model 219 Model 221
BA88.20-P-1001-01D Nut/bolt, rear crossmember to longitudinal member Nm 50 50
ENGINE HOOD - BA88.40-P-1000-01M
Model 216, 221
ENGINE HOOD
Number Designation Model 216 Model 221
BA88.40-P-1001- Bolt, engine hood lock bottom section to Nm 10 10
01M radiator crossmember
BA88.40-P-1002- Nut, engine hood catch upper section to Nm - 8
01M engine hood
BA88.40-P-1003- Bolt/nut, engine hood to engine hood Nm 8 8
01M hinge
BA88.40-P-1004- Screw for engine hood hinge on body Nm 10 10
01M
BA88.40-P-1005- Bolt, safety hook to engine hood Nm 8 8
01M
TRUNK LID - BA88.50-P-1000-01D
Model 216, 219, 221
TRUNK LID
Number Designation Model 216 Model 219 Model 221
BA88.50-P-1001- Bolt to lock striker Nm - 9 9
01D
BA88.50-P-1002- Bolt, trunk lid lock to trunk Nm 9 9 9
01D lid
BA88.50-P-1003- Bolt, hinge bracket to trunk Nm 10 10 10
01D lid
BA88.50-P-1004- Bolt, handle plate to trunk lid Nm - 9 -
01D
BA88.50-P-1005- Nut on trunk lid hinge to rear Nm - 20 -
01D shelf
BA88.50-P-1006- Nut, actuation bracket of Nm - 9 -
01D remote trunk closing to hinge
bracket of trunk lid
BA88.50-P-1007- Nut, remote trunk closing to Nm - 9 -
01D C-pillar bolt-on point
BA88.50-P-1008- Nut, remote trunk closing to Nm - 9 -
01D bolt-on point of rear shelf
sheet metal
OUTSIDE MIRRORS - BA88.70-P-1000-01B
Model 216, 219, 221
OUTSIDE MIRRORS
Number Designation Model 216 Model 219 Model 221
BA88.70-P-1001- Screw, outside mirror to front Nm - 2 -
01B door
BA88.70-P-1002- Bolt, mirror fold-in motor to Nm 11 11 11
01B mirror base
EXTERIOR REARVIEW MIRRORS - BA88.70-P-1000-01C
Type 221
OUTSIDE MIRRORS
Number Designation Model 221
BA88.70-P-1001-01C Screw for outside rearview mirror on front door Nm 2
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: DETACHABLE BODY COMPONENTS,
EXTERIOR FLAPS - BE88.00-Z-9999AZ
MODEL all
Engine hood MODEL 202 up to 31.10.93 BE88.40-P-1000-01A
Gap dimension bumper MODEL 202, 203, 208.3 /4, 209, 210 BE88.20-P-1000-01A
Trunk lid MODEL 170 BE88.50-P-1000-01A
BASIC KNOWLEDGE
ELECTRIC OUTSIDE MIRRORS, LOCATION OF COMPONENTS - GF88.79-P-0003-01LE
Illustrated on model 221.0
Fig. 153: Locating Electric Outside Mirrors Components
Courtesy of MERCEDES-BENZ USA
ELECTRIC OUTSIDE MIRRORS, BLOCK DIAGRAM - GF88.79-P-0003-02LE
Fig. 154: Electric Outside Mirrors Block Diagram
Courtesy of MERCEDES-BENZ USA
ELECTRIC OUTSIDE MIRRORS, FUNCTION - GF88.79-P-0003LE
MODEL 216.3, 221.0 /1 as of model year 09 /YoM 08
Electric outside mirrors, general
In order to adapt to the different driving situations, the outside mirrors are electrically adjustable. The heated
outside mirrors can be heated and folded down additionally.
They are adjusted by the driver-side outside mirror and trunk lid power window switch group (S20/1).
The electric outside mirror function contains the following partial functions, which are described in separate
documents:
Mirror glass adjustment of left/right outside mirror
Heat left/right outside mirror
Folding down left/right outside mirror
Passenger side outside mirror park position (on model 221 with code (275) Memory package
(driver seat, steering column, mirror) or model 216)
Automatic dimming outside and inside rearview mirrors (on model 221 with code (249) Automatic
dimming inside and outside rearview mirror (driver) or model 216)
Storing and calling outside mirror position (on model 221 with code (275) Memory package (driver
seat, steering column, mirror) or model 216)
Electric outside mirrors, location of GF88.79-P-
components 0003-01LE
GF88.79-P-
Electric outside mirrors, block diagram
0003-02LE
Mirror lens adjustment left/right outside GF88.79-P-
mirror, function 2008LE
Heat left/right outside rearview mirrors GF88.79-P-
function 2000LE
GF88.79-P-
Fold left/right outside mirror, function
2002LE
Model 216,
Passenger-side outside mirror park GF88.79-P-
Model 221 with code (275) Memory package
position, function 2006LE
(drivers seat, steering column, mirrors)
Model 216,
Automatic dimming outside mirror and GF88.79-P-
Model 221 with code (249) Automatic
inside rearview mirror, function 2010LE
dimming inside and outside mirror (driver)
Model 216,
Store and call outside mirror position, GF88.79-P-
Model 221 with code (275) Memory package
function 2013LE
(drivers seat, steering column, mirrors)
ELECTRICALLY ADJUSTABLE OUTSIDE MIRRORS, LOCATION OF COMPONENTS - GF88.79-
P-0005-01SX
Shown on model 221.0
Fig. 155: Locating Electrically Adjustable Outside Mirrors Components
Courtesy of MERCEDES-BENZ USA
ELECTRICALLY ADJUSTABLE OUTSIDE MIRROR, BLOCK DIAGRAM - GF88.79-P-0005-02SX
Fig. 156: Electrically Adjustable Outside Mirror Block Diagram
Courtesy of MERCEDES-BENZ USA
ELECTRICALLY ADJUSTABLE OUTSIDE MIRRORS, FUNCTION - GF88.79-P-0005SX
MODEL 216.3, 221.0 /1 up to Model Year 8
Function
The individual functions of the
left electrically adjustable and heated outside mirror (M21/1) and the
right electrically adjustable and heated outside mirror (M21/2) are actuated by the
Left front door control unit (N69/1) on model 221 or Left door control unit (N69/1) on model 216 and
Right front door control unit (N69/2) on model 221 or Right door control unit (N69/2) on model 216
Functions manually to be selected can be operated via the driver power window, outside mirror and trunk lid
switch group (S20/1)
Possible functions
Mirror selection between left outside mirror and right outside mirror
Adjust mirror lens horizontally and vertically
Move left and right outside mirror to garage position
Automatic dimming left outside and inside mirror (on model 221 with code (249) Automatic dimming
inside and outside mirror (driver) or model 216)
Store position of left outside mirror and right outside mirror (on model 221 with code (275) Memory
package (driver seat, steering column, mirrors) or model 216)
Move right outside mirror to park position (on model 221 with code (275) Memory package (driver seat,
steering column, mirrors) or model 216)
The mirror lenses are heated:
When activating the heated rear window or
automatically, depending on the outside temperature and air humidity.
Electrically adjustable outside mirrors, GF88.79-P-
location of components 0005-01SX
Electrically adjustable outside mirror, GF88.79-P-
block diagram 0005-02SX
Mirror lens adjustment left/right outside GF88.79-P-
mirror, function 2008SX
GF88.79-P-
Fold left/right outside mirror, function
2002SX
Model 216
Automatic dimming outside mirror and GF88.79-P-
Model 221 with code (249) Automatic
inside rearview mirror, function 2010SX
dimming inside and outside mirror (driver)
Model 216
Passenger-side outside mirror park GF88.79-P-
Model 221 with code (275) Memory package
position, function 2006SX
(driver seat, steering column, mirrors)
Model 216
Store and call outside mirror position, GF88.79-P-
Model 221 with code (275) Memory package
function 2013SX
(driver seat, steering column, mirrors)
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF ELECTRIC OUTSIDE MIRRORS -
GF88.79-P-0997LE
MODEL 216.3, 221.0 /1 as of model year 09 /YoM 08
GF88.79-P-
Electric outside mirrors, function
0003LE
Electric outside mirrors, location of GF88.79-P-
components 0003-01LE
GF88.79-P-
Electric outside mirrors, block diagram
0003-02LE
Mirror lens adjustment left/right outside GF88.79-P-
mirror, function 2008LE
Heat left/right outside rearview mirrors GF88.79-P-
function 2000LE
GF88.79-P-
Fold left/right outside mirror, function
2002LE
Model 216,
Passenger-side outside mirror park GF88.79-P-
Model 221 with code (275) Memory package
position, function 2006LE
(drivers seat, steering column, mirrors)
Model 216,
Automatic dimming outside mirror and GF88.79-P-
Model 221 with code (249) Automatic
inside rearview mirror, function 2010LE
dimming inside and outside mirror (driver)
Model 216,
Store and call outside mirror position, GF88.79-P-
Model 221 with code (275) Memory package
function 2013LE
(drivers seat, steering column, mirrors)
Overview of system components, GF88.79-P-
electric outside mirrors 9997LE
TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR ELECTRICALLY ADJUSTABLE
OUTSIDE REARVIEW MIRROR - GF88.79-P-0999SX
MODEL 216.3, 221.0 /1 up to Model Year 8
Electrically adjustable outside mirrors, GF88.79-P-
function 0005SX
Electrically adjustable outside mirrors, GF88.79-P-
location of components 0005-01SX
Electrically adjustable outside mirror, GF88.79-P-
block diagram 0005-02SX
Mirror lens adjustment left/right outside GF88.79-P-
mirror, function 2008SX
GF88.79-P-
Fold left/right outside mirror, function
2002SX
Model 216
Automatic dimming outside mirror and GF88.79-P-
Model 221 with code (249) Automatic
inside rearview mirror, function 2010SX
dimming inside and outside mirror (driver)
Model 216
Passenger-side outside mirror park GF88.79-P-
Model 221 with code (275) Memory package
position, function 2006SX
(driver seat, steering column, mirrors)
Model 216
Store and call outside mirror position, GF88.79-P-
Model 221 with code (275) Memory package
function 2013SX
(drivers seat, steering column, mirrors)
Overview of system components for GF88.79-P-
electrically adjustable outside mirror 9998SX
HEAT LEFT/RIGHT OUTSIDE REARVIEW MIRRORS FUNCTION - GF88.79-P-2000LE
MODEL 216.3, 221.0 /1 as of model year 09 /YoM 08
Function requirements, general
C. 61 ON (with automatic switch-on)
On-board electrical system consumer shutoff not active
Heat left/right outside mirror, general
The outside mirror heater keeps the mirror glasses free of ice and fog.
The outside mirror heater is switched on automatically or manually.
Heat left/right outside mirror, function sequence
The heated outside mirror is automatically switched on and off dependent on the outside temperature and the
dew point temperature.
The outside temperature is sensed by the outside temperature indicator temperature sensor (B14) and relayed to
the front SAM control unit with fuse and relay module (N10/1) which transmits the signal to the interior CAN.
The dew point temperature is sensed by the KLA multifunction sensor (B31/1) and relayed to the AAC control
unit (N22/1), which transmits the signal to the interior CAN.
The left front door control unit (N69/1) (model 221) or left door control unit (N69/1) (model 216) and the right
front door control unit (N69/2) (model 221) or right door control unit (N69/2) (model 216) read in the signals
and switch the outside mirror heater on or off.
The outside mirror heater is switched on when the vehicle engine is running if
Outside temperature > or = Dew point temperature + 2 °C (programmable via STAR DIAGNOSIS)
outside temperature < 15 °C
The outside mirror heater is switched off when the vehicle engine is running if
Outside temperature > or = Dew point temperature + 5 °C (programmable via STAR DIAGNOSIS)
Outside temperature > 16 °C=
If the dew point temperature value is implausible, the default value is used.
When the rear window heater is switched on and off, the outside mirror heater is also switched on and off.
A signal is transmitted to the rear SAM control unit with fuse and relay module (N10/2) by the upper control
panel control unit (N72/1) or AAC control unit and is placed on the interior CAN. The door control units read in
the signals and switch the outside mirror heater on and off.
Detailed information is given in the separate function description "Heated rear window (HSS)".
Model PE88.79-P-2055-
216 97CAA
Electrical function schematic for mirror heater
Model PE88.79-P-2055-
221 97SAA
Front SAM control unit with fuse and relay module, component
N10/1 GF54.21-P-6070LE
description
Rear SAM control unit with fuse and relay module, component
N10/2 GF54.21-P-6030LE
description
Automatic air conditioning control unit component description N22/1 GF83.40-P-3012LE
N69/1
Left door control unit, component description Model GF72.29-P-4124LA
216
N69/1
Left front door control unit, component description Model GF72.29-P-4141LE
221
N69/2
Right door control unit, component description Model GF72.29-P-4128LA
216
N69/2
Right front door control unit, component description Model GF72.29-P-4142LE
221
Upper control panel control unit, component description N72/1 GF54.21-P-6040LE
Component description for the EZS control unit N73 GF80.57-P-6003LE
FOLD LEFT/RIGHT OUTSIDE MIRROR, FUNCTION - GF88.79-P-2002LE
MODEL 216.3, 221.0 /1 as of model year 09 /YoM 08
Function requirements, general
Mirror glass adjustment not active
On-board electrical system consumer shutoff not active
Folding left/right outside mirror, general
The outside mirror housings can be folded in and out electrically in pairs. This can be done both automatically
as well as manually. If circuit 15R is switched off during an active housing adjustment, the housing adjustment
is nevertheless completed.
If a new housing adjustment request is recognized during an active housing adjustment, the housing adjustment
is directly switched to the opposite direction.
The fold left/right outside mirror function comprises the following subfunctions:
Manual folding in/out, function sequence
Automatic folding in/out, function sequence
Additional function requirements for manual folding in and out
C. 15R On
Vehicle speed v < 47 km/h
Manual folding in/out, function sequence
When the outside mirror fold-in/out switch (S20/1s9) in the driver outside mirror and trunk lid power window
switch group (S20/1) is pressed momentarily, the mirror housings folded in (garage position) or folded out
(driving position).
The corresponding adjustment request is read by the left front door control unit (N69/1) (model 221) or left door
control unit (N69/1) (model 216) via the front door LIN.
The left door control unit takes over the master function during adjustment and relays the signals to the right
front door control unit (N69/2) (model 221) or right door control unit (N69/2) (model 216) via the interior
CAN.
The left door control unit actuates the power folding mirror motor (M21/1m3) in the left electrically adjustable
and heated outside mirror (M21/1) and the right door control unit actuates the power folding mirror motor
(M21/2m3) in the right electrically adjustable and heated outside mirror (M21/2).
The mirror fold-in function is no longer possible at a vehicle speed of v > or = 47 km/h.
The instrument cluster (A1) transmits the vehicle speed signal via the central CAN to the central gateway
control unit (N93), which relays the signal to the left door control unit via the interior CAN.
Additional function requirements for automatic folding in and out
C. 15C OFF
Function in COMAND controller unit (A40/3) activated
Mirror housing actuated last in folding out direction (with fold-in function)
Mirror housing previously folded in automatically (with fold-out function)
Automatic folding in/out, function sequence
When the vehicle is locked using the central locking system (CL [ZV]) from the outside with the transmitter key
(A8/1), both mirror housings are folded in automatically.
The mirror housings are folded out again the next time the CL is unlocked and the driver or passenger door is
opened.
The status of the driver door is sensed by the left front rotary tumbler switch (A85s1) (model 221) or right
rotary tumbler switch (A85s1) (model 216). The signal from the left rotary tumbler switch is read in by the left
door control unit.
The status of the passenger door is sensed by the right front rotary tumbler switch (A85/1s1) (model 221) or
right rotary tumbler switch (A85/1s1) (model 216). The signal from the right rotary tumbler switch is read in by
the right door control unit.
If the mirror housings are still folded in with circuit 15R ON by a previous automatic folding-in procedure, the
mirror housings are folded out immediately.
If the mirror housings were folded in manually prior to that, the mirror housings are not actuated via the
automatic adjustment.
PE88.79-P-2057-
Model 216
Electrical function schematic for 97CAA
folding outside mirrors PE88.79-P-2057-
Model 221
97SAA
Instrument cluster, component GF54.30-P-
A1
description 6000LE
A40/3
With code (526) COMAND with single DVD
GF82.85-P-
drive (without navigation) or
3136LE
Code (527) COMAND APS with single DVD
COMAND controller unit, drive (with navigation)
component description
GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
Left door control unit, component N69/1 GF72.29-P-
description Model 216 4124LA
Left front door control unit, N69/1 GF72.29-P-
component description Model 221 4141LE
Right door control unit, component N69/2 GF72.29-P-
description Model 216 4128LA
Right front door control unit, N69/2 GF72.29-P-
component description Model 221 4142LE
Component description for the EZS GF80.57-P-
N73
control unit 6003LE
Central gateway control unit, GF54.21-P-
N93
component description 4170LE
FOLD LEFT/RIGHT OUTSIDE MIRROR, FUNCTION - GF88.79-P-2002SX
MODEL 216.3, 221.0 /1 up to Model Year 8
Fig. 157: Fold Outside Mirror Function Diagram
Courtesy of MERCEDES-BENZ USA
Manually folding-in/out, function
Function requirements
C. 15R On
No mirror lens adjustment active
Speed signal < 47 km/h for folding in mirror housing
Function
When the outside mirror fold-in/out switch is switched momentarily, the mirror housings can be moved to the
garage position (folded in) or driving position (folded out). The corresponding adjustment request is read in by
the left door control unit via door LIN.
The left door control unit has the master function during adjustment and relays the signal to the right front door
control unit via the passenger compartment CAN-B bus.
The left door control unit actuates the mirror fold-in motor in the left outside mirror and the right door control
unit actuates the mirror fold-in motor in the right outside mirror.
If the function requirement c. 15R ON is not present after starting to fold in or out the adjustment is continued
until the end position is reached.
Automatically folding in/out, function
Function requirements
Circuit 15C OFF
Function in COMAND controller unit activated
Mirror housing last actuated in folding out direction (when folding in)
Mirror housing previously folded in automatically (when folding out)
Function
When the vehicle is locked with the central locking (CL) from outside with the transmitter key (A8/1), both
mirror housings are folded in automatically (garage position). The next time the vehicle is unlocked with the CL
and the driver or passenger door are opened, the mirror housings are returned to the previous position
If the mirror housings are still folded in with circuit 15R ON by a previous automatic folding-in procedure, the
mirror housings are folded out immediately.
If the mirror housings were manually adjusted to the garage position, the mirror housings are not adjusted via
the automatic adjustment
The master for this function is the left front door control unit, responsible for adjusting the left mirror housing
as well as for transmission of the corresponding signals to the right front door control unit via the interior CAN
to actuate the right outside mirror housing.
Abort conditions
Movement to the position is interrupted if:
Active outside mirror lens adjustment
Manual fold-in/out
After interruption, function is continued.
A40/3
Model 221.0/1 without code (498) GF82.85-P-
Japanese version and without code (494) 3136SX
COMAND controller unit, component USA version
description Model 221.0/2 with code (498) Japanese GF82.85-P-
version 3136SXJ
Model 221.0/1 with code (494) USA GF82.85-P-
version 3136SXU
GF88.79-P-
Outside mirror, component description M21/1, M21/2
4003SX
N69/1 GF72.29-P-
Driver-side front door control unit, Type 216.3 6000SC
component description GF72.29-P-
Model 221.0/1
6000SX
N69/2 GF72.29-P-
Passenger-side front door control unit, Type 216.3 6010SC
component description GF72.29-P-
Model 221.0/1
6010SX
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS) component description 6000SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
Driver power window, outside mirror and
GF54.25-P-
trunk lid switch group, component S20/1
4230SX
description
PASSENGER-SIDE OUTSIDE MIRROR PARK POSITION, FUNCTION - GF88.79-P-2006LE
MODEL 216.3 as of model year 09 /YoM 08
MODEL 221.0 /1 with CODE (275) Memory package (driver seat, steering column, mirrors) as of model
year 09 /YoM 08
Function requirements, general
C. 15R On
Front doors closed
Reverse gear engaged
The passenger mirror can be selected on the left or right outside mirror adjustment selection switch
(S20/1s10).
No manual mirror lens adjustment actuated or memory request active.
Function in COMAND controller unit (A40/3) activated
Position measurement supplies valid readings
Passenger side outside mirror park position, general
To monitor the curb while backing up, a park position of the right electrically adjustable and heated outside
mirror (M21/2) can be stored and actuated electrically.
The function of the passenger side outside mirror park position comprises the following subfunctions:
Actuate park position function sequence
Store park position function sequence
Move to drive position function sequence
Actuate park position function sequence
The status reverse gear engaged is transmitted by the intelligent servo module for DIRECT SELECT (A80) via
the drive CAN to the CDI control unit (N3/9) (on diesel engine) or ME-SFI control unit (N3/10) (on gasoline
engine) and from there to the central gateway control unit (N93) via the chassis CAN. The signal is transmitted
from the central gateway control unit to the right front door control unit (N69/2) (model 221) or right door
control unit (N69/2) (model 216) via the interior CAN and the right outside mirror is adjusted to the stored park
position.
Function requirements for storing park position
Reverse gear engaged
Store park position function sequence
First adjust desired position of the right outside mirror manually via the outside mirror adjustment rocker switch
(S20/1s12).
The park position is stored by the left front seat operation switch group (S22).
After momentarily pressing the memory switch (S22s6) and actuating the outside mirror adjustment selection
switch within t = 3 s to the passenger side position, the momentary outside mirror position is stored as park
position in the right door control unit.
Move to drive position function sequence
The right outside mirror is automatically returned to the original position, when:
a forward gear is engaged and a time of approx. t = 10 s has elapsed or
the vehicle speed is greater than t = 10 km/h or
the outside mirror adjustment selection switch is switched to the driver mirror position.
The original mirror position is resumed, even when the right outside mirror has been moved to the park position
manually.
If the right outside mirror is located in the park position with circuit 15 Off, it is returned after t = 0.6 s when
circuit 15 is switched back on and the transmission is no longer shifted to reverse. If the reverse gear is
recognized with circuit 15 On, the mirror moves to the last park position set after 0.6 s.
PE88.79-P-2054-
Model 216
Function schematic for electric passenger-side outside 97CAA
mirror park position
Model 221
97SAA
Instrument cluster, component description A1 GF54.30-P-6000LE
A80 GF27.19-P-
Intelligent servo module for DIRECT SELECT, With transmission 722.6 4020ACS
component description GF27.19-P-
With transmission 722.9
4020AHS
N3/9
GF07.16-P-
On engine 629.9 in
6000OA
Component description for CDI control unit model 221
On engine 642.9 in GF07.16-P-
model 221 6000OHL
N3/10 GF07.61-P-
For engine 156 6000MAS
GF07.61-P-
On engine 272
6000MIS
ME-SFI [ME] control unit, component description
GF07.61-P-
On engine 273
6000MLS
GF07.61-P-
On engine 275
6000MOS
N69/1
Left door control unit, component description GF72.29-P-4124LA
Model 216
N69/1
Left front door control unit, component description GF72.29-P-4141LE
Model 221
N69/2
Right door control unit, component description GF72.29-P-4128LA
Model 216
N69/2
Right front door control unit, component description GF72.29-P-4142LE
Model 221
Component description for the EZS control unit N73 GF80.57-P-6003LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
PASSENGER-SIDE OUTSIDE MIRROR PARK POSITION, FUNCTION - GF88.79-P-2006SX
MODEL 216.3 up to Model Year 8
MODEL 221.0 /1 with CODE (275) Memory package (driver seat, steering column, mirrors) up to Model
Year 8
Fig. 158: Passenger-Side Outside Mirror Park Position Function Diagram
Courtesy of MERCEDES-BENZ USA
Function requirements
C. 15R On
Outside mirror adjustment switch in passenger mirror position
No manual mirror lens adjustment actuated or memory request active.
Function in COMAND controller unit (A40/3) activated
Function
If the left front door control unit or right front door control unit receives the message "Reverse gear engaged",
the right outside mirror is moved to park position stored for the transmitter key (A8/1).
Abort the function
The right outside mirror is automatically returned to the original position, when:
Reverse gear signal is not recognized after 10 s or
vehicle speed is greater than 10 km/h or
outside mirror adjustment selection switch is switched to driver mirror position.
The original position is resumed, even when the right outside mirror has been moved to the park position
manually. If the right outside mirror is located in the park position with circuit 15 Off, it is returned after 0.6 s
when circuit 15 is switched back on and the transmission is no longer shifted to reverse. If reverse gear is
recognized with circuit 15 On, the mirror moves to the park position after 0.6 s.
Store park position
Function requirements
C. 15R On
Reverse gear engaged
First adjust desired position of the right outside mirror manually via the outside mirror adjustment rocker
switch.
The park position is stored by the left front seat operation switch group.
When the memory switch is pressed momentarily and then the outside mirror adjustment switch in the
passenger-side position is actuated within 3s, the momentary outside mirror position is stored as park position.
The request to store the park position is transmitted to the left door control unit and from there relayed to the
right door control unit via the interior CAN. The position and storage data is stored in the right door control
unit.
A1 GF54.30-P-
Instrument cluster, component description
Model 221 6000SX
A80
GF27.19-P-
Model 221 with
4015SX
Intelligent servo module (ISM) component description transmission 722.9
Model 221 with GF27.19-P-
transmission 722.6 4015SXA
GF88.79-P-
Outside mirror, component description M21/1, M21/2
4003SX
N3/9
GF07.16-P-
CDI control unit component description Model 221.0/1 with engine
6000SX
642
N3/10
GF07.61-P-
ME-SFI [ME] control unit, component description Model 221 with engines
6000V
272.965 and 273.961
N3/10
GF07.61-P-
ME-SFI control unit, location/task/design/function Model 221 with engine
5000M
275.953/982
N69/1 GF72.29-P-
Type 216.3 6000SC
Driver-side front door control unit, component description
GF72.29-P-
Model 221.0/1
6000SX
N69/2 GF72.29-P-
Passenger-side front door control unit, component Model 216.3 6010SC
description GF72.29-P-
Model 221.0/1
6010SX
Electronic ignition/starter switch control unit (EIS) GF80.57-P-
N73
component description 6000SX
GF54.21-P-
Central gateway control unit, component description N93
4170SX
Front seat adjustment switch group, component GF91.29-P-
S22
description 5220SX
Driver power window, outside mirror and trunk lid switch GF54.25-P-
S20/1
group, component description 4230SX
MIRROR LENS ADJUSTMENT LEFT/RIGHT OUTSIDE MIRROR, FUNCTION - GF88.79-P-2008LE
MODEL 216.3, 221.0 /1 as of model year 09 /YoM 08
Function requirements, general
C. 15R On
Storage of mirror glass position not active
Valid mirror selection available
Left/right outside mirror adjustment, general
The heated and electrically adjustable outside rearview mirror, left (M21/1) or heated and electrically adjustable
outside rearview mirror, right (M21/2) are selected via the left or right outside mirror adjustment selection
switch (S20/1s10).
The outside mirror can be adjusted vertically or horizontally with the outside mirror adjustment rocker switch
(S20/1s12) in the driver outside mirror and trunk lid power window switch group (S20/1).
The adjustment request is read in via the front door LIN by the left front door control unit (N69/1) (model 221)
or left door control unit (N69/1) (model 216), which relays the information for the right outside mirror to the
right front door control unit (N69/2) (model 221) or right door control unit (N69/2) (model 216) via the interior
CAN.
The left door control unit actuates the mirror adjustment up/down motor (M21/1m1) or mirror adjustment in/out
motor (M21/1m2) in the left outside mirror.
The right door control unit actuates the mirror adjustment up/down motor (M21/2m1) or mirror adjustment
in/out motor (M21/2m2) in the right outside mirror.
Model 216 PE88.79-P-2051-97CAA
Electrical function schematic for mirror lens adjustment
Model 221 PE88.79-P-2051-97SAA
N69/1
Left door control unit, component description GF72.29-P-4124LA
Model 216
N69/1
Left front door control unit, component description GF72.29-P-4141LE
Model 221
N69/2
Right door control unit, component description GF72.29-P-4128LA
Model 216
N69/2
Right front door control unit, component description GF72.29-P-4142LE
Model 221
Component description for the EZS control unit N73 GF80.57-P-6003LE
MIRROR LENS ADJUSTMENT LEFT/RIGHT OUTSIDE MIRROR, FUNCTION - GF88.79-P-2008SX
MODEL 216.3, 221.0 /1 up to Model Year 8
Fig. 159: Outside Mirror Lens Adjustment Function Diagram
Courtesy of MERCEDES-BENZ USA
Function requirements
Circuit 15R
Function
Selection of left outside mirror or right outside mirror to be adjusted is accomplished via the outside mirror
adjustment selection switch.
The vertical and horizontal adjustment is performed via the outside mirror adjustment toggle switch in the
driver-side switch group.
The adjustment request is read in via front door LIN by the left front door control unit, which relays the
information for the right outside mirror to the right door control unit via the interior CAN. The left door control
unit actuates the mirror adjustment motors in the left outside mirror.
The right door control unit actuates the mirror adjustment motors in the right outside mirror.
M21/1, GF88.79-P-
Outside mirror, component description
M21/2 4003SX
N69/1 GF72.29-P-
Type 216.3 6000SC
Driver-side front door control unit, component description
Model GF72.29-P-
221.0/1 6000SX
N69/2 GF72.29-P-
Type 216.3 6010SC
Passenger-side front door control unit, component description
Model GF72.29-P-
221.0/1 6010SX
Electronic ignition/starter switch control unit (EIS) component GF80.57-P-
N73
description 6000SX
GF91.29-P-
Front seat adjustment switch group, component description S22
5220SX
AUTOMATIC DIMMING OUTSIDE MIRROR AND INSIDE REARVIEW MIRROR, FUNCTION -
GF88.79-P-2010LE
MODEL 216.3 as of model year 09 /YoM 08
MODEL 221.0 /1 with CODE (249) Automatically dimming inside rearview mirror and outside mirror
(driver) as of model year 09 /YoM 08
Function requirements
Reverse gear not engaged
Interior illumination not switched on
The reverse gear status is transmitted by the central gateway control unit (N93) to the interior CAN.
Automatically dimming outside mirror and inside rearview mirror, function sequence
The mirror glass of the inside rearview mirror (A67) and left electrically adjustable and heated outside mirror
(M21/1) is electro-chromatically dimmable. This is realized by a layer of electrolyte gel in the mirror which
controls the light permeability in increments depending on the voltage applied.
The inside rearview mirror unit senses the ambient light via the mirror dimming sensor, forward (A67h1) and
the light hitting the mirror glass via the mirror dimming sensor, rearward (A67h2).
The inside rearview mirror evaluates these input variables and supplies dimming information to the overhead
control panel control unit (N70), which transmits the message for mirror dimming to the passenger
compartment CAN-B bus.
The left front door control unit (N69/1) (model 221) or left door control unit (N69/1) (model 216) relays the
dimming information and transmits the corresponding actuation voltage to the mirror dimming circuit
(M21/1h1) in the left electrically adjustable and heated outside mirror.
The inside mirror dimming information is sent to the overhead control panel control unit, which supplies the
voltage to the inside rearview mirror dimming circuit.
If an interior lamp is switched on during mirror dimming or the reverse gear is engaged, the dimming is
interrupted.
Model 216 PE88.79-P-2056-97CAA
Electrical function schematic for automatic dimming mirror
Model 221 PE88.79-P-2056-97SAA
N69/1
Left door control unit, component description GF72.29-P-4124LA
Model 216
N69/1
Left front door control unit, component description GF72.29-P-4141LE
Model 221
Overhead control panel control unit, component description N70 GF82.20-P-5216LE
Component description for the EZS control unit N73 GF80.57-P-6003LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
Inside rearview mirror unit, component description A67 GF68.49-P-2105LE
AUTOMATIC DIMMING OUTSIDE MIRROR AND INSIDE REARVIEW MIRROR, FUNCTION -
GF88.79-P-2010SX
MODEL 216.3 up to Model Year 8
MODEL 221.0 /1 with CODE (249) Automatically dimming inside rearview mirror and outside mirror
(driver) up to Model Year 8
Fig. 160: Automatic Dimming Outside Mirror And Inside Rearview Mirror Function Diagram
Courtesy of MERCEDES-BENZ USA
Function requirements
C. 15R On
Function
The mirror lens of the inside rearview mirror and left outside mirror can be dimmed electro-chromatically. This
is realized by a layer of electrolyte gel in the mirror which controls the light permeability in increments
depending on the voltage applied. The inside rearview mirror senses the ambient light via the front mirror
dimming sensor and the light hitting the surface of the mirror lens via the rear mirror dimming sensor.
The inside rearview mirror evaluates these input variables and supplies dimming information to the overhead
control panel control unit which transmits the message for mirror dimming to the passenger compartment CAN-
B bus.
The left door control unit relays the dimming information and supplies the corresponding actuation voltage to
the automatic dimming mirror of the left outside mirror. The dimming information for the inside rearview
mirror is taken over by the overhead control panel control unit, which supplies the voltage to the mirror
dimming of the inside rearview mirror.
If an interior lamp is switched on during mirror dimming or the reverse gear is engaged, the dimming is
interrupted.
GF68.49-P-
Inside rearview mirror unit, component description A67
2105SX
M21/1, GF88.79-P-
Outside mirror, component description
M21/2 4003SX
N69/1 GF72.29-P-
Type 216.3 6000SC
Driver-side front door control unit, component description
Model GF72.29-P-
221.0/1 6000SX
GF82.20-P-
Overhead control panel control unit, component description N70
5216SX
Electronic ignition/starter switch control unit (EIS) component GF80.57-P-
N73
description 6000SX
STORE AND CALL OUTSIDE MIRROR POSITION, FUNCTION - GF88.79-P-2013LE
MODEL 216.3 as of model year 09 /YoM 08
MODEL 221.0 /1 with CODE (275) Memory package (driver seat, steering column, mirrors) as of model
year 09 /YoM 08
Function requirements, general
C. 15R On
Store and call outside mirror position, general
To increase comfort, it is possible to store the mirror position together with the seat and steering column
positions.
The function store /call outside mirror position comprises the following partial functions:
Function sequence for storing outside mirror position
Function sequence for calling outside mirror position
Function sequence for storing outside mirror position
Three memory locations can be assigned manually with the left front seat adjustment group (S22).
For this purpose press memory switch (S22s6) and hold down, parallel to this momentarily press one of the
following switches:
Memory 1 switch (S22s7)
Memory 2 switch (S22s8)
Memory 3 switch (S22s9)
As an alternative the memory switch can be actuated for t = 40 ms and one of the memory switches 1, 2 or 3 can
be actuated momentarily for t = 3 s.
The signal for storage request is relayed by the left front door control unit (N69/1) (model 221) or left door
control unit (N69/1) (model 216) to the left front door control unit (N32/1) via the interior CAN. It transmits the
storage request to store the position data to the left door control unit and right front door control unit (N69/2)
(model 221) or right door control unit (N69/2) (model 216).
When switching off the motor (as of c. 15C) and when the driver door is closed, the current position of the
left outside mirror and right outside mirror is stored automatically in the corresponding door control unit.
The position of the steering column and driver seat are stored and an acknowledgment tone sounds in the
instrument cluster (A1).
Additional function requirements for calling outside mirror position
Circuit 15R ON or driver door open
No manual outside mirror adjustment requested by the driver outside mirror and trunk lid power window
switch group (S20/1)
Function sequence for calling outside mirror position
The position stored in the left door control unit and right door control unit can be called via the left front seat
operation switch group.
For this purpose, press desired memory switch 1, 2 or 3. The left seat control unit receives the request by the left
door control unit via the interior CAN and relays it to the left door control unit and right door control unit via
the interior CAN.
The left door control unit actuates the left outside mirror and right door control unit actuates the right outside
mirror as long as the memory switch 1, 2, 3 is pressed or the end position for the memory location selected is
reached.
The steering column and driver seat are moved to the associated memory positions for the selected memory
location at the same time when the outside mirror positions are retrieved.
The last position of the driver seat, steering column and outside mirror is adjusted as of circuit 15C ON.
Model PE88.79-P-2058-
Electrical function schematic for storing and calling outside mirror 216 97CAA
position Model PE88.79-P-2058-
221 97SAA
Left front seat control unit, component description N32/1 GF91.29-P-5230LE
N69/1
Left door control unit, component description Model GF72.29-P-4124LA
216
N69/1
Left front door control unit, component description Model GF72.29-P-4141LE
221
N69/2
Right door control unit, component description Model GF72.29-P-4128LA
216
N69/2
Right front door control unit, component description Model GF72.29-P-4142LE
221
Component description for the EZS control unit N73 GF80.57-P-6003LE
STORE AND CALL OUTSIDE MIRROR POSITION, FUNCTION - GF88.79-P-2013SX
MODEL 216.3 up to Model Year 8
MODEL 221.0 /1 with CODE (275) Memory package (driver seat, steering column, mirrors) up to Model
Year 8
Fig. 161: Store And Call Outside Mirror Position Function Diagram
Courtesy of MERCEDES-BENZ USA
Store outside mirror position
Function requirements
C. 15R On
Function
All totaled, three memories can be stored manually:
Press and hold memory switch; simultaneously actuate memory switch 1, 2 or 3 momentarily or actuate
memory switch for at least 40 ms and momentarily actuate memory switch 1, 2 or 3 for 3 s.
The signal for memory request is relayed to the left front seat control unit by the left door control unit via the
interior CAN. It relays the memory request to both door control units.
When switching off the motor (as of circuit 15C) and when the driver door is closed, the current position of the
left and right outside mirror is stored automatically in the corresponding door control unit.
When storing, also the positions of the steering column and the driver seat are stored.
Call outside mirror position
Function requirements
Circuit 15R ON or driver door open
No manual seat, mirror or steering column adjustment actuated
Function
The position stored in the left door control unit and right door control unit can be called via the seat operation
switch group. For this purpose, press desired memory switch 1, 2 or 3.
The left seat control unit receives the memory request by the left door control unit via the interior CAN and
relays it to the left door control unit and right door control unit via the interior CAN.
The left door control unit actuates the left outside mirror and right door control unit actuates the right outside
mirror as long as the memory switch 1, 2, 3 is pressed or the position for the memory location selected is
reached.
The steering column and driver seat are moved to the associated memory positions for the selected memory
location at the same time when the outside mirror positions are retrieved.
The last position of the driver seat, steering column and outside mirror is adjusted as of circuit 15C ON.
M21/1, GF88.79-P-
Outside mirror, component description
M21/2 4003SX
GF91.29-P-
Left front seat control unit, component description N32/1
5230SX
N69/1 GF72.29-P-
Type 216.3 6000SC
Driver-side front door control unit, component description
Model GF72.29-P-
221.0/1 6000SX
N69/2 GF72.29-P-
Passenger-side front door control unit, component description Model 216.3 6010SC
Model GF72.29-P-
221.0/1 6010SX
Electronic ignition/starter switch control unit (EIS) component GF80.57-P-
N73
description 6000SX
GF91.29-P-
Front seat adjustment switch group, component description S22, S23
5220SX
OUTSIDE MIRROR, COMPONENT DESCRIPTION - GF88.79-P-4003SX
MODEL 216.3, 221.0 /1 up to Model Year 8
Design
The following components are installed in the left electrically adjustable and heated outside mirror (M21/1) and
right electrically adjustable and heated outside mirror (M21/2):
Mirror up/down adjustment motor (M21/1m1, M21/2m1)
Mirror in/down adjustment motor (M21/1m2, M21/2m2)
Mirror fold-in motor (M21/1m3, M21/2m3)
Mirror heater (M21/1r1, M21/2r1)
Left outside mirror ambient lamp (M21/1e1)
Right outside mirror ambient lamp (M21/2e1)
Automatic dimming mirror (M21/1h) (on model 221 with code (249) Automatic dimming inside rearview
mirror and outside mirror (driver) and on model 216)
Left outside mirror turn signal lamp (E6/5)
Right outside mirror turn signal lamp (E6/6)
On model 221 with code (275) Memory package (driver seat, steering column, mirrors) and on model 216,
the mirror adjustment motors are equipped with one potentiometer (M21/1r2, M21/1r3, M21/2r2, M21/2r3)
each for sensing the position of the mirror lens. The mirror fold-in motors are integrated firmly in the frame of
the corresponding mirror and cannot be replaced separately. The mirror adjustment motors are combined as
drive unit.
The mirror heater and the automatic dimming mirror are integrated directly into the mirror lens.
Automatic dimming mirror function
The mirror lens is electro-chromatically dimmable. This is realized by a layer of electrolyte gel in the mirror
which controls, in increments, the light transmission, depending on the voltage applied.
Actuation
All components are actuated directly by the
Left front door control unit (N69/1) on model 221 or Left door control unit (N69/1) on model 216 and
Right front door control unit (N69/2) on model 221 or Right door control unit (N69/2) on model 216
OVERVIEW OF SYSTEM COMPONENTS, ELECTRIC OUTSIDE MIRRORS - GF88.79-P-9997LE
MODEL 216.3, 221.0 /1 as of model year 09 /AEJ 08
Instrument cluster, component GF54.30-P-
A1
description 6000LE
A40/3
with code (526) COMAND with single DVD drive GF82.85-P-
(without navigation) or Code (527) COMAND APS with 3136LE
COMAND controller unit, single DVD drive (with navigation)
component description GF82.85-P-
With code (529) HIGH Class Japan
3136LEJ
With code (530) COMAND APS USA (with navigation GF82.85-P-
system) 3136LEU
A80 GF27.19-P-
Intelligent servo module for With TRANSMISSION 722.6 4020ACS
DIRECT SELECT, component
description GF27.19-P-
With transmission 722.9
4020AHS
N3/9 GF07.16-P-
Component description for CDI On engine 629.9 in model 221 6000OA
control unit GF07.16-P-
On engine 642.9 in model 221
6000OHL
N3/10 GF07.61-P-
On engine 156 6000MAS
GF07.61-P-
On engine 272
ME-SFI [ME] control unit, 6000MIS
component description GF07.61-P-
On engine 273
6000MLS
GF07.61-P-
On engine 275
6000MOS
Front SAM control unit with
GF54.21-P-
fuse and relay module, N10/1
6070LE
component description
Rear SAM control unit with
GF54.21-P-
fuse and relay module, N10/2
6030LE
component description
Automatic air conditioning
GF83.40-P-
control unit component N22/1
3012LE
description
Left front seat control unit, GF91.29-P-
N32/1
component description 5230LE
Left door control unit, N69/1 GF72.29-P-
component description Model 216 4124LA
Left front door control unit, N69/1 GF72.29-P-
component description Model 221 4141LE
Right door control unit, N69/2 GF72.29-P-
component description Model 216 4128LA
Right front door control unit, N69/2 GF72.29-P-
component description Model 221 4142LE
Overhead control panel control GF82.20-P-
N70
unit, component description 5216LE
Upper control panel control GF54.21-P-
N72/1
unit, component description 6040LE
Component description for the GF80.57-P-
N73
EZS control unit 6003LE
Central gateway control unit, GF54.21-P-
N93
component description 4170LE
Inside rearview mirror unit, GF68.49-P-
A67
component description 2105LE
Table of contents for function
GF88.79-P-
description of electric outside
0997LE
mirrors
OVERVIEW OF SYSTEM COMPONENTS FOR ELECTRICALLY ADJUSTABLE OUTSIDE
MIRROR - GF88.79-P-9998SX
MODEL 216.3, 221.0 /1 up to Model Year 8
A1 GF54.30-P-
Instrument cluster, component description
Model 221.0/1 6000SX
A40/3
Model 221.0/1 without code (498) GF82.85-P-
Japanese version and without code 3136SX
COMAND controller unit, component (494) USA version
description Model 221.0/2 with code (498) GF82.85-P-
Japanese version 3136SXJ
Model 221.0/1 with code (494) USA GF82.85-P-
version 3136SXU
Inside rearview mirror unit, component GF68.49-P-
A67
description 2105SX
A80 GF27.19-P-
Intelligent servo module (ISM) component Model 221 with transmission 722.9 4015SX
description GF27.19-P-
Model 221 with transmission 722.6
4015SXA
Outside mirror, component description M21/1, M21/2
4003SX
N3/9 GF07.16-P-
CDI control unit component description
Model 221 with engine 642 6000SX
N3/10
ME-SFI [ME] control unit, component GF07.61-P-
Model 221 with engine 272.965,
description 6000V
273.961
N3/10
ME-SFI control unit, GF07.61-P-
Model 221.0/2 with engine
location/task/design/function 5000M
275.952/982
Left front seat control unit, component GF91.29-P-
N32/1
description 5230SX
N69/1 GF72.29-P-
Driver-side front door control unit, component Type 216.3 6000SC
description GF72.29-P-
Model 221.0/1
6000SX
N69/2 GF72.29-P-
Passenger-side front door control unit, Model 216.3 6010SC
component description GF72.29-P-
Model 221.0/1
6010SX
Overhead control panel control unit, component GF82.20-P-
N70
description 5216SX
Electronic ignition/starter switch control unit GF80.57-P-
N73
(EIS) component description 6000SX
Central gateway control unit, component GF54.21-P-
N93
description 4170SX
Driver power window, outside mirror and trunk GF54.25-P-
S20/1
lid switch group, component description 4230SX
Front seat adjustment switch group, component GF91.29-P-
S22, S23
description 5220SX
Table of contents, function description for GF88.79-P-
electrically adjustable outside rearview mirror 0999SX
WIRING DIAGRAMS
OVERVIEW OF WIRING DIAGRAMS DETACHABLE BODY COMPONENTS, OUTSIDE
MIRRORS - PE88.00-P-1100SAA
MODEL 221
Wiring diagram of outside mirrors Model 221.0/1 left outside mirror PE88.79-P-2000-97SAA
Wiring diagram of outside mirrors Model 221.0/1 right outside PE88.79-P-2000-97SAB
mirror
ELECTRIC WIRING DIAGRAMS: PASSENGER CARS: DETACHABLE BODY COMPONENTS,
EXTERIOR FLAPS - PE88.00-Z-9999AZ
MODEL all
Survey of wiring diagrams detachable body PE88.00-P-
MODEL 163
components, outside mirrors 1100E
Survey of wiring diagrams detachable body PE88.00-P-
MODEL 168
components, exterior mirrors 1100GC
Survey of wiring diagrams of detachable body PE88.00-P-
MODEL 170
components, outside mirrors 1100B
Overview of wiring diagrams for detachable PE88.00-P-
MODEL 199
body components, outside mirrors 1100LA
Survey of wiring diagrams of detachable body PE88.00-P-
MODEL 202, 208 as of 1.6.97
components, outside mirrors 1100D
Overview of wiring diagrams detachable body PE88.00-P-
MODEL 203
components, outside mirrors 1100FA
Overview of wiring diagrams detachable body MODEL 203.7 Function schematics, PE88.00-P-
components, outside mirrors only present in WIS 1100FB
Survey of wiring diagrams, detachable body PE88.00-P-
MODEL 209
components, outside mirrors 1100BA
Survey of wiring diagrams of detachable body PE88.00-P-
MODEL 211
components, outside mirrors 1100DA
Survey of electric wiring diagrams of detachable PE88.00-P-
MODEL 215
body components, outside mirrors 1100CA
Overview of wiring diagrams detachable body PE88.00-P-
MODEL 216
components, outside mirrors 1100CAA
Overview of wiring diagrams detachable body PE88.00-P-
MODEL 219
components, outside mirrors 1100XA
Survey of electric wiring diagrams of detachable PE88.00-P-
MODEL 220
body components, outside mirrors 1100SA
Survey of wiring diagrams detachable body MODEL 220 with CODE (979) PE88.00-P-
components, outside mirrors Special protection version 1100SB
Overview of wiring diagrams detachable body PE88.00-P-
MODEL 221
components, outside mirrors 1100SAA
Overview of wiring diagrams detachable body PE88.00-P-
MODEL 230...
components, outside mirrors 1100KB
Overview of wiring diagrams detachable body MODEL 230 Circuit diagrams, block PE88.00-P-
components, outside mirrors diagrams 1100KA
Survey of wiring diagrams of detachable body PE88.00-P-
MODEL 240
components, outside mirrors 1100HA
Overview of wiring diagrams detachable body PE88.00-P-
MODEL 245
components, outside mirrors 1100BAA
Overview of wiring diagrams detachable body MODEL 251 Function schematics, PE88.00-P-
components, outside mirrors only available in the WIS 1100RAB
Survey of wiring diagrams detachable body parts, PE88.00-P-
MODEL 210
exterior mirrors 1100A
WIRING DIAGRAM OF OUTSIDE MIRRORS - PE88.79-P-2000-97SAA
MODEL 221.0 /1 left outside mirror
Code: Designation: Position:
A0 Color code key 15L
E6/5 Left outside mirror turn signal lamp 1L
M21/1 Left electrically adjustable and heated outside mirror 5L
M21/1e1 Left outside mirror ambient lamp 7L
M21/1e2 Left Blind Spot Assist readiness and warning indicator 11K
M21/1e3 Left blind spot assist indicator lamp 11K
M21/1h1 Automatic dimming mirror 2L
M21/1m1 Mirror up/down adjustment motor 5J
M21/1m2 Mirror in/out adjustment motor 5K
M21/1m3 Mirror fold-in motor 8L
M21/1r1 Mirror heater 3L
M21/1r2 Mirror up/down adjustment potentiometer 6J
M21/1r3 Mirror in/out adjustment potentiometer 6K
N69/1 Left front door control unit 4A
N69/1 Left front door control unit 11A
U910 Valid for Blind Spot Assist 9H
Fig. 162: Outside Mirrors Wiring Diagram
Courtesy of MERCEDES-BENZ USA
WIRING DIAGRAM OF OUTSIDE MIRRORS - PE88.79-P-2000-97SAB
MODEL 221.0 /1 right outside mirror
Code: Designation: Position:
A0 Color code key 15L
E6/6 Right outside mirror turn signal lamp 1L
M21/2 Right electrically adjustable and heated outside mirror 5L
M21/2e1 Right outside mirror ambient lamp 7L
M21/2e2 Right Blind Spot Assist readiness and warning indicator 11K
M21/2e3 Right blind spot assist indicator lamp 11K
M21/2h1 Automatic dimming mirror 2L
M21/2m1 Mirror up/down adjustment motor 5J
M21/2m2 Mirror in/out adjustment motor 5K
M21/2m3 Mirror fold-in motor 8L
M21/2r1 Mirror heater 3L
M21/2r2 Mirror up/down adjustment potentiometer 6J
M21/2r3 Mirror in/out adjustment potentiometer 6K
N69/2 Right front door control unit 4A
N69/2 Right front door control unit 11A
U910 Valid for Blind Spot Assist 9H
Fig. 163: Outside Mirrors - Wiring Diagram
Courtesy of MERCEDES-BENZ USA
WIRING DIAGRAM OF OUTSIDE MIRRORS - PE88.79-P-2000-99SAA
MODEL 221.0 /1 left outside mirror
Code: Designation: Position:
A0 Explanation of color codes 15L
E6/5 Left exterior mirror turn signal lamp 1L
M21/1 Left electrically adjustable and heated exterior mirror 2L
M21/1 Left electrically adjustable and heated exterior mirror 3L
M21/1 Left electrically adjustable and heated exterior mirror 5L
M21/1e1 Left outside mirror ambient lamp 7L
M21/1m1 Mirror up/down adjustment motor 4J
M21/1m2 Mirror in/out adjustment motor 4K
M21/1m3 Mirror fold-in motor 8L
M21/1r2 Mirror up/down adjustment potentiometer 6J
M21/1r3 Mirror in/out adjustment potentiometer 6K
N69/1 Left front door control module 4A
Fig. 164: Outside Mirrors - Wiring Diagram
Courtesy of MERCEDES-BENZ USA
WIRING DIAGRAM OF OUTSIDE MIRRORS - PE88.79-P-2000-99SAB
MODEL 221.0 /1 right outside mirror
Code: Designation: Position:
A0 Explanation of color codes 15 L
E6/6 Right exterior mirror turn signal lamp 1L
M21/2 Right electrically adjustable and heated exterior mirror 4L
M21/2e1 Right outside mirror ambient lamp 7L
M21/2h1 Automatic dimming mirror 2L
M21/2m1 Mirror up/down adjustment motor 4J
M21/2m2 Mirror in/out adjustment motor 4K
M21/2m3 Mirror fold-in motor 8L
M21/2r1 Mirror heater 3L
M21/2r2 Mirror up/down adjustment potentiometer 6J
M21/2r3 Mirror in/out adjustment potentiometer 6K
N69/2 Right front door control module 4A
Fig. 165: Outside Mirrors Wiring Diagram
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR MIRROR LENS ADJUSTMENT - PE88.79-P-2051-
97SAA
Code: Designation: Position:
1 Circuit 15, status
1 Circuit 15, status
2 Outside mirror adjustment switch group, status
3 Mirror adjustment motor, request
4 Mirror adjustment motor, actuation
4 Mirror adjustment motor, actuation
A8/1 Transmitter key
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
LIN B1 Front door LIN
M21/1 Left electrically adjustable and heated outside mirror
M21/2 Right electrically adjustable and heated outside mirror
N69/1 Left front door control unit
N69/2 Right front door control unit
N73 EIS [EZS] control unit
S20/1 Driver power window, outside mirror and trunk lid switch group
Fig. 166: Mirror Lens Adjustment - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
FUNCTION SCHEMATIC FOR ELECTRIC PASSENGER-SIDE OUTSIDE MIRROR PARK
POSITION - PE88.79-P-2054-97SAA
Code: Designation: Position:
1 Circuit 15, status
1 Circuit 15, status
2 Reverse gear, status
2 Reverse gear, status
2 Reverse gear, status
3 Vehicle speed, signal
3 Vehicle speed, signal
4 Store passenger-side outside mirror park position, request
4 Store passenger-side outside mirror park position, request
5 Outside mirror adjustment switch group, status
6 Mirror adjustment motor, request
7 Mirror adjustment motor, actuation
8 Mirror adjustment motor, signal
A1 Instrument cluster
A8/1 Transmitter key
A80 Intelligent servo module for DIRECT SELECT
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN C Drive train CAN
CAN E Chassis CAN
CAN F Central CAN
LIN B1 Front door LIN
LIN B1 Front door LIN
M21/2 Right electrically adjustable and heated outside mirror
M21/2m1 Mirror up/down adjustment motor
M21/2m2 Mirror in/out adjustment motor
N3/10 ME-SFI [ME] control unit
N3/10 ME-SFI [ME] control unit
N3/9 CDI control unit
N69/1 Left front door control unit
N69/2 Right front door control unit
N73 EIS [EZS] control unit
N93 Central gateway control unit
S20/1 Driver power window, outside mirror and trunk lid switch group
S20/1s10 Left/right outside mirror adjustment selection switch
S20/1s12 Outside mirror adjustment rocker switch
S22 Left front seat operation switch group
S22s6 Memory switch
U74 Valid for diesel engines
U75 Valid for gasoline engines
Fig. 167: Electric Passenger-Side Outside Mirror Park Position - Function Schematic (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 168: Electric Passenger-Side Outside Mirror Park Position - Function Schematic (2 Of 2)
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR MIRROR HEATER - PE88.79-P-2055-97SAA
Code: Designation: Position:
1 Circuit 15, status
1 Circuit 15, status
1 Circuit 15, status
1 Circuit 15, status
2 Circuit 61, status
3 Outside temperature indicator temperature sensor, signal
3 Outside temperature indicator temperature sensor, signal
4 Dew point sensor, signal
4 Dew point sensor, signal
5 Rear window heater, request
5 Rear window heater, request
6 Rear window heater, status
7 Mirror heater, actuation
A8/1 Transmitter key
B14 Outside temperature display temperature sensor
B31/1 AAC [KLA] multifunction sensor
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
M21/1 Left electrically adjustable and heated outside mirror
M21/2 Right electrically adjustable and heated outside mirror
N10/1 Front SAM control unit with fuse and relay module
N10/2 Rear SAM control unit with fuse and relay module
N22/1 AAC [KLA] control unit
N69/1 Left front door control unit
N69/2 Right front door control unit
N72/1 Upper control panel control unit
N73 EIS [EZS] control unit
Fig. 169: Mirror Heater - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR AUTOMATIC DIMMING MIRROR - PE88.79-P-
2056-97SAA
Code: Designation: Position:
1 Circuit 15, status
1 Circuit 15, status
2 Reverse gear, status
2 Reverse gear, status
2 Reverse gear, status
3 Automatic dimming mirror light sensor, status
4 Mirror dimming, request
4 Mirror dimming, request
5 Mirror dimming, actuation
A67 Inside rearview mirror unit
A8/1 Transmitter key
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
M21/1 Left electrically adjustable and heated outside mirror
M21/1h1 Automatic dimming mirror
N69/1 Left front door control unit
N70 Overhead control panel control unit
N73 EIS [EZS] control unit
N93 Central gateway control unit
Fig. 170: Automatic Dimming Mirror - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR FOLDING OUTSIDE MIRRORS - PE88.79-P-2057-
97SAA
Code: Designation: Position:
1 Circuit 15, status
1 Circuit 15, status
1 Circuit 15, status
2 Outside mirror adjustment switch group, status
3 Vehicle speed, signal
3 Vehicle speed, signal
3 Vehicle speed, signal
4 Central locking (CL[ZV]), status
4 Central locking (CL[ZV]), status
4 Central locking (CL[ZV]), status
5 Door rotary tumbler switch, status
5 Door rotary tumbler switch, status
5 Door rotary tumbler switch, status
5 Door rotary tumbler switch, status
6 Automatic power folding mirrors, status
6 Automatic power folding mirrors, status
6 Automatic power folding mirrors, status
7 Mirror folding motor, request
8 Mirror folding motor, actuation
8 Mirror folding motor, actuation
A1 Instrument cluster
A40/3 COMAND control unit
A8/1 Transmitter key
A85/1s1 Right front rotary tumbler switch
A85s1 Left front rotary tumbler switch
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN F Central CAN
CAN F Central CAN
LIN B1 Front door LIN
M21/1 Left electrically adjustable and heated outside mirror
M21/1m3 Mirror fold-in motor
M21/2 Right electrically adjustable and heated outside mirror
M21/2m3 Mirror fold-in motor
N69/1 Left front door control unit
N69/2 Right front door control unit
N73 EIS [EZS] control unit
N93 Central gateway control unit
S20/1 Driver power window, outside mirror and trunk lid switch group
S20/1s9 Outside mirror fold-in/fold-out switch
U52 Valid for Japan
U54 Valid for all except Japan
Fig. 171: Folding Outside Mirrors - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR STORING AND CALLING OUTSIDE MIRROR
POSITION - PE88.79-P-2058-97SAA
Code: Designation: Position:
1 Circuit 15, status
1 Circuit 15, status
2 Door rotary tumbler switch, status
3 Outside mirror adjustment switch group, status
4 Adjust or store memory position, request
4 Adjust or store memory position, request
5 Store memory positions, request
5 Store memory positions, request
6 Actuator motors, actuation
6 Actuator motors, actuation
7 Outside mirror actuator motor, signal
7 Outside mirror actuator motor, signal
A8/1 Transmitter key
A85s1 Left front rotary tumbler switch
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
CAN B Interior CAN
LIN B1 Front door LIN
LIN B1 Front door LIN
M21/1 Left electrically adjustable and heated outside mirror
M21/1m1 Mirror up/down adjustment motor
M21/1m2 Mirror in/out adjustment motor
M21/2 Right electrically adjustable and heated outside mirror
M21/2m1 Mirror up/down adjustment motor
M21/2m2 Mirror in/out adjustment motor
N32/1 Left front seat control unit
N69/1 Left front door control unit
N69/2 Right front door control unit
N73 EIS [EZS] control unit
S20/1 Driver power window, outside mirror and trunk lid switch group
S22 Left front seat operation switch group
S22s6 Memory switch
S22s7 Memory 1 switch
S22s8 Memory 2 switch
S22s9 Memory 3 switch
Fig. 172: Storing And Calling Outside Mirror Position - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS
202 589 11 63 00 ASSEMBLY TOOL - WS88.00-P-0011K
FG 88/Set K
MODEL 124, 140, 202, 203.0 /2, 204, 208, 210, 211.0 /2 /6, 212, 220, 221
Use:
Assembly tool for removing and installing engine hoods Mercedes star
Fig. 173: Identifying Assembly Tool (202 589 11 63 00)
Courtesy of MERCEDES-BENZ USA
221 589 06 23 00 SET OF TEMPLATES - WS88.00-P-0062K
Group 88/Set K
MODELS 221
Use:
Set of cutting templates for installing model designation on trunk lid and fender.
Fig. 174: Identifying Set Of Templates (221 589 06 23 00)
Courtesy of MERCEDES-BENZ USA
221 589 00 98 00 PROTECTIVE COVERING - WS88.00-P-0065K
FG 88/72 Set K
MODEL 203, 219, 221
Use:
To press on trim and handle strips.
NOTE: In combination with roller W 168 589 05 63 00.
Fig. 175: Identifying Protective Covering (221 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
001 589 00 31 00 CLAMPING TOOL - WS88.00-P-0068B
FG 88/Set B
MODEL 212, 216, 221
Use:
Clamping tool for installing outside mirror to mirror mount.
Fig. 176: Identifying Clamping Tool (001 589 00 31 00)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS: PASSENGER CARS: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS
- WS88.00-Z-9999AZ
MODEL all
WS00.00-P-
000 589 40 37 00 Clamp FG 00/01/07/18/20/ 47/82/88
0005Z
WS88.00-P-
001 589 00 31 00 Clamping tool FG 88/Set B
0068B
107 589 00 37 00 Assembly WS88.00-P-
FG 88/Set K
lever 0001K
110 589 03 59 00 Mounting FG 00/01/05/13/18/ WS00.00-P-
wedge 26/42/54/67/68/72/77/80/82/83/88/91/ Set K 0274K
FG 00/26/27/31/32/33/ WS67.00-P-
115 589 03 59 00 Long wedge
41/47/54/62/67/68/72/77/80/82/83/86/ 88/91/98/Set K 0002K
WS67.00-P-
124 589 21 63 00 Cutting blade FG 65/67/72/77/88/ Set K
0008K
WS67.00-P-
124 589 40 63 00 Cutting blade FG 67/88/Set K
0009K
FG 00/Set Z FG 01/05/06/07/09/14/15/18/20/22/25/26/ WS00.00-P-
129 589 00 91 00 Record plug
27/29/32/33/35/42/46/47/68/82/83/88/ 91/Set B 0255Z
WS60.00-P-
129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K
0027K
129 589 12 23 00 Set of adhesive
FG 88/Set K
plate 0002K
WS91.00-P-
140 589 02 33 00 Pulling hook FG 46/67/68/72/77/80/ 82/83/ 88/91/Set B
0024K
WS88.00-P-
140 589 18 63 00 Puller hook FG 88/Set K
0003K
140 589 27 23 00 Set of adhesive
WS88.00-P-
templates for model designation FG 88/Set K
0004K
plate, complete
140 589 28 23 00 Set of adhesive
WS88.00-P-
templates for model FG 88/Set K
0005K
identification
140 589 29 23 00 Set of adhesive
WS88.00-P-
templates for model designation FG 88/Set K
0006K
plate, complete
140 589 31 23 00 Mount for WS88.00-P-
FG 88/Set K
glue-on letters 0015K
WS88.00-P-
140 589 34 23 00 Assembly tool FG 88/Set K
0008K
WS88.00-P-
163 589 00 21 00 Spacer gauge FG 88/set K
0031K
163 589 17 23 00 Template Set, WS88.00-P-
FG 88/set K
Model Designation 0019K
WS88.00-P-
163 589 20 23 00 Template Group 88/set K
0044K
WS88.00-P-
163 589 21 23 00 Template Group 88/set K
0045K
WS88.00-P-
163 589 22 23 00 Template FG 88/Set K
0053K
WS88.00-P-
164 589 02 23 00 Template Group 88/Set B
0066B
WS88.00-P-
164 589 06 23 00 Template Group 88/Set B
0057B
WS54.00-P-
168 589 02 31 00 Unlocking tool FG 54/88/Set B
0051B
168 589 05 23 00 Gluing WS88.00-P-
FG 88/Set K
templates 0017K
168 589 09 23 00 Model WS88.00-P-
FG 88/set K
designation mount 0032K
168 589 10 23 00 Model WS88.00-P-
FG 88/set K
designation mount 0033K
169 589 05 23 00 Set of gluing WS88.00-P-
Group 88/Set K
templates 0056K
WS72.00-P-
170 589 04 63 00 Support FG 72/77/88/Set K
0015K
170 589 05 23 00 Gluing WS88.00-P-
FG 77/88/Set K
templates for model designation 0016K
170 589 07 23 00 Model WS88.00-P-
FG 88/set K
designation mount 0039K
171 589 03 23 00 Set of WS88.00-P-
Group 88/Set K
templates 0054K
199 589 01 23 00 Drilling WS88.00-P-
FG 88/Set B
template 0061B
WS88.00-P-
202 589 11 63 00 Assembly tool FG 88/Set K
0011K
202 589 14 23 00 Set of adhesive
WS88.00-P-
templates for model designation FG 88/Set K
0012K
plate
202 589 16 23 00 Gluing WS88.00-P-
FG 88/Set K
template for compressor 0014K
202 589 17 63 00 Cutting blade, WS67.00-P-
FG 67/77/88/Set K
straight, 35 mm blade length 0011K
WS88.00-P-
202 589 20 23 00 Templates FG 88/Kit K
0028K
WS88.00-P-
202 589 21 23 00 Templates FG 88/Kit K
0029K
WS88.00-P-
202 589 23 23 00 Template Group 88/Set K
0058K
WS88.00-P-
203 589 01 23 00 Templates FG 88/Kit K
0023K
WS88.00-P-
203 589 02 23 00 Templates FG 88/set K
0024K
WS88.00-P-
203 589 12 23 00 Templates Group 88/Set K
0040K
208 589 03 23 00 Gluing WS88.00-P-
FG 88/Set K
templates 0018K
208 589 05 23 00 Model WS88.00-P-
FG 88/set K
designation mount 0034K
WS88.00-P-
208 589 06 23 00 Templates FG 88/Kit K
0027K
209 589 02 23 00 Set of gluing WS88.00-P-
Group 88/Set K
templates 0043K
WS00.00-P-
210 589 00 71 00 Hand pump FG 00/01/07/09/20/25/ 27/32/33/43/46/88
0280Z
210 589 15 23 00 Set of adhesive
WS88.00-P-
templates for model designation FG 88/Set K
0013K
plate
WS88.00-P-
210 589 23 23 00 Templates FG 88/Set K
0030K
210 589 25 23 00 Model WS88.00-P-
FG 88/set K
designation mount 0035K
210 589 26 23 00 Model WS88.00-P-
FG 88/set K
designation mount 0036K
210 589 27 23 00 Model WS88.00-P-
FG 88/set K
designation mount 0037K
210 589 28 23 00 Model WS88.00-P-
FG 88/set K
designation mount 0038K
WS88.00-P-
211 589 09 23 00 Template FG 88/set K
0050K
WS88.00-P-
215 589 15 23 00 Templates FG 88/Kit K
0026K
WS88.00-P-
219 589 03 23 00 Template Group 88/Set B
0055B
220 589 02 63 00 Trunk lid WS88.00-P-
FG 88/Kit K
spring holder 0021K
220 589 03 31 00 Trunk lid WS88.00-P-
FG 88/Kit K
spring tensioner 0022K
WS88.00-P-
220 589 06 23 00 Templates FG 88/Set K
0020K
221 589 00 98 00 Protective WS88.00-P-
FG 88/72 Set K
covering 0065K
221 589 06 23 00 Set of WS88.00-P-
Group 88/Set K
templates 0062K
WS60.00-P-
230 589 00 31 00 Adapter set FG 60/61/88/Set K
0084K
WS88.00-P-
230 589 05 23 00 Template FG 88/set K
0041K
WS88.00-P-
230 589 05 63 00 Strut FG 88/set K
0042K
WS65.00-P-
230 589 07 23 00 Gage GROUP 65/88/Set K
0012K
WS72.00-P-
230 589 08 63 00 Adapter FG 72/88/Set B
0023B
WS88.00-P-
240 589 00 37 00 Pliers FG 88/Set K
0052K
WS88.00-P-
240 589 05 23 00 Template FG 88/Set K
0051K
240 589 06 23 00 Set of WS88.00-P-
Group 88/Set B
templates 0064B
245 589 02 23 00 Set of WS88.00-P-
Group 88/Set K
templates 0060K
WS88.00-P-
251 589 04 23 00 Template Group 88/Set K
0063K
WS68.00-P-
452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K
0012K
904 589 02 10 00 Screwdriver WS88.00-P-
Group 88/Set B
insert 0059B
ACCESSORIES & BODY, CAB
Doors - Testing & Repair - S-Class (221)
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: DOORS - AR72.00-Z-9221AA
MODEL 221
MODEL 221.176 with CODE (Z07) Top
AR72.14-P-
Adjust center door protection with CODE (Z19) S600 Pullman
0015SXS
Guard state sedan
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Adjust front door
(Z07) Top protection 0550SX
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Adjust front door
protection 0550SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Adjust rear door
(Z07) Top protection 0650SX
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Adjust rear door
protection 0650SXS
Assemble/disassemble door lining in MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
rear door (Z07) Top protection 1040SX
Cover window frame on front door with MODEL 221.1 with CODE (Z07) Top AR72.10-P-
leather protection 0600SXS
Cover window frame on rear door with MODEL 221.1 with CODE (Z07) Top AR72.12-P-
leather protection 0500SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Disassemble/assemble front door lining
(Z07) Top protection 1030SX
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Remove/install armrest on front door
(Z07) Top protection 1033SX
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Remove/install armrest on rear door
(Z07) Top protection 1020SX
MODEL 221.176 with CODE (Z07) Top
AR72.14-P-
Remove/install center door protection with CODE (Z19) S600 Pullman
0010SXS
Guard state sedan
Remove/install crank window in front MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
door (Z07) Top protection 1900SX
Remove/install crank window in front MODEL 221.1 with CODE (Z07) Top AR72.10-P-
door protection with hydraulic power windows 1900SXS
Remove/install crank window in rear MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
door (Z07) Top protection 1910SX
Remove/install crank window in rear MODEL 221.1 with CODE (Z07) Top AR72.12-P-
door protection with hydraulic power windows 1910SXS
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Remove/install door foil on front door
protection with hydraulic power windows 1010SXS
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Remove/install door foil on rear door
protection with hydraulic power windows 0105SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Remove/install door frame seal
(Z07) Top protection 2120SX
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Remove/install door frame seal
protection 2120SXS
Remove/install door frame seal on rear MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
door (Z07) Top protection 1015SX
Remove/install door frame seal on rear MODEL 221.1 with CODE (Z07) Top AR72.12-P-
door protection 1015SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Remove/install door holder
(Z07) Top protection 2100SX
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Remove/install door holder
protection with hydraulic power windows 2100SXS
Remove/install door interior actuating AR72.12-P-
MODEL 221.0 /1
mechanism on rear side door 2310SX
Remove/install door joint seal on front AR72.10-P-
MODEL 221.0 /1
door 1780SX
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Remove/install door module
(Z07) Top protection 0900SX
Remove/install door pocket on front MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
door lining (Z07) Top protection 1045SX
Remove/install door pocket on front MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
door lining (Z07) Top protection 1030SX
Remove/install drive motor for rear door AR72.29-P-
MODEL 221...
side window roller blind 1890SX
Remove/install drive motor for rear door MODEL 221.1 with CODE (Z07) Top AR72.29-P-
side window roller blind protection 1890SXS
Remove/install fixed window in rear MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
door (Z07) Top protection 1970SX
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Remove/install front door
(Z07) Top protection 0500SX
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Remove/install front door
protection 0500SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.29-P-
Remove/install front door control unit
(Z07) Top protection 1000SX
MODEL 221.1 with CODE (Z07) Top AR72.29-P-
Remove/install front door control unit
protection 1000SXS
Remove/install front door inside door AR72.10-P-
MODEL 221.0/ 1
opening 2420SX
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Remove/install front door lining
(Z07) Top protection 1000SX
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Remove/install front door lining
protection 1000SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Remove/install front door lock
(Z07) Top protection 4011SX
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Remove/install front door lock
protection with hydraulic power windows 4011SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
Remove/install front door window lifter
(Z07) Top protection 1800SX
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Remove/install front door window lifter
protection with hydraulic power windows 1800SXS
MODEL 221.1 with CODE (Z07) Top AR72.10-P-
Remove/install inner door panel
protection with hydraulic power windows 0104SXS
Remove/install inner paneling at MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
window frame of front door (Z07) Top protection 6580SX
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Remove/install outer rear door handle
(Z07) Top protection 2410SX
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Remove/install outer rear door handle
protection 2410SXS
Remove/install outside door handle on MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
front door (Z07) Top protection 2400SX
Remove/install outside door handle on MODEL 221.1 with CODE (Z07) Top AR72.10-P-
front door protection 2400SXS
Remove/install power window hydraulic MODEL 221.1 with CODE (Z07) Top AR72.29-P-
pump protection with hydraulic power windows 0300SXS
Remove/install power window motor in MODEL 221.0 MODEL 221.1 except CODE AR72.29-P-
rear door (Z07) Top protection 1880SX
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Remove/install rear door
(Z07) Top protection 0600SX
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Remove/install rear door
protection 0600SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.29-P-
Remove/install rear door control unit
(Z07) Top protection 1100SX
MODEL 221.1 with CODE (Z07) Top AR72.29-P-
Remove/install rear door control unit
protection 1100SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Remove/install rear door holder
(Z07) Top protection 2100SX
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Remove/install rear door holder
protection with hydraulic power windows 2100SXS
Remove/install rear door inner door MODEL 221.1 with CODE (Z07) Top AR72.12-P-
panel protection with hydraulic power windows 0104SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Remove/install rear door lining
(Z07) Top protection 1010SX
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Remove/install rear door lining
protection 1010SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Remove/install rear door lock
(Z07) Top protection 2510SX
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Remove/install rear door lock
protection with hydraulic power windows 2510SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Remove/install rear door module
(Z07) Top protection 0103SX
Remove/install rear door triangular MODEL 221.1 with CODE (Z07) Top AR72.12-P-
window protection with hydraulic power windows 1940SXS
MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
Remove/install rear door window lifter
(Z07) Top protection 1810SX
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Remove/install rear door window lifter
protection with hydraulic power windows 1810SXS
Remove/install seal (top) on front door MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
window frame (Z07) Top protection 1550SX
Remove/install seal (top) on front door MODEL 221.1 with CODE (Z07) Top AR72.10-P-
window frame protection 1550SXS
Remove/install seal (upper) on rear door MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
window frame (Z07) Top protection 1550SX
Remove/install seal (upper) on rear door MODEL 221.1 with CODE (Z07) Top AR72.12-P-
window frame protection 1550SXS
AR72.12-P-
Remove/install side window roller blind MODEL 221...
2000SX
MODEL 221.1 with CODE (Z07) Top AR72.12-P-
Remove/install side window roller blind
protection 2000SXS
Remove/install trim strip on front door AR72.10-P-
MODEL 221.0 /1
lining 1050SX
Remove/install trim strip on front door AR72.12-P-
MODEL 221.0 /1
lining 1050SX
Remove/install trim strip on front door MODEL 221.0 MODEL 221.1 except CODE AR72.10-P-
window frame (Z07) Top protection 1710SX
Remove/install trim strip on front door MODEL 221.1 with CODE (Z07) Top AR72.10-P-
window frame protection 1710SXS
Remove/install trim strip on rear door MODEL 221.0 MODEL 221.1 except CODE AR72.12-P-
window frame (Z07) Top protection 1710SX
Remove/install trim strip on rear door MODEL 221.1 with CODE (Z07) Top AR72.12-P-
window frame protection 1710SXS
MODEL 221.176 with CODE (Z07) Top
AR72.14-P-
Remove/install window in center door protection with CODE (Z19) S600 Pullman
0150SXS
Guard state sedan
Remove/installing front door power MODEL 221.0 MODEL 221.1 except CODE AR72.29-P-
window motor (Z07) Top protection 1860SX
REMOVE/INSTALL INNER DOOR PANEL - AR72.10-P-0104SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 1: Identifying Inner Door Panel Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove door lining from left AR72.10-P-
1
or right front door 1000SXS
Disconnect electrical
connector from driver door
2 pressure sensor (B48/7) or
front passenger door pressure
sensor (B48/8)
Disconnect electrical
connector on left front door
3
woofer (H4/1h2) or right front
door woofer (H4/2h2)
Remove all electrical wiring
Observe routing for electrical wiring harnesses on
4 harnesses fastened to inner
inner door panel (1).
door panel (1)
Disconnect all electrical
connectors from left front door
5
control unit (N69/1) or right
front door control unit (N69/2)
Press grommets for electrical
wiring harnesses and release
6
cable inward through inner
door panel (1)
Separate door foil (2) from AR72.10-P-
7
inner door panel (1) 1010SXS
*BA72.10-
8 Remove bolts (3)
P-1001-01R
Guide release cable and electrical wiring harnesses
Remove inner door panel (1) through inner door panel (1). Remove electrical wiring
9
from front door harnesses and hydraulic lines in front area of door
inner panel (1) at side.
Remove inner sealing rail (4)
10.1 When replacing inner door panel (1).
from inner door panel (1)
Remove driver door pressure When replacing inner door panel (1).
sensor (B48/7) or front Manual pliers, see GOTIS
11.1 passenger door pressure sensor http://gotis.aftersales.mercedes-benz.com
(B48/8) from inner door panel *BR00.45-
(1) Rivet 4.8 x 12.70
Z-1011-13A
Remove left front door control When replacing inner door panel (1).
unit (N69/1) or right front
12.1 *BA72.10-
door control unit (N69/2) from
inner door panel (1) P-1018-01R
13 Install in the reverse order
FRONT DOOR
Model 221 with code
Number Designation
Z07/Z07+Z19
BA72.10-P-1001-
Bolt, inner door panel of front door Nm 8
01R
BA72.10-P-1018- Bolt, door control unit to inner door
Nm 5
01R panel
REMOVE/INSTALL FRONT DOOR - AR72.10-P-0500SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 2: Identifying Front Door Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being jammed When moving components, ensure
or pinched when removing, installing or aligning that no body parts or limbs are AS00.00-Z-
hoods, doors, trunk lid/ rear-end door or sliding within the operating range of 0011-01A
roof. moving parts.
Completely move crank window in front door
1
(1) downward
Switch off ignition and remove transmitter key Keyless Go start/stop button
2 or Keyless Go start/stop button from EIS control only on vehicles with code (889)
unit Keyless Go.
3 Unclip cover (2) from door lining (3) Fig. 3
4 Disconnect electrical connectors (4).
Disconnect electrical connector (5) from left
5 front door control unit (N69/1) or right front
door control unit (N69/2)
6 Unclip protective hose (6) from front door (1). Fig. 3
Pull electric wiring harness (7) out of front door
7
(1).
Carefully unclip door holder
Unclip door holder (8) from A-pillar mount with
8 (8), if necessary, use rag to protect
suitable screwdriver.
against paint damage.
*BA72.10-P-
9 Remove caps (9) and unscrew bolts below
1003-01Q
Carefully remove front door (1).
Remove front door (1) from door hinges with aid
10 Danger of damaging paint on front
of helper and lay down on suitable subsurface
door (1) and front fender.
11 Install in the reverse order
Check adjustment of front door (1), correct if AR72.10-P-
12
necessary. 0550SX
FRONT DOOR
Number Designation Model 221
BA72.10-P-1003-01Q Bolt to door hinge shaft Nm 25
Fig. 3: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL FRONT DOOR - AR72.10-P-0500SXS
MODEL 221.1 with CODE (Z07) Top protection
Shown on vehicle with hydraulic power windows
Fig. 4: Identifying Front Door Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear of moving AS00.00-Z-
removing, installing or aligning
parts. 0011-01A
hoods, doors, trunk lids, liftgates
or sliding roof
Remove crank window on left AR72.10-P-
1.1 On vehicles with hydraulic power windows.
and right front door (1) 1900SXS
Remove window from left or
1.2 On vehicles without hydraulic power windows.
right front door (1)
Risk of injury caused by moving
No parts of the body or limbs should be within
parts that can pinch, crush or, in AS00.00-Z-
the operating range of the mechanism when
extreme cases, even sever 0009-01A
moving components.
extremities
Release pressure in pressure
AR72.10-P-
2.1 reservoir for hydraulic power On vehicles with hydraulic power windows.
1800-06SXS
window in front door
Remove screw (2) and remove
3.1 On vehicles with hydraulic power windows.
clamp (3)
Mark installation position of
4.1 hydraulic lines (4) on valve block On vehicles with hydraulic power windows.
(5).
On vehicles with hydraulic power windows.
Use only suitable stop plugs or lint-free rags
Detach hydraulic lines (4) from for plugging. Lint or contamination can
openings in hydraulic lines (4) cause damage.
5.1 and valve block (5) *BA72.10-
P-1002-01R
Unclip protective hose (6) from
6 Fig. 3
front door (1).
Guide electrical wiring harnesses
7
out of front door (1)
Guide hydraulic lines (4) out of
8.1 On vehicles with hydraulic power windows.
front door (1)
Remove caps (7) and remove *BA72.10-
9
bolts below P-1014-01R
Press door holder (8) off of ball
10 Fig. 3
head bolt (9) on A-pillar
Carefully remove front door (1) to prevent
Remove front door (1) from door damage to front door (1) and front fender.
11 See GOTIS for multifunctional lift/holding
hinge halves on A-pillar
device http://gotis.aftersales.mercedes-
benz.com
12 Install in the reverse order
Check adjustment of front door AR72.10-P-
13
(1), correct if necessary. 0550SXS
Check fill level of power window
14.1 hydraulic pump; correct if
necessary On vehicles with hydraulic power windows.
Power window system - check oil AP67.30-P-
level 6710SX
FRONT DOOR
Number Designation Model 221 with code Z07/Z07+Z19
BA72.10-P-1002-01R Bolt, hydraulic line to valve block Nm 7
BA72.10-P-1014-01R Bolt to door hinge shaft Nm 25
Fig. 5: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
ADJUST FRONT DOOR - AR72.10-P-0550SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 6: Identifying Front Door, Locking Eye And Bolts
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
Checking
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear AS00.00-Z-
installing or aligning hoods, doors, trunk lids, of moving parts. 0011-01A
liftgates or sliding roof
AR60.00-P-
0700-01SX
Check gap dimensions on front door (1) all the *BE60.00-P-
1
way round 1002-01R
Fig. 7
Adjust
Mark installation position of
2 Remove lock striker (2) locking eye (2) to facilitate
installation.
0700-01SX
Loosen bolts (3) on A-pillar and adjust *BE60.00-P-
3 corresponding gap dimensions by moving 1002-01R
front door (1)
Fig. 7
*BA72.10-P-
4 Tighten screws (3)
1002-01Q
The contour of the front fender
Loosen bolts (4) on inner door panel and
5 adjust transition between front fender and must be flush with the contour of the
front door (1) or project by a
front door (1) by moving front door (1).
maximum of 1 mm.
*BA72.10-P-
6 Tighten bolts (4)
1001-01Q
Insert locking eye (2) and screw in bolts (5) up It should still be possible to adjust
7
to stop the locking eye (2).
The contour of the front door (1)
Adjust transition between front door (1) and must be flush with the contour of the
8
rear door by moving locking eye (2). rear door or project by a maximum of
1 mm.
*BA72.10-P-
9 Tighten screws (5)
1004-01Q
Repair paint damage on screw heads (3, 4)
10
with touch-up paint pen
CHECK VALUES FOR GAPS
Number Designation Model 221
BE60.00-P- Gap dimension Front door to A- Dimension "D" mm 4.5 (±0.5)
1002-01R pillar
Front door to fender Dimension "E" mm 4 (±0.5)
Front door to rear Dimension "F" mm 4.5 (±0.5)
door
Trim strip at front Dimension "G" mm 4.5 (±0.5)
door to roof frame
Trim strip at rear Dimension "H" mm 4.5 (±0.5)
door to roof frame
Rear door to side Dimension "I" mm 4.5 (±0.5)
section, bottom
Front door cover to Dimension "S" mm 4.5 (±0.5)
rear door cover See picture AR60.00-P-0700-
01SX
FRONT DOOR
Number Designation Model 221
BA72.10-P-1001-01Q Bolt, door hinge on front door Nm 32
BA72.10-P-1002-01Q Bolt, door hinge on A-pillar Nm 32
BA72.10-P-1004-01Q Bolt, locking eye to B-pillar Nm 28
Fig. 7: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
ADJUST FRONT DOOR - AR72.10-P-0550SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 8: Identifying Front Door Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
22.10.08 Value changed: Bolt, door hinge to front door *BA72.10-P-1012-01R
Value changed: Bolt, door hinge to a-pillar *BA72.10-P-1013-01R
Checking
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear of AS00.00-Z-
installing or aligning hoods, doors, moving parts. 0011-01A
trunk lids, liftgates or sliding roof
AR60.00-
P-0700-
Check gap dimensions on front door (1) 01SX
1 *BE60.00-
all the way round
P-1002-01R
Fig. 7
Adjust
Remove striker wedge (2) at bottom of
2
front door (1)
Mark installation position of locking eye
3 Remove lock striker (4)
(4), to facilitate reinstallation.
Do not support front door (1) on outer
Support front door (1) with floor jack
paneling, otherwise, the front door (1) can be
and suitable block of wood, position
4 damaged by its high dead weight.
below mounting location of striker
See GOTIS for NIKE passenger car floor jack
wedge (2)
http://gotis.aftersales.mercedes-benz.com
AR60.00-
P-0700-
Loosen screws (5) on A-pillar and Adjust gap dimensions at front door (1) by 01SX
5 adjust corresponding gap dimensions lifting or lowering floor jack. *BE60.00-
by moving front door (1) P-1002-01R
Fig. 7
*BA72.10-
6 Tighten screws (5)
P-1013-01R
Remove bolts (6) on front door (1) and
adjust transition between front fender The contour of the front fender must be
7 flush with the contour of the front door (1) or
and front door (1) by moving front door
(1) project by a maximum of 1 mm.
Tighten bolts (6), lower and remove *BA72.10-
8 See GOTIS for NIKE passenger car floor jack P-1012-01R
floor jack
http://gotis.aftersales.mercedes-benz.com
Insert lock striker (4) and screw in bolts It should still be possible to adjust the
9
(3) up to stop locking eye (4).
Adjust transition between front door (1) The contour of the front door (1) must be
10 and rear door by moving locking eye flush with the contour of the rear door or
(4). project by a maximum of 1 mm.
*BA72.10-
11 Tighten screws (3)
P-1015-01R
12
with suitable touch-up paint pen
13 Install striker wedge (2) Only tighten bolts on striker wedge (2)
hand-tight.
*BR00.45-
14 Coat oval head screw (7) with grease Multipurpose grease Z-1034-
06A
Carefully close and open front door (1)
and determine on basis of grease
impression on oval head screw (7),
The front door (1) is supported on the oval
whether height of striker wedge (2)
head screws (7) by the striker wedge (2) so that
15 requires correction by inserting shims.
If the front door (1) is hard to close or its entire dead weight is not on the locking eye
(4). The front door (1) should be easy to close.
cannot be closed at all, correct the
height of the striker wedge (2) by
removing shims
*BA72.10-
16 Tighten bolts on striker wedge (2)
P-1020-01R
CHECK VALUES FOR GAPS
Number Designation Model 221
BE60.00-P- Gap dimension Front door to A-pillar Dim. "D" mm 4.5 (±0.5)
1002-01R Front door to fender Dim. "E" mm 4 (±0.5)
Front door to rear door Dim. "F" mm 4.5 (±0.5)
Trim strip at front door to Dim. "G" mm 4.5 (±0.5)
roof frame
Trim strip at rear door to Dim. "H" mm 4.5 (±0.5)
roof frame
Rear door to side section, Dim. "I" mm 4.5 (±0.5)
bottom
Front door cover to rear Dim. "S" mm 4.5 (±0.5)
door cover See picture AR60.00-P-0700-
01SX
FRONT DOOR
Model 221 with
Number Designation code Z07/Z07+Z19
BA72.10-P-1012-01R Bolt, door hinge on front door Nm 40
BA72.10-P-1013-01R Bolt, door hinge on A-pillar Nm 40
BA72.10-P-1015-01R Bolt, locking eye to B-pillar Nm 28
BA72.10-P-1020-01R Bolt, closing wedge to front door Nm 5
Fig. 9: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1034-06A MB multipurpose grease A 001 989 34 51 10
COVER WINDOW FRAME ON FRONT DOOR WITH LEATHER - AR72.10-P-0600SXS
MODEL 221.1 with CODE (Z07) Top protection
Shown on right front door, vehicle with hydraulic power windows
Fig. 10: Identifying Leather, Sealing And Mirror Triangle Armor Plate
Courtesy of MERCEDES-BENZ USA
Fig. 11: Identifying Leather & Markings
Courtesy of MERCEDES-BENZ USA
Shown on right front door
Removing
Completely lower crank window in left or On vehicles with hydraulic power
1.1
right front door windows.
On vehicles with hydraulic power AR72.10-P-
2.1 Remove inner door panel on front door
windows. 0104SXS
On vehicles without hydraulic power
2.2 Remove window on left or right front door
windows.
3 Pull seal (2) off window frame
4 Remove mirror triangle armor plate (3)
AR72.10-P-
5 Remove door frame seal on front door
2120SXS
6 Pull leather (1) off window frame
Clean adhesive areas of seal (2) and leather *BR00.45-Z-
7 Pure benzine/benzine
(1) on window frame 1048-04A
Cover window frame
Lay out leather (1) with rear on suitable
8
surface
The marking (4) indicates the inner
Draw marking (4) with an interval of approx.
9 adhesive edge of the leather (1) at the
2 cm from inner edge on outside of leather (1)
bottom edge of the window frame.
window frame over entire surface with MB *BR00.45-Z-
10 MB special adhesive
special adhesive 1002-02A
Position leather (1) with marking (4) on inner
edge of window frame at rear corner (arrow) Ensure that bonding is wrinkle-
11
and smooth in both directions from the corner free.
with suitable tool
Bond leather (1) to inside area of window
frame. Then turn over on upper edge, again Ensure that bonding is wrinkle-
12
starting at rear corner (arrow) and smooth free.
starting from the corner
Bond leather (1) to window frame section for
13 section and step for step and smooth with Ensure that bonding is wrinkle-
free.
suitable tool
Draw a marking (5) outside of leather (1) at a
14 distance of approx. 14 mm from the upper
inner edge of the window frame
Cut off leather (1) along marking (5) with Repair paint damage to window
15
suitable blade frame with suitable touch-up paint pen.
Adapt leather (1) to contours of window
Ensure that bonding is wrinkle-
16 frame in area of mirror triangle and cut to
match course of window frame (picture A) free.
Adapt leather (1) to contours of window
Ensure that bonding is wrinkle-
17 frame in rear area of window frame and cut to
match course of window frame (picture B) free.
Coat inside of window frame and rear of *BR00.45-Z-
18 MB special adhesive
leather (1) with MB special adhesive 1002-02A
Turn over leather (1) on inner edge of
Ensure that bonding is wrinkle-
19 window frame to outside, smooth with
free.
suitable tool and cut off along outer edge
Install
Clean adhesive area of door frame seal on *BR00.45-Z-
20 Pure benzine/benzine
window frame 1048-04A
*BA72.10-P-
21 Install mirror triangle armor plate (3)
1009-01R
*BR00.45-Z-
22 Glue on seal (2) onto window frame MB special adhesive
1002-02A
AR72.10-P-
23 Install door frame seal on front door
2120SXS
On vehicles with hydraulic power AR72.10-P-
24.1 Install inner door panel on front door
windows. 0104SXS
On vehicles without hydraulic power
24.2 Install front door window
windows.
On vehicles with hydraulic power
25.1 Close crank window
windows.
FRONT DOOR
Model 221 with code
Number Designation Z07/Z07+Z19
BA72.10-P-1009-01R Bolt, mirror triangle armor plate on front door Nm 37
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-
Adhesive Terokal 2444 A 000 989 92 71
1002-02A
Otto Fischar GmbH &
Co. KG
Kaiserstrasse 221
BR00.45-Z- Pure benzine/benzine 100/140 (free of aromatic compounds), 66133 Saarbrucken
1048-04A 5-liter metal canister, article no.: 17042 Germany
Tel +49 681 98217-0
Fax: +49 681 98217-99
www.fischar.de
REMOVE/INSTALL DOOR MODULE - AR72.10-P-0900SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 12: Identifying Door Module Components (1 Of 2)
Riveted door module shown
Shown on model 221.0
Fig. 13: Identifying Door Module Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
18.3.09 Remove screwed door module, newly included Step 10.2
Remove/install
Remove crank window on left and AR72.10-P-
1
right front door (1) 1900SX
2 Remove paneling (3)
*BA72.10-
3 Remove bolts (4)
P-1006-01Q
Remove outer door handle from AR72.10-P-
4
front door (1) 2400SX
5 Take off seals (5)
Loosen bolts (6), slide bearing
6 bracket (7) toward front and unhook
front door (1).
Disconnect door wiring harness (8)
from left front door control unit
7 (N69/1) or right front door control
unit (N69/2) and from vehicle wiring
harnesses (9)
8 Unclip clip (10)
Do not disconnect vehicle wiring harnesses
(9) from left front door control unit (N69/1) or
Unscrew bolt (11) and remove left right front door control unit (N69/2)
front door control unit (N69/1) or
9 *BA72.10-
right front door control unit (N69/2)
and lay down to side. P-1011-01Q
*BR00.45-
Loctite 262
Z-1059-02A
As of 1.2.2009, the door module is screwed
to the inner door panel.
Fig. 14
10.1 Cut rivet heads out of rivets (12, 13) Installation: Fasten door module (2) to
front door (1) with new rivets (12, 13). Then Fig. 15
coat rivet heads (13) with sealing adhesive.
Hand riveting tool gotis://K_68-80_06.0
*BR00.45-
Sealant
Z-1013-02A
When screwing in the screws, start them by
hand, otherwise, the thread in the inner door
panel could be damaged.
If a door module is installed in a new door,
screw in the screws with a battery-powered
screwdriver. Do not tilt screw more than 10
10.2 Unscrew bolts degrees when screwing in, otherwise, leakage
may occur between the door module and inner
door panel.
Installation: Always replace screws.
Installation: Screws with larger diameter
are available from the Parts Department to
replace stripped screws.
AR72.10-P-
11 Remove door holder
2100SX
Loosen door module (2) from front Do not bend door module (2). Replace door
12
door (1) and remove module (2) if bent.
Press rivet residues out of rivets (12, On riveted door modules.
13
13) Fig. 16
Completely remove rivet residues Completely remove rivet residues on riveted
14 and drilling chips from front door door modules. Remaining rivet residues cause
(1). corrosion damage.
15 Install in the reverse order
FRONT DOOR
Number Designation Model 221
BA72.10-P-1006-01Q Bolt, door lock to front door Nm 7
BA72.10-P-1011-01Q Bolt, door control unit to door module Nm 5
Fig. 14: Identifying Rivet Milling Cutter (171 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
Fig. 15: Identifying Milling Bit Crown (171 589 00 39 01)
Courtesy of MERCEDES-BENZ USA
Fig. 16: Identifying Press-Out Tool (221 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013- Sealant 221, 310 ml, DB supply specification
A 001 989 64 20
02A 6069.20
Henkel Loctite Deutschland
GmbH
Arabellastrasse 17
BR00.45-Z-1059- 81925 Munchen
Loctite 262
02A Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
REMOVE/INSTALL FRONT DOOR LINING - AR72.10-P-1000SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 17: Identifying Front Door Lining Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 18: Identifying Front Door Lining Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Wind crank window fully down
Loosen mirror triangle cover (2) and lay
2 Fig. 19
down to side with line connected.
3 Remove cover (3) from door lining (2) Fig. 19
Disconnect connector (4) from left front
4 door control module (N69/1) or right
front door control module (N69/2)
5 Open armrest (5).
6 Slide cover (6) upward and remove
7 Unclip covering (7)
Installation: Apply screw securing Fig. 19
agent to bolt threads (8, 9).
8 Unscrew bolts (8, 9) *BA72.10-P-
1009-01Q
*BR00.45-Z-
Loctite 262
1059-02A
Move long wedge directly onto each
mounting clips and ensure that retaining lugs
Press door lining (1) on mounting clips on mounting clips do not tear out of door
9
off of inner door panel lining (1).
Fig. 19
Remove door lining (1) upward out of
10 guide (arrow) until Bowden cable (10)
is accessible.
Unhook Bowden cable (10) from inner
11
door opener (11)
12 Remove door lining (1)
13 Install in the reverse order
FRONT DOOR
Number Designation Model 221
BA72.10-P-1009-01Q Bolt, door lining to door module Nm 8
Fig. 19: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Henkel Loctite Deutschland GmbH
BR00.45-Z-1059-02A Loctite 262 Arabellastrasse 17
81925 Munchen
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
REMOVE/INSTALL FRONT DOOR LINING - AR72.10-P-1000SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 20: Identifying Front Door Lining Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to
AH67.00-P-
windows installed in special
0003-01FB
high-security vehicles
Switch off the ignition and
1 remove the transmitter key from
the EIS control unit
Clip cover (2) onto door lining
2 Fig. 19
(1) on left or right front door
Disconnect electrical connectors
(3, 4) from left front door control
3
unit (N69/1) or right front door
control unit (N69/2)
4 Remove bolts (5)
Remove hidden bolts (arrows) *BA72.10-
5
below armrest P-1011-01R
Insert long wedge immediately next to the
locking pins (6) and unclip locking pins (6)
Pry off door lining (1) at locking individually. Ensure that locking pins (6) do not tear
6
pins (6) on front door out of door lining (1).
Fig. 19
As soon as the door lining (1) is detached, ensure
Detach door lining (1) from front that the electrical wiring harness for the left front
7 door until release cable is door tweeter or right front door tweeter is not under
accessible too much tension. Otherwise, the left front door
tweeter or right front door tweeter can be damaged.
Unhook release cable from
8
inside door opener
Disconnect electrical connector
from left front door tweeter or
9
right front door tweeter and
remove door lining (1)
10 Install in the reverse order
FRONT DOOR
Model 221 with code
Number Designation Z07/Z07+Z19
BA72.10-P-1011-01R Bolt, door lining to inner door panel Nm 8
Fig. 21: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL DOOR FOIL ON FRONT DOOR - AR72.10-P-1010SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 22: Identifying Front Door Foil Components
Courtesy of MERCEDES-BENZ USA
Removing
Remove door lining from left or AR72.10-P-
1
right front door 1000SXS
Risk of injury caused by moving
parts that can pinch, crush or, in AS00.00-Z-
extreme cases, even sever No parts of the body or limbs should be 0009-01A
extremities within the operating range of the mechanism
Release pressure in pressure when moving components.
AR72.10-P-
2 reservoir for hydraulic power
1800-06SXS
window in front door
Remove door hydraulic power
3 window relay socket (K4/4) with
bracket (3)
Remove bracket (2) with left front
4 door woofer (H4/1h2) or right front
door woofer (H4/2h2)
Expose electrical wiring harness (4)
and disconnect connector from left
5 front door hydraulic power window
or right front door hydraulic power
window
Remove splitter protection strips (5) Cut through butyl cord on rear of splitter
6
on front door protection strips (5) with suitable blade.
7 Mark installation position of
(7)
Remove hydraulic lines (6) from Use only suitable stop plugs or lint-free
valve block (7). Then plug openings rags for plugging. Lint or contamination can
8
in hydraulic lines (6) and valve contaminate the hydraulic system and thereby
block (7) cause damage.
9 Remove mounting anchor (8)
Cut through butyl cord carefully and
Cut through butyl cord on rear of carefully separate door foil (1). Otherwise,
10
door foil (1) with suitable blade paint or the seal (9) behind the valve block (7)
can be damaged.
Install
When replacing the door foil (1) remove
remains of butyl cord from inner door panel,
Check door foil (1) for damage, door lock armor plate and seal (9) and clean
11
replace if necessary. bonding surface.
*BR00.45-Z-
Cleaner
1025-04A
If sections of the butyl cord are damaged,
replace only the damaged section. Route new
butyl cord parallel to the damaged butyl cord
on the door foil (1). Previously clean bonding
Inspect butyl cords for damages, surface.
12
replace if necessary
*BR00.45-Z-
Sealing cord
1086-01A
*BR00.45-Z-
Cleaner
1025-04A
Ensure that door foil (1) is correctly
Align door foil (1) on front door and positioned on front door.
13
roll on
Fig. 23
Coat corresponding screws with thread
sealant and tighten in a number of cycles. The
butyl cord then settles on the rear.
14 Install splitter protection strips (5) *BA72.10-P-
1006-01R
*BR00.45-Z-
Loctite 577
1067-01A
Connect left front door hydraulic
power window connector or right
15 front door hydraulic power window
connector and route electrical
wiring harness (4)
Attach hydraulic lines (6) to valve *BA72.10-P-
16
block (7) 1002-01R
door woofer (H4/1h2) or right front of cycles. The butyl cord will still settle.
17
door woofer (H4/2h2)
Install door hydraulic power
Tighten appropriate screws in a number
18 window relay socket (K4/4) with
of cycles. The butyl cord will still settle.
bracket (3)
19 Install mounting anchor (8)
AR72.10-P-
20 Install door lining in front door
1000SXS
Check fill level of power window
21
hydraulic pump; correct if necessary
Power window system - check oil AP67.30-P-
level 6710SX
FRONT DOOR
Model 221 with code
Number Designation Z07/Z07+Z19
BA72.10-P-1002-01R Bolt, hydraulic line to valve block Nm 7
BA72.10-P-1006-01R Bolt on front door splinter guard Nm 8
Fig. 23: Identifying Roller (168 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Henkel Loctite Deutschland
GmbH
Arabellastrasse 17
BR00.45-Z- 81925 Munchen
Loctite 577
1067-01A Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
1025-04A Cleaner A 005 989 19 71
DISASSEMBLE/ASSEMBLE FRONT DOOR LINING - AR72.10-P-1030SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 24: Identifying Front Door Lining Components
Courtesy of MERCEDES-BENZ USA
Shown on left door lining
Disassemble/assemble
Lay door lining (1) front side down on AR72.10-P-
1 Remove door lining (1) from front door
suitable subsurface to prevent damage 1000SX
Remove door pocket (5) front door AR72.10-P-
2
lining (1) 1045SX
Remove trim strip (2) from front door AR72.10-P-
3
lining (1) 1050SX
Remove inside door opener (3) from AR72.10-P-
4
front door lining (1) 2420SX
Remove electric wiring harness (6) at
5
rear of door lining (1).
6 Assemble in reverse order
REMOVE/INSTALL ARMREST ON FRONT DOOR - AR72.10-P-1033SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 25: Identifying Front Door Armrest Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove door lining (1) from Lay door lining (1) front side down on suitable AR72.10-P-
1
front door subsurface to prevent damage 1000SX
Unscrew screws (4) on
2
covering (2)
Unscrew bolts (5) from
3
armrest (3).
Raise cover (2) and remove
4
armrest (3).
5 Install in the reverse order
REMOVE/INSTALL DOOR POCKET ON FRONT DOOR LINING - AR72.10-P-1045SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 26: Identifying Front Door Pocket Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 27: Identifying Front Door Pocket Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 28: Identifying Front Door Pocket Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Removal
Lay door lining (2) front side AR72.10-P-
1 Remove door lining (2) from front door down on suitable subsurface to
1000SX
prevent damage
On vehicles with code (595) Heat and
noise insulating infrared-reflective
Detach insulating mat (6) in area of plastic spot
2.1 laminated glass for rear and side
welds (3, 12, 13).
windows or code (596) Heat-
insulating glass
AR72.10-P-
3 Remove armrest (4)
1033SX
Disconnect electrical connector from driver
power window, outside mirror and trunk lid
4
switch group (S20/1) or front passenger power
window switch (21/2) and remove cover (5).
Remove left front door entrance/exit lamp
(E17/3) or right front door entrance/exit lamp
5
(E17/4) and guide electrical line to rear of door
lining (2).
Remove front left door warning lamp (E17/19)
6 or front right door warning lamp (E17/21) and
guide electrical line to rear of door lining (2).
When initially removing door pocket
Knock plastic spot welds (3, 12, 13) off of with (1).
7.1
chisel (11) Flat side of chisel blade (11)
Use chisel (11) with a blade width of
10 mm according to DIN 5139.
Bend open clamping plates (10, 14, 16) with When removing door pocket (1) a
7.2
suitable screwdriver and remove from pins (9) second time
8 Remove door pocket (1) from door lining (2).
Install
If the door pocket (1) has already
been removed, replace door pocket.
9 Insert door pocket (1) in door lining (2)
Ensure that door pocket (1) is seated
properly on door lining (2).
Install new clamping plates (10,
14, 16). Use suitable socket wrench to
Press clamping plates (10, 14, 16) over pins (9, press down clamping plates (10, 14,
10 16).
15, 17) on door pocket (1).
The clamping plates (10, 14, 16)
should make firm contact with door
lining (2).
Shorten pins (9, 15, 17) down to approx. 2 mm
When initially replacing door pocket
11.1 above clamping plates (10, 14, 16) with side
(1).
cutting pliers.
Install left front door entrance/exit lamp (E17/3)
12
or right front door entrance/exit lamp (E17/4)
Install front left door warning lamp (E17/19) or
13
front right door warning lamp (E17/21)
Connect electrical connector to driver power
window, outside mirror and trunk lid switch
14 group (S20/1) or front passenger power window
switch (21/2) and position cover (5) on door
lining (2).
AR72.10-P-
15 Install armrest (4)
1033SX
On vehicles with code (595) Heat and
noise insulating infrared-reflective
laminated glass for rear and side
16.1 Glue insulating mat (6) onto the door lining (2). windows or code (596) Heat-
insulating glass
*BR00.45-Z-
Special glue
1002-02A
AR72.10-P-
17 Install door lining (2)
1000SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1002-02A Adhesive Terokal 2444 A 000 989 92 71
REMOVE/INSTALL TRIM STRIP ON FRONT DOOR LINING - AR72.10-P-1050SX
MODEL 221.0 /1
Fig. 29: Identifying Front Door Lining Trim Strip Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Lay door lining (1) front side down on
suitable subsurface to prevent damage
1 Remove door liner (1) from front door Vehicles without code (Z07) Top protection AR72.10-P-
1000SX
AR72.10-P-
Vehicles with code (Z07) Top protection
1000SXS
On vehicles with code (595) Heat and noise
insulating infrared reflecting laminated glass
Loosen sound deadening mat (2) from for rear and side windows or with code (596)
2.1 door lining (1) until bolts (3) are Heat insulating glass
accessible.
Installation: Glue insulating mat (2) to *BR00.45-Z-
door lining (1). 1002-02A
Remove left front door inside handle
illumination (E17/11) or right front
3
door inside handle illumination
(E17/12)
Disconnect electrical connector from On vehicles with code (876) interior light
4.1
trim strip (4). package
5 Remove bolts (3)
6 Remove trim strip (4)
7 Install in the reverse order
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1002-02A Adhesive Terokal 2444 A 000 989 92 71
REMOVE/INSTALL SEAL (TOP) ON FRONT DOOR WINDOW FRAME - AR72.10-P-1550SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 30: Identifying Front Door, Trim & Seal Strip
Courtesy of MERCEDES-BENZ USA
Remove
1 Open front door (1)
Loosen sealing (2) on upper window frame (arrow
2
A) and front window frame (arrow B)
3 Pull sealing (2) out of trim strip (3).
Install
Ensure that sealing (2) is
Coat trim strip (3) with lubricant and install sealing seated correctly.
4
(2) in trim strip (3). *BR00.45-Z-
Antifriction agent
1010-06A
5 Close front door (1).
REPAIR MATERIALS
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL SEAL (TOP) ON FRONT DOOR WINDOW FRAME - AR72.10-P-1550SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 31: Identifying Sealing & Trim Strip
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to
AH67.00-P-
windows installed in special high-
0003-01FB
security vehicles
1 Open left or right front door
Detach seal (1) from window frame
2
at top (arrow A) and front (arrow B)
Installation: Coat trim strip (2) with
liquid lubricant. Ensure that seal (1) is seated
3 Pull seal (1) out of trim strip (2). properly in trim strip (2).
*BR00.45-Z-
Antifriction agent
1010-06A
4 Install in the reverse order
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL TRIM STRIP ON FRONT DOOR WINDOW FRAME - AR72.10-P-1710SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 32: Identifying Front Door Window Frame Trim Strip Components
Courtesy of MERCEDES-BENZ USA
Shown on left front door
MODIFICATION NOTES
23.9.05 Riveter changed Step 11
Remove/install
AR72.10-P-
1 Remove sealing (2) from trim strip (1).
1550SX
2 Completely lower crank window
Remove left electrically adjustable and
Fig. 3
heated outside mirror (M21/1) or right
electrically adjustable and heated outside
3
mirror (M21/2), lay down inside with *BA88.70-
electrical line connected and mirror P-1001-01C
triangle seal (3) detached.
Cover door lining and left electrically
(M21/1) or right electrically adjustable
and heated outside mirror (M21/2) to
4
protect against drilling chips falling
down.
5 Remove outer sealing rail (4) Fig. 3
Do not pull door frame seal (6) downward
Pull door frame seal (6) downward in too forcefully, otherwise the glued door frame
6 areas of rivets (9) and fasten with strips seal (6) can detach from the window frame.
of adhesive tape (7). This prevents damaging the door frame
seal (6) when drilling out the rivets (9) later.
Mask gap between door frame seal (6)
This ensures that no chips or drilling
7 and window frame over entire length
residues fall into the gap.
with strips of adhesive tape (8).
Mask end of rivet (10) from inside with This ensures that the end of the rivet does
8
strips of adhesive tape not fall into the front door when drilling out.
Mask A-pillar opposite rivet (10) with Otherwise the paint on the A-pillar can be
9
strips of adhesive tape. damaged when drilling out the rivet (10).
Do not drill through rivets (9, 10) to
Drill out rivet heads on rivets (9, 10) prevent damaging the window frame.
10
with dia. 3.5 mm bit. Manual pliers, see GOTIS
http://gotis.aftersales.mercedes-benz.com
Remaining rivet residues cause corrosion
11 Completely remove rivet residues.
damage.
Installation: Repair paint damage on
Loosen trim strip (1) and remove from window frame before assembly.
12
window frame.
Fig. 3
13 Install in the reverse order
OUTSIDE MIRRORS
Number Designation Model 221
BA88.70-P-1001-01C Screw for outside rearview mirror on front door Nm 2
Fig. 33: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TRIM STRIP ON FRONT DOOR WINDOW FRAME - AR72.10-P-1710SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 34: Identifying Trim Strip, Door Sealing Frame And Rivet
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to
AH67.00-P-
windows installed in special high-
0003-01FB
security vehicles
Remove top seal on window frame AR72.10-P-
1
on left or right front door 1550SXS
Do not pull door frame seal (2) down with too
Pull door frame seal (2) downward
much force, otherwise, it detaches from the
in area of rivets (3) and fasten with
2 window frame.
suitable adhesive tape to window
frame This prevents damaging the door frame seal
(2) when drilling out rivets (3) later.
Mask off gap between door frame
seal (2) and window frame over This prevents drilling chips and rivet residues
3
entire length with suitable adhesive from falling into gap.
tape
Mask off A-pillar across front rivet This prevents damage to the paint on the A-
4
(3) with suitable adhesive tape pillar.
Do not drill through rivets (3), otherwise, the
Drill out rivet heads (3) with drill window frame is damaged.
5
bit (3.5 mm dia.) See GOTIS for manual pliers, cordless drill/ diver
http://gotis.aftersales.mercedes-benz.com
Complete remove rivet residues and Any rivet residues and chips remaining cause
6
chips corrosion damage.
Installation: Repair paint damage on window
Loosen trim strip (1) and remove frame with suitable touch-up paint pen.
7
from window frame
Fig. 3
8 Install in the reverse order
Fig. 35: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL DOOR JOINT SEAL ON FRONT DOOR - AR72.10-P-1780SX
MODEL 221.0 /1
Fig. 36: Identifying Front Door & Sealing
Courtesy of MERCEDES-BENZ USA
Removing
AR72.10-P-
Vehicles without code (Z07) Top protection
0500SX
1 Remove front door (1)
AR72.10-P-
Vehicles with code (Z07) Top protection
0500SXS
Bonding surface must be free of grease and
dust
Remove sealing (2) and clean Removal disk, 100 mm dia. with fixing shank, 3M
2 Deutschland GmbH D-41453 Neuss
bonding surface with eraser disc
Drill, see GOTIS
http://gotis.aftersales.mercedes-benz.com
*BR00.45-Z-
Cleaner
1025-04A
Notes on removing glue residues
AH00.00-P-
and foils on paint and metal
0013-01AK
surfaces with eraser disc
Install
Glue on sealing (2) from bottom
3 Fig. 37
upward and roll on
AR72.10-P-
Vehicles without code (Z07) Top protection
0500SX
4 Install front door (1)
AR72.10-P-
Vehicles with code (Z07) Top protection
0500SXS
Fig. 37: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
RELEASE PRESSURE IN PRESSURE RESERVOIR FOR HYDRAULIC POWER WINDOW IN
FRONT DOOR - AR72.10-P-1800-06SXS
When relieving the pressure in the pressure reservoir for the hydraulic power window on the front door,
ensure that the transmitter key is removed from the EIS control unit.
1. Open front door and remove emergency operation handle (1) from door lining.
The emergency operation handle (1) serves for manual actuation of the hydraulic valves in the block
valve (2) for lifting and lowering the crank window.
Fig. 38: Releasing Pressure In Pressure Reservoir
Courtesy of MERCEDES-BENZ USA
2. Attach emergency operation handle (1) to bottom valve actuation, pull upward and hold until crank
window is fully lowered.
3. Attach emergency operation handle (1) to upper valve actuation, pull down and hold until crank window
is fully rolled up.
4. Roll crank window up and down until it stops indicating that the pressure in the pressure reservoir is
completely relieved.
Rolling the crank window up and down causes the hydraulic oil to flow out of hydraulic reservoir
back into the power window hydraulic pump.
REMOVE/INSTALL FRONT DOOR WINDOW LIFTER - AR72.10-P-1800SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 39: Identifying Front Door Window Lifter Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
17.8.06 Tool changed Steps 3.1, 3.2
Remove/install
Remove door module (1) from left AR72.10-P-
1
and right front door. 0900SX
Remove left front power window
AR72.29-P-
2 motor (M10/3) or right front power
1860SX
window motor (M10/4)
When initially removing power window (3).
Drill out rivet heads (2) with 6.5 mm Installation: Fasten power window (3) to
3.1 door module (1) with new rivets (2).
dia. bit.
Manual pliers, see GOTIS
http://gotis.aftersales.mercedes-benz.com
When repeatedly removing power window (3).
Fig. 14
3.2 Cut rivet heads out of rivets (2). Installation: Fasten power window (3) to
door module (1) with new rivets (2). Fig. 15
Manual pliers, see GOTIS
http://gotis.aftersales.mercedes-benz.com
Remove power window (3) from door
4
module (1).
5 Install in the reverse order
Fig. 40: Identifying Rivet Milling Cutter (171 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
Fig. 41: Identifying Milling Bit Crown (171 589 00 39 01)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL FRONT DOOR WINDOW LIFTER - AR72.10-P-1800SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 42: Identifying Front Door Window Lifter Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 43: Identifying Front Door Window Lifter Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury from pinching or
Secure windows against dropping; use only AS67.00-Z-
crushing hands and feet when
specified lifting tools; wear safety shoes. 0003-01A
working on windows.
Notes on avoiding damage to
AH67.00-P-
windows installed in special high-
0003-01FB
security vehicles
Completely close crank window (2) Ensure that the door frame seal on the front
on left or right front door and door is not damaged when supporting.
1
secure against falling down with
clamping pliers Fig. 44
Remove door foil (3) from front AR72.10-P-
2
door 1010SXS
Remove inner door panel (4) from AR72.10-P-
3
front door 0104SXS
Remove bolts (5) and remove door Cut through butyl cord on rear of door lock
4
lock armor plate (6) armor plate (6) with suitable blade.
Remove bolts (7) and remove
5
retaining rails (8)
Remove bolts (9) and remove
6
power window (1) from front door
Install
Position power window (1) in front *BA72.10-P-
7
door and tighten bolts (9) 1004-01R
*BA72.10-P-
8 Align power window (1) and crank 1003-01R
another, position retaining rails (8) *BR00.45-Z-
Loctite 270 sealant
and tighten bolts (7) 1008-02A
9 Remove clamping pliers Fig. 44
If sections of the butyl cord are damaged,
replace only the damaged section. Route new
butyl rubber cord parallel to damaged butyl cord.
Check butyl cord on rear of door Previously clean bonding surface.
10 lock armor plate (6) for damage,
replace if necessary *BR00.45-Z-
Sealing cord
1086-01A
*BR00.45-Z-
Cleaner
1025-04A
Coat bolts (5) with sealer.
*BA72.10-P-
Position door lock armor plate (6)
11 1019-01R
on front door and tighten bolts (5)
*BR00.45-Z-
Loctite 577
1067-01A
Install inner door panel (4) on front AR72.10-P-
12
door 0104SXS
When power window (1) has been replaced.
Check adjustment of hydraulic When the crank window (2) is rolled up
completely, the hydraulic power window doors
13.1 power window doors limit switch
(S21/24), correct if required limit switch (S21/24) must be depressed, if
necessary, loosen bolts (10) and correct
adjustment.
AR72.10-P-
14 Install door foil (3) on front door
1010SXS
FRONT DOOR
Model 221 with
Number Designation code Z07/Z07+Z19
BA72.10-P-1003-01R Screw for window lift on crank window Nm 23
BA72.10-P-1004-01R Bolt, power window on front door Nm 23
BA72.10-P-1019-01R Bolt, door lock armor plate on front door Nm 8
Fig. 44: Identifying Chuck (220 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Henkel Loctite Deutschland
GmbH
Arabellastrasse 17
BR00.45-Z- 81925 Munchen
Loctite 577
1067-01A Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
BR00.45-Z-
Quick-acting adhesive, Loctite 270 A 002 989 93 71
1008-02A
BR00.45-Z-
Cleaner A 005 989 19 71
1025-04A
REMOVE/INSTALL CRANK WINDOW IN FRONT DOOR - AR72.10-P-1900SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 45: Identifying Crank Window Components
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury due to hands being crushed when Secure window to prevent it AS67.00-Z-
window glass is not secure from falling down. 0002-01A
Do not yet disconnect AR72.10-P-
1 Remove door lining from left or right front door
electrical connectors. 1000SX
2 Remove covers (3) from access openings.
Switch on ignition and move crank window (1) up After moving up crank
3
until bolts (4) are accessible. window (1), switch off ignition.
Disconnect connector from left front door control
AR72.10-P-
4 unit or right front door control unit and remove door
1000SX
lining from working area.
5 Remove bolts (4)
6 Remove inner sealing rail (2) Fig. 3
Mask inner edge of window channel to protect crank
7
window (1).
Remove crank window (1) from window channel in
8
front door
Install
Insert crank window (1) into window channel of
9
front door
Remove adhesive tape from window channel of
10
crank window (1).
Screw bolts (4) into front and rear window mount Position bolt (4) only so
11 that crank window (1) can still
(5).
be moved.
12 Install inner sealing rail (2)
Connect connector with left front door control unit AR72.10-P-
13
or right front door control unit 1000SX
Switch on ignition and move crank window (1) The crank window (1) is
14
upward to stop fastened during this operation
Move crank window (1) down until bolts (4) are After moving down crank
15
accessible window (1) switch off ignition.
*BA72.10-P-
16 Tighten bolts (4)
1012-01Q
17 Install covers (3)
AR72.10-P-
18 Install door lining in front door
1000SX
FRONT DOOR
Number Designation Model 221
Fig. 46: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CRANK WINDOW IN FRONT DOOR - AR72.10-P-1900SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 47: Identifying Front Door Crank Window Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury from pinching
Secure windows against dropping; use only specified AS67.00-Z-
or crushing hands and feet
lifting tools; wear safety shoes. 0003-01A
when working on windows.
Notes on avoiding damage to
AH67.00-P-
windows installed in special
0003-01FB
high-security vehicles
Completely close crank Ensure that the door frame seal on the front door is
not damaged when supporting.
front door and secure against
1 falling down with clamping Fig. 44
pliers
Remove inner door panel (2) AR72.10-P-
2
from front door 0104SXS
Cut through butyl cord on rear of door lock armor
plate (4) with suitable blade.
Installation: Check butyl cord on rear of door
lock armor plate (4) for damage, replace if necessary.
If sections of the butyl cord are damaged, replace only
the damaged section. Route new butyl rubber cord
parallel to damaged butyl cord. Previously clean
bonding surface.
Remove bolts (3) and remove Coat bolts (3) with sealer.
3
door lock armor plate (4)
*BA72.10-
P-1019-01R
*BR00.45-
Loctite 577
Z-1067-01A
*BR00.45-
Sealing cord
Z-1086-01A
*BR00.45-
Cleaner
Z-1025-04A
*BA72.10-
Remove bolts (5) and remove P-1003-01R
4
retaining rails (6) *BR00.45-
Loctite 270 sealant
Z-1008-02A
Completely lower power
window using emergency Position emergency operation handle on lower
5
actuation on valve block (7) valve actuation on valve block (7) and pull upward.
and cover
Installation: Ensure that door handle cover armor
plate (9) is properly installed in the window guide rail
Remove screws (8) and remove and is flush with the crank window (1), otherwise, the
6 door handle cover armor plate window guide seal in the window guide rail is
(9) damaged.
*BA72.10-
P-1005-01R
Detach clamping pliers and Aid of helper required.
7 carefully lower crank window
(1) Fig. 44
Lift crank window (1) in rear
Aid of helper required.
area, tilt upward and remove
8 Installation: Ensure that crank window (1) is
from front door upward and
outward properly seated in window guide rails.
9 Install in the reverse order
FRONT DOOR
Model 221 with
Number Designation code Z07/Z07+Z19
BA72.10-P-1003-01R Screw for window lift on crank window Nm 23
BA72.10-P-1005-01R Bolt, door handle cover armored plate on crank Nm 23
window
BA72.10-P-1019-01R Bolt, door lock armor plate on front door Nm 8
Fig. 48: Identifying Chuck (220 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Henkel Loctite Deutschland
GmbH
Arabellastrasse 17
BR00.45-Z- 81925 Munchen
Loctite 577
1067-01A Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
BR00.45-Z-
Quick-acting adhesive, Loctite 270 A 002 989 93 71
1008-02A
BR00.45-Z-
Cleaner A 005 989 19 71
1025-04A
REMOVE/INSTALL DOOR HOLDER - AR72.10-P-2100SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 49: Identifying Door Holder Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR72.10-P-
1 Remove front door lining
1000SX
Carefully unclip door holder (2), if
Press door holder (2) off of bracket
2 necessary use rag to protect against paint
(3) with suitable screwdriver.
damage.
*BA72.10-P-
1008-01Q
3 Unscrew screw (4)
*BR00.45-Z-
Loctite 262
1059-02A
Installation: Moisten grommets in front
Remove door holder (2) from door door with lubricant to facilitate installation.
4
module (1) toward rear. *BR00.45-Z-
Antifriction agent
1010-06A
5 Install in the reverse order
FRONT DOOR
Number Designation Model 221
BA72.10-P-1008-01Q Bolt, door holder to door module Nm 25
REPAIR MATERIALS
Number Designation Order number
Arabellastrasse 17
81925 Munchen
Germany
BR00.45-Z-1059-02A Loctite 262
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL DOOR HOLDER - AR72.10-P-2100SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 50: Identifying Door Holder Components
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury caused by fingers being
pinched or crushed when removing, installing Keep body parts and limbs well clear AS00.00-Z-
or aligning hoods, doors, trunk lids, tailgates or of moving parts. 0011-01A
sliding roof.
When working on unsecured front door, ensure
that it does not swing completely open,
otherwise, the front door and front fenders can
be damaged.
Remove inner door panel (2) from left or right AR72.10-P-
1
front door 0104SXS
Remove bracket (3) with left front door woofer
2
(H4/1h2) or right front door woofer (H4/2h2)
Cut through butyl cord on rear of
3 Remove door foil (4) in front area of front door
door foil (4) with suitable blade.
Pry off door holder (1) of ball head bolt (5) on
4 Fig. 3
front door
Pry off door holder (1) of ball head bolt (6) on
5 Fig. 3
A-pillar
This allows the door holder (1) to
be pulled through the grommet (7)
Moisten grommet (7) and front part of door
6 more easily.
holder (1) with liquid lubricant
*BR00.45-Z-
Antifriction agent
1010-06A
Pull door holder (1) carefully toward inside Counterhold grommet (7)
7 through grommet (7) and remove from front from inside; otherwise, it can separate
door from the front door or be damaged.
Install
Moisten grommet (7) and front part of door *BR00.45-Z-
8 Antifriction agent
holder (1) with liquid lubricant 1010-06A
Counterhold grommet (7) from
Insert door holder (1) into front door and
9 outside; otherwise, it can separate
carefully press outward through grommet (7)
from the front door or be damaged.
Press door holder (1) onto ball head bolt (6) on Ensure that door holder (1) is
10
A-pillar properly seated on ball head bolt (6).
Press door holder (1) onto ball head bolt (5) on Ensure that door holder (1) is
11
front door properly seated on ball head bolt (5).
AR72.10-P-
12 Install inner door panel (2) on front door
0104SXS
Attach bracket (3) with left front door woofer
13
(H4/1h2) or right front door woofer (H4/2h2)
AR72.10-P-
14 Install door lining in front door
1000SXS
Fig. 51: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL DOOR FRAME SEAL - AR72.10-P-2120SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 52: Identifying Door Frame Seal Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
20.7.06 Position of door sealing frame sealing lip in relation to upper seal Step 7
Removing
Remove door liner (1) from front AR72.10-P-
1
door 1000SX
Remove inner paneling (2) from AR72.10-P-
2
window frame. 6580SX
3 Remove trim panel (3)
Completely remove door frame
4
seal (4) from front door.
Bonding surface must be free of grease and
dust
Remove glue residues from front Removal disk, 100 mm dia. with fixing shank, 3M
5 door and clean bonding surface Deutschland GmbH D-41453 Neuss
with eraser disc. Hand drill, refer to GOTIS
http://gotis.aftersales.mercedes-benz.com
Cleaner
1025-04A
Notes on removing glue residues
AH00.00-P-
and foils on paint and metal
0013-01AK
surfaces with eraser disc
Install
Ensure that door frame seal (4) is seated
Glue door frame seal (4) onto correctly.
6
front door and roll on
Fig. 37
Position sealing lip on door Sealing lip on door sealing frame (4) must be
7 sealing frame (4) in relation to located above the upper seal.
upper seal. Fig. 19
8 Install paneling (3)
Install inner paneling (2) on AR72.10-P-
9
window frame 6580SX
AR72.10-P-
10 Install door liner (1) on front door
1000SX
Fig. 53: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 54: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
REMOVE/INSTALL DOOR FRAME SEAL - AR72.10-P-2120SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 55: Identifying Door Frame Seal Components
Courtesy of MERCEDES-BENZ USA
Removing
Notes on avoiding damage
to windows installed in AH67.00-P-
special high-security 0003-01FB
vehicles
Remove door lining from AR72.10-P-
1
left or right front door 1000SXS
The paneling (2) is glued on and is damaged when
2 Remove paneling (2) removed.
Fig. 19
Completely remove door
3 frame seal (1) from front
door
The bonding surfaces must be absolutely free of grease
and dust.
Dia. 100 mm removal disk with mounting shaft
Remove adhesive residues
3M Deutschland GmbH D-41453 Neuss
4 on front door and clean
Hand drill, refer to GOTIS
bonding surfaces
http://gotis.aftersales.mercedes-benz.com
*BR00.45-
Cleaner
Z-1025-04A
Notes on removing
adhesive residues and foils
AH00.00-P-
on paint and metal surfaces
0013-01AK
with surface conditioning
disks
Install
The door frame seal (1) must run parallel to the front
Align door frame seal (1) splitter protection strip on the front door. Ensure that the
5 on front door, glue on and door frame seal (1) is properly seated on the seal (3) at the
roll on top of the window frame.
Fig. 37
Observe instructions for using primer precisely. This is
the only way to ensure a reliable and durable adhesive
Pretreat bonding surfaces connection.
on front door with primer
6 *BR00.45-
and glue on new paneling Primer
Z-1030-02A
(2)
*BR00.45-
Double-sided adhesive tape
Z-1075-02A
Install door lining in front AR72.10-P-
7
door 1000SXS
Fig. 56: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 57: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1030-
Scotch 3M 4297 Primer A 004 989 29 71
02A
Henkel Loctite Deutschland
Teroson double-sided adhesive tape GmbH
For bonding trim strips and emblems (UV-resistant and Arabellastrasse 17
BR00.45-Z-1075- weatherproof, black) 81925 Munich
02A (Width: 12 mm) Order no.: 107.64 A Germany
(Width: 19 mm) Order no.: 107.96 K Tel. +49-89-9268-0
(Width: 25 mm) Order no.: 117.05 Y Fax + 49-89-9101978
www.Loctite.de
BR00.45-Z-1025-
Cleaner A 005 989 19 71
04A
REMOVE/INSTALL OUTSIDE DOOR HANDLE ON FRONT DOOR - AR72.10-P-2400SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0 with code (889) Keyless Go
Fig. 58: Identifying Outside Door Handle Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove outer door handle guide *BA72.10-
1
from front door P-1005-01Q
On vehicles without code (889) Keyless go
Pull outer door handle (1) out of
2.1 bearing bracket (5) toward rear and Installation: Ensure that seals (3) are seated
correctly on front door and outer door handle (1)
remove
in bearing bracket.
On vehicles with code (889) Keyless go
Arrest connection (4) of electrical connector
Pull outer door handle (1) out of (2) on bearing bracket (5) in assembly position
bearing bracket (5) toward rear, Installation: After connecting electrical
2.2
disconnect electrical connector (2) connector (2), unlock connection (4) on bearing
and remove outer door handle (1) bracket (5) and press inward. Ensure that seals (3)
are seated correctly on front door and outer door
handle (1) in bearing bracket
3 Install in the reverse order
FRONT DOOR
Number Designation Model 221
BA72.10-P-1005-01Q Bolt, lock cylinder guide to front door Nm 3
REMOVE/INSTALL OUTSIDE DOOR HANDLE ON FRONT DOOR - AR72.10-P-2400SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 59: Identifying Outer Door Handle & Guide
Courtesy of MERCEDES-BENZ USA
Remove/install
right front door, loosen screw beneath and 1016-01R
1
remove outer door handle guide (2)
Installation: Ensure that seals are
Pull outer door handle (1) out of bearing
2 seated correctly on front door and outer
bracket toward rear and remove
door handle (1) in bearing bracket.
3 Install in the reverse order
FRONT DOOR
Model 221 with code
Number Designation Z07/Z07+Z19
BA72.10-P-1016-01R Bolt, guide of lock cylinder to front door Nm 3
REMOVE/INSTALL FRONT DOOR INSIDE DOOR OPENING - AR72.10-P-2420SX
MODEL 221.0/ 1
Fig. 60: Identifying Front Door Inside Door Opening Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove trim strip from door lining (1) on AR72.10-P-
1
front door 1050SX
On vehicles with code (595) Heat and
noise insulating infrared reflecting
laminated glass for rear and side
Loosen insulating mat (2) on door lining (2) windows or with code (596) Heat
2.1
until inside door opener (3) is accessible. insulating glass
Installation: Glue insulating mat *BR00.45-
(2) to door lining (1). Z-1002-02A
3 Unscrew bolts (4, 5) Rechargeable drill/screwdriver
Remove left front seat operation switch group
(S22) with left interior CL switch (S85/5) or
Do not disconnect electrical
4 right front seat operation switch group (S23)
connector (6).
with right interior CL switch (S85/6) from
door lining (1).
Remove inside door opener (3) from door
5
lining (1).
6 Install in the reverse order
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1002-02A Adhesive Terokal 2444 A 000 989 92 71
REMOVE/INSTALL FRONT DOOR LOCK - AR72.10-P-4011SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 61: Identifying Front Door Lock Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
12.9.05 Clearance in door lock Model 221 *BE72.10-P-1001-01G
Remove
AR72.10-P-
1 Remove door module (3)
0900SX
Remove electric wiring harness (2)
2
from door lock (1).
Unclip door lock (1) from door lock
3
bracket (4).
Unclip bearing bracket (6) from door
4.1 When replacing door lock (1)
lock (1)
5.1 Remove cover (8) When replacing door lock (1)
Unhook Bowden cables (9, 10) from
6.1 When replacing door lock (1)
locking bar (13) on door lock (1)
Install
(1) Hook locking bar (13) into upper hole
7.1
in safety lever on door lock (1).
Hook Bowden cables (9, 10) into door
8.1 When replacing door lock (1)
lock (1)
9.1 Install bearing bracket (6) on door lock When replacing door lock (1)
Install door handle (5) in bearing
10.1 When replacing door lock (1)
bracket (6).
Install door handle guide (14) in
11.1 When replacing door lock (1)
bearing bracket (6).
When replacing door lock (1)
Adjust clearance (A) on adjusting screw *BE72.10-P-
12.1 Lift anti-twist lock on bearing bracket 1001-01G
(7)
(6) to turn adjusting screw (7).
13.1 Install new cover (8) When replacing door lock (1)
Remove door handle (5) from bearing
14.1 When replacing door lock (1)
bracket (6).
Remove door handle guide (14) from
15.1 When replacing door lock (1)
bearing bracket (6).
Install door lock (1) on door lock Ensure that grommets (11, 12) are
16
bracket (4). seated correctly in door module (3).
Install electric wiring harness (2) on
17
door lock (1).
AR72.10-P-
18 Install door module (3)
0900SX
TEST VALUES FOR FRONT DOOR
Number Designation Model 221
BE72.10-P-1001-01G Clearance in door lock mm 1.3 (+0.3)
REMOVE/INSTALL FRONT DOOR LOCK - AR72.10-P-4011SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 62: Identifying Front Door Lock Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove inner door panel (2) AR72.10-P-
1
from left or right front door 0104SXS
Cut through butyl cord on rear of door lock armor
plate (3) with suitable blade.
Installation: Check butyl cord on rear of door lock
armor plate (3) for damage, replace if necessary. If
sections of the butyl cord are damaged, replace only the
damaged section. Clean surface to be glued. Coat rear
screws with sealant.
Remove door lock armor
2 *BA72.10-
plate (3)
P-1019-01R
*BR00.45-
Loctite 577
Z-1067-01A
*BR00.45-
Sealing cord
Z-1086-01A
*BR00.45-
Cleaner
Z-1025-04A
Installation: Check clearance (A) and, if necessary,
Loosen adjusting nuts (4), adjust with adjusting nuts (4) on Bowden cable (5). For
from bracket (6) and unhook is felt and measure clearance (A) between outer door
from door lock (1) handle guide (13) and outer door handle (12).
3
*BE72.10-P-
Clearance
1001-01H
Pull off window guide seal Installation: Glue in window guide seal (7) into
(7) on rear window guide rail window guide rail (8).
4
(8) until screws (9, 10) are *BR00.45-
accessible MB special adhesive
Z-1002-02A
Installation: Completely remove adhesive residues
from window guide rail (8) and clean adhesive area.
Remove bolts (9, 10) and *BA72.10-
5
remove window guide rail (8) P-1007-01R
*BR00.45-
Cleaner
Z-1025-04A
Remove bolts (11) and *BA72.10-
6
remove door lock (1) P-1017-01R
7 Install in the reverse order
TEST VALUES FOR FRONT DOOR
Number Designation Model 221 with code Z07
BE72.10-P-1001-01H Clearance mm 3 to 5
FRONT DOOR
Model 221 with
Number Designation code Z07/Z07+Z19
BA72.10-P-1007-01R Bolt, window guide rail to front door Nm 8
BA72.10-P-1017-01R Bolt, door lock to front door Nm 7
BA72.10-P-1019-01R Bolt, door lock armor plate on front door Nm 8
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
Henkel Loctite Deutschland
GmbH
Arabellastrasse 17
BR00.45-Z- 81925 Munchen
Loctite 577
1067-01A Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-
Adhesive Terokal 2444 A 000 989 92 71
1002-02A
1025-04A Cleaner A 005 989 19 71
REMOVE/INSTALL INNER PANELING AT WINDOW FRAME OF FRONT DOOR - AR72.10-P-
6580SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 63: Identifying Inner Paneling
Courtesy of MERCEDES-BENZ USA
Remove/install
AR72.10-P-
1 Remove front door lining
1000SX
Unclip inner paneling (1) and Installation: Position door sealing frame
2
remove above inner paneling (1).
3 Install in the reverse order
REMOVE/INSTALL REAR DOOR MODULE - AR72.12-P-0103SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 64: Identifying Rear Door Module Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Illustrated on module 221.0 with riveted door module
Shown on model 221.0
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
18.3.09 "Remove screwed door module" added Step 16.2
Remove/install
Risk of injury due to hands being
Secure window to prevent it from falling AS67.00-Z-
crushed when window glass is not
down. 0002-01A
secure
Remove door lining on left and right AR72.12-P-
1
rear door (1) 1010SX
2 Remove cover (3) from access opening
Connect connector from left rear
power window switch or right rear
3 power window switch with left rear
door control unit (N69/3) or right rear
door control unit (N69/4)
Switch on ignition and close crank After moving up crank window, switch off
4
window until bolt (4) is accessible ignition.
Installation: Completely slide crank
window toward rear and tighten with bolt (4).
5 Unscrew bolt (4)
*BA72.12-
P-1011-01M
Completely slide crank window
6 upward and secure against falling
down with suitable adhesive tape
Disconnect connector from left rear
power window switch or right rear
7 power window switch or from left rear
door control unit (N69/3) or right rear
door control unit (N69/4)
Disconnect door wiring harness (8)
from left rear door control unit (N69/3)
8
or right rear door control unit (N69/4)
and from vehicle wiring harness (9)
Do not remove vehicle wiring harness (9)
Expose vehicle wiring harness (9) and
9 from left rear door control unit (N69/3) or right
disconnect electrical connectors
rear door control unit (N69/4).
Remove outer door handle from rear AR72.12-P-
10
door (1) 2410SX
11 Take off seals (5)
Loosen bolts (6) and unhook bearing
12
bracket (7) from rear door (1).
13 Remove paneling (11)
*BA72.12-
14 Remove bolts (12)
P-1006-01M
Unscrew bolts (13) and lay left rear
door control unit (N69/3) or right rear
*BA72.12-
15 door control unit (N69/4) down to side
P-1012-01M
with vehicle wiring harness (9)
connected.
As of 1.2.2009, the door module is
screwed to the inner door panel.
Fig. 14
Cut rivet heads out of rivets (14, 15, Installation: Fasten door module (2) to
16.1
16) rear door (1) with new rivets (14, 15, 16). Then Fig. 15
apply sealant glue to rivet heads (16).
Hand riveting tool gotis://K_68-80_06.0
*BR00.45-
Sealant
Z-1013-02A
When screwing in the screws, start them
by hand, otherwise, the thread in the inner door
panel could be damaged.
If a door module is installed in a new door,
screw in the screws with a battery-powered
screwdriver. Do not tilt screw more than 10
16.2 Unscrew bolts degrees when screwing in, otherwise, leakage
may occur between the door module and inner
door panel.
Installation: Always replace screws.
Installation: Screws with larger diameter
are available from the Parts Department to
replace stripped screws.
Remove door holder from rear door AR72.12-P-
17
(1). 2100SX
Loosen door module (2) from rear Do not bend door module (2).
18
door (1) and remove. Replace door module (2) if bent.
Press rivet residues out of rivets (15, On riveted door modules.
19
16) Fig. 16
Loosen adhesive tape from crank
20 window and place crank window in
rear door (1).
On riveted door modules.
21 Press rivet residues out of rivet (14).
Fig. 16
Completely remove rivet residues on
residues cause corrosion damage.
Completely remove rivet residues and Installation: Before removing rivet
22 residues and drilling chips, completely slide
drilling chips from rear door (1).
crank window upward and secure against
falling down with adhesive tape.
23 Install in the reverse order
REAR DOOR
Number Designation Model 221
BA72.12-P-1006-01M Bolt, door lock to rear door Nm 7
BA72.12-P-1011-01M Bolt, window to power window Nm 8
BA72.12-P-1012-01M Bolt, door control unit to door module Nm 8
Fig. 66: Identifying Rivet Milling Cutter (171 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
Fig. 67: Identifying Milling Bit Crown (171 589 00 39 01)
Courtesy of MERCEDES-BENZ USA
Fig. 68: Identifying Press-Out Tool (221 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013-02A Sealant 221, 310 ml, DB supply specification 6069.20 A 001 989 64 20
REMOVE/INSTALL REAR DOOR INNER DOOR PANEL - AR72.12-P-0104SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove side window roller
AR72.12-P-
1 blind (2) from left or right rear
2000SXS
door
Disconnect electrical connector
from rear door pressure sensor,
2 driver-side (B48/9) or rear door
pressure sensor, passenger-side
(B48/10)
Remove all electrical wiring
harnesses fastened to inner door Observe routing for electrical wiring harnesses on
3
panel (1) from inner door panel inner door panel (1).
(1)
Disconnect all electrical
connectors from left rear door
4
control unit (N69/3) or right
rear door control unit (N69/4)
Press grommets for electrical
wiring harnesses and release
5
cable inward through inner door
panel (1)
Separate door foil (3) from AR72.12-P-
6
inner door panel (1) 0105SXS
*BA72.12-
7 Remove bolts (4)
P-1001-01N
Guide release cable and electrical wiring
Remove inner door panel (1) harnesses through inner door panel (1). Remove
8
from rear door electrical wiring harnesses and hydraulic lines in front
area of door inner panel (1) at side.
Remove inner sealing rail (5)
9.1 When replacing inner door panel (1).
from inner door panel (1)
Remove rear door pressure When replacing inner door panel (1).
sensor, driver-side (B48/9) or See GOTIS for manual pliers
10.1 rear door pressure sensor, http://gotis.aftersales.mercedes-benz.com
passenger-side (B48/10) from *BR00.45-
inner door panel (1) Rivet 4.8 x 12.70
Z-1011-13A
Remove left rear door control When replacing inner door panel (1).
unit (N69/3) or right rear door
11.1 *BA72.12-
control unit (N69/4) from inner
door panel (1) P-1023-01N
12 Install in the reverse order
REAR DOOR
Model 221 with code
Number Designation Z07/ Z07+Z19
BA72.12-P-1001-01N Bolt, inner door panel of rear door Nm 8
BA72.12-P-1023-01N Bolt, door control unit to inner door panel Nm 5
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1011-13A Rivet 4.8 12.70 n910002 001129
REMOVE/INSTALL DOOR FOIL ON REAR DOOR - AR72.12-P-0105SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 70: Identifying Rear Door Foil Components
Courtesy of MERCEDES-BENZ USA
Removing
Remove side window
AR72.12-P-
1 roller blind (2) from left
2000SXS
or right rear door
Remove splitter
Cut through butyl cord on rear of splitter protection
2 protection strips (3) from
rear door strips (3) with suitable blade.
Remove mounting
3
anchor (5)
Cut through butyl cord Cut through butyl cord carefully and carefully separate
4 on rear of door foil (1) door foil (1). Otherwise, the paint and seal (4) can be
with suitable blade damaged.
Install
butyl cord from inner door panel, door lock armor plate and
Check door foil (1) for seal (4) and clean bonding surface.
5 damage, replace if
necessary *BR00.45-Z-
Cleaner
1025-04A
If sections of the butyl cord are damaged, replace only
the damaged section. Route new butyl cord parallel to the
damaged butyl cord on the door foil (1). Previously clean
Inspect butyl cords for bonding surface.
6 damage, replace if
*BR00.45-Z-
necessary Sealing cord
1086-01A
*BR00.45-Z-
Cleaner
1025-04A
Ensure that door foil (1) is correctly positioned on front
Align door foil (1) on door.
7
front door and roll on
Fig. 23
Install mounting anchor
8
(5)
Coat corresponding screws with thread sealant and
tighten in a number of cycles. The butyl cord then settles on
the rear.
Install splitter protection
9 *BA72.12-P-
strips (3)
1002-01N
*BR00.45-Z-
Loctite 577
1067-01A
Install side window AR72.12-P-
10
roller blind (2) 2000SXS
REAR DOOR
Model 221 with code
Number Designation Z07/ Z07+Z19
BA72.12-P-1002-01N Screw, splinter guard on rear door Nm 8
Fig. 71: Identifying Roller (168 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Henkel Loctite Deutschland
GmbH
Arabellastrasse 17
BR00.45-Z- 81925 Munchen
Loctite 577
1067-01A Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
BR00.45-Z-
Cleaner A 005 989 19 71
1025-04A
COVER WINDOW FRAME ON REAR DOOR WITH LEATHER - AR72.12-P-0500SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 72: Identifying Leather, Gluing Areas And Trim
Courtesy of MERCEDES-BENZ USA
Fig. 73: Identifying Leather, Marking And Window Frame Areas
Courtesy of MERCEDES-BENZ USA
Removing
Notes on avoiding damage to windows installed AH67.00-P-
in special high-security vehicles 0003-01FB
Remove paneling *2(from window frame on
1 Fig. 3
left or right rear door
AR72.12-P-
2 Remove door frame seal from rear door
1015SXS
3 Pull leather (1) off window frame
Clean adhesive areas (A, B, C) on window *BR00.45-Z-
4 Pure benzine/benzine
frame 1048-04A
Cover window frame
Coat rear of leather (1) and adhesive area (A)
*BR00.45-Z-
5 on window frame over entire surface with MB MB special adhesive
1002-02A
special adhesive
Position bottom edge of leather (1) on inner Start at upper corner of window
6 butt edge (arrow) on window frame and smooth frame. Ensure that bonding is
along adhesive area (A) with suitable tool wrinkle-free.
Coat adhesive area (B) on window frame over *BR00.45-Z-
7 MB special adhesive
full surface with MB special adhesive 1002-02A
Smooth leather (1) in upper corner of window
8
directions toward the outside free.
Glue on leather (1) in adhesive area (B) starting
Ensure that bonding is wrinkle-
9 at top toward rear and then at top toward front
and smooth with suitable tool free.
Coat adhesive area (C) on window frame over *BR00.45-Z-
10 MB special adhesive
full surface with MB special adhesive 1002-02A
Glue on leather (1) in adhesive area (C) starting
Ensure that bonding is wrinkle-
11 in middle toward rear and smooth with suitable
free.
tool
This relieves the tension in the
12 Notch leather (1) not in contact in rear area leather (1), and ensures that it can
glued wrinkle-free.
Glue on leather (1) in adhesive area (C) starting
13 in middle toward front and smooth with Ensure that bonding is wrinkle-
free.
suitable tool
This relieves the tension in the
14 Notch leather (1) not in contact in front area leather (1), and ensures that it can
glued wrinkle-free.
Draw marking (3) with a distance of approx. 14
15
mm from upper inner edge of window frame
Cut off leather (1) along marking (3) with Repair damage to paint with
16
suitable blade suitable touch-up paint pen.
Adapt leather (1) to contour of window frame
17
in front area and cut (picture E)
Adapt leather (1) to contour of window frame
18
in rear area and cut (picture D)
Install
Completely remove adhesive residues from *BR00.45-Z-
19 Pure benzine/benzine
adhesive area for door frame seal 1048-04A
AR72.12-P-
20 Install door frame seal
1015SXS
21 Install paneling (2) on window frame
Fig. 74: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-
Adhesive Terokal 2444 A 000 989 92 71
1002-02A
Otto Fischar GmbH &
Co. KG
Kaiserstrasse 221
BR00.45-Z- Pure benzine/benzine 100/140 (free of aromatic compounds), 66133 Saarbrucken
1048-04A 5-liter metal canister, article no.: 17042 Germany
Tel +49 681 98217-0
Fax: +49 681 98217-99
www.fischar.de
REMOVE/INSTALL REAR DOOR - AR72.12-P-0600SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 75: Identifying Rear Door Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being jammed When moving components, ensure
or pinched when removing, installing or that no body parts or limbs are AS00.00-Z-
aligning hoods, doors, trunk lid/rear-end door or within the operating range of 0011-01A
sliding roof. moving parts.
1 Open front door
Completely move crank window in rear door (1)
2
downward
or Keyless Go start/stop button from EIS control only on vehicles with code (889)
3
unit Keyless Go.
Disconnect left rear door separation point
4 (X35/3) or right rear door separation point
(X35/4)
Carefully unclip door holder
Unclip door holder (4) from B-pillar bracket
5 (4), if necessary, use rag to protect
with suitable screwdriver.
against paint damage.
6 Remove caps (2) from bolts (3)
*BA72.12-P-
7 Unscrew screws (3)
1003-01M
Open front door (1), remove from door hinges
Remove rear door (1) carefully.
8 with aid of helper and lay down on suitable
subsurface Danger of damaging paint.
9 Install in the reverse order
Check adjustment of rear door (1), correct if AR72.12-P-
10
necessary. 0650SX
REAR DOOR
Number Designation Model 221
BA72.12-P-1003-01M Bolt to door hinge shaft Nm 25
REMOVE/INSTALL REAR DOOR - AR72.12-P-0600SXS
MODEL 221.1 with CODE (Z07) Top protection
Shown on vehicle with hydraulic power windows
Fig. 76: Identifying Rear Door Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
installing or aligning hoods, doors, trunk moving parts. 0011-01A
lids, tailgates or sliding roof.
Remove crank window from left or right AR72.12-P-
1.1 On vehicles with hydraulic power windows.
rear door 1910SXS
Remove window on left or right rear On vehicles without hydraulic power
1.2
door windows.
Disconnect left rear door separation
2 point (X35/3) or right rear door
separation point (X35/4)
3 Loosen protective tube (2) from B-pillar
Guide hydraulic lines (3) from rear door
4.1 On vehicles with hydraulic power windows.
(1) and protective tubing (2)
Press door holder (4) off of ball head
5 Fig. 3
bolt (5) on B-pillar
Remove caps (6) and remove bolts *BA72.12-P-
6
below 1019-01N
Carefully remove rear door (1) to
prevent damage to rear door (1) and front
Remove rear door (1) from door hinge door.
7
halves on B-pillar See GOTIS for multifunctional lift/holding
device http://gotis.aftersales.mercedes-
benz.com
8 Install in the reverse order
Check adjustment of rear door (1), AR72.12-P-
9
correct if necessary. 0650SXS
REAR DOOR
Number Designation Model 221 with code Z07/ Z07+Z19
BA72.12-P-1019-01N Bolt to door hinge shaft Nm 25
Fig. 77: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
ADJUST REAR DOOR - AR72.12-P-0650SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 78: Identifying Rear Door, Locking Eye And Bolts
Courtesy of MERCEDES-BENZ USA
Checking
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear of AS00.00-Z-
installing or aligning hoods, doors, trunk moving parts. 0011-01A
lids, liftgates or sliding roof
AR60.00-P-
0700-01SX
Check gaps on rear door (1) all the way *BE60.00-P-
1
around. 1002-01R
Fig. 7
Adjust
2 Remove lock striker (2) Mark installation position of locking
eye (2) to facilitate installation.
3 Open front door
AR60.00-P-
corresponding gap dimensions by moving *BE60.00-P-
4 rear door (1) 1002-01R
Fig. 7
*BA72.12-P-
5 Tighten screws (3)
1002-01M
Loosen bolts on inner door panel (4) and The contour of the front door (1)
6 adjust transition from front door to rear door must be flush with the contour of the rear
(1) by moving rear door (1) door project by a maximum of 1 mm.
*BA72.12-P-
7 Tighten bolts (4)
1001-01M
Insert striker eye (2) and screw in bolts (5) to It should still be possible to adjust
8
stop the lock striker (2).
Adjust transition between rear door (1), rear The contour of the rear door (1) must
9 be flush with the contours of the rear
fender and roof paneling by moving lock
striker (2). fender and roof paneling or project by a
maximum of 1 mm
*BA72.12-P-
10 Tighten screws (5)
1004-01M
Repair paint damage on screw heads (3, 4)
11
with touch-up paint pen
CHECK VALUES FOR GAPS
Number Designation Model 221
BE60.00-P- Gap Front door to A-pillar Dimension "D" mm 4.5 (±0.5)
1002-01R dimension Front door to fender Dimension "E" mm 4 (±0.5)
Front door to rear door Dimension "F" mm 4.5 (±0.5)
Trim strip at front door to roof Dimension "G" mm 4.5 (±0.5)
frame
Trim strip at rear door to roof Dimension "H" mm 4.5 (±0.5)
frame
Rear door to side section, Dimension "I" mm 4.5 (±0.5)
bottom
Front door cover to rear door Dimension "S" mm 4.5 (±0.5)
cover See picture AR60.00-P-0700-
01SX
REAR DOOR
Number Designation Model 221
BA72.12-P-1001-01M Bolt, door hinge to rear door Nm 32
BA72.12-P-1002-01M Bolt, door hinge to B-pillar Nm 32
BA72.12-P-1004-01M Bolt for locking eye on C-pillar Nm 28
Fig. 79: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
ADJUST REAR DOOR - AR72.12-P-0650SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 80: Identifying Rear Door Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
24.10.08 Value modified: Bolt, door hinge to rear door *BA72.12-P-1017-01N
Value modified: Bolt, door hinge to B-pillar *BA72.12-P-1018-01N
Checking
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear of AS00.00-Z-
installing or aligning hoods, doors, moving parts. 0011-01A
trunk lids, tailgates or sliding roof.
AR60.00-
1 P-0700-
around. *BE60.00-
P-1002-01R
Fig. 7
Adjust
Remove striker wedge (2) at bottom of
2
rear door (1)
Mark installation position of locking eye
3 Remove locking eye (4)
(4), to facilitate reinstallation.
Support rear door (1) with floor jack Do not support rear door (1) on outer
paneling, otherwise, the rear door (1) can be
and suitable block of wood, position
4 damaged by its high dead weight.
below mounting location of striker
See GOTIS for NIKE passenger car floor jack
wedge (2)
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AR60.00-
P-0700-
Loosen bolts (5) on B-pillar and adjust Adjust gap dimensions at rear door (1) by 01SX
5 corresponding gap dimensions by lifting or lowering floor jack. *BE60.00-
moving rear door (1). P-1002-01R
Fig. 7
*BA72.12-
Tighten bolts (5), lower and remove
6 See GOTIS for NIKE passenger car floor jack P-1018-
floor jack
http://gotis.aftersales.mercedes-benz.com 01N
Loosen bolts (6) on rear door and adjust The contour of the front door must be flush
7 transition of front door to rear door (1) with the contour of the rear door (1) or project
by moving rear door (1). by a maximum of 1 mm.
*BA72.12-
8 Tighten bolts (6) P-1017-
01N
Insert locking eye (4) and screw in It still should be possible to adjust the
9
bolts (3) up to stop locking eye (4).
The contour of the rear door (1) must be
Adjust transition between rear door (1),
10 flush with the contours of the rear fender and
rear fender and roof paneling by
roof paneling or project by a maximum of 1
moving locking eye (4).
mm
*BA72.12-
11 Tighten screws (3) P-1020-
01N
Repair paint damage to screw heads
12
with suitable touch-up paint pen
Only tighten bolts on striker wedge (2)
13 Install striker wedge (2)
hand-tight.
*BR00.45-
14 Coat oval head screw (7) with grease Multipurpose grease Z-1034-
06A
Carefully close and open rear door (1)
and determine on basis of grease
impression on oval head screw (7),
The rear door (1) is supported on the oval
whether height of striker wedge (2)
head screws (7) by the striker wedge (2) so that
15 requires correction by inserting shims.
If the rear door (1) is hard to close or its entire dead weight is not on the locking eye
(4). The rear door (1) should be easy to close.
cannot be closed at all, correct the
height of the striker wedge (2) by
removing shims
*BA72.12-
16 Tighten bolts on striker wedge (2) P-1025-
01N
CHECK VALUES FOR GAPS
Number Designation Model 221
BE60.00-P- Gap dimension Front door to A-pillar Dim. "D" mm 4.5 (±0.5)
1002-01R Front door to fender Dim. "E" mm 4 (±0.5)
Front door to rear door Dim. "F" mm 4.5 (±0.5)
Trim strip at front door to roof Dim. "G" mm 4.5 (±0.5)
frame
Trim strip at rear door to roof Dim. "H" mm 4.5 (±0.5)
frame
Rear door to side section, Dim. "I" mm 4.5 (±0.5)
bottom
Front door cover to rear door Dim. "S" mm 4.5 (±0.5)
cover See picture AR60.00-P-0700-01SX
REAR DOOR
Model 221 with code
Number Designation Z07/ Z07+Z19
BA72.12-P-1017-01N Bolt, door hinge to rear door Nm 40
BA72.12-P-1018-01N Bolt, door hinge to B-pillar Nm 40
BA72.12-P-1020-01N Bolt, locking eye to C-pillar Nm 28
BA72.12-P-1025-01N Bolt, stop wedge on rear door Nm 5
Fig. 81: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1034-06A MB multipurpose grease A 001 989 34 51 10
REMOVE/INSTALL REAR DOOR LINING - AR72.12-P-1010SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 82: Identifying Rear Door Lining Components (Model 221.0)
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
Shown on model 221.1
Fig. 83: Identifying Door Lining & Bolt (Model 221.1)
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Wind crank window fully down
With model 221.0
2.1 Unscrew bolt (2) and unclip speaker cover (3).
Fig. 3
*BA72.12-P-
3 Unscrew screw (4)
1009-01M
With model 221.0
4.1 Unscrew bolt (5). *BA72.12-P-
1009-01M
With model 221.1
4.2 Unscrew bolt (11). *BA72.12-P-
1009-01M
Move mounting wedge
directly onto clips (6) and
ensure that retainer tabs on clips
Unclip door lining (1) and remove from rear door do not tear out of door lining
5 (1).
until electrical connector (7) are accessible.
Installation: Replace Fig. 3
damaged clips (6).
Disconnect electrical connectors (7) from left rear The number of electrical
6 door control unit (N69/3) or right rear door control connectors (7) can vary
unit (N69/4) and connector of electrical line (8) from depending on the equipment.
tweeter (H4/4h1)
Unhook Bowden cable (9) from door opener (10) and
7
remove door lining (1).
8 Install in the reverse order
REAR DOOR
Number Designation Model 221
BA72.12-P-1009-01M Bolt, door lining to door module Nm 8
Fig. 84: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REAR DOOR LINING - AR72.12-P-1010SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 85: Identifying Rear Door Lining Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to
AH67.00-P-
windows installed in special high-
0003-01FB
security vehicles
Switch off the ignition and
1 remove the transmitter key from
the EIS control unit
Remove concealed screws
*BA72.12-
2 (arrows) below armrest on door
P-1016-01N
lining (1) on left or right rear door
Insert long wedge immediately next to the
locking pins (4) and unclip locking pins (4)
Pry off door lining (1) at locking individually. Ensure that the retaining pins (4) do
3 not tear out of the door lining (1) and thereby
pins (4) on rear door
damage the door lining (1).
Fig. 19
As soon as the door lining (1) is detached,
Detach door lining (1) from rear ensure that the electrical wiring harness for the left
door until left rear door control rear door tweeter or right rear door tweeter is not
4
unit (N69/3) or right rear door under too much tension. Otherwise, the left rear
control unit (N69/4) is accessible door tweeter or right rear door tweeter can be
damaged.
Disconnect electrical connectors
(2, 3) from left rear door control
5
unit (N69/3) or right rear door
control unit (N69/4)
Unhook release cable from inside
6
door opener
Disconnect electrical connector
from left rear door tweeter or right
7
rear door tweeter and remove
door lining (1)
8 Install in the reverse order
REAR DOOR
Model 221 with code
Number Designation Z07/ Z07+Z19
BA72.12-P-1016-01N Bolt, door lining to inner door panel Nm 8
Fig. 86: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL DOOR FRAME SEAL ON REAR DOOR - AR72.12-P-1015SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 87: Identifying Rear Door Frame Seal Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
20.7.06 Position of door sealing frame sealing lip in relation to upper seal Step 7
Removing
AR72.12-P-
1 Remove rear door lining
1010SX
2.1 Remove side window roller blind rear doors 2000SX
Remove inner paneling (1) from On vehicles without code (297) Roller sun blinds
2.2
window frame in rear doors
3 Remove cover (2)
Completely remove door frame
4
seal (3) from rear door
Bonding surface must be free of grease and
dust
Removal disk, 100 mm dia. with fixing shank, 3M
Remove glue residues from rear Deutschland GmbH D-41453 Neuss
5
door and clean bonding surface Hand drill, refer to GOTIS
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*BR00.45-Z-
Cleaner
1025-04A
Notes on removing glue residues
AH00.00-P-
and foils on paint and metal
0013-01AK
surfaces with eraser disc
Install
Ensure that door frame seal (3) is seated
Align door frame seal (3) on rear correctly.
6
door, glue on and roll on
Fig. 37
Position sealing lip on door frame Sealing lip on door frame seal (3) must be
7 seal (3) in relation to upper seal located above the upper seal (4).
(4). Fig. 19
8 Install paneling (2)
Install inner paneling (1) on On vehicles without code (297) Roller sun blinds
9.1
window frame in rear doors
On vehicles with code (297) Roller sun blinds in AR72.12-P-
9.2 Install side window roller blind
rear doors 2000SX
AR72.12-P-
10 Install rear door lining
1010SX
Courtesy of MERCEDES-BENZ USA
Fig. 89: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
REMOVE/INSTALL DOOR FRAME SEAL ON REAR DOOR - AR72.12-P-1015SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 90: Identifying Door Frame Seal Cover & Sealing
Courtesy of MERCEDES-BENZ USA
Removing
Notes on avoiding damage
to windows installed in AH67.00-P-
special high-security 0003-01FB
vehicles
Remove door lining from AR72.12-P-
1
left or right rear door 1010SXS
The paneling (2) is glued on and is damaged when
2 Remove paneling (2) removed.
Fig. 19
Completely remove door
3 frame seal (1) from rear
door
The bonding surfaces must be absolutely free of grease
and dust.
Dia. 100 mm removal disk with mounting shaft
Remove adhesive residues
3M Deutschland GmbH D-41453 Neuss
4 on rear door and clean
Hand drill, refer to GOTIS
bonding surfaces
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*BR00.45-
Cleaner
Z-1025-04A
Notes on removing
adhesive residues and foils
AH00.00-P-
on paint and metal surfaces
0013-01AK
with surface conditioning
disks
Install
The door frame seal (1) must run parallel to the front
Align door frame seal (1) door frame seal (1) is properly seated on the seal (3) at the
5 on rear door, glue on and top of the window frame.
roll on Fig. 37
Observe instructions for using primer precisely. This is
the only way to ensure a reliable and durable adhesive
Pretreat bonding surfaces connection.
on front door with primer
6 *BR00.45-
and glue on new paneling Primer
Z-1030-02A
(2)
*BR00.45-
Double-sided adhesive tape
Z-1075-02A
AR72.12-P-
7 Install door lining
1010SXS
Fig. 91: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 92: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
Scotch 3M 4297 Primer A 004 989 29 71
02A
Henkel Loctite Deutschland
Teroson double-sided adhesive tape GmbH
For bonding trim strips and emblems (UV-resistant and Arabellastrasse 17
BR00.45-Z-1075- weatherproof, black) 81925 Munich
02A (Width: 12 mm) Order no.: 107.64 A Germany
(Width: 19 mm) Order no.: 107.96 K Tel. +49-89-9268-0
(Width: 25 mm) Order no.: 117.05 Y Fax + 49-89-9101978
www.Loctite.de
BR00.45-Z-1025-
Cleaner A 005 989 19 71
04A
REMOVE/INSTALL ARMREST ON REAR DOOR - AR72.12-P-1020SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 93: Identifying Rear Door Armrest Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Open rear door
2 Remove speaker cover (4)
3 Remove bolts (5)
4 Raise covering (2) and ashtray (3).
5 Slide armrest (1) approx. 1 to 2 cm toward front and remove
6 Install in the reverse order
REMOVE/INSTALL DOOR POCKET ON FRONT DOOR LINING - AR72.12-P-1030SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 94: Identifying Front Door Pocket Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
Fig. 95: Identifying Door Lining, Plastic Spot Welds & Chisel
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
Fig. 96: Identifying Door Lining Components
Courtesy of MERCEDES-BENZ USA
Removing
Lay door lining (2) front AR72.12-P-
1 Remove door liner (2) from rear door side down on suitable 1010SX
subsurface to prevent damage
On vehicles with code (595)
Heat and noise insulating
Detach insulating mat (6) in area of plastic spot welds infrared-reflective laminated
2.1
(3, 12, 13). glass for rear and side windows
or Code (596) Heat-insulating
glass
3.1 Remove speaker cover (8) With model 221.1
AR72.12-P-
4 Remove armrest (4)
1020SX
5 Remove ashtray (7).
Disconnect electrical connector from left rear power
window switch (S21/3) or left rear door power
window/roller blind switch group (S21/21) or right
6 Depending on equipment.
rear power window switch (S21/4) or right rear door
power window/ roller blind switch group (S21/22) and
remove covering (5).
Remove left rear door entrance/exit lamp (E17/5) or
7 right rear door entrance/exit lamp (E17/6) and guide
electrical line to rear of door lining (2).
8 Remove left rear door warning lamp (E17/20) or right
line to rear of door lining (2).
When initially removing door
pocket (1).
Knock plastic spot welds (3, 12, 13) off of with chisel Flat side of chisel blade
9.1 (11) should point upward.
(11)
Use chisel (11) with a blade
width of 10 mm, according to
DIN 5139.
Bend open clamping plates (10, 14, 16) with suitable When removing door pocket (1)
9.2
screwdriver and remove from pins (9) a second time
10 Remove door pocket (1) from door lining (2).
Remove left rear door tweeter or left rear door tweeter
11.1 When replacing door pocket (1).
from door pocket (1).
Install
Install left rear door tweeter or left rear door tweeter
12.1 When replacing door pocket (1).
in door pocket (1).
If the door pocket (1) has
already been removed, replace
13 Insert door pocket (1) in door lining (2) door pocket. Ensure that door
pocket (1) is seated properly on
door lining (2).
Install new clamping plates
(10, 14, 16). Use suitable socket
wrench to press down clamping
Press clamping plates (10, 14, 16) over pins (9, 15,
14 plates (10).
17) on door pocket (1).
The clamping plates (10, 14, 16)
should make firm contact with
door lining (2).
Shorten pins (9, 15, 17) down to approx. 2 mm above
15
clamping plates (10, 14, 16) with side cutting pliers.
Install left rear door entrance/exit lamp (E17/5) or
16
right rear door entrance/exit lamp (E17/6)
Install left rear door warning lamp (E17/20) or right
17
rear door warning lamp (E17/22)
AR72.12-P-
18 Install armrest (4)
1020SX
19 Install ashtray (7).
Connect electrical connector on left rear power
window switch (S21/3) or left rear door power
window/roller blind switch group (S21/21) or right
20 Depending on equipment.
rear power window switch (S21/4) or right rear door
power window/ roller blind switch group (S21/22) and
remove covering (5).
21.1 Install speaker cover (8) With model 221.1
On vehicles with code (595)
Heat and noise insulating
infrared-reflective laminated
glass for rear and side windows
22.1 Glue insulating mat (6) onto door lining (2). or code (596) Heat-insulating
glass
*BR00.45-
Special glue
Z-1002-02A
AR72.12-P-
23 Install door lining (2)
1010SX
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1002-02A Adhesive Terokal 2444 A 000 989 92 71
ASSEMBLE/DISASSEMBLE DOOR LINING IN REAR DOOR - AR72.12-P-1040SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 97: Identifying Rear Door Lining Components
Courtesy of MERCEDES-BENZ USA
Shown with code (276) Memory in rear,
Code (872) Electrically heated left and right rear seats
Disassemble/assemble
Lay door lining (1) front side down on AR72.12-P-
1 Remove door lining (1) from rear door
suitable subsurface to prevent damage 1010SX
Remove armrest (4) from door lining AR72.12-P-
2
(1) 1020SX
3 Remove covering (7)
4 lining (1) 1030SX
Remove trim strip (2) from door lining AR72.12-P-
5
(1). 1050SX
Remove inner door opener (3) from AR72.12-P-
6
door lining (1) 2310SX
Remove wiring harness (6) from rear
7
of door lining (1)
8 Assemble in reverse order
REMOVE/INSTALL TRIM STRIP ON FRONT DOOR LINING - AR72.12-P-1050SX
MODEL 221.0 /1
Fig. 98: Identifying Door Lining, Bolts And Trim Strip
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0
Remove/install
Lay door lining (1) front side down on suitable
subsurface to prevent damage
1 Remove door liner (1) from rear door Vehicles without code (Z07) Top AR72.12-P-1010SX
protection
Vehicles with code (Z07) Top AR72.12-P-
protection 1010SXS
Disconnect electrical connector from
2.1 On vehicles with code (876) interior light package
trim strip (3)
3 Remove bolts (2)
4 Remove trim strip (3)
5 Install in the reverse order
REMOVE/INSTALL SEAL (UPPER) ON REAR DOOR WINDOW FRAME - AR72.12-P-1550SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 99: Identifying Rear Door Window Frame Components
Courtesy of MERCEDES-BENZ USA
Removing
1 Open front door and rear door (1)
Loosen seal (2) from upper and
2
lower window frame (arrows A, B)
3 Pull seal (2) out of trim strip (3).
Removal disk, 100 mm dia. with fixing shank,
3M Deutschland GmbH D-41453 Neuss
Remove seal (2) from rear door and Hand drill, refer to GOTIS
4 clean bonding surface on front door http://gotis.aftersales.mercedes-benz.com
(1) edge with eraser disc
*BR00.45-Z-
Cleaner
1025-04A
Notes on removing glue residues
AH00.00-P-
and foils on paint and metal
0013-01AK
surfaces with eraser disc
Install
Do not stretch seal (2) when gluing on,
Glue seal (2) to front door edge otherwise leakage can occur.
5
from bottom upward and press on
Fig. 37
Ensure that seal (2) is seated correctly.
Coat trim strip (3) with lubricant
6 *BR00.45-Z-
and install seal (2) in trim strip (3). Antifriction agent
1010-06A
7 Close front door and rear door (1)
Fig. 100: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL SEAL (UPPER) ON REAR DOOR WINDOW FRAME - AR72.12-P-1550SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 101: Identifying Sealing & Trim Strip
Courtesy of MERCEDES-BENZ USA
Removing
Open front door and rear door on
1
left and right side of vehicle
Detach seal (1) from window frame
2
at top (arrow A) and rear (arrow B)
3 Pull seal (1) out of trim strip (2).
The bonding surface should be absolutely
free of grease and dust.
Dia. 100 mm eraser disc with mounting shaft 3M
Remove seal (1) from rear door and
Deutschland GmbH D-41453 Neuss
4 clean bonding surface on front door
Hand drill, refer to GOTIS
edge with eraser disc
http://gotis.aftersales.mercedes-benz.com
*BR00.45-Z-
Cleaner
1025-04A
Notes on removing glue residues
AH00.00-P-
and foils on paint and metal
0013-01AK
surfaces with eraser disc
Install
Glue seal (1) onto front door edge Do not stretch seal (1) when gluing on,
5 of door from bottom to top and otherwise, leakage can occur.
press down with roller Fig. 37
Ensure that seal (1) is seated properly in trim
Coat trim strip (2) with lubricant
strip (2).
6 and install sealing (1) in trim strip
(2). *BR00.45-Z-
Antifriction agent
1010-06A
7 Close front door and rear door
Fig. 102: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL TRIM STRIP ON REAR DOOR WINDOW FRAME - AR72.12-P-1710SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 103: Identifying Rear Door Window Frame Trim Strip Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
23.9.05 Riveter changed Step 7
Remove/install
Completely open crank window
1
in left or right rear door
Loosen sealing (1) from trim strip AR72.12-
2
(7). P-1550SX
Do not pull door frame seal (2) downward too
Pull door frame seal (2)
forcefully, otherwise the glued door frame seal (2)
downward in areas of rivets (6)
3 can detach from the window frame (5).
and fasten with strips of adhesive
tape (3). This prevents damaging the door frame seal (2)
when drilling out the rivets (6) later.
Mask gap between door frame
seal (2) and window frame (5) This ensures that no chips or drilling residues fall
4
over entire length with strips of into the gap.
adhesive tape (4).
Plug opening (arrow) in front This prevents drilling chips and rivet residues
5
area of window frame (5). from falling into the window frame (5).
6 against chips falling down.
Do not drill through rivets (6) to prevent
Drill out rivet heads on rivets (6) damaging the window frame (5)
7
with 3.5 mm dia. bit. Manual pliers, see GOTIS
http://gotis.aftersales.mercedes-benz.com
Unscrew bolt (8) from window
8
separator bar (9) at top
Completely remove rivet Remaining rivet residues cause corrosion
9
residues. damage.
Installation: Repair paint damage on window
Loosen trim strip (7) from frame (5) before installation.
10
window frame (5) and remove
Fig. 3
11 Install in the reverse order
Fig. 104: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TRIM STRIP ON REAR DOOR WINDOW FRAME - AR72.12-P-1710SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 105: Identifying Trim Strip, Door Sealing Frame, Bolt And Rivet
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to
AH67.00-P-
windows installed in special high-
0003-01FB
security vehicles
Remove top seal on window frame AR72.12-P-
1
on left or right rear door 1550SXS
Do not pull door frame seal (2) down with too
Pull door frame seal (2) downward much force, otherwise, it detaches from the
2 in area of rivets (3) and fasten with window frame.
adhesive tape to window frame This prevents damaging the door frame seal
(2) when drilling out the rivets (3) later.
Mask off gap between door frame
This ensures that no chips or drilling residues
3 seal (2) and window frame over
entire length with adhesive tape fall into the gap.
Seal opening in window frame This ensures that no chips or drilling residues
4
below front rivet (3) fall into the window frame.
Do not drill through rivets (3), otherwise, the
Drill out rivet heads (3) with drill window frame is damaged.
5
bit (3.5 mm dia.) See GOTIS for manual pliers, cordless drill/diver
http://gotis.aftersales.mercedes-benz.com
Remove bolt (4) in area of window
6
separator bar
Any rivet residues and chips remaining cause
7 Completely remove rivet residues.
corrosion damages.
Installation: Repair paint damage on window
Loosen trim strip (1) and remove frame with suitable touch-up paint pen.
8
from window frame
Fig. 3
9 Install in the reverse order
Fig. 106: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
RELEASE PRESSURE IN PRESSURE RESERVOIR FOR HYDRAULIC POWER WINDOW IN
REAR DOOR - AR72.12-P-1810-06SXS
When relieving the pressure in the pressure reservoir for the hydraulic power window on the rear door,
ensure that the transmitter key is removed from the EIS control unit.
1. Open rear door and remove emergency operation handle (1) from door lining.
The emergency operation handle (1) serves for manual actuation of the hydraulic valves in the block
valve (2) for lifting and lowering the crank window.
Fig. 107: Releasing Pressure In Pressure Reservoir
Courtesy of MERCEDES-BENZ USA
2. Attach emergency operation handle (1) to bottom valve actuation, pull upward and hold until crank
window is fully lowered.
3. Attach emergency operation handle (1) to upper valve actuation, pull down and hold until crank window
is fully rolled up.
4. Roll crank window up and down until it stops indicating that the pressure in the pressure reservoir is
completely relieved.
Rolling the crank window up and down causes the hydraulic oil to flow out of hydraulic reservoir
back into the power window hydraulic pump.
REMOVE/INSTALL REAR DOOR WINDOW LIFTER - AR72.12-P-1810SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 108: Identifying Rear Door Window Lifter Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
17.8.06 Tool changed Steps 4.1, 4.2
Remove/install
Remove door module (1) from left AR72.12-P-
1
and right rear door. 0103SX
Remove left rear power window
AR72.29-P-
2 motor (M10/5) or right rear power
1880SX
window motor (M10/6)
Loosen left rear door control unit
(N69/3) or right rear door control *BA72.12-P-
3
unit (N69/4) from door module (1) 1012-01M
until rivets (2) are accessible.
When initially removing power window (3).
Drill out rivet heads (2) with 6.5 mm
4.1 Manual pliers, see GOTIS
dia. bit.
http://gotis.aftersales.mercedes-benz.com
When repeatedly removing power window (3).
Fig. 14
4.2 Cut rivet heads out of rivets (2). Installation: Fasten power window (3) to
door module (1) with new rivets (2). Fig. 15
Manual pliers, see GOTIS
http://gotis.aftersales.mercedes-benz.com
Remove power window (3) from
5
door module (1).
6 Install in the reverse order
REAR DOOR
Number Designation Model 221
BA72.12-P-1012-01M Bolt, door control unit on door module Nm 8
Fig. 109: Identifying Rivet Milling Cutter (171 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
Fig. 110: Identifying Milling Bit Crown (171 589 00 39 01)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REAR DOOR WINDOW LIFTER - AR72.12-P-1810SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 111: Identifying Rear Door Window Lifter Components
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury from pinching and
Secure windows against dropping, use only AS67.00-Z-
crushing hands and feet when
specified lifting tools, wear protective shoes. 0003-01A
working on windows.
Notes on avoiding damage to
AH67.00-P-
windows installed in special
0003-01FB
high-security vehicles
Completely close crank window
1 in left or right rear door and Fig. 44
clamping pliers
AR72.12-P-
2 Remove door foil from rear door
0105SXS
AR72.12-P-
3 Remove inner door panel
0104SXS
Remove bolts (2) and retaining
4
rail (3)
Risk of injury caused by moving
parts that can pinch, crush or, in AS00.00-Z-
extreme cases even sever 0009-01A
extremities. Keep body parts and limbs well clear of moving
parts.
Release pressure in pressure
AR72.12-P-
5 reservoir for hydraulic power
1810-06SXS
window (1) in rear door
Mark installation position of
6 hydraulic lines (4) on valve block
(5)
Remove hydraulic lines (4) from Use only suitable stop plugs or lint-free rags
valve block (5). Then plug for plugging. Lint or contamination can
7
openings in hydraulic lines (4) contaminate the hydraulic system and thereby
and valve block (5) cause damage.
Remove bolts (6) and remove
8
power window (1) from rear door
Install
*BA72.12-P-
1004-01N
Position power window (1) in *BA72.12-P-
9
rear door and tighten bolts (6) 1005-01N
*BA72.12-P-
1006-01N
Attach hydraulic lines (4) to *BA72.12-P-
10
valve block (5). 1027-01N
Align power window (1) and *BA72.12-P-
crank window hole patterns with 1007-01N
11
one another, position retaining *BR00.45-Z-
rails (3) and tighten bolts (2) Quick glue
1008-02A
12 Remove clamping pliers Fig. 44
AR72.12-P-
13 Install inner door panel
0104SXS
Check adjustment of hydraulic When power window (1) has been replaced.
power window rear door limit When the crank window is rolled up
14.1 completely, the hydraulic power window rear
switch (S21/25), correct if
required door limit switch (S21/25) must be depressed; if
adjustment.
AR72.12-P-
15 Install door oil at rear door
0105SXS
Check fill level of power window
16 hydraulic pump; correct if
necessary
Power window system - check oil AP67.30-P-
level 6710SX
REAR DOOR
Model 221 with
Number Designation code Z07/ Z07+Z19
BA72.12-P-1004-01N Bolt, power window on door lock armored plate Nm 23
BA72.12-P-1005-01N Bolt, power window on rear door armored plate Nm 23
BA72.12-P-1006-01N Bolt, power window on rear door Nm 23
BA72.12-P-1007-01N Screw for window lift on crank window Nm 23
BA72.12-P-1027-01N Bolt, hydraulic line to valve block Nm 7
Fig. 112: Identifying Clamping Pliers (220 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1008-02A Quick-acting adhesive, Loctite 270 A 002 989 93 71
REMOVE/INSTALL CRANK WINDOW IN REAR DOOR - AR72.12-P-1910SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 113: Identifying Crank Window Components (Without Code 297)
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0 without code (297) Roller sun blind in rear doors
Shown on model 221.1 with code (297) Roller sun blinds in rear doors
Fig. 114: Identifying Crank Window Components (With Code 297)
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury due to hands being crushed when Secure window to prevent it from AS67.00-Z-
window glass is not secure falling down. 0002-01A
AR72.12-P-
1 Remove door lining from rear door
1010SX
On vehicles with code (297) Roller
2.1 Remove cover strip (8) upward with pulling hook sun blinds in rear doors
Fig. 116
3 Remove inner sealing rail (2) Fig. 3
4 Remove outer sealing rail (4) Fig. 3
Installation: Use liquid
lubricant. Position window guide
seal (9) in window separator bar (3)
Pull window guide seal (9) out of window and window frame with end shaft of
5 roller.
separator bar (3).
Fig. 37
*BR00.45-Z-
Antifriction agent
1010-06A
6 Unscrew bolt (11).
Installation: Coat window
separator bar (3) in bottom area
with lubricant and install.
Unscrew bolt (10) and remove window separator
7 *BA72.12-P-
bar (3).
1013-01M
*BR00.45-Z-
Antifriction agent
1010-06A
8 Take out cover (5)
Connect power window switch of door lining
removed to left rear door control unit (N69/3) or After moving up crank window
9 right rear door control unit (N69/4). Switch on (1) switch off ignition and
ignition and move crank window (1) until bolt (6) disconnect power window switch.
is accessible.
Installation: Completely slide
crank window (1) toward rear and
10 Unscrew bolt (6). tighten with bolt (6).
*BA72.12-P-
1011-01M
Remove crank window (1) from rear door
11
window channel upward
12 Install in the reverse order
REAR DOOR
Number Designation Model 221
BA72.12-P-1011-01M Bolt, window to power window Nm 8
BA72.12-P-1013-01M Bolt, corner window separator bar to inner door Nm 8
panel
Fig. 115: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 116: Identifying Pulling Hook (140 589 02 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 117: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL CRANK WINDOW IN REAR DOOR - AR72.12-P-1910SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 118: Identifying Crank Window Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury from pinching
Secure windows against dropping, use only specified AS67.00-Z-
and crushing hands and feet
lifting tools, wear protective shoes. 0003-01A
when working on windows.
Notes on avoiding damage to
AH67.00-P-
windows installed in special
0003-01FB
high-security vehicles
Remove power window (2) of
AR72.12-P-
1 crank window (1) on left and
1810SXS
right rear door
*BA72.12-P-
2 Remove armored plate (3)
1003-01N
Remove locking bar armor plate *BA72.12-P-
3
(4) 1015-01N
Cut through butyl cord on rear of door lock
armor plate (5) with suitable blade.
Installation: Check butyl cord on rear of door
lock armor plate (5) for damage, replace if
necessary. If sections of the butyl cord are damaged,
be glued. Coat rear screws with sealant.
*BA72.12-P-
1013-01N
*BA72.12-P-
1014-01N
Remove door lock armor plate
4 *BR00.45-Z-
(5) Loctite 577
1067-01A
*BR00.45-Z-
Sealing cord
1086-01A
*BR00.45-Z-
Cleaner
1025-04A
Pull off bottom section of Installation: Glue in bottom section of window
window guide seal (6) on rear guide seal (6) into window guide rail (7).
5
window guide rail (7) until *BR00.45-Z-
screws (8, 9) are accessible MB special adhesive
1002-02A
Installation: Completely remove adhesive
residues from window guide rail (7) and clean
bonding surfaces.
Remove bolts (8, 9) and remove
6 *BA72.12-P-
window guide rail (7)
1009-01N
*BR00.45-Z-
Cleaner
1025-04A
Remove bolts (10, 11) and
*BA72.12-P-
7 remove side door lock armor
1012-01N
plate (12)
Remove clamping pliers and Aid of helper required.
8
carefully lower crank window (1) Fig. 44
Pull off upper section of window Installation: Glue in upper section of window
guide seal (6) from window guide seal (6) in window separator bar (13).
9
separator bar (13) until screws *BR00.45-Z-
(14, 15) are accessible MB special adhesive
1002-02A
Installation: Completely remove adhesive
residues from window separator bar (13) and clean
bonding surfaces.
Remove bolts (14, 15) and *BA72.12-P-
10 remove window separator bar 1010-01N
(13) *BA72.12-P-
1011-01N
*BR00.45-Z-
Cleaner
1025-04A
Remove bolt (16) and remove
11 exterior covering located in front
of window separator bar (13)
12 rear door toward inside Aid of helper required.
13 Install in the reverse order
REAR DOOR
Model 221 with
Number Designation code Z07/ Z07+Z19
BA72.12-P-1003-01N Bolt, armor plate to rear door Nm 8
BA72.12-P-1009-01N Bolt, window guide rail on side door lock armored Nm 8
plate
BA72.12-P-1010-01N Bolt, window separator bar to rear door window Nm 5
frame
BA72.12-P-1011-01N Bolt, window separator bar on side door lock Nm 8
armored plate
BA72.12-P-1012-01N Bolt, side door lock armored plate on rear door Nm 23
BA72.12-P-1013-01N Bolt, door lock armored plate on side door lock Nm 28
armored plate
BA72.12-P-1014-01N Bolt, door lock armored plate to rear door Nm 8
BA72.12-P-1015-01N Bolt, locking bar armored plate to door lock armored Nm 28
plate
Fig. 119: Identifying Clamping Pliers (220 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
Henkel Loctite Deutschland
GmbH
BR00.45-Z- Arabellastrasse 17
Loctite 577 81925 Munchen
1067-01A
Germany
Tel. +49 899268-0
www.Loctite.de
BR00.45-Z-
Adhesive Terokal 2444 A 000 989 92 71
1002-02A
BR00.45-Z-
Cleaner A 005 989 19 71
1025-04A
REMOVE/INSTALL REAR DOOR TRIANGULAR WINDOW - AR72.12-P-1940SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 120: Identifying Rear Door Triangular Window Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury from pinching
Secure windows against dropping, use only specified AS67.00-Z-
and crushing hands and feet
lifting tools, wear protective shoes. 0003-01A
when working on windows.
Notes on avoiding damage to
AH67.00-P-
windows installed in special
0003-01FB
high-security vehicles
Remove power window (2) of
AR72.12-P-
1 crank window on left and right
1810SXS
rear door
Remove locking bar armor plate *BA72.12-P-
2
(3) 1015-01N
Cut through butyl cord on rear of door lock
armor plate (4) with suitable blade.
Installation: Check butyl cord on rear of door
lock armor plate (4) for damage, replace if
necessary. If sections of the butyl cord are damaged,
replace only the damaged section. Clean surface to
be glued. Coat rear screws with sealant.
*BA72.12-P-
Remove door lock armor plate 1013-01N
3
(4)
*BA72.12-P-
1014-01N
*BR00.45-Z-
Loctite 577
1067-01A
*BR00.45-Z-
Sealing cord
1086-01A
*BR00.45-Z-
Cleaner
1025-04A
Pull off bottom section of Installation: Glue in bottom section of window
window guide seal (5) on rear guide seal (5) into window guide rail (6).
4
window guide rail (6) until *BR00.45-Z-
screws (7, 8) are accessible MB special adhesive
1002-02A
Installation: Completely remove adhesive
residues from window guide rail (6) and clean
adhesive area.
Remove bolts (7, 8) and remove
5 *BA72.12-P-
window guide rail (6)
1009-01N
*BR00.45-Z-
Cleaner
1025-04A
Remove bolts (9, 10) and remove *BA72.12-P-
6
side door lock armor plate (11) 1012-01N
Remove clamping pliers and Aid of helper required.
7 carefully lower crank window
(12) Fig. 44
Pull off upper section of window Installation: Glue in upper section of window
guide seal (5) from window guide seal (5) in window separator bar (13).
8
separator bar (13) until screws *BR00.45-Z-
(14, 15) are accessible MB special adhesive
1002-02A
Installation: Completely remove adhesive
residues from window separator bar (13) and clean
bonding area.
Remove bolts (14, 15) and
*BA72.12-P-
9 remove window separator bar
1010-01N
(13)
*BA72.12-P-
1011-01N
*BR00.45-Z-
Cleaner
1025-04A
Remove bolt (16) and remove
10 exterior covering located in front
of window separator bar (13)
Remove stationary window (1)
11
from rear door toward front
12 Install in the reverse order
REAR DOOR
Model 221 with
Number Designation code Z07/ Z07+Z19
BA72.12-P-1009-01N Bolt, window guide rail on side door lock armored Nm 8
plate
BA72.12-P-1010-01N Bolt, window separator bar to rear door window Nm 5
frame
BA72.12-P-1011-01N Bolt, window separator bar on side door lock Nm 8
armored plate
BA72.12-P-1012-01N Bolt, side door lock armored plate on rear door Nm 23
BA72.12-P-1013-01N Bolt, door lock armored plate on side door lock Nm 28
armored plate
BA72.12-P-1014-01N Bolt, door lock armored plate to rear door Nm 8
BA72.12-P-1015-01N Bolt, locking bar armored plate to door lock armored Nm 28
plate
Fig. 121: Identifying Clamping Pliers (220 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
Henkel Loctite Deutschland
Arabellastrasse 17
81925 Munchen
BR00.45-Z- Germany
Loctite 577
1067-01A Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-
Adhesive Terokal 2444 A 000 989 92 71
1002-02A
BR00.45-Z-
Cleaner A 005 989 19 71
1025-04A
REMOVE/INSTALL FIXED WINDOW IN REAR DOOR - AR72.12-P-1970SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.1 with code (297) Roller sun blinds in rear doors
Fig. 122: Identifying Rear Door Fixed Window Components (With Code 297)
Courtesy of MERCEDES-BENZ USA
Shown on model 221.0 without code (297) Roller sun blinds in rear doors
Fig. 123: Identifying Rear Door Fixed Window Components (Without Code 297)
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove door lining (1) from AR72.12-P-
1
rear door 1010SX
On vehicles with code (297) Roller sun blinds in rear
Remove cover strips (2, 3) doors
2.1
upward with pulling hook
Fig. 116
3 Remove inner sealing rail (5) Fig. 3
4 Remove outer sealing rail (6) Fig. 3
Installation: Use liquid lubricant. Position
window guide seal (4) in window separator bar (9)
Loosen window guide rail (4) and window frame with end of roller shaft.
5 in area of window separator
Fig. 37
bar (9)
*BR00.45-Z-
Antifriction agent
1010-06A
6 Unscrew bolt (8).
Installation: Coat window separator bar (9) in
bottom area with lubricant and install.
Unscrew bolt (7) and remove *BA72.12-P-
7
window separator bar (9) 1013-01M
*BR00.45-Z-
Antifriction agent
1010-06A
Installation: Coat seal of stationary window
Remove stationary window (10) with lubricant and insert.
8
(10) *BR00.45-Z-
Antifriction agent
1010-06A
9 Install in the reverse order
REAR DOOR
Number Designation Model 221
BA72.12-P-1013-01M Bolt, corner window separator bar to inner door Nm 8
panel
Fig. 124: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 125: Identifying Pulling Hook (140 589 02 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 126: Identifying Roller (171 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL SIDE WINDOW ROLLER BLIND - AR72.12-P-2000SX
MODEL 221.0 with CODE (297) Roller sun blinds in rear doors
MODEL 221.1 with CODE (297) Roller sun blinds in rear doors except CODE (Z07) Top protection
Fig. 127: Identifying Side Window Roller Blind Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.1
Fig. 128: Identifying Side Window Roller Blind & Motors
Courtesy of MERCEDES-BENZ USA
Removal
AR72.12-P-
1 Remove door lining from left or right rear door
1010SX
Disconnect electrical connector (2) from left rear door control unit
2
(N69/3) or right rear door control unit (N69/4)
Loosen inner paneling (7) from window frame until front bolts (5) are
3
accessible
4 Unscrew screws (3, 4, 5)
5 Remove clamp (6)
Press side window roller blind (1) off of inner door panel and window
6 Fig. 3
frame and remove together with inner paneling (7).
Install
*BA72.12-P-
Position side window roller blind (1) with inner paneling (7) on door 1014-01M
7
module and on window frame (arrow) and tighten bolts (3, 4) *BA72.12-P-
1015-01M
Pull inner paneling (7) on front window frame to side and tighten bolts *BA72.12-P-
8
(5). 1014-01M
9 Position door frame seal above inner paneling (7).
10 Install clip (6).
Connect electrical connector (2) to left rear door control unit (N69/3) or
11
right rear door control unit (N69/4)
AR72.12-P-
12 Install rear door lining
1010SX
REAR DOOR
Number Designation Model 221
BA72.12-P-1014- Bolt, rear side roller blind to rear door M5 Nm 5
01M M6 Nm 8
BA72.12-P-1015- Bolt, gearbox to door module Nm 8
01M
Fig. 129: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL SIDE WINDOW ROLLER BLIND - AR72.12-P-2000SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 130: Identifying Side Window Roller Blind Components
Courtesy of MERCEDES-BENZ USA
Shown on vehicle with hydraulic power windows
Remove/install
AR72.12-P-
1 Remove door lining (2) from left or right rear door
1010SXS
2 Remove paneling (3) from window frame Fig. 3
Expose electrical wiring harness and disconnect electrical
3 connector (4) from left rear door control unit (N69/3) or right
rear door control unit (N69/4)
Disconnect electrical connector (5) on left rear door woofer
4
(H4/3h2) or right rear door woofer (H4/4h2)
On vehicles with
Remove door hydraulic power window relay socket (K4/4)
5.1 hydraulic power
from bracket (6)
windows.
Remove bracket (6) together with left rear door woofer
6
(H4/3h2) or right rear door woofer (H4/4h2)
Remove bolts (7) on bracket of left rear side roller blind motor *BA72.12-P-
7
(M24/5) or right rear side roller blind motor (M24/6) 1024-01N
*BA72.12-P-
8 Remove bolts (8)
1024-01N
9 Remove bolts (9, 10) and remove side window roller blind (1)
10 Install in the reverse order
Normalize left rear side roller blind motor (M24/5) or right rear
11 side roller blind motor (M24/6) by moving side window roller
blind (1) all the way up and down
REAR DOOR
Model 221 with
Number Designation code Z07/ Z07+Z19
BA72.12-P-1024- Bolt, rear side roller blind to rear door M5 Nm 4
01N M6 Nm 4
Fig. 131: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REAR DOOR HOLDER - AR72.12-P-2100SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 132: Identifying Rear Door Holder Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR72.12-P-
1 Remove door lining from rear door
1010SX
Carefully unclip door holder (2); if
Press door holder (2) off of bracket (3)
2
on B-pillar with suitable screwdriver. necessary, use rag to protect against paint
damage.
*BA72.12-P-
1008-01M
3 Unscrew screw (4)
*BR00.45-Z-
Loctite 262
1059-02A
with lubricant to facilitate installation.
Remove door holder (2) toward rear
4 *BR00.45-Z-
from door module (1). Antifriction agent
1010-06A
5 Install in the reverse order
REAR DOOR
Number Designation Model 221
BA72.12-P-1008-01M Bolt, door holder to door module Nm 25
REPAIR MATERIALS
Number Designation Order number
Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
BR00.45-Z-1059-02A Loctite 262 Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL REAR DOOR HOLDER - AR72.12-P-2100SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 133: Identifying Rear Door Holder Components
Courtesy of MERCEDES-BENZ USA
Removing
When working on unsecured rear door,
ensure that it does not swing all the way
open, otherwise, the rear door can be
damaged.
Remove door lining from left or right rear AR72.12-P-
1
door 1010SXS
Remove door hydraulic power window relay
2
socket (K4/4) from bracket (2)
Remove bracket (2) with left rear door
3 woofer (H4/3h2) or right rear door woofer
(H4/4h2)
Remove bracket (3) with left rear side roller
4 blind motor (M24/5) or right rear side roller
blind motor (M24/6)
Separate door foil (4) in front and bottom AR72.12-P-
5
area of rear door 0105SXS
6 Remove door holder armor plate (5)
Pry off door holder (1) of ball head bolt (6)
7 Fig. 3
on rear door
Pry off door holder (1) of ball head bolt (7)
8 Fig. 3
on B-pillar
This allows the door holder (1) to
Moisten grommet (8) and front part of door be pulled through the grommet (8) *BR00.45-Z-
9
holder (1) with liquid lubricant more easily. 1010-06A
Antifriction agent
Turn door holder (1), carefully pull inward Counterhold grommet (8) from
10 through grommet (8) and remove from rear inside; otherwise, it can separate from
door toward rear the rear door or be damaged.
Install
Moisten grommet (8) and front part of door *BR00.45-Z-
11 Antifriction agent
holder (1) with liquid lubricant 1010-06A
Insert door holder (1) into rear door and Counterhold grommet (8) from
12
carefully press outward through grommet (8) outside; otherwise, it can separate from
the rear door or be damaged.
Press door holder (1) onto ball head bolt (7) Ensure that door holder (1) is
13
on B-pillar properly seated on ball head bolt (7).
Press door holder (1) onto ball head bolt (6) Ensure that door holder (1) is
14
on rear door properly seated on ball head bolt (6).
*BA72.12-P-
15 Install door holder armor plate (5)
1026-01N
AR72.12-P-
16 Fasten door foil (4) to rear door
0105SXS
Install bracket (3) with left rear side roller
*BA72.12-P-
17 blind motor (M24/5) or right rear side roller
1024-01N
blind motor (M24/6)
Install bracket (2) with left rear door woofer
18
(H4/3h2) or right rear door woofer (H4/4h2)
Install door hydraulic power window relay
19
socket (K4/4) to bracket (2)
AR72.12-P-
20 Install rear door lining
1010SXS
REAR DOOR
Model 221 with
Number Designation code Z07/ Z07+Z19
BA72.12-P-1024- Bolt, rear side roller blind to rear door M5 Nm 4
01N M6 Nm 4
BA72.12-P-1026- Bolt, armored plate door holder on rear door Nm 28
01N
Fig. 134: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67
REMOVE/INSTALL DOOR INTERIOR ACTUATING MECHANISM ON REAR SIDE DOOR -
AR72.12-P-2310SX
MODEL 221.0 /1
Fig. 135: Identifying Rear Door Interior Actuating Mechanism Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Vehicles without code AR72.12-P-
Remove door lining (1) on left and right rear door and (Z07) Top protection 1010SX
1
lay with front side down on suitable subsurface. Vehicles with code (Z07) AR72.12-P-
Top protection 1010SXS
Loosen bolts from trim strip on door lining (1) of rear AR72.12-P-
2
door 1050SX
Remove left rear inner door handle illumination (E17/13)
3
or right rear inner door handle illumination (E17/14)
4 Unscrew bolts (3, 4)
Remove left rear seat control switch group (S55/1) or Do not disconnect
5
right rear seat control switch group (S55/2) electrical connector (5).
6 Remove inside door opener (2) from door lining (1)
7 Install in the reverse order
REMOVE/INSTALL OUTER REAR DOOR HANDLE - AR72.12-P-2410SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0 with code (889) Keyless Go
Fig. 136: Identifying Outer Rear Door Handle Components
Courtesy of MERCEDES-BENZ USA
Remove/install
*BA72.12-
Remove outer door handle guide P-1005-01M
1
(1) from rear door
TORX-screwdriver, length 250 mm, T20
On vehicles without code (889) Keyless Go
Pull outer door handle (1) out of
Installation: Ensure that the seals (3) are
2.1 bearing bracket (5) toward rear and
seated correctly at the rear door and the outer door
remove
handle (1) in the bearing bracket (5).
On vehicles with code (889) Keyless Go
Arrest connection (4) of electrical connector
Pull outer door handle (1) out of (2) on bearing bracket (5) in assembly position
bearing bracket (5) toward rear, Installation: Unlock connection (4) at bearing
2.2
disconnect electrical connector (2) bracket (5) and press toward inside after
and remove outer door handle (1) connecting the electrical connector (2). Ensure
that seals (3) are seated correctly on rear door and
outer door handle (1) in bearing bracket (5)
3 Install in the reverse order
REAR DOOR
Number Designation Model 221
BA72.12-P-1005-01M Bolt, guide on rear door Nm 3
REMOVE/INSTALL OUTER REAR DOOR HANDLE - AR72.12-P-2410SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 137: Identifying Outer Rear Door Handle & Guide
Courtesy of MERCEDES-BENZ USA
Remove/install
*BA72.12-P-
Remove grommet on front side of left and 1021-01N
1 right rear door, loosen screw beneath and
remove outer door handle guide (2) TORX-screwdriver, length 250 mm,
T20
Pull outer door handle (1) out of bearing Installation: Ensure that seals are
2 seated correctly on rear door and outer
bracket toward rear and remove
door handle (1) in bearing bracket.
3 Install in the reverse order
REAR DOOR
Model 221 with code
Number Designation Z07/ Z07+Z19
BA72.12-P-1021-01N Bolt, guide on rear door Nm 3
REMOVE/INSTALL REAR DOOR LOCK - AR72.12-P-2510SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 138: Identifying Rear Door Lock Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
12.9.05 Clearance in door lock Model 221 *BE72.12-P-1001-01D
Remove
AR72.12-P-
1 Remove door module (4)
0103SX
Remove electric wiring harness (2)
2
from door lock (1).
3 Remove lock button (3). Mark installation position.
Unclip door lock (1) from door lock
4
bracket (5)
Unclip bearing bracket (7) from door
5.1 When replacing door lock (1)
lock (1)
6.1 Remove cover (9) When replacing door lock (1)
Remove Bowden cables (10, 11) from
7.1 When replacing door lock (1)
locking bar (14) on door lock (1)
Install
When replacing door lock (1)
Hook locking bar (14) into door lock
8.1 Hook locking bar (14) into lower hole
(1)
in safety lever on door lock (1).
Hook Bowden cables (10, 11) into door
9.1 When replacing door lock (1)
lock (1)
Install bearing bracket (7) on door lock
10.1 When replacing door lock (1)
(1)
Clip door handle (6) into bearing
11.1 When replacing door lock (1)
bracket (7).
Install door handle guide (15) in bearing
12.1 When replacing door lock (1)
bracket (7).
When replacing door lock (1)
Adjust clearance (A) on adjusting screw *BE72.12-P-
13.1 Lift ant-twist lock on bearing bracket 1001-01D
(8)
(7) to turn adjusting screw (8).
14.1 Install new cover (9) When replacing door lock (1)
Remove door handle (6) from bearing
15.1 When replacing door lock (1)
bracket (7).
Remove door handle guide (15) from
16.1 When replacing door lock (1)
bearing bracket (7).
Install door lock (1) on door lock Ensure that grommets (12, 13) are
17
bracket (5). seated correctly in door module (4).
18 Install lock button (3).
19 Attach wiring harness (2)
AR72.12-P-
20 Install door module (4)
0103SX
CHECK AND ADJUSTMENT VALUES FOR REAR DOOR
Number Designation Model 221
BE72.12-P-1001-01D Clearance in door lock mm 1.3 (+0.3)
REMOVE/INSTALL REAR DOOR LOCK - AR72.12-P-2510SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 139: Identifying Rear Door Lock Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Remove inner door panel from AR72.12-P-
1
left or right rear door 0104SXS
Remove locking bar armor *BA72.12-
2
plate (2) P-1015-01N
Cut through butyl cord on rear of door lock armor
plate (3) with suitable blade.
Installation: Check butyl cord on rear of door lock
armor plate (3) for damage, replace if necessary. If
sections of the butyl cord are damaged, replace only
Remove door lock armor plate the damaged section. Clean surface to be glued.
3
(3) Coat rear screws with sealant.
*BA72.12-
P-1013-01N
*BA72.12-
P-1014-01N
*BR00.45-
Loctite 577
Z-1067-01A
*BR00.45-
Sealing cord
Z-1086-01A
*BR00.45-
Cleaner
Z-1025-04A
Pull off bottom section of Installation: Glue in bottom section of window
window guide seal (4) on rear guide seal (4) into window guide rail (5).
4
window guide rail (5) until *BR00.45-
screws (6, 7) are accessible MB special adhesive
Z-1002-02A
Installation: Completely remove adhesive
residues from window guide rail (5) and clean adhesive
area.
Remove bolts (6, 7) and
5 *BA72.12-
remove window guide rail (5)
P-1009-01N
*BR00.45-
Cleaner
Z-1025-04A
Remove bolts (8, 9) and
*BA72.12-
6 remove side door lock armor
P-1012-01N
plate (10)
Installation: Check clearance (A) and, if
necessary, adjust with adjusting nuts (11) on Bowden
Loosen adjusting nuts (11),
cable (12). For this purpose, pull outer door handle
remove Bowden cable (12) *BE72.12-P-
7 (15) until resistance is felt and measure clearance (A)
from bracket (13) and unhook 1001-01E
between outer door handle guide (16) and outer door
from door lock (1)
handle (15).
Clearance in door lock
Remove bolts (14), remove *BA72.12-
8
door lock (1) P-1022-01N
9 Install in the reverse order
CHECK AND ADJUSTMENT VALUES FOR REAR DOOR
Number Designation Model 221 with code Z07
BE72.12-P-1001-01E Clearance in door lock mm 3 to 5
REAR DOOR
Model 221 with
Number Designation code Z07/ Z07+Z19
BA72.12-P-1009-01N Bolt, window guide rail on side door lock armored Nm 8
plate
BA72.12-P-1012-01N Bolt, side door lock armored plate on rear door Nm 23
BA72.12-P-1013-01N Bolt, door lock armored plate on side door lock Nm 28
armored plate
BA72.12-P-1014-01N Bolt, door lock armored plate to rear door Nm 8
BA72.12-P-1015-01N Bolt, locking bar armored plate to door lock armored Nm 28
plate
BA72.12-P-1022-01N Bolt, door lock to rear door Nm 7
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
Henkel Loctite Deutschland
GmbH
Arabellastrasse 17
BR00.45-Z- 81925 Munchen
Loctite 577
1067-01A Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de
BR00.45-Z-
Adhesive Terokal 2444 A 000 989 92 71
1002-02A
BR00.45-Z-
Cleaner A 005 989 19 71
1025-04A
REMOVE/INSTALL CENTER DOOR - AR72.14-P-0010SXS
MODEL 221.176 with CODE (Z07) Top protection with CODE (Z19) S600 Pullman Guard state sedan
Fig. 140: Identifying Center Door Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear of moving AS00.00-Z-
removing, installing or aligning
parts. 0011-01A
hoods, doors, trunk lids, liftgates or
sliding roof
Before opening and closing the center door
1 Open center door (1) (1) open front and rear door. The center door (1)
should be slammed, not pushed closed.
AR72.14-P-
2 Remove window in center door (1)
0150SXS
Disconnect electrical door
3
separation point (2)
Press door holder (3) off of ball stud
4 Fig. 3
(4) on B1-pillar
Remove caps (5) and remove bolts *BA72.14-
5
below P-1004-01B
Carefully remove center door (1) to prevent
Remove center door (1) from door damage to front door and rear door.
6
hinge leaves on B1-pillar See GOTIS for multifunctional lift/holding device
http://gotis.aftersales.mercedes-benz.com
7 Install in the reverse order
Check adjustment of center door (1), AR72.14-P-
8
correct if necessary 0015SXS
CENTER DOOR
Number Designation Model 221.176 with code Z07 and code Z19
BA72.14-P-1004-01B Bolt at door hinge shaft Nm 25
Fig. 141: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
ADJUST CENTER DOOR - AR72.14-P-0015SXS
MODEL 221.176 with CODE (Z07) Top protection with CODE (Z19) S600 Pullman Guard state sedan
Fig. 142: Identifying Center Door Components
Courtesy of MERCEDES-BENZ USA
Checking
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear of AS00.00-Z-
installing or aligning hoods, doors, moving parts. 0011-01A
trunk lids, liftgates or sliding roof
*BE60.00-
1 Check gaps around center door (1) P-1005-01R
Fig. 7
Adjust
Remove striker wedge (2) at bottom of
2
center door (1)
3 Remove lock striker (4) Mark installation position of lock striker
(4), to facilitate reinstallation.
Support center door (1) with floor jack Do not support center door (1) on outer
and suitable block of wood, position paneling, otherwise, the center door (1) can be
4 damaged by its high dead weight.
below mounting location of striker
wedge (2) See GOTIS for NIKE passenger car floor jack
http://gotis.aftersales.mercedes-benz.com
Loosen bolts (5) on B1-pillar and adjust Adjust gap dimensions at center door (1) *BE60.00-
5 corresponding gap dimensions by by lifting or lowering floor jack. P-1005-01R
moving center door (1) Fig. 7
*BA72.14-
6 Tighten bolts (5)
Loosen bolts (6) on center door (1) and
The contour of the front door (1) must be
adjust transition between front door and
7 flush with the contour of the center door or
center door (1) by moving center door
project by a maximum of 1 mm.
(1)
Tighten bolts (6), lower and remove *BA72.14-
8 See GOTIS for NIKE passenger car floor jack P-1006-01B
floor jack
http://gotis.aftersales.mercedes-benz.com
Insert lock striker (4) and screw in bolts It should still be possible to adjust the lock
9
(3) up to stop striker (4).
Adjust transition between center door The contour of the center door (1) must be
10 (1) and rear door by moving lock striker flush with the contour of the rear door or
(4). project by a maximum of 1 mm.
*BA72.14-
11 Tighten screws (3)
P-1007-01B
Repair paint damage to screw heads
12
with suitable touch-up paint pen
Only tighten bolts on striker wedge (2)
13 Install striker wedge (2)
hand-tight.
*BR00.45-
14 Coat oval head screw (7) with grease Multipurpose grease Z-1034-
06A
Carefully close and open center door
(1) and determine on basis of grease
impression on raised head screw (7),
whether height of striker wedge (2) The front door (1) is supported on the oval
head screws (7) by the striker wedge (2) so that
15 requires correction by inserting shims.
If the front door (1) is hard to close or its entire dead weight is not on the lock striker
(4). The front door (1) should be easy to close.
cannot be closed at all, correct the
height of the striker wedge (2) by
removing shims
16 Tighten bolts on striker wedge (2)
CHECK VALUES FOR GAPS
Number Designation Model 221
BE60.00-P-1005- Gap Center door to front door Dimension "T" mm 4.5 (±0.5)
01R dimension Center door to rear door Dimension "U" mm 4.5 (±0.5)
Trim strip of center door to Dimension "V" mm 4.5 (±0.5)
roof frame See picture -
CENTER DOOR
Model 221.176 with code Z07 and
Number Designation
code Z19
BA72.14-P-1005- Bolt for door hinge assembly to B1-S-
Nm 40
01B pillar
BA72.14-P-1006- Screw for door hinge on inner door
Nm 40
01B panel
BA72.14-P-1007-
Bolt, lock striker to B2-pillar Nm 28
01B
Fig. 143: Identifying Feeler Gauge (129 589 03 21 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1034-06A MB multipurpose grease A 001 989 34 51 10
REMOVE/INSTALL WINDOW IN CENTER DOOR - AR72.14-P-0150SXS
MODEL 221.176 with CODE (Z07) Top protection with CODE (Z19) S600 Pullman Guard state sedan
Fig. 144: Identifying Center Door Window Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 145: Identifying Center Door Window Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury caused by hands
or feet being pinched or crushed Secure windows against dropping; use only specified AS67.00-Z-
when working on windshield or lifting tools; wear safety shoes. 0003-01A
windows
Notes on avoiding damage to
AH67.00-P-
windows installed in special
0003-01FB
high-security vehicles
Lift waistline trim strip (2) from rear, then lift
toward front piece by piece
Remove waistline trim strip (2)
1 The waistline trim strip (2) is glued to the center
from center door (1)
door (1) and the window (6) and is damaged when Fig. 3
removed. For this reason always replace waistline
trim strip (2).
Remove B-joint seal (3) from
2
front trim strip (4)
Carefully loosen front trim (4)
3 and rear trim (5) along rubber
seal (arrows).
The front trim (4) and rear trim (5) are glued to
trim (5) starting at top this reason always replace front trim (4) and rear trim
4
downward from center door (1). (5).
The rubber seal (arrows) is glued to the window
Carefully loosen rubber seal
5 (6). If the rubber seal (arrows) should be damaged,
(arrows) from window (6).
replace.
Cut leather coating on window
6 frame (8) in area of bolts (9) in
cross pattern
Lift cut leather coating on
Carefully loosen leather from window frame to
7 window frame (8) out of center
prevent damaging leather.
door (1).
Secure window (6) against
8 falling down with clamping Fig. 44
pliers
9 Remove bolts (10)
Remove inside door handle (11)
10
from inner door panel (14).
Unhook release cable (12) from
11
inside door handle (11)
12 Remove bolts (13)
Remove inner door panel (14) Guide release cable (12) through inner door panel
13
from center door (1) (14).
Detach door foil from center Carefully cut butyl cord between door foil and
14 center door (1). Carefully detach door foil. Otherwise
door (1)
paint can be damaged.
*BA72.14-P-
15 Unscrew bolts (15)
1001-01B
Remove lock cover guard plate
16 Unhook release cable (12) from door lock (18).
(16)
*BA72.14-P-
17 Remove bolts (17)
1002-01B
18 Remove door lock (18)
Fasten nuts (19) to adjustment This secures the nuts (19) against twisting on the
19
screws (20) with adhesive tape adjustment screws (20).
Completely turn nuts (21)
20
upward
*BA72.14-P-
21 Remove bolts (9)
1003-01B
Remove rear glass channel
guard plate (23) and front glass
22
channel guard plate (24)
downward from center door (1).
Remove clamping pliers only when window (6) is
23 Remove clamping pliers
secured against falling down by two helpers
Fig. 44
Lower window (6) down to To lower the window (6) at least helpers are
24
console (22) required.
Remove window (6) toward To remove window (6) at least two helpers are
25
outside from center door (1) required.
Cut off remaining adhesive from
26 consoles (7) with suitable
scraper
Repair paint damage on *BR00.45-Z-
27
consoles (7) with primer stick 1012-07A
Install
Insert window (6) from outside
To install window (6) at least two helpers are
28 into center door (1) and set
down on console (21) required.
Completely move window (6)
29 Aid of 2 helpers required.
upward into window frame
Secure window (6) against
30 falling down with clamping Fig. 44
pliers
Install rear glass channel guard
plate (23) and front glass
31
channel guard plate (24) from
bottom in center door (1).
*BA72.14-P-
32 Screw in bolts (9)
1003-01B
Slide adjustment screws (20) The adjustment screws (20) should make contact
33 upward until nuts (19) and with plates (25). If this is not the case, adjust
consoles (22) make contact adjustment screws (20) accordingly.
Tighten nuts (21) on adjustment
34
screws (20)
35 Remove clamping pliers Fig. 44
If sections of the sealing strip are damaged,
replace only the damaged section. Lay new sealing
strip parallel to damaged sealing strip on door lock.
Check sealing strip o door lock Previously clean bonding surface.
36 (18) for damage, replace if
*BR00.45-Z-
necessary. Cleaner
1025-04A
*BR00.45-Z-
Sealing strip
1036-01A
37 Install door lock (18).
Use Loctite thread locking agent.
38 Screw in bolts (17) *BA72.14-P-
1002-01B
*BR00.45-Z-
Loctite 243
1066-01A
Insert lock cover guard plate
39 Hook release cable (12) into door lock (18)
(16)
*BA72.14-P-
40 Screw in bolts (15)
1001-01B
When replacing door foil, remove butyl cord
residues from inner door panel and clean bonding
Check door foil for damage,
41 surface
replace if necessary
*BR00.45-Z-
Cleaner
1025-04A
If sections of the butyl cord are damaged, replace
only the damaged section. Route new butyl cord
parallel to the damaged butyl cord on the door foil.
Inspect butyl cords for damages, Previously clean bonding surface.
42
replace if necessary *BR00.45-Z-
Sealing cord
1086-01A
*BR00.45-Z-
Cleaner
1025-04A
Ensure that door foil is correctly positioned on
Align door foil on center door center (1).
43
(1) and roll on
Fig. 23
Install inner door panel (14) on Guide release cable (12) through inner door panel
44
center door (1) (14).
45 Screw in bolts (13)
Hook release cable (12) into
46
inside door handle (11)
Install inside door handle (11)
47
on inner door panel (14)
48 Screw in bolts (10)
Glue cut window frame leather *BR00.45-Z-
49 Universal adhesive
coating (8) to center door 1003-02A
The bonding areas on the front trim (4) and rear
trim (5) must be free of dust and grease to prevent
Clean new front trim (4) and
50 adhesion problems when bonding in.
new rear front trim (5) at rear.
*BR00.45-Z-
Cleaner
1025-04A
Intermediate piece Fig. 149
Cartridge gun gotis://K_67.0_02.0
51 Prepare adhesive cartridge
*BR00.45-Z-
Adhesive Sika 555
1009-02B
Install front trim (4) and rear trim (5) on consoles
(7) within 10 minutes after applying adhesive
starts to decrease.
52 Apply adhesive to consoles (7) *BR00.45-Z-
Adhesive Sika 555
1009-02B
Do not perform any actions for approx. 2 h during
the curing time for the adhesive, because this can
change the installation position of the front trim (4)
Install front trim (4) and rear
53 and rear trim (5)
trim (5) on center door (1)
Align front trim (4) and rear trim (5)
Fix front trim (4) and rear trim (5) in place with
adhesive strips.
Install B-joint seal (3) on front
54
trim (4)
Carefully remove exiting adhesive.
*BR00.45-Z-
Bond front trim (4) and rear trim Terostat MS 930 black
55 1040-02B
(5) to rubber seal (arrows)
Pure benzine/benzine 100/140 (free of aromatic *BR00.45-Z-
compounds), 5-liter metal canister, article no.: 17042 1048-04A
Apply adhesive to beltline on *BR00.45-Z-
56 Terostat MS 930 black
center door (1) 1040-02B
Install waistline trim strip (2) on
57
center door (1)
Carefully remove exiting adhesive.
*BR00.45-Z-
Glue rubber seal to waistline Terostat MS 930 black
58 1040-02B
trim strip (2) with window (6)
Pure benzine/benzine 100/140 (free of aromatic *BR00.45-Z-
compounds), 5-liter metal canister, article no.: 17042 1048-04A
Carefully remove exiting adhesive.
Glue rubber seal (arrows) to *BR00.45-Z-
Terostat MS 930 black
59 1040-02B
window (6)
Pure benzine/benzine 100/140 (free of aromatic *BR00.45-Z-
compounds), 5-liter metal canister, article no.: 17042 1048-04A
CENTER DOOR
Model 221.176 with
Number Designation code Z07 and code Z19
BA72.14-P-1001-01B Bolt at guard plate for lock cover Nm 8
BA72.14-P-1002-01B Screw at door lock Nm 10
BA72.14-P-1003-01B Bolt at guard plate for glass channel Nm 28
Fig. 146: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 147: Identifying Chuck (220 589 04 31 00)
Courtesy of MERCEDES-BENZ USA
Fig. 148: Identifying Roller (168 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 149: Identifying Intermediate Piece (000 589 86 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-
Sealing strip A 140 989 00 98
1036-01A
BR00.45-Z-
Loctite 243 A 613 989 09 71
1066-01A
BR00.45-Z- Soft top frame sealing profile with metal core 35 m,
A 005 989 12 71 10
1086-01A SEALANT/butyl Bostik 1127
BR00.45-Z-
Adhesive/Dekalin 3649 A 000 989 82 71
1003-02A
BR00.45-Z-
Cleaner A 005 989 19 71
1025-04A
Otto Fischar GmbH & Co. KG
Kaiserstrasse 221 66133
BR00.45-Z- Pure benzine/benzine 100/140 (free of aromatic Saarbrucken Germany
1048-04A compounds), 5-liter metal canister, article no.: 17042 Tel +49 681 98217-0
Fax:+49 681 98217-99
www.fischar.de
BR00.45-Z-
Primer stick A 000 986 27 50
1012-07A
Sika Deutschland GmbH
Stuttgarter Straße 139 72574
BR00.45-Z- Bad Urach 0 Germany
Adhesive Sika 555
1009-02B Tel. +49 7125 940-761
Fax +49 7125 940-763
www.sika-industry.de
Henkel Teroson GmbH
Hans-Bunte-Strasse 4 69123
BR00.45-Z- Heidelberg Germany
Terostat MS 930 black
1040-02B Tel. +49 6221704-0
Fax +49 6221704-698
www.teroson.de
REMOVE/INSTALL POWER WINDOW HYDRAULIC PUMP - AR72.29-P-0300SXS
MODEL 221.1 with CODE (Z07) Top protection with hydraulic power windows
Fig. 150: Identifying Power Window Hydraulic Pump Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Switch off the ignition and remove the transmitter
1
key from the EIS control unit
Power window in front AR72.10-P-
Relieve pressure in pressure reservoir of hydraulic door 1800-06SXS
2
power window AR72.12-P-
Power window in rear door
1810-06SXS
3 Remove spare tire in trunk
Remove cover (2) of power window hydraulic pump
4
(Y71/1)
Unlock retainer (4) and
Expose and disconnect all hydraulic lines (3) on
5 disconnect hydraulic lines
power window hydraulic pump (Y71/1)
(3).
Separate power supply hydraulic unit power supply
6 connector (X201) and power window control lines
connector (X202)
Remove nuts (5) and remove power window
7 hydraulic pump (Y71/1) from trunk together with
carrier plate (6)
8 Install in the reverse order
Check fill level of power window hydraulic pump
9
(Y71/1); correct if necessary
AP67.30-P-
Power window system - check oil level
6710SX
REMOVE/INSTALL FRONT DOOR CONTROL UNIT - AR72.29-P-1000SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 151: Identifying Front Door Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to electronic
AH54.00-P-
components due to electrostatic
0001-01A
discharge
When replacing left front door control
unit (N69/1) or right front door control
Buffer basic data of left front door
unit (N69/2).
control unit (N69/1) or right front door
1.1 Installation: Transfer buffered basic
control unit (N69/2) in STAR
DIAGNOSIS data to new left front door control unit
(N69/1) or new right front door control
unit (N69/2).
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
AR72.10-P-
2 Remove front door lining
1000SX
Switch off ignition and withdraw
Keyless Go start/stop button only for
3 transmitter key or Keyless Go start/stop
vehicles with code (889) Keyless Go.
button from the EIS [EZS] control unit
Disconnect electrical connectors (1)
Installation: Ensure that electrical
4 from left front door control unit (N69/1)
lines are routed properly.
or right front door control unit (N69/2)
Disconnect electrical connectors (2) and Installation: Ensure that electrical
5
unclip from carrier plate (6). lines are routed properly.
6 Separate cable tie (3)
7 Unclip clip (4)
Unscrew bolt (5) and remove left front
*BA72.10-P-
8 door control unit (N69/1) or right front
1011-01Q
door control unit (N69/2)
9 Install in the reverse order
FRONT DOOR
Number Designation Model 221
BA72.10-P-1011-01Q Bolt, door control unit on door module Nm 5
REMOVE/INSTALL FRONT DOOR CONTROL UNIT - AR72.29-P-1000SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 152: Identifying Front Door Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
When replacing left front door control
unit (N69/1) or right front door control
Buffer basic data for left door control unit unit (N69/2).
1.1 (N69/1) or right front door control unit Installation: Transfer buffered
(N69/2) in STAR DIAGNOSIS basic data to new left front door control
unit (N69/1) or new right front door
control unit (N69/2).
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
Remove door lining from left or right AR72.10-P-
2
front door 1000SXS
Switch off the ignition and remove the
3
transmitter key from the EIS control unit
Expose electrical wiring harnesses in area
Observe routing of electrical wiring
4 of left front door control unit (N69/1) or
harnesses.
right front door control unit (N69/2)
Disconnect all electrical connectors from
5 left front door control unit (N69/1) or
right front door control unit (N69/2)
Remove screws (1) and remove left front
door control unit (N69/1) or right front *BA72.10-P-
6
door control unit (N69/2) from inner door 1018-01R
panel (2)
7 Install in the reverse order
FRONT DOOR
Model 221 with code
Number Designation Z07/Z07+Z19
BA72.10-P-1018-01R Bolt, door control unit to inner door panel Nm 5
REMOVE/INSTALL REAR DOOR CONTROL UNIT - AR72.29-P-1100SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 153: Identifying Rear Door Control Units & Bolt
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
When replacing left rear door control
unit (N69/3) or right rear door control
Intermediate store basic data of left rear
unit (N69/4).
door control unit (N69/3) or right rear
1.1 Installation: Transfer buffered
door control unit (N69/4) in STAR
DIAGNOSIS basic data to new left rear door control
unit (N69/3) or new right rear door
control unit (N69/4).
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
AR72.12-P-
2 Remove rear door lining
1010SX
Switch off ignition and withdraw Keyless Go start/stop button only
3 transmitter key or Keyless Go start/stop for vehicles with code (889) Keyless
button from the EIS [EZS] control unit Go.
Disconnect all electrical connectors from
Installation: Ensure that electrical
4 left rear door control unit (N69/3) or
right rear door control unit (N69/4) lines are routed properly.
Unscrew bolts (1) and remove left rear
*BA72.12-P-
5 door control unit (N69/3) or right rear
1012-01M
door control unit (N69/4)
6 Install in the reverse order
REAR DOOR
Number Designation Model 221
BA72.12-P-1012-01M Bolt, door control unit on door module Nm 8
REMOVE/INSTALL REAR DOOR CONTROL UNIT - AR72.29-P-1100SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 154: Identifying Rear Door Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
When replacing left rear door control
unit (N69/3) or right rear door control
Intermediate store basic data of left rear unit (N69/4).
door control unit (N69/3) or right rear
1.1 Installation: Transfer buffered
door control unit (N69/4) in STAR
basic data to new left rear door control
DIAGNOSIS
unit (N69/3) or new right rear door
control unit (N69/4).
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
Remove door lining from left or right rear AR72.12-P-
2
door 1010SXS
Switch off the ignition and remove the
3
transmitter key from the EIS control unit
Disconnect all electrical connectors from
4 left rear door control unit (N69/3) or right
rear door control unit (N69/4)
Remove screws (1) and remove left rear
door control unit (N69/3) or right rear *BA72.12-P-
5
door control unit (N69/4) from inner door 1023-01N
panel (2)
6 Install in the reverse order
REAR DOOR
Model 221 with code
Number Designation Z07/ Z07+Z19
BA72.12-P-1023-01N Bolt, door control unit to inner door Nm 5
panel
REMOVE/INSTALLING FRONT DOOR POWER WINDOW MOTOR - AR72.29-P-1860SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Fig. 155: Identifying Front Door Power Window Motor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR72.10-P-
1 Remove door lining from left or right front door
1000SX
2 Disconnect electrical connector (1)
*BA72.10-P-
3 Remove bolts (2)
1010-01Q
Loosen left front power window motor (M10/3) or right front power
4 Fig. 3
window motor (M10/4) and remove
5 Install in the reverse order
6 Normalize power window motor
FRONT DOOR
Number Designation Model 221
BA72.10-P-1010-01Q Bolt, power window motor to door module Nm 3
Fig. 156: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL POWER WINDOW MOTOR IN REAR DOOR - AR72.29-P-1880SX
MODEL 221.0
MODEL 221.1 except CODE (Z07) Top protection
Shown on model 221.0
Fig. 157: Identifying Rear Door Power Window Motor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR72.12-P-
1 Remove door lining from left or right rear door
1010SX
2 Disconnect electrical connector (1)
*BA72.12-P-1010-
3 Remove bolts (2)
01M
Loosen left rear power window motor (M10/5) or right rear power
4 Fig. 3
window motor (M10/6) and remove
5 Install in the reverse order
6 Normalize power window motor
REAR DOOR
Number Designation Model 221
BA72.12-P-1010-01M Bolt, power window motor to door Nm 3
module
Fig. 158: Identifying Wedge Tool (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL DRIVE MOTOR FOR REAR DOOR SIDE WINDOW ROLLER BLIND -
AR72.29-P-1890SX
MODEL 221.0 with CODE (297) Roller sun blinds in rear doors
MODEL 221.1 with CODE (297) Roller sun blinds in rear doors except CODE (Z07) Top protection
Fig. 159: Identifying Rear Door Side Window Roller Blind Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.1
Remove/install
AR72.12-P-
1 Remove door lining on left and right rear door (1).
1010SX
Disconnect electrical connector (2) from left rear door control unit (N69/3) or
2
right rear door control unit (N69/4)
*BA72.29-P-
3 Remove bolts (3)
1001-01B
Remove left rear side roller sun blind motor (M24/5) or right rear side roller sun
4
blind motor (M24/6)
5 Install in the reverse order
Normalize left rear side roller blind motor (M24/5) or right rear side roller blind
6 motor (M24/6) by completing moving up corresponding rear side roller blind
when performing final function test.
REAR DOOR - ELECTRICAL SYSTEM
Number Designation Model 221
BA72.29-P-1001-01B Bolt, rear side roller blind motor to Nm 3
gearbox
REMOVE/INSTALL DRIVE MOTOR FOR REAR DOOR SIDE WINDOW ROLLER BLIND -
AR72.29-P-1890SXS
MODEL 221.1 with CODE (Z07) Top protection
Fig. 160: Identifying Rear Door Side Window Roller Blind Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR72.12-P-
1 Remove door lining from left or right rear door
1010SXS
Disconnect electrical connector (1) from left rear door control
2
unit (N69/3) or right rear door control unit (N69/4)
Expose electrical wiring harness of left rear side roller blind Observe routing
3 of electrical wiring
motor (M24/5) or right rear side roller blind motor (M24/6)
harness.
*BA72.29-P-
4 Remove bolts (2)
1001-01B
Remove left rear side roller sun blind motor (M24/5) or right
5
rear side roller sun blind motor (M24/6)
6 Install in the reverse order
rear side roller blind motor (M24/6) by moving corresponding
7
rear side roller blind all the way up and down
REAR DOOR - ELECTRICAL SYSTEM
Number Designation Model 221
BA72.29-P-1001-01B Bolt, rear side roller blind motor to gearbox Nm 3
DTC INDEX
ME9.7 Engine 273
ENGINE PERFORMANCE DTCS
ME9.7 Engine 273
MB DTC Generic DTC Description Only - No Test
Available
59 P0014 Continuous camshaft adjustment
(RIGHT): Incorrect position of the
exhaust camshaft (P0014)
60 P0015 Continuous camshaft adjustment
(RIGHT): Incorrect position of the
exhaust camshaft (P0015)
63 P0024 Continuous camshaft adjustment
(LEFT): Incorrect position of the
exhaust camshaft (P0024)
64 P0025 Continuous camshaft adjustment
(LEFT): Incorrect position of the
exhaust camshaft (P0025)
65 P2091 Component Y49/7 (Right
camshaft exhaust solenoid) has a
short circuit to positive. (P2091)
66 P2090 Component Y49/7 (Right
camshaft exhaust solenoid) has a
short circuit to ground. (P2090)
67 P0013 Component Y49/7 (Right
camshaft exhaust solenoid) has an
open circuit in the wiring. (P0013)
69 P2091 Component Y49/6 (Left camshaft
exhaust solenoid) has a short
circuit to positive. (P2091)
70 P2090 Component Y49/6 (Left camshaft
exhaust solenoid) has a short
circuit to ground. (P2090)
71 P0013 Component Y49/6 (Left camshaft
exhaust solenoid) has an open
circuit in the wiring. (P0013)
73 P2123 Check potentiometer of
component B37 (Accelerator
pedal sensor). Hall sensor 1 :
Short circuit to positive (P2123)
77 P2122 Check potentiometer of
component B37 (Accelerator
pedal sensor). Hall sensor 1 :
Short circuit to ground or open
circuit (P2122)
81 P2128 Check potentiometer of
component B37 (Accelerator
pedal sensor). Hall sensor 2 :
Short circuit to positive (P2128)
85 P2127 Check potentiometer of
component B37 (Accelerator
pedal sensor). Hall sensor 2 :
Short circuit to ground or open
circuit (P2127)
89 P2138 B37 (Accelerator pedal sensor) :
Voltage of Hall sensor 1 does not
agree with voltage of Hall sensor
2. (P2138)
93 P0651 B37 (Accelerator pedal sensor) :
Power supply (P0651)
117 P0336 Number of teeth on sensor rotor
too high or too low or wiring error
(P0336)
119 P0336 No tooth space on sensor rotor
detected or wiring error (P0336)
120 P0336 Tooth space on sensor rotor
temporarily not detected or wiring
error (P0336)
153 P0599 Component Y110 (Three-disk
thermostat valve) has a short
circuit to positive. (P0599)
154 P0598 Component Y110 (Three-disk
thermostat valve) has a short
circuit to ground. (P0598)
155 P0597 Component Y110 (Three-disk
thermostat valve) has an open
circuit in the wiring. (P0597)
160 P2135 M16/6 (Throttle valve actuator) :
Actual value potentiometer 1 or 2
has failed. (P2135)
161 P0123 M16/6 (Throttle valve actuator) :
Actual value potentiometer 1 :
Short circuit to positive or open
circuit (P0123)
162 P0122 M16/6 (Throttle valve actuator) :
Actual value potentiometer 1 :
Short circuit to ground (P0122)
164 P2135 M16/6 (Throttle valve actuator) :
There is a comparison error
between actual value
potentiometers 1 and 2. (P2135)
165 P0223 M16/6 (Throttle valve actuator) :
Actual value potentiometer 2 :
Short circuit to positive or open
circuit (P0223)
166 P0222 M16/6 (Throttle valve actuator) :
Actual value potentiometer 2 :
Short circuit to ground (P0222)
168 P2135 M16/6 (Throttle valve actuator) :
There is a comparison error
between actual value
potentiometers 2 and 1. (P2135)
185 P2101 M16/6 (Throttle valve actuator) :
Output stage (P2101)
186 P2101 M16/6 (Throttle valve actuator) :
Output stage (P2101)
187 P2101 M16/6 (Throttle valve actuator) :
Output stage (P2101)
188 P2101 M16/6 (Throttle valve actuator) :
Output stage (P2101)
189 P2111 M16/6 (Throttle valve actuator) :
Mechanical fault (P2111)
190 P2112 M16/6 (Throttle valve actuator) :
Mechanical fault (P2112)
193 P0638 M16/6 (Throttle valve actuator) :
Mechanical fault (P0638)
194 P0638 M16/6 (Throttle valve actuator) :
Mechanical fault (P0638)
200 P2101 M16/6 (Throttle valve actuator) :
Position Throttle valve (P2101)
204 P2176 The safety fuel shutoff is active.
(P2176)
205 P2101 M16/6 (Throttle valve actuator) :
Position Throttle valve (P2101)
206 P2101 M16/6 (Throttle valve actuator) :
Position Throttle valve (P2101)
212 P0638 M16/6 (Throttle valve actuator) :
The component was replaced
without performing throttle valve
adaptation. (P0638)
216 P2101 M16/6 (Throttle valve actuator) :
(P2101)
217 P2176 M16/6 (Throttle valve actuator) :
The throttle valve is jamming or is
stiff. (P2176)
218 P2176 M16/6 (Throttle valve actuator) :
The throttle valve is jamming or is
stiff. (P2176)
224 P2176 M16/6 (Throttle valve actuator) :
Perform throttle valve adaptation.
(P2176)
228 P0638 M16/6 (Throttle valve actuator) :
Throttle valve jamming (iced up)
(P0638)
230 - Due to a possible leak in the
intake air system, an implausible
signal was received from oxygen
sensor 1 (cylinder bank 1).
234 - Due to a possible leak in the
intake air system, an implausible
signal was received from oxygen
sensor 1 (cylinder bank 2).
237 - The request for fan output is
implausible.
271 P0011 Continuous camshaft adjustment
(RIGHT): Incorrect position of the
intake camshaft (P0011)
272 P0012 Continuous camshaft adjustment
(RIGHT): Incorrect position of the
intake camshaft (P0012)
275 P0021 Continuous camshaft adjustment
(LEFT): Incorrect position of the
intake camshaft (P0021)
276 P0022 Continuous camshaft adjustment
(LEFT): Incorrect position of the
intake camshaft (P0022)
277 P2089 Component Y49/5 (Right
camshaft intake solenoid) has a
short circuit to positive. (P2089)
278 P2088 Component Y49/5 (Right
camshaft intake solenoid) has a
short circuit to ground. (P2088)
279 P0010 Component Y49/5 (Right
camshaft intake solenoid) has an
open circuit in the wiring. (P0010)
281 P2093 Component Y49/4 (Left camshaft
intake solenoid) has a short circuit
to positive. (P2093)
282 P2092 Component Y49/4 (Left camshaft
intake solenoid) has a short circuit
to ground. (P2092)
283 P0020 Component Y49/4 (Left camshaft
intake solenoid) has an open
circuit in the wiring. (P0020)
301 P0262 The injection valve output stage of
cylinder 1 detects a short circuit to
positive. (P0262)
302 P0261 The injection valve output stage of
cylinder 1 detects a short circuit to
ground. (P0261)
303 P0201 The injection valve output stage of
cylinder 1 detects a line
discontinuity. (P0201)
305 P0274 The injection valve output stage of
cylinder 5 detects a short circuit to
positive. (P0274)
306 P0273 The injection valve output stage of
cylinder 5 detects a short circuit to
ground. (P0273)
307 P0205 The injection valve output stage of
cylinder 5 detects a line
discontinuity. (P0205)
309 P0271 The injection valve output stage of
cylinder 4 detects a short circuit to
positive. (P0271)
310 P0270 The injection valve output stage of
cylinder 4 detects a short circuit to
ground. (P0270)
311 P0204 The injection valve output stage of
cylinder 4 detects a line
discontinuity. (P0204)
313 P0265 The injection valve output stage of
cylinder 2 detects a short circuit to
positive. (P0265)
314 P0264 The injection valve output stage of
cylinder 2 detects a short circuit to
ground. (P0264)
315 P0202 The injection valve output stage of
cylinder 2 detects a line
discontinuity. (P0202)
317 P0277 The injection valve output stage of
cylinder 6 detects a short circuit to
positive. (P0277)
318 P0276 The injection valve output stage of
cylinder 6 detects a short circuit to
ground. (P0276)
319 P0206 The injection valve output stage of
cylinder 6 detects a line
discontinuity. (P0206)
321 P0268 The injection valve output stage of
cylinder 3 detects a short circuit to
positive. (P0268)
322 P0267 The injection valve output stage of
cylinder 3 detects a short circuit to
ground. (P0267)
323 P0203 The injection valve output stage of
cylinder 3 detects a line
discontinuity. (P0203)
325 P0280 The injection valve output stage of
cylinder 7 detects a short circuit to
positive. (P0280)
326 P0279 The injection valve output stage of
cylinder 7 detects a short circuit to
ground. (P0279)
327 P0207 The injection valve output stage of
cylinder 7 detects a line
discontinuity. (P0207)
329 P0283 The injection valve output stage of
cylinder 8 detects a short circuit to
positive. (P0283)
330 P0282 The injection valve output stage of
cylinder 8 detects a short circuit to
ground. (P0282)
331 P0208 The injection valve output stage of
cylinder 8 detects a line
discontinuity. (P0208)
337 P0171 Self-adaptation of mixture
formation for enrichment at partial
load for the right cylinder bank is
above the permissible limit.
(P0171)
338 P0172 Self-adaptation of mixture
formation for enleanment at partial
load for the right cylinder bank is
below the permissible limit.
(P0172)
339 - This fault can be ignored and
erased.
340 - This fault can be ignored and
erased.
341 P0174 Self-adaptation of mixture
formation for enrichment at partial
load for the left cylinder bank is
above the permissible limit.
(P0174)
342 P0175 Self-adaptation of mixture
formation for enleanment at partial
load for the left cylinder bank is
below the permissible limit.
(P0175)
343 - This fault can be ignored and
erased.
344 - This fault can be ignored and
erased.
353 P0460 B4 (Fuel level sensor) (P0460)
354 P0460 B4 (Fuel level sensor) (P0460)
355 P0460 B4 (Fuel level sensor) (P0460)
356 P0460 B4 (Fuel level sensor) (P0460)
365 P0620 Operational fault of component
G2 (generator) (P0620)
405 P0115 Component Y16/2 (Heating
system shutoff valve) has a short
circuit to positive. (P0115)
406 P0115 Component Y16/2 (Heating
system shutoff valve) has a short
circuit to ground. (P0115)
407 P0115 Component Y16/2 (Heating
system shutoff valve) has an open
circuit in the wiring. (P0115)
420 P0141 Heating of component G3/6 (Right
O2 sensor, after TWC [KAT]) :
Heating capacity is too low.
(P0141)
424 P0038 Heating of component G3/5 (Left
O2 sensor, after TWC [KAT]) :
Heating capacity is too low.
(P0038)
425 P0141 Heating of component G3/6 (Right
O2 sensor, after TWC [KAT]) :
Short circuit to positive (P0141)
O2 sensor, after TWC [KAT]) :
Short circuit to ground (P0037)
427 P0036 Heating of component G3/6 (Right
O2 sensor, after TWC [KAT]) :
Open circuit (P0036)
429 P0058 Heating of component G3/5 (Left
O2 sensor, after TWC [KAT]) :
Short circuit to positive (P0058)
430 P0057 Heating of component G3/5 (Left
O2 sensor, after TWC [KAT]) :
Short circuit to ground (P0057)
431 P0056 Heating of component G3/5 (Left
O2 sensor, after TWC [KAT]) :
Open circuit (P0056)
433 P0135 Heating of component G3/4 (Right
O2 sensor, before TWC [KAT]) :
Short circuit to positive /
Resistance of sensor heater too
low (P0135)
435 P0607 The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P0607)
436 P0135 Heating of component G3/4 (Right
O2 sensor, before TWC [KAT]) :
Heating capacity is too low.
(P0135)
437 P0155 Heating of component G3/3 (Left
O2 sensor, before TWC [KAT]) :
Short circuit to positive /
Resistance of sensor heater too
low (P0155)
438 - This fault can be ignored and
erased.
439 P0607 The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P0607)
440 P0155 Heating of component G3/3 (Left
O2 sensor, before TWC [KAT]) :
Heating capacity is too low.
(P0155)
441 P0032 Heating of component G3/4 (Right
O2 sensor, before TWC [KAT]) :
Short circuit to positive (P0032)
442 P0031 Heating of component G3/4 (Right
O2 sensor, before TWC [KAT]) :
Short circuit to ground (P0031)
443 P0030 Heating of component G3/4 (Right
O2 sensor, before TWC [KAT]) :
Open circuit (P0030)
445 P0052 Heating of component G3/3 (Left
O2 sensor, before TWC [KAT]) :
Short circuit to positive (P0052)
446 P0051 Heating of component G3/3 (Left
O2 sensor, before TWC [KAT]) :
Short circuit to ground (P0051)
447 P0050 Heating of component G3/3 (Left
O2 sensor, before TWC [KAT]) :
Open circuit (P0050)
449 - The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P064D)
450 - The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P064D)
451 - The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P064D)
452 - The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P064D)
453 - The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P064E)
454 - The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P064E)
455 - The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P064E)
456 - The electronic analysis system for
the O2 sensor in the engine control
unit is defective. (P064E)
477 - This fault can be ignored and
erased.
478 - This fault can be ignored and
erased.
479 - This fault can be ignored and
erased.
485 - Power output limited because of
excessively high temperature of
coolant
489 - Relay 'Fuel pump'
490 - Relay 'Fuel pump'
491 - Relay 'Fuel pump'
493 P0324 The knock control has a
malfunction. (P0324)
494 P0324 The knock control has a
malfunction. (P0324)
496 P0324 The knock control has a
malfunction. (P0324)
500 P0324 The knock control has a
malfunction. (P0324)
501 P0328 Component A16/1 (knock sensor
1, right) has a short circuit to
positive. (P0328)
502 P0327 Component A16/1 (knock sensor
1, right) has a short circuit to
ground. (P0327)
504 P0325 Component A16/1 (knock sensor
1, right) has an electrical fault.
(P0325)
505 P0333 Component A16/2 (knock sensor
2, left) has a short circuit to
positive. (P0333)
506 P0332 Component A16/2 (knock sensor
2, left) has a short circuit to
ground. (P0332)
508 P0330 Component A16/2 (knock sensor
2, left) has an electrical fault.
(P0330)
509 P2270 G3/6 (Right O2 sensor, after TWC
[KAT]) : Aging (P2270)
510 P2271 G3/6 (Right O2 sensor, after TWC
[KAT]) : Aging (P2271)
511 P0139 G3/6 (Right O2 sensor, after TWC
[KAT]) : Aging (P0139)
513 P2272 G3/5 (Left O2 sensor, after TWC
[KAT]) : Aging (P2272)
514 P2273 G3/5 (Left O2 sensor, after TWC
[KAT]) : Aging (P2273)
515 P0159 G3/5 (Left O2 sensor, after TWC
[KAT]) : Aging (P0159)
521 P2004 Diagnosis of tumble flap 'Intake
manifold' : Short circuit to ground
of sensor lines / Tumble flap
shafts stick in the actuated
position. (P2004)
522 P2006 Diagnosis of tumble flap 'Intake
manifold' : Open circuit of sensor
lines / Tumble flap shafts stick in
the nonactuated position. (P2006)
524 P2005 Diagnosis of tumble flap 'Intake
manifold' : Short or open circuit in
sensor lines / Mechanical fault of
one actuating lever / Sensor faulty,
replace sensor. (P2005)
537 - B2/5 (Hot film mass air flow
sensor)
549 P0138 G3/6 (Right O2 sensor, after TWC
[KAT]) : Short circuit to positive /
Resistance of sensor heater too
low (P0138)
550 P0136 G3/6 (Right O2 sensor, after TWC
[KAT]) : Short circuit to ground
(P0136)
551 P0140 G3/6 (Right O2 sensor, after TWC
[KAT]) : Discontinuity of signal
line (P0140)
552 P0136 G3/6 (Right O2 sensor, after TWC
[KAT]) : Short circuit between
signal line and line to sensor
heater (P0136)
553 P0158 G3/5 (Left O2 sensor, after TWC
[KAT]) : Short circuit to positive /
Resistance of sensor heater too
low (P0158)
554 P0156 G3/5 (Left O2 sensor, after TWC
[KAT]) : Short circuit to ground
(P0156)
555 P0160 G3/5 (Left O2 sensor, after TWC
[KAT]) : Discontinuity of signal
line (P0160)
556 P0156 G3/5 (Left O2 sensor, after TWC
[KAT]) : Short circuit between
signal line and line to sensor
heater (P0156)
559 P2626 G3/4 (Right O2 sensor, before
TWC [KAT]) : Open circuit
(P2626)
563 P2629 G3/3 (Left O2 sensor, before
TWC [KAT]) : Open circuit
(P2629)
565 P2237 G3/4 (Right O2 sensor, before
TWC [KAT]) : Voltage is too
high. (P2237)
567 P2237 G3/4 (Right O2 sensor, before
TWC [KAT]) : Open circuit
(P2237)
568 P2237 G3/4 (Right O2 sensor, before
TWC [KAT]) : Signal voltage is
implausible. (P2237)
569 P2240 G3/3 (Left O2 sensor, before
TWC [KAT]) : Voltage is too
high. (P2240)
571 P2240 G3/3 (Left O2 sensor, before
TWC [KAT]) : Open circuit
(P2240)
572 P2240 G3/3 (Left O2 sensor, before
TWC [KAT]) : Signal voltage is
implausible. (P2240)
573 P0130 G3/4 (Right O2 sensor, before
TWC [KAT]) : Voltage is too
high. (P0130)
574 P0130 G3/4 (Right O2 sensor, before
TWC [KAT]) : Voltage is too low.
(P0130)
577 P0150 G3/3 (Left O2 sensor, before
TWC [KAT]) : Voltage is too
high. (P0150)
578 P0150 G3/3 (Left O2 sensor, before
TWC [KAT]) : Voltage is too low.
(P0150)
583 P2243 G3/4 (Right O2 sensor, before
TWC [KAT]) : Open circuit
(P2243)
587 P2247 G3/3 (Left O2 sensor, before
TWC [KAT]) : Open circuit
(P2247)
591 P2251 G3/4 (Right O2 sensor, before
TWC [KAT]) : Open circuit
(P2251)
595 P2254 G3/3 (Left O2 sensor, before
TWC [KAT]) : Open circuit
(P2254)
600 P0040 O2 sensors upstream TWC : Plug
connections of the O2 sensors are
wrongly connected. (P0040)
620 P2279 Check intake tract for unmetered
air. (P2279)
629 P0300 Misfiring (P0300)
630 P0300 Misfiring (P0300)
632 P0300 Misfiring (P0300)
633 P0301 Misfiring of cylinder 1 : Damages
TWC (P0301)
634 P0301 Misfiring of cylinder 1 :
Worsening of exhaust emission
values (P0301)
636 P0301 Misfiring of cylinder 1 :
Worsening of exhaust emission
values after engine start (P0301)
637 P0305 Misfiring of cylinder 5 : Damages
TWC (P0305)
638 P0305 Misfiring of cylinder 5 :
Worsening of exhaust emission
values (P0305)
640 P0305 Misfiring of cylinder 5 :
Worsening of exhaust emission
values after engine start (P0305)
641 P0304 Misfiring of cylinder 4 : Damages
TWC (P0304)
642 P0304 Misfiring of cylinder 4 :
Worsening of exhaust emission
values (P0304)
644 P0304 Misfiring of cylinder 4 :
Worsening of exhaust emission
values after engine start (P0304)
645 P0302 Misfiring of cylinder 2 : Damages
TWC (P0302)
646 P0302 Misfiring of cylinder 2 :
Worsening of exhaust emission
values (P0302)
648 P0302 Misfiring of cylinder 2 :
Worsening of exhaust emission
values after engine start (P0302)
649 P0306 Misfiring of cylinder 6 : Damages
TWC (P0306)
650 P0306 Misfiring of cylinder 6 :
Worsening of exhaust emission
values (P0306)
652 P0306 Misfiring of cylinder 6 :
Worsening of exhaust emission
values after engine start (P0306)
653 P0303 Misfiring of cylinder 3 : Damages
TWC (P0303)
654 P0303 Misfiring of cylinder 3 :
Worsening of exhaust emission
values (P0303)
656 P0303 Misfiring of cylinder 3 :
Worsening of exhaust emission
values after engine start (P0303)
657 P0307 Misfiring of cylinder 7 : Damages
TWC (P0307)
658 P0307 Misfiring of cylinder 7 :
Worsening of exhaust emission
values (P0307)
660 P0307 Misfiring of cylinder 7 :
Worsening of exhaust emission
values after engine start (P0307)
661 P0308 Misfiring of cylinder 8 : Damages
TWC (P0308)
662 P0308 Misfiring of cylinder 8 :
Worsening of exhaust emission
values (P0308)
664 P0308 Misfiring of cylinder 8 :
Worsening of exhaust emission
values after engine start (P0308)
688 - This fault can be ignored and
erased.
693 - M4/7 (Engine and AC electric
suction fan with integrated
control) : Output stage
694 - M4/7 (Engine and AC electric
suction fan with integrated
control) : Output stage
695 - M4/7 (Engine and AC electric
suction fan with integrated
control) : Output stage
703 P0335 B70 (Crankshaft Hall sensor) :
Check wiring of signal line and
voltage. (P0335)
704 P0339 B70 (Crankshaft Hall sensor) :
Check wiring of signal line and
voltage. (P0339)
732 P0014 Continuous camshaft adjustment
(RIGHT): Incorrect position of the
exhaust camshaft (P0014)
736 P0024 Continuous camshaft adjustment
(LEFT): Incorrect position of the
exhaust camshaft (P0024)
740 P0010 Continuous camshaft adjustment
(RIGHT): Incorrect position of the
intake camshaft (P0010)
744 P0020 Continuous camshaft adjustment
(LEFT): Incorrect position of the
intake camshaft (P0020)
745 P0171 Self-adaptation of mixture
formation for enrichment at idle
for the right cylinder bank is
above the permissible limit.
(P0171)
746 P0172 Self-adaptation of mixture
formation for enleanment at idle
for the right cylinder bank is
below the permissible limit.
(P0172)
747 - This fault can be ignored and
erased.
748 - This fault can be ignored and
erased.
749 P0174 Self-adaptation of mixture
formation for enrichment at idle
for the left cylinder bank is above
the permissible limit. (P0174)
750 P0175 Self-adaptation of mixture
formation for enleanment at idle
for the left cylinder bank is below
the permissible limit. (P0175)
751 - This fault can be ignored and
erased.
752 - This fault can be ignored and
erased.
753 P0343 B6/5 (Right intake camshaft Hall
sensor) : Short circuit to positive
or open circuit (P0343)
754 P0342 B6/5 (Right intake camshaft Hall
sensor) : Short circuit to ground
(P0342)
755 P0341 B6/5 (Right intake camshaft Hall
sensor) : The alternation frequency
of the signal value is implausible.
(P0341)
756 P0341 B6/5 (Right intake camshaft Hall
sensor) : The time of the signal
value change is implausible.
(P0341)
757 P0348 B6/4 (Left intake camshaft Hall
sensor) : Short circuit to positive
or open circuit (P0348)
758 P0347 B6/4 (Left intake camshaft Hall
sensor) : Short circuit to ground
(P0347)
759 P0346 B6/4 (Left intake camshaft Hall
sensor) : The alternation frequency
of the signal value is implausible.
(P0346)
760 P0346 B6/4 (Left intake camshaft Hall
sensor) : The time of the signal
value change is implausible.
(P0346)
761 P0368 B6/7 (Right exhaust camshaft Hall
sensor) : Short circuit to positive
or open circuit (P0368)
762 P0367 B6/7 (Right exhaust camshaft Hall
sensor) : Short circuit to ground
(P0367)
763 P0366 B6/7 (Right exhaust camshaft Hall
sensor) : The alternation frequency
of the signal value is implausible.
(P0366)
764 P0366 B6/7 (Right exhaust camshaft Hall
sensor) : The time of the signal
value change is implausible.
(P0366)
765 P0393 B6/6 (Left exhaust camshaft Hall
sensor) : Short circuit to positive
or open circuit (P0393)
766 P0392 B6/6 (Left exhaust camshaft Hall
sensor) : Short circuit to ground
(P0392)
767 P0391 B6/6 (Left exhaust camshaft Hall
sensor) : The alternation frequency
of the signal value is implausible.
(P0391)
768 P0391 B6/6 (Left exhaust camshaft Hall
sensor) : The time of the signal
value change is implausible.
(P0391)
771 P0340 The camshaft Hall sensors were
not detected. (B6/4 (Left intake
camshaft Hall sensor) | B6/5
(Right intake camshaft Hall
sensor) | B6/6 (Left exhaust
camshaft Hall sensor) | B6/7
(Right exhaust camshaft Hall
sensor)) (P0340)
773 - The signal of the oxygen sensor
upstream of the catalytic converter
of the right cylinder bank is
shifted towards 'Lean'. (P2A00)
774 - The signal of the oxygen sensor
upstream of the catalytic converter
of the right cylinder bank is
shifted towards 'Rich'. (P2A00)
775 P2195 The signal of the oxygen sensor
upstream of the catalytic converter
of the right cylinder bank is
shifted towards 'Lean'. (P2195)
776 P2196 The signal of the oxygen sensor
upstream of the catalytic converter
of the right cylinder bank is
shifted towards 'Rich'. (P2196)
777 - The signal of the oxygen sensor
upstream of the catalytic converter
of the left cylinder bank is shifted
towards 'Lean'. (P2A03)
778 - The signal of the oxygen sensor
upstream of the catalytic converter
of the left cylinder bank is shifted
towards 'Rich'. (P2A03)
779 P2197 The signal of the oxygen sensor
upstream of the catalytic converter
of the left cylinder bank is shifted
towards 'Lean'. (P2197)
780 P2198 The signal of the oxygen sensor
upstream of the catalytic converter
of the left cylinder bank is shifted
towards 'Rich'. (P2198)
789 - This fault can be ignored and
erased.
790 - This fault can be ignored and
erased.
793 - This fault can be ignored and
erased.
794 - This fault can be ignored and
erased.
810 P0410 Malfunction of secondary air
injection at right bank of cylinders
(function chain) (P0410)
814 P0410 Malfunction of secondary air
injection at left bank of cylinders
(function chain) (P0410)
817 P2440 The secondary air valve (cylinder
bank 1) is jammed open. (P2440)
821 P2442 The secondary air valve (cylinder
bank 2) is jammed open. (P2442)
849 P0459 Y58/1 (Purge control valve) :
Short circuit to positive /
Switchover valve permanently
closed (P0459)
850 P0458 Y58/1 (Purge control valve) :
Short circuit to ground /
Switchover valve permanently
open (P0458)
851 P0444 Y58/1 (Purge control valve) :
Open circuit / Switchover valve
permanently closed (P0444)
856 P0128 Component Y110 (Three-disk
thermostat valve) jams in opened
position. : Coolant temperature
rises too slowly. (P0128)
857 P0118 B11/4 (Coolant temperature
sensor) : Short circuit to ground
(P0118)
858 P0117 B11/4 (Coolant temperature
sensor) : Short circuit to positive /
Open circuit (P0117)
859 P0117 B11/4 (Coolant temperature
sensor) (P0117)
860 P0116 B11/4 (Coolant temperature
sensor) : Shunt fault / Sensor
characteristic curve (P0116)
865 P0563 Voltage supply of component
Motor electronics / Battery voltage
too high (P0563)
866 P0562 Voltage supply of component
Motor electronics / Battery voltage
too low (P0562)
868 P0607 Voltage supply of component
Motor electronics / Battery voltage
too low for ADC (P0607)
872 - The torque calculation of the
control unit has a malfunction.
(P061B)
876 P0726 The input signal of the engine
speed has a malfunction. (P0726)
889 P0607 Control module has an internal
error. (P0607)
890 P0607 Control module has an internal
error. (P0607)
891 P0607 Control module has an internal
error. (P0607)
893 P0607 Control module has an internal
error. (P0607)
894 P0607 Control module has an internal
error. (P0607)
895 P0607 Control module has an internal
error. (P0607)
897 P0607 Control module has an internal
error. (P0607)
898 P0607 Control module has an internal
error. (P0607)
900 P0607 Control module has an internal
error. (P0607)
904 P2138 The values from the position
sensors of the accelerator pedal
are implausible in relation to each
other. (P2138)
908 P2414 G3/4 (Right O2 sensor, before
TWC [KAT]) : Signal implausible
(P2414)
912 P2415 G3/3 (Left O2 sensor, before
TWC [KAT]) : Signal implausible
(P2415)
916 P0604 Control module has an internal
error. (P0604)
920 P0605 Control module has an internal
error. (P0605)
922 P0606 Control module has an internal
error. (P0606)
923 P0606 Control module has an internal
error. (P0606)
924 P0606 Control module has an internal
error. (P0606)
940 - S9/1 (Stop lamp switch)
942 P0422 The efficiency of the right
catalytic converter is insufficient.
(function chain) (P0422)
946 P0422 The efficiency of the left catalytic
converter is insufficient. (function
chain) (P0422)
954 P2422 Mechanical defect or component
Y58/4 (Activated charcoal canister
shut-off valve) permanently closed
(P2422)
957 P0447 Component Y58/4 (Activated
charcoal canister shut-off valve)
has a short circuit to positive.
(P0447)
958 P0448 Component Y58/4 (Activated
charcoal canister shut-off valve)
has a short circuit to ground.
(P0448)
959 P0446 Component Y58/4 (Activated
charcoal canister shut-off valve)
has an open circuit in the wiring.
(P0446)
969 P0453 Tank pressure sensor diagnosis :
Short circuit to positive (P0453)
970 P0452 Tank pressure sensor diagnosis :
Short circuit to ground (P0452)
976 P0607 Control module has an internal
error. (P0607)
980 P0350 Ignition output stage 2 (P0350)
981 P0351 Ignition coil primary current of
cylinder 1 is too high. (P0351)
982 P0351 Ignition coil primary current of
cylinder 1 is too low. (P0351)
983 P0351 Signal fault of ignition coil
diagnosis of cylinder 1 (P0351)
984 P0351 Ignition coil primary current of
cylinder 1 alternates between too
high and too low. (P0351)
985 P0355 Ignition coil primary current of
cylinder 5 is too high. (P0355)
986 P0355 Ignition coil primary current of
cylinder 5 is too low. (P0355)
987 P0355 Signal fault of ignition coil
diagnosis of cylinder 5 (P0355)
988 P0355 Ignition coil primary current of
cylinder 5 alternates between too
high and too low. (P0355)
989 P0354 Ignition coil primary current of
cylinder 4 is too high. (P0354)
990 P0354 Ignition coil primary current of
cylinder 4 is too low. (P0354)
991 P0354 Signal fault of ignition coil
diagnosis of cylinder 4 (P0354)
992 P0354 Ignition coil primary current of
cylinder 4 alternates between too
high and too low. (P0354)
993 P0352 Ignition coil primary current of
cylinder 2 is too high. (P0352)
994 P0352 Ignition coil primary current of
cylinder 2 is too low. (P0352)
995 P0352 Signal fault of ignition coil
diagnosis of cylinder 2 (P0352)
996 P0352 Ignition coil primary current of
cylinder 2 alternates between too
high and too low. (P0352)
997 P0356 Ignition coil primary current of
cylinder 6 is too high. (P0356)
998 P0356 Ignition coil primary current of
cylinder 6 is too low. (P0356)
999 P0356 Signal fault of ignition coil
diagnosis of cylinder 6 (P0356)
1000 P0356 Ignition coil primary current of
cylinder 6 alternates between too
high and too low. (P0356)
1001 P0353 Ignition coil primary current of
cylinder 3 is too high. (P0353)
1002 P0353 Ignition coil primary current of
cylinder 3 is too low. (P0353)
1003 P0353 Signal fault of ignition coil
diagnosis of cylinder 3 (P0353)
1004 P0353 Ignition coil primary current of
cylinder 3 alternates between too
high and too low. (P0353)
1005 P0357 Ignition coil primary current of
cylinder 7 is too high. (P0357)
1006 P0357 Ignition coil primary current of
cylinder 7 is too low. (P0357)
1007 P0357 Signal fault of ignition coil
diagnosis of cylinder 7 (P0357)
1008 P0357 Ignition coil primary current of
cylinder 7 alternates between too
high and too low. (P0357)
1009 P0358 Ignition coil primary current of
cylinder 8 is too high. (P0358)
1010 P0358 Ignition coil primary current of
cylinder 8 is too low. (P0358)
1011 P0358 Signal fault of ignition coil
diagnosis of cylinder 8 (P0358)
1012 P0358 Ignition coil primary current of
cylinder 8 alternates between too
high and too low. (P0358)
1013 P2301 The control line to the ignition coil
of cylinder 1 has a short circuit to
positive. (P2301)
1014 P2300 The control line to the ignition coil
of cylinder 1 has a short circuit to
ground. (P2300)
1015 P0351 The control line to the ignition coil
of cylinder 1 has an open circuit.
(P0351)
1016 P0351 The output stage to ignition coil of
cylinder 1 detects an electrical
fault. (P0351)
1017 P2313 The control line to the ignition coil
of cylinder 5 has a short circuit to
positive. (P2313)
1018 P2312 The control line to the ignition coil
of cylinder 5 has a short circuit to
ground. (P2312)
1019 P0355 The control line to the ignition coil
of cylinder 5 has an open circuit.
(P0355)
1020 P0355 The output stage to ignition coil of
cylinder 5 detects an electrical
fault. (P0355)
1021 P2310 The control line to the ignition coil
positive. (P2310)
1022 P2309 The control line to the ignition coil
of cylinder 4 has a short circuit to
ground. (P2309)
1023 P0354 The control line to the ignition coil
of cylinder 4 has an open circuit.
(P0354)
1024 P0354 The output stage to ignition coil of
cylinder 4 detects an electrical
fault. (P0354)
1025 P2304 The control line to the ignition coil
of cylinder 2 has a short circuit to
positive. (P2304)
1026 P2303 The control line to the ignition coil
of cylinder 2 has a short circuit to
ground. (P2303)
1027 P0352 The control line to the ignition coil
of cylinder 2 has an open circuit.
(P0352)
1028 P0352 The output stage to ignition coil of
cylinder 2 detects an electrical
fault. (P0352)
1029 P2316 The control line to the ignition coil
of cylinder 6 has a short circuit to
positive. (P2316)
1030 P2315 The control line to the ignition coil
of cylinder 6 has a short circuit to
ground. (P2315)
1031 P0356 The control line to the ignition coil
of cylinder 6 has an open circuit.
(P0356)
1032 P0356 The output stage to ignition coil of
cylinder 6 detects an electrical
fault. (P0356)
1033 P2307 The control line to the ignition coil
of cylinder 3 has a short circuit to
positive. (P2307)
1034 P2306 The control line to the ignition coil
of cylinder 3 has a short circuit to
ground. (P2306)
1035 P0353 The control line to the ignition coil
of cylinder 3 has an open circuit.
(P0353)
1036 P0353 The output stage to ignition coil of
cylinder 3 detects an electrical
fault. (P0353)
1037 P2319 The control line to the ignition coil
of cylinder 7 has a short circuit to
positive. (P2319)
1038 P2318 The control line to the ignition coil
of cylinder 7 has a short circuit to
ground. (P2318)
1039 P0357 The control line to the ignition coil
of cylinder 7 has an open circuit.
(P0357)
1040 P0357 The output stage to ignition coil of
cylinder 7 detects an electrical
fault. (P0357)
1041 P2322 The control line to the ignition coil
of cylinder 8 has a short circuit to
positive. (P2322)
1042 P2321 The control line to the ignition coil
of cylinder 8 has a short circuit to
ground. (P2321)
1043 P0358 The control line to the ignition coil
of cylinder 8 has an open circuit.
(P0358)
1044 P0358 The output stage to ignition coil of
cylinder 8 detects an electrical
fault. (P0358)
1045 P0172 Lambda control, before TWC
right : Lambda control is at lean
stop. (P0172)
1046 P0171 Lambda control, before TWC
right : Lambda control is at rich
stop. (P0171)
1047 P0170 Lambda control, before TWC
right : Control implausible
(P0170)
1048 P0170 Lambda control, before TWC
right (P0170)
1049 P0175 Lambda control, before TWC left :
Lambda control is at rich stop.
(P0175)
1050 P0174 Lambda control, before TWC left :
Lambda control is at lean stop.
(P0174)
1051 P0173 Lambda control, before TWC left :
Control implausible (P0173)
1052 P0173 Lambda control, before TWC left
(P0173)
1053 - This fault can be ignored and
erased.
1057 - This fault can be ignored and
erased.
1061 - The load limit is active.
1065 P2258 Relay for air pump : Short circuit
to positive (P2258)
1066 P2257 Relay for air pump : Short circuit
to ground (P2257)
1067 P0418 Relay for air pump : Open circuit
(P0418)
1069 P0413 Y32 (Air pump switchover
valve) : Short circuit to positive
(P0413)
1070 P0414 Y32 (Air pump switchover
valve) : Short circuit to ground
(P0414)
1071 P0412 Y32 (Air pump switchover
valve) : Open circuit (P0412)
1073 P2010 Y22/6 (variable intake manifold
switchover valve) : Short circuit to
positive (P2010)
1074 P2009 Y22/6 (variable intake manifold
switchover valve) : Short circuit to
ground (P2009)
1075 P2008 Y22/6 (variable intake manifold
switchover valve) : Open circuit
(P2008)
1077 P2421 Mechanical defect or component
Y58/1 (Purge control valve) is
permanently open (P2421)
1078 P2421 Mechanical defect or component
Y58/1 (Purge control valve) is
permanently open (P2421)
1081 P0442 Purge control system has slight
leak / Leak in hose connection or
shutoff valve of activated charcoal
canister (P0442)
1085 P0455 Major leak in purge system / Hose
in system not connected or filler
cap open (P0455)
1089 P0456 Purge control system has a slight
leak (minor leak) (P0456)
1097 P0446 Mechanical defect or component
Y58/4 (Activated charcoal canister
shut-off valve) is permanently
open (P0446)
1098 P0446 Mechanical defect or component
Y58/4 (Activated charcoal canister
shut-off valve) is permanently
open (P0446)
1101 - B14 (Ambient temperature display
temperature sensor) : Short circuit
to positive
1102 - B14 (Ambient temperature display
temperature sensor) : Short circuit
to ground
1103 - B14 (Ambient temperature display
temperature sensor) : Open circuit
in wiring
1104 - B14 (Ambient temperature display
temperature sensor) : Plausibility
error
1105 P2505 The voltage at relay 'Circuit 87' is
too high. (P2505)
1106 P2505 The voltage at relay 'Circuit 87' is
too low. (P2505)
1108 P2505 The voltage at relay 'Circuit 87' is
too low. (P2505)
1117 P0606 Control module has an internal
error. (P0606)
1118 P0606 Control module has an internal
error. (P0606)
1119 P0606 Control module has an internal
error. (P0606)
1185 P2010 Y22/9 (Intake manifold tumble
flap switchover valve) : Short
circuit to positive (P2010)
1186 P2009 Y22/9 (Intake manifold tumble
flap switchover valve) : Short
circuit to ground (P2009)
1187 P2008 Y22/9 (Intake manifold tumble
flap switchover valve) : Open
circuit (P2008)
1197 P0017 Constant adjustment of exhaust
camshaft of right cylinder bank in
direction 'Advanced' (P0017)
1198 P0017 Constant adjustment of exhaust
camshaft of right cylinder bank in
direction 'Retarded' (P0017)
1199 P0017 Constant adjustment of exhaust
camshaft of right cylinder bank in
direction 'Advanced' (P0017)
1200 P0017 Constant adjustment of exhaust
camshaft of right cylinder bank in
direction 'Retarded' (P0017)
1201 P0019 Constant adjustment of exhaust
camshaft of left cylinder bank in
direction 'Advanced' (P0019)
1202 P0019 Constant adjustment of exhaust
camshaft of left cylinder bank in
direction 'Retarded' (P0019)
1203 P0019 Constant adjustment of exhaust
camshaft of left cylinder bank in
direction 'Advanced' (P0019)
1204 P0019 Constant adjustment of exhaust
camshaft of left cylinder bank in
direction 'Retarded' (P0019)
1205 P0016 Constant adjustment of intake
camshaft of right cylinder bank in
direction 'Advanced' (P0016)
1206 P0016 Constant adjustment of intake
camshaft of right cylinder bank in
direction 'Retarded' (P0016)
1207 P0016 Constant adjustment of intake
camshaft of right cylinder bank in
direction 'Advanced' (P0016)
1208 P0016 Constant adjustment of intake
camshaft of right cylinder bank in
direction 'Retarded' (P0016)
1209 P0018 Constant adjustment of intake
camshaft of left cylinder bank in
direction 'Advanced' (P0018)
1210 P0018 Constant adjustment of intake
camshaft of left cylinder bank in
direction 'Retarded' (P0018)
1211 P0018 Constant adjustment of intake
camshaft of left cylinder bank in
direction 'Advanced' (P0018)
1212 P0018 Constant adjustment of intake
camshaft of left cylinder bank in
direction 'Retarded' (P0018)
1301 P0451 B4/3 (Fuel tank pressure sensor) :
Short circuit to positive (P0451)
1302 P0451 B4/3 (Fuel tank pressure sensor) :
Short circuit to ground (P0451)
1303 P0451 B4/3 (Fuel tank pressure sensor) :
Open circuit (P0451)
1304 P0451 B4/3 (Fuel tank pressure sensor) :
Signal implausible (P0451)
1305 - Component Y10/1 (Power steering
pump pressure regulator valve)
has a short circuit to positive.
1306 - Component Y10/1 (Power steering
pump pressure regulator valve)
has a short circuit to ground.
1307 - Component Y10/1 (Power steering
pump pressure regulator valve)
has an open circuit in the wiring.
1313 P2072 Throttle valve jamming (iced up)
(P2072)
1314 P2072 Throttle valve jamming (iced up)
(P2072)
1315 P2072 Throttle valve jamming (iced up)
(P2072)
1316 P2072 Throttle valve jamming (iced up)
(P2072)
1337 - Alternator serial interface
1345 P0104 B2/5 (Hot film mass air flow
sensor) : Loose contact with low
frequency (P0104)
1346 P0104 B2/5 (Hot film mass air flow
sensor) : Loose contact with high
frequency (P0104)
1347 P0102 B2/5 (Hot film mass air flow
sensor) : Open circuit / Short
circuit to ground or to positive
(P0102)
1349 P0068 The measured air mass is
implausible compared to the
position of the throttle valve.
(P0068)
1350 P0101 The measured air mass is
implausible compared to the
position of the throttle valve.
(P0101)
1351 P0101 The measured air mass is
position of the throttle valve.
(P0101)
1352 P0101 The measured air mass is
implausible compared to the
position of the throttle valve.
(P0101)
1360 P0041 O2 sensors downstream TWC :
Plug connections of the O2
sensors are wrongly connected.
(P0041)
1361 P2229 Sensor 'Ambient pressure' in
control module Motor electronics
(P2229)
1362 P2228 Sensor 'Ambient pressure' in
control module Motor electronics
(P2228)
1365 P2227 Sensor 'Ambient pressure' in
control module Motor electronics :
Implausible value (P2227)
1366 P2227 Sensor 'Ambient pressure' in
control module Motor electronics :
Implausible value (P2227)
1367 - Control module has an internal
error.
1368 P2227 Sensor 'Ambient pressure' in
control module Motor electronics :
Implausible value (P2227)
1389 - Air injection diagnosis
1390 - Air injection diagnosis
1392 - Air injection diagnosis
1425 - Wheel speed signal is implausible.
1461 P0116 B11/4 (Coolant temperature
sensor) : Coolant temperature is
too high. (P0116)
1462 P0116 B11/4 (Coolant temperature
sensor) : Coolant temperature is
too low. (P0116)
1463 P0116 The engine temperature from the
engine control module is
implausible. Signal voltage is
implausible. (P0116)
1464 P0116 The engine temperature from the
engine control module is
implausible. Shunt fault / Sensor
characteristic curve (P0116)
1599 P0071 Plausibility error between signal
of temperature sensor in intake
pipe and signal of outside
temperature sensor (P0071)
1600 P0071 Plausibility error between signal
of temperature sensor in intake
pipe and signal of outside
temperature sensor (P0071)
1857 - Ratio of HFM signal to intake
manifold pressure is too high.
1858 - Ratio of HFM signal to intake
manifold pressure is too low.
1861 - This fault can be ignored and
erased.
1909 P0108 B28 (Pressure sensor) : Short
circuit to positive or open circuit
(P0108)
1910 P0107 B28 (Pressure sensor) : Short
circuit to ground (P0107)
1913 P0106 B28 (Pressure sensor) :
Implausible value (P0106)
1914 P0106 B28 (Pressure sensor) :
Implausible value (P0106)
1915 P0106 B28 (Pressure sensor) :
Implausible value (P0106)
1916 P0106 B28 (Pressure sensor) :
Implausible value (P0106)
1921 - SBC : Undervoltage supply
2013 - CAN bus OFF : Short circuit
Engine CAN bus
2017 - CAN bus OFF : Short circuit
Powertrain-Bus
2021 - CAN bus OFF : Short circuit
Engine CAN bus
2025 P0112 Component B2/5b1 (Intake air
temperature sensor) has a short
circuit to ground. (P0112)
2026 P0113 Component B2/5b1 (Intake air
temperature sensor) has a short
circuit to positive or an open
circuit. (P0113)
2029 P0111 The value of component B2/5b1
(Intake air temperature sensor) is
implausible. (P0111)
2030 P0111 The value of component B2/5b1
(Intake air temperature sensor) is
implausible. (P0111)
2032 P0111 The value of component B2/5b1
(Intake air temperature sensor)
does not change. (P0111)
2037 - Fault during the mixture
adaptation (multiplicative or
additive) bank 1
2041 - Fault during the mixture
adaptation (multiplicative or
additive) bank 2
2045 - Physical fill level fault: upper
limit exceeded
2046 - Physical fill level fault: upper
limit exceeded (tank 2)
2048 - Physical fill level fault: signal
implausible
2053 - PremAir sensor : Short circuit to
positive
2054 - PremAir sensor : Short circuit to
ground
2056 - PremAir sensor has exceeded the
upper range limit.
2060 - Wrong installation location of the
PremAir sensors
2064 - Coding of the PremAir sensors is
implausible.
2065 - Component B11/4 (Coolant
temperature sensor) has a short
circuit to ground.
2066 P0118 Component B11/4 (Coolant
temperature sensor) has a short
circuit to positive or an open
circuit. (P0118)
2069 P0073 Component B14 (Ambient
temperature display temperature
sensor) has a short circuit to
positive. (P0073)
2070 P0072 Component B14 (Ambient
temperature display temperature
sensor) has a short circuit to
ground. (P0072)
2071 - B14 (Ambient temperature display
temperature sensor) : No CAN
message. (U0155)
2089 - The mixture in the right cylinder
bank is too lean in the partial load
range.
2090 - The mixture in the right cylinder
bank is too rich in the partial load
range.
2091 - The mixture in the right cylinder
bank is too lean when idling.
2092 - The mixture in the right cylinder
bank is too rich when idling.
2093 - The mixture in the left cylinder
bank is too lean in the partial load
range.
2094 - The mixture in the left cylinder
bank is too rich in the partial load
range.
2095 - The mixture in the left cylinder
bank is too lean when idling.
2096 - The mixture in the left cylinder
bank is too rich when idling.
2141 - This fault can be ignored and
erased.
2145 - This fault can be ignored and
erased.
2149 - This fault can be ignored and
erased.
2157 P2539 Component B4/7 (Fuel pressure
sensor) has an electrical fault.
(P2539)
2161 - This fault can be ignored and
erased.
2165 - The idle speed is too high during
catalytic converter warm-up.
2166 - The idle speed is too low during
catalytic converter warm-up.
2167 - This fault can be ignored and
erased.
2168 - This fault can be ignored and
erased.
2169 P2542 Component B4/7 (Fuel pressure
sensor) has a short circuit to
positive. (P2542)
2173 P2541 Component B4/7 (Fuel pressure
sensor) has a short circuit to
ground. (P2541)
2177 - The power supply at the input of
the control unit 'combustion
engine' has a sporadic
malfunction.
2181 P0101 The air mass measured by hot film
MAF sensor is too low. / The
cycle duration of the HFM signal
is too long. (P0101)
2182 P0101 The air mass measured by the hot
film MAF sensor is too high. / The
cycle duration of the HFM signal
is too short. (P0101)
2185 P1999 The idle speed with warm engine
is above the permissible range
limit. (P1999)
2186 P1999 The idle speed with warm engine
is below the permissible range
limit. (P1999)
2189 P0507 The idle speed is too high during
catalytic converter warm-up.
(P0507)
2190 P0506 The idle speed is too low during
catalytic converter warm-up.
(P0506)
2193 - Open circuit in right oxygen
sensor upstream of TWC [KAT]
(lambda control was switched off).
(P2A00)
2197 - Open circuit in left oxygen sensor
upstream of TWC [KAT] (lambda
control was switched off).
(P2A03)
2225 - The left fuel level sensor has a
short circuit to positive.
2226 - The left fuel level sensor has a
short circuit to ground.
2227 - The left fuel level sensor has an
electrical fault.
2228 - The left fuel level sensor has an
electrical fault.
2229 - The left fuel level sensor has an
electrical fault.
2230 - This fault can be ignored and
erased.
2232 - This fault can be ignored and
erased.
2233 - This fault can be ignored and
erased.
2234 - The coolant temperature is
implausible relative to the intake
air temperature.
2237 - Coolant temperature sensor 1 has
a malfunction.
2269 - This fault can be ignored and
erased.
2270 - This fault can be ignored and
erased.
2281 - The input for the digital crash
signal has a short circuit to
positive.
2285 - The CAN signal from circuit 15
does not match the signal via the
hardware line. (Signal via CAN =
0)
2289 - The CAN signal from circuit 15
does not match the signal via the
hardware line. (Signal via
hardware line = 0)
2297 - This fault can be ignored and
erased.
2301 - This fault can be ignored and
erased.
2305 - G3/6 (Right O2 sensor, after TWC
[KAT]) : Time between rich and
lean switching too long.
2307 - G3/6 (Right O2 sensor, after TWC
[KAT]) : Time between rich and
lean switching too long.
2309 - G3/5 (Left O2 sensor, after TWC
[KAT]) : Time between rich and
lean switching too long.
2311 - G3/5 (Left O2 sensor, after TWC
[KAT]) : Time between rich and
lean switching too long.
2313 - Torque control has a malfunction.
2317 - This fault can be ignored and
erased.
2333 - Self-adjustment of the mixture
formation of the right cylinder
bank is erratic.
2334 - Self-adjustment of the mixture
formation of the right cylinder
bank is erratic.
2335 - Self-adjustment of the mixture
formation of the right cylinder
bank is erratic.
2336 - Self-adjustment of the mixture
formation of the right cylinder
bank is erratic.
2337 - Self-adjustment of the mixture
formation of the left cylinder bank
is erratic.
2338 - Self-adjustment of the mixture
formation of the left cylinder bank
is erratic.
2339 - Self-adjustment of the mixture
formation of the left cylinder bank
is erratic.
2340 - Self-adjustment of the mixture
formation of the left cylinder bank
is erratic.
2341 - The right fuel level sensor has a
short circuit to positive.
2342 - The right fuel level sensor has a
short circuit to ground.
2343 - The right fuel level sensor has an
electrical fault.
2344 - The right fuel level sensor has an
electrical fault.
2345 - The right fuel level sensor has an
electrical fault.
2349 - Component G3/4 (Right O2
sensor, before TWC [KAT]) has a
malfunction.
2350 - Component G3/4 (Right O2
sensor, before TWC [KAT]) has a
malfunction.
2353 - Component G3/3 (Left O2 sensor,
before TWC [KAT]) has a
malfunction.
2354 - Component G3/3 (Left O2 sensor,
before TWC [KAT]) has a
malfunction.
2357 - The control line to component
M4/7 (Engine and AC electric
suction fan with integrated
control) has Short circuit to
positive.
2358 - The control line to component
M4/7 (Engine and AC electric
suction fan with integrated
control) has Short circuit to
ground.
2359 - The control line to component
M4/7 (Engine and AC electric
suction fan with integrated
control) has Open circuit.
2362 - Overtemperature or undervoltage
at component M4/7 (Engine and
AC electric suction fan with
integrated control)
2366 - Component M4/7 (Engine and AC
electric suction fan with integrated
control) has a malfunction.
2369 - This fault can be ignored and
erased.
2373 - Actuation of the radiator shutters
has a malfunction.
2377 - The position of the exhaust
camshaft (cylinder bank 2)
deviates from the specified value
during cold start.
2381 - The position of the intake
camshaft (cylinder bank 2)
deviates from the specified value
during cold start.
2385 - The position of the intake
camshaft (cylinder bank 1)
deviates from the specified value
in direction 'Retarded' during cold
start.
2389 - The position of the intake
camshaft (cylinder bank 2)
deviates from the specified value
in direction 'Retarded' during cold
start.
2393 - Ignition angle setting has a
malfunction during a cold start.
2397 - The ignition angle setting has a
malfunction during cold starting
(partial load operation).
2401 - The pressure sensor/pressure
switch of the evaporative emission
control system has a malfunction.
D600 - The control unit software 'CODE'
and 'DATA' do not comply.
D601 - Control unit software 'CODE'
missing or is corrupt.
D606 - Control unit software 'DATA'
missing or is corrupt.
E0009 - CAN signal 'Torque request' from
control unit Air conditioning is
implausible.
E0013 - CAN signal 'Torque request' from
control unit Air conditioning is
implausible.
E0025 - CAN signal 'Torque request' from
control unit Distronic is
implausible.
E0113 - CAN signal 'Stop lamp' from
control unit Traction systems is
implausible.
E0257 - One or more signals sent from
control unit Traction systems via
the CAN bus is implausible.
E0297 - CAN signal 'Torque request' from
control unit Traction systems is
implausible.
E0386 - CAN message from control
module N15/3 (Electronic
transmission control (ETC
[EGS])) : Coding error.
E0387 - CAN message from control
module N15/3 (Electronic
transmission control (ETC
[EGS])) : Coding error.
E0390 - CAN message from control
module N15/3 (Electronic
transmission control (ETC
[EGS])) : Coding error.
E0391 - CAN message from control
module N15/3 (Electronic
transmission control (ETC
[EGS])) : Coding error.
E0733 - CAN signal 'Fuel tank level' from
control unit A1 (Instrument
cluster) is implausible.
E0845 - CAN signal 'Torque request' from
control unit Transmission is
implausible.
E0925 P2158 CAN signal 'Vehicle speed at front
axle' from control unit Traction
systems is implausible. (P2158)
E0927 P2158 CAN signal 'Vehicle speed at front
axle' from control unit Traction
systems is implausible. (P2158)
E0929 - CAN signal 'Vehicle speed' from
control unit Traction systems is
implausible.
E0931 - CAN signal 'Vehicle speed' from
control unit Traction systems is
implausible.
E0961 - The filler cap is not closed.
E1124 P0513 Start enable of DAS not sent : See
fault codes in control unit EZS
(P0513)
E1281 - CAN signal 'Torque request' from
control unit Air conditioning is
implausible.
E1285 - One or more signals sent from
control unit Distronic via the CAN
bus is implausible.
E1289 - CAN signal 'Stop lamp' from
control unit Traction systems is
implausible.
E1293 - No CAN message was received
from control unit N93 (Central
gateway control unit).
E1297 - This fault can be ignored and
erased.
E1309 - Fault or disturbance in CAN
message from control unit
Traction systems
E1317 - One or more signals sent from
control unit N73 (EIS [EZS]
control unit) via the CAN bus is
implausible.
E1321 - No CAN message was received
from control unit N73 (EIS [EZS]
control unit).
E1325 - This fault can be ignored and
erased.
E1329 - This fault can be ignored and
erased.
E1333 - One or more signals sent from
control unit Traction systems via
the CAN bus is implausible.
E1353 - No CAN message was received
from control unit A1 (Instrument
cluster).
E1369 - One or more signals sent from
control unit Traction systems via
the CAN bus is implausible.
E1373 - No CAN message was received
from control unit Traction
systems.
E1377 - One or more signals sent from
control unit N80 (Steering column
module) via the CAN bus is
implausible.
E1381 - No CAN message was received
from control unit N80 (Steering
column module).
E1385 - This fault can be ignored and
erased.
E1393 - One or more signals sent from
control unit N51/2 (ABC control
module) via the CAN bus is
implausible.
E1397 - No CAN message was received
from control unit N51/2 (ABC
control module).
E1401 - One or more signals sent from
control unit Transmission via the
CAN bus is implausible.
E1405 - No CAN message was received
from control unit Transmission.
(U0101)
E1409 - One or more signals sent from
control unit Transmission via the
CAN bus is implausible.
E1413 - Monitoring of signal 'Torque
request' by control unit Distronic
has stopped.
E1417 - Monitoring of signal 'Torque
request' by control unit Traction
systems has stopped.
E1421 - Monitoring of signal 'Torque
request' by control unit
Transmission has stopped.
E1433 - No CAN message was received
from control unit N15/5
(Electronic selector lever module
(ESM [EWM])) or A80
(Intelligent servo module for
DIRECT SELECT).
E1436 - One or more of the signals
transmitted by control unit N15/5
(Electronic selector lever module
(ESM [EWM])) or A80
(Intelligent servo module for
DIRECT SELECT) via the CAN
bus are implausible.
E1437 - No CAN message was received
from control unit Air conditioning.
E1441 - One or more signals sent from
control unit Air conditioning via
the CAN bus is implausible.
E1593 P2610 The engine off time has an
implausible value. (P2610)
E1594 P2610 The engine off time has an
implausible value. (P2610)
E1595 P2610 The engine off time has an
implausible value. (P2610)
E1596 P2610 The engine off time has an
implausible value. (P2610)
E1665 - Fault present in control module
Transmission
E1669 - Fault present in control module
Transmission
E1673 - Fault present in control module
Transmission
E1677 - Fault present in control module
Transmission
E1681 - Fault present in control module
Transmission
E1685 - Fault present in control module
Transmission
E1689 - Fault present in control module
Transmission
E1693 - Fault present in control module
Transmission
E1697 - Fault present in control module
Transmission
E1701 - Fault present in control module
Transmission
E1705 - Fault present in control module
Transmission
E1709 - Fault present in control module
Transmission
E1713 - Fault present in control module
Transmission
E1717 - Fault present in control module
Transmission
E1721 - Fault present in control module
Transmission
E1725 - Fault present in control module
Transmission
E1729 P0702 Fault present in control module
Transmission (P0702)
E1733 P0748 Fault present in control module
Transmission (P0748)
E1737 P0778 Fault present in control module
Transmission (P0778)
E1741 P0798 Fault present in control module
Transmission (P0798)
E1745 P2716 Fault present in control module
Transmission (P2716)
E1749 P2725 Fault present in control module
Transmission (P2725)
E1753 P2734 Fault present in control module
Transmission (P2734)
E1757 P2810 Fault present in control module
Transmission (P2810)
E1761 P2759 Fault present in control module
Transmission (P2759)
E1765 P0642 Fault present in control module
Transmission (P0642)
E1769 P0643 Fault present in control module
Transmission (P0643)
E1773 P0706 Fault present in control module
Transmission (P0706)
E1777 P0722 Fault present in control module
Transmission (P0722)
E1781 P2767 Fault present in control module
Transmission (P2767)
E1785 P0717 Fault present in control module
Transmission (P0717)
E1789 P0730 Fault present in control module
Transmission (P0730)
E1793 P0563 Fault present in control module
Transmission : Battery voltage too
high (P0563)
E1797 P0562 Fault present in control module
Transmission : Battery voltage too
low (P0562)
E1801 P0723 Fault present in control module
Transmission (P0723)
E1805 P2768 Fault present in control module
Transmission (P2768)
E1809 P2766 Fault present in control module
Transmission (P2766)
E1813 P0718 Fault present in control module
Transmission (P0718)
E1817 P0716 Fault present in control module
Transmission (P0716)
E1821 P0219 Fault present in control module
Transmission (P0219)
E1825 P2757 Fault present in control module
Transmission (P2757)
E1829 - Fault present in control module
Transmission
E1833 - Fault present in control module
Transmission
E1837 - Fault present in control module
Transmission
E1841 - Fault present in control module
Transmission
E1845 - Fault present in control module
Transmission
E1849 - Fault present in control module
Transmission
E1853 - Fault present in control module
Transmission
E1865 - No CAN message was received
from control unit N118 (Fuel
pump control module).
E1869 - One or more signals sent from
control unit PSM Parameterizable
Special Module via the CAN bus
is implausible.
E1889 - This fault can be ignored and
erased.
E1893 - No CAN message was received
from control unit N82 (Battery
control module).
E1897 - Timeout of the PremAir
temperature signal
E2051 - CAN signal 'Fuel tank level' from
control unit A1 (Instrument
cluster) is implausible.
E2073 - This fault can be ignored and
erased.
E2077 - This fault can be ignored and
erased.
E2081 - No CAN message was received
from control unit N118 (Fuel
pump control module). (U0109)
E2085 - This fault can be ignored and
erased.
E2137 - A/C compressor2 : CAN
transmission error of signal from
component AC compressor
(Toggle error / Parity error)
E2201 - One or more of the signals
transmitted by control unit N15/5
(Electronic selector lever module
(ESM [EWM])) or A80
(Intelligent servo module for
DIRECT SELECT) via the CAN
bus are implausible.
E2321 - The engine off time has an
implausible value.
E2322 - The engine off time has an
implausible value.
E2323 - The engine off time has an
implausible value.
E2324 - The engine off time has an
implausible value.
E2326 - The engine off time has an
implausible value.
ACCESSORIES & BODY, CAB
Electrical System, Equipment & Instructions - Special Tools - S-Class (221)
SPECIAL TOOLS
124 589 00 21 00 SOCKET BOX (35-PIN) - WS54.00-P-0002B
FG 42/54/Set B
MODEL all
MODIFICATION NOTES
4.3.11 Replaced by 000 589 00 21 00 test box FG 00/01/Set B WS00.00-P-0034B
Use:
35-pin socket box for contacting electrical systems in combination with model-specific test cable sets
Fig. 1: Identifying Socket box (35-pin) (124 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
129 589 00 21 00 126-PIN SOCKET BOX - WS54.00-P-0008B
FG 00/42/54/91 / Set B
MODEL all
MODIFICATION NOTES
4.3.11 Replaced by 000 589 00 21 00 test box FG 00/01/SetB WS00.00-P-0034B
Use:
126-pin socket box for contacting electrical systems in combination with model-specific test cable sets
Fig. 2: Identifying 126-Pin Socket Box (129 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 01 ADAPTER CABLE - WS54.00-P-0050-01B
FG 42/43/54/Set B
MODELS all
MODIFICATION NOTES
15.11.98 Replacement for 210 589 05 63 00
Use:
Adapter line with MQS socket contacts for testing systems with MQS contacts, e.g. side airbag sensors. (Kit= 1
each black and red)
Fig. 3: Identifying Adapter Cable (220 589 00 99 01)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 02 ADAPTER LINE - WS54.00-P-0050-02B
FG 42/43/54/Set B
MODELS all
MODIFICATION NOTES
15.11.98 Replacement for 210 589 06 63 00
Use:
Adapter line with MQS pin contacts for testing systems with MQS contacts, e.g. side airbag sensors. (Kit= 1
each black and red)
Fig. 4: Identifying Adapter Line (220 589 00 99 02)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 03 ADAPTER LINE - WS54.00-P-0050-03B
FG 42/43/54/Set B
MODELS all
MODIFICATION NOTES
15.11.98 Replacement for 140 589 21 63 00
Use:
Adapter line with 1 mm socket for testing systems with contacts of 1 mm diameter, e.g. door wiring W140.
(Kit= 1 each black and red)
Fig. 5: Identifying Adapter Line (220 589 00 99 03)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 04 ADAPTER LINE - WS54.00-P-0050-04B
FG 42/43/54/Set B
MODELS all
MODIFICATION NOTES
15.11.98 Replacement for 140 589 22 63 00
Use:
Adapter line with 1 mm pin for testing systems with contacts of 1 mm diameter, e.g. door wiring W140. (Kit= 1
each black and red)
Fig. 6: Identifying Adapter Line (220 589 00 99 04)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 05 ADAPTER LINE - WS54.00-P-0050-05B
FG 42/43/54/Set B
MODELS all
Use:
Adapter line with 1.5 mm socket for testing systems with contacts of 1.5 mm diameter. (Kit= 1 each black and
red)
Fig. 7: Identifying Adapter Line (220 589 00 99 05)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 06 ADAPTER LINE - WS54.00-P-0050-06B
FG 42/43/54/Set B
MODELS all
MODIFICATION NOTES
15.11.98 Replacement for 170 589 02 63 00
Use:
Adapter line with pin 1.5 mm for testing systems with contacts of 1.5 mm diameter e.g. (Kit= 1 each black and
red)
Fig. 8: Identifying Adapter Line (220 589 00 99 06)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 07 ADAPTER LINE - WS54.00-P-0050-07B
FG 15/25/42/43/54/Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 21
Use:
Adapter line with 2.5 mm jack for testing systems with 2.5 mm dia. contacts. (Set=1 black and red each)
Fig. 9: Identifying Adapter Line (220 589 00 99 07)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 08 ADAPTER LINE - WS54.00-P-0050-08B
FG 15/42/43/54 / Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 21
Use:
Adapter line with 2.5 mm pin for testing systems with 2.5 mm dia. contacts. (Set=1 black and red each)
Fig. 10: Identifying Adapter Line (220 589 00 99 08)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 09 ADAPTER LINE - WS54.00-P-0050-09B
FG 15/42/43/54/Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 22
Use:
Adapter line with 4 mm jack for testing systems with 4 mm dia. contacts. (Set=1 black and red each)
Fig. 11: Identifying Adapter Line (220 589 00 99 09)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 10 ADAPTER LINE - WS54.00-P-0050-10B
FG 15/42/43/54/Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 22
Use:
Adapter line with 2.8 mm blade receptacle for testing systems with 2.8 x 0.8 mm contacts. (Set=1 black and red
each)
Fig. 12: Identifying Adapter Line (220 589 00 99 10)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 11 ADAPTER LINE - WS54.00-P-0050-11B
FG 00/09/15/42/43/54/ Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 21
Use:
Adapter line with 2.8 mm flat plug for testing systems with 2.8 x 0.8 mm contacts. (Set=1 black and red each)
Fig. 13: Identifying Adapter Line (220 589 00 99 11)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 12 ADAPTER LINE - WS54.00-P-0050-12B
FG 15/42/43/54/ Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 22
Use:
Adapter line with 6.3 mm blade receptacle for testing systems with 6.3 x 0.8 mm contacts. (Set=1 black and red
each)
Fig. 14: Identifying Adapter Line (220 589 00 99 12)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 13 ADAPTER LINE - WS54.00-P-0050-13B
FG 15/42/43/54 / Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 22
Use:
Adapter line with 6.3 mm flat plug for testing systems with 6.3 x 0.8 mm contacts. (Set=1 black and red each)
Fig. 15: Identifying Adapter Line (220 589 00 99 13)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 20 TEST CABLE - WS54.00-P-0050-14B
FG 15/20/25/42/43/54/ Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 23
Use:
Test wire 2 m with protection against accidental contact (Set=1 black and red each)
Fig. 16: Identifying Test Cable (220 589 00 99 20)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 21 ALLIGATOR CLIP - WS54.00-P-0050-15B
FG 15/42/43/54/ Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 24
Use:
Blank alligator clip with clamping range up to 5 mm pin diameter (Set = 2 ea.)
Fig. 17: Identifying Alligator Clip (220 589 00 99 21)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 22 SAFETY CLAMP - WS54.00-P-0050-16B
FG 15/25/42/43/54/Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 201 589 00 99 24
Use:
Safety clamp, with protection against accidental contact and clamping range up to 30 mm bolt diameter (Set=1
black and red each)
Fig. 18: Identifying Safety Clamp (220 589 00 99 22)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 23 CLAMP TEST PROBE - WS54.00-P-0050-17B
FG 15/42/43/54 / Set B
MODEL all
MODIFICATION NOTES
15.11.98 Replacement for 291 589 00 99 24
Use:
Terminal test probe for contacting pins and wires up to max. diameter 4 mm. (Set=1 black and red each)
Fig. 19: Identifying Clamp Test Probe (220 589 00 99 23)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 24 CONNECTION PLUG - WS54.00-P-0050-18B
FG 42/43/54/Set B
MODELS all
Use:
Connector with measuring pick-off for making Y-connections with adapter cables 220 589 00 99 01 up to 220
589 00 99 13 for dynamic measurements. (Set=2 off)
Fig. 20: Identifying Connection Plug (220 589 00 99 24)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 33 SAFETY CABLE - WS54.00-P-0050-22B
FG 42/43/54/Set B
MODELS all
MODIFICATION NOTES
15.11.98 Replacement for 124 589 37 63 00
Use:
Safety cable 15 amps for securing electric components against incorrect contacting
Fig. 21: Identifying Safety Cable (220 589 00 99 33)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 14 ADAPTER LINE - WS54.00-P-0050-25B
FG 54/Set B
MODEL all
Use:
Adapter line with CP1, 5 contact pin for checking systems with CP1, 5 contacts, e.g. engine wiring M271CNG
(set = one piece each black and red).
Fig. 22: Identifying Adapter Line (220 589 00 99 14)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 25 EMPTY CASE - WS54.00-P-0050-26B
FG54/Set B
MODEL all
MODIFICATION NOTES
5.6.08 Replaced by 220 589 05 99 01 empty case WS54.00-P-0050-29B
Use:
Empty case for replacement requirement.
Fig. 23: Identifying Empty Case (220 589 00 99 25)
Courtesy of MERCEDES-BENZ USA
220 589 05 99 01 EMPTY CASE - WS54.00-P-0050-29B
FG54/Set B
MODEL all
MODIFICATION NOTES
5.6.08 Replacement for 220 589 00 99 25 empty case WS54.00-P-0050-26B
Use:
Empty case for storing separate parts of the electrical connection set 220 589 05 99 00.
Fig. 24: Identifying Empty Case (220 589 05 99 01)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 37 ADAPTER CABLE - WS54.00-P-0050-37B
FG54/15/Set B
ENGINE 266, 272, 273, 640
Use:
2-pin adapter cable for voltage and resistance measurement and checking of signals at electric components such
as pressure transducer at exhaust gas recirculation valve and at boost pressure positioner for OM640 as well as
actuation of the injection valves for M266/272/273.
Fig. 25: Identifying Adapter Cable (220 589 00 99 37)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 38 ADAPTER CABLE - WS54.00-P-0050-38B
FG54/Set B
MODEL 216, 221, 204
Use:
2-pin adapter cable for voltage and resistance measurement and checking of signals at voltage distributor of
CAN bus for powerplant, telematics, vehicle dynamics, suspension, interior and central area.
Fig. 26: Identifying Adapter Cable (220 589 00 99 38)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 39 ADAPTER CABLE - WS54.00-P-0050-39B
FG54/Set B
MODEL 216, 221
Use:
8-pin adapter cable for voltage/resistance measurement and for checking signals on front end CAN bus.
Fig. 27: Identifying Adapter Cable (220 589 00 99 39)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 06 ADAPTER LINE - WS54.00-P-00506B
FG 42/43/54/Set B
MODELS all
MODIFICATION NOTES
15.11.98 Replacement for 170 589 02 63 00
Use:
Adapter line with pin 1.5 mm for testing systems with contacts of 1.5 mm diameter e.g. (Kit= 1 each black and
red)
Fig. 28: Identifying Adapter Line (220 589 00 99 06)
Courtesy of MERCEDES-BENZ USA
220 589 00 99 00 ELECTRICAL CONNECTION KIT - WS54.00-P-0050B
FG 00 FG 01/13/15/20/25/42/43/47/54/72/Set B
MODEL all
MODIFICATION NOTES
22.11.04 Replacement for 201 589 00 99 00
6.8.07 Replaced by 220 589 05 99 00 WS00.00-P-0279Z
Part 220 589 00 99 01 Adapter line WS54.00-P-0050-01B
Part 220 589 00 99 02 Adapter line WS54.00-P-0050-02B
Part 220 589 00 99 03 Adapter line WS54.00-P-0050-03B
Part 220 589 00 99 04 Adapter line WS54.00-P-0050-04B
Part 220 589 00 99 05 Adapter line WS54.00-P-0050-05B
Part 220 589 00 99 06 Adapter line WS54.00-P-0050-06B
Part 220 589 00 99 07 Adapter line FG 25/42/43/54/Set B WS54.00-P-0050-07B
Part 220 589 00 99 08 Adapter line WS54.00-P-0050-08B
Part 220 589 00 99 09 Adapter line WS54.00-P-0050-09B
Part 220 589 00 99 11 Adapter line WS54.00-P-0050-11B
Part 220 589 00 99 12 Adapter line WS54.00-P-0050-12B
Part 220 589 00 99 13 Adapter line WS54.00-P-0050-13B
Part 220 589 00 99 20 Test cable FG 25/42/43/54/Set B WS54.00-P-0050-14B
Part 220 589 00 99 21 Alligator clip WS54.00-P-0050-15B
Part 220 589 00 99 22 Safety clamp FG 25/42/43/54/Set B WS54.00-P-0050-16B
Part 220 589 00 99 23 Clamp test probe WS54.00-P-0050-17B
Part 220 589 00 99 24 Connector WS54.00-P-0050-18B
Part 220 589 00 99 25 Empty case FG54/Set B WS54.00-P-0050-26B
Part 220 589 00 99 30 Adapter cable WS54.00-P-0050-19B
Part 220 589 00 99 31 Adapter cable WS54.00-P-0050-20B
Part 220 589 00 99 33 Safety cable WS54.00-P-0050-22B
140 589 12 21 00 Baseline current draw test adapter 1 WS54.00-P-0015B
140 589 13 21 00 Quiescent current test adapter 2 WS54.00-P-0016B
000 581 06 54 Pliers
Further use FG 42/Set B WS42.00-N-3062B
Further use FG 43/Set B WS43.00-N-3053B
Use:
Electrical connection kit for contacting during voltage/current/resistance measurements and for connection of
the compression tester.
Fig. 29: Identifying Electrical Connection Kit (220 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
000 589 88 63 00 REMOVAL ASSEMBLY - WS54.00-P-0067B
FG 54/82/Set B
MODEL all
Use:
Removal fixture for removing the radio and the instrument cluster combination.
NOTE: Previous A-basic number 00083330561 is replaced as the removal fixture does
not remain in the vehicle but is used as a tool.
Fig. 30: Identifying Removal Assembly (000 589 88 63 00)
Courtesy of MERCEDES-BENZ USA
169 589 00 37 00 PLIERS - WS54.00-P-0073B
FG 54/Set B
MODEL 163, 164, 166, 168, 169, 170, 171, 172, 197, 203, 204, 207, 208, 209, 210, 211, 212, 216, 218, 219,
221, 230, 245, 246, 251, 451
Use:
Pliers for removing 12V sockets and cigar lighters with an SAE standard
Fig. 31: Identifying Pliers (169 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
203 589 06 63 00 PROGRAMMING ADAPTER - WS54.00-P-0074B
FG 54/Set B
MODEL 164, 169, 171, 203, 211, 215, 220, 221, 251
MODIFICATION NOTES
3.7.08 Replaced by 203 589 07 63 00 Test adapter FG 82/Set B WS82.00-P-0145B
Use:
Programming adapter for programming the Universal Cell phone Interface MOST control unit in the vehicle
when using a Notebook and special software.
Fig. 32: Identifying Programming Adapter (203 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS: PASSENGER CARS: ELECTRICAL SYSTEM, EQUIPMENT AND
INSTRUMENTS - WS54.00-Z-9999AZ
MODEL all
WS54.00-P-
000 589 01 21 00 Calibration device FG 54/Set B
0022B
000 589 13 99 00 Wiring harness WS00.19-P-
FG 00 FG 14/46/47/54/82/83/ Set B
repair kit, basic 0007B
WS00.19-P-
000 589 13 99 01 Crimp set overview FG00/54/Set B
0007-01B
WS00.19-P-
000 589 13 99 02 blade insert FG00/54/Set B
0007-02B
WS00.19-P-
000 589 13 99 03 Empty case FG00/54/Set B
0007-03B
000 589 13 99 10 MCP 2.8 ELA WS00.19-P-
FG00/54/Set B
crimping set 0007-10B
000 589 13 99 30 MCP 2.8 / Fl. blade WS00.19-P-
FG00/54/83/Set B
2.8 / JPT / SPT 0007-30B
FG 00/01/07/08/13/ 14/18/20/22/28/33/ WS00.00-P-
000 589 54 37 00 Clamp
46/47/54/82/83/Set B 0006Z
WS54.00-P-
000 589 88 63 00 Removal assembly FG 54/82/Set B
0067B
001 589 00 91 00 Set of protective WS01.00-P-
FG 01/54/Set B
covers 0110B
001 589 01 91 00 Set of protective WS01.00-P-
FG 01/08/09/14/15/ 54/83/ Set B
covers 0111B
001 589 02 91 00 Set of protective WS01.00-P-
FG 01/09/46/54 / Set B
covers 0112B
WS01.00-P-
003 589 03 37 00 Hose clamp pliers FG 01/07/09/18/20/ 46/54/ set B
0113B
WS54.00-P-
110 589 00 59 00 Puller hook FG 54/Set K
0001K
FG 00/01/05/13/18/ 26/42/54/67/68/72/ WS00.00-P-
110 589 03 59 00 Mounting wedge
77/80/82/83/88/91/ Set K 0274K
FG 00/26/27/31/32/33/ 41/47/54/62/67/68/ WS67.00-P-
115 589 03 59 00 Long wedge
72/77/80/82/83/86/ 88/91/98/Set K 0002K
WS54.00-P-
124 589 00 21 00 Socket box (35-pin) FG 42/54/Set B
0002B
WS15.00-P-
124 589 09 63 00 Ohm decade FG 15/54/Set C
0009C
WS54.00-P-
124 589 19 21 00 Pulse counter FG 54/Set B
0004B
126 589 05 21 00 Test adapter for WS54.00-P-
FG 54/Set B
electronic CC 0006B
WS54.00-P-
129 589 00 09 00 Pin socket FG 54/Set B
0007B
WS54.00-P-
129 589 00 21 00 126-pin socket box FG 00/42/54/91 / Set B
0008B
WS54.00-P-
129 589 01 09 00 Pin socket FG 54/Set B
0040B
WS54.00-P-
140 589 01 33 00 Mounting lever FG 54/Set A
0009A
WS54.00-P-
140 589 01 63 00 Contacting module 1 FG 54/Set B
0010B
WS54.00-P-
140 589 02 33 00 Pulling hook FG 46/54/68/82/83/91/Set B
0011B
WS54.00-P-
140 589 05 09 00 Pronged wrench FG 54/set B
0045B
WS54.00-P-
140 589 06 31 00 Unlocking tool FG 54/Set B
0044B
WS54.00-P-
140 589 06 63 00 Contacting box FG 54/Set B
0013B
WS54.00-P-
140 589 10 33 00 Spacer FG 54/Set B
0014B
140 589 12 21 00 Baseline current WS54.00-P-
FG 42/43/54/Set B
draw test adapter 1 0015B
140 589 13 21 00 Quiescent current WS54.00-P-
FG 42/43/54/Set B
test adapter 2 0016B
WS54.00-P-
140 589 14 63 00 Adapter FG 54/Set B
0017B
WS54.00-P-
140 589 43 63 00 -pin test cable FG 54/Set B
0020B
164 589 07 63 00 SCRCM adapter WS54.00-P-
FG 54/Set B
cable 0082B
168 589 01 62 00 Removal/installation WS54.00-P-
FG 54/Set B
device 0070B
WS54.00-P-
168 589 02 31 00 Unlocking tool FG 54/88/Set B
0051B
WS54.00-P-
169 589 00 37 00 Pliers FG 54/Set B
0073B
WS54.00-P-
169 589 04 63 00 Test adapter FG 54/Set B
0083B
201 589 00 99 00 Electrical connection WS15.00-N-
FG 15/54/Set C
kit 0014C
WS54.00-P-
202 589 03 33 00 Unlocking tool FG 54/Set B
0021B
203 589 06 63 00 Programming WS54.00-P-
FG 54/Set B
adapter 0074B
204 589 03 63 00 Adapter cable (20- WS54.00-P-
FG 54/Set B
pin) 0077B
WS54.00-P-
204 589 04 63 00 6-pin adapter cable FG 54/Set B
0084B
210 589 02 33 00 Unlocking tool for WS54.00-P-
FG 54/Set B
SPT / JPT contacts 0042B
211 589 03 21 00 Set of SBC flash WS54.00-P-
FG 54/Set B
adapters 0072B
WS54.00-P-
211 589 03 21 01 15-pin adapter cable FG54/Set B
0072-01B
WS54.00-P-
211 589 03 21 02 9-pin adapter cable FG54/Set B
0072-02B
WS54.00-P-
211 589 03 21 03 SBC module FG54/Set B
0072-03B
211 589 04 21 00 SBC programming WS54.00-P-
FG 54/Set B
adapter set 0075B
WS54.00-P-
211 589 04 21 01 15-pin adapter cable FG54/Set B
0075-01B
WS54.00-P-
211 589 04 21 02 Plug adapter FG54/Set B
0075-02B
WS54.00-P-
211 589 04 21 03 Adapter cable FG54/Set B
0075-03B
WS54.00-P-
211 589 04 21 04 Set of mirrors FG54/Set B
0075-04B
211 589 04 21 05 Adapter cable (9- WS54.00-P-
FG54/Set B
pin) 0075-05B
WS54.00-P-
211 589 04 21 06 Reference plug FG54/Set B
0075-06B
WS54.00-P-
211 589 08 63 00 Adapter cable FG 54/Set B
0068B
WS54.00-P-
212 589 01 63 00 38-pin adapter cable FG 54/Set B
0079B
WS54.00-P-
212 589 03 63 00 18-pin adapter cable FG 54/Set B
0080B
220 589 00 99 00 Electrical connection BWS54.00-P-
FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/Set
kit 0050B
WS54.00-P-
220 589 00 99 01 Adapter cable FG 42/43/54/Set B
0050-01B
WS54.00-P-
220 589 00 99 02 Adapter line FG 42/43/54/Set B
0050-02B
WS54.00-P-
220 589 00 99 03 Adapter line FG 42/43/54/Set B
0050-03B
WS54.00-P-
220 589 00 99 04 Adapter line FG 42/43/54/Set B
0050-04B
WS54.00-P-
220 589 00 99 05 Adapter line FG 42/43/54/Set B
0050-05B
WS54.00-P-
220 589 00 99 06 Adapter line FG 42/43/54/Set B
0050-06B
WS54.00-P-
220 589 00 99 07 Adapter line FG 15/25/42/43/54/Set B
0050-07B
WS54.00-P-
220 589 00 99 08 Adapter line FG 15/42/43/54 / Set B
0050-08B
WS54.00-P-
220 589 00 99 09 Adapter line FG 15/42/43/54/Set B
0050-09B
WS54.00-P-
220 589 00 99 10 Adapter line FG 15/42/43/54/Set B
0050-10B
WS54.00-P-
220 589 00 99 11 Adapter line FG 00/09/15/42/43/54/ Set B
0050-11B
WS54.00-P-
220 589 00 99 12 Adapter line FG 15/42/43/54/ Set B
0050-12B
WS54.00-P-
220 589 00 99 13 Adapter line FG 15/42/43/54 / Set B
0050-13B
WS54.00-P-
220 589 00 99 14 Adapter line FG 54/Set B
0050-25B
WS54.00-P-
220 589 00 99 15 Set of adapter cables FG 54/Set B
0050-28B
WS54.00-P-
220 589 00 99 20 Test cable FG 15/20/25/42/43/54/ Set B
0050-14B
WS54.00-P-
220 589 00 99 21 Alligator clip FG 15/42/43/54/ Set B
0050-15B
WS54.00-P-
220 589 00 99 22 Safety clamp FG 15/25/42/43/54/Set B
0050-16B
WS54.00-P-
220 589 00 99 23 Clamp test probe FG 15/42/43/54 / Set B
0050-17B
WS54.00-P-
220 589 00 99 24 Connection plug FG 42/43/54/Set B
0050-18B
WS54.00-P-
220 589 00 99 25 Empty case FG54/Set B
0050-26B
WS54.00-P-
220 589 00 99 30 Adapter cable FG 42/43/54/Set B
0050-19B
WS54.00-P-
220 589 00 99 31 Adapter cable FG 42/43/54/Set B
0050-20B
WS54.00-P-
220 589 00 99 33 Safety cable FG 42/43/54/Set B
0050-22B
WS54.00-P-
220 589 00 99 34 Adapter cable Group 42/43/54/Set B
0050-23B
WS54.00-P-
220 589 00 99 35 Adapter cable FG 00/09/20/42/43/54/Set B
0050-24B
WS54.00-P-
220 589 00 99 36 Adapter cable FG54/Set B
0050-27B
WS54.00-P-
220 589 00 99 37 Adapter cable FG54/15/Set B
0050-37B
WS54.00-P-
220 589 00 99 38 Adapter cable FG54/Set B
0050-38B
WS54.00-P-
220 589 00 99 39 Adapter cable FG54/Set B
0050-39B
WS00.19-P-
220 589 01 99 05 JPT crimping set FG 00/54/83/Set B
0001-05B
WS00.19-P-
220 589 01 99 10 Crimp pliers FG 00/14/54/83/Set B
0001-09B
WS00.19-P-
220 589 01 99 15 Positioner, JPT FG00/54/Set B
0001-14B
220 589 01 99 20 Unlocking device WS00.19-P-
FG00/54/Set B
with RK 1.5 ejector 0001-18B
220 589 01 99 21 Replacement sleeve, WS00.19-P-
FG00/54/Set B
RK 1.5 0001-19B
220 589 01 99 30 Unlocking device WS00.19-P-
FG00/14/54/Set B
with RK 2.5 ejector 0001-20B
WS00.19-P-
220 589 01 99 31 Spare sleeve, RK 2.5 FG00/54/Set B
0001-21B
WS00.19-P-
220 589 01 99 40 Wire stripper FG 00/54/83/Set B
0001-22B
WS00.19-P-
220 589 01 99 41 Reflector FG 00/54/83/Set B
0001-23B
WS00.19-P-
220 589 01 99 42 Adapter FG 00/54/83/Set B
0001-24B
220 589 01 99 50 Blade holder with WS00.19-P-
FG00/14/54/83/Set B
clamping pliers 0001-25B
WS00.19-P-
220 589 01 99 60 MQS blade FG00/54/Set B
0001-35B
220 589 01 99 74 Plastic can 151 x 99 WS00.19-P-
FG00/54/Set B
x 44 0001-42B
220 589 01 99 75 Plastic can 61 x 54 x WS00.19-P-
FG00/54/Set B
38 0001-43B
220 589 01 99 76 Plastic can 53 x 37 x WS00.19-P-
FG00/54/Set B
24 0001-44B
WS00.19-P-
220 589 01 99 77 Adhesive labels FG00/54/Set B
0001-45B
WS00.19-P-
220 589 01 99 82 JPT ELA crimp set FG00/54/Set B
0002-08B
WS00.19-P-
220 589 01 99 85 MQS crimping set FG00/54/Set B
0002-11B
220 589 01 99 86 MQS ELA crimping WS00.19-P-
FG00/54/Set B
set 0002-12B
WS00.19-P-
220 589 01 99 92 Positioner, JPT ELA FG00/54/Set B
0002-15B
WS00.19-P-
220 589 01 99 95 Positioner, MQS FG00/54/Set B
0002-18B
220 589 01 99 96 Positioner, MQS WS00.19-P-
FG00/54/Set B
ELA 0002-19B
220 589 02 99 00 Wiring harness WS00.19-P-
FG 00 FG 54/83/Set B
repair kit 0002B
220 589 04 99 00 New passenger car WS00.19-P-
FG 00 FG 46/47/54/82/83/Set B
wiring harness repair kit 0006B
220 589 05 99 00 Electrical connection BWS00.00-P-
FG 00/01/09/13/15/ 20/25/42/43/47/54/ 72/Set
kit 0279Z
WS54.00-P-
220 589 05 99 01 Empty case FG54/Set B
0050-29B
WS15.00-P-
221 589 01 62 00 Eyebolt set FG 15/54/Set B
0059B
285 589 00 21 00 Cooler vacuum WS20.00-P-
FG 01/08/20/54/Set B
filling device 0030B
WS08.00-P-
451 589 08 63 00 Warning label FG 08/54/Set K
0003K
WS20.00-N-
639 589 00 91 00 Test cap FG 20/54/Set B
3035B
WS54.00-N-
645 589 05 63 00 Test cable FG 54/Set B
3030B
WS54.00-N-
645 589 06 63 00 Assembly hook FG 54/Set B
3024B
930 589 00 99 00 Supplemental truck WS00.19-N-
FG 00/14/54/67 / Set B
wiring harness repair kit 0004B
WS00.19-N-
930 589 00 99 07 MCP 6.3 crimp set FG 00/54/67/Set B
0004-13B
WS00.19-N-
930 589 00 99 08 MCP 6.3 crimp set FG 00/54/67/Set B
0004-14B
WS00.19-N-
930 589 00 99 25 MCP 6.3 positioner FG00/54/67/Set B
0004-15B
WS00.19-N-
930 589 00 99 26 MCP 6.3 positioner FG00/54/67/Set B
0004-16B
ACCESSORIES & BODY, CAB
Electrical System - Body - Torque Specifications - S-Class (221)
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: ELECTRICAL SYSTEM BODY - BA82.00-Z-
9999AZ
MODEL all
Additional stop BA82.10-P-
MODEL 211.2
lamp 1000-05A
BA82.62-P-
Antenna MODEL 203.0, 209, 210.0 /2, 211, 218, 219
1000-01A
BA82.62-P-
Antenna MODEL 166, 172, 204, 207, 212, 221
1000-01D
BA82.62-P-
Antenna MODEL 169.0 /3, 245
1000-01C
BA82.62-P-
Antenna MODEL 163
1000-01B
Antenna amplifier BA82.62-P-
MODEL 169, 245
module 1000-02B
Antenna amplifier BA82.62-P-
MODEL 199.3
module 1000-02A
Front axle level MODEL 172, 199, 211, 215, 216, 220, 221, 230, 240 MODEL BA82.10-P-
sensor 171 with CODE (614) Bi-xenon headlamp unit 1000-01A
Front axle level BA82.10-P-
MODEL 251
sensor 1000-01C
Front axle level BA82.10-P-
MODEL 164.1 /8, 166
sensor 1000-01B
Headlamp cleaning BA82.15-P-
MODEL 202
system 1000-01A
BA82.10-P-
Headlamp unit MODEL 199.376
1000-06A
BA82.00-P-
Mounting bracket MODEL 211
1000-01A
BA82.00-P-
Mounting bracket MODEL 219
1000-01B
Rear axle level BA82.10-P-
MODEL 172, 216, 221
sensor 1000-02E
Rear axle level BA82.10-P-
MODEL 251
sensor 1000-02D
MODEL 164.1 /8, 166
sensor 1000-02C
Rear axle level MODEL 215, 220, 230 with CODE (487) Active Body Control BA82.10-P-
sensor (ABC) MODEL 220, 240 1000-02A
Rear axle level BA82.10-P-
MODEL 199
sensor 1000-02B
Rear entertainment MODEL 164, 166, 204, 211, 212, 218, 219, 221, 251 except BA82.60-P-
unit CODE (864) Rear entertainment system 1000-01A
BA82.10-P-
Roof sign mount MODEL 245
1000-03B
BA82.10-P-
Roof sign mount MODEL 203.0 /2, 211.0
1000-03A
BA82.10-P-
Roof sign mount MODEL 221
1000-03C
BA82.62-P-
Sound amplifier MODEL 199
1000-03A
BA82.80-P-
Tablet PC mount MODEL 164, 204, 211, 212, 218, 219, 221, 251
1000-01A
BA82.95-P-
Tilting cone sensor MODEL 199
1000-01A
BA82.30-P-
Windshield washer MODEL 129
1000-01E
BA82.30-P-
Windshield washer MODEL 163
1000-01C
Windshield washer BA82.35-P-
MODEL 164.1 /8, 166
system 1000-01B
Windshield washer BA82.35-P-
MODEL 240
system 1000-01A
BA82.30-P-
Windshield wiper MODEL 168, 414.700
1000-01D
MODEL 170, 171, 172, 199, 202, 203, 208, 209, 210, 211.0 /2 /6, BA82.30-P-
Windshield wiper
215, 220, 230, 240 1000-01A
BA82.30-P-
Windshield wiper MODEL 216, 221.0 /1
1000-01L
BA82.30-P-
Windshield wiper MODEL 197
1000-01N
BA82.30-P-
Windshield wiper MODEL 169, 245
1000-01H
BA82.30-P-
Windshield wiper MODEL 164.1 /8, 166
1000-01J
BA82.30-P-
Windshield wiper MODEL 246
1000-01O
BA82.30-P-
Windshield wiper MODEL 204, 207, 212, 218
1000-01M
Windshield wiper MODEL 251 1000-01K
BA82.30-P-
Windshield wiper MODEL 219.3
1000-01I
FRONT AXLE LEVEL SENSOR - BA82.10-P-1000-01A
Model 171, 172, 199, 211, 215, 216, 220, 221, 230, 240
FRONT AXLE LEVEL SENSOR
Model 171 Model Model Model 211
Number Designation
with code 614 172 199 with Airmatic
BA82.10-P- Nut, level sensor link rod to upper
Nm - - - 10
1001-01A control arm
BA82.10-P-
Nut, connecting rod to level sensor Nm 5 8 - 5
1002-01A
BA82.10-P- Bolt/nut of level sensor to retaining
Nm - - - -
1003-01A plate
BA82.10-P- Screw, headlamp range adjustment
Nm - - 5 -
1004-01A front axle sensor to frame
BA82.10-P- Bolt, sensor linkage to transverse
Nm - - 10 -
1005-01A control arm
BA82.10-P- Screw, linkage to headlamp range
Nm - - 2 -
1006-01A adjustment front axle sensor
Nut for sensor with bracket to
BA82.10-P-
"console for upper transverse Nm - - - 8
1007-01A
control arm"
BA82.10-P- Bracket with ball stud for link rod
Nm - 20 - -
1008-01A at torsion bar
BA82.10-P- Screw/bolt, turning angle sensor
Nm - 8 - -
1009-01A bracket to body
BA82.10-P- Screw/bolt, turning angle sensor to
Nm - 4 - -
1010-01A bracket
FRONT AXLE LEVEL SENSOR
Model Model Model Model
Number Designation
215 216 220 221
BA82.10-P- Nut, level sensor link rod to upper control
Nm 10 6 10 10
1001-01A arm
BA82.10-P-
Nut, connecting rod to level sensor Nm 5 6 5 5
1002-01A
BA82.10-P-
Bolt/nut of level sensor to retaining plate Nm 4 4 4 5
1003-01A
BA82.10-P- Screw, headlamp range adjustment front axle
Nm - - - -
1004-01A sensor to frame
BA82.10-P-
Bolt, sensor linkage to transverse control arm Nm - - - -
1005-01A
BA82.10-P- Screw, linkage to headlamp range adjustment
Nm - - - -
1006-01A front axle sensor
BA82.10-P- Nut for sensor with bracket to "console for
Nm - - - -
1007-01A upper transverse control arm"
BA82.10-P- Bracket with ball stud for link rod at torsion
Nm - - - -
1008-01A bar
BA82.10-P- Screw/bolt, turning angle sensor bracket to
Nm - - - -
1009-01A body
BA82.10-P-
Screw/bolt, turning angle sensor to bracket Nm - - - -
1010-01A
FRONT AXLE LEVEL SENSOR
Model Model
Number Designation
230 240
BA82.10-P-1001-
Nut, level sensor link rod to upper control arm Nm 10 5
01A
BA82.10-P-1002-
Nut, connecting rod to level sensor Nm 5 5
01A
BA82.10-P-1003-
Bolt/nut of level sensor to retaining plate Nm 4 10
01A
BA82.10-P-1004- Screw, headlamp range adjustment front axle sensor to
Nm - -
01A frame
BA82.10-P-1005-
Bolt, sensor linkage to transverse control arm Nm - -
01A
BA82.10-P-1006- Screw, linkage to headlamp range adjustment front axle
Nm - -
01A sensor
BA82.10-P-1007- Nut for sensor with bracket to "console for upper transverse
Nm - -
01A control arm"
BA82.10-P-1008-
Bracket with ball stud for link rod at torsion bar Nm - -
01A
BA82.10-P-1009-
Screw/bolt, turning angle sensor bracket to body Nm - -
01A
BA82.10-P-1010-
Screw/bolt, turning angle sensor to bracket Nm - -
01A
REAR AXLE LEVEL SENSOR - BA82.10-P-1000-02E
Model 172, 216, 221
REAR AXLE LEVEL SENSOR
Number Designation Model 221
172 216 487 with code 487
BA82.10-P-
Nut, connecting rod to level sensor Nm 8 6 10 10
1001-02E
BA82.10-P-
Bolt, level sensor to retaining plate Nm 4 - 5 5
1002-02E
BA82.10-P-
Nut, retaining plate to frame floor Nm 20 - 10 10
1003-02E
BA82.10-P- Nut, linkage rod bracket to spring
Nm 22 22 - 22
1004-02E control arm
BA82.10-P- Nut of retaining shell of torsion bar
Nm - - 5 -
1005-02E intermediate lever to torsion bar
ROOF SIGN MOUNT - BA82.10-P-1000-03C
Model 221
ROOF RACK BRACKET
Number Designation Model 221
BA82.10-P-1001-03C Roof sign mounting on vehicle roof Nm 16
WINDSHIELD WIPER - BA82.30-P-1000-01L
Model 216, 221
WINDSHIELD WIPER
Number Designation Model 216 Model 221.0/1
BA82.30-P-1001-01L Nut to wiper arm Nm 33 33
BA82.30-P-1002-01L Nut/screw for wiper motor to body Nm 20 20
REAR ENTERTAINMENT UNIT - BA82.60-P-1000-01A
Model 164, 166, 204, 211, 212, 218, 219, 221, 251
MODIFICATION NOTES
20.8.09 Value changed: Screw/bolt to rear entertainment unit bracket
REAR ENTERTAINMENT UNIT
Model 164, 166, 204, 211, 212, 218, 219,
Number Designation
221, 251
BA82.60-P-1001- Screw/bolt to rear entertainment unit
Nm 19
01A bracket
ANTENNA - BA82.62-P-1000-01D
Model 166, 172, 204, 207, 212, 221
MODIFICATION NOTES
11.2.08 Value changed: Bolt, antenna base to vehicle roof Model 221
ANTENNA
Model Model Model Model
Number Designation
166 172 204 207
BA82.62-P-1001- Screw, antenna base to vehicle
Nm 3 - 3 3
01D roof
BA82.62-P-1002- Screw/bolt, antenna base to trunk
Nm - 3 - 3
01D lid
ANTENNA
Number Designation Model 212 Model 221
BA82.62-P-1001-01D Screw, antenna base to vehicle roof Nm 3 3
BA82.62-P-1002-01D Screw/bolt, antenna base to trunk lid Nm - -
TABLET PC MOUNT - BA82.80-P-1000-01A
Model 164, 204, 211, 212, 218, 219, 221, 251
TABLET PC MOUNT
Model 164, 204, 211, 212, 218, 219,
Number Designation
221, 251
BA82.80-P-1001- Screw/bolt, tablet PC mount bracket to
Nm 19
01A seat
ACCESSORIES & BODY, CAB
Electrical System, Equipment & Instructions - Testing & Repair - S-Class (221)
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM, EQUIPMENT AND
INSTRUMENTS - AR54.00-Z-9000AA
MODEL all
Initial filling of battery MODELS all AR54.10-P-0001Z
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM, EQUIPMENT AND
INSTRUMENTS - AR54.00-Z-9221AA
MODEL 221
AR54.65-P-
Calibration of the backup camera MODEL 207, 212, 216, 218, 221...
0022SX
Carry out disable/initial startup of
AR54.10-P-
high-voltage on-board electrical MODEL 221.095 /195 with ENGINE 272.974
1150SXH
system
Central gateway control unit AR54.21-P-
MODEL 216.3, 221.0 /1
(ZGW), remove and install 0817SX
AR54.10-P-
Charge battery MODEL 216, 221...
1130SX
AR54.10-P-
Charge battery MODEL 216, 221...
1130SY
AR54.10-P-
Charge high-voltage battery MODEL 221.095 /195 with ENGINE 272.974
1170SXH
Check battery condition before MODEL 164, 169, 171, 203, 204, 207, 209, 211, 216, AR54.10-P-
vehicle delivery 219, 221, 230, 240, 245, 251 (except, 245.286) 1132A
Check condition of additional MODEL 216, 221 with CODE (B03) ECO start/stop AR54.10-P-
battery function 1128SX
AR54.10-P-
Check condition of battery MODEL 216, 221...
1129SX
AR54.10-P-
Check condition of battery MODEL 216, 221...
1129SY
Disconnect/connect battery ground AR54.10-P-
MODEL 216.3, 221.0 /1
line 0003SX
Maintaining vehicle voltage supply
AR54.10-P-
when performing test and diagnosis MODEL 216, 221...
1127SX
work on vehicle
Maintaining vehicle voltage supply
AR54.10-P-
when performing test and diagnosis MODEL 216, 221...
1127SY
work on vehicle
MODEL 129, 163, 164, 166, 168, 169, 170, 171, 199,
203, 204, 207, 208, 209, 210, 211, 212, 215, 216, AR54.21-P-
Programming of control units
218, 219, 220, 221, 230, 240, 245, 246, 251, 450, 0014Y
452, 454, 461, 463...
MODEL 129, 163, 164, 168, 169, 170, 171, 199, 203,
AR54.21-P-
Programming of control units 204, 207, 208, 209, 210, 211, 212, 215, 216, 218,
0014Z
219, 220, 221, 230, 240, 245, 246, 251, 461, 463...
AR54.10-P-
Remove/install additional battery MODEL 216, 221...
0007SX
AR54.10-P-
Remove/install additional battery MODEL 216, 221
0007SXS
Remove/install additional battery MODEL 216, 221 with CODE (B03) ECO start/stop AR54.15-P-
relay function 2000SX
Remove/install additional fan for
AR54.30-P-
instrument cluster/COMAND MODEL 216.3, 221.0 /1
6000SX
display
MODEL 216.3, 221.0 /1 with CODE (218) Backup AR54.65-P-
Remove/install backup camera
camera 0030SX
remove/install backup camera AR54.65-P-
MODEL 216, 221...
control unit 0025SX
AR54.10-P-
Remove/install battery sensor MODEL 216, 221...
0002SX
AR54.10-P-
Remove/install battery sensor MODEL 221.095/ 195
0002SXH
MODEL 168, 170, 171, 197, 203, 204, 207, 208, 209, AR54.10-P-
Remove/install cigarette lighter
210, 211, 212, 216, 219, 221, 230... 0030TX
AR54.25-P-
Remove/install cockpit switch group MODEL 216.3, 221.0 /1
1000SX
AR54.25-P-
Remove/install combination switch MODEL 216.3, 221.0 /1
2800SX
AR54.10-P-
Remove/install DC/DC converter MODEL 221.095/ 195
1350SXH
Remove/install front central MODEL 221.0 /1 up to 31.5.09 except CODE (800) AR54.21-P-
operating unit Model year 2010 0500SX
Remove/install front central MODEL 221.0 /1 as of 1.6.09 MODEL 221.0 /1 with AR54.21-P-
operating unit CODE (800) Model year 2010 0500SXH
AR54.15-P-
Remove/install front prefuse box MODEL 216, 221...
1330SX
AR54.15-P-
Remove/install front prefuse box MODEL 216, 221...
1330SY
Remove/install high-voltage battery MODEL 221.095 /195 with ENGINE 272.974
1140SXH
AR54.30-P-
Remove/install instrument cluster MODEL 216.3, 221.0 /1
6015SX
Remove/install interior AR54.15-P-
MODEL 216, 221...
compartment prefuse box 1350SX
Remove/install multifunction AR54.21-P-
MODEL 172, 204, 207, 212, 216, 218, 221...
camera 3000EW
Remove/install multifunction AR54.21-P-
MODEL 216, 221.0 /1
steering wheel electronics unit 2050SX
Remove/install Night View Assist MODEL 212, 216.3, 218, 221.0 /1 with CODE (610) AR54.30-P-
control unit Night vision assist 3000SX
Remove/install Night View Assist MODEL 216.3, 221.0 /1 with CODE (610) Night AR54.30-P-
control unit vision assist 3100SX
Remove/install on-board electrical
AR54.15-P-
network line pyrofuse in vehicle MODEL 216, 221...
1262SX
power supply control unit
Remove/install on-board electrical AR54.10-P-
MODEL 216, 221...
system battery 0009SX
Remove/install on-board electrical AR54.10-P-
MODEL 221.095/ 195
system battery 0009SXH
Remove/install on-board electrical AR54.10-P-
MODEL 216, 221...
system battery 0009SY
Remove/install Parktronic system MODEL 221.0 /1 with CODE (220) Parktronic AR54.65-P-
(PTS) control unit system (PTS) 0006SX
AR54.10-P-
Remove/install pyrofuse MODEL 221.095 /195 with ENGINE 272.974
1180SXH
Remove/install quiescent current
AR54.15-P-
cutout relay in vehicle power supply MODEL 216, 221...
1266SX
control unit
Remove/install radar sensors control AR54.65-P-
MODEL 221.0 /1 with CODE (229) Park Assist
unit 0040SX
Remove/install rear control panel MODEL 221.0 /1 with CODE (864) Rear AR54.21-P-
control unit entertainment system 1266SX
Remove/install SAM control unit AR54.21-P-
MODEL 216.3, 221.0 /1
with fuse and relay box in trunk 1258SX
Remove/install SAM with fuse and AR54.21-P-
MODEL 216.3, 221.0 /1
relay box, left front 1260SX
AR54.10-P-
Remove/install starter battery MODEL 216, 221...
0008SX
AR54.10-P-
Remove/install starter battery MODEL 221...
0008SXS
Remove/install steering column AR54.25-P-
MODEL 221.0 /1, 216
module 2802SX
front central operating unit MODEL 216.3, 221.0 /1 0501SX
Remove/install upper control panel AR54.21-P-
MODEL 216.3, 221.0 /1
control unit 1262SX
Remove/install vehicle power AR54.21-P-
MODEL 216, 221...
supply control unit 0100SX
MODEL 216.3, 221.0 /1 as of 1.6.07 with CODE
Remove/install voltage supply of AR54.65-P-
(218) Backup camera except CODE (498) Japan
backup camera 0032SX
version
MODEL 168, 169, 170, 171, 197, 203, 204, 208, 209, AR54.10-P-
Remove/install 12 Volt socket
210, 211, 216, 219, 221, 230, 245... 1000TX
Removing and installing steering AR54.25-P-
MODEL 216.3, 221.0 /1
column adjustment switch 2804SX
MODEL 124, 126, 129, 140, 163, 164, 166, 168, 169,
Repair supplemental restraint 170, 171, 172, 197, 202, 203, 204, 207, 208, 209, AR54.18-P-
system (SRS) squib wiring harness 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 0600A
240, 245, 246, 251, 414, 461, 463...
MODEL 129, 163, 164, 166, 168, 169, 170, 171, 199,
203, 204, 207, 208, 209, 210, 211, 212, 215, 216, AR54.21-P-
SCN coding of control units
218, 219, 220, 221, 230, 240, 245, 246, 251, 450, 0015X
452, 454, 461, 463...
INITIAL FILLING OF BATTERY - AR54.10-P-0001Z
MODELS all
Maximum fluid level
Fig. 1: Filling Battery
Filling
Risk of explosion from explosive gas. Risk
No fire, sparks, naked flames or
of poisoning and caustic burns from
smoking. Wear acid-protective gloves,
swallowing battery electrolyte. Risk of AS54.10-Z-
clothing and eye protection. Pour
injury from caustic burns to eyes and skin 0001-01A
battery electrolyte only into suitable
from battery electrolyte or from handling
and appropriately marked containers.
damaged lead acid batteries.
Let the battery stand for
approximately 20 minutes and
Pour in battery electrolyte up to inner level afterwards control the fluid level if
1 necessary.
marking with a filling device
*WE58.40-
Z-1001-22A
AH54.10-P-
Notes on battery All models
0001-01A
WORKSHOP EQUIPMENT
WE58.40-Z-1001-22A Tank emptying device
REMOVE/INSTALL BATTERY SENSOR - AR54.10-P-0002SX
MODEL 216.3 as of 2.6.08
MODEL 216.3 with CODE (809) model year 2009
MODEL 221.0 /1 (except 221.095 /195) as of 2.6.08
MODEL 221.0 /1 with CODE (809) model year 2009
Fig. 2: Identifying Battery Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Disconnect ground line (1) from the on-board AR54.10-P-
1
electrical system battery (G1) 0003SX
Disconnect electrical connector (2) from battery
2
sensor (B95)
3 Remove battery terminal cover (3)
Disconnect positive line (4) from on-board
4
electrical system battery (G1)
Use counterwrench for
holding the pin.
5 Unscrew nut (5)
*BA54.10-P-
1028-01C
6 Remove ground line (1) with battery sensor (B95)
7 Install in the reverse order
BATTERY
Number Designation Model 216 Model 221
BA54.10-P-1028- Bolt/nut, ground line of battery M8 Nm 16 16
01C to body
END INTERNAL ON-BOARD ELECTRICAL SYSTEM FUNCTIONS - AR54.10-P-0003-01SX
Before disconnecting the ground lines, the voltage must be removed from the vehicle by terminating the
internal on-board electrical system functions.
1. Move selector lever position to "P".
2. Switch off all electrical consumers.
3. Turn transmitter key in EIS [EZS] control unit to position "0".
4. Turn transmitter key in EIS [EZS] control unit to position "2" and wait for approx. 30 s.
5. Turn transmitter key in EIS [EZS] control unit to position "0" and leave in EIS [EZS] control unit.
The internal on-board electrical system functions are now ended.
DISCONNECT AND DISCONNECT GROUND LINE FROM ON-BOARD ELECTRICAL SYSTEM
WITH ONE BATTERY - AR54.10-P-0003-02SX
Risk of explosion caused No fire, sparks, open AS54.10-Z-0001-01A
by oxyhydrogen gas. Risk flames or smoking. Wear
of poisoning and caustic acid-resistant gloves,
burns caused by clothing and glasses. Only
swallowing battery acid. pour battery acid into
Risk of injury caused by suitable and appropriately
burns to skin and eyes marked containers.
from battery acid or when
handling damaged lead-
acid batteries
Notes on battery AH54.10-P-0001-01A
Shown on model 221
Fig. 3: Identifying Ground Line And Negative Terminal Of On-Board Electrical System Battery
Courtesy of MERCEDES-BENZ USA
1. Loosen nut on ground line (1) and remove ground line (1) from negative terminal of on-board electrical
system battery (G1).
Installation: Ensure that the ground line (1) is seated tightly, otherwise the electrical system may be
damaged.
2. Connect in reverse order.
DISCONNECT AND DISCONNECT GROUND LINE FROM ON-BOARD ELECTRICAL SYSTEM
WITH ONE BATTERY - AR54.10-P-0003-02SXS
Risk of explosion caused No fire, sparks, open AS54.10-Z-0001-01A
by oxyhydrogen gas. Risk flames or smoking. Wear
of poisoning and caustic acid-resistant gloves,
burns caused by clothing and glasses. Only
swallowing battery acid. pour battery acid into
Risk of injury caused by suitable and appropriately
burns to skin and eyes marked containers.
from battery acid or when
handling damaged lead-
acid batteries
Notes on battery AH54.10-P-0001-01A
Shown on model 221
Fig. 4: Identifying Ground Line And Negative Terminal Of On-Board Electrical System Battery
Courtesy of MERCEDES-BENZ USA
1. Loosen nut on ground line (1) and remove ground line (1) from negative terminal of on-board electrical
system battery (G1).
Installation: Ensure that the ground line (1) is seated tightly, otherwise the electrical system may be
damaged.
2. Using a diode test lamp, check the electrical system for voltage between the positive line of the on-board
electrical system battery (G1) and the disconnected ground line (1).
If the diode test lamp lights up, the on-board electrical system is still active because of a defect in the
electrical system.
In this case the ground line of the additional battery should be disconnected.
After this the electrical system is to be repaired upon completion of the work carried out.
3. Connect in reverse order.
DISCONNECT/CONNECT GROUND LINE FROM ON-BOARD ELECTRICAL SYSTEM WITH
TWO BATTERIES - AR54.10-P-0003-03SX
Risk of explosion caused No fire, sparks, open AS54.10-Z-0001-01A
by oxyhydrogen gas. Risk flames or smoking. Wear
of poisoning and caustic acid-resistant gloves,
burns caused by clothing and glasses. Only
swallowing battery acid. pour battery acid into
Risk of injury caused by suitable and appropriately
burns to skin and eyes marked containers.
from battery acid or when
handling damaged lead-
acid batteries
Notes on battery AH54.10-P-0001-01A
BATTERY
Number Designation Model 216 Model 221
BA54.10-P-1028- Bolt/nut, ground line of battery M8 Nm 16 16
01C to body
Illustrated on model 221.0
1. Loosen nut on ground line (1) and remove ground line (1) from negative terminal of starter battery
(G1/4).
Installation: Pay attention to tight seating of ground line (1), otherwise damage to the negative
terminal of the starter battery (G1/4) and electrical system can occur.
Fig. 5: Identifying Ground Line And Negative Terminal Of On-Board Electrical System Battery
Courtesy of MERCEDES-BENZ USA
2.1 Lift up trim of cargo area floor, remove bolt of ground line (2) of on-board electrical system battery
(G1) on longitudinal member and set ground line (2) aside.
Not when removing on-board electrical system battery (G1).
Installation: Observe tightening torque.
2.2 Loosen nut on ground line (2) and remove ground line (2) from negative terminal of on-board
electrical system battery (G1).
When removing the on-board electrical system battery (G1).
Installation: Pay attention to tight seating of ground line (2), otherwise damage to the negative
terminal of the on-board electrical system battery (G1) and electrical system can occur.
3 Connect in reverse order.
DISCONNECT/CONNECT GROUND LINE FROM ON-BOARD ELECTRICAL SYSTEM WITH
TWO BATTERIES - AR54.10-P-0003-03SXS
Risk of explosion caused No fire, sparks, open AS54.10-Z-0001-01A
by oxyhydrogen gas. Risk flames or smoking. Wear
of poisoning and caustic acid-resistant gloves,
burns caused by clothing and glasses. Only
swallowing battery acid. pour battery acid into
Risk of injury caused by suitable and appropriately
burns to skin and eyes marked containers.
from battery acid or when
handling damaged lead-
acid batteries
Notes on battery AH54.10-P-0001-01A
BATTERY
Number Designation Model 221
BA54.10-P-1028- Bolt/nut, ground line of battery to body M8 Nm 16
01C
1. Loosen nut on ground line (2) and remove ground line (2) from negative terminal of on-board electrical
system battery (G1).
Installation: Pay attention to tight seating of ground line (2), otherwise damage to the negative
terminal of the on-board electrical system battery (G1) and electrical system can occur.
Fig. 6: Identifying Ground Line And On-Board Electrical System Battery
Courtesy of MERCEDES-BENZ USA
2.1 Lift up trim of cargo area floor, remove bolt (4) of ground line (3) of starter battery (G1/4) on
longitudinal member and set aside ground line (3).
Not when removing the starter battery (G1/4).
Installation: Observe tightening torque.
2.2 Loosen nut on ground line (3) and remove ground line (3) from negative terminal of starter battery
(G1/4).
When removing the starter battery (G1/4).
Installation: Pay attention to tight seating of ground line (3), otherwise damage to the negative
terminal of the starter battery (G1/4) and electrical system can occur.
3 Connect in reverse order.
DISCONNECT/CONNECT BATTERY'S GROUND CABLE - AR54.10-P-0003A
MODEL 163, 168, 170, 202, 208, 210, 129, 414.700
Model 210
Fig. 7: Identifying Battery Ground Cable Components
Courtesy of MERCEDES-BENZ USA
1.1 Open engine hood Model 163
Open battery cover in
1.2 Model 168, 414
passenger side footwell
AR91.12-P-
1.3 Remove rear seat Model 210.0
1700F
Fold rear seat cushion
forwards and remove
1.4 Type 210.2
battery compartment
cover
Flip up trunk luggage
1.5 Model 202.01/02/03/12/13, 208
cover
Remove cargo space
1.6 Model 202.07/08/09/18/19
cover
Remove battery cover in
1.7 Model 129
right-hand side of trunk
Model 163, 210: Insulate terminal of ground cable to
avoid unintentional contact between the ground cable (1) and
Disconnect battery the ground point W10 (model 210) or W16/4 (model 163).
2
ground cable Connect quiescent current retention unit if necessary.
Model 170 ,
Model 210 up to 02/97,
Model 129 :
After opening the vehicle, wait for at least 4 minutes before
disconnecting the battery, otherwise the alarm will be
triggered.
Model 163: Tighten the nut (5) of the ground line (1) to
the specified torque. Perform the following operations only if *BA54.10-P-
3 Connect ground cable
no quiescent current retention unit was connected. 1017-01C
Model 163
AR82.60-P-
4 code radio MB Audio 5 (model 168).
7502-01GC
Sound 10, 20, 30 radio and Audio 10 comfort radio, D2B
AR82.60-P-
networked (model 414.600/700)
7502-01A
Becker 2000 (models 202, 210, 129)
AR82.60-P-
Becker Mexico, Grand Prix, Europa, Avus (model 129)
7502-01C
AR82.60-P-
MB (models 163, 170, 202, 208, 210)
7502-01B
AR82.60-P-
Hi-Line, Premium with Bose (model 163)
7502-01GH
Set time on instrument
5 Set time on stationary heater time if necessary.
cluster
Activating steering AR46.10-P-
6.1 Model 129, 163, 168, 210 with ADS (code 217a)
angle sensor 0300-01A
AR46.10-L-
Model 414.600/700
0300-01VA
Model 163 with code 414.
Synchronize Open tilt/slide sunroof and hold down switch.
7.1
titling/sliding roof Tilting/sliding roof mechanism moves to end position, pulls
back 1/4 turn and stops.
Model 163, 168 with code 417.
Synchronize lamella
8.1 Close the lamella roof and hold down the switch for 5 to
roof
10 seconds.
Model 163 as of VIN A289565, X754620 model 168,
414.600/700.
Synchronize power
9.1 Press the switch for the power windows to the 1st
windows
actuation point, and then hold down for another 5 seconds
after the window has reached its top end position.
BATTERY
Number Designation Model 163
BA54.10-P-1017-01C Nut, ground cable to body Nm 18
DISCONNECT/CONNECT BATTERY GROUND LINE - AR54.10-P-0003SX
MODEL 216.3, 221.0 /1
Disconnect, connect
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant gloves,
caused by swallowing battery acid. Risk of AS54.10-Z-
clothing and glasses. Only pour
injury caused by burns to skin and eyes from 0001-01A
battery acid into suitable and
battery acid or when handling damaged lead-
appropriately marked containers.
acid batteries
AH54.10-P-
Notes on battery
0001-01A
AH54.10-P-
Notes on AGM battery
0002-01A
Model 216.3, 221.0/1 up to 1.6.08
End internal on-board electrical system Model 216.3, 221.0/1 without code AR54.10-P-
1.1
functions (809) 0003-01SX
Model year 2009
Model 216.3, 221.0/1 as of 2.6.08 or
Switch off ignition and withdraw transmitter with code (809) Model year 2009
1.2 key or Keyless Go start/stop button from the Keyless Go start/stop button only
EIS [EZS] control unit for vehicles with code (889) Keyless
Go.
Model 216, 221 up to 1.6.08 except AR54.10-P-
code (809) Model year 2009 0003-03SX
Model 221 as of 2.6.08 with code
(Z07) Top protection
Disconnect ground line from on-board AR54.10-P-
2.1 Model 221 with code (809) Model
electrical system with two batteries 0003-03SXS
year 2009 and with code (Z07) Top
protection
*BA54.10-
P-1028-01C
Model 216, 221 (except
221.095 /195) as of 2.6.08 or with
code (809) Model year 2009, Except AR54.10-P-
code (B03) ECO start-stop function 0003-02SX
except CODE (Z07) Maximum
protection
Disconnect ground line from on-board Model 216.3, 221.0/1 with code AR54.10-P-
2.2
electrical system with one battery (B03) ECO start/stop function 0003-02SXS
AR54.10-P-
Model 221.095/195 0003-
02SXH
*BA54.10-
P-1028-01C
3 Connect in the reverse order.
On vehicles without code (527)
COMAND APS (with navigation),
without code (529) HIGH Class
4 Reset clock
Japan and without code (530)
COMAND APS USA (with
navigation)
5 Read out and erase fault memory Model 221.095/195
BATTERY
Number Designation Model 216 Model 221
BA54.10-P-1028- Bolt/nut, ground line of battery M8 Nm 16 16
01C to body
REMOVE/INSTALL ADDITIONAL BATTERY - AR54.10-P-0007SX
MODEL 216.3 as of 2.6.08
MODEL 216.3 with CODE (809) Model year 2009
MODEL 221.0 /1 as of 2.6.08
MODEL 221.0 /1 with CODE (809) Model year 2009
Shown on model 221
Fig. 8: Identifying Additional Battery Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AH54.10-P-
Notes on battery
0001-01A
AH54.10-P-
Notes on AGM battery
0002-01A
1 Unclip fuse box (1) on instrument panel Fig. 9
2 Take out insulation mat (2)
Only disconnect the
Loosen cover under instrument panel (4) and place to AR68.10-P-
3 electrical connector of the left
one side with electrical lines connected 1500SX
front footwell lamp.
4 Unscrew bolt (3)
Remove bracket (5) with additional battery (G1/7) and
5 central gateway control unit (N93) downwards with
electrical lines connected
Remove additional battery (G1/7) with electrical lines
6
connected from the bracket (5)
Disconnect electrical connectors (6) from additional
7
battery (G1/7)
8 Install in the reverse order
Fig. 9: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ADDITIONAL BATTERY - AR54.10-P-0007SXS
MODEL 216, 221
Shown on model 216
Fig. 10: Identifying Additional Battery Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant gloves,
caused by swallowing battery acid. Risk of AS54.10-Z-
clothing and glasses. Only pour battery
injury caused by burns to skin and eyes 0001-01A
acid into suitable and appropriately
from battery acid or when handling damaged
marked containers.
lead-acid batteries
AH54.10-P-
Notes on battery
0001-01A
AH54.10-P-
Notes on AGM battery
0002-01A
All the electrical consumers must
Switch off all electrical consumers, switch
1 off ignition and remove transmitter key from be switched off, otherwise they may be
damaged when unclipping and
EIS [EZS] control unit
clipping on the ground line (3).
AR68.30-P-
2 Remove center paneling (1) in trunk
4600SX
Remove bolt (2) and detach ground line (3)
*BA54.10-
3 from additional battery for ECO start/stop
P-1029-01C
function (G1/13)
4 Remove cover (4) of positive line (5)
If the diode test lamp lights up, the
on-board electrical system is still
active because of a defect in the
electrical system.
In this case the ground line of the
Using diode test lamp, check on-board battery (on-board electrical system
electrical system for voltage between battery) should be disconnected.
5 positive line (5) of ECO start/stop function See: ?
additional battery (G1/13) and a suitable Disconnect/connect battery ground
ground point line
Cover positive line (5), there is a
AR54.10-P-
risk of short circuit!
0003SX
After this the electrical system is to
be repaired upon completion of the
work carried out.
Unscrew bolt (6) and remove positive line *BA54.10-
6
(5) P-1029-01C
7 Unscrew nut (8) of bracket (9)
8 Swivel bracket (9) upwards
Remove additional battery for ECO start/stop
9
function (G1/13) from battery holder
10 Install in the reverse order
BATTERY
Number Designation Model 216 Model 221
BA54.10-P-1029- Bolt, battery cable to battery M6 Nm 5 5
01C terminal on additional battery
REMOVE/INSTALL STARTER BATTERY - AR54.10-P-0008SX
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Shown on model 221
Fig. 11: Identifying Starter Battery Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of explosion caused by oxyhydrogen gas.
No fire, sparks, open flames or
Risk of poisoning and caustic burns caused
smoking. Wear acid-resistant AS54.10-
by swallowing battery acid. Risk of injury
gloves, clothing and glasses. Only Z-0001-
caused by burns to skin and eyes from battery
pour battery acid into suitable and 01A
acid or when handling damaged lead-acid
appropriately marked containers.
batteries
AH54.10-
Notes on battery P-0001-
01A
Do not disconnect ground line AR54.10-
Disconnect ground line (4) from starter battery
1 from on-board electrical system
(G1/4) P-0003SX
battery.
2 Remove retaining bracket (1)
Installation: Pay attention to
Disconnect positive lead (3) on starter battery tight seating of the positive line (3)
3 otherwise damage to the positive
(G1/4)
terminal and electrical system can
occur.
If the starter battery (G1/4) is
replaced the defective starter
4
battery (G1/4) must be properly
Detach bleed hose (2) and remove starter
disposed of. Refer to: ?
battery (G1/4)
OS54.10-
Dispose of battery P-0001-
01Z
5 Install in the reverse order
REMOVE/INSTALL STARTER BATTERY - AR54.10-P-0008SXS
MODEL 221.1 as of 2.6.08 with CODE (Z07) Top protection
MODEL 221.1 with CODE (809) Model year 2009 with CODE (Z07) Top protection
Fig. 12: Identifying Starter Battery Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
19.3.09 Value modified: Bolt, battery bracket to body, Nm *BA54.10-P-1027-01C
Remove/install
Risk of explosion caused by oxyhydrogen gas.
No fire, sparks, open flames or
Risk of poisoning and caustic burns caused
smoking. Wear acid-resistant
by swallowing battery acid. Risk of injury AS54.10-Z-
gloves, clothing and glasses. Only
caused by burns to skin and eyes from battery 0001-01A
pour battery acid into suitable and
acid or when handling damaged lead-acid
appropriately marked containers.
batteries
AH54.10-P-
Notes on battery
0001-01A
AH54.10-P-
Notes on AGM battery
0002-01A
Disconnect ground line (1) on starter battery Disconnect ground line (1) on AR54.10-P-
1 on-board electrical system with
(G1/4) and on-board electrical system battery 0003SX
two batteries.
Remove bolt (4), place bracket (5) to one side *BA54.10-
2
and pull starter battery (G1/4) forwards slightly P-1027-01C
Installation: Pay attention to
Remove cover (2) and disconnect positive line tight seating of the positive line (3)
3 (3) on the positive terminal of the starter otherwise damage to the positive
battery (G1/4) terminal and electrical system can
occur.
Installation: Observe routing
without kinks of the vent hose
4 Detach vent hose from starter battery (G1/4) otherwise the ventilation of the
starter battery (G1/4) is not
guaranteed.
If the starter battery (G1/4) is
replaced the defective starter
5
battery (G1/4) must be properly
Remove starter battery (G1/4)
disposed of. Refer to: ?
OS54.10-P-
Dispose of battery
0001-01Z
6 Install in the reverse order
BATTERY
Number Designation Model 221
BA54.10-P-1027- Bolt, battery bracket to body M6 Nm 8
01C M8 Nm 23
REMOVE/INSTALL ON-BOARD ELECTRICAL SYSTEM BATTERY - AR54.10-P-0009SX
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Shown on model 221
Fig. 13: Identifying On-Board Electrical System Battery Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
19.3.09 Value modified: Bolt, battery bracket to body, Nm Model 221 *BA54.10-P-1027-01C
Remove/install
Risk of explosion caused by oxyhydrogen gas.
No fire, sparks, open flames or
Risk of poisoning and caustic burns caused
smoking. Wear acid-resistant
by swallowing battery acid. Risk of injury AS54.10-Z-
gloves, clothing and glasses. Only
caused by burns to skin and eyes from battery 0001-01A
pour battery acid into suitable and
acid or when handling damaged lead-acid
appropriately marked containers.
batteries
AH54.10-P-
Notes on battery
0001-01A
AH54.10-P-
Notes on AGM battery
0002-01A
AR54.10-P-
1 Disconnect ground line on the starter battery
0003SX
Model 216.3, 221.0, 221.1 without AR68.30-P-
2.1 Remove center paneling in trunk
code (Z07) Maximum protection 4600SX
Model 221.1 with code (Z07) Top
Remove trim in center of trunk or implement protection AR68.30-P-
2.2
carrier plate Removal of trim parts 4600SXS
depending on vehicle equipment.
AR64.10-P-
3 Remove reinforcement at rear of rear shelf (3)
1200SX
4
electrical system battery (G1) slightly P-1027-01C
Installation: Pay attention to
Disconnect ground line (1) at negative terminal tight seating of the ground line (1)
5 otherwise damage to the negative
of on-board electrical system battery (G1)
terminal and electrical system can
occur.
Installation: Pay attention to
Disconnect positive line (2) from positive tight seating of the positive line (2)
6 terminal of the on-board electrical system otherwise damage to the positive
battery (G1) terminal and electrical system can
occur.
Installation: Observe kink-free
routing of the bleed hose otherwise
Detach vent hose from on-board electrical
7 the venting of the on-board
system battery (G1)
electrical system battery (G1) is
not guaranteed.
If the on-board electrical
system battery (G1) is replaced,
8 the defect on-board electrical
Remove on-board electrical system battery
system battery (G1) must be
(G1)
disposed of properly. Refer to: ?
OS54.10-P-
Dispose of battery
0001-01Z
9 Install in the reverse order
BATTERY
Number Designation Model 216 Model 221
M6 Nm 8 8
BA54.10-P-1027-01C Bolt, battery bracket to body
M8 Nm 23 23
REMOVE/INSTALL ON-BOARD ELECTRICAL SYSTEM BATTERY - AR54.10-P-0009SY
MODEL 216.3 as of 2.6.08
MODEL 216.3 with CODE (809) Model year 2009
MODEL 221.0 /1 as of 2.6.08
MODEL 221.0 /1 (except 221.095 /195) with CODE (809) Model year 2009
Shown on model 221.0
Fig. 14: Identifying On-Board Electrical System Battery Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of explosion caused by oxyhydrogen gas.
No fire, sparks, open flames or
Risk of poisoning and caustic burns caused
smoking. Wear acid-resistant AS54.10-
by swallowing battery acid. Risk of injury
gloves, clothing and glasses. Only Z-0001-
caused by burns to skin and eyes from battery
pour battery acid into suitable and 01A
acid or when handling damaged lead-acid
appropriately marked containers.
batteries
AH54.10-
Notes on battery P-0001-
01A
AH54.10-
Notes on AGM battery P-0002-
01A
Do not disconnect the ground
line from the starter battery.
Model 221.1 as of 2.6.08 with code AR54.10-
Disconnect ground line (1) from the on-board
1 (Z07) Top protection
electrical system battery (G1) P-0003SX
Model 221.1 with code (809)
Model year 2009 with code (Z07)
Top protection
2 Unscrew bolt (5) and remove bracket (4)
Unscrew nut (8) and remove retaining bracket
3
(9)
4 Remove battery terminal cover (6)
positive line (7) is fitted securely to
Disconnect positive line (7) from on-board the positive terminal, otherwise the
5
electrical system battery (G1) positive terminal and electrical
system could be damaged.
If the on-board electrical system
battery (G1) is replaced, the defect
6 on-board electrical system battery
Detach vent hose (3) and remove on-board (G1) must be disposed of properly.
electrical system battery (G1) Refer to: ?
OS54.10-
Dispose of battery P-0001-
01Z
7 Install in the reverse order
REMOVE/INSTALL CIGARETTE LIGHTER - AR54.10-P-0030TX
MODEL 168, 170, 171, 197, 203, 204, 207, 208, 209, 210, 211, 216, 219, 221, 230
MODEL 212 except CODE (279) Electronic gear selector
Shown on model 219
Fig. 15: Removing/Installing Cigarette Lighter
Courtesy of MERCEDES-BENZ USA
Remove/install
On vehicles with code (889) Keyless Go, keep pressing
Switch off the ignition and remove the KEYLESS-GO start/stop button until the ignition is
1 the transmitter key from the EIS switched off. Remove the Keyless Go chipcard or
control unit transmitter key from vehicle and store beyond reach of the
transmitter (at least 2 m).
2.1 Open ashtray Except model 204, 207, 212
2.2 Remove ashtray housing (5) Model 204, 207, 212
Pull insert (1) out of the housing
3 (3) of the cigarette lighter with
front ashtray illumination (R3)
The spigots of the pliers (2) must engage in the cutouts
Insert pliers (2) into the housing
of the housing (3) (arrows A).
4 (3) and pull the housing (3) out of
the clamping sleeve (4) Fig.
16
Disconnect electrical connector of
5 cigarette lighter with front ashtray Except model 204, 207, 212
illumination (R3x1)
Unclip clamping sleeve (4) from
the ashtray housing by pressing Installation: Pay attention to the correct installation
6
back the catch hooks (arrows B) position of the clamping sleeve (4).
(5) and remove
7 Install in the reverse order
Fig. 16: Identifying Pliers (169 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL 12 VOLT SOCKET - AR54.10-P-1000TX
MODEL 168, 169, 170, 171, 197, 203, 204, 208, 209, 210, 211, 216, 219, 221, 245
MODEL 230 except CODE (P99) Special model "AMG Black Series"
Illustrated on model 219
Fig. 17: Removing/Installing 12 Volt Socket
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Switch off ignition
Open flap (1) of vehicle interior socket
2
(X58/1)
The trunnion of the pliers (2) must engage in
Unlock vehicle interior socket (X58/1) using the cutouts of the housing of the vehicle interior
3 pliers (2) and pull out until the electrical socket (X58/1) (arrows).
connector (3) is accessible Fig.
16
Disconnect electrical connector (3) and remove Installation: Pay attention to correct
4 installation position of vehicle interior socket
vehicle interior socket (X58/1)
(X58/1).
5 Install in the reverse order
Fig. 18: Identifying Pliers (169 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
MAINTAINING VEHICLE VOLTAGE SUPPLY WHEN PERFORMING TEST AND DIAGNOSIS
WORK ON VEHICLE - AR54.10-P-1127SX
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Shown on model 221
Fig. 19: Maintaining Vehicle Voltage Supply When Performing Work
Courtesy of MERCEDES-BENZ USA
Risk of explosion caused by oxyhydrogen gas. No fire, sparks, open flames or
Risk of poisoning and caustic burns caused by smoking. Wear acid-resistant AS54.10-
swallowing battery acid. Risk of injury caused gloves, clothing and glasses. Only Z-0001-
by burns to skin and eyes from battery acid or pour battery acid into suitable and 01A
when handling damaged lead-acid batteries appropriately marked containers.
AH54.10-
Notes on battery P-0001-
01A
The steps required to maintain the vehicle
voltage supply should not be performed:
When working on restraint systems
When working on lines without contact
protection
With welding work
Otherwise the electrical system or electronic
components will be damaged
AH54.10-
Notes on AGM battery P-0002-
01A
battery charger must be connected to maintain
the on-board power supply voltage due to the
high current requirement
1 Remove cover of charging terminal point (5)
Only use charger with fully
Clip on positive terminal of charger (2) at the insulated positive terminal of
2
load support point (5) charger (2), otherwise there is a risk
of short circuit.
Use a charger with at least 30 A
Clip ground terminal of charger (1) onto the charging current and 13.5 V
3 negative terminal of the starter battery (G1/4) charging voltage, otherwise the on-
and switch on charger board electrical system battery
could be partially discharged.
On completion of test diagnosis
4 Switch off and disconnect charger
work on the vehicle.
5 Fit cover on charging terminal point (5)
MAINTAINING VEHICLE VOLTAGE SUPPLY WHEN PERFORMING TEST AND DIAGNOSIS
WORK ON VEHICLE - AR54.10-P-1127SY
MODEL 216.3 as of 2.6.08
MODEL 216.3 with CODE (809) Model year 2009
MODEL 221.0 /1 as of 2.6.08
MODEL 221.0 /1 with CODE (809) Model year 2009
Shown on model 221
Fig. 20: Maintaining Vehicle Voltage Supply When Performing Work
Courtesy of MERCEDES-BENZ USA
Risk of explosion caused by oxyhydrogen gas. No fire, sparks, open flames or
Risk of poisoning and caustic burns caused by smoking. Wear acid-resistant AS54.10-
swallowing battery acid. Risk of injury caused gloves, clothing and glasses. Only Z-0001-
by burns to skin and eyes from battery acid or pour battery acid into suitable and 01A
when handling damaged lead-acid batteries appropriately marked containers.
AH54.10-
Notes on battery P-0001-
01A
The steps required to maintain the vehicle
voltage supply should not be performed:
When working on restraint systems
When working on lines without contact
protection
With welding work
Otherwise the electrical system or electronic
components will be damaged
AH54.10-
Notes on AGM battery P-0002-
01A
For longer test and diagnostic operations, a
battery charger must be connected to maintain
the on-board power supply voltage due to the
Remove cover of engine compartment prefuse
1
box (F32/3)
Connect charger positive terminal (1) to charging
2 terminal point (4) of engine compartment prefuse
box (F32/3)
Use a charger with at least 30 A
Connect charger ground terminal (2) to ground charging current and 13.5 V
3 terminal point (3) on wheel well and switch on charging voltage, otherwise the on-
charger board electrical system battery
could be partially discharged.
On completion of test diagnosis
4 Switch off and disconnect charger
work on the vehicle.
Install cover of engine compartment prefuse box
5
(F32/3)
CHECK CONDITION OF ADDITIONAL BATTERY - AR54.10-P-1128SX
MODEL 216, 221 with CODE (B03) ECO start/stop function
Shown on model 216
Fig. 21: Checking Condition Of Additional Battery
Courtesy of MERCEDES-BENZ USA
Removing
Risk of explosion caused by
oxyhydrogen gas. Risk of poisoning
No fire, sparks, open flames or smoking.
and caustic burns caused by
Wear acid-resistant gloves, clothing and AS54.10-Z-
swallowing battery acid. Risk of
glasses. Only pour battery acid into suitable 0001-01A
injury caused by burns to skin and
and appropriately marked containers.
eyes from battery acid or when
handling damaged lead-acid batteries
AH54.10-
Notes on battery P-0001-
01A
AH54.10-
Notes on AGM battery P-0002-
01A
AR68.30-P-
1 Remove center paneling (1) in trunk
4600SX
Checking
If leaks found, replace additional battery
for ECO start/stop function (G1/13).
2 Visually inspect additional battery for See: ?
ECO start/stop function (G1/13) for Remove/install additional battery for ECO AR54.10-P-
signs of external leaks start/stop function (G1/13) 0007SXS
Dispose of on-board electrical system OS54.10-P-
battery 0001-01Z
AR54.10-P-
1129-01A
Charge additional battery for ECO
3 *BE54.10-
start/stop function (G1/13) Cold test current
P-1002-
Battery tester gotis://E_15/54_02.0
01A
For an additional battery for ECO start/stop
function (G1/13), that has been detached
from the on-board electrical system, and if
the "Surface voltage" message is shown on
Reduce increased voltage after the Midtronics battery test / test equipment AR54.10-P-
4
charging process display. 1129-03A
Battery tester gotis://E_15/54_02.0
If the voltage increases after removal,
check the additional battery for the ECO
start/stop function (G1/13) again.
With the test code "Charge and check" on
the Midtronics battery tester.
Charge additional battery for ECO AR54.10-P-
5 After charging, check additional battery
start/stop function (G1/13) 1130SY
for the ECO start/stop function (G1/13)
again.
Install
AR68.30-P-
6 Install center paneling (1) into trunk
4600SX
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 12 AH
BE54.10-P-1002-01A Cold test current as per EN A 170
CHECK BATTERY - AR54.10-P-1129-01A
P-1129-
Check battery
01A
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant AS54.10-
caused by swallowing battery acid. Risk of
gloves, clothing and glasses. Only Z-0001-
injury caused by burns to skin and eyes from
pour battery acid into suitable and 01A
battery acid or when handling damaged lead-
appropriately marked containers.
acid batteries
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 12 AH 30 AH 35 Ah 42 AH
BE54.10-P-1002-01A Cold test current as per EN A 170 540 520 340
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 46 AH 60 Ah VRLA 60 AH 61 AH
BE54.10-P-1002-01A Cold test current as per EN A 420 680 510 540
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 62 AH 70 Ah VRLA 74 AH 80 Ah VRLA
BE54.10-P-1002-01A Cold test current as per EN A 480 760 680 800
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 84 AH 90 Ah VRLA 95 Ah VRLA 100 Ah
BE54.10-P-1002-01A Cold test current as per EN A 700 950 850 760
In model 414 the battery must be disconnected for the tests. Otherwise the electrical system may be
damaged.
If possibly, perform test on remaining vehicles with battery installed and connected. Do not connect tester to
jump start or charging terminal point, always connect it directly with the battery.
Battery tester gotis://E_15/54_02.0
All test steps and entries must be performed thoroughly, otherwise the test result will be distorted.
Test prerequisites:
Tester with software release 2.0
Ignition off
Rotary light switch in position "0"
Audio component (e.g. radio) switched off
Battery voltage higher than 12.4 V
Good contact of the tester on the battery
If the message "Surface voltage" is displayed during the test, the tester has detected that the battery voltage is
apparently too high. This increased voltage can be reduced as follows:
Battery installed: Decrease increased voltage as per the specifications of the tester (e.g. switch on driving
lights).
Battery removed: reduce increased voltage using a suitable volt/amp(s) tester (load battery for approx. 60
s with 20 A to 30 A amps).
As an example, the test procedure for passenger cars is described below.
1. Clip tester (1) on to battery.
Once the tester is connected the current measured battery voltage is displayed for approx. 2 s. If a so-
called "System noise" is detected by the tester, check whether all consumers are switched off and wait
(for approx. 2 min), until the quiescent current is minimized and the bus systems are switched off.
Fig. 22: Identifying Battery Tester
Courtesy of MERCEDES-BENZ USA
2. Follow the menu and select according to the situation:
In vehicle (battery connected to on-board electrical system)
Not in vehicle (battery disconnected from on-board electrical system)
Confirm selection with "Enter".
Fig. 23: Display Battery Selection - According To Situation
Courtesy of MERCEDES-BENZ USA
3. Follow the menu and select according to the situation:
12 - 114 AH (battery capacity 12 - 114 Ah)
115 AH > (battery capacity > or =115 Ah)
Confirm selection with "Enter".
Fig. 24: Display Battery Selection - Battery Capacity
Courtesy of MERCEDES-BENZ USA
4. Follow menu and select battery type:
Normal
VRLA
Confirm selection with "Enter".
Fig. 25: Display Battery Selection - Battery Type
Courtesy of MERCEDES-BENZ USA
5. Follow the menu selection and select the test standard for the cold cranking amps.
The test standard is printed on behind the specification of the cold cranking amps.
If the imprint of the test standard is not available, select the cold cranking amps "EN".
Example: 12 V 46 Ah 420 A --> Select EN.
Confirm selection with "Enter".
Fig. 26: Display Selection Of Battery Testing For Cold Cranking Amps
Courtesy of MERCEDES-BENZ USA
6. Read off cold cranking amps and enter in tester.
Example: 12 V 46 Ah 420 cold cranking amps --> 420 A.
Confirm input with "Enter".
The battery test starts after confirmation of the cold cranking amps entry.
The test result or one of the following messages appears after approx. 15 s:
Test code --> Step 7
Vehicle model --> Step 9
Temperature < 0 °C /< 0 °C --> Step 10
Before charging / After charging --> Step 10 Step 11
Surface voltage DETECTED (see above)
Fig. 27: Display Test Result Of Cold Cranking Amps
Courtesy of MERCEDES-BENZ USA
7. Read off test code with "Enter" and continue accordingly:
"Battery in good condition":
No further measures required.
"Charge and test":
Fully charge battery and retest (battery voltage < 12.4 V).
"Replace battery":
Replace battery if this message appears.
8. Print out test code and file in a tamperproof manner.
9. Follow the menu and select test mode:
Cars
Taxi
Confirm selection with "Enter".
Fig. 28: Display Selection Of Test Mode
Courtesy of MERCEDES-BENZ USA
10. Follow the menu and select test mode:
> 0 °C
< 0 °C
Confirm selection with "Enter"
Fig. 29: Display Selection Of Test Mode - Above 0°C And Below 0°C
Courtesy of MERCEDES-BENZ USA
11. Follow the menu and select test mode:
BEFORE CHARGE
AFTER CHARGE
Confirm selection with "Enter".
Fig. 30: Display Selection Of Test Mode - Before Charge And After Charge
Courtesy of MERCEDES-BENZ USA
12. Perform additional menu-assisted function (e.g. starting several times and switching on consumers).
Only in taxi test mode if displayed in menu.
CHECK BATTERY VOLTAGE BY MEANS OF THE INSTRUMENT CLUSTER (IC) - AR54.10-P-
1129-02SX
The voltage display can be called up in the instrument cluster via the basic menu.
1. Turn transmitter key into position "Circuit 15R On".
2. Set display in instrument cluster to "Trip" and switch to "Trip counter" display.
3. Press and hold "Accept call" button in the right multifunction steering wheel button group. Also press the
"OK" button in the left multifunction steering wheel button group and hold both buttons for approx. 3 s.
Display changes to "Vehicle data".
4. Press "OK" button in the left multifunction steering wheel button group.
Display changes to values for the 12V on-board electrical system.
Using the "Up" or "Down" button in the left multifunction steering wheel button group enables the values
for the high-voltage on-board electrical system for hybrid cars to also be displayed.
REDUCE INCREASED VOLTAGE AFTER CHARGING PROCESS - AR54.10-P-1129-03A
AR54.10-
Reduce increased voltage after charging
P-1129-
process
03A
Risk of explosion caused by oxyhydrogen
gas. Risk of poisoning and caustic burns No fire, sparks, open flames or
injury caused by burns to skin and eyes from gloves, clothing and glasses. Only Z-0001-
battery acid or when handling damaged lead- pour battery acid into suitable and 01A
acid batteries appropriately marked containers.
Test prerequisites:
Battery removed or disconnected
On the battery test "Surface voltage" appears in the display of the battery tester/test equipment
1. Disconnect battery tester/test equipment.
2. Observe basic setting of the volt-amp(s) tester (1), if necessary adjust the knob (3) to 16 V and knob (4)
to 50 A.
3. Clip load pliers (5) onto the battery.
4. Connect terminals (7) to corresponding load clamps (5).
5. Place current clamp (6) around positive line of battery.
Pay attention to current direction. The measurement takes place via an inductive coil in the current
clamp (6).
6. Switch on Volt/Amp(s) tester (1) via operating lever (2) and load battery with 20 A to 30 A for approx.
60 s.
The increased voltage is now reduced.
Fig. 31: Identifying Battery Tester/Test Equipment Components
CHECK CONDITION OF BATTERY - AR54.10-P-1129SX
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Starter battery (G1/4), shown on model 221
Fig. 32: Checking Condition Of Starter Battery
Courtesy of MERCEDES-BENZ USA
On-board electrical system battery (G1), shown on model 221
Fig. 33: Checking Condition Of On-Board Electrical System Battery
Courtesy of MERCEDES-BENZ USA
Removing
Risk of explosion caused by
oxyhydrogen gas. Risk of
caused by swallowing battery acid-resistant gloves, clothing and glasses. Only
acid. Risk of injury caused by pour battery acid into suitable and appropriately
AS54.10-Z-
burns to skin and eyes from marked containers.
0001-01A
battery acid or when handling
damaged lead-acid batteries
AH54.10-
Notes on battery P-0001-
01A
AH54.10-
Notes on AGM battery P-0002-
01A
Model 216.3, 221.0, 221.1 without code (Z07)
AR68.30-
1.1 Remove center paneling in trunk Maximum protection for checking the on-board
P-4600SX
electrical system battery (G1).
Model 221.1 with code (Z07) Maximum protection
for checking the on-board electrical system battery
Remove paneling in center of
(G1). AR68.30-
1.2 luggage compartment or
Remove trim parts depending on the vehicle P-4600SXS
equipment carrier plate
equipment until the on-board electrical system
battery (G1) can be checked.
Checking
If leaks are found: Replace starter battery
(G1/4) and/or on-board electrical system battery
(G1).
Visual inspection for external Refer to: ?
2
leaks AR54.10-
Remove/install starter battery (G1/4)
P-0008SX
Remove/install on-board electrical system battery AR54.10-
(G1) P-0009SX
Check fluid level in starter
3 battery (G1/4), add distilled water not with AGM battery
if necessary
AR54.10-
P-1129-
Test starter battery (G1/4) and/or 01A
4 on-board electrical system battery
(G1) Cold test current *BE54.10-
Midtronics battery tester with test clamps P-1002-
http://gotis.aftersales.mercedes-benz.com 01A
On starter battery (G1/4) or on-board electrical
system battery (G1) that is disconnected from the
Reduce increased voltage after on-board electrical system and where the message AR54.10-
5 charging process using volt-amp "Surface voltage" appears in the display of the P-1129-
(s) tester Midtronics battery tester. 03A
Midtronics battery tester
benz.com
After reducing increased voltage, retest starter
battery (G1/4) and/or on-board electrical system
battery (G1).
With the test code "Charge and check" on the
Charge starter battery (G1/4) Midtronics battery tester. AR54.10-
6 and/or on-board electrical system
After charging, retest starter battery (G1/4) P-1130SX
battery (G1)
and/or on-board electrical system battery (G1).
Install
Model 216.3, 221.0, 221.1 without code (Z07)
AR68.30-
7.1 Install center paneling in trunk Maximum protection after checking the on-board
P-4600SX
electrical system battery (G1).
Install paneling in center of Model 221.1 with code (Z07) Maximum protection
AR68.30-
7.2 luggage compartment or after checking the on-board electrical system
P-4600SXS
equipment carrier plate battery (G1).
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 35 Ah 60 Ah VRLA 60 AH
BE54.10-P-1002-01A Cold test current as per EN A 520 680 510
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 70 Ah VRLA 90 Ah VRLA 95 Ah VRLA
BE54.10-P-1002-01A Cold test current as per EN A 760 950 850
CHECK CONDITION OF BATTERY - AR54.10-P-1129SY
MODEL 216.3 as of 2.6.08
MODEL 216.3 with CODE (809) Model year 2009
MODEL 221.0 /1 as of 2.6.08
MODEL 221.0 /1 with CODE (809) Model year 2009
Shown on model 221
Fig. 34: Identifying On-Board Electrical System Battery & Terminal Clamps
Courtesy of MERCEDES-BENZ USA
Model 221.1 as of 2.6.08 with code (Z07) Top protection
Fig. 35: Locating Starter Battery
Courtesy of MERCEDES-BENZ USA
Removing
Risk of explosion caused by
oxyhydrogen gas. Risk of poisoning
No fire, sparks, open flames or smoking.
and caustic burns caused by
Wear acid-resistant gloves, clothing and AS54.10-Z-
swallowing battery acid. Risk of
glasses. Only pour battery acid into suitable 0001-01A
injury caused by burns to skin and
and appropriately marked containers.
eyes from battery acid or when
handling damaged lead-acid batteries
AH54.10-
Notes on battery P-0001-
01A
AH54.10-
Notes on AGM battery P-0002-
01A
Model 221.1 with code (Z07) Top protection
and model 221.095/ 195
Model 221.1 with code (Z07) Top protection AR68.30-
Used to test starter battery (G1/4) P-4600SXS
Remove center paneling in trunk or Model 221.095/ 195 for checking the on-
1
implement carrier plate board electrical system battery (G1)
Remove trim parts depending on the AR68.30-
vehicle equipment until the starter battery P-4600SX
(G1/4) or on-board electrical system battery
(G1) can be checked.
Checking
In the event of leakage, replace on-board
2 electrical system battery (G1): ?
Except model 221.095 /195
battery (G1) for external leakage P-0009SY
AR54.10-P-
Model 221.095 / 195
0009SXH
Model 221.1 with code (Z07) Top protection
In the event of leaks, replace starter
Inspect starter battery (G1/4) for
3 battery (G1/4): ?
external leakage
AR54.10-
Remove/install starter battery (G1/4).
P-0008SXS
AR54.10-
P-1129-
Test on-board electrical system battery 01A
4
(G1) and/or starter battery (G1/4) Cold test current
*BE54.10-
Battery test/test equipment
P-1002-01A
gotis://E_15/54_02.0
On starter battery (G1/4) or on-board
electrical system battery (G1) that is
disconnected from the on-board electrical
system and where the message "Surface
Reduce increased voltage after AR54.10-
voltage" appears in the display of the
5 charging process using volt-amp(s) P-1129-
Midtronics battery tester.
tester 03A
Battery tester gotis://E_15/54_02.0
After reducing increased voltage, retest
starter battery (G1/4) and/or on-board
electrical system battery (G1).
With the test code "Charge and check" on
the Midtronics battery tester.
Charge starter battery (G1/4) and/or AR54.10-
6 Check starter battery (G1/4) or on-board
on-board electrical system battery (G1) P-1130SY
electrical system battery (G1) again after
charging.
Install
Model 221.1 with code (Z07) Top protection
and model 221.095/ 195
Model 221.1 with code (Z07) Top protection AR68.30-
Used to test starter battery (G1/4) P-4600SXS
Remove center paneling in trunk or Model 221.095/ 195 for checking the on-
7
implement carrier plate board electrical system battery (G1)
Remove trim parts depending on the AR68.30-
vehicle equipment until the starter battery P-4600SX
(G1/4) or on-board electrical system battery
(G1) can be checked.
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 35 Ah 60 Ah VRLA
BE54.10-P-1002-01A Cold test current as per EN A 520 680
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 70 Ah VRLA 80 Ah VRLA
BE54.10-P-1002-01A Cold test current as per EN A 760 800
TEST AND ADJUSTMENT VALUES FOR THE BATTERY
Number Designation 90 Ah VRLA 95 Ah VRLA 100 Ah
BE54.10-P-1002-01A Cold test current as per EN A 950 850 760
CHARGE BATTERY - AR54.10-P-1130SX
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Charge starter battery (G1/4), Shown on model 221
Fig. 36: Checking Starter Battery
Courtesy of MERCEDES-BENZ USA
Charge on-board electrical system battery, Shown on model 221
Fig. 37: Charging On-Board Electrical System Battery
Courtesy of MERCEDES-BENZ USA
Checking
Check condition of AR54.10-
1
battery P-1129SX
Removing
Detach charging point For charging the on-board electrical system battery installed in the
2
cover (3) trunk.
Charging
Do not reverse polarity and only use fully-insulated terminal
clamps, risk of short circuit!
Pay attention to the correct installation position of the vent hose
and stop plugs otherwise battery acid which runs out will damage
the vehicle.
Connect battery
3 Use charger with at least 30 A charging current due to the high
charger
current requirement. Always clip the ground terminal (1) of the
charger onto the negative terminal of the starter battery (G1/4).
When charging the on-board electrical system battery always clip
the positive terminal (2) of the charger onto the charge support
point (5).
Discharged absorbent glass mat batteries which have a voltage
below 7 V are not "detected" according to charger model,
Charge starter battery therefore here, before charging, a second charged battery (with 12
V rated voltage) must be clipped on in parallel to the absorbent
(G1/4) or on-board
4 glass mat battery.
electrical system
battery Normal charging: Charging current max. 10 % of battery capacity:
e.g. max. 10 A charging current for a 100 Ah battery.
Rapid charging: charging current max. 50 % of battery capacity
for 30 min: e.g. max. 50 A charging current for a 100 Ah battery.
Disconnect battery Always switch off charger beforehand in order to prevent
5
charger arcing.
Checking
Check battery after AR54.10-
6
charging P-1129SX
Install
Install charging point
7 After charging the on-board electrical system battery.
cover (3)
CHARGE BATTERY - AR54.10-P-1130SY
MODEL 216.3 as of 2.6.08
MODEL 216.3 with CODE (809) Model year 2009
MODEL 221.0 /1 as of 2.6.08
MODEL 221.0 /1 with CODE (809) Model year 2009
Shown on model 221
Fig. 38: Charging Battery
Courtesy of MERCEDES-BENZ USA
Checking
AR54.10-
1 Check condition of battery
P-1129SY
Removing
Remove cover of engine
2 compartment prefuse box
(F32/3)
Charging
Connect charger positive
terminal (1) to charging
3 terminal point (4) of engine
compartment prefuse box
(F32/3)
Do not connect with incorrect polarity, risk of short-
Connect charger ground
circuit.
terminal (2) to ground terminal
4 Use a charger with at least 30 A charging current and
point (3) on wheel well and
switch on charger 13.5 V charging voltage, otherwise the on-board electrical
system battery could be partially discharged.
Discharged AGM batteries which have a voltage
below 7 V may not be "recognized" depending on the
voltage of 12 V) must therefore be connected in parallel
to the AGM battery before charging.
Normal charging: Charging current max. 10 % of battery
Charge on-board electrical capacity: e.g. max. 10 A charging current for a 100 Ah
5
system battery (G1) battery.
Rapid charging: charging current max. 50 % of battery
capacity for 30 min: e.g. max. 50 A charging current for a
100 Ah battery.
Always switch off charger beforehand in order to
6 Disconnect battery charger
prevent arcing.
Checking
AR54.10-
7 Check battery after charging
P-1129SY
Install
Install cover of engine
8 compartment prefuse box
(F32/3)
CHECK BATTERY CONDITION BEFORE VEHICLE DELIVERY - AR54.10-P-1132A
MODEL 164, 169, 171, 203, 204, 207, 209, 211, 216, 219, 221, 230, 240, 245, 251 (except, 245.286)
Checking
Switch on driving lamps for 60 This reduces the surface voltage of the
1
seconds battery.
Model 164, 169, 171, 211.2, 211.6, 219, 240,
245, 251
AR54.10-P-1129-
Model 203 as of 1.6.02
02A
Model 209, 230 as of 1.6.03
Model 211.0 as of 1.3.03
Check battery voltage by means of Model 204 without code (442) Comfort AR54.10-P-1129-
2 multifunction steering wheel 02CWA
instrument cluster
Model 204 with code (442) Comfort
AR54.10-P-1129-
multifunction steering wheel,
02CWB
Model 207
AR54.10-P-1129-
Model 216, 221
02SX
With battery voltage less than 12.4 V
AR54.10-P-
Models 169, 245
1129AK
AR54.10-P-
Model 204, 207
1129CW
AR54.10-P-
Model 164
1129GZ
Model 240 AR54.10-P-1129H
Model 230 without code (P99) Special model
AR54.10-P-1129I
"AMG Black Series"
Model 230 with code (P99) Special model AR54.10-P-
"AMG Black Series" 1129RBS
Model 203, 209 AR54.10-P-1129P
AR54.10-P-
Model 251
1129RT
3 Check battery
Model 216, 221 up to 1.6.08 without code AR54.10-P-
(809) Model year 2009 1129SX
Model 216, 221 as of 2.6.08
AR54.10-P-
Model 216, 221 with code (809) Model year
1129SY
2009
AR54.10-P-
Model 211, 219
1129TX
Model 171 AR54.10-P-1129V
Document measured battery voltage
4
in handover report
CHANGE FUSE ASSIGNMENT FOR TLC [HDS] CONTROL UNIT ON REAR SAM CONTROL
UNIT WITH FUSE AND RELAY MODULE - AR54.15-P-1255-08SX
Fig. 39: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Courtesy of MERCEDES-BENZ USA
Fig. 40: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Courtesy of MERCEDES-BENZ USA
Fig. 41: Identifying Fuse And Relay Module Components
Courtesy of MERCEDES-BENZ USA
1. Unclip fuse holder (1) at slot 147 of rear SAM control unit with fuse and relay module (N10/2).
2. Remove fuse 30A (2) from fuse holder (1).
3. Remove electrical line (3) from fuse holder (1) and insert into new fuse holder (4).
The color of the new fuse holder (4) must match the color coding (arrow) of slot 151.
4. Insert fuse 30A (2) into new fuse holder (4).
5. Insert new fuse holder (4) in slot 151 of the rear SAM control unit with fuse and relay module (N10/2).
6. Update the fuse assignment sheet by hand.
The fuse assignment sheet is located next to the left instrument panel fuse box.
REMOVE/INSTALL ON-BOARD ELECTRICAL NETWORK LINE PYROFUSE IN VEHICLE
POWER SUPPLY CONTROL UNIT - AR54.15-P-1262SX
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Shown on model 221
Fig. 42: Identifying Vehicle Power Supply Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Detach vehicle power supply control unit Disconnect ground line from AR54.21-P-
1 (N82/1) and swivel to one side with electrical starter battery and on-board 0100SX
lines connected (arrow) electrical system battery.
Open housing (1) of vehicle power supply
2
control unit (N82/1)
3 Disconnect electrical connector (4)
Loosen electrical line of on-board electrical
4 network line pyrofuse (N82/1f1) from the cable
brackets (3) and expose
*BA54.15-P-
5 Unscrew nuts (2)
1001-01F
Remove on-board electrical network line
6
pyrofuse (N82/1f1)
7 Install in the reverse order
FUSE AND RELAY BOX
Number Designation Model 216 Model 221.0/1
BA54.15-P-1001-01F Nut, pyrofuse to vehicle power supply control unit Nm 10 10
REMOVE/INSTALL QUIESCENT CURRENT CUTOUT RELAY IN VEHICLE POWER SUPPLY
CONTROL UNIT - AR54.15-P-1266SX
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Illustrated on model 221
Fig. 43: Identifying Quiescent Current Cutout Relay Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Detach vehicle power supply control unit Disconnect ground line from AR54.21-P-
1 (N82/1) and swivel to one side with electrical starter battery and on-board 0100SX
lines connected (arrow) electrical system battery.
Open housing (1) of vehicle power supply
2
control unit (N82/1)
3 Disconnect electrical connector (3)
*BA54.15-P-
4 Unscrew nuts (2)
1002-01F
Remove quiescent current cutout relay
5
(N82/1k1)
6 Install in the reverse order
FUSE AND RELAY BOX
Model Model
Number Designation
216 221.0/1
BA54.15-P-1002- Nut, quiescent current cutout relay to vehicle power
Nm 10 10
01F supply control unit
REMOVE/INSTALL FRONT PREFUSE BOX - AR54.15-P-1330SX
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Shown on model 221
Fig. 44: Identifying Front Prefuse Box Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Disconnect ground line (1) of starter battery Disconnect ground line (1) on on- AR54.10-P-
1 (G1/4) and the on-board electrical system board electrical system with two 0003SX
battery batteries.
Unclip cover (2) on the front prefuse box
2
(F32)
Detach electrical lines (3) at the top of the Installation: The electrical lines (3)
3
prefuse box at the front (F32) are coded.
The number of the electrical lines (4)
differs depending on the vehicle
Detach electrical lines (4) at the top of the
4 equipment.
prefuse box at the front (F32)
Installation: The electrical lines (4)
are coded.
Unclip prefuse box at front (F32) (arrows A), Installation: Pay attention to correct
5
pull out upwards and place to one side seat of prefuse box at front (F32).
6
bottom of prefuse box at front (F32)
7 Remove prefuse box at front (F32)
8 Install in the reverse order
REMOVE/INSTALL FRONT PREFUSE BOX - AR54.15-P-1330SY
MODEL 216.3 as of 2.6.08
MODEL 216.3 with CODE (809) Model year 2009
MODEL 221.0 /1 as of 2.6.08
MODEL 221.0 /1 with CODE (809) Model year 2009
Shown on model 221
Fig. 45: Identifying Engine Compartment Prefuse Box Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Vehicles as of 2.6.08 without code (Z07) Top
protection
Disconnect ground line (1) from the AR54.10-P-
1.1 Vehicles with code (809) Model year 2009
on-board electrical system battery (G1) 0003SX
without code (Z07) Top protection
electrical systems with one battery.
Model 221.1 as of 2.6.08 with code (Z07) Top
protection
Disconnect ground line (1) from on-
Model 221.1 with code (809) Model year 2009 AR54.10-P-
1.2 board electrical system battery (G1)
with code (Z07) Top protection 0003SX
and starter battery
Disconnect the ground line (1) on on-board
electrical systems with two batteries.
Unclip cover (2) from engine
2
compartment prefuse box (F32/3)
Detach electrical lines (3) on top of
Installation: The electrical lines (3) are
3 engine compartment prefuse box
coded.
(F32/3)
Unclip engine compartment prefuse Installation: Make sure that the engine
4 box (F32/3) (arrows A), lift out and compartment prefuse box (F32/3) is seated
place to one side correctly.
Disconnect electrical connector (4) at
5 bottom of engine compartment prefuse
box (F32/3)
Disconnect electrical connector (5) at Pull out the retaining pin (6) slightly and
6 bottom of engine compartment prefuse push down the retaining pin (6) to unlock the
box (F32/3) electrical connector (5) (arrow B).
Remove engine compartment prefuse
7
box (F32/3)
8 Install in the reverse order
REMOVE/INSTALL INTERIOR COMPARTMENT PREFUSE BOX - AR54.15-P-1350SX
MODEL 216.3 as of 2.6.08
MODEL 216.3 with CODE (809) Model year 2009
MODEL 221.0 /1 as of 2.6.08
MODEL 221.0 /1 with CODE (809) Model year 2009
Shown on model 221
Fig. 46: Identifying Interior Compartment Prefuse Box Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Move the front passenger
1 seat into the rearmost
position
Vehicles as of 2.6.08 without code (Z07) Maximum
protection
Disconnect ground line at
Vehicles with code (809) Model year 2009 without code AR54.10-
2.1 the on-board electrical (Z07) Maximum protection P-0003SX
system battery
Disconnect ground line from on-board electrical
system with one battery
Model 221.1 as of 2.6.08 with code (Z07) Maximum
protection
Disconnect ground line from Model 221.1 with code (809) Model year 2009 with code
AR54.10-
2.2 on-board electrical system (Z07) Maximum protection
P-0003SX
battery and starter battery
Disconnect ground line from on-board electrical
system with two batteries
Fold back floor covering (1)
3
in passenger footwell
Unscrew nuts (2) on footrest
4
(3)
5 Fold down footrest (3)
Detach electrical line (4) on
6 left of the interior prefuse
box (F32/4)
Disconnect electrical
Pull out retaining spigot (6) slightly and press down the
7 connector (5) at top of
interior prefuse box (F32/4) retaining spigot (6) to release the electrical connector (5).
Disconnect electrical
8 connector (7) at top of
interior prefuse box (F32/4)
Detach electrical lines (8) on The number of the electrical lines (8) differs depending
9 the right of the interior on the vehicle equipment.
prefuse box (F32/4) Installation: The electrical lines (8) are coded.
Remove cap (9) from
10
electrical line (10)
Disconnect electrical line
11 (10) from interior prefuse
box (F32/4)
When removing the interior prefuse box for the first time
(F32/4).
Installation: If the interior prefuse box (F32/4) is
replaced, the new interior prefuse box (F32/4) is fastened
Remove interior prefuse box
12.1 (F32/4) from the threaded by pushing on the threaded pins (12).
If the old interior prefuse box (F32/4) is reinstalled,
pins (12)
additional screwing on with nuts (11) is necessary, as the
housing of the interior prefuse box (F32/4) is damaged in
the area of the threaded pin (12) during removal and can
no longer be fastened adequately.
Unscrew nuts (11) and
remove interior prefuse box During repeated removal of the interior prefuse box
12.2
(F32/4) from the threaded (F32/4).
pins (12)
13 Install in the reverse order
REMOVE/INSTALL ADDITIONAL BATTERY RELAY - AR54.15-P-2000SX
MODEL 216, 221 with CODE (B03) ECO start/stop function
Shown on model 216
Fig. 47: Identifying Additional Battery Relay Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Detach ground line of on-board electrical system battery AR54.10-P-0003SX
Detach ground line from additional battery for ECO start/stop function AR54.10-P-
2
(G1/13) 0007SXS
3 Unscrew nuts (2) and remove relay for ECO start/stop function (K98)
4 Take off cover (3)
5 Unscrew nuts (4) and remove electrical line (6)
6 Unscrew nuts (5) and remove electrical line (7)
7 Disconnect electrical connector (8)
8 Remove relay for ECO start/stop function (K98)
9 Install in the reverse order
REPAIR WIRING HARNESS BY MEANS OF AXIAL SOLDER CONNECTORS - AR54.18-P-0100-
06A
1. Expose damaged cable or plug/coupling in easily accessible position and cut off.
Separate cores in wiring harness offset by approx. 45 mm.
Fig. 48: Separating Cores In Wiring Harness
Courtesy of MERCEDES-BENZ USA
2. Cut new section of cable to match old cable.
3. Remove 15 mm of insulation at end of cables.
Pull cut-off insulation off the line while turning.
Fig. 49: Identifying Insulation Removing Length At Ends
Courtesy of MERCEDES-BENZ USA
4. Select axial solder connector by means of cable cross-section.
5. Push the axial solder connector on line beyond the solder point.
Push on the thinner side of the axial solder connector first.
Fig. 50: Pushing Axial Solder Connector On Line
Courtesy of MERCEDES-BENZ USA
6. Twist the line ends together.
7. Push back the axial solder connector on the transposition while turning.
Fig. 51: Twisting Line Ends Together
Courtesy of MERCEDES-BENZ USA
8. Heat up axial solder connector with a preheated hot air blower (with electronic temperature control) to
400 °C.
Hot air blower gotis://E_15/54_12.0
Use welding bead catcher in the vehicle interior in order to avoid damage due to liquid solder.
Until the soldering ring has dissolved and the covering has positioned itself properly around the lines.
Fig. 52: Heating Up Axial Solder Connector
Courtesy of MERCEDES-BENZ USA
9. Check soldered point.
It must not be possible to see the soldering ring of the axial soldered connector any more. The
covering must contact the lines properly.
Fig. 53: Identifying Correct And Incorrect Soldered Point
Courtesy of MERCEDES-BENZ USA
10. Apply axial solder connector to the lines and wrap repaired area round with fabric tape.
The axial solder connectors must not lie directly above one another.
Fig. 54: Wrapping Axial Solder Connectors
Courtesy of MERCEDES-BENZ USA
CHECKING WIRING HARNESS - AR54.18-P-0600-01A
Fig. 55: Identifying Electrical Connection Kit (220 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
Fig. 56: Identifying 126-Pin Socket Box (129 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
During tests on the supplemental restraint system control unit a corresponding test cable must be used in
combination with the 126-pin socket box.
1. Connect electrical connection kit with test cable.
2. Check lines for resistance using a continuity meter as per the wiring diagram, starting at the
corresponding control unit.
The resistance must be < 0.5 ohms.
3. Perform system test in accordance with diagnosis specifications.
REPAIR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SQUIB WIRING HARNESS - AR54.18-P-
0600A
MODEL 124, 129, 140, 163, 164, 166, 168, 169, 170, 171, 172, 197, 202, 203, 204, 207, 208, 209, 210, 211,
212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 246, 251, 414, 461 as of 1.4.94, 463
MODEL 126 with CODE (291) Airbag for driver and front passenger (for front passenger only if driver
airbag standard) with CODE (442) Airbag in steering wheel
Fig. 57: Identifying Wiring Harness And Solder Connector
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by Store airbag units with deployment side facing
performing testing or repair work up; do not expose to temperatures greater than AS91.00-Z-
on airbag or emergency tensioning 100 °C. When working on these units, disconnect 0001-01A
retractor units. the power supply.
Store airbag units with deployment side facing
performing testing or repair work 100 °C. When working on these units, disconnect
AS91.00-Z-
on airbag or emergency tensioning power supply and unplug the SRS test connector
0001-01B
retractor units. (X11/13).
Risk of injury to skin and eyes
Wear safety gloves, protective clothing and safety AS00.00-Z-
caused by handling hot or glowing
glasses, if necessary. 0002-01A
objects.
Risk of injury caused by burns to
skin and eyes. Risk of poisoning
Work in well ventilated rooms only. Wear safety AS00.19-Z-
caused by inhaling fumes when
glasses with side protection and protective gloves. 0001-01A
working with heat-shrinkable
tubing.
AH00.19-
Notes on replacement of safety-
P-1000-
relevant and special components
08A
AH91.00-
Assessment of airbag and belt Model 124, 126, 129 up to 30.6.93, 140, 202 up
P-0006-
tensioner units in accident vehicles to 30.6.93
01A
AH91.00-
Assessment of airbag and belt Except model 124, 126, 129 up to 30.6.93, 140,
P-0006-
tensioner units in accident vehicles 202 up to 30.6.93
01B
AH00.19-
Notes on cable protection P-1000-
11A
Remove detachable body
1
components in area to be repaired
AR00.19-
P-0100-
09A
Wiring harness repair kit, basic Fig. 39
New passenger vehicle wiring harness repair
Repair wiring harness (1) using Fig. 40
2 kit
solder connector (2)
Wire stripper Fig. 62
Reflector Fig. 63
Adapter Fig. 64
Welding bead catcher Fig. 60
Hot air blower gotis://E_15.54_12.0
AR00.19-
Protect repair area after cable
3 P-0100-
repairs
08A
AR54.18-
Function check on completion of repair. P-0600-
4 Check wiring harness (1) 01A
Electrical connection set Fig. 55
126-pin socket box Fig. 56
5 Install in the reverse order
Fig. 58: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Courtesy of MERCEDES-BENZ USA
Fig. 59: Identifying 126-Pin Socket Box (129 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 60: Identifying Welding Bead Catcher (129 589 01 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 61: Identifying Electrical Connection Kit (220 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
Fig. 62: Identifying Wire Stripper (220 589 01 99 40)
Courtesy of MERCEDES-BENZ USA
Fig. 63: Identifying Reflector (220 589 01 99 41)
Courtesy of MERCEDES-BENZ USA
Fig. 64: Identifying Adapter (220 589 01 99 42)
Courtesy of MERCEDES-BENZ USA
Fig. 65: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Courtesy of MERCEDES-BENZ USA
ONLINE SCN CODING - AR54.21-P-0013-01X
The following work instructions describe the procedure for the online software calibration number (SCN)
coding with Xentry Flash.
Precondition for SCN coding:
Networked STAR DIAGNOSIS diagnosis system
User ID and password for Xentry flash (user on aftersales platform)
Entry into coding in the Diagnosis Assistance System (DAS)
1. Select control unit.
2. Select menu item "control unit adaptations" or "initial startup". Continue with "F3".
3. Select menu item "SCN coding". Continue with "F3".
4. Select "Online (networked STAR DIAGNOSIS device)" menu item. Continue with "F3".
5. Enter user ID and password into the login screen. Continue with "Log in".
After logging in the SCN coding data are automatically queried in the background and the control unit
is then coded.
6. Press "F11" to print out the order log and enclose the repair order.
The order record can also be stored in the Diagnosis Assistance system (DAS). This is done by
clicking on "F11", "Print to file", selecting "printout of test step" and entering a file name. In StarUtilities,
the StarPad program can be used to display and printout the order log at the "Logs" menu item.
7. Continue with "F2".
The SCN coding of the control unit is completed.
OFFLINE SCN CODING - AR54.21-P-0013-04X
The following work instructions describe the procedure for the online software calibration number (SCN)
coding with Xentry Flash. The SCN coding data are requested by fax through the Star Diagnosis User Help
Desk.
For the Off-line fallback process Daimler ERG reserves the right to invoice 9 EUR per fax query.
Precondition for offline SCN coding:
STAR DIAGNOSIS diagnosis system with printer
Fax device
The offline SCN coding is broken down into 2 steps:
A. Determine vehicle data for offline SCN coding from vehicle. The vehicle data is used to create the fax
form for ordering the SCN coding data through the Star Diagnosis Help Desk.
B. Perform SCN coding. The coding is performed with the SCN coding data from the Star Diagnosis Help
Desk.
A. Determine vehicle data for offline SCN coding from the vehicle.
1. Select control unit in Diagnosis Assistance System (DAS).
2. Select menu item "control unit adaptations" or "initial startup". Continue with "F3".
3. Select menu item "SCN coding". Continue with "F3".
4. Select "Offline (STAR DIAGNOSIS device not-networked)" menu item. Continue with "F3".
5. Confirm note on sequence of SCN coding with "F2".
6. Completely fill out fax form and click "F11" to print out.
If an email address is entered in the fax form, you will be sent the SCN coding data per email. If
a fax number is entered in the fax form, you will be sent the SCN coding data per fax.
7. Send printed out fax form to the given fax no. for the Star Diagnosis Help Desk.
B. Perform SCN coding. The coding is performed with the SCN coding data from the Star Diagnosis
Help Desk.
If the SCN coding data are received per email, burn the data to a CD or save the data on a USB
removable storage device and identify accordingly. Unpack the Zip files first when doing so.
8 In the Diagnosis Assistance System (DAS) choose the "Step 2: Perform SCN coding" menu item.
Continue with "F3".
9.1 Select keyboard input using "F4".
For SCN coding data per fax.
9.2 Insert CD or connect USB removable storage device.
For SCN coding data per email.
10.1 Enter SCN coding data manually into the DAS.
For SCN coding data per fax.
10.2 Confirm using "F3" and import the data per CD or USB removable storage device.
For SCN coding data per email.
11 Perform SCN coding.
12 Switch ignition on/off.
Control unit specific, refer to specification in DAS.
13 Press "F11" to print out the order log and enclose the repair order.
The order log can also be stored on the DAS. This is done by clicking on "F11", "Print to file",
selecting "printout of test step" and entering a file name. In StarUtilities, the StarPad program can
be used to display and printout the order log at the "Logs" menu item.
14 Continue with "F2".
The SCN coding of the control unit is completed. Scrap the CD following successful SCN
coding as per the guidelines for theft-relevant parts (DTR 69/00). The scrapping process is to be
documented on the repair order. The data on the USB removable storage device are to be deleted
properly once they have been used.
PROGRAM CONTROL UNIT - AR54.21-P-0014-01Y
Offline programming with Release CD
1. Start Diagnosis Assistance System (DAS) and select category/vehicle model.
2. Select control unit.
Selection of main menu, systems and select the control unit to be programmed.
3. Select menu item "control unit adaptations".
4. Select menu item "control unit programming".
5. Select menu item "Program control unit using DVD or removable storage device".
6. With new software press the "F3" button and program the control unit.
Display appears if new software is present.
Only perform the following steps, if no communication (communication error) is possible between the
Diagnosis Assistance System (DAS) and control unit.
7. Eliminate the cause of the error message using the test steps in the "error messages" menu.
If the cause of the fault cannot be found or eliminated, please inform the STAR DIAGNOSIS User
Help Desk. Replace control unit in agreement with STAR DIAGNOSIS User Help Desk.
8. If necessary determine the part number of the control unit and replace the control unit.
9. Select menu item "Initial startup with automatic adoption of settings from the old control unit" or "Initial
startup without automatic adoption of the settings from the old control unit" in the main menu. Then
select "Repair functions" and carry out "Replace control unit".
When installing new control unit
PROGRAM CONTROL UNIT - AR54.21-P-0014-01Z
Offline programming with special release CD.
1. Start Diagnosis Assistance System (DAS) and select category/vehicle model.
2. Select control unit.
Selection of main menu, systems and select the control unit to be programmed.
3. Select menu item "control unit adaptations".
4. Select menu item "control unit programming".
5. Select "Offline (STAR DIAGNOSIS device not-networked)" menu item.
6. Select menu item "Program control unit using DVD or removable storage device".
7. Insert Special Release CD.
The programming of the control unit now starts automatically.
PROGRAMMING OF CONTROL UNITS - AR54.21-P-0014Y
MODEL 129.058 /063 /067 /076, 163, 164, 166, 168, 169, 170, 171, 199, 203, 204, 207, 208, 209, 210, 211,
212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 246, 251, 450, 452, 454,
461.302 /304 /305 /331 /332 /333 /334 /340 /342 /343 /344 /345 /346,
463.206 /208 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /306 /308 /30
(except, 245.286) Offline programming with Release CD
During the entire work procedure a sufficiently large
voltage supply must be provided for the vehicle's on-board
electrical system. Otherwise undervoltage damage may
occur to the control units.
Notes on programming AH54.21-P-
control units 0001-03Y
Connect STAR
DIAGNOSIS and start
Diagnosis Assistance
System (DAS)
Model 129, 163, 164, 166, 168, 169, 170, 171, 199, 203,
AD00.00-P-
204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219,
2000-04A
1 220, 221, 230, 240, 245, 246, 251, 461, 463
Connect STAR AD00.00-P-
Model 450
DIAGNOSIS and read out 2000-04SM
fault memory AD00.00-P-
Model 452
2000-04RR
AD00.00-P-
Model 454
2000-04FF
AR54.21-P-
2 Program control unit
0014-01Y
Perform software calibration
AR54.21-P-
3 number (SCN) coding for Only when required, refer to DAS.
0015X
control units
4 Run teach-in procedures Only when required, refer to DAS.
Read out and erase fault
5
memory
Disconnect STAR
6
DIAGNOSIS
PROGRAMMING OF CONTROL UNITS - AR54.21-P-0014Z
MODEL 129.058 /063 /067 /076, 163, 164, 168, 169, 170, 171, 199, 203, 204, 207, 208, 209, 210, 211, 212,
215, 216, 218, 219, 220, 221, 230, 240, 245, 246, 251,
461.302 /304 /305 /331 /332 /333 /334 /340 /342 /343 /344 /345 /346,
463.206 /208 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /306 /308 /30
(except, 245.286) Offline programming with Special Release CD
An adequate power supply to the vehicle
onboard electrical system is to be
ensured as damage to the control units
may arise if undervoltage occurs
AH54.21-
Notes on programming control units
P-0001-03Z
Flow chart for offline programming with AH54.21-
Special Release CD P-0001-04Z
Connect STAR DIAGNOSIS, start
Diagnosis Assistance System (DAS) and
Communication with control unit is
1 select category/vehicle model
established.
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
Determine the part number of the control
Only required if data cannot be read out of the
2 unit with the aid of the current parts
control unit.
catalog
If the control unit does not communicate with
the DAS or the problem cannot be eliminated
Contact STAR DIAGNOSIS User Help with the monthly Release CD or DAS-DVD.
3
Desk Have ready the event log of the initial quick
test, the control unit version and if necessary
the documentation for the repair order.
This information is needed for problem
solving. From this information the Special
Fax log of initial quick test, control unit Release CD is prepared at LC/MPC GLC
version and if necessary documentation Germersheim.
4
on the repair order to the STAR STAR DIAGNOSIS User Help Desk reports to
DIAGNOSIS User Help Desk the workshop and gives the replacement part
number, incl. "ES 2", of the Special Release
CD.
"ES 2" is also to be specified next to the part
number when ordering.
Order the Special Release CD via the Preparation and shipment of Special Release
5
usual ordering channels CD at LC/MPC GLC Germersheim. LC/MPC
GLC Germersheim sends the Special Release
CD via the usual sales/ marketing channel.
Program the control unit after receipt of AR54.21-P-
6
the Special Release CD 0014-01Z
Carry out redocumentation in the vehicle Only after successfully programming the
7 documentation system (FDOK/VeDok) control unit.
in the FDOK/VeDok screen If no FDOK/VeDok access is available,
Germersheim, to get redocumentation carried
out there.
AR54.21-P-
8 Perform SCN coding of control units Only when required, refer to DAS.
0015X
9 Run teach-in procedures Only when required, refer to DAS.
Read out fault memory, erase if
10
necessary
11 Disconnect STAR DIAGNOSIS
SCN CODING OF CONTROL UNITS - AR54.21-P-0015X
MODEL 129.058 /063 /067 /076, 163, 164, 166, 168, 169, 170, 171, 199, 203, 204, 207, 208, 209, 210, 211,
212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 246, 251, 450, 452, 454,
461.302 /304 /305 /331 /332 /333 /334 /340 /342 /343 /344 /345 /346,
463.206 /208 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254 /270 /271 /303 /306 /308 /30
During the entire work procedure a sufficiently large
voltage supply must be provided for the vehicle's on-board
electrical system. Otherwise undervoltage damage may
occur to the control units.
Connect STAR
DIAGNOSIS and start
Diagnosis Assistance
System (DAS)
Model 129, 163, 164, 166, 168, 169, 170, 171, 199, 203,
AD00.00-P-
204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219,
2000-04A
1 220, 221, 230, 240, 245, 246, 251, 461, 463
Connect STAR AD00.00-P-
Model 450
DIAGNOSIS and read out 2000-04SM
fault memory AD00.00-P-
Model 452
2000-04RR
AD00.00-P-
Model 454
2000-04FF
Perform online Software
AR54.21-P-
2.1 Calibration Number (SCN) With networked STAR DIAGNOSIS diagnosis system
0013-01X
coding
Perform offline Software
With non-networked STAR DIAGNOSIS diagnosis AR54.21-P-
2.2 Calibration Number (SCN)
system 0013-04X
coding
Read out fault memory,
3
erase if necessary
Disconnect STAR
4
DIAGNOSIS
MODEL 216.3 up to 1.6.08 except CODE (809) Model year 2009
MODEL 221.0 /1 up to 1.6.08 except CODE (809) Model year 2009
Shown on model 221
Fig. 66: Identifying Vehicle Power Supply Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Model 216.3, model 221.0, model
AR68.30-P-
1.1 Remove center paneling in trunk 221.1 without code (Z07) Maximum
4600SX
protection
Model 221.1 with code (Z07) Top
Remove paneling in center of luggage protection AR68.30-P-
1.2
compartment or equipment carrier plate Depending on vehicle 4600SXS
configuration.
Disconnect ground line on the starter Disconnect ground line from on- AR54.10-P-
2 battery and on the on-board electrical board electrical system with two 0003SX
system battery (G1) batteries
3 Unscrew nuts (1).
Remove electrical system control unit
4
(N82/1)
The number of electrical
5 Unscrew electrical connections (A) connectors (A) depends on the
vehicle equipment.
*BA54.10-P-
1007-01C
The number of electrical
6 Separate electrical connectors (B) connectors (B) depends on the
vehicle equipment.
Remove vehicle power supply control unit
7
(N82/1)
8 Install in the reverse order
Carry out initial startup of the vehicle
9 power supply control unit (N82/1) using
STAR DIAGNOSIS After replacing vehicle power
supply control unit (N82/1).
Connect STAR DIAGNOSIS and read out AD00.00-P-
fault memory 2000-04A
BATTERY
Model Model
Number Designation
216 221
BA54.10-P-1007- Nut, line connection to vehicle power supply control M6 Nm 7 7
01C unit M8 Nm 10 10
REMOVE/INSTALL FRONT CENTRAL OPERATING UNIT - AR54.21-P-0500SX
MODEL 221.0 /1 up to 31.5.09 except CODE (800) Model year 2010
Fig. 67: Identifying Front Central Operating Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Temporarily store basic data from front When replacing the front central
1.1 central operating unit (A40/9) in STAR operating unit (A40/9).
DIAGNOSIS Installation: Transfer the temporarily
Connect STAR DIAGNOSIS and read stored basic data to the new front central AD00.00-P-
out fault memory operating unit (A40/9). 2000-04A
Switch off ignition and withdraw
Keyless Go start/stop button only for
2 transmitter key or Keyless Go start/stop
button from the EIS [EZS] control unit vehicles with code (889) Keyless Go.
AR54.21-P-
3 Remove turn/push control
0501SX
Press release button (3) and lift armrest On vehicles without code (582) Rear air
4.1
(1) towards the rear conditioning
Press release button (2) and open On vehicles with code (582) Rear air
4.2
telephone or stowage compartment (11) conditioning
Unlock telephone or stowage
compartment (11) using suitable tools On vehicles with code (582) Rear air
5
through the openings (arrows) and lift conditioning
towards the rear
6 Unclip cover (14) from center console Fig. 68
Close off stowage compartment
ventilation via adjustment wheel (13) and On vehicles without code (582) Rear air
7
unclip maintenance flap (7) using a conditioning
suitable screwdriver (12)
The number of electrical connectors
Expose wiring harness in center console
8 (8) varies depending on the vehicle
and separate electrical connectors (8)
equipment.
AR68.20-P-
9 Remove trim at rear of center console
5169SX
10 Unclip hinge cover (5)
11 Remove bolts (4, 6)
On vehicles without code (386)
Preinstallation for telephone "Handy",
Lift trim (10) at front, guide it backwards UPCI system or without code (388)
out of center console together with Telephone "Handy", UPCI system
12.1
telephone or stowage compartment (11)
Installation: Ensure that the wiring
and remove
harness of the front central operating unit
(A40/9) is correctly routed.
On vehicles with code (386)
Preinstallation for telephone "Handy",
front central operating unit (A40/9) is Telephone "Handy", UPCI system
accessible Installation: Ensure that the wiring
12.2
harness of the front central operating unit
(A40/9) is correctly routed.
Remove bolts (9) and remove front
13 central operating unit (A40/9) from trim
(10)
Information on preventing damage to
AH54.00-P-
electronic components due to
0001-01A
electrostatic discharge
14 Install in the reverse order
Fig. 68: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL FRONT CENTRAL OPERATING UNIT - AR54.21-P-0500SXH
MODEL 221.0 /1 as of 1.6.09
MODEL 221.0 /1 with CODE (800) Model year 2010
Fig. 69: Identifying Front Central Operating Unit, Screw And Center Control Trim
Courtesy of MERCEDES-BENZ USA
Remove/install
electronic components due to electrostatic 0001-01A
discharge
Temporarily store basic data from front When replacing the front central
1 central operating unit (A40/9) in STAR operating unit (A40/9).
DIAGNOSIS Installation: Transfer the
temporarily stored basic data to the
Connect STAR DIAGNOSIS and read out new front central operating unit AD00.00-P-
fault memory (A40/9). 2000-04A
Switch off ignition and withdraw Keyless Go start/stop button only
2 transmitter key or Keyless Go start/stop for vehicles with code (889) Keyless
button from the EIS [EZS] control unit Go.
AR54.21-P-
3 Remove turn/push control
0501SX
AR68.20-P-
4 Remove center console trim (2)
2107SXH
Remove bolts (1) and remove central front
5 operating unit (A40/9) from center console
trim (2)
6 Install in the reverse order
REMOVE/INSTALL TURN/PUSH CONTROL FOR FRONT CENTRAL OPERATING UNIT -
AR54.21-P-0501SX
MODEL 216.3, 221.0 /1
Shown on model 221 with code (388) Telephone "Handy", UPCI system
Fig. 70: Identifying Turn/Push Control Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Model 216, 221 without code (386)
Preinstallation for telephone "Handy", UPCI
system or without code (388) Telephone
Release hand rest (2) by passing
"Handy", UPCI system or without code (498)
suitable screwdriver through opening
1.1 Japan version or without code (389) Mobile
(arrow A) and remove hand rest
phone preinstallation with universal interface,
housing (3)
USA/Canada
Model 221 without code (359) TELE AID
emergency call system
Model 216, 221 with code (386)
Preinstallation for telephone "Handy", UPCI
Open hand rest (2) and release center system or with code (388) Telephone "Handy",
console button group (S148) by passing UPCI system or with code (498) Japan version
suitable screwdriver through opening or with code (389) Mobile phone
1.2
(arrow A), disconnect electrical preinstallation with universal interface,
connector and remove center console USA/Canada
button group (S148) Model 221 with code (359) TELE AID
emergency call system except code (807)
Model year 2007)
2 housing (3)
Position firmer chisel at center of
*WH58.30-
3 covering (5), knock in covering (5) and
Installation: Replace the covering (5). Z-1043-04A
pry off
Installation: The turn/push control (1)
Unscrew bolt (6) and remove turn/push must be inserted correctly into the two mounts
4 (arrows B) on the gearing neck (7) of the front
control (1)
central operating unit, otherwise it may not be
seated securely.
5 Install in the reverse order
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1043-04A Plug-in chisel as per DIN 5139 with blade width 10 mm,
CENTRAL GATEWAY CONTROL UNIT (ZGW), REMOVE AND INSTALL - AR54.21-P-0817SX
MODEL 216.3, 221.0 /1
Shown on model 221 up to 1.6.08 without code (809) Model year 2009
Fig. 71: Identifying Central Gateway Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing AH54.00-
damage to electronic components P-0001-
due to electrostatic discharge 01A
Stage basic data from the central
When installing new central gateway control unit
1 gateway control unit (N93) in
(N93).
STAR DIAGNOSIS
Install: Transfer the buffered basic data to the
Connect STAR DIAGNOSIS AD00.00-P-
new central gateway control unit (N93).
and read out fault memory 2000-04A
Remove cover below dashboard Model 216.3, 221.0/1 up to 1.6.08 without code AR68.10-P-
2.1
on left (809) Model year 2009 1500SX
Model 216.3, 221.0/1 as of 2.6.08
Loosen cover under instrument Model 216.3, 221.0/1 with code (809) Model year
AR68.10-P-
2.2 panel and place to one side with 2009
1500SX
electrical lines connected Only disconnect the electrical connector of the
left front footwell lamp.
Switch off ignition and withdraw
transmitter key or Keyless Go Keyless Go start/stop button only for vehicles
3
start/stop button from the EIS with code (889) Keyless Go.
[EZS] control unit
On model 216.3, 221.0/1 as of 2.6.08 or model
Unclip central gateway control 216.3, 221.0/1 with code (809) Model year 2009
4 unit (N93) from bracket (1) and the central gateway control unit (N93) is
remove downwards assembled on the left in the instrument panel next
to the left instrument panel fuse box.
Separate electrical connector (3)
5 and remove central gateway
control unit (N93)
6 Install in the reverse order
REMOVE/INSTALL SAM CONTROL UNIT WITH FUSE AND RELAY BOX IN TRUNK - AR54.21-
P-1258SX
MODEL 216.3, 221.0 /1
Shown on model 221 up to 1.6.08 without code (809) Model year 2009
Fig. 72: Identifying SAM Control Unit Components
Courtesy of MERCEDES-BENZ USA
Fig. 73: Identifying Rear SAM Control Unit With Fuse And Relay Module And Bow
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
19.3.09 Value modified: Bolt, battery bracket to body, Nm Model 221 *BA54.10-P-1027-01C
Remove/install
Information on preventing damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
The SAM control unit (2) of the rear SAM
control unit with fuse and relay module assembly
(N10/2) can be removed or replaced separately.
See steps 1 to 8.
Temporarily store basic data from SAM control When replacing the SAM control
1 unit (2).
unit (2) in STAR DIAGNOSIS
Installation: Transfer the
memory the new SAM control unit (2). 2000-04A
AR64.10-P-
2 Remove rear shelf reinforcement
1200SX
Switch off ignition and withdraw transmitter key Keyless Go start/stop button
3 or Keyless Go start/stop button from the EIS only for vehicles with code (889)
[EZS] control unit Keyless Go.
Model 216.3, 221.0/1 up to
Detach bracket of on-board electrical system 1.6.08 without code (809) Model
4.1 battery (G1) and swing on-board electrical year 2009
system battery (G1) to one side *BA54.10-
P-1027-01C
Model 221.1 as of 2.6.08 with
code (Z07)
Maximum protection
Model 221.1
with code (809) Model year 2009
with code (Z07) Maximum
Detach bracket of starter battery and swing protection
4.2
starter battery to one side
On the above vehicles the
starter battery is fitted in the
trunk instead of the on-board
electrical system battery (G1).
*BA54.10-
P-1027-01C
Disconnect electrical connector of luggage On vehicles with code (889)
5
compartment Keyless-Go antenna (A2/35) Keyless go
Remove bolts (1) and pull forward rear SAM
Installation: Ensure that no
control unit with fuse and relay module (N10/2)
electrical lines are pinched
6 until the wiring harness (3) and wiring harness
otherwise there is the danger of
(4) is accessible behind the rear SAM control
damaging the electrical system.
unit with fuse and relay module (N10/2)
Expose wiring harness (3) and wiring harness (4) Installation: Observe routing
7
on the rear panel and fixing of wiring harnesses.
When replacing the SAM control
Unlock SAM control unit (2) (arrows), remove unit (2) separately.
from rear SAM control unit with fuse and relay
8 Number of electrical
module (N10/2) and disconnect electrical
connectors can vary according to
connectors
vehicle equipment.
Depending on the battery system
fitted, disconnect the
AR54.10-P-
9 Disconnect ground cable corresponding ground lines in
0003SX
order to de-energize the on-board
electrical system.
The number of electrical
from the rear SAM control unit with fuse and differs depending on the vehicle
10
relay module (N10/2) equipment.
Remove rear SAM control unit with fuse and
11
relay module (N10/2)
Unlock SAM control unit (2) (arrows) and When replacing the rear SAM
12 remove from rear SAM control unit with fuse control unit with fuse and relay
and relay module (N10/2) module (N10/2).
When replacing the rear SAM
Remove bracket from rear SAM control unit
13 control unit with fuse and relay
with fuse and relay module (N10/2)
module (N10/2).
Compare the fuse and relay fittings of the new
rear SAM control unit with fuse and relay When replacing the rear SAM
14 module (N10/2) with that of the old rear SAM control unit with fuse and relay
control unit with fuse and relay module (N10/2) module (N10/2).
and adapt fittings if necessary
15 Install in the reverse order
BATTERY
Number Designation Model 216 Model 221
M6 Nm 8 8
BA54.10-P-1027-01C Bolt, battery bracket to body
M8 Nm 23 23
REMOVE/INSTALL SAM WITH FUSE AND RELAY BOX, LEFT FRONT - AR54.21-P-1260SX
MODEL 216.3, 221.0 /1
Shown on model 221 with engine 273
Fig. 74: Identifying SAM With Fuse And Relay Box Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
The SAM control unit (7) of the assembly front
SAM control unit with fuse and relay module
(N10/1) can be removed or replaced separately.
See steps 1.1 to 7.1.
When replacing the SAM
Temporarily store basic data from the SAM control
1.1 control unit (7).
unit (7) in STAR DIAGNOSIS
Installation: Transfer
basic data stored temporarily
AD00.00-P-
to the new SAM control unit
Connect STAR DIAGNOSIS and read out fault 2000-04A
(7).
memory
STAR DIAGNOSIS *WH58.30-
diagnosis system Z-1048-13A
Switch off ignition and detach transmitter key or Keyless Go start/stop
2 Keyless Go start/stop button from EIS [EZS] button only for vehicles with
control unit code (889) Keyless Go.
On vehicles with control
3 Remove cover (1) unit in cover (1): Place cover
unit installed and connected.
Separate electrical connectors (3, 5) and fuse The number of fuse
4 holders from front SAM control unit with fuse and holders (A) depends on the
relay module (N10/1) vehicle equipment.
Remove bolts (4), raise front SAM control unit
5 with fuse and relay module (N10/1) and place to
one side
The number of electrical
Separate electrical connectors (B) from SAM
6 connectors (B) depends on
control unit (7)
the vehicle equipment.
When replacing SAM control
7.1 Unlock SAM control unit (7) (arrows) and remove
unit (7) separately.
Disconnect ground line at starter battery and on- AR54.10-P-
8
board electrical system battery 0003SX
Separate positive leads (6) and electrical connectors The number of electrical
9 (C) from the front SAM control unit with fuse and connectors (C) depends on
relay module (N10/1) the vehicle equipment.
Remove front SAM control unit with fuse and relay
10
module (N10/1)
Compare the fuse and relay components provided
of the new front SAM control unit with fuse and When replacing the front
11.1 relay module (N10/1) with the old front SAM SAM control unit with fuse
control unit with fuse and relay module (N10/1), and relay module (N10/1).
adapt components provided if necessary
12 Install in the reverse order
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
REMOVE/INSTALL UPPER CONTROL PANEL CONTROL UNIT - AR54.21-P-1262SX
MODEL 216.3, 221.0 /1
Shown on model 221
Fig. 75: Identifying Upper Control Panel Control Unit, Trim Strip And Bolts
Courtesy of MERCEDES-BENZ USA
Remove/install
Model AR68.10-P-
1.1 Remove trim strip (1) from instrument panel
221 1180SX
Model
1.2 Remove cover for upper control panel control unit (N72/1) AR68.20-P-2314SC
216
Unscrew bolts (2) and remove upper control panel control unit
2
(N72/1)
Notes on avoiding damage to electronic components due to AH54.00-P-0001-
electrostatic discharge 01A
3 Install in the reverse order
REPLACE CONTROL KNOB OF REAR CONTROL PANEL CONTROL UNIT - AR54.21-P-1266-
01SX
1. Fit circlip (2) into grooves on control knob (1) as shown.
2. Push control knob (1) onto shaft of RCP [HBF] control unit.
3. Engage circlip (2) on shaft of RCP [HBF] control unit using a suitable tool.
Install the circlip (2) carefully and cover the center armrest trim with a suitable protective cover in
order to avoid damage.
4. Check that the control knob (1) is properly seated on the shaft of the RCP [HBF] control unit.
The control knob (1) must be seated on the shaft of the RCP [HBF] control unit without play.
Fig. 76: Identifying Circlip & Control Knob
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REAR CONTROL PANEL CONTROL UNIT - AR54.21-P-1266SX
MODEL 221.0 /1 with CODE (864) Rear entertainment system
Fig. 77: Identifying Center Armrest Trim & Bolts
Courtesy of MERCEDES-BENZ USA
Fig. 78: Identifying Rear Control Panel Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Temporarily store basic data from RCP When replacing the RCP [HBF]
1.1 [HBF] control unit (N72/2) in STAR control unit (N72/2).
DIAGNOSIS Installation: Transfer the
temporarily stored basic data to the AD00.00-P-
Connect STAR DIAGNOSIS and read out new RCP [HBF] control unit (N72/2). 2000-04A
fault memory STAR DIAGNOSIS diagnosis *WH58.30-Z-
system 1048-13A
Remove audio/video controller control AR82.60-P-
2
unit in rear compartment 2000SX
3 Remove bolts (3)
Lift center armrest trim (2), turn it over
4 and disconnect electrical connector from
RCP [HBF] control unit (N72/2)
Unclip control knob (1) carefully
otherwise the center armrest trim (2)
may be damaged.
Cover center armrest trim (2) with a clean
5 Installation: Replace control
rag and unclip control knob (1) upwards Fig. 68
knob (1).
See: ?
Replace control knob of rear control AR54.21-P-
panel control unit 1266-01SX
Remove bolts (4) and remove RCP [HBF]
6 control unit (N72/2) from center armrest
trim (2)
7 Install in the reverse order
Fig. 79: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
REMOVE/INSTALL MULTIFUNCTION STEERING WHEEL ELECTRONICS UNIT - AR54.21-P-
2050SX
MODEL 216, 221.0 /1
Fig. 80: Identifying Multifunction Steering Wheel Electronics Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to
electrostatic discharge 0001-01A
Multifunction steering wheel
electronics units (A74/1) that have
already been replaced must be
identified by an adhesive label.
The multifunction steering wheel electronics
unit (A74/1) should be replaced once only in the AR46.10-P-
1 Remove steering wheel (1)
steering wheel (1). If it has to be removed again, 0100SX
the steering wheel (1) must be replaced.
2 Separate electrical connectors (2)
*BA46.10-P-
3 Remove bolts (3)
1002-02I
Remove multifunction steering wheel
4
electronics unit (A74/1)
Make sure that the retaining lugs are engaged
5 Transfer springs (4)
correctly.
Blow out threaded holes (5) in
6
steering wheel (1)
7 Install in the reverse sequence
STEERING WHEEL
Number Designation Model 216 Model 221
BA46.10-P-1002-02I Bolt, electronic unit to steering wheel Nm 7 7
REMOVE/INSTALL MULTIFUNCTION CAMERA - AR54.21-P-3000EW
MODEL 207 with CODE (513) Speed Limit Assist with CODE (608) Adaptive high beams assist
MODEL 204, 212, 216, 218, 221 (except 204.9) with CODE (238) Active Lane Keeping Assist with CODE
(476) Automatic lane recognition with CODE (513) Speed Limit Assist with CODE (608) Adaptive high
beams assist
MODEL 172.4 with CODE (513) Speed Limit Assist
Shown on model 212
Fig. 81: Identifying Multifunction Camera Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Switch off ignition and remove transmitter key
KEYLESS-GO start/stop button only
(A8/1) or KEYLESS-GO start/stop button
1 on vehicles with code (889) Keyless-
(S2/3) from electronic ignition lock control
Go.
unit (N73)
Swivel inside rearview mirror (A67) to one
2
side
Model 172.4, 204, 212, 218, 221
3.1 Unclip and remove cover (1) Model 207.3, 216 up to model year
2011
Model 207.4, 216 as of model year
3.2 Slide cover (1) fully forward and remove
2011
Model 212 with code (Z04) Light
armoring
4 Remove splinter protection
*BA63.20-P-
1004-01B
Position assembly wedge between the bracket
5 (4) and the windshield and multifunction Mounting wedge Fig. 68
camera (A40/11) and unlock catch hooks (3)
Guide multifunction camera (A40/11) out of
On model 204, 207, only one
6 the rear brackets in the direction of the arrow
and disconnect electrical connectors (2) electrical connector (2) is fitted.
7 Install in the reverse order
The calibration target for the Night
Calibrate multifunction camera (A40/11) using View Assist is required to calibrate the AD00.00-P-
8 multifunction camera (A40/11).
Star Diagnosis 2000-04A
Calibration target for Night Vision
Assist gotis://E_82_03.
PILLARS
Model 212 with code
Number Designation
Z04
BA63.20-P-1004- Nut/bolt, splinter guard to rain/light sensor guard
Nm 12
01B plate
Fig. 82: Identifying Mounting Wedge (110 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL COCKPIT SWITCH GROUP - AR54.25-P-1000SX
MODEL 216.3, 221.0 /1
MODIFICATION NOTES
23.2.10 This document has been replaced by a document with increased picture content
OV00.01-P-1901-07A
Unless otherwise shown, instructions are shown by means of model series 221.
Fig. 83: Removing Cockpit Switch Group (Step 1)
Courtesy of MERCEDES-BENZ USA
Fig. 84: Removing Cockpit Switch Group (Step 2)
Courtesy of MERCEDES-BENZ USA
Fig. 85: Removing Cockpit Switch Group (Step 3)
Courtesy of MERCEDES-BENZ USA
Courtesy of MERCEDES-BENZ USA
Fig. 87: Removing Cockpit Switch Group (Step 5)
Courtesy of MERCEDES-BENZ USA
Fig. 88: Removing Cockpit Switch Group (Step 6)
Courtesy of MERCEDES-BENZ USA
Fig. 89: Removing Cockpit Switch Group (Step 7 & 8)
Courtesy of MERCEDES-BENZ USA
Fig. 90: Removing Cockpit Switch Group (Step 9)
Courtesy of MERCEDES-BENZ USA
To install, reverse removal procedure.
REMOVE STEERING COLUMN SWITCH MODULE - AR54.25-P-2800-01SX
When the steering wheel is detached the fanfare horns and airbag clock spring contact (A45) must not be
twisted otherwise this can be damaged.
1. Unscrew bolt (1).
Bolt (1) is secured to prevent it from falling out.
2. Disconnect steering column switch module (2) complete with fanfare horns and airbag clock spring
contact (A45) from jacket tube.
Fig. 91: Identifying Bolt, Steering Column Switch Module & Fanfare Horns And Airbag Clock
Spring Contact
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL COMBINATION SWITCH - AR54.25-P-2800SX
MODEL 216.3, 221.0 /1
Fig. 92: Identifying Combination Switch Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove steering angle sensor AR46.10-P-0300SX
2 Remove steering column adjustment/steering wheel heater switch AR54.25-P-2804SX
3 Unscrew screw (1)
4 Remove combination switch (S4) from carrier plate (2)
5 Install in the reverse order
6 Carry out function check of combination switch (S4)
MODEL 221.0 /1, 216
MODIFICATION NOTES
Perform initialization of DTR control unit after replacing steering column tube module, Step
25.11.08
added 3
Remove/install
Steering column tube module and steering
angle sensor form one component and can
only be replaced together where necessary
AR46.10-P-
1 Remove steering column tube module See remove/install steering angle sensor.
0300SX
2 Install in the reverse order
After replacing steering column tube
Perform initialization of DTR control unit module on vehicles with code (219)
3
with STAR DIAGNOSIS Distronic (DTR) or code (233)
DISTRONIC PLUS
REMOVING AND INSTALLING STEERING COLUMN ADJUSTMENT SWITCH - AR54.25-P-
2804SX
MODEL 216.3, 221.0 /1
Fig. 93: Identifying Steering Column Adjustment/Steering Wheel Heater Switch, Carrier Plate And Bolts
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove steering angle sensor AR46.10-P-0300SX
2 Remove bolts (3)
3 Remove switch (S59/1) from carrier plate (2)
4 Install in the reverse order
5 Perform function check on switch (S59/1)
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02ESX
Deactivate/activate easy entry/exit feature
1. Insert key into EIS [EZS] control unit (N73).
2. Turn the turn/push control (A40/9s11) until the basic menu "Vehicle" is shown against a highlighter bar
in the COMAND display (A40/8).
3. Confirm the selection by pressing the turn/push control (A40/9s11).
4. Turn the turn/push control (A40/9s11) until the menu item "Easy entry/exit" appears in bold.
5. Confirm the selection by pressing the turn/push control (A40/9s11).
Fig. 94: Identifying COMAND Display, Control Unit And Turn/Push Control
Courtesy of MERCEDES-BENZ USA
6. Note the option of easy entry/exit chosen by the customer.
7. Turn the turn/push control (A40/9s11) until in the selection list "off" is shown against a highlighter bar.
8. Confirm the selection by pressing the turn/push control (A40/9s11).
9. At the conclusion of the work set the option of easy entry/ exit again chosen by the customer.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02GZA
Activate tire pressure monitor.
Before activating tire pressure monitor: correct tire pressures of all wheels.
1. Switch on ignition.
2. Press the system selection button (S110s3) repeatedly until the kilometer reading is displayed in the
multifunction display (A1p13).
3. Press the scroll forward/back button (S110s1) repeatedly until the tire pressure display appears in the
multifunction display (A1p13).
4. Press trip odometer reset button (A1s3).
Fig. 95: Identifying System Selection, Scroll Forward/Back Buttons And Multifunction Display
Courtesy of MERCEDES-BENZ USA
5. Confirm the note in the multifunction display (A1p13) by pressing the button + and -, setting of specific
functions and volume control (S111s1)
The tire pressure display only appears after driving for a few minutes.
6. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02OPS
Check engine oil level.
The vehicle must be horizontal for at least 5 minutes with the engine switched off at operating temperature,
otherwise there will be measuring errors.
1. Switch on ignition.
2. Press the system selection button (S110s3) repeatedly until the "Service" menu appears in bolt in the
multifunction display (A1p13).
3. Press the scroll forward/back button (S110s1) repeatedly and select "engine oil level".
Fig. 96: Identifying Multifunction Display, Forward/Back And System Selection Buttons
Courtesy of MERCEDES-BENZ USA
The note "engine oil level, measurement in progress, correct measurement only if the vehicle is level"
appears in the multifunction display (A1p13).
5. The measurement result is shown in the multifunction display (A1p13).
6. Correct the engine oil level if necessary and check engine oil level again.
7. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAC
Activate tire pressure loss warning.
Before activating the tire pressure loss warning: Correct the tire pressure in all wheels
Setting on multifunction steering wheel (4 buttons)
1. Switch on ignition.
2. Press system selection button (S110s3) repeatedly until the "Tire Pressure menu: R" menu is shown with
a highlighter bar in the multifunction display (A1p13).
Fig. 97: Identifying Multifunction Display, System Selection, Reset And Back Buttons
Courtesy of MERCEDES-BENZ USA
3. Press reset button (S110s7).
The note "monitoring active restart: R." is shown in the multifunction display (A1p13).
4. Press reset button (S110s7).
The note "Tire Pressure OK? Yes+ Abort -" is shown in the multifunction display (A1p13).
5. Press button + (S111s1) for tire pressure activation of run flat indicator.
The note "Tire pressure monitoring restarted" is shown in the multifunction display (A1p13).
After the teach-in phase the tire pressure loss warner monitors the adjusted tire pressure in all four
tires.
6. Switch off ignition.
Settings on comfort multifunction steering wheel (12 buttons)
1. Switch on ignition.
2. Press the system selection button (S110s3) repeatedly until the "Service" menu is shown with a
highlighter bar in the multifunction display (A1p13).
3. Select "Tire pressure" using the scroll forward/back button (S110s1).
Fig. 98: Identifying Multifunction Display, System Selection, Scroll Forward/Back And OK Buttons
Courtesy of MERCEDES-BENZ USA
4. Press OK button (S110s6).
The note "Tire pressure now OK?" is displayed in the multifunction display (A1p13).
5. Press OK button (S110s6) for tire pressure activation of run flat indicator.
The note "Run flat indicator active, restart with OK" is shown in the multifunction display (A1p13).
6. Select "Yes" with scroll forward/back button (S110s1).
7. Press OK button (S110s6).
The note "Run flat indicator restarted" is shown in the multifunction display (A1p13).
After the teach-in phase the tire pressure loss warner monitors the adjusted tire pressure in all four
tires.
8. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAE
Restart tire pressure loss warning
1. Correct the tire pressure of all complete wheels.
2. Switch on ignition.
3. Keep pressing the system select button (S110s3) until the "Service" menu is highlighted with a bar in the
multifunction display (A1p13).
Shown on model 212.002
Fig. 99: Identifying Multifunction Display And Scroll Forward/Back, System Selection, OK And
Accept/Terminate Phone Call Buttons
Courtesy of MERCEDES-BENZ USA
4. Select "Tire pressure" with the scroll forward/back button (S110s1).
5. Press OK button (S110s6).
The message "Tire pressure monitoring active. Restart with OK" is displayed on the multifunction
display (A1p13).
6. Press OK button (S110s6) to activate tire pressure monitoring.
7. Select "Yes" with scroll forwards and backwards button (S110s1).
8. Press OK button (S110s6).
The note "Tire pressure monitoring active restart with OK" is shown in the multifunction display
(A1p13).
After the teach-in phase the tire pressure loss warning monitors the tire pressure adjusted in all four tires.
9. Switch off ignition.
ENTER SETTINGS AT THE OPERATING SYSTEM - AR54.30-P-1000-02RAH
Activate the tire pressure monitoring system
Before activating tire pressure monitoring system: correct tire pressure of all wheels.
1. Switch on ignition.
2. Press system select/voice control pushbutton (S110s3) repeatedly until the mileage is displayed on the
multifunction display (A1p13).
3. Press the scroll forward/back pushbutton (S110s1) repeatedly until the tire pressure is displayed on the
multifunction display (A1p13).
4. Press the reset button (A1s1).
Fig. 100: Identifying System Select/Voice Control, Scroll Forward/Back Pushbuttons And
Multifunction Display
Courtesy of MERCEDES-BENZ USA
5. Confirm the information shown on the multifunction display (A1p13) by pressing the + and -, setting of
specific functions and volume control button (S111s1).
The tire pressure is displayed a few minutes after the driver begins to drive the vehicle.
6. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAM
Activate tire pressure monitor.
Before activating tire pressure monitoring system: correct tire pressure of all wheels.
1. Switch on ignition.
2. Press the system selection button (S110s3) repeatedly until the kilometer reading is displayed in the
multifunction display (A1p13).
3. Press the scroll forward/back button (S110s1) repeatedly until (A1p13) the tire pressure display or the
message "TIRE PRESSURE MONITOR, PRESSURE DISPLAY AFTER DRIVING FOR A FEW
MINUTES, REACTIVATE WITH R-BUTTON" is shown in the multifunction display.
Fig. 101: Identifying System Selection, Scroll Forward/Back Buttons And Multifunction Display
Courtesy of MERCEDES-BENZ USA
4. Press reset button.
5. Inquiry "ACT. Confirm MONITOR TIRE PRESSURE?" in the multifunction display (A1p13) by
pressing the button + and -, setting specific functions and volume control (S111s1)
The message "TIRE PRESSURE MONITOR ACTIVATED" appears in the multifunction display
(A1p13).
6. Drive the vehicle for several minutes.
Until the individual tire pressure values are detected, the (A1p13) the message "TIRE PRESSURE
MONITOR, PRESSURE DISPLAY AFTER DRIVING FOR A FEW MINUTES, REACTIVATE WITH
R-BUTTON" is shown in the multifunction display.
7. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAR
Activate the tire pressure monitoring system
Before activating tire pressure monitor: correct tire pressures of all wheels.
1. Switch on ignition.
2. Press scrolling forwards/backwards button (S110s1) until the tire pressure display appears in the right
multifunction display (A1p15).
Fig. 102: Identifying Scrolling Forwards/Backwards Buttons And Multifunction Displays
Courtesy of MERCEDES-BENZ USA
3. Press instrument illumination brightness control and reset button (A1r1).
The message "Monitor current tire pressure" appears in the left multifunction display (A1p13)."
4. Press button + and -, setting specific functions and volume control (S111s1).
The message "Tire pressure monitor activates pressure display after driving for a few minutes "A1p13
appears in the left multifunction display."
5. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAS
Activate tire pressure monitor.
Before activating tire pressure monitor: correct tire pressures of all wheels.
1. Switch on ignition.
2. Press the system selection button (S110s3) repeatedly until the menu "Service" appears in bold in the
multifunction display (A1p13).
3. Use the scroll forward/back button (S110s1) to select "Tire pressure".
Fig. 103: Identifying Multifunction Display, System Selection And Scroll Forward/Back Buttons
Courtesy of MERCEDES-BENZ USA
4. Press OK button (S110s6).
The note "Tire pressure display appears after driving for a few minutes" or the current tire pressures
are shown in the multifunction display (A1p13).
5. Press lower scroll forward/back button (S110s1)
"Adopt current pressures as new guidance values?" appears in the multifunction display (A1p13).
6. Press OK button (S110s6).
The note "Tire pressure monitor reactivated" appears in the multifunction display (A1p13).
7. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAT
Activate tire pressure monitor.
Before activating tire pressure monitor: correct tire pressures of all wheels.
1. Switch on ignition.
2. Press system selection button (S110s3) repeatedly until (A1p13) the basic display (kilometer reading or
temperature display) or speed display is shown.
Fig. 104: Identifying Trip Odometer Reset Button, System Selection Button And Multifunction
Display
Courtesy of MERCEDES-BENZ USA
3. Press the scroll forward/back button (S110s1) repeatedly until the tire pressure display appears in the
multifunction display (A1p13).
4. Press trip odometer reset button (A1s3).
5. Confirm the note in the multifunction display (A1p13) by pressing the button + and -, setting of specific
functions and volume control (S111s1)
The tire pressure display only appears after driving for a few minutes.
6. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAU
Restart tire pressure monitor
1. Correct the tire pressure of all complete wheels.
2. Switch on ignition.
3. Keep pressing the system select button (S110s3) until the "Service" menu is highlighted with a bar in the
multifunction display (A1p13).
Shown on model 212.002
Fig. 105: Identifying Multifunction Display, Scroll Forward/Back, System Selection And
Accept/Terminate Phone Call Buttons
Courtesy of MERCEDES-BENZ USA
4. Select "Tire pressure" with the scroll forward/back button (S110s1).
5. Press OK n/ (S110s6) press.
In the multifunction display (A1p13) the current tire pressures or the note "Tire pressure display
appears after driving for a few minutes".
6. Press scroll forward/back button (S110s1).
The note "Adopt current pressures as new guideline values" is shown in the multifunction display
(A1p13).
7. Press OK n/ (S110s6) press.
The note "Tire pressure monitoring active restart with OK" is shown in the multifunction display
(A1p13).
After a few minutes' driving the tire pressures are displayed and monitored.
8. Switch off ignition.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAV
Activate tire pressure loss warning
Before activating the tire pressure loss warning: Correct the tire pressure in all wheels Otherwise tire
pressures deviating from the specified value are monitored!
1. Switch on ignition.
2. Press scroll forward/back button (S110s1) repeatedly until "TIRE PRESSURE MONITORING
REACTIVATION WITH+" appears in the upper multifunction display (A1p13).
Fig. 106: Identifying Scroll Forward/Back Button And Upper Multifunction Display
Courtesy of MERCEDES-BENZ USA
3. Press the upper of the buttons + and -, adjustment of specific functions and volume control (S111s1).
4. To confirm the message "TIRE PRESSURE NOW OK?", press the upper of the + and - button,
adjustment of specific functions and volume control (S111s1).
The current tire pressure is only monitored after a teach-in phase while driving.
PERFORM ADJUSTMENTS TO THE CONTROL SYSTEM - AR54.30-P-1000-02RAW
Activate tire pressure loss warning.
Prior to activation of the tire pressure loss warning: Correct tire pressure in all wheels otherwise the tire
pressures deviating from the specified value will be monitored
1. Switch on ignition.
2. Press the system selection button (S110s3) repeatedly until the menu "Service" appears in bold in the
multifunction display (A1p13).
3. Use the scroll forward/back button (S110s1) to select "Tire pressure".
Fig. 107: Identifying Multifunction Display, System Selection Button And Scroll Forward/Back
Buttons
Courtesy of MERCEDES-BENZ USA
4. Press OK button (S110s6).
The note "Tire pressure monitoring active, reactivation with OK" appears in the multifunction display
(A1p13).
5. Press OK button (S110s6) to reactivate tire pressure monitoring.
"Tire pressure now OK?" appears in the multifunction display (A1p13).
6. Use the scroll forward/back button (S110s1) to select "Yes".
7. Press OK button (S110s6).
The note "Tire pressure monitor reactivated" appears in the multifunction display (A1p13).
8. Switch off ignition.
REMOVE/INSTALL NIGHT VIEW ASSIST CONTROL UNIT - AR54.30-P-3000SX
MODEL 212, 216.3, 218, 221.0 /1 with CODE (610) Night vision assist
Shown on model 221
Fig. 108: Identifying Night View Assist Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Switch off ignition and remove transmitter KEYLESS-GO start/stop button
1 key or KEYLESS-GO stop/start button from only on vehicles with code (889)
the EIS (EZS) control unit Keyless-Go.
Swivel inside rearview mirror (A67) to one
2
side
Model 212, 218, 221
3.1 Unclip and remove cover (1)
model 216 up to model year 2011
3.2 Slide cover (1) all way forward and remove Model 216 as of model year 2011
Model 212 with CODE (Z04) Light
armoring
4 Remove splinter protection
*BA63.20-P-
1004-01B
Unclip mounting clamp (2) and swing
5
downwards
Installation: Do not touch lens of
Remove Night View Assist camera (B84/2)
6 Night View Assist camera (B84/2) with
and disconnect electrical connector (3)
the fingers.
7 Install in the reverse order
The calibration target is required to
Calibrate Night View Assist camera (B84/2) calibrate the Night View Assist camera AD00.00-P-
8 (B84/2).
using Star Diagnosis 2000-04A
Calibration target for Night Vision
Assist gotis://E_82_03.0
PILLARS
Model 212 with code
Number Designation
Z04
BA63.20-P-1004- Nut/bolt, splinter guard to rain/light sensor guard
Nm 12
01B plate
REMOVE/INSTALL NIGHT VIEW ASSIST CONTROL UNIT - AR54.30-P-3100SX
MODEL 216.3, 221.0 /1 with CODE (610) Night vision assist
Shown on model 221
Fig. 109: Identifying Night View Assist Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to
AH54.00-P-
electronic components due to
0001-01A
electrostatic discharge
Switch off ignition and withdraw
transmitter key or Keyless Go Keyless Go start/stop button only for
1
start/stop button from the EIS vehicles with code (889) Keyless Go.
[EZS] control unit
Model 221.0/1 without code (Z07) Top AR68.30-P-
Remove left door sill molding
2 protection 4100SX
panel (1)
AR68.30-P-
Model 221.1 with CODE (Z07) Top protection
4100SXS
Loosen edge guard (2) in the lower
3
area of the A-pillar
Unhook floor covering (3) and
4
push to one side
Unscrew nuts (4) and remove
5 Night View Assist control unit
(N101)
6
(5)
7 Install in the reverse order
Calibrate Night View Assist When replacing Night View Assist control unit
8.1 (N101).
control unit (N101)
Calibration target for Night View Assist, refer
Connect STAR DIAGNOSIS and to GOTIS http://gotis.aftersales.mercedes- AD00.00-P-
read out fault memory benz.com 2000-04A
REMOVE/INSTALL ADDITIONAL FAN FOR INSTRUMENT CLUSTER/COMAND DISPLAY -
AR54.30-P-6000SX
MODEL 216.3, 221.0 /1
Fig. 110: Identifying Instrument Cluster/COMAND Display Fan Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR68.10-
1 Remove cover below instrument panel on left
P-1500SX
2 Unscrew bolt (1) and remove air duct (2)
3 Remove bolts (3)
Guide instrument cluster/COMAND display Installation: Counterhold air duct (5)
4 additional fan (M4/13) upwards out of the and insert instrument cluster/COMAND
put down in the footwell duct (5).
Detach instrument cluster/COMAND display
5
additional fan separation point (X120/1)
6 Install in the reverse order
REMOVE/INSTALL INSTRUMENT CLUSTER - AR54.30-P-6015SX
MODEL 216.3, 221.0 /1
Shown on model 221
Fig. 111: Identifying Instrument Cluster, Covering And Bolt
Courtesy of MERCEDES-BENZ USA
Remove/install
Store basic data from instrument cluster (A1) When installing new instrument
1.1 cluster (A1).
temporarily in STAR DIAGNOSIS
Installation: Transfer the
cached basic data to the new AD00.00-P-
Connect STAR DIAGNOSIS and read out instrument cluster (A1). 2000-04A
fault memory STAR DIAGNOSIS diagnosis *WH58.30-Z-
system 1048-13A
2 Move steering column back and down
Switch off ignition and withdraw transmitter Keyless Go start/stop button
3 key or Keyless Go start/stop button from the only for vehicles with code (889)
EIS [EZS] control unit Keyless Go.
In working area, cover trim strip on
4
instrument panel with clean rag
AR54.25-P-
5 Remove cockpit switch group
1000SX
Unclip covering (1) on instrument cluster
6 Fig. 9
(A1)
7 Remove bolts (2), remove instrument cluster
electrical connector at rear
Notes on avoiding damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
8 Install in the reverse order
Fig. 112: Identifying Long Wedge (115 589 03 59 00)
Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
REMOVE/INSTALL PARKTRONIC SYSTEM (PTS) CONTROL UNIT - AR54.65-P-0006SX
MODEL 221.0 /1 with CODE (220) Parktronic system (PTS)
Fig. 113: Identifying Parktronic System Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
Buffer basic data of the PTS control unit
1.1 When installing new Parktronic
(N62) in STAR DIAGNOSIS
Installation: Transfer the
Connect STAR DIAGNOSIS and read out AD00.00-P-
temporarily stored basic data to the
fault memory 2000-04A
new Parktronic control unit (N62).
Switch off ignition and withdraw transmitter Keyless Go start/stop button only
2 key or Keyless Go start/stop button from the for vehicles with code (889) Keyless
EIS [EZS] control unit Go.
Do not bend the hinge arm
passage frame (2) otherwise the
Loosen panel in side of luggage plastic will become discolored.
3 compartment (3) and swivel to one side until Vehicles without code (Z07) Top AR68.30-P-
the PTS control unit (N62) is accessible protection 4600SX
Vehicles with code (Z07) Top AR68.30-P-
protection 4600SXS
Separate electrical connectors on the PTS
4
control unit (N62)
5 Remove PTS control unit (N62)
6 Install in the reverse order
CALIBRATION OF THE BACKUP CAMERA - AR54.65-P-0022SX
MODEL 216.3, 221.0 /1 up to 31.5.07 with CODE (218) Backup camera
MODEL 207.3, 212.0 /1, 216.3, 218.3, 221.0 /1 with CODE (218) Backup camera with CODE (498) Japan
version
Shown on model 221
Fig. 114: Identifying Calibration Of Backup Camera
Courtesy of MERCEDES-BENZ USA
Calibrate backup camera
The backup camera must be calibrated in the
following cases:
After replacing the reversing camera control
unit
After removing the backup camera
After removing the trunk lid
After adjusting the trunk lid
After changes to the suspension which
influence the suspension level
After work on the steering system which
influences the learned steering angle values e.g.
replacing the steering angle sensor
Drive the vehicle onto a level
The suspension level must be on drive mode drive
1 surface and place the front wheels
mode.
in the straight-ahead position
Align the calibration template (1) If necessary fabricate the calibration template (1)
parallel and central to the vehicle as per the dimensions (B, C) (e.g. out of wood or
2
rear on the floor as per dimension cardboard packaging) and provide with contrast
(A) strips.
Connect Star Diagnosis, read out
See the menu item "Reversing camera control AD00.00-P-
3 fault memory and calibrate
unit" for instructions. 2000-04A
reversing camera
REMOVE/INSTALL BACKUP CAMERA CONTROL UNIT - AR54.65-P-0025SX
MODEL 216.3, 221.0 /1 up to 31.5.07 with CODE (218) Backup camera
MODEL 216.3, 221.0 /1 as of 1.6.07 with CODE (498) Japan version with CODE (218) Backup camera
Shown on model 221
Fig. 115: Identifying Backup Camera Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Switch off ignition and withdraw transmitter
Keyless Go start/stop button only for
1 key or Keyless Go start/stop button from the
vehicles with code (889) Keyless Go.
EIS [EZS] control unit
Do not bend the hinge arm passage
frame (2) otherwise the plastic will
Loosen the trim in the side of the luggage become discolored.
compartment (1) and swivel to one side until
2 Vehicles without code (Z07) Top AR68.30-P-
the backup camera control unit (N66/2) is
protection. 4600SX
accessible
Model 221.1 with code (Z07) Top AR68.30-P-
protection. 4600SXS
3 Unscrew the nuts (7) from the bracket (4)
Loosen nuts (5) and bolt (6), detach bracket (4)
4
and place to one side with lines connected
5 Remove backup camera control unit (N66/2)
6 Disconnect electrical connector (8)
7 Remove backup camera control unit (N66/2)
8 Install in the reverse order
When replacing the backup camera
control unit (N66/2).
The backup camera and steering AR54.65-P-
9 Calibrate backup camera control unit (N66/2)
angle sensor must be calibrated when 0022SX
the backup camera control unit (N66/2)
is replaced.
REMOVE/INSTALL BACKUP CAMERA - AR54.65-P-0030SX
MODEL 216.3, 221.0 /1 with CODE (218) Backup camera
Shown on model 221
Fig. 116: Identifying Backup Camera Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on model 221
Fig. 117: Identifying Backup Camera Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove license plate from trunk lid (1)
2 Remove umbrella holder (3)
Remove hazard warning triangle (5)
3
and detach bracket (4)
4 Remove cover (6)
5 Remove hinge bracket trim pieces (2)
6 Remove trunk lid paneling (7)
Pull backup camera connector Installation: Position backup camera
7 (B84/3x1) out of protective sleeve (8) connector (B84/3x1) with protective sleeve (8)
and separate free from chafing.
8 Remove bolts (9)
Unclip handle strip cover (13) from
Installation: Model 221 check adhesive
9 inside, starting at the right-hand side of
the tape (12) and replace if necessary.
Unclip backup camera (B84/3) from
10
the trunk lid (1)
11 Install in the reverse order
Vehicle up to 31.5.07 or with code (498) Japan
version
AR54.65-P-
12 Calibrate backup camera (B84/3) If only the backup camera (B84/3) was 0022SX
removed, the steering angle sensor does not
have to be calibrated.
REMOVE/INSTALL VOLTAGE SUPPLY OF BACKUP CAMERA - AR54.65-P-0032SX
MODEL 216.3, 221.0 /1 as of 1.6.07 with CODE (218) Backup camera except CODE (498) Japan version
Shown on model 221
Fig. 118: Identifying Backup Camera Voltage Supply Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
Switch off ignition and withdraw transmitter key Keyless Go start/stop button
1 or Keyless Go start/stop button from the EIS [EZS] only for vehicles with code (889)
control unit Keyless Go.
2 Open trunk floor paneling (3)
Do not bend the hinge arm
passage frame (2) otherwise the
Detach side paneling in luggage compartment (1) plastic will become discolored.
3 and swing to side until reversing camera power Vehicles without code (Z07) Top AR68.30-P-
supply module (N66/10) is accessible protection. 4600SX
Model 221.1 with code (Z07) Top AR68.30-P-
protection. 4600SXS
4 Separate electrical connectors (4)
Press catch tab (5) and pull backup camera voltage
5 supply module (N66/10) off bracket (arrow) and
remove
6 Install in the reverse order
REMOVE/INSTALL RADAR SENSORS CONTROL UNIT - AR54.65-P-0040SX
MODEL 221.0 /1 with CODE (229) Park Assist
Fig. 119: Identifying Radar Sensors Control Unit Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on avoiding damage to electronic AH54.00-P-
components due to electrostatic discharge 0001-01A
Do not bend the hinge arm
passage frame (2) otherwise the
Release side trim in luggage compartment (3) plastic will become discolored.
1 and swivel to one side until the radar sensor Vehicles without code (Z07) Top AR68.30-P-
control unit (SGR) (N62/1) is accessible protection 4600SX
Vehicles with code (Z07) Top AR68.30-P-
protection 4600SXS
Disconnect electrical connector (4) from radar
2
sensors control unit (SGR) (N62/1)
Remove radar sensors control unit (SGR)
3
(N62/1) from bracket (5)
4 Install in the reverse order
5.1 Check software release, update if necessary Only when replacing radar
sensors control unit (SGR)
Connect STAR DIAGNOSIS and read out fault (N62/1) or when replacing radar AD00.00-P-
memory sensors. 2000-04A
ACCESSORIES & BODY, CAB
Electrical System - Body - Basic Knowledge - S-Class (221)
BASIC KNOWLEDGE
ELECTRONIC TOLL COLLECTION (ETC) FUNCTION - GF82.88-P-0001SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
Location of components shown on model 221
Fig. 1: Locating Electronic Toll Collection Components
Courtesy of MERCEDES-BENZ USA
Networking of components
Fig. 2: Networking Of Electronic Toll Collection Components
Courtesy of MERCEDES-BENZ USA
Function
The Electronic Toll Collection System (ETC) is a component of the navigation system.
ETC was developed in order to simplify payments for toll roads. The electronic toll collection (ETC) antenna
and the electronic toll collection (ETC) control unit are installed in the vehicle for this purpose. An electronic
toll collection (ETC) antenna is used by the electronic toll collection (ETC) control unit to communicate with
the toll collection center and it automatically processes all payment modalities, without the driver having to stop
the vehicle. For automatic payment a special ETC card must be inserted into the electronic toll collection (ETC)
control unit. All information concerning the user and the fees that have already been paid are stored on this
card. The electronic toll collection (ETC) control unit is connected in the vehicle over an RS-232C interface to
the COMAND controller unit.
The ETC system also has voice output and visual output (pop-ups).
The voice output is:
ETC card read error
ETC card not accepted
ETC card reader error
ETC gate communication error
Detailed information about previous fee payments (if the UP or RPT button is pressed)
The pop-ups on the COMAND display are:
COMAND controller unit booted and no ETC card inserted ("Please insert ETC card into ETC unit, when
using ETC")
COMAND controller unit booted and ETC card inserted ("ETC is available. Please eject ETC card from
ETC unit, when you leave the vehicle for security.")
Approaching a fee payment station (e.g. "ETC gate on left side is permitted.")
Positive feedback from fee payment station ("Passing OK, Fee: xx.xx Yen")
Negative feedback (no authorization) ("Please Stop")
Electronic toll collection (ETC) control unit component description GF82.88-P-5000SXJ
Electronic toll collection (ETC) antenna component description GF82.88-P-5001SXJ
ELECTRONIC TOLL COLLECTION (ETC) TABLE OF CONTENTS FOR FUNCTION
DESCRIPTION - GF82.88-P-0999SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
GF82.88-P-
Electronic Toll Collection (ETC) function
0001SXJ
Overview of system components, Electronic Toll Collection (ETC) component GF82.88-P-
description 9999SXJ
ELECTRONIC TOLL COLLECTION, FUNCTION - GF82.88-P-2000LEJ
MODEL 216 with CODE (529) HIGH Class Japan as of model year 09/YoM 08
MODEL 221 with CODE (529) HIGH Class Japan as of model year 09/YoM 08
Function requirements
"Circuit 15R ON"
COMAND controller unit (A40/3) has been activated via the "ON" button (A40/9s6) at the front central
operating unit (A40/9)
Electronic Toll Collection System (ETC) card inserted
General
The ETC simplifies the process of payment on toll roads. It settles payment procedures automatically without
the driver having to stop the car.
The ETC has its own power supply. However, voice output is not possible when the COMAND controller
unit is switched off.
Function sequence
The Electronic Toll Collection antenna (ETC) (A2/94) and Electronic Toll Collection control unit (ETC)
(A50/3) are installed in the vehicle for transmitting and receiving the data. The Electronic Toll Collection
control unit (ETC) communicates with the toll booth over the ETC antenna. For automatic payment a special
ETC card must be inserted into the electronic toll collection (ETC) control unit. All information concerning the
user and the fees that have already been paid are stored on this card. At the vehicle side, the electronic toll
collection (ETC) control unit is connected via an RS-232C interface to the COMAND controller unit. The ETC
also has voice output and visual output (pop-ups).
The voice output is:
ETC card read error
ETC card not accepted
ETC card reader error
ETC gate communication error
Detailed information on the last fee payments (menu, navigation system, navigation system menu, ETC
history)
ETC card not inserted
Visual outputs (pop-ups) on the Audio/COMAND display (A40/8) are:
COMAND controller unit booted and no ETC card inserted
COMAND controller unit booted and ETC card inserted
Positive feedback from toll booth
Negative feedback (if no authorization)
Electrical function diagram for COMAND ETC Model 216 PE82.85-P-2058-97CAA
Model 221 PE82.85-P-2058-97SAA
COMAND controller unit, component description A40/3 GF82.85-P-3136LEJ
COMAND display, component description A40/8 GF54.30-P-6110LE
Front central operating unit, component description A40/9 GF54.21-P-4500LE
ELECTRONIC TOLL COLLECTION (ETC) CONTROL UNIT COMPONENT DESCRIPTION -
GF82.88-P-5000SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
Illustrated on model 221
Fig. 3: Locating Electronic Toll Collection Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The electronic toll collection (ETC) control unit is attached to a bracket and installed in the glove compartment
together with the bracket.
Tasks
The Electronic Toll Collection System (ETC) was developed to make payment easier on toll roads. A separate
electronic toll collection (ETC) antenna (A2/94) is used by the electronic toll collection (ETC) control unit to
communicate with the toll collection center and it automatically processes all payment modalities, without the
driver having to stop the vehicle.
ELECTRONIC TOLL COLLECTION (ETC) ANTENNA COMPONENT DESCRIPTION - GF82.88-P-
5001SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
Illustrated on model 221
Fig. 4: Locating Electronic Toll Collection Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The electronic toll collection (ETC) antenna is installed on the dashboard behind the windshield on a bracket.
Tasks
The electronic toll collection (ETC) antenna transmits and receives the Electronic Toll Collection System (ETC)
signals to/from the toll collection center that are processed by the electronic toll collection (ETC) control unit
(A50/3).
OVERVIEW OF SYSTEM COMPONENTS, ELECTRONIC TOLL COLLECTION (ETC)
COMPONENT DESCRIPTION - GF82.88-P-9999SXJ
MODEL 221.0 /1 with CODE (498) Japan version up to Model Year 8
MODEL 216.3 with CODE (498) Japan version up to Model Year 8
Electronic Toll Collection (ETC) control unit component description GF82.88-P-5000SXJ
Electronic Toll Collection (ETC) antenna component description GF82.88-P-5001SXJ
Electronic Toll Collection (ETC) table of contents for function description GF82.88-P-0999SXJ
MULTIFUNCTION STEERING WHEEL, FUNCTION - GF82.90-P-0001SX
MODEL 221 up to model year 08/YoM 07 Illustrated:
Fig. 5: Identifying Multifunction Steering Wheel Buttons
Courtesy of MERCEDES-BENZ USA
Illustrated:
Fig. 6: Identifying Steering Wheel Gear Shifters
Courtesy of MERCEDES-BENZ USA
Networking of components
Fig. 7: Networking Of Multifunction Steering Wheel Components
Courtesy of MERCEDES-BENZ USA
The multifunction steering wheel (MFL), in combination with the multifunction display (A1p13) of the
instrument cluster (A1), serves to enhance active driving safety in road traffic. The driver can concentrate on the
traffic without distraction when controlling and operating various vehicle components. The MFL allows the
driver to operate and call up the systems and their submenus: The number of menus is dependent on the vehicle
equipment level. e. :
Cellular telephone
Audio
Navigation
Vehicle and setting configuration
Fault and warning messages (if applicable)
Tire pressure monitor
The selected system is displayed in the multifunction display of the instrument cluster.
The fanfare horns are operated via the impact plate of the multifunction steering wheel.
When changing to another system, the start screen of the selected system is always displayed and not the
submenu last selected in this system.
Left multifunction steering wheel button group
The left multifunction steering wheel button group contains the system selection button (S110s3), OK button
(S110s6) and the scroll forward/back button (S110s1). Each of the systems can be called with the system
selection button. It is possible here to "scroll" forward and backward from system to system. It is also possible
to "scroll" forward and backward with the scroll forward and backward button within a system, i.e. additional
submenus can be called up. The OK button can be used to accept the selection.
Right multifunction steering wheel button group
The right multifunction steering wheel button group contains the accept/terminate phone call button (S111s3),
and the buttons + and - for setting of specific functions and volume control (S111s1). A telephone call can be
accepted or terminated with the accept/ terminate phone call button.
The buttons + and - for setting specific functions and volume control can be used to adjust the volume of the
currently active system.
VCS [SBS] on button
The VCS [SBS] on button can be used to activate the voice control system (VCS [SBS]). An acoustic signal is
emitted after activation has taken place.
"Back" and SBS off button
The "Back" and SBS off button is used to deactivate the voice control system.
Signal transmission
The signals are read in via the steering LIN by the steering column module (N80) and transferred to the chassis
CAN.
Steering wheel gear shift
The following functions are possible using the left steering wheel gear shifter and right steering wheel gear
shifter:
Preselection of shift range.
Shifting into a gear from which the vehicle can be easily accelerated or decelerated.
Direct shifting of all forward gears.
Transfer of shift signals
The left steering wheel gear shifter and right steering wheel gear shifter are read in via the steering LIN by the
steering column module. The steering column module transfers the "Upshift" or "Shift down" signal to the
chassis CAN. The ETC [EGS] control unit (N15/3) actuates the gear change.
Gear shifts which would lead to impermissibly high or low motor speeds are not carried out.
Scanning of switch positions, function GF82.90-P-3001SX
REAR ENTERTAINMENT, LOCATION OF COMPONENTS - GF82.90-P-0002-01LE
up to 31.5.09
Fig. 8: Locating Rear Entertainment Components (Up To 31.5.09)
Courtesy of MERCEDES-BENZ USA
As of 1.6.09 with code (810) Sound system
Fig. 9: Locating Rear Entertainment Components (With Code 810 Sound System)
Courtesy of MERCEDES-BENZ USA
As of 1.9.10 with code (811) Advanced Sound-System
Fig. 10: Locating Rear Entertainment Components (With Code 811 Advanced Sound System)
Courtesy of MERCEDES-BENZ USA
REAR ENTERTAINMENT BLOCK DIAGRAM - GF82.90-P-0002-03LE
up to 31.5.09
Fig. 11: Rear Entertainment Block Diagram (up To 31.5.09)
Courtesy of MERCEDES-BENZ USA
Fig. 12: Rear Entertainment Block Diagram (With Code 810 Sound System)
Courtesy of MERCEDES-BENZ USA
As of 1.6.09 with code (810) Sound system
As of 1.9.10 with code (811) Advanced Sound System
Fig. 13: Rear Entertainment Block Diagram (With Code 811 Advanced Sound System)
Courtesy of MERCEDES-BENZ USA
REAR ENTERTAINMENT, OPERATING INSTRUCTIONS - GF82.90-P-0002-04LE
The operating instructions for the rear entertainment system are compiled as follows:
"ON/OFF" button on the left rear display (A40/5) or on the right rear display (A40/6)
Left screen button (N72/2s5) or right screen button (N72/2s4)
Rear rotary pushbutton (N72/2s8) on RCP [HBF] control unit (N72/2)
Left "Back" button (N72/2s7) or right "Back" button (N72/2s6)
Screen layout
Operating the disc applications
Operation of TV application (with code (863) Digital/analog TV tuner)
Operating the AUX application
System settings
Multi user
ON/OFF button on the rear display
When the "ON/OFF" button on the rear display is pressed, the corporate identity screen is displayed first for
approx. 6 s. Then the last rear entertainment application called up on the particular rear display is started. The
application used last is stored when the particular rear display is switched off.
Screen button
The left screen button activates the left rear display for menu guidance and the right screen button activates the
right rear display for menu guidance.
Rear rotary pushbutton on RCP [HBF] control unit
The menus or menu items displayed on the particular rear display can be selected using the rear rotary
pushbutton on the RCP [HBF] control unit.
To this end, the rear rotary pushbutton can be actuated in the following ways:
Turn to the left or right
Push to the front, rear, left or right
Press down vertically
In order to move within a menu bar (status bar, application bar, application field, function bar or system
setting), the rear rotary pushbutton is turned or pushed to the left or right. The rear rotary pushbutton is pressed
down vertically in order to select a menu or menu item in the particular menu bar or confirm a setting. The rear
rotary pushbutton is pushed forward (line above) or to the rear (line below) in order to change the menu bar.
Button "Back"
The next menu level up is accessed using the left "Back" button or the right "Back" button.
Screen layout
The screen of the particular rear display is divided into the 5 areas listed below (from top to bottom):
Status bar
Application bar ("Disc", "TV" (with code (863) Digital/analog TV tuner, "AUX1", "AUX2")
Application field
Function bar (subfunctions depending on application)
System settings ("Display", "Language", "Speakers")
Operating the disc applications
If the "Disc" menu item is activated, the screen relating to the application appears on the particular rear display.
A distinction is made here between the following media types:
Audio or MP3-CD
Video or MP3-DVD
Audio or MP3-CD
If an audio or MP3-CD is in the DVD drive of the DVD player (A40/4), the corresponding screen is displayed
when the "Disc" menu item is activated.
The following information is displayed in the application field of the particular rear display:
Number of current title
Elapsed time of the current track
Number of tracks on the CD
Playback mode
In addition, the following actions are also possible:
Setting options via the function bar
Track selection using skip function
Fast Forward or Rewind
Setting options via the function bar
"CD":
Playback mode ("Normal track sequence", "Track mix")
"Track list":
List for directly selecting tracks (e.g. track 1 or track 2, etc.)
Title selection using skip function
Turning or pushing the rear rotary pushbutton to the left will play the track that is before the current track in the
track list. Turning or pushing the rear rotary pushbutton to the right will play the track after the current track.
Fast Forward or Rewind
The playback position can be changed by pushing and holding the rear rotary pushbutton to the right (forward)
or left (back).
Video or MP3-DVD
If a video or MP3-DVD is in the DVD drive of the DVD player, the corresponding screen is displayed when the
"Disc" menu item is activated.
The DVD video picture is displayed in the application field of the particular rear display.
In addition, the following actions are also possible:
Setting options via the function bar
Chapter selection using skip function
Fast Forward or Rewind
Full screen
Setting options via the function bar
"DVD-V":
Settings menu ("DVD functions", "Brightness", "Contrast", "Color", "16:9 optimized", "4:3" or
"Wide screen")
Pause:
Temporarily interrupts playback; the current position is stored and the menu item changes to "Play"
Stop:
Stops playback
Chapter selection using skip function
Operation of TV application (with code (863) Digital/analog TV
Turning or pushing the rear rotary pushbutton to the left will play the chapter that is before the current chapter
in the chapter list. Turning or pushing the rear rotary pushbutton to the right will play the chapter after the
current chapter.
Fast Forward or Rewind
The playback position can be changed by pushing and holding the rear rotary pushbutton to the right (forward)
or left (back).
Full screen
If the slider is in the application field, the "Full screen" option can be selected. Selecting this option causes the
menu bars to be hidden and the video image to fill the entire screen. Full-screen mode is deactivated by pressing
image is now displayed only in the application field.
tuner)
When the "TV" menu item is activated and the TV combination tuner (analog/digital) (A90/1) is ready, the
corresponding screen appears.
The TV picture is displayed in the application field.
In addition, the following actions are also possible:
Setting options via the function bar
Full screen
Setting options via the function bar
"TV":
Settings menu ("Brightness", "Contrast", "Color", "16:9 optimized", "4:3" or "Wide screen")
Full screen
If the slider is in the application field, the "Full screen" option can be selected. Selecting this option causes the
menu bars to be hidden and the TV image to fill the entire screen on the corresponding rear display. Full-screen
mode is deactivated by pressing the rear rotary pushbutton down vertically. The menu bars are shown again
immediately and the video image is now displayed only in the application field.
Operating the AUX application
From the application bar it is possible to operate two devices connected to the DVD player. The devices at the
AUX inputs are recognized automatically. The relevant screen is displayed, depending on whether a device with
video or audio output is detected. The respective connected device is, however, not controlled by the DVD
player but by the actual device connected at the AUX input. A distinction is made here between the following
device types:
Video equipment
Audio equipment
Video equipment
If video equipment is recognized at the AUX input, the video picture received is displayed in full-screen mode
on the particular rear display. Pressing the rear rotary pushbutton down vertically ends full-screen mode. The
corresponding screen appears.
Using the menu item in the function bar it is possible to modify the following audio and video settings:
"AUX":
Settings ("Brightness", "Contrast", "Color", "16:9 optimized", "4:3" or "Wide screen")
Audio equipment
If audio equipment is recognized at the AUX input, the corresponding screen appears.
Using the menu item in the function bar it is possible to modify the following settings:
"AUX":
No settings possible
System settings
In the system settings it is possible to make changes in the following menu items:
"Display"
"Language"
"Speakers" (with code (810) Sound system)
"Display"
The "Display" menu item offers the following options for the particular rear display:
"Display off"
"Day screen"
"Night screen"
"Automatic"
"Language"
The system language is selected in the "Language" menu item.
"Speakers" (with code (810) Sound system)
The audio tuner control unit (N93/1) outputs the audio signals over the speaker system via direct lines as a
function of the volume set at the COMAND controller unit (A40/3). From the "Speakers" menu item it is
possible to select whether the analog audio signals of the rear display are to be audible over the speaker system.
This option is only available if both rear displays are switched on. If just one rear display is switched on,
the analog audio signal of this rear display is output automatically.
Multi user
If both rear displays are in use, a distinction is made between one active and one passive side. Active in this
If, for example, the right rear display is active, then the user on the left rear side must first activate his/her left
rear display to be able to change any settings. The right rear display or the left rear display can be activated
using the left screen button or the right screen button on the RCP [HBF] control unit (N72/2).
REAR ENTERTAINMENT, OPERATING INSTRUCTIONS - GF82.90-P-0002-04LEA
Remote control (F) for operating rear entertainment system
Fig. 14: Identifying Remote Control Buttons For Operating Rear Entertainment System
Courtesy of MERCEDES-BENZ USA
Rear entertainment system, general
The rear entertainment system is operated using the system's remote control. Menu guidance uses the left rear
display (A40/5) or the right rear display (A40/6) and the navigation buttons, which after being selected must be
confirmed using the "OK" button. The following basic functions can be controlled:
"DISC" basic function
"TV" basic function (with code (863) Digital/analog TV tuner)
"COMAND" basic function
"Aux" base function
"System" base function
"DISC" basic function
The "Disc" base function is started automatically by inserting a CD/ DVD into the DVD player (A40/4). It can
If the "Disc" base function is called up by means of the remote control and there is no data storage device
in the DVD player, a fault message appears on the rear display.
The following information is shown on the rear display:
Data storage device type ("CD", "DVD-A", "DVD-V", "MP3")
Track number
Track name (if stored on data storage device)
Elapsed playback time
Graphical time and track display
Current playback option
Function bar with appropriate items
The function bar can be used to select the following items and to make settings:
Playback options:
"CD" (in CD mode)
"DVD-A" (in audio DVD mode)
"DVD-V" (in video DVD mode)
"MP3" (in MP3 mode)
Pause (in DVD mode)
Stop (in DVD mode)
"Track list" (in CD/DVD mode) or "Folder" (in MP3 mode)
"Treble"
"Bass"
The following playback options are available:
"Normal track sequence"
"Track shuffle" (in CD/DVD mode)
"Folder shuffle" (in MP3 mode)
Playback errors can occur when copied audio or video data storage devices are played back.
The large number of available data storage devices means that it is impossible to guarantee that the rear
entertainment system can play back all copied CDs/DVDs.
"TV" basic function (with code (863) Digital/analog TV tuner)
If the "TV" basic function is called up, the TV screen is displayed in full-screen mode in the application field on
the active rear display. A control menu displaying the station currently selected appears in the status bar.
The function bar can be used to select the following items and to make settings:
"TV":
"Station list" (receivable stations)
"Channel input" (precise channel input)
"Brightness"
"Contrast"
"TV standard"
"Audio"
"Auto memory"
"Preset station buttons"
"Info"
"Text" (videotext)
"Treble"
"Bass"
"COMAND" basic function
The "COMAND" basic function is called up using the remote
"Color"
"16:9 optimized"
"4:3"
"Wide screen"
"Fix channel"
control ("COMAND" option in the basic screen).
The appropriate basic screen appears on the rear display.
The function bar can be used to select the following items and to make settings:
"COMAND switched off"
"No COMAND source active"
"Aux" base function
The "Aux" base function is called up using the remote control (select "Aux" in the basic screen).
The appropriate basic screen appears on the rear display.
The function bar can be used to select the following items and to make settings:
"COMAND"
"Source"
"Aux drive"
"Aux display"
"COMAND"
"Treble"
"Bass"
"System" base function
The system settings are used to define screen-related settings such as design and language.
All system settings can be made individually for each rear display without influencing the other rear display.
"Settings"
"Language" (system language)
"Day design"
"Night design"
"Automatic"
"Brightness"
"Display off"
REAR ENTERTAINMENT, FUNCTION - GF82.90-P-0002LE
MODEL 221 with CODE (864) Rear entertainment system as of model year 2009 /YoM 08
Function requirements, general
Circuit 30g ON
Rear entertainment system general
The rear entertainment system uses CD/DVD data storage devices to provide audiovisual entertainment for the
rear passengers. An AUX connector, e.g. DVD player, MP3 player, video camera or games console can be
connected to the rear entertainment system. For vehicles with code (863) Digital/analog TV tuner the rear
passengers can also enjoy TV station reception.
The rear entertainment system comprises the following components:
DVD player (A40/4)
Left rear display (A40/5)
Right rear display (A40/6)
Cable-connected headphones or as of 1.6.09 infrared (IR) and as of 1.9.10 wifi headphones (cordless)
RCP (HBF) control unit (N72/2) (up to 31.5.09)
IR remote control
As of 1.6.09 the RCP (HBF) control unit functions are implemented using the IR remote control.
The rear entertainment system is enhanced by the optional use of the following components:
Audio tuner control unit (with code (N93/1) (with code 810) Sound system)
Digital sound processor (A2/69) (as of 1.9.10 with code (811) Advanced Sound System)
TV combination tuner (analog/digital) (A90/1) (with code (863) Digital/analog TV tuner)
The following media sources are available to the rear passengers:
AUX
Audio CD / DVD or MP3-CD / DVD
Video DVD
TV (with code (863) Digital/analog TV tuner)
The DVD player and the rear displays are subscribers of the telematics CAN (CAN A) and communicate with
the following control units:
COMAND controller unit (A40/3)
TV combination tuner (analog/digital)
RCP (HBF) control unit (up to 31.5.09)
For vehicles with code (810) Sound system or code (811) Advanced Sound System and code (863)
Digital/analog TV tuner, data is exchanged through the following control units over the Media Oriented System
Transport (MOST):
COMAND control unit
TV combination tuner (analog/digital)
Audio tuner control unit
The rear entertainment system is operated through the controls on the remote control. Rear passengers can then
select the menus in line with the menu guidance for each active rear display.
The control signals for the remote control are sent over IR interfaces to each active rear display or the
SPLITVIEW display (A40/10).
The rear entertainment system also provides access to the active audio, AUX, video or TV application of the
COMAND controller unit over the IR interface of the SPLITVIEW display. To this end, the IR remote control
enables the media source of the COMAND controller unit for the rear entertainment system to be selected and
activated in the menu of the currently active rear display.
The rear passengers basically have access to each media source of the COMAND controller unit, except the
media interface. It is not possible however, to have front and rear passengers call up different media sources at
the same time (except with code (518) Media interface).
Audio signals are sent over the IR interfaces or radio frequencies (as of 1.9.10) from the rear display to the
headphones (cordless). If corded headphones are used, the audio signals are transmitted as analog signals from
the rear display to the headphones via a cable. Rear passengers can also listen to audio on the vehicle's speaker
system.
The rear entertainment system consists of the following subfunctions, which are described in separate
documents:
Rear entertainment switch on/off behavior and system settings, function
Rear entertainment disk applications, function
Rear entertainment TV reception function (with code (863) Digital/analog TV tuner)
Rear entertainment AUX applications, function
GF82.90-P-0002-
Rear entertainment, location of components
01LE
GF82.90-P-0002-
Rear entertainment block diagram
03LE
GF82.90-P-0002-
Rear entertainment, operating instructions Up to 31.5.09
04LE
GF82.90-P-0002-
As of 1.6.09
04LEA
Rear entertainment switch on/off behavior and GF82.90-P-
Up to 31.5.09
system settings, function 2002LE
GF82.90-P-
As of 1.6.09
2002LEA
GF82.90-P-
Rear entertainment disk applications, function Up to 31.5.09
2003LE
GF82.90-P-
As of 1.6.09
2003LEA
Up to 31.5.09
GF82.90-P-
Rear entertainment, TV reception, function For code (863) Digital/analog
1003LE
TV tuner
As of 1.6.09
GF82.90-P-
For code (863) Digital/analog
1003LEA
TV tuner
GF82.90-P-
Rear entertainment AUX applications, function Up to 31.5.09
2004LE
As of 1.6.09 2004LEA
REAR ENTERTAINMENT, FUNCTION - GF82.90-P-0002SX
MODEL 221.0 /1 with CODE (864) Rear entertainment system except CODE (494) USA version up to
Model Year 8
The rear entertainment is the overall entertainment system for passengers in the rear.
The central elements of the rear entertainment are the
audio/video controller control unit (N66/3),
left rear display (A40/5),
right rear display (A40/6) and
RCP [HBF] control unit (N72/2).
Function requirements
All functions are available as of an active circuit 30G. The system can be made operational by switching on the
rear display (left rear display and right rear display).
The functions of the audio tuner control unit (N93/1) (with code (810) Sound system) are rendered available
when the COMAND control unit (A40/3) and circuit 15R are switched on.
Rear entertainment overview (full equipment)
Fig. 15: Identifying Rear Entertainment Components
Courtesy of MERCEDES-BENZ USA
Rear entertainment block diagram
Fig. 16: Rear Entertainment Block Diagram
Courtesy of MERCEDES-BENZ USA
Audio/video controller control unit
The central element of the system is the audio/video controller control unit. It controls the
integrated DVD disk drive,
TV combination tuner (analog/digital) and
optional devices, which may be connected to the AUX inputs.
Fig. 17: Identifying Audio/Video Controller Control Unit
Courtesy of MERCEDES-BENZ USA
The audio/video controller control unit enables rear passengers to use all audio and video sources installed on
and in the control unit during a journey irrespective of the COMAND control unit actually installed in it.
The user can operate the audio/video controller control unit using the RCP [HBF] control unit and the rear
display control buttons.
The audio/video controller control unit is connected over the telematics CAN with the COMAND control unit.
The COMAND control unit (with code (810) Sound system) controls the audio signal output over the vehicle
speakers.
To this end, the signals are sent over an analog connection from the audio/video controller control unit to the
audio tuner control unit.
Additionally, the audio signals are also emitted over headphones, which can be connected to the 3.5 mm
headphone socket on the rear displays.
Image transmission between the TV combination tuner (analog/ digital) and audio/video controller control unit
is by way of a direct connection.
Playing CDs and DVDs with the DVD player
The DVD player is integrated into the audio/video controller control unit.
The interface is generated by the audio/video controller control unit and is shown on the rear displays.
Headphones are used for the audio output. On vehicles equipped with a sound system (Code 810), audio signal
output can also take place via the audio tuner control unit and the vehicle speakers.
Additional functions over the AUX inputs
The AUX inputs of the audio/video controller control unit can be used to connect two additional video/audio
devices on the rear entertainment system.
External devices can be e.g.
portable DVD player,
video camera,
MP3 player and
games consoles.
RCP [HBF] control unit
The user can actuate the rear entertainment functions at the RCP [HBF] control unit.
Fig. 18: Identifying RCP Control Unit
Courtesy of MERCEDES-BENZ USA
The settings desired by the user can be made using the following controls:
Turn/push control
Left "Activate screen" button
Right "Activate screen" button
"Back" button (twice)
Television reception by TV combination tuner (analog/digital)
Fig. 19: Identifying TV Combination Tuner (Analog/Digital) And Audio Tuner Control Unit
Courtesy of MERCEDES-BENZ USA
The TV combination tuner (analog/digital) provides the following functions:
Multistandard color (PAL, NTSC, Secam), multistandard sound and channel lists
Integrated DVB-T for digital TV reception (ECE)
Station identification (name of television channel)
Station comparison and alternatively sound comparison for analog operation or over a so-called "service
descriptor" for digital operation
List of stations with maximum 100 stations that can currently be received
Playing part of a track, function
Teletext with page memory
Digital image storage for bypassing "dead zones"
Adaptive Video quality evaluation
Parallel sound scheme with quality assessment
The interface is generated by the audio/video controller control unit and shown on the rear displays (left rear
display, right rear display).
It is possible to make settings to the brightness, contrast, color, bass and treble from the rear. Channel selection,
however, can only be made using the COMAND control unit and the front central operating unit.
Headphones are used for the audio output.
On vehicles equipped with a sound system code (810), audio signal output can also take place over the audio
tuner control unit and the vehicle speakers.
The audio tuner control unit is connected to the Media Oriented System Transport (MOST). Control takes place
by the COMAND control unit.
Left rear display, right rear display
The rear displays, which are integrated into the head restraints, are used for visualization of all application-
relevant data in the rear entertainment system.
Fig. 20: Identifying Rear Displays
Courtesy of MERCEDES-BENZ USA
This means e.g. graphical displays for user guidance and operation as well as the display of video signals.
Each display has buttons for switching on/off and for regulating brightness and volume.
Apart from this, a photo sensor has been integrated for automatic brightness adaptation as well as a headphone
connection (3.5 mm).
For transmission of audio and video signals between the audio/ video controller control unit and the rear
displays, the so-called LVDS standard (LVDS = Low-Voltage Differential Signaling) is used.
Communication between the rear displays, audio/video controller control unit and other components in the rear
entertainment system takes place over the telematics CAN.
RCP [HBF] control unit, component
GF54.21-P-4510SX
description
Audio/video controller, component
GF82.60-P-3102SX
description
With code (863) Digital/analog TV
TV tuner, component description GF82.60-P-3110SX
Audio tuner control unit, component
Except code (810) Sound system GF82.62-P-3132SX
description
GF82.62-P-
with CODE (810) Sound system
3132SXS
COMAND control unit, component
except CODE (498) Japanese version GF82.85-P-3136SX
description
GF82.85-P-
with CODE (498) Japan version
3136SXJ
Left/right rear display, component
GF82.90-P-4020SX
description
TABLE OF CONTENTS, FUNCTION DESCRIPTION, REAR AREA ENTERTAINMENT - GF82.90-
P-0998LE
MODEL 221 with CODE (864) Rear entertainment system as of model year 2009 /YoM 08
GF82.90-P-
Rear entertainment, function
0002LE
GF82.90-P-0002-
Rear entertainment, location of components
01LE
GF82.90-P-0002-
Rear entertainment block diagram
03LE
GF82.90-P-0002-
Rear entertainment, operating instructions Up to 31.5.09
04LE
GF82.90-P-0002-
As of 1.6.09
04LEA
Rear entertainment switch on/off behavior and GF82.90-P-
Up to 31.5.09
system settings, function 2002LE
GF82.90-P-
As of 1.6.09
2002LEA
GF82.90-P-
Rear entertainment disk applications, function Up to 31.5.09
2003LE
GF82.90-P-
As of 1.6.09
2003LEA
Up to 31.5.09
GF82.90-P-
Rear entertainment, TV reception, function For code (863) Digital/analog
1003LE
TV tuner
As of 1.6.09
GF82.90-P-
For code (863) Digital/analog
1003LEA
TV tuner
GF82.90-P-
Rear entertainment AUX applications, function Up to 31.5.09
2004LE
GF82.90-P-
As of 1.6.09
2004LEA
Overview of system components for rear GF82.90-P-
entertainment system 9995LE
LIST OF CONTENTS, FUNCTION DESCRIPTION, REAR ENTERTAINMENT - GF82.90-P-0998SX
MODEL 221.0 /1 with CODE (864) Rear entertainment system except CODE (494) USA version up to
Model Year 8
Rear entertainment, function GF82.90-P-0002SX
Overview of rear entertainment system components, component description GF82.90-P-9996SX
MULTIFUNCTION STEERING WHEEL, FUNCTION DESCRIPTION CONTENTS - GF82.90-P-
0999SX
MODEL 221 up to model year 08/YoM 07
GF82.90-P-
Multifunction steering wheel, function
0001SX
GF82.90-P-
Scanning of switch positions, function
3001SX
Overview of system components for multifunction steering wheel, component GF82.90-P-
description 9997SX
REAR ENTERTAINMENT, TV RECEPTION, FUNCTION - GF82.90-P-1003LE
MODEL 221 up to 31.5.09 with CODE (864) Rear entertainment system with CODE 863 Digital/analog
TV tuner as of model year 2009 /YoM 08
Function requirements, general
Circuit 30g ON and telematics CAN (CAN A) for t = 10 min active (a vehicle door is opened)
Rear entertainment TV reception general
The TV combination tuner (analog/digital) (A90/1) (with code (863) Digital/analog TV tuner) provides all the
customary playback options familiar from the predecessor model series. The interface is generated by the DVD
player (A40/4) in the "TV" menu and shown on the screen of the left rear display (A40/5) or right rear display
(A40/6).
The TV application and the relevant settings (brightness, contrast and color) can be called up and modified
using the controls on the RCP (HBF) control unit (N72/2):
Right screen button (N72/2s4)
Left screen button (N72/2s5)
Right "Back" button (N72/2s6)
Left "Back" button (N72/2s7)
Rear rotary pushbutton (N72/2s8)
The signals for the listed controls on the RCP (HBF) control unit are read in by the RCP (HBF) control unit and
sent over the telematics CAN to the DVD player. The additional settings using the respective buttons on the rear
display are also sent over the telematics CAN to the DVD player.
When the left rear display is switched on, the TV application can only be run on the left rear display.
When the right rear display is switched on, the TV application can only be run on the right rear display.
When the left rear display and right rear display are switched on, the TV application can be called up on both
rear displays. Only when operating the TV application through the RCP (HBF) control unit does the left screen
button or the right screen button need to be used to select the corresponding display.
The "Rear entertainment TV reception" function consists of the following subfunctions:
Selection of TV channel function sequence
Function sequence for settings in "TV" menu on rear display
Transmission of audio and picture signals function sequence
Selection of TV channel function sequence
The TV channel is chosen through the COMAND controller unit (A40/3) and the front central operating unit
(A40/9). The screen button is used to activate the menu on the rear display screen. The user can select the "TV"
menu with the aid of the front central operating unit and then the desired TV channel through the COMAND
display (A40/8).
The TV combination tuner receives the TV signals from the TV antennas 1 to 4 in the rear window over the
following path:
Direct lines
Rear window antenna amplifier module (A2/12)
Direct lines
The front central operating unit sends the control signals over the telematics CAN to the COMAND controller
unit. The COMAND controller unit evaluates them, generates the picture signals for the interface on the
COMAND display and sends them over a low voltage differential signal (LVDS) line to the COMAND display.
The COMAND controller unit also sends the control signals of the front central operating unit over the Media
Oriented System Transport (MOST) to the TV combination tuner.
The TV combination tuner then sends, on the one hand, the signals of the received and selected TV channel
over a direct line to the COMAND controller unit and, on the other hand, the analog audio signals over a stereo
line and the analog picture signals over a Y-brightness (luminance)/C-color information (chrominance) (Y/C)
line to the DVD player.
The DVD player forwards the analog audio and picture signals over a low voltage differential signaling line to
the respective display. The user interface is displayed on the screen of the respective rear display.
Function sequence for settings in "TV" menu on rear display
The DVD player generates the interface for the "TV" menu item on the rear display screen. With the aid of the
listed controls on the RCP (HBF) control unit the following menu in the function bar can be used to change the
relevant settings:
"TV":
Settings ("Brightness", "Contrast", "Color", "16:9 optimized", "4:3" or "Wide screen")
The following setting can also be made:
Full screen
Full screen
If the slider is in the application field, the "Full screen" option can be selected. Selecting this option
causes all the menu bars to be hidden and the video picture to fill the entire screen on the rear display.
Full-screen mode is deactivated by pressing the rear rotary pushbutton down vertically.
The hidden menu bars are shown again immediately and the video image is now displayed only in the
application field.
The signals for the listed controls on the RCP (HBF) control unit are read in by the RCP (HBF) control
unit and sent over the telematics CAN to the DVD player. The DVD player evaluates these signals.
Transmission of audio and picture signals function sequence
After the signals of the receiving and selected TV channel are received by the TV combination tuner and
after the signals for the listed controls on the RCP (HBF) control unit and the relevant buttons on the rear
display are received, the DVD player then generates the audio and picture signals.
The audio and picture signals are sent by the DVD player over the respective low voltage differential
signaling line to the rear display. The picture signals are shown on the screen of the rear display.
The signals for this are transmitted by the COMAND controller unit via the Media Oriented System
Transport (MOST) to the audio tuner control unit (N93/1).
The DVD player sends the audio signals over a direct line to the audio tuner control unit. The audio tuner
control unit emits the audio signals at the following speakers:
Left rear door speaker group (H4/3)
Right rear door speaker group (H4/4)
Audio signals are emitted over the headphones that are connected to the headphones socket on the rear
display.
Alternatively, the audio signals for vehicles with code (810) Sound system can also be emitted through
the vehicle's speaker system. The audio signals are output at the volume set at the COMAND controller
unit.
Bass module speaker (H4/17)
Center cockpit speaker (centerfill) (H4/27)
Left rear surround speaker (H4/54)
Right rear surround speaker (H4/57)
Left front door Sound tweeter (H4/68)
Right front door Sound tweeter (H4/69)
Left front door Sound woofer and midrange speaker group (H4/72)
Right front door Sound woofer and midrange speaker group (H4/73)
Electrical function schematic
PE82.90-P-
for rear entertainment TV
2053-97SAA
reception
A40/3 With code (526) COMAND with single
Component description for DVD drive (without navigation) or with code (527) GF82.85-P-
COMAND controller unit COMAND APS with single DVD drive (with 3136LE
navigation)
Component description for
GF82.90-P-
rear entertainment DVD A40/4
4009LE
player
Component description for GF82.90-P-
A40/5, A40/6
rear display left/ right 4020LE
COMAND display, GF54.30-P-
A40/8 Without code (867) SPLITVIEW
component description 6110LE
Front central operating unit, GF54.21-P-
A40/9
component description 4500LE
TV combination tuner
GF82.90-P-
(analog/digital), component A90/1 For code (863) Digital/analog TV tuner
4019LE
description
RCP [HBF] control unit, GF54.21-P-
N72/2
component description 4510LE
Audio tuner control unit, GF82.62-P-
N93/1 With code (810) Sound system
component description 3132LES
REAR ENTERTAINMENT, TV RECEPTION, FUNCTION - GF82.90-P-1003LEA
MODEL 221 with CODE (864) Rear entertainment system with CODE 863 Digital/analog TV tuner as of
model year 2010 /YoM 09 model refinement package
Function requirements, general
Telematics CAN (CAN A) active
Rear entertainment system is switched on
Rear entertainment, TV reception, general
The TV picture and the interface are generated by the left rear display (A40/5) or right rear display (A40/6)
when the "TV" menu in the application bar is selected and shown on the screen of the particular display.
The TV reception function is operated using the remote control.
The control signals are transmitted to the following components via infrared (IR) interfaces:
SPLITVIEW display (A40/10) (with code (867) SPLITVIEW)
Left rear display
Right rear display
When the TV application is started, the TV picture appears on the rear display in full-screen mode. A control
menu displaying the station currently selected appears in the status bar of the rear display.
Irrespective of the settings on the COMAND controller unit (A40/3), the analog and digital TV stations
that can currently be received can be selected for the rear display.
Function sequence for TV reception
The TV combination tuner (analog/digital) (A90/1) receives TV signals from TV antennas 1 to 4 in the rear
window over the following route:
Direct lines
Rear window antenna amplifier module (A2/12)
Direct lines
The TV combination tuner evaluates the TV signals and transmits the analog audio signals via a stereo line and
the analog picture signals via a Y-brightness (luminance)/C-color information (chrominance) (Y/C) line to the
DVD player (A40/4). The DVD player forwards the analog audio signals via a stereo line and the analog picture
signals via a Y/C line to the rear display. The interface is displayed on the screen of the rear display.
The TV channel is selected using the corresponding remote control. The control signals from the remote control
are transmitted to the rear display via the IR interface on the remote control. The rear display forwards the
signals to the TV combination tuner via the telematics CAN. The TV combination tuner evaluates these signals
and transmits analog audio signals over a stereo line and analog picture signals via a Y/C line to the DVD
player.
The DVD player forwards the analog audio signals via a stereo line and the analog picture signals via a Y/C line
to the rear display. On receiving the analog picture signals of the TV channel from the TV combination tuner,
the rear display generates the digital picture signals for displaying on the screen. The analog audio signals for
the TV station are converted in the rear display and sent over the IR interface (up to 31.8.10) or wifi interface
(as of 1.9.10) of the rear display to the IR interface or the wifi interface of the headphones (cordless). The
volume is controlled by means of the volume control integrated in the headphones.
Alternatively, it is possible to output the audio signals over the vehicle's speaker system.
The audio signals are output at the volume set at the COMAND controller unit. The volume setting is sent by
the COMAND controller unit over the Media Oriented System Transport (MOST) to the audio tuner control
unit (N93/1) or the digital sound processor (A2/69) (as of 1.9.10 with code (811) Advanced Sound System).
The audio signals of the TV combination tuner (analog/digital) are transmitted via the DVD player directly to
the audio tuner control unit.
The audio signals are emitted on vehicles with code (810) Sound system at the following speakers:
Left rear door speaker group (H4/3)
Right rear door speaker group (H4/4)
Bass module speaker (H4/17)
Center cockpit speaker (centerfill) (H4/27)
Left rear surround speaker (H4/54)
Right rear surround speaker (H4/57)
Left front door Sound tweeter (H4/68)
Right front door Sound tweeter (H4/69)
Left front door Sound woofer and midrange speaker group (H4/72)
Right front door Sound woofer and midrange speaker group (H4/73)
For vehicles with code (811) Advanced Sound system, audio is emitted over the following speakers:
Speaker Left front door (H4/5)
Right front door speaker (H4/6)
Bass module speaker
Center cockpit speaker (centerfill)
Left front door tweeter (H4/33)
Right front door tweeter (H4/34)
Left rear door tweeter (H4/35)
Right rear door tweeter (H4/36)
Left rear surround speaker
Right rear surround speaker
Left front door woofer (H4/64)
Left rear door woofer (H4/66)
Right rear door woofer (H4/67)
The woofer and bass box speaker are actuated by the sound amplifier (A2/13), which is regulated by the
digital sound processor.
Electrical function schematic
PE82.90-P-
for rear entertainment TV
2053-97SAB
reception
A2/69
Digital sound processor, GF82.62-P-
As of YoM 10 with code (811) Advanced Sound
component description 5011LE
System
A40/3
Component description for With code (526) COMAND with single DVD drive GF82.85-P-
COMAND controller unit (without navigation) or with code (527) COMAND 3136LE
APS with single DVD drive (with navigation)
Component description for
GF82.90-P-
rear entertainment DVD A40/4
4009LE
player
Component description for GF82.90-P-
A40/5, A40/6
rear display left/ right 4020LEA
COMAND display, A40/8 GF54.30-P-
component description Without code (867) SPLITVIEW 6110LE
SPLITVIEW display, A40/10 GF54.30-P-
component description With code (867) SPLITVIEW 6120LE
TV combination tuner
GF82.90-P-
(analog/digital), component A90/1
4019LE
description
Audio tuner control unit, GF82.62-P-
N93/1
component description 3132LES
REAR ENTERTAINMENT SWITCH ON/OFF BEHAVIOR AND SYSTEM SETTINGS, FUNCTION -
GF82.90-P-2002LE
MODEL 221 up to 31.5.09 with CODE (864) Rear entertainment system as of model year 2009 /YoM 08
Function requirements, general
Circuit 30 ON and telematics CAN (CAN A) for t = 10 min active (a vehicle door is opened) or circuit
15R ON
Rear entertainment system is switched on and operating properly
Rear entertainment ON/OFF behavior and system settings, general
on or off using the "ON/ OFF" button on the left rear display (A40/5) or the right rear display (A40/6).
The following applications are available following switch-on:
"Disk":
"TV" (with code (863) Digital/analog TV tuner)
"AUX1" (e.g. video camera, MP3 player or games console)
"AUX2" (e.g. video camera, MP3 player or games console)
Pressing the "ON/OFF" button on the left rear display only switches on the left rear display, and the listed
applications can only be run on the left rear display.
Pressing the "ON/OFF" button on the right rear display only switches on the right rear display, and the listed
applications can only be run on the right rear display.
Pressing the "ON/OFF" button on the left rear display and on the right rear display switches on both rear
displays, and the listed applications can be run on both rear displays. Only when operating the applications
using the RCP (HBF) control unit (N72/2) is it necessary to use the left screen button (N72/2s5) or the right
screen button (N72/2s4) to select the respective rear display.
The following settings can also be made after switch-on:
System settings
Background illumination control on rear display
Audio signal volume control
The rear entertainment ON/OFF behavior and system settings function consists of the following subfunctions:
Switch on function sequence
Function sequence for additional settings through RCP (HBF) control unit
Function sequence for additional settings using buttons on rear display
Switch off function sequence
Switch on function sequence
The switch-on signal from the "ON/OFF" button on the rear display is forwarded over the telematics CAN to
the DVD player (A40/4). The DVD player then sends for approx. t = 6 s the audio and picture signals for the
corporate identity screen over a low voltage differential signal (LVDS) line to the rear display. The DVD player
then sends the audio and picture signals of the application that was last active before switch-off over the low
voltage differential signal (LVDS) line to the rear display.
For vehicles with code (810) Sound system and for selection of the "speaker" setting in the "System setting"
area, the audio signals are also sent over a direct line to the audio tuner control unit (N93/1).
The "System settings" menu on the lower screen edge of the rear display can be used to make the relevant
settings in the following menu items:
"Display":
"Display off"
"Day screen"
"Night screen"
"Automatic"
"Language": Selection of system language
"Speaker" (with code (810) Sound system): Output of audio signals as of circuit 15R ON status over the
speaker system
If both rear displays are switched on, the "Speaker" menu item can be used to select the respective rear
display, whose audio signals are to be emitted as of circuit 15R ON status at the speaker system.
Selection of the menu items and the settings are made using the controls on the RCP (HBF) control unit:
Right screen button
Left screen button
Right "Back" button (N72/2s6)
Left "Back" button (N72/2s7)
Rear rotary pushbutton (N72/2s8)
The screen button is used to activate the menu on the rear display screen.
Function sequence for additional settings using buttons on rear display
The following buttons on the rear display can be used to make the relevant settings on the respective rear
display:
"-" and "+" buttons (with a sun as symbol):
Background illumination control on display
"-" and "+" buttons ("VOL" lettering)
Audio signal volume control
The signals for the listed buttons are sent over the telematics CAN to the DVD player. The DVD player
evaluates the signals and sends the audio and picture signals over the respective low voltage differential
signaling line to the rear display. For vehicles with code (810) Sound system and for selection of the "speaker"
setting in the "System setting" area, the audio signals are also sent as of circuit 15R ON status over a direct line
to the audio tuner control unit.
Along with the manual control for the background illumination for the rear display a photosensor is also
integrated into the rear display. The signals are read in, evaluated and transformed as with the manual control of
the background illumination for the respective rear display.
Switch off function sequence
The switch-off signal from the "ON/OFF" button on the rear display is forwarded over the telematics CAN to
the DVD player.
The DVD player then saves the last used application of the rear display and interrupts the forwarding of the
audio and picture signals.
Electrical function schematic for rear entertainment PE82.90-P-2052-
switch on/off behavior and system settings 97SAA
Component description for rear entertainment DVD GF82.90-P-
A40/4
player 4009LE
GF82.90-P-
Component description for rear display left/ right A40/5, A40/6
4020LE
GF54.21-P-
RCP [HBF] control unit, component description N72/2
4510LE
N93/1
GF82.62-P-
Audio tuner control unit, component description With code (810)
3132LES
Sound system
REAR ENTERTAINMENT SWITCH ON/OFF BEHAVIOR AND SYSTEM SETTINGS, FUNCTION -
GF82.90-P-2002LEA
MODEL 221 with CODE (864) Rear entertainment system as of model year 2010 /YoM 09 model
refinement package
Function requirements, general
Telematics CAN (CAN A) active
Rear entertainment system is operating properly
Rear entertainment ON/OFF behavior and system settings general The rear entertainment system is operated
using the system's remote control. The "System" base function can be used to select the following items and to
make settings:
"Settings"
"Display off"
With overvoltage or undervoltage, the DVD player (A40/4) switches off the rear entertainment system
automatically.
The rear entertainment ON/OFF behavior and system settings function consists of the following subfunctions:
ON/OFF via remote control, function sequence
System settings, function sequence
Automatic switch off function sequence
ON/OFF via remote control, function sequence
The rear entertainment system is switched on using the ON/OFF button on the remote control. The left rear
display (A40/5) or the right rear display (A40/6) must be selected beforehand using the control wheel on the
remote control.
The control signals from the remote control are transmitted to the appropriate rear display via infrared (IR)
interfaces.
The rear display then sends an ON signal via the telematics CAN to the DVD player, which is then activated.
At the same time, the rear display generates for approx. t = 6 s the audio and video signals for the corporate
identity display on the screen.
The rear entertainment system is also switched off using the ON/ OFF button on the remote control.
The control signal from the remote control is transmitted to the appropriate rear display via IR interfaces.
The rear display then sends the OFF signal via the telematics CAN to the DVD player, which then switches off.
The application last run is stored in the rear display and continued the next time the rear display is switched on.
System settings, function sequence
The system settings are used to define screen-related settings such as design and language.
All system settings can be made individually for each rear display without influencing the other rear display.
The settings are made using the remote control. The control signals from the remote control are transmitted to
the appropriate rear display via IR interfaces.
The following settings can be made:
"Settings"
"Language"
"Day design"
"Night design"
"Automatic"
"Brightness" (background illumination of the rear display)
"Display off" (The screen of the rear display is switched off; the system is, however, not switched off.
Pressing the "OK" button on the remote control switches the screen on again.)
Automatic switch off function sequence
When the transmitter key (A8/1) is removed from the EIS [EZS] control unit (N73) (circuit 15C OFF), the
message announcing that the transmitter key has been removed and the query as to whether the application is to
be continued appears on the active rear display.
If the "OK" button on the remote control is then pressed, the active application can be continued if called up
within approx. t = 30 min (timeout).
The status of circuit 15 is read in via the following path:
EIS [EZS] control unit
Interior CAN (CAN B)
Central gateway control unit (N93)
Central CAN (CAN F)
COMAND controller unit (A40/3)
Telematics CAN
DVD player, rear display
Electrical function schematic for
PE82.90-P-
rear entertainment switch on/off
2052-97SAB
behavior and system settings
A40/3 With code (526) COMAND with single
COMAND controller unit, DVD drive (without navigation) or with code GF82.85-P-
component description (527) COMAND APS with single DVD drive 3136LE
(with navigation)
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
Rear entertainment DVD player GF82.90-P-
A40/4
component description 4009LE
Rear display left/right component GF82.90-P-
A40/5, A40/6
description 4020LEA
Component description for EIS GF80.57-P-
N73
[EZS] control unit 6003LE
Central gateway control unit, GF54.21-P-
N93
component description 4170LE
REAR ENTERTAINMENT DISK APPLICATIONS, FUNCTION - GF82.90-P-2003LE
MODEL 221 up to 31.5.09 with CODE (864) Rear entertainment system as of model year 2009 /YoM 08
Function requirements, general
Circuit 30g ON and telematics CAN (CAN A) for t = 10 min active (a vehicle door is opened) or circuit
15R ON
Rear entertainment system is switched on and operating properly
COMAND controller unit (A40/3) is switched on
Data storage device inserted into DVD drive of DVD player (A40/4)
Rear entertainment disc applications, general
The following applications are available in the "Disc" menu:
Audio or MP3-CD
Video or MP3-DVD
In the audio or MP3-CD application, with the switched-on left rear display (A40/5) or right rear display (A40/6)
an audio or MP3-CD inserted into the DVD drive of the DVD player can be played back. In the video or MP3-
DVD application, the switched-on rear display can be used to view a video or MP3-DVD inserted into the DVD
drive of the DVD player and it can be listened to using headphones connected to the headphones socket. On
vehicles with code (810) Sound system audio output through the vehicle's speaker system is also possible.
The disc applications and the relevant settings can be called up and changed using the following controls on the
RCP (HBF) control unit (N72/2):
Right screen button (N72/2s4)
Left screen button (N72/2s5)
Right "Back" button (N72/2s6)
Left "Back" button (N72/2s7)
Rear rotary pushbutton (N72/2s8)
When the left rear display is switched on, the disc application can only be run in the left rear display.
When the right rear display is switched on, the disc application can only be run in the right rear display.
When the left rear display and right rear display are switched on, the disc application can be run on both rear
displays. Only when operating the disc applications through the RCP (HBF) control unit does the screen button
on the respective rear display have to be selected.
The "Rear entertainment disc applications" function consists of the following subfunctions:
Function sequence for playing back an audio or MP3-CD
Function sequence for playing back a video or MP3-DVD
Transmission of audio and picture signals function sequence
Function sequence for playing back an audio or MP3-CD
The DVD drive integrated into the DVD player deciphers the data for the inserted audio or MP3-CD and
forwards it internally to the DVD player. The DVD player then uses the data from the audio or MP3-CD to
generate the audio and picture signals for the rear display.
The following information is shown on the application field of the screen on the rear display:
Number of current title
Elapsed time of the current track
Number of tracks on the CD
Playback mode
Now the function bar of the rear display screen with the listed RCP (HBF) control unit controls can be used to
make the following settings:
"CD":
Playback mode ("Normal track sequence", "Track mix")
"Track list":
List for directly selecting tracks (e.g. track 1 or track 2, etc.)
The signals for the listed controls on the RCP (HBF) control unit are read in by the RCP (HBF) control unit and
sent over the telematics CAN to the DVD player.
The additional settings using the respective buttons on the rear display are also sent over the telematics CAN to
the DVD player. The DVD player evaluates these signals.
Function sequence for playing back a video or MP3-DVD
The DVD drive integrated into the DVD player deciphers the data for the inserted video or MP3-DVD and
forwards it internally to the DVD player. The DVD player then uses the data from the video or MP3-DVD to
generate the audio and picture signals for the rear display. The DVD video picture is displayed in the
application field of the rear display.
Now the function bar of the rear display screen with the listed RCP (HBF) control unit controls can be used to
make the following settings:
"DVD-V":
Settings ("DVD functions", "Brightness", "Contrast", "Color", "16:9 optimized", "4:3" or "Wide
screen")
Pause:
Temporarily interrupts playback; the current position is stored and the menu item changes to "Play"
Stop:
Stops playback
The signals for the listed controls on the RCP (HBF) control unit are read in by the RCP (HBF) control unit and
sent over the telematics CAN to the DVD player.
The additional settings using the respective buttons on the rear display are also sent over the telematics CAN to
the DVD player. The DVD player evaluates these signals.
Transmission of audio and picture signals function sequence
After deciphering the data for the audio or MP3-CD or the video or MP3-DVD and after receiving the signals
for the listed controls on the RCP (HBF) control unit as well as the relevant buttons on the rear display, the
DVD player generates the audio and picture signals. The audio and picture signals are sent by the DVD player
over the respective low voltage differential signal (LVDS) line to the rear display.
The picture signals are shown on the screen of the respective rear display. Audio signals are emitted over the
headphones that are connected to the headphones socket on the rear display.
Alternatively, the audio signals for vehicles with code (810) Sound system can also be emitted through the
vehicle's speaker system. The audio signals are output at the volume set at the COMAND controller unit. The
signals for this are transmitted by the COMAND controller unit via the Media Oriented System Transport
(MOST) to the audio tuner control unit (N93/1).
As of circuit 15R ON status the DVD player sends the audio signals over a direct line to the audio tuner control
unit.
This outputs the audio signals over the following speakers:
Left rear door speaker group (H4/3)
Right rear door speaker group (H4/4)
Bass module speaker (H4/17)
Center cockpit speaker (centerfill) (H4/27)
Left rear surround speaker (H4/54)
Right rear surround speaker (H4/57)
Left front door Sound tweeter (H4/68)
Right front door Sound tweeter (H4/69)
Left front door Sound woofer and midrange speaker group (H4/72)
Right front door Sound woofer and midrange speaker group (H4/73)
Electrical function schematic for rear entertainment PE82.90-P-2051-
disk applications 97SAA
Component description for COMAND controller
A40/3 GF82.85-P-3136LE
unit
Component description for rear entertainment DVD
A40/4 GF82.90-P-4009LE
player
Component description for rear display left/ right A40/5, A40/6 GF82.90-P-4020LE
RCP [HBF] control unit, component description N72/2 GF54.21-P-4510LE
N93/1
Audio tuner control unit, component description
system 3132LES
REAR ENTERTAINMENT DISK APPLICATIONS, FUNCTION - GF82.90-P-2003LEA
MODEL 221 with CODE (864) Rear entertainment system as of model year 2010 /YoM 09 model
refinement package
Function requirements, general
Telematics CAN (CAN A) active
Data storage device is inserted into the DVD drive of the DVD player (A40/4) or the COMAND
controller unit (A40/3)
Rear entertainment disc applications, general
The following video or audio sources are available to the rear passengers in the "Disc" basic function: DVD
player or COMAND controller unit
Video DVD
Audio CD or DVD
MP3-CD or DVD
After inserting a CD/DVD into the DVD player's drive, the video or audio source is automatically recognized
and started. Depending on the video or audio source, the corresponding screen in the "Disc" basic function is
shown on the left rear display (A40/5) or the right rear display (A40/6). The rear passengers can now view or
hear the video or audio source inserted into the DVD drive of the DVD player on the rear display. The menus
and their submenus are displayed on the screen of the rear display.
Furthermore, the rear entertainment system also permits access to video or audio sources of the COMAND
controller unit, and alternatively it is also possible for the driver and the front passenger to select video or audio
sources of the DVD player. The disk applications are operated using the remote control.
The control signals are transmitted via the infrared (IR) interface of the remote control to the respective IR
interface of the rear display or the SPLITVIEW display (A40/10) (with code (867) SPLITVIEW). The controls
of the COMAND controller unit are also available to the driver.
Rear entertainment disk applications, function sequence
The DVD drive integrated in the DVD player decodes the digital data of the inserted audio or video source and
passes this data on internally to the DVD player. The DVD player generates the analog audio and video signals
from the digital data. The audio signals are then transmitted to the appropriate rear display via a stereo line. On
receiving the analog picture signals from the DVD player via the Y-brightness (luminance)/C-color information
(chrominance) (Y/ C) line, the respective rear display generates the digital picture signals for the corresponding
screen. The digital picture signals are displayed via the rear display.
Due to the large number of available data storage devices, it is impossible to guarantee that the rear
entertainment system can play back a burned CD/DVD.
CD/DVD videos conforming to the "PAL" or "NTSC" standard which fulfill the following conditions can be
played back as standard:
"Region code 2" (for Europe)
"Region code 0" (no region code)
On vehicles without code (494) USA version, the rear entertainment system is factory-set to "Region code 2".
The country-specific coding is performed using the IS tester.
After receiving the analog audio signals via the stereo line from the DVD player or from the COMAND
controller unit, the respective rear display generates the analog IR signals or radio signals (as of 1.9.10). These
are transmitted via the IR interface of the respective rear display to the display and the IR interface (up to
31.8.10) or radio interface (as of 1.9.10) of the respective connected headphones to these (cordless).
Alternatively, it is possible to output the audio signals via the vehicle's speaker system. The audio signals are
output at the volume set at the COMAND controller unit. For this, the signals are sent by the COMAND
controller unit via Media Oriented System Transport (MOST) to the audio tuner control unit (N93/1) or to the
digital sound processor (A2/69) (as of 1.9.10 with code (811) Advanced sound system). The audio signals are
transmitted via the DVD player directly to the audio tuner control unit.
On vehicles with code (810) Sound system, the audio signals are output over the following speakers:
Left rear door speaker group (H4/3)
Right rear door speaker group (H4/4)
Bass module speaker (H4/17)
Center cockpit speaker (centerfill) (H4/27)
Left rear surround speaker (H4/54)
Right rear surround speaker (H4/57)
Left front door Sound tweeter (H4/68)
Right front door Sound tweeter (H4/69)
Left front door Sound woofer and midrange speaker group (H4/72)
Right front door Sound woofer and midrange speaker group (H4/73)
On vehicles with code (811) Advanced sound system, the audio signals are output over the following speakers:
Speaker Left front door (H4/5)
Right front door speaker (H4/6)
Bass module speaker
Center cockpit speaker (centerfill)
Left front door tweeter (H4/33)
Right front door tweeter (H4/34)
Left rear door tweeter (H4/35)
Right rear door tweeter (H4/36)
Left rear surround speaker
Right rear surround speaker
Left front door woofer (H4/64)
Right front door woofer (H4/65)
Left rear door woofer (H4/66)
Right rear door woofer (H4/67)
The woofers and bass box speaker are actuated by the sound amplifier (A2/13), which is controlled by the
digital sound processor.
Electrical function schematic
PE82.90-P-
for rear entertainment disk
2051-97SAB
applications
A2/69
Digital sound processor, GF82.62-P-
As of YoM 10 with code (811) Advanced sound
component description 5011LE
system
A40/3
Component description for With code (526) COMAND with single DVD drive GF82.85-P-
COMAND controller unit (without navigation) or with code (527) COMAND 3136LE
APS with single DVD drive (with navigation)
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
Component description for
GF82.90-P-
rear entertainment DVD A40/4
4009LE
player
Component description for GF82.90-P-
A40/5, A40/6
rear display left/ right 4020LEA
COMAND display, A40/8 GF54.30-P-
component description Without code (867) SPLITVIEW 6110LE
SPLITVIEW display, A40/10 GF54.30-P-
component description With code (867) SPLITVIEW 6120LE
Audio tuner control unit, GF82.62-P-
N93/1
component description 3132LES
REAR ENTERTAINMENT AUX APPLICATIONS, FUNCTION - GF82.90-P-2004LE
MODEL 221 up to 31.5.09 with CODE (864) Rear entertainment system as of model year 2009 /YoM 08
Function requirements, general
Circuit 30g ON and telematics CAN (CAN A) active for t = 10 min (a vehicle door is opened) or circuit
15R ON
COMAND controller unit (A40/3) is switched on
Video unit or audio equipment is connected to AUX input 1 or AUX input 2 of the DVD player (A40/4)
Rear entertainment AUX applications, general
2 additional video units or pieces of audio equipment can be connected to the rear entertainment system via the
two AUX inputs of the DVD player. These may be portable DVD players, video cameras, MP3 players or
games consoles, for example.
No equipment-specific interface for these video units or this audio equipment is provided by the DVD player.
Only one interface is provided for the following setting in the menu "AUX 1" or "AUX 2":
Control of the background illumination of the left rear display (A40/5) or right rear display (A40/6)
The video units or audio equipment are controlled using the video unit or audio equipment itself.
The video or audio device is detected automatically. Depending on whether a device with video or audio output
is detected, the corresponding screen is displayed on the respective rear display.
Video or audio output is performed automatically.
The settings in the menu "AUX 1" or "AUX 2" occur via the following controls of the rear control panel control
unit (N72/2):
Right screen button (N72/2s4)
Left screen button (N72/2s5)
Right "Back" button (N72/2s6)
Left "Back" button (N72/2s7)
Rear rotary pushbutton (N72/2s8)
With the left rear display switched on, the video or audio output and the settings can only be performed in
the left rear display. With the right rear display switched on, the video or audio output and the settings can only
be performed in the right rear display. With the left rear display and right rear display switched on, the video or
audio output and the settings can be performed in both rear displays. The respective rear display must be
selected using the screen button only when performing settings via the rear control panel control unit.
The rear entertainment AUX applications function comprises the following subfunctions:
Video unit detected function sequence
Audio unit detected function sequence
Transmission of audio and picture signals function sequence
The DVD player automatically recognizes the connection of a video unit via the AUX input 1 or AUX input 2.
The DVD player uses the transmitted data of the video unit to generate the audio and picture signals for the rear
display. The video image is shown in fullscreen mode in the application field of the screen on the rear display.
Full-screen mode is ended by pressing the rear rotary pushbutton vertically down. The hidden menu bars are
shown again immediately and the video image is now displayed only in the application field.
Now the following settings can be made via the following menu item in the function bar of the screen on the
rear display using the listed controls of the rear control panel control unit:
"AUX":
Settings menu ("Brightness", "Contrast", "Color", "16:9 optimized", "4:3" or "Wide screen")
If the slider is in the application field, the "Full screen" option can be selected. This causes all menu bars to be
hidden and the video image to be shown in full-screen mode again.
The signals of the listed controls of the rear control panel control unit are read in by the rear control panel
control unit and sent via telematics CAN to the DVD player.
The additional settings via the respective buttons at the rear display are also sent via telematics CAN to the
DVD player. The DVD player evaluates these signals.
Audio unit detected function sequence
The DVD player automatically recognizes the connection of audio equipment via the AUX input 1 or AUX
input 2. The DVD player uses the transmitted data of the audio equipment to generate the audio and picture
signals for the rear display. All menu bars are shown on the screen of the rear display. Now the corresponding
settings can be changed using the listed controls of the rear control panel control unit via the following menu
item in the function bar:
"AUX"
No settings possible
The signals of the listed controls of the rear control panel control unit are read in by the rear control panel
control unit and sent via telematics CAN to the DVD player.
The additional settings via the respective buttons at the rear display are also sent via telematics CAN to the
DVD player. The DVD player evaluates these signals.
Transmission of audio and picture signals function sequence
After transmitting the data from the video unit or audio equipment and after reception of the signals of the listed
controls of the rear control panel control unit as well as of the respective buttons at the rear display, the DVD
player generates the audio and picture signals. The audio and picture signals are sent by the DVD player via the
respective low voltage differential signal (LVDS) line to the rear display.
The picture signals are output via the screen of the respective rear display. The audio signals are output via the
headphones that are connected to the headphone jacks at the rear displays.
The signals for this are transmitted by the COMAND controller unit via the Media Oriented System Transport
(MOST) to the audio tuner control unit (N93/1).
As of the status Circuit 15R ON, the DVD player sends the audio signals via a direct line to the audio tuner
control unit. The audio tuner control unit outputs the audio signals over the following speakers:
Left rear door speaker group (H4/3)
Right rear door speaker group (H4/4)
Bass module speaker (H4/17)
As an alternative, there is also the option of outputting the audio signals via the speaker system of the vehicle on
vehicles with code (810) Sound system.
The audio signals are output at the volume set at the COMAND controller unit.
Center cockpit speaker (centerfill) (H4/27)
Left rear surround speaker (H4/54)
Right rear surround speaker (H4/57)
Left front door Sound tweeter (H4/68)
Right front door Sound tweeter (H4/69)
Left front door Sound woofer and midrange speaker group (H4/72)
Right front door Sound woofer and midrange speaker group (H4/73)
Electrical function schematic for rear entertainment PE82.90-P-2050-
AUX applications 97SAA
Component description for COMAND controller GF82.85-P-
A40/3
unit 3136LE
Component description for rear entertainment DVD GF82.90-P-
A40/4
player 4009LE
GF82.90-P-
Component description for rear display left/ right A40/5, A40/6
4020LE
GF54.21-P-
RCP [HBF] control unit, component description N72/2
4510LE
N93/1
GF82.62-P-
Audio tuner control unit, component description With code (810) Sound
3132LES
system
REAR ENTERTAINMENT AUX APPLICATIONS, FUNCTION - GF82.90-P-2004LEA
MODEL 221 with CODE (864) Rear entertainment system as of model year 2010 /YoM 09 model
refinement package
Function requirements, general
Telematics CAN (CAN A) active
COMAND controller unit (A40/3) is switched on
Video or audio devices are connected to the AUX jack of the left rear display (A40/5), right rear display
(A40/6), DVD player (A40/4) or to the COMAND controller unit
Rear entertainment AUX applications, general
The AUX jack on the DVD player, on a rear display or on the COMAND controller unit can be used to connect
external audio or video equipment (e.g. portable MP3 player or games console) to the rear entertainment
system.
The rear entertainment AUX applications are then operated using the remote control. The control signals are
transmitted over the infrared (IR) interfaces in accordance with the desired AUX source to the following
components:
SPLITVIEW display (A40/10) (with code (867) SPLITVIEW)
Left rear display
Right rear display
The control signals are transmitted via the telematics CAN to the component that is to be operated using the
remote control.
If an audio source is connected, the background (headphones picture) remains and the source is played back (no
automatic recognition!). If a video source is connected, this is automatically recognized and the background
disappears and the video source is played back. As soon as it has been detected, this is indicated in the "Aux"
menu on the active rear display.
The audio and video units are operated at the units themselves. The received data is displayed graphically on the
active rear display.
From the received data, the rear display or the DVD player generates analog or digital audio signals and digital
picture signals for display on the rear display.
If the external audio or video unit is not connected to a rear display, the analog picture signals are passed on to
the rear display via the following path.
For COMAND controller unit AUX source:
COMAND control unit
Y brightness (luminance)/C color information (chrominance) (Y/ C) line
DVD player
Y/C line
Rear display
For DVD player AUX source:
DVD player
Y/C line
Rear display
The analog audio signals are passed on to the rear display via the following path.
For COMAND controller unit AUX source:
COMAND control unit
Stereo line
DVD player
Stereo line
Rear display
For DVD player AUX source:
DVD player
Stereo line
Rear display
The analog audio signals of the AUX source are converted in the rear display. The audio signals are transmitted
via the IR interface (up to 31.8.10) or radio interface (as of 1.9.10) of the rear display to the IR interface or radio
interface of the headphones (cordless).
The volume can be adjusted via the volume control integrated in the headphones. Alternatively, it is possible to
output the audio signals via the vehicle's speaker system. The audio signals are output at the volume set at the
COMAND controller unit. For this, the signals are sent by the COMAND controller unit via Media Oriented
System Transport (MOST) to the audio tuner control unit (N93/1) or to the digital sound processor (A2/69) (as
of 1.9.10 with code (811) Advanced sound system).
The audio signals of the AUX application are transmitted via the DVD player directly to the audio tuner control
unit. On vehicles with code (810) Sound system, the audio signals are output over the following speakers:
Left rear door speaker group (H4/3)
Right rear door speaker group (H4/4)
Bass module speaker (H4/17)
Center cockpit speaker (centerfill) (H4/27)
Left rear surround speaker (H4/54)
Right rear surround speaker (H4/57)
Left front door Sound tweeter (H4/68)
Right front door Sound tweeter (H4/69)
Left front door Sound woofer and midrange speaker group (H4/72)
Right front door Sound woofer and midrange speaker group (H4/73)
On vehicles with code (811) Advanced sound system, the audio output takes place over the following speakers:
Speaker Left front door (H4/5)
Right front door speaker (H4/6)
Bass module speaker
Center cockpit speaker (centerfill)
Left front door tweeter (H4/33)
Right front door tweeter (H4/34)
Left rear door tweeter (H4/35)
Right rear door tweeter (H4/36)
Left rear surround speaker
Right rear surround speaker
Left front door woofer (H4/64)
Right front door woofer (H4/65)
Left rear door woofer (H4/66)
Right rear door woofer (H4/67)
The woofers and bass box speaker are actuated by the sound amplifier (A2/13), which is controlled by the
digital sound processor.
Electrical function schematic
PE82.90-P-
for rear entertainment AUX
2050-97SAB
applications
A2/69
Digital sound processor, GF82.62-P-
As of YoM 10 with code (811) Advanced sound
component description 5011LE
system
A40/3
Component description for With code (526) COMAND with single DVD drive GF82.85-P-
COMAND controller unit (without navigation) or with code (527) COMAND 3136LE
APS with single DVD drive (with navigation)
With code (530) COMAND APS USA (with GF82.85-P-
navigation system) 3136LEU
Component description for
GF82.90-P-
rear entertainment DVD A40/4
4009LE
player
Component description for GF82.90-P-
A40/5, A40/6
rear display left/ right 4020LEA
COMAND display, A40/8 GF54.30-P-
component description Without code (867) SPLITVIEW 6110LE
SPLITVIEW display, A40/10 GF54.30-P-
component description With code (867) SPLITVIEW 6120LE
Audio tuner control unit, GF82.62-P-
N93/1
component description 3132LES
SCANNING OF SWITCH POSITIONS, FUNCTION - GF82.90-P-3001SX
MODEL 221 up to model year 08/YoM 07
Illustrated:
Fig. 21: Identifying Multifunction Steering Wheel Buttons
Courtesy of MERCEDES-BENZ USA
Function
The left multifunction steering wheel button group, OK button (S110s6), "back" and SBS off button, right
multifunction steering wheel button group and VCS [SBS] on buttons can be used to actuate the multifunction
display (A1p13) in the instrument cluster (A1). The button settings of the multifunction steering wheel (MFL)
are read in via the steering LIN by the steering column module (N80) and forwarded from there to the chassis
CAN. The number of menus is dependent on the vehicle equipment level.
List of options within right multifunction steering wheel button group and VCS [SBS] on button in descending
order of their priority rating:
Accept call
Terminate call
Louder
Quieter
Muting
Switch on voice command
List of options within left multifunction steering wheel button group and "back" and SBS off button in
descending order of their priority rating:
Upward
Downward
To right
To left
Confirm selection (OK)
Switch menu level ("back") or switch off voice command
Example:
If the driver presses the "+" pushbutton (specific function setting and volume control (S111s1)) of the
multifunction steering wheel, the volume of the sound system is usually increased. However, if the
multifunction display is currently showing another setting such as, e.g. the interior lights OFF delay time, this
setting is changed when the driver presses the "+" pushbutton. The volume stays the same.
Multifunction steering wheel button group, component description GF82.90-P-4001SX
MULTIFUNCTION STEERING WHEEL BUTTON GROUP COMPONENT DESCRIPTION -
GF82.90-P-4001SX
MODEL 221 up to Model Year 8
Illustrated:
Fig. 22: Identifying Multifunction Steering Wheel Buttons
Courtesy of MERCEDES-BENZ USA
Multifunction steering wheel button group location
The left multifunction steering wheel button group, "back" and SBS off button, right multifunction steering
wheel button group and VCS [SBS] on button are located within easily visible and accessible range of the driver
on the multifunction steering wheel (MFL).
Button groups and multifunction steering wheel button, task
The button groups and buttons in the multifunction steering wheel can be used to operate the displays and
menus in the multifunction display (A1p13) of the instrument cluster (A1) and to accept telephone calls. The
VCS [SBS] on button and "back" and SBS off button can be used to switch the voice control system on and off.
COMPONENT DESCRIPTION FOR REAR ENTERTAINMENT DVD PLAYER - GF82.90-P-4009LE
MODEL 221 with CODE (864) Rear entertainment system as of model year 2009 /YoM 08
up to 31.5.09
Fig. 23: Locating Rear Entertainment DVD Player (Up To 31.5.09)
Courtesy of MERCEDES-BENZ USA
Location
The DVD player is located under the RCP [HBF] control unit between the rear seats.
As of 1.6.09
Fig. 24: Locating Rear Entertainment DVD Player (As Of 1.6.09)
Courtesy of MERCEDES-BENZ USA
Location
The DVD player is located under the RCP [HBF] control unit between the rear seats.
Shown from front, up to 31.5.09
Fig. 25: Identifying DVD Player Components (Up To 31.5.09)
Courtesy of MERCEDES-BENZ USA
Shown from front, as of 1.6.09
Fig. 26: Identifying DVD Player Components (As Of 1.6.09)
Courtesy of MERCEDES-BENZ USA
Task
The DVD player can implement the following applications and display the interface with the menus on the left
rear display (A40/5) or right rear display (A40/6):
Disc: audio or video CD or audio or video DVD
TV (with code (863) Digital/analog TV tuner)
AUX (e.g. video camera, MP3 player or games console)
System settings (left rear display or right rear display OFF, day design, night design and automatic)
The DVD player performs the following tasks:
Recognition of connected audio or video sources
Receive signals
Converting signals
Transmit signals
Recognition of connected audio or video sources
The DVD player recognizes the connection of the following audio or video sources:
AUX: e.g. portable DVD player, video camera, MP3 players or games console
Integrated DVD drive: audio or video CD or audio or video DVD
TV (with code (863) Digital/analog TV tuner): TV combination tuner (analog/digital) (A90/1)
Receive signals
The DVD player receives signals over the following connections:
Direct lines
Telematics CAN (CAN A)
Direct lines
The following signals are received via direct lines:
Analog picture signals from the TV combination tuner (analog/ digital) (with code (863) Digital/analog
TV tuner) via the Y-brightness (luminance)/C-color information (chrominance) (Y/C) line
Analog audio signals from the TV combination tuner (analog/ digital)
Analog video and audio signals from audio/video sources connected to AUX jack
Digital video and audio signals from the audio CD, video CD, or audio DVD, video DVD inserted in the
DVD drive
Telematics CAN
The DVD player communicates with the following components:
RCP [HBF] control unit
Left rear display
Right rear display
COMAND controller unit (A40/3)
The signals are received via the telematics CAN.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Converting signals
The incoming analog or digital audio and picture signals are converted to analog signals for output of audio and
picture signals.
Transmit signals
The DVD player transmits signals over the following connections:
Direct line
Low voltage differential signal (LVDS) line (up to 31.5.09)
Telematics CAN
Direct line
The DVD player sends audio signals via direct lines to the audio tuner control unit (N93/1) (with code (810)
Sound system or code (811) Advanced sound system).
The DVD player also sends audio signals via direct lines and video signals via Y/C line to the left rear display
LVDS line (up to 31.5.09)
The DVD player transmits analog audio and picture signals to the left rear display and/or to the right rear
display.
Telematics CAN
The DVD player communicates with the following components:
RCP [HBF] control unit
Left rear display
Right rear display
COMAND control unit
The signals are transmitted via the telematics CAN. The functions resulting therefrom are described in the
corresponding function descriptions (see block diagram or function schematic).
Wiring diagram of audio/video controller control unit up to 31.5.09 PE82.60-P-2103-97SAB
As of 1.6.09 PE82.60-P-2103-97SAC
TV COMBINATION TUNER (ANALOG/DIGITAL), COMPONENT DESCRIPTION - GF82.90-P-
4019LE
MODEL 216, 221 with CODE (863) Digital/analog TV tuner as of model year 2009 /YoM 08
Shown on model 221, up to 31.5.09
Fig. 27: Locating TV Combination Tuner (Analog/Digital)
Courtesy of MERCEDES-BENZ USA
Location
The TV combination tuner (analog/digital) is installed on the left in the trunk.
Task
The TV combination tuner (analog/digital) performs the following tasks:
Reading in analog and digital TV signals
Evaluating input factors
Output of output values
Exchange of control commands and transmission of audio signals and data of the additional TV
services
Reading in analog and digital TV signals
Signals are read in via the following connection:
Direct line
Direct line
The following signals are read in via direct lines:
Electronic wake-up for Media Oriented System Transport (MOST)
Analog and digital TV signals from TV antennas 1 to 4 over the rear window antenna amplifier module
(A2/12)
Evaluation of input factors
The amplified TV signals are evaluated internally and separated into video and audio signals.
Output of output values
The initial parameters are output via the following connection:
Direct line
Direct line
The following signals are sent via direct lines:
Control signals to the rear window antenna amplifier module
Video signals to the COMAND controller unit (A40/3) via a Y -brightness (luminance)/C - color
information (chrominance) (Y/ C) line
Video signals to the DVD player (A40/4) via a Y/C line
(in model 221 with code (864) Rear entertainment system)
Exchange of control commands and transmission of audio signals and data of the additional TV services
The TV combination tuner (analog/digital) is a MOST subscriber and correspondingly transmits the following
data:
Control data
Audio signals
Additional data, e.g. for videotext
In model 221 with code (864) Rear entertainment system, the TV combination tuner (analog/digital) is a
telematics CAN subscriber. The functions resulting therefrom are described in the corresponding function
descriptions (see block diagram or function schematic).
Wiring diagram of TV tuner Model 216 PE82.60-P-2220-99CAA
Model 221 PE82.60-P-2220-99SAA
REAR DISPLAY LEFT/RIGHT COMPONENT DESCRIPTION - GF82.90-P-4020LE
MODEL 221 up to 31.5.09 with CODE (864) Rear entertainment system as of model year 2009 /YoM 08
Fig. 28: Locating Rear Displays
Courtesy of MERCEDES-BENZ USA
Location
The left rear display is located on the rear of the left front seat head restraint. The right rear display is located on
the rear of the left front seat head restraint.
Task
The rear displays have the following tasks:
Visualization of all user-relevant information
Reading in of signals
Transmitting signals
Visualization of all user-relevant information
The following user-relevant information is displayed on the rear displays:
Graphic displays for user guidance
Operation
Display of digital image signals
The background illumination for the specific rear display can be adjusted with the left "-" and "+" keys
(brightness symbol). The volume of the audio output can be set with the right "-" and "+" keys (label "VOL").
Reading in of signals
Signals are read in via the following connections:
Telematics CAN (CAN A)
Low-Voltage Differential Signal (LVDS) line
Telematics CAN
The rear displays are subscribers on the telematics CAN.
The signals are read in by the rear displays.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
LVDS line
The following signals are read in via the LVDS line:
Audio and video signals from audio video controller (N66/3)
Transmitting signals
The signals are sent via the following connections:
Direct line
Telematics CAN
Direct line
The following signals are sent via a direct line:
Audio signals over the integrated headphone socket
Telematics CAN
The rear displays are subscribers on the telematics CAN.
The signals are sent by the rear displays.
The functions resulting therefrom are described in the corresponding function descriptions (see block
diagram or function schematic).
Design
Fig. 29: Design Of Rear Display
Courtesy of MERCEDES-BENZ USA
An audio amplifier for the headphones socket (3.5 mm) is also integrated into the unit. The rear displays
consist of 8 -Thin Film Transistor (TFT) displays with 16:9 format and a resolution of 800x480 pixels.
The color depth is 3 x 6 bits. The rear displays can display a maximum of 262.144 colors.
Wiring diagram for audio video controller control unit PE82.60-P-2103-99SAB
COMPONENT DESCRIPTION FOR REAR DISPLAY LEFT/RIGHT - GF82.90-P-4020LEA
MODEL 221 with CODE (864) Rear entertainment system as of model year 2010 /YoM 09 model
refinement package
Fig. 30: Locating Rear Displays
Courtesy of MERCEDES-BENZ USA
Location
The left rear display is located on the rear of the head restraint on the front seat. The right rear display is located
on the rear of the head restraint on the right front seat. The rear displays are of identical design and the decision
as to whether the left or right display is used is made via the "Side" pin (left = "Side" pin to ground (circuit 31),
right = "Side" pin not assigned).
Task
Visualization of user-relevant information
Connection detection of connected audio and video unit
Power and resource management
Reading in of signals
Generation of picture signals
Generation of infrared (IR) signals (up to 31.8.10)
Generation of radio signals (as of 1.9.10)
Output of audio signals
Transmit signals
Visualization of user-relevant information
The following user-relevent information is indicated on the rear display:
Graphic displays for user guidance
Operation
Display of digital picture signals
The following audio/video devices can be connected via the AUX jack:
Portable DVD player
Video cameras
MP3 player
Game consoles
Connection detection of connected video units
The rear displays recognize whether a video unit is connected to the AUX connection.
Power and resource management
The rear displays recognize overvoltage and undervoltage and react accordingly.
Reading in of signals
Signals are read in via the following connections:
Direct lines
Telematics CAN (CAN A)
Infrared interface
Direct lines
The following signals are read in via direct lines:
DVD player (A40/4)
Analog audio and picture signals from audio equipment or a video unit connected to AUX connection
Telematics CAN
The rear displays are subscribers on the telematics CAN. The signals are read in by the rear displays.
The functions resulting therefrom are described in the corresponding function descriptions (see block diagram
or function schematic).
Infrared interface
The following signals are read in via the infrared interface:
Control signals from remote control in position "L REAR", "R REAR"
Generation of picture signals
The rear displays generate digital picture signals from analog picture signals to display the associated screen on
the display.
Generation of IR signals (up to 31.8.10)
The rear displays generate analog IR audio signals from the analog audio signals for transmission to headphones
(cordless) connected via the IR interface.
Generation of radio signals (as of 1.9.10)
The rear displays generate analog radio audio signals (2.4 GHz) from the analog audio signals for transmission
to headphones (cordless) connected via the radio interface.
Output of audio signals
Output of audio signals via following options:
Analog (headphone wired)
IR/radio (cordless headphones)
The volume of the audio signals can only be adjusted via the remote control for headphones connected by
cable to the integrated headphone socket. For headphones (cordless) connected via the IR/radio interface, the
volume of the audio signals is adjusted via the volume control integrated into the IR/radio headphones.
Transmit signals
The signals are transmitted via the following connections:
Direct lines
Telematics CAN
Direct lines
The following signals are transmitted in via direct lines:
Electrical analog signals (frequency) (audio signals) to headphones connected via cable
Telematics CAN
The rear displays are subscribers on the telematics CAN. The signals are transmitted by the rear display.
or function schematic).
Fig. 31: Identifying Left Rear Display Headphones Socket, IR Interface And AUX Jack
Courtesy of MERCEDES-BENZ USA
Design
An audio amplifier and an 8 thin film transistor (TFT) display in 16:9 format with a resolution of 800 x 480
pixels is integrated into the rear display. The color depth is 3 x 6 bit. The rear display can display a maximum of
262.144.
Wiring diagram of audio/video controller control unit PE82.60-P-2103-97SAC
LEFT/RIGHT REAR DISPLAY, COMPONENT DESCRIPTION - GF82.90-P-4020SX
MODEL 221.0 /1 with CODE (864) Rear entertainment system except CODE (494) USA version up to
Model Year 8
Location
Fig. 32: Identifying Rear Display
Courtesy of MERCEDES-BENZ USA
Fig. 33: Identifying Rear Display Components
Courtesy of MERCEDES-BENZ USA
The rear displays (left rear display and right rear display) belong to the seat delivery contents and are installed
in the front seat head restraints.
Task
The rear displays are used for visualization of all application-relevant data in the rear entertainment system.
These are e.g. the graphical displays for user guidance, operation and the display of video signals from the TV
combination tuner (analog/digital) (A90/1) or the audio/video controller control unit (N66/3).
Function
Along with an on/off switch for activation of the rear entertainment system, buttons for regulating brightness
and volume are also available.
All displays are generated and managed in the audio/video controller control unit. The RCP [HBF] control unit
(N72/2) is used to control the rear entertainment functions.
Transmission of audio and video data from the audio/video controller control unit to the left rear display and to
the right rear display is performed using the standardized digital LVDS transmission method (Low Voltage
Differential Signaling).
Communication between the displays, the audio/video controller control unit and other components in the rear
entertainment system takes place over the telematics CAN.
Design
8 -TFT color display, horizontally pivotable
Display in 15:9 format
Maximum resolution, 800 x 480 dpi, 3 x 6 bit color depth
Integrated light sensor for measuring ambient brightness
Integrated audio amplifier for headphone connection (3.5 mm)
LVDS interface for reception of video and audio signals
Telematics CAN interface for exchanging data
Located under the rear displays is a control bar with the following controls:
Light sensor
On/off switch (ON/OFF button) for switching system or displays on and off
Buttons -/+ for regulating brightness (display background illumination)
Buttons -/+ for regulating volume "VOL"
Headphone socket
OVERVIEW OF SYSTEM COMPONENTS FOR REAR ENTERTAINMENT SYSTEM - GF82.90-P-
9995LE
MODEL 221 with CODE (864) Rear entertainment system as of model year 2009 /YoM 08
Digital sound processor, A2/69 GF82.62-P-
component description As of YoM 10 with code (811) Advanced sound system 5011LE
A40/3
Component description for With code (526) COMAND with single DVD drive GF82.85-P-
COMAND controller unit (without navigation) or with code (527) COMAND APS 3136LE
with single DVD drive (with navigation)
With code (530) COMAND APS USA (with navigation GF82.85-P-
system) 3136LEU
Component description for GF82.90-P-
A40/4
rear entertainment DVD player 4009LE
Component description for GF82.90-P-
A40/5, A40/6 up to 31.5.09
rear display left/ right 4020LE
GF82.90-P-
As of 1.6.09
4020LEA
Front central operating unit, GF54.21-P-
A40/9
component description 4500LE
SPLITVIEW display, A40/10 GF54.30-P-
component description As of 1.6.09 with code (867) SPLITVIEW 6120LE
TV combination tuner
A90/1 GF82.90-P-
(analog/digital), component
For code (863) Digital/analog TV tuner 4019LE
description
RCP [HBF] control unit, GF54.21-P-
N72/2 up to 31.5.09
component description 4510LE
EZS control unit, component GF80.57-P-
N73
description 6003LE
Component description for GF54.21-P-
N93
central gateway control unit 4170LE
Audio tuner control unit, GF82.62-P-
N93/1
component description 3132LES
Table of contents, function
GF82.90-P-
description, rear area
0998LE
entertainment
OVERVIEW OF REAR ENTERTAINMENT SYSTEM COMPONENTS, COMPONENT
DESCRIPTION - GF82.90-P-9996SX
MODEL 221.0 /1 with CODE (864) Rear entertainment system except CODE (494) USA version up to
Model Year 8
GF54.21-P-
RCP [HBF] control unit, component description
4510SX
GF82.60-P-
Audio/video controller, component description
3102SX
With code (863) Digital/analog TV GF82.60-P-
TV tuner, component description
tuner 3110SX
GF82.62-P-
Audio tuner control unit, component description Except code (810) Sound system
3132SX
GF82.62-P-
with CODE (810) Sound system
3132SXS
except CODE (498) Japanese GF82.85-P-
COMAND control unit, component description
version 3136SX
GF82.85-P-
with CODE (498) Japan version
3136SXJ
GF82.90-P-
Left/right rear display, component description
4020SX
List of contents, function description, rear GF82.90-P-
entertainment 0998SX
OVERVIEW OF SYSTEM COMPONENTS FOR MULTIFUNCTION STEERING WHEEL,
COMPONENT DESCRIPTION - GF82.90-P-9997SX
MODEL 221 up to model year 08/YoM 07
Multifunction steering wheel button group, component description GF82.90-P-4001SX
Multifunction steering wheel, function description contents GF82.90-P-0999SX
TELE AID OPERATION - GF82.95-P-0001SXX
MODEL 221.0 /1 as of 1.9.06 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
Location of components shown on model 221
Fig. 34: Locating Tele Aid Components
Courtesy of MERCEDES-BENZ USA
Networking of components shown on model 221
Fig. 35: Networking Of Tele Aid Components
Courtesy of MERCEDES-BENZ USA
The emergency call system control unit is used to implement current and future vehicle-related services. The
vehicle-related services currently supported are:
Telematic Alarm Identification on Demand (emergency call system) (TELE AID) (incl. police emergency
call number "911") manual/automatic
MB information call
Telediagnosis/roadside assistance
Tracking (dynamic assignment)
Remote Door Unlock (vehicle remote door locking)
Remote Door Lock (vehicle remote door unlocking)
Authorization
The emergency call system control unit is not used for regular telephone calls.
All vehicle-related services are integrated in the emergency call system control unit and they run fully
automatically.
The information is shown in the COMAND display and in the multifunction display (A1p13) of the instrument
cluster. As position finding is required for the vehicle-related services, the navigation unit integrated in the
emergency call system control unit is used. The navigation unit is a global positioning system (GPS) receiver in
the emergency call system control unit, which allows precise position finding. The position and direction of
travel of the vehicle are determined automatically and provided in the form of a history. The navigation unit
receives its GPS data over the antenna splitter from the telephone and GPS roof antenna (on model 221) or from
the telephone and GPS antenna (A2/49) (on model 216). The communication unit is a cellular phone that was
adjusted to the American cellular mobile telephone network and is only used to process the telematics functions.
The communication unit transmits and receives its data over the telephone and GPS roof antenna (on model
221) or over the telephone and GPS antenna (on model 216). A prerequisite for using the vehicle-related
services, however, is a communication module of the emergency call system control unit that is authorized for
the respective vehicle-related service.
Function requirements
Each vehicle-related service must be authorized separately. In the event of a defect or missing authorization, a
fault message appears in the multifunction display of the instrument cluster and in the COMAND display.
Self-test
After activation of circuit 15R, the emergency call system control unit performs a self-test (for approx. 3.5 s). If
the self-test is successful, the TELE AID is operational. If a fault is detected, the multifunction display of the
instrument cluster shows a corresponding fault message.
Basic functions
The TELE AID offers of the following basic functions:
Performs cyclic self-diagnosis
Keeps vehicle data available and transmits them securely in case of requirement
Transmits data messages (via SMS, not with Advanced Mobile Phone System (AMPS))
Placing telephone calls in hands-free mode
Emergency call system
In the event that the driver has an emergency in a remote area, a Customer Assistance Center (CAC) technician
can use a voice connection to obtain an overview of the situation in the vehicle interior with the aid of the
emergency call system control unit and initiate the appropriate emergency measures (automatic emergency
call). It is also always possible to transmit a manual emergency call by actuating the SOS pushbutton switch in
the overhead control panel control unit. The TELE AID is activated in 2 different ways:
Automatically, in the event of a crash (through the crash data of the supplemental restraint system (SRS))
Manually by actuating the SOS pushbutton switch in the overhead control panel control unit
In both cases, an emergency message is transmitted immediately to the closest emergency center. Contents of
the emergency call message are:
vehicle position, direction of travel and history
vehicle data and crash detection (severity of the accident)
customer data of the emergency service provider
Authorization
A prerequisite for using the vehicle-related services is a communication module of the emergency call system
control unit that is authorized for the respective vehicle-related service. In other words, the communication
module of the emergency call system control unit must have been configured ex factory with the telephone
number of the corresponding service provider.
Subsequently, the user has to authorize himself in the CAC with this call number. The authorization can already
be done, in part, at the factory. The vehicle-related services are activated by pressing the corresponding button
in the MB-Info and telediagnosis button group or for a manual emergency call by pressing the SOS pushbutton
switch in the overhead control panel control unit.
After activation, the emergency call system control unit sends an SMS to the CAC. Once the SMS is sent (not
with AMPS), a voice connection is immediately established to the CAC.
Misuse of emergency call alarm is subject to punishment!
Terminating the emergency call
Usually, the emergency service center deactivates the emergency call.
After several unsuccessful attempts to establish a connection, the emergency call system control unit stops
trying to establish an emergency call.
Voice connection to vehicle, function GF82.95-P-2006SXU
Telediagnosis, function GF82.95-P-2008SXU
MB information, function GF82.95-P-2010SXU
Display of TELE AID status, function GF82.95-P-2015SXR
Emergency call, function GF82.95-P-2016SXU
Vehicle remote door unlocking, function GF82.95-P-2018SXR
Vehicle remote door locking, function GF82.95-P-2019SXR
Position finding, function GF82.95-P-3000SXR
Selecting telephone antenna, function GF82.95-P-3001SXR
EMERGENCY CALL SYSTEM, LOCATION OF COMPONENTS - GF82.95-P-0004-01LEU
Shown without code (811) Advanced Sound System
Fig. 36: Locating Emergency Call System Components - Without Code 811 Advanced Sound System
Courtesy of MERCEDES-BENZ USA
Shown with code (811) Advanced Sound System, as of 1.9.10
Fig. 37: Locating Emergency Call System Components - With Code 811 Advanced Sound System
Courtesy of MERCEDES-BENZ USA
EMERGENCY CALL SYSTEM BLOCK DIAGRAM - GF82.95-P-0004-02LEU
Shown without code (811) Advanced Sound System
Fig. 38: Emergency Call System Block Diagram - Without Code (811) Advanced Sound System
Courtesy of MERCEDES-BENZ USA
Shown with code (811) Advanced Sound System, as of 1.9.10
Fig. 39: Emergency Call System Block Diagram - With Code (811) Advanced Sound System
Courtesy of MERCEDES-BENZ USA
EMERGENCY CALL SYSTEM, FUNCTION - GF82.95-P-0004LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Circuit 30 or Circuit 15R
Emergency call system authorized and operating properly
Each vehicle-related service is authorized separately
An emergency call system control unit (N123/4) communication module authorized for the corresponding
vehicle-related service is configured ex-factory with the telephone number of the corresponding service
provider
The customer is registered and authorized at the service center
One mobile phone network is available in sufficient strength and quality
Self-test
After activation of circuit 15R, the emergency call system control unit performs a self-test (for approx. t = 3.5
s). If the self-test is successful, the emergency call system is then ready for operation.
If a fault occurs, depending on the type of fault a fault message appears in the instrument cluster (A1), and
the red light-emitting diodes (LEDs) in the SOS push button (S93/3), the MB info button (S93/6s1) and the
telediagnosis button (S93/6s2) are permanently actuated. Depending on the fault type, the fault is also stored in
the emergency call system control unit's memory.
General
The emergency call system control unit enables the following vehicle-related services to be realized:
Authorization
Emergency call (E-Call) manual or automatic, including police emergency call number "911"
MB-Info call
Breakdown assistance (Roadside Assistance)
Vehicle tracking
Vehicle remote door unlock
Vehicle remote door lock
The emergency call system control unit is not used for regular telephone calls.
The emergency call system consists of the following subfunctions which are described in separate documents:
Voice connection between vehicle and service center
MB information call
Display of emergency call system status
Manual or automatic emergency call
Data from restrain systems control unit
Vehicle remote unlocking
Vehicle remote locking
Vehicle tracking
Roadside assistance
Position finding
Telephone antenna selection
Prioritization
All listed vehicle-related services run automatically in the emergency call system control unit. The emergency
call system control unit has a priority management feature to ensure that it does not have to manage several
vehicle-related services at the same time. This determines the point at which a vehicle-related service is to be
activated and which vehicle-related service has a higher priority. Depending on which vehicle-related service is
to be activated, the emergency call system control unit releases resources in accordance with the priority list and
activates the vehicle-related service or refuses activation because a vehicle-related service with a higher priority
is already active. Automatically completing an emergency call has the highest priority.
Priority Service
1 Automatic alarm call
2 Manual emergency call
3 Vehicle tracking
4 Roadside assistance
5 MB information call
6 Authorization
7 Vehicle remote unlocking
7 Vehicle remote locking
Emergency call system, location of components Model 216 GF82.95-P-0004-01LAU
Model 221 GF82.95-P-0004-01LEU
Emergency call system block diagram Model 216 GF82.95-P-0004-02LAU
Model 221 GF82.95-P-0004-02LEU
Voice connection between vehicle and service center, function GF82.95-P-2022LEU
MB information, function GF82.95-P-2010LEU
Display of emergency call system status, function GF82.95-P-2023LEU
Manual or automatic emergency call, function GF82.95-P-2024LEU
Restraint system control unit data, function GF82.95-P-3005LEU
Vehicle remote door unlock, function GF82.95-P-2018LEU
Vehicle remote door locking, function GF82.95-P-2019LEU
Vehicle tracking, function GF82.95-P-2021LEU
Breakdown assistance, function GF82.95-P-2020LEU
Position finding, function GF82.95-P-3000LEU
Selecting telephone antenna, function GF82.95-P-3001LEU
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF EMERGENCY CALL SYSTEM -
GF82.95-P-0996LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Emergency call system, function GF82.95-P-0004LEU
Emergency call system, location of components Model 216 GF82.95-P-0004-01LAU
Model 221 GF82.95-P-0004-01LEU
Emergency call system block diagram Model 216 GF82.95-P-0004-02LAU
Model 221 GF82.95-P-0004-02LEU
Voice connection between vehicle and service center, function GF82.95-P-2022LEU
MB information, function GF82.95-P-2010LEU
Display of emergency call system status, function GF82.95-P-2023LEU
Manual or automatic emergency call, function GF82.95-P-2024LEU
Restraint system control unit data, function GF82.95-P-3005LEU
Vehicle remote door unlock, function GF82.95-P-2018LEU
Vehicle remote door locking, function GF82.95-P-2019LEU
Vehicle tracking, function GF82.95-P-2021LEU
Breakdown assistance, function GF82.95-P-2020LEU
Position finding, function GF82.95-P-3000LEU
Selecting telephone antenna, function GF82.95-P-3001LEU
Overview of system components, emergency call system GF82.95-P-9995LEU
CONTENTS, FUNCTION DESCRIPTION OF TELE AID - GF82.95-P-0999SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Model 221.0/1 up to 31.12.05 with code GF82.95-P-
TELE AID operation
(494) USA version 0001SXU
Model 221.0/1 as of 1.1.06 up to 31.8.06 GF82.95-P-
with code (494) USA version 0001SXR
Model 221.0/1 as of 1.9.06 with code (494)
USA version
Model 221.0/1 with code (389) Mobile GF82.95-P-
phone preinstallation with universal 0001SXX
interface, USA/ Canada
Model 216.3
GF82.95-P-
Voice connection to vehicle, function
2006SXU
GF82.95-P-
Telediagnosis, function
2008SXU
GF82.95-P-
MB information, function
2010SXU
Model 221.0/1 up to 31.12.05 with code GF82.95-P-
Display of TELE AID status, function
(494) USA version 2015SXU
Model 221.0/1 as of 1.1.06 with code (494)
USA version
Model 221.0/1 with code (389) Mobile GF82.95-P-
phone preinstallation with universal 2015SXR
interface, USA/ Canada
Model 216.3
GF82.95-P-
Emergency call, function
2016SXU
Model 221.0/1 up to 31.12.05 with code GF82.95-P-
Vehicle remote door unlocking, function
(494) USA version 2018SXU
Model 221.0/1 as of 1.1.06 with code (494)
USA version
Model 221.0/1 with code (389) Mobile GF82.95-P-
phone preinstallation with universal 2018SXR
interface, USA/ Canada
Model 216.3
Model 221.0/1 up to 31.12.05 with code GF82.95-P-
Vehicle remote door locking, function
(494) USA version 2019SXU
Model 221.0/1 as of 1.1.06 with code (494)
USA version
Model 221.0/1 with code (389) Mobile GF82.95-P-
phone preinstallation with universal 2019SXR
interface, USA/ Canada
Model 216.3
Model 221.0/1 up to 31.12.05 with code GF82.95-P-
Position finding, function
(494) USA version 3000SXU
Model 221.0/1 as of 1.1.06 with code (494)
USA version
Model 221.0/1 with code (389) Mobile GF82.95-P-
phone preinstallation with universal 3000SXR
interface, USA/ Canada
Model 216.3
Model 221.0/1 up to 31.12.05 with code GF82.95-P-
Selecting telephone antenna, function
(494) USA version 3001SXU
Model 221.0/1 as of 1.1.06 with code (494)
USA version
Model 221.0/1 with code (389) Mobile GF82.95-P-
phone preinstallation with universal 3001SXR
interface, USA/ Canada
Model 216.3
Restraint system control unit data, function GF82.95-P-3005SXU
Overview of system components for the
GF82.95-P-
TELE AID emergency call system,
9997SXU
component description
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Irrespective of the type of emergency call, a voice connection to the Customer Assistance Center (CAC) is
established immediately after the SMS has been transmitted (not with Advanced Mobile Phone System
(AMPS)) and the user can talk to a service receptionist. Both, the emergency call and the information service
are free services provided by Mercedes-Benz customer support. The hands-free system microphone group
(A67b1) is used for voice input. Voice output is performed exclusively over the cockpit center speaker
(centerfill) (H4/27). The center cockpit speaker (centerfill) is actuated via a discrete line by the emergency call
system control unit (N123/4).
On model 221 up to 31.8.06, voice input is conducted over the 4 microphones integrated in the hands-free
system microphone group in the inside rearview mirror unit (A67). On model 221 as of 1.9.06 and on model
216, voice input is conducted over the 2 microphones integrated into the hands-free system microphone group
in the inside rearview mirror unit.
Telephone and GPS roof antenna Model 221.0/1 up to 31.12.05 with code (494) USA GF82.62-P-
component description version 4119SX
Model 221.0/1 as of 1.1.06 up to 31.8.06 with code GF82.62-P-
(494) USA version 4119SXR
Model 221.0/1 as of 1.9.06 with code (494) USA
version
Model 221.0/1 with code (389) Mobile phone GF82.62-P-
preinstallation with universal interface, USA/ 4119SXX
Canada
Model 216.3
Model 221.0/1 as of 1.1.06 with code (494) USA
version
Frequency switchover control unit, Model 221.0/1 with code (389) Mobile phone GF82.62-P-
component description preinstallation with universal interface, USA/ 4204SXU
Canada
Model 216.3
Speaker system, component GF82.62-P-
description 4220SXS
Emergency call system control Model 221.0/1 up to 31.12.05 with code (494) USA GF82.95-P-
unit, component description version 3212SXU
Model 221.0/1 as of 1.1.06 with code (494) USA
version
Model 221.0/1 with code (389) Mobile phone GF82.95-P-
preinstallation with universal interface, USA/ 3212SXR
Canada
Model 216.3
Emergency call antenna Model 221.0/1 up to 31.12.05 with code (494) USA GF82.95-P-
component description version 4000SXU
Emergency call antenna splitter GF82.95-P-
component description 4001SXU
Emergency call system backup GF82.95-P-
antennas component description 4002SXU
TELEDIAGNOSIS, FUNCTION - GF82.95-P-2008SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8 MODEL 221.0 /1 with CODE (389)
Mobile phone preinstallation with universal interface, USA/Canada up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Actuation
The telediagnosis call can be triggered by pressing the telediagnosis button (with a wrench symbol on it)
(S93/6s2) in the MB-Info and telediagnosis button group (S93/6). Pressing the telediagnosis button for longer
than 0.5 s activates the telediagnosis call. Activation of the telediagnosis call is indicated by the light emitting
diode (LED) integrated in the telediagnosis button flashing on and off. Regardless of the request, the
telediagnosis button is read in by the emergency call system control unit (N123/4) over a discrete line. The
emergency call system control unit automatically sets up a voice connection to the Customer Assistance Center
(CAC).
Telediagnosis call (roadside assistance call)
When the telediagnosis button is pressed, an SMS (not with Advanced Mobile Phone System (AMPS)) is
automatically sent to the CAC. Data, which are automatically transmitted in the event of a telediagnosis, are:
Vehicle position
Customer identification data
Vehicle identification data
Condition data
Fault code
Transmitting a telediagnosis telegram
In the event of a service call (telediagnosis), active telephone connections are interrupted. The emergency call
system control unit transmits an SMS (not with AMPS) to the closest CAC and establishes a telephone
connection to the CAC.
Telephone and GPS roof Model 221.0/1 up to GF82.62-P-4119SX
antenna component 31.12.05 with code (494)
description USA version
Model 221.0/1 as of GF82.62-P-4119SXR
1.1.06 up to 31.8.06 with
code (494) USA version
Model 221.0/1 as of GF82.62-P-4119SXX
1.9.06 with code (494)
USA version
Model 221.0/1 with code
(389) Mobile phone
preinstallation with
universal interface, USA/
Canada
Model 216.3
Frequency switchover Model 221.0/1 as of GF82.62-P-4204SXU
control unit, component 1.1.06 with code (494)
description USA version
Model 221.0/1 with code
(389) Mobile phone
preinstallation with
universal interface, USA/
Canada
Model 216.3
Speaker system, GF82.62-P-4220SXS
component description
Emergency call system Model 221.0/1 up to GF82.95-P-3212SXU
control unit, component 31.12.05 with code (494)
description USA version
Model 221.0/1 as of GF82.95-P-3212SXR
1.1.06 with code (494)
USA version
Model 221.0/1 with code
(389) Mobile phone
preinstallation with
universal interface, USA/
Canada
Model 216.3
MB-Info and GF82.95-P-3213SXU
telediagnosis button
group, component
description
Emergency call antenna Model 221.0/1 up to GF82.95-P-4000SXU
component description 31.12.05 with code (494)
USA version
Emergency call antenna GF82.95-P-4001SXU
splitter component
description
Emergency call system GF82.95-P-4002SXU
backup antennas
component description
MB INFORMATION, FUNCTION - GF82.95-P-2010LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Circuit 30
Emergency call system authorized and operating properly
The vehicle-related MB-Info call service is separately authorized
An emergency call system control unit (N123/4) communication module authorized for the vehicle-
related MB-Info call service is configured ex-factory with the telephone number of the corresponding
service provider
The customer is registered and authorized at the service center
One mobile phone network is available in sufficient strength and quality
Triggering an MB-Info call by pressing the MB-Info button (S93/6s1) > 0.5 s
A higher-priority vehicle-related service is not active
General
The MB-Info call function enables the customer to call up information on Mercedes-Benz brand products as
well as further voice-based services (e.g. hotel booking).
This vehicle-related service is primarily an oral information service that is provided via the communications
module integrated into the emergency call system control unit.
The MB-Info function consists of the two following subfunctions:
MB-Info call function sequence
Function sequence for remote destination feed or points of interest (POI)
MB-Info call function sequence
The MB-Info button is read in by the emergency call system control unit over a discrete line. The emergency
call system control unit then completes a voice connection to the service center. After the service center replies
with a special tone, the emergency call system control unit automatically sends an SMS with the following data
to the service center over the integrated communication module:
Vehicle position
Customer identification data
Vehicle identification data
The communication module integrated into the emergency call system control unit transmits and receives the
mobile phone signals or data via the following route:
Direct line
Frequency switchover control unit (N96), model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Emergency call antenna (A2/52), model 216
Telephone and GPS roof antenna (A2/49), model 221
The emergency call antenna is integrated in the GPS antenna (A2/49a2) in model 216.
As long as the MB-Info call is active, the light emitting diode (LED) integrated into the MB-Info button
flashes. This is also indicated in the instrument cluster (A1) and on the COMAND display (A40/8).
In the event of an MB-Info call, other vehicle-related services (e.g. vehicle remote door unlock) are
interrupted.
If the telephone and GPS roof antenna, model 221, or the emergency call antenna, model 216, fails (e.g.
malfunction caused by rollover) the emergency call system control unit transmits and receives the mobile radio
signals and data via the following route in order to transfer mobile radio signals and mobile radio data:
Direct line
Emergency call system antenna splitter (A2/25)
Direct line
Emergency call system left backup antenna (A2/54)
Emergency call system right backup antenna (A2/55)
Function sequence for remote destination feed or points of interest (POI)
During an MB-Info call, for example, the address of a hotel can be loaded into the navigation module in the
COMAND controller unit (A40/3).
The service center transmits the address of the hotel by means of mobile phone signals or data to the COMAND
control unit via the following route:
Emergency call antenna, model 216
Telephone and GPS roof antenna, model 221
Frequency switchover control unit, model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Direct line
Emergency call system control unit
Diagnostic CAN
Central gateway control unit (N93)
Central CAN
The customer confirms receipt of the hotel address and can then start the navigation.
Detailed information on starting the navigation is given in the specific system description for the
COMAND controller unit.
The displays for remote destination feed or points of interest (POI) are shown by the emergency call system
control unit on the display of the COMAND controller unit via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
COMAND controller unit
Low voltage differential signal (LVDS) line
Electrical function diagram for MB information, function Model 216 PE82.95-P-2067-97CAA
Model 221 PE82.95-P-2067-97SAA
Instrument cluster, component description A1 GF54.30-P-6000LE
COMAND controller unit, component description A40/3 GF82.85-P-3136LEU
COMAND display, component description A40/8 GF54.30-P-6110LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
Emergency call system control unit, component description N123/4 GF82.95-P-3212LEU
MB INFORMATION, FUNCTION - GF82.95-P-2010SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Actuation
The MB-Info call can be triggered by pressing the MB-Info and telediagnosis button (S93/6s1) (symbol is the
letter "i") in the MB-Info and telediagnosis button group (S93/6). The system is activated by pressing the MB-
Info-call button for longer than 0.5 s. Activation of the MB-Info call is indicated by the light emitting diode
(LED) integrated in the MB-Info call button flashing on and off. Regardless of the request, the MB-Info button
is read in by the emergency call system control unit (N123/4) over a discrete line. The emergency call system
control unit automatically sets up a voice connection to the Customer Assistance Center (CAC).
Generating an MB-Info call telegram
The service is activated by the user by actuating the MB-Info button. Once the service is authorized and no
service with higher priority is active, the emergency call system control unit sends an SMS (not with Advanced
Mobile Phone System (AMPS)) to the CAC. The SMS contains the following data:
Vehicle position
Customer identification data
Vehicle identification data
Transmitting an MB-Info call telegram
In the event of a service call (MB-Info call), any currently active telephone connections are interrupted. The
emergency call system control unit transmits an SMS (not with AMPS) to the closest CAC and establishes a
telephone connection to the CAC.
Telephone and GPS roof antenna Model 221.0/1 up to 31.12.05 with code (494) USA GF82.62-P-
component description version 4119SX
Model 221.0/1 as of 1.1.06 up to 31.8.06 with code GF82.62-P-
(494) USA version 4119SXR
Model 221.0/1 as of 1.9.06 with code (494) USA
version
Model 221.0/1 with code (389) Mobile phone GF82.62-P-
preinstallation with universal interface, USA/ 4119SXX
Canada
Model 216.3
Model 221.0/1 as of 1.1.06 with code (494) USA
version
Frequency switchover control unit, Model 221.0/1 with code (389) Mobile phone GF82.62-P-
component description preinstallation with universal interface, USA/ 4204SXU
Canada
Model 216.3
Speaker system, component GF82.62-P-
description 4220SXS
Emergency call system control Model 221.0/1 up to 31.12.05 with code (494) USA GF82.95-P-
unit, component description version 3212SXU
Model 221.0/1 as of 1.1.06 with code (494) USA
version
Model 221.0/1 with code (389) Mobile phone GF82.95-P-
preinstallation with universal interface, USA/ 3212SXR
Canada
Model 216.3
MB-Info and telediagnosis button GF82.95-P-
group, component description 3213SXU
Emergency call antenna component Model 221.0/1 up to 31.12.05 with code (494) USA GF82.95-P-
description version 4000SXU
component description 4001SXU
Emergency call system backup GF82.95-P-
antennas component description 4002SXU
DISPLAY OF TELE AID STATUS, FUNCTION - GF82.95-P-2015SXR
MODEL 221.0 /1 as of 1.1.06 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
The state display in the SOS pushbutton switch (S93/3) serves for checking the function of the Telematic Alarm
Identification on Demand (emergency call system) (TELE AID).
Switch-on characteristics
Every time TELE AID is switched on, the state display of the SOS pushbutton switch comes on for 4 s and thus
signals TELE AID readiness. If there is no fault, the state display of the SOS pushbutton switch goes out after 4
s.
Fault behavior
A TELE AID error is present if the state display of the SOS pushbutton does not go out 4 s after switching on or
if it comes on at a later time. In the event of a fault, a fault message appears in the multifunction display
(A1p13) of the instrument cluster (A1).
Triggering a TELE AID telediagnosis
When a TELE AID telediagnosis has been triggered, the state display of the SOS pushbutton flashes at a
frequency of approx. 1 Hz. In addition, a state message appears in the multifunction display of the instrument
cluster and in the COMAND display (A40/8). If it was not possible to carry out TELE AID telediagnosis, the
state display of the SOS pushbutton switch is illuminated without interruption. Furthermore, a fault message
appears in the multifunction display of the instrument cluster. When a voice connection is established, the state
display of the SOS pushbutton switch returns to the status it was in before a TELE AID telediagnosis was
triggered. A status message appears in the instrument cluster of the multifunction display and in the COMAND
display.
If the TELE AID is in diagnostic mode, the state display of the SOS pushbutton switch also starts to flash
on and off.
Continuous illumination of the state display of the SOS pushbutton switch can have the following causes:
Power supply too low
No or wrong subscriber identification module (SIM) card installed
Communication with restraint system control unit (N2/7) interrupted
Communication error with the ESP control unit (N47-5)
Error in SOS pushbutton switch
Error in Global Positioning System (GPS) antenna system
Reception interference (emergency call system left backup antenna (A2/54), emergency call system right
backup antenna (A2/55) or telephone and GPS roof antenna (A2/49) (on model 221) or telephone and
GPS antenna (A2/49) (on model 216)
Vehicle is not authorized or is in the progress of authorization
Memory fault in emergency call system control unit (N123/4)
Personal Identification Number (PIN) has not been stored in the emergency call system control unit by
the user or at the factory
Integrated telephone components in emergency call system control unit faulty
The emergency call system control unit can be coded using STAR DIAGNOSIS so that despite missing
authorization neither the state displays of the SOS pushbutton switch light up, nor the corresponding messages
are shown in the instrument cluster of the multifunction display and in the COMAND display. Deactivation of
the status display must be confirmed by the customer to the dealer, in writing, on a preprinted form.
State displays
Fig. 40: SOS Pushbutton Switch Timing Chart
Courtesy of MERCEDES-BENZ USA
The state displays provide the driver with an overview of the TELE AID status. This can be seen by the state
display of the SOS pushbutton switch either flashing on and off or being illuminated continuously.
GPS antenna splitter, component GF82.62-P-
description 3129SXU
Telephone and GPS roof antenna Model 221.0/1 as of 1.1.06 up to 31.8.06 with code GF82.62-P-
component description (494) USA version 4119SXR
Model 221.0/1 as of 1.9.06 with code (494) USA
Model 221.0/1 with code (389) Mobile phone
preinstallation with universal interface, USA/ GF82.62-P-
Canada 4119SXX
Model 216.3
Frequency switchover control unit, GF82.62-P-
component description 4204SXU
SOS switch, component GF82.95-P-
description 3210SXU
Emergency call system control GF82.95-P-
unit, component description 3212SXR
Emergency call antenna splitter GF82.95-P-
component description 4001SXU
Emergency call system backup GF82.95-P-
antennas component description 4002SXU
Restraint systems control unit, GF91.60-P-
component description 4048SX
EMERGENCY CALL, FUNCTION - GF82.95-P-2016SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Actuation
In the event that the driver has an emergency in a remote area, a Customer Assistance Center (CAC) technician
can use the data received (SMS and a voice connection) from the emergency call system control unit (N123/4)
to obtain an overview of the situation in the vehicle interior and then initiate the appropriate emergency
measures. A Telematic Alarm Identification on Demand (emergency call system) (TELE AID) emergency call
can be initiated automatically or manually.
Manual emergency call
A manual emergency call can be made at any time. A manual emergency call is triggered by actuating the SOS
pushbutton switch (S93/3) labeled with "SOS". It is integrated into the overhead control panel control unit
(N70).
The SOS pushbutton switch is read in by the emergency call system control unit over a discreet line. To
manually trigger an emergency call, the SOS pushbutton switch has to be actuated for more than 0.5 s. The red
light emitting diode (LED) in the SOS pushbutton switch flashes on and off for the duration of the emergency
call. After this, an emergency call message is sent immediately to the nearest emergency call center.
automatic alarm call
An automatic emergency call is possible after "circuit 15R ON". A vehicle crash is automatically detected by
the restraint systems control unit (N2/7). The emergency call system control unit receives the crash information
as a digital crash signal from the restraint systems control unit via a discrete line, and additionally (redundantly)
via the interior CAN. In the event of an accident, an emergency call is automatically sent out immediately.
An emergency call is sent out regardless of the severity of the accident. In the event of a crash triggering, the
red LED in the SOS pushbutton switch flashes on and off for the duration of the emergency call. The user can
now get in contact with the emergency call center by telephone. After the conversation is completed, the
connection is deactivated by the emergency call center. The emergency call system control unit deactivates the
emergency call request both for a manual and an automatic emergency call after several unsuccessful attempts.
It is only permissible to trigger a TELE AID emergency call in case of an emergency; violations are a
punishable offense.
Generating an emergency call telegram
In the event of an emergency call, all the data for an emergency call telegram are compiled by the emergency
call system control unit. The following data are automatically transmitted as an SMS (not with Advanced
Mobile Phone System (AMPS)) in the event of an emergency telegram:
Subscriber identification module (SIM) data
Phone number
Type of deployment (manual or automatic emergency call)
Vehicle data (e.g. circuit status)
Crash information (severity of accident), only for an automatic emergency call
Vehicle position and history
Direction of travel and speed
Transmitting an emergency call telegram
In the event of an emergency call, in addition to active telephone connections, active service calls (MB-Info or
telediagnosis) are also interrupted. The emergency call system control unit transmits an emergency call telegram
to the closest emergency call center and then establishes a telephone connection to the emergency call center. If
the emergency call was started automatically and the connection to the emergency call center was not possible,
a telephone connection is automatically established to the police emergency phone number "911". In this case,
no emergency call data are transmitted. The emergency call data must then be communicated verbally. This
process can be configured for manual calls.
The TELE AID must be authorized for transmission of an emergency call telegram.
Restraint system control unit data, function GF82.95-P-3005SXU
VEHICLE REMOTE DOOR UNLOCK, FUNCTION - GF82.95-P-2018LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Circuit 30
No undervoltage or overvoltage
Emergency call system authorized and operating properly
The vehicle-related vehicle remote door unlock service is separately authorized
An emergency call system control unit (N123/4) communication module authorized for the corresponding
vehicle-related service is configured ex-factory with the telephone number of the corresponding service
provider
The customer is registered and authorized at the service center
One mobile phone network is available in sufficient strength and quality
Telephone call by customer to service center and request for vehicle remote door unlock as well as
identification (authorization) at service center
Actuation of the trunk lid external operation switch (S88/8) for at least t = 15 s at a time agreed upon with
the service center
A higher-priority vehicle-related service is not active
Vehicle-related service Vehicle remote door unlock activated in EIS control unit (N73)
General
The vehicle remote door unlock function allows customers to have the vehicle unlocked remotely when the
have locked the transmitter key (A8/1), for example, and a 2nd transmitter key is not available.
Function sequence
Actuation of the tailgate external operation switch is received by the emergency call system control unit via the
following route:
Direct line
Rear SAM control unit with fuse and relay module (N10/2)
Interior CAN
Central gateway control unit (N93)
Diagnostic CAN
The emergency call system control unit then automatically transmits an SMS with the following data to the
service center, via the communication module integrated into emergency call system control unit:
Vehicle identification number (FIN)
Vehicle model
The communication module integrated into the emergency call system control unit transmits the mobile phone
signals or data via the following route:
Direct line
Frequency switchover control unit (N96), model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Emergency call antenna (A2/52), model 216
Telephone and GPS roof antenna (A2/49), model 221
The emergency call antenna is integrated in the GPS antenna (A2/49a2) in model 216.
The service center compares the data sent with the request and customer legitimization and if the data matches a
"vehicle remote door unlock request" is sent to the vehicle. the communication module integrated into the
emergency call system control unit receives the "Vehicle remote door unlock request" and the mobile phone
signals or data over the following via the following route:
Emergency call antenna, model 216
Telephone and GPS roof antenna, model 221
Frequency switchover control unit, model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Direct line
After receiving the "Vehicle remote door unlock request", the emergency call system control unit transfers the
request to the EIS control unit via the following route:
Diagnostic CAN
Central gateway control unit
Chassis CAN
The EIS [EZS] control unit then initiates the unlocking of all vehicle doors and the unlocking of the trunk lid.
If the "Vehicle remote door unlock request" is refused by the service center because, for example, the trunk
lid external operation switch was not actuated at the time agreed on or legitimization was incorrect, the vehicle
remote door unlock function is disabled for t = 15 min.
The execution of the vehicle remote door unlock is displayed by a message in the instrument cluster (A1).
Moreover, the red light-emitting diode (LED) in the SOS pushbutton switch (S93/3) flashes.
In the event of vehicle remote door unlock, other vehicle-related services (e.g. MB-Info call) are
interrupted.
If the telephone and GPS roof antenna, model 221, or the emergency call antenna, model 216, fails (e.g.
malfunction caused by rollover) the emergency call system control unit transmits and receives the mobile radio
signals and data via the following route in order to transfer mobile radio signals and mobile radio data:
Direct line
Emergency call system antenna splitter (A2/25)
Direct line
Emergency call system left backup antenna (A2/54)
Emergency call system right backup antenna (A2/55)
The maximum period of time between actuation of the trunk lid external operation switch and unlocking
all vehicle doors and unlocking the trunk lid is t = 5 min (normally t = 1 min).
Electrical function diagram for vehicle remote unlocking, Model PE82.95-P-2065-
function 216 97CAA
Model PE82.95-P-2065-
221 97SAA
Instrument cluster, component description A1 GF54.30-P-6000LE
Rear SAM control unit with fuse and relay module, component
N10/2 GF54.21-P-6030LE
description
Component description for the EZS control unit N73 GF80.57-P-6003LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
Emergency call system control unit, component description N123/4 GF82.95-P-3212LEU
VEHICLE REMOTE DOOR UNLOCKING, FUNCTION - GF82.95-P-2018SXR
MODEL 221.0 /1 as of 1.1.06 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
General
The vehicle remote door unlock function is a vehicle-related service of the Telematic Alarm Identification on
Demand (emergency call system) (TELE AID) system. If the transmitter key (A8/1) was locked in the vehicle
and no 2nd transmitter key is available, the service provider can remotely unlock the vehicle. The following
function requirements must be met:
C. 30 ON
The TELE AID has been authorized by the service provider
A cellular mobile telephone network in adequate quality is available
To activate the service, the customer needs the Personal Identification Number (PIN) and the vehicle
model
How to proceed
The customer contacts the service provider via telephone. The Customer Assistance Center (CAC) technician
then requires the user name and PIN, which were assigned during authorization of the TELE AID, as well as the
vehicle model to be able to check the authorization for vehicle remote door unlocking. Once the CAC employee
has checked the request, the driver has to return to the vehicle and operate the trunk lid external operation
switch (S88/8) for at least 15 s. The emergency call system control unit (N123/4) establishes a telephone
connection to the service provider. The CAC employee compares the request of the vehicle with the customer
request that was made over the phone. If the data match, the CAC employee enables the function with the
corresponding "Remote Door Unlock" message, which is transmitted to the vehicle. The vehicle is unlocked.
Function sequence
Operation of the trunk lid external operation switch is read in by the rear SAM control unit with fuse and relay
module (N10/2) and forwarded via the interior CAN to the central gateway control unit (N93). The central
gateway control unit forwards the "Trunk lid external operation switch" message via the diagnostic CAN to the
emergency call system control unit. The emergency call system control unit establishes a telephone connection
to the service provider after receiving the "Trunk lid external operation switch operated" message. Depending
on the mobile phone network quality, the phone connection is established over the frequency switchover control
unit (N96) and, for model 221, over the telephone and GPS roof antenna (A2/49) or, for model 216, over the
telephone and GPS antenna (A2/49) or over the emergency call system antenna splitter (A2/25) and over the
emergency call system left backup antenna (A2/54) as well as the emergency call system right backup antenna
(A2/55).
The CAC employee checks whether the customer has made a request over the phone and whether the
corresponding authorization is present and transmits the corresponding "Remote Door Unlock" message to the
vehicle. The emergency call system control unit transmits the message received to the central gateway control
unit via the diagnostic CAN. The central gateway control unit transmits the message via the chassis CAN to the
EIS control unit (N73), which initiates the unlocking of the vehicle. Once the customer has opened a vehicle
door, he/she can confirm with the CAC employee using the voice connection that still exists that the remote
door unlocking of the vehicle has been successful. Following this, the connection is terminated by the CAC
employee.
Telephone and GPS roof antenna Model 221.0/1 as of 1.1.06 up to 31.8.06 with code GF82.62-P-
component description (494) USA version 4119SXR
Model 221.0/1 as of 1.9.06 with code (494) USA
version
Model 221.0/1 with code (389) Mobile phone GF82.62-P-
preinstallation with universal interface, USA/ 4119SXX
Canada
Model 216.3
Frequency switchover control unit, GF82.62-P-
component description 4204SXU
Emergency call system control GF82.95-P-
unit, component description 3212SXR
Emergency call antenna splitter GF82.95-P-
component description 4001SXU
antennas component description 4002SXU
VEHICLE REMOTE DOOR LOCKING, FUNCTION - GF82.95-P-2019LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Circuit 30
No undervoltage or overvoltage
Emergency call system authorized and operating properly
The vehicle-related vehicle remote door locking service is separately authorized
An emergency call system control unit (N123/4) communication module authorized for the corresponding
vehicle-related service is configured ex-factory with the telephone number of the corresponding service
provider
The customer is registered and authorized at the service center
One mobile phone network is available in sufficient strength and quality
Telephone call by customer to service center and request for vehicle remote door lock as well as
legitimization (authorization) at service center
A higher-priority vehicle-related service is not active
Vehicle-related service "Vehicle remote door lock" activated in EIS [EZS] control unit (N73)
General
The vehicle remote locking function enables the customer to lock his/her vehicle remotely if he/she has
forgotten to lock the vehicle.
Function sequence
The service center checks the query and customer legitimization and if the data matches up a "Vehicle remote
door lock request" is sent to the vehicle.
The "vehicle remote door lock request" is received by the communication module integrated into the emergency
call system control unit via the following route:
Emergency call antenna (A2/52), model 216
Telephone and GPS roof antenna (A2/49), model 221
Frequency switchover control unit (N96), model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Direct line
The emergency call antenna is integrated in the GPS antenna (A2/49a2) in model 216.
After receiving the "Vehicle remote door lock request", the emergency call system control unit transfers the
request to the EIS [EZS] control unit via the following route:
Diagnostic CAN
Central gateway control unit (N93)
Chassis CAN
The EIS [EZS] control unit then checks whether the locking of all vehicle doors and the locking of the trunk lid
is possible. If it is possible to lock all the vehicle doors and the trunk lid, then the EIS [EZS] control unit
initiates the locking of all the vehicle doors and the locking of the trunk lid. If not, feedback is sent to the
service center in the same way as for the "vehicle remote door lock request".
If the vehicle doors and the trunk lid have been locked, feedback is also sent to the service center via the same
route as the "vehicle remote door lock request".
After receiving the feedback, the CAC notifies the customer of the vehicle remote locking result (locked: yes or
no) via the phone call which is still active.
If the telephone and GPS roof antenna, model 221, or the emergency call antenna, model 216, fails (e.g.
malfunction caused by rollover) the emergency call system control unit transmits and receives the mobile radio
signals and data via the following route in order to transfer mobile radio signals and mobile radio data:
Direct line
Emergency call system antenna splitter (A2/25)
Direct line
Emergency call system left backup antenna (A2/54)
Emergency call system right backup antenna (A2/55)
Electrical function diagram for vehicle remote door lock, Model PE82.95-P-2071-
function 216 97CAA
Model PE82.95-P-2071-
221 97SAA
Component description for the EZS control unit N73 GF80.57-P-6003LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
Emergency call system control unit, component description N123/4 GF82.95-P-3212LEU
VEHICLE REMOTE DOOR LOCKING, FUNCTION - GF82.95-P-2019SXR
MODEL 221.0 /1 as of 1.1.06 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
General
The vehicle remote locking function is part of the Telematic Alarm Identification on Demand (emergency call
system) (TELE AID). The customer has forgotten to lock the vehicle. The customer can initiate the remote
vehicle locking via the service provider. The following function requirements must be met:
C. 30 ON
The TELE AID has been authorized by the service provider
A cellular mobile telephone network in adequate quality is available
To activate the service, the customer requires the Personal Identification Number (PIN) and the vehicle
model
How to proceed
The customer contacts the service provider via telephone. The Customer Assistance Center (CAC) technician
then requires the user name and PIN, which were assigned during authorization of the TELE AID, as well as the
vehicle model to be able to check the authorization for vehicle remote locking. The CAC employee transmits
the "Remote Door Lock" message to the vehicle. The vehicle checks the request and transmits a message to the
service provider that contains the information whether or not it was possible to lock the vehicle. Then the CAC
employee informs the customer of the result.
Function sequence
The CAC employee checks the customer request made over the phone and transmits the Remote Door Lock
request (vehicle remote door locking) to the vehicle. The emergency call system control unit (N123/4) receives
the "Remote Door Lock" message depending on the mobile phone network quality over the frequency
switchover control unit (N96) and, for model 221, over the telephone and GPS roof antenna (A2/49) or, for
model 216, over the telephone and GPS antenna (A2/49) or over the emergency call system antenna splitter
(A2/25) and over the emergency call system left backup antenna (A2/54) as well as the emergency call system
right backup antenna (A2/55), and forwards this message over the diagnostic CAN to the central gateway
control unit (N93).
The central gateway control unit transmits the request to the EIS control unit (N73) via the chassis CAN. The
EIS control unit checks whether the vehicle can be locked and transmits the result to the central gateway control
unit. The central gateway control unit forwards the result to the emergency call system control unit. The
emergency call system control unit transmits the result to the service provider via the cellular mobile telephone
network. Then the CAC employee informs the customer of the result.
Telephone and GPS roof antenna Model 221.0/1 as of 1.1.06 up to 31.8.06 with code GF82.62-P-
component description (494) USA version 4119SXR
Model 221.0/1 as of 1.9.06 with code (494) USA
version GF82.62-P-
Model 221.0/1 with code (389) Mobile phone 4119SXX
Canada
Model 216.3
Frequency switchover control unit, GF82.62-P-
component description 4204SXU
Emergency call system control GF82.95-P-
unit, component description 3212SXR
Emergency call antenna splitter GF82.95-P-
component description 4001SXU
Emergency call system backup GF82.95-P-
antennas component description 4002SXU
BREAKDOWN ASSISTANCE, FUNCTION - GF82.95-P-2020LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Circuit 30
Emergency call system authorized and operating properly
The vehicle-related breakdown assistance service is separately authorized
An emergency call system control unit (N123/4) communication module authorized for the vehicle-
related breakdown assistance is configured ex-factory with the telephone number of the corresponding
service provider
The customer is registered and authorized at the service center
One mobile phone network is available in sufficient strength and quality
Actuation of breakdown assistance by pressing telediagnosis button (S93/6s2) > 0.5 s
A higher-priority vehicle-related service is not active
General
With the breakdown assistance function it is possible for the customer to contact the service center in the event
of a problem with the vehicle, for example. The service center can now initiate effective remedial measures
taking other vehicle-specific data into consideration.
The breakdown assistance function consists of the two following subfunctions:
Breakdown assistance function sequence
Function sequence for remote destination feed or points of interest (POI)
Breakdown assistance function sequence
The telediagnosis button is read in by the emergency call system control unit over a discrete line. The
emergency call system control unit then completes a voice connection to the service center. After the service
center replies with a special tone, the emergency call system control unit automatically sends an SMS with the
following data to the service center over the integrated communication module:
Vehicle position
Customer identification data
Vehicle identification data
The communication module integrated into the emergency call system control unit transmits and receives the
mobile phone signals or data via the following route:
Direct line
Frequency switchover control unit (N96), model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Emergency call antenna (A2/52), model 216
Telephone and GPS roof antenna (A2/49), model 221
The emergency call antenna is integrated in the GPS antenna (A2/49a2) in model 216.
As long as the breakdown assistance is active, the light-emitting diode (LED) integrated into the
telediagnosis button flashes. This is also indicated in the instrument cluster (A1) and on the COMAND display
(A40/8).
If the telephone and GPS roof antenna, model 221, or the emergency call antenna, model 216, fails (e.g.
malfunction caused by rollover) the emergency call system control unit transmits and receives the mobile radio
signals and data via the following route in order to transfer mobile radio signals and mobile radio data:
Direct line
Emergency call system antenna splitter (A2/25)
Direct line
Emergency call system left backup antenna (A2/54)
Emergency call system right backup antenna (A2/55)
In the event of breakdown assistance, other vehicle-related services (e.g. MB-Info call) are interrupted.
Function sequence for remote destination feed or points of interest (POI)
In the event of breakdown assistance, it is possible for example, to load the address of a workshop into the
navigation module of the COMAND controller unit (A40/3). A facility for starting navigation directly or saving
the address in the destination memory is provided in the form of a pop-up.
The service center sends the address of the workshop via mobile radio signals and data via the following route:
Emergency call antenna, model 216
Telephone and GPS roof antenna, model 221
Frequency switchover control unit, model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Direct line
Emergency call system control unit
Diagnostic CAN
Central gateway control unit (N93)
Central CAN
The customer confirms receipt of the workshop and can then start the navigation.
Detailed information on starting the navigation is given in the specific system description for the
COMAND controller unit.
The displays for remote destination feed or points of interest (POI) are shown by the emergency call system
control unit on the display of the COMAND controller unit via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
COMAND controller unit
Low voltage differential signal (LVDS) line
Electrical function diagram for breakdown assistance, Model PE82.95-P-2068-
function 216 97CAA
Model PE82.95-P-2068-
221 97SAA
Instrument cluster, component description A1 GF54.30-P-6000LE
COMAND controller unit, component description A40/3 GF82.85-P-3136LEU
COMAND display, component description A40/8 GF54.30-P-6110LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
Emergency call system control unit, component description N123/4 GF82.95-P-3212LEU
VEHICLE TRACKING, FUNCTION - GF82.95-P-2021LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Circuit 30
Emergency call system authorized and operating properly
The vehicle-related vehicle tracking service is authorized separately
The customer is registered and authorized at the service center
One mobile phone network is available in sufficient strength and quality
General
The following points are vehicle tracking objectives:
Retrieval of stolen or misappropriated vehicles
Fast assistance in the event of "car jacking"
The vehicle tracking function consists of the two following subfunctions:
"Theft Alarm" function sequence, with code (551) Antitheft alarm system (ATA)
Function sequence for vehicle theft telephone message from customer to police and then to service
center
"Tracking" function sequence
"Theft Alarm" function requirements, with code (551) Antitheft alarm system (ATA)
Anti-theft alarm system (ATA) active for > 30 s
"Theft Alarm" function sequence, with code (551) Antitheft alarm system (ATA)
If the anti-theft alarm system is triggered, the emergency call system control unit (N123/4) receives an "ATA
alarm" message via the following route:
Rear SAM control unit with fuse and relay module (N10/2)
Interior CAN
Central gateway control unit (N93)
Diagnostic CAN
The "ATA alarm" message is transmitted by the communication module integrated into the emergency call
system control unit to the service center via the following route:
Direct line
Frequency switchover control unit (N96), model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Emergency call antenna (A2/52), model 216
Telephone and GPS roof antenna (A2/49), model 221
The emergency call antenna is integrated in the GPS antenna (A2/49a2) in model 216.
The service center receives the "ATA alarm" message and advises the customer by telephone that the ATA
alarm has been triggered. "Tracking" will not yet be accomplished by the service center.
Function requirements for vehicle theft telephone message from customer to police and then to service
center
Customer has been notified about the activation of the ATA [EDW] alarm by the service center
Customer notices that vehicle has been stolen
Function sequence for vehicle theft telephone message from customer to police and then to service center
If the customer has been informed by the service center that his vehicle has been stolen or if the customer
himself notices that the vehicle has been stolen, it is first necessary for the customer to report the theft to the
police. The customer receives a special number from the police, which confirms that the vehicle theft has been
reported.
With this special number, the customer can report to the service center, by telephone, and give this special
number to the employee there. The service center checks the request and legitimation (authorization) of the
customer.
"Tracking" function requirements
Vehicle reported as stolen by customer, by telephone, to police and then to service center as well as
legitimation (authorization) by service center
An emergency call system control unit communication module authorized for the corresponding vehicle-
related service is configured ex-factory with the telephone number of the corresponding service provider
A higher-priority vehicle-related service is not active
No faults in Global Positioning System (GPS) antenna system and signals present from at least 3 GPS
satellites
"Tracking" function sequence
After reporting the theft to the service center and legitimation (authorization) by the service center, an initiation
command is sent to the vehicle.
The initiation command is received by the communication module integrated into the emergency call system
control module via the following route:
Emergency call antenna, model 216
Telephone and GPS roof antenna, model 221
Frequency switchover control unit, model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Direct line
The emergency call system control unit then activates the GPS position finding and also the voice connection to
the vehicle. Then the communication module integrated into the emergency call system control unit sends the
position data to the service provided in the same manner as the "ATA alarm" message.
The position data is transmitted cyclically and for the following events:
When a specific distance is exceeded
Recognition of damage or manipulation to the vehicle
Status "Circuit 15 ON" or "Circuit 15 OFF" (ignition switched on or off)
The service center forwards the location of the vehicle to the responsible command staff (e.g. police). The
command staff can then decide whether or not to speak to the driver.
Vehicle tracking can only be deactivated by the service center.
If the telephone and GPS roof antenna, model 221, or the emergency call antenna, model 216, fails (e.g.
malfunction caused by rollover) the emergency call system control unit transmits and receives the mobile radio
signals and data via the following route in order to transfer mobile radio signals and mobile radio data:
Direct line
Emergency call system antenna splitter (A2/25)
Direct line
Emergency call system left backup antenna (A2/54)
Emergency call system right backup antenna (A2/55)
Model PE82.95-P-2064-
Electrical function diagram for vehicle
216 97CAA
Model PE82.95-P-2064-
221 97SAA
Rear SAM control unit with fuse and relay module, component
N10/2 GF54.21-P-6030LE
description
Central gateway control unit, component description N93 GF54.21-P-4170LE
Emergency call system control unit, component description N123/4 GF82.95-P-3212LEU
VOICE CONNECTION BETWEEN VEHICLE AND SERVICE CENTER, FUNCTION - GF82.95-P-
2022LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 2009 /YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 2009 /YoM 08
Function requirements
Terminal 30
Each vehicle-related service is authorized separately
An emergency call system control unit (N123/4) communication module authorized for the corresponding
vehicle-related service is configured ex-factory with the telephone number of the corresponding service
provider
The customer is registered and authorized at the service center
One mobile phone network is available in sufficient strength and quality
One of the following vehicle-related services is present:
Manual or automatic emergency call (E-Call)
MB-Info call
Breakdown assistance (Roadside Assistance)
Vehicle tracking
General
Regardless of the type of vehicle-related service initiated (e.g. MB-Info call), a voice connection is established
to the Service Center. After feedback by the Service Center with a special tone, an SMS is sent to the Service
Center with the appropriate data (vehicle identification number (VIN) and vehicle model, etc.). Then the
customer can speak to a service receptionist over the existing voice connection.
Function sequence
The hands-free system microphone group (A67b1), integrated into the inside rearview mirror, is used for voice
input. The signals of the hands-free system microphone group are sent over direct lines to the voice control
system control unit (VCS [SBS]) (N41/3) (with code (813) Voice control system (VCS [SBS]) up to 31.5.09) or
to the COMAND controller unit (A40/3) (as of 1.6.09) and forwarded from there to the emergency call system
control unit.
The communication module integrated into the emergency call system control unit then transmits the hands-free
system microphone group signals to the service center. The communication module integrated into the
emergency call system control unit transmits and receives the mobile phone signals or data in the following
way:
Direct line
Frequency switchover control unit (N96), model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
Emergency call antenna (A2/52), model 216
Telephone and GPS roof antenna (A2/49), model 221
The emergency call antenna on model 216 is integrated into the GPS antenna (A2/49a2).
If the telephone and GPS roof antenna malfunctions, model 221, or the emergency call antenna, model
216, (e.g. defective through rollover) the emergency call system control unit sends and receives the mobile
radio signals or mobile radio data as follows to transmit the mobile radio signals or mobile radio data:
Direct line
Emergency call system antenna splitter (A2/25)
Direct line
Emergency call system left backup antenna (A2/54)
Emergency call system right backup antenna (A2/55)
Voice output is performed exclusively over the cockpit center speaker (Centerfill) (H4/27). This is actuated over
direct lines by the emergency call system control unit and muted by means of a mute signal for all other
application (e.g. audio mode). At the same time, the emergency call system control unit sends a mute signal
over a direct line to the audio tuner control unit (N93/1) or the digital sound processor (A2/69) (model 221 as of
1.9.10 with code (811) Advanced Sound System), to mute the following speakers: Model 216:
Left door rear speaker (H4/3)
Right door rear speaker (H4/4)
Bass box speaker (H4/17)
Left rear surround speaker (H4/54)
Right rear surround speaker (H4/57)
Left door sound tweeter (H4/68)
Right door sound tweeter (H4/69)
Left door sound woofer and midrange speaker group (H4/72)
Right door sound woofer and midrange speaker group (H4/73)
Model 221 except model 221 (as of 1.9.10) with code (811) Advanced Sound System:
Left rear door speaker group (H4/3)
Right rear door speaker group (H4/4)
Bass box speaker
Left rear surround speaker
Right rear surround speaker
Left front door sound tweeter (H4/68)
Right front door sound tweeter (H4/69)
Left front door sound woofer and midrange speaker group (H4/72)
Right front door sound woofer and midrange speaker group (H4/73)
Model 221 (as of 1.9.10) with code (811) Advanced Sound System:
Speaker Left front door (H4/5)
Right front door speaker (H4/6)
Bass module speaker
Left front door tweeter (H4/33)
Right front door tweeter (H4/34)
Left rear door tweeter (H4/35)
Right rear door tweeter (H4/36)
Left rear surround speaker
The woofers and bass box speaker on model 221 (as of 1.9.10) with code (811) Advanced Sound System
are actuated by the sound amplifier (A2/13), which is controlled by the digital sound processor.
Normally, the voice connection is deactivated by the service center or by the customer.
Right rear surround speaker
Left front door woofer (H4/64)
Right front door woofer (H4/65)
Left rear door woofer (H4/66)
Right rear door woofer (H4/67)
The establishment of a voice connection to the service center is interrupted by the communication module
integrated into the emergency call system control unit after several unsuccessful dialing attempts.
Electrical function diagram for voice PE82.95-P-
Model 216
connection between vehicle and service 2069-97CAA
PE82.95-P-
Model 221
2069-97SAA
A2/69
Digital sound processor, component GF82.62-P-
Model 221 as of YoM 10 with code
description 5011LE
(811) Advanced Sound System
Component description for COMAND GF82.85-P-
A40/3
controller unit 3136LEU
N41/3
Component description for voice control GF82.70-P-
With code (813) Voice control
system (VCS [SBS]) control unit 4300LE
system (VCS) up to 31.5.09
Component description for central GF54.21-P-
N93
gateway control unit 4170LE
Audio tuner control unit, component GF82.62-P-
N93/1
description 3132LES
Component description for emergency GF82.95-P-
N123/4
call system control unit 3212LEU
DISPLAY OF EMERGENCY CALL SYSTEM STATUS, FUNCTION - GF82.95-P-2023LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Emergency call system authorized and operating properly
The following vehicle-related services are authorized separately:
Automatic emergency call (E-Call)
Manual emergency call (E-Call)
Breakdown assistance (Roadside Assistance)
MB-Info call
Vehicle remote door unlock
Vehicle remote door lock
The customer is registered and authorized at the service center
An emergency call system control unit (N123/4) communication module authorized for the corresponding
vehicle-related service is configured ex-factory with the telephone number of the corresponding service
provider
One mobile phone network is available in sufficient strength and quality
Triggering of correspondingly listed vehicle-related services
Global Positioning System (GPS) present
Triggering of the listed vehicle-related services is described in detail in the respective subfunctions.
General
The two red light-emitting diodes (LED) integrated into the SOS pushbutton switch (S93/3) serve to indicate the
following actions:
Emergency call system self-test
Emergency call system ready state
Automatic or manual emergency call active
Malfunctions in the emergency call system are also indicated on the instrument cluster (A1), depending on
the type of malfunction.
The LED integrated into the Telediagnosis button (S93/6s2) flashes when the breakdown assistance is active.
This is also indicated in the instrument cluster and on the COMAND display (A40/8).
The LED integrated into the MB-Info button (S93/6s1) flashes when an MB-Info call is active. This is also
indicated in the instrument cluster and on the COMAND display.
The execution of the vehicle remote door unlock is displayed by a message in the instrument cluster. In
addition, a red LED in the SOS push button flashes.
The display function for the emergency call system status consists of the following subfunctions:
Function sequence for emergency call system status in non-actuated state
Function sequence for emergency call system status for automatic emergency call
Function sequence for emergency call system status for manual emergency call
Function sequence for emergency call system status for breakdown assistance
Function sequence for emergency call system status for MB-Info call
Function sequence for emergency call system status for vehicle remote door unlock
Function sequence for emergency call system status for vehicle remote door lock
Function requirement for emergency call system status in non-actuated state
Circuit 15R
Function sequence for emergency call system status in non-actuated state
As soon as circuit 15R is activated, the two red LEDs integrated into the SOS pushbutton switch illuminate
during the emergency call system control unit self-test for t = 3.5 s.
Actuation is accomplished by the emergency call system control unit via a discrete line.
This signals the self-test and check of the following emergency call system states:
Emergency call system control unit power supply
Functions within the emergency call system control unit (e.g. integrated communication module or
memory)
Communication with restrain systems control unit (N2/7) and ESP control module (N47-5)
SOS pushbutton switch function (e.g. jammed or opened emergency call system button)
Emergency call system antenna splitter (A2/25)
Emergency call system left backup antenna function (A2/54)
Emergency call system right backup antenna function (A2/55)
Antenna splitter function (A2/5)
Frequency switchover control unit (N96) function, model 221 with code (389) Mobile phone
preinstallation with universal interface, USA/Canada
Emergency call antenna (A2/52) function, model 216
Telephone and GPS roof antenna (A2/49) function, model 221
The emergency call antenna is integrated in the GPS antenna (A2/49a2) in model 216. Circuit 15R
receives the emergency call system control unit from the EIS control unit (N73) via the following route:
Chassis CAN
Central gateway control unit (N93)
Diagnostic CAN
The emergency call system control unit communicates with the restrain systems control unit ("LIFE signal"
every 500 ms) and the ESP control unit via the following route:
Diagnostic CAN
Central gateway control unit
Chassis CAN
The following components are checked each over a discrete line:
Emergency call system antenna splitter
TELE AID backup antennas
Antenna splitter
Restraint systems control unit
Emergency call antenna, model 216
Telephone and GPS roof antenna, model 221
Frequency switchover control unit, model 221 with code (389) Mobile phone preinstallation with
universal interface, USA/Canada
If a malfunction is not present, the two red LEDs integrated into the SOS pushbutton switch extinguish after t =
4 s signaling that the emergency call system is ready for operation.
If a fault exists, it is stored in the memory of the emergency call system control unit. Depending on the fault
type, a message is also displayed in the instrument cluster and the two red LEDs integrated in the SOS push
button are permanently actuated by the emergency call system control unit via a direct line.
The message is displayed in the instrument cluster by the emergency call system control unit via the following
route:
Diagnostic CAN
Central gateway control unit
Central CAN
Function requirements for emergency call system status for automatic emergency call
Circuit 15R
Function sequence for emergency call system status for automatic emergency call
After an automatic emergency call has been triggered (crash recognition including crash level), the emergency
call system control unit actuates one of the two red LEDs integrated into the SOS push button intermittently via
a direct line. One of the two LEDs flashes throughout the actuation period. This is also indicated in the
instrument cluster and on the COMAND display. This is displayed on the instrument cluster via the following
route:
Diagnostic CAN
Central gateway control unit
Central CAN
The display on the COMAND screen is transmitted via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
COMAND controller unit (A40/3)
Low voltage differential signal (LVDS) line
Function requirements for emergency call system status for manual emergency call
Circuit 30
Function sequence for emergency call system status for manual emergency call
After a manual emergency call has been triggered with the SOS push button, the emergency call system control
unit actuates one of the two red LEDs integrated into the SOS push button intermittently via a direct line. One
of the two LEDs flashes throughout the actuation period. This is also indicated in the instrument cluster and on
the COMAND display. This is displayed on the instrument cluster via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
The display on the COMAND screen is transmitted via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
COMAND controller unit
LVDS line
Function requirements for emergency call system status for breakdown assistance
Circuit 30
Function sequence for emergency call system status for breakdown assistance
After the breakdown assistance has been triggered with the telediagnosis button, the emergency call system
control unit actuates the red LED integrated into the telediagnosis button intermittently via a direct line. The
LED flashes during the actuation period. This is also indicated in the instrument cluster and on the COMAND
This is displayed on the instrument cluster via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
The display on the COMAND screen is transmitted via the following route:
Diagnostic CAN
Central gateway control unit
Function sequence for emergency call system status for MB-Info call
After triggering the MB-Info call using the MB-Info button, the emergency call system control unit
intermittently actuates the red LED integrated into the MB-Info button via a direct line. The LED flashes during
the actuation period. This is also indicated in the instrument cluster and on the COMAND display. This is
displayed on the instrument cluster via the following route:
Diagnostic CAN
Central CAN
COMAND controller unit
LVDS line
Function requirements for emergency call system status for MB-Info call
Circuit 30
Central gateway control unit
Central CAN
The display on the COMAND screen is transmitted via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
COMAND controller unit
LVDS line
Function requirements for emergency call system status for vehicle remote door unlock
Circuit 30
Function sequence for emergency call system status for vehicle remote door unlock
After the vehicle remote door unlock feature has been triggered by a telephone call to the service center, the
emergency call system control unit actuates the red LED integrated into the SOS push button intermittently via
a direct line after actuating the trunk lid external operation switch (S88/8). Moreover, the emergency call system
control unit displays the message on the instrument cluster via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
Function sequence for emergency call system status for vehicle remote door lock
After the vehicle remote door lock feature has been triggered by a telephone call to the service center, the
emergency call system control unit actuates the red LED integrated into the SOS push button intermittently via
a direct line. The emergency call system control unit also displays the message in the instrument cluster after
actuating the transmitter key (A8/1) via the following route:
Diagnostic CAN
Central gateway control unit
Central CAN
State displays, emergency call system status
Fig. 41: State Display Of Emergency Call System Status
Courtesy of MERCEDES-BENZ USA
Electrical function diagram for status display of emergency call Model PE82.95-P-2061-
system, function 216 97CAA
Model PE82.95-P-2061-
221 97SAA
Instrument cluster, component description A1 GF54.30-P-6000LE
GF82.85-P-
COMAND controller unit, component description A40/3
3136LEU
COMAND display, component description A40/8 GF54.30-P-6110LE
Restraint systems control unit, component description N2/7 GF91.60-P-4048LE
ESP control unit, component description N47-5 GF42.45-P-5118LE
Component description for the EZS control unit N73 GF80.57-P-6003LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
GF82.95-P-
Emergency call system control unit, component description N123/4
3212LEU
MANUAL OR AUTOMATIC EMERGENCY CALL, FUNCTION - GF82.95-P-2024LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements, general
Emergency call system authorized and operating properly
The vehicle-related manual or automatic emergency call (E-Call), including police emergency number
"911", is authorized separately
An emergency call system control unit (N123/4) communication module authorized for the corresponding
vehicle-related service is configured ex-factory with the telephone number of the corresponding service
provider
The customer is registered and authorized at the service center
One mobile phone network is available in sufficient strength and quality
Global Positioning System (GPS) present
Communication between the emergency call system control unit and the restraint systems control unit
(N2/7) is operating error-free
Production mode deactivated (accomplished following final factory inspection)
Improper actuation of a manual or automatic emergency call is punishable by law!
General
In the event that a driver is confronted with an emergency situation in a remote location, a service center
employee can obtain an overview of the situation inside the vehicle with the aid of the data received from the
emergency call system control unit (voice connection and SMS) and initiate the action required for help. An
emergency call be triggered manually or automatically. The objectives of these emergency calls are:
Automatic alerting of the rescue services after an accident
Alerting of rescue workings at the press of a button (own emergency situation, observed accident)
Reduction of rescue times through fast emergency notification with details on exact location involved
The emergency call function consists of the following subfunctions:
Function sequence for initiating manual emergency call
Function sequence for initiating automatic emergency call
Function sequence for transmission of emergency call data and communication with the service
center
Function requirements for initiating manual emergency call
Circuit 30
Triggering a manual emergency call by pressing the SOS push button (S93/3) > 0.5 s
A higher-priority vehicle-related service is not active
Function sequence for initiating manual emergency call
The emergency call system control unit reads in the SOS pushbutton switch directly via a discrete line.
Function requirements for initiating automatic emergency call
Circuit 15R
Triggering an automatic emergency call by the crash signal and receiving the crash level from the
restrain systems control unit
Function sequence for initiating automatic emergency call
The emergency call system control unit receives the crash signal from the restraint systems control unit
via a discrete line. Simultaneously. the emergency call system control unit receives the crash signal
(redundant) and the crash level from the restrain systems control unit via the following route:
Chassis CAN
Central gateway control unit (N93)
Diagnostic CAN
Function sequence for transmission of emergency call data and communication with the service
center
After a manual or automatic emergency call has been triggered, the emergency call system control unit
completes a voice connection to the service center.
After the service center replies with a special tone, the emergency call system control unit automatically
sends an SMS with the following data to the service center over the integrated communication module:
Vehicle position, direction of ravel and history
Vehicle data and crash analysis (accident severity)
The communication module integrated into the emergency call system control unit transmits and receives
the mobile phone signals or data via the following route:
- Direct line
Frequency switchover control unit (N96), model 221 with code (389) Mobile phone preinstallation
with universal interface, USA/Canada, and direct line
Emergency call antenna (A2/52), model 216
Telephone and GPS roof antenna (A2/49), model 221
The emergency call antenna is integrated in the GPS antenna (A2/49a2) in model 216.
If connection to the service center cannot be established when an automatic emergency call is
triggered, a voice connection is automatically set up using the emergency number "911" and it is then
necessary to communicate the listed data verbally.
When a manual or automatic emergency call is active, this status is indicated by the two red light-
emitting diodes (LED), integrated into the SOS pushbutton switch, flashing. This is also indicated in the
instrument cluster (A1) and on the COMAND display (A40/8).
In the event of a manual or automatic emergency call, other vehicle-related services (e.g. MB-Info
call) are interrupted.
If the telephone and GPS roof antenna, model 221, or the emergency call antenna, model 216, fails
(e.g. malfunction caused by rollover) the emergency call system control unit transmits and receives the
mobile radio signals and data via the following route in order to transfer mobile radio signals and mobile
radio data:
Direct line
Emergency call system antenna splitter (A2/25)
Direct line
Emergency call system left backup antenna (A2/54)
Emergency call system right backup antenna (A2/55)
Electrical function diagram for manual or automatic Model PE82.95-P-2066-
emergency call, function 216 97CAA
Model PE82.95-P-2066-
221 97SAA
Instrument cluster, component description A1 GF54.30-P-6000LE
COMAND display, component description A40/8 GF54.30-P-6110LE
Restraint systems control unit, component description N2/7 GF91.60-P-4048LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
GF82.95-P-
Emergency call system control unit, component description N123/4
3212LEU
POSITION FINDING, FUNCTION - GF82.95-P-3000LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Emergency call system authorized and operating properly
Proper communication with ESP control unit (N47-5)
An emergency call system control unit (N123/4)communication module authorized for the corresponding
vehicle-related service is configured ex-factory with the telephone number of the corresponding service
provider
General
For the Global Positioning System (GPS) position finding, the emergency call system control unit requires the
satellite-supported GPS. It is available worldwide. The GPS satellites permanently transmit time and position
data (longitude and latitude). GPS position finding is irretrievable after vehicle transport (e.g. by train or ferry
or after towing). Relocating with GPS (after interruption of satellite reception) may require several minutes (up
to 20 min when emergency call system control unit is commissioned). Basic position finding runs parallel to
GPS position finding. The position finding function consists of the following subfunctions:
Function sequence for GPS position finding
Basic position finding function sequence
GPS position finding function requirements
Status "Circuit 15R ON" or one of the following vehicle-related services actuated:
Emergency call (E-Call) manual or automatic, including police emergency call number "911"
MB-Info call
Breakdown assistance (Roadside Assistance)
Vehicle tracking
No fault in GPS antenna systems and signals from at least 3 GPS satellites
Function sequence for GPS position finding
The GPS receiver that is integrated in the emergency call system control unit receives the GPS signals from the
GPS antenna (A2/49a2), model 216, or the telephone and GPS roof antenna (A2/49), model 221, via the
following route:
Direct line
Antenna splitter (A2/5)
Direct line
The GPS signals are used by the emergency call system control unit to calculate the current vehicle position
(receiver). In addition, the vehicle's direction of travel is determined with the aid of the sequence of the
locations calculated with GPS.
Basic position finding function requirements
Status "Circuit 15R ON"
Basic position finding function sequence
For basic position finding, the emergency call control unit requires the following information:
Wheel speed signals
Distance traveled data
Direction of travel data (forwards or backwards)
The wheel speed signals are detected by the following RPM sensors:
Left front RPM sensor (L6/1)
Right front RPM sensor (L6/2)
Left rear RPM sensor (L6/3)
Right rear RPM sensor (L6/4)
The wheel speed signals from the RPM sensors are received by the emergency call system control unit via the
following route:
Direct line
ESP control unit
Chassis CAN
Central gateway control unit (N93)
Diagnostic CAN
The distance traveled data from the instrument cluster (A1) is received by the emergency call system control
unit via the following route:
Central CAN
Central gateway control unit
Diagnostic CAN
The emergency call system control unit receives the data on the direction of travel (forwards or backwards)
from the central gateway control unit over the diagnostic CAN. After this the emergency call system control
unit uses the distance traveled, the vehicle alignment and the direction of travel to calculate the vehicle position
(degree of longitude and degree of latitude) at any given time.
Error during position finding
Basic position finding is falsified when a vehicle rolls backwards with "circuit 15 OFF" (ignition switched off)
or if it is transported somewhere. In both instances, the deviation is automatically corrected by the navigation
processor integrated into the emergency call system control unit when it receives GPS data.
Electrical function diagram for position finding, functionModel 216 PE82.95-P-2070-97CAA
Model 221 PE82.95-P-2070-97SAA
Instrument cluster, component description A1 GF54.30-P-6000LE
ESP control unit, component description N47-5 GF42.45-P-5118LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
Emergency call system control unit, component description N123/4 GF82.95-P-3212LEU
POSITION FINDING, FUNCTION - GF82.95-P-3000SXR
MODEL 221.0 /1 as of 1.1.06 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
If an accident occurs, the emergency call system control unit (N123/4) automatically generates an emergency
call telegram containing the vehicle position data and transmits the telegram over the cellular telephone system
of the vehicle. The emergency call signal reaches the service provider. With the equipment there, the exact
position of the vehicle is determined using the position data. The vehicle position data are determined in parallel
with 2 methods which complement each other. The methods are known as Global Positioning System (GPS)
position finding and basic position finding.
GPS position finding
The GPS is a satellite-assisted localizing system that has been set up by the American Ministry of Defense. It is
free and available worldwide.
The GPS satellites permanently transmit time and position data (longitude and latitude). GPS position finding is
irreplaceable for journeys outside the digitized map area and after vehicle transport (e.g. by train or ferry or
after towing). Relocating with GPS (after interruption of satellite reception) may require several minutes (up to
20 min when emergency call system control unit is commissioned). The processor and receiver unit for the GPS
are integrated into the emergency call system control unit. If signals from at least 3 satellites are received on
model 221 over the telephone and GPS roof antenna (A2/49), or on model 216 over the telephone and GPS
antenna (A2/49), it is possible to calculate the position and the accuracy of position finding of the receiver
(vehicle). In addition, the vehicle's direction of travel is determined with the aid of the sequence of the locations
calculated with GPS.
Basic location finding
For basic position finding, which runs in parallel to the GPS position finding, the emergency call system control
unit requires the following information:
The signals processed by the ESP control unit (N47-5) from the left front RPM sensor (L6/1), right front
RPM sensor (L6/2), left rear RPM sensor (L6/3) and right rear RPM sensor (L6/4) are sent to the central
gateway control unit (N93) over the chassis CAN. The central gateway control unit receives the message
and transmits it over the diagnostic CAN to the emergency call system control unit.
The data of the turn rate sensor (gyro sensor) integrated in the emergency call system control unit (the
emergency call system control unit uses these data to calculate the vehicle orientation (compass
direction)).
The data on the direction of travel (forward or reverse).
The basic position finding is performed continuously by the emergency call system control unit with "circuit
15R ON". The current vehicle position (longitude/latitude) is calculated from the traveled distance under
consideration of the vehicle orientation and direction of travel.
Errors with basic position finding
Rolling backwards with "circuit 15 OFF" (ignition switched off) or a transport of the vehicle can falsify the
position finding. In both cases, when GPS data are received, the deviation is automatically corrected by the
navigation processor integrated into the emergency call system control unit.
Tracking (dynamic assignment)
Tracking is used e.g. to be able to track stolen vehicles.
Actuation
To track the vehicle, the function has to be activated first. The following possibilities exist to do this:
Customer reports the theft
The anti-theft alarm system (ATA) is active for more than 30 s
The difference in procedures only lies in how tracking is activated.
Reporting a theft (over the phone)
The customer calls the service provider and reports the theft of the vehicle. Next, the customer has to prove
his/her identity. This is accomplished with the user name and the Personal Identification Number (PIN) of the
customer. If the service provider has determined that the message has been received from a proper customer
then the function is activated by telephone.
To do so, the service provider transmits an initiation command to the vehicle. The vehicle receives the message
on model 221 over the telephone and GPS roof antenna and on model 216 over the telephone and GPS antenna
and forwards the message to the emergency call system control unit.
The emergency call system control unit activates the locating calculation, which is performed with the aid of the
satellite signals that are received on model 221 over the telephone and GPS roof antenna and on model 216 over
the telephone and GPS antenna. Next, the emergency call system control unit cyclically transmits the position
data to the service provider. The service provider forwards the location of the vehicle to the command staff (e.g.
police). The command staff can activate the hands-free system and decide, whether to eavesdrop or talk to the
driver.
ATA (automatic)
If the ATA is triggered and is active for more than 30 s, the emergency call system control unit establishes a
voice connection to the command staff. The emergency call system control unit activates the locating
calculation, which is performed with the aid of the satellite signals that are received on model 221 over the
telephone and GPS roof antenna and on model 216 over the telephone and GPS antenna.
Following this, the emergency call system control unit sends the position data cyclically to the service provider
on model 221 over the telephone and GPS roof antenna and on model 216 over the telephone and GPS antenna.
The service provider forwards the location of the vehicle to the command staff (e.g. police).
Tracking can only be deactivated by the service provider.
GPS antenna splitter, component GF82.62-P-
description 3129SXU
Telephone and GPS roof antenna Model 221.0/1 as of 1.1.06 up to 31.8.06 with code GF82.62-P-
component description (494) USA version 4119SXR
Model 221.0/1 as of 1.9.06 with code (494) USA
version
Model 221.0/1 with code (389) Mobile phone GF82.62-P-
preinstallation with universal interface, USA/ 4119SXX
Canada
Model 216.3
Frequency switchover control unit, GF82.62-P-
component description 4204SXU
Emergency call system control GF82.95-P-
unit, component description 3212SXR
Emergency call antenna splitter GF82.95-P-
component description 4001SXU
Emergency call system backup GF82.95-P-
antennas component description 4002SXU
SELECTING TELEPHONE ANTENNA, FUNCTION - GF82.95-P-3001LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Status circuit 30 or "Circuit 15R ON"
Emergency call system authorized and operating properly
Defective GPS antenna (A2/49a2), model 216, or GPS and telephone antenna (A2/49), model 221, or
poor reception
The emergency call antenna (A2/52) is integrated in the GPS antenna in model 216.
General
Normally the mobile phone signals or data for the following vehicle-related services are transmitted and
received by the communication module integrated into the emergency call system control unit (N123/4), model
216, or the GPS and telephone roof antenna, model 221:
Authorization (provisioning)
Emergency call (E-Call) manual or automatic, including police emergency call number "911"
MB-Info call
Breakdown assistance (Roadside Assistance)
Vehicle tracking
Vehicle remote door unlock
Vehicle remote door lock
In the event of a fault in the emergency call antenna, model 216, or the telephone and GPS roof antenna, model
221, the communication model integrated into the emergency call system control unit automatically transmits
and receives via the left emergency call system backup antenna (A2/54) and the right emergency call system
backup antenna (A2/55).
Function sequence
The emergency call system control unit monitors the emergency call antenna, model 216, or the telephone and
GPS roof antenna, model 221, via a direct line.
The emergency call system control unit detects the failure (e.g. malfunction caused by rollover) or inadequate
reception on the emergency call antenna, model 216, or the telephone and GPS roof antenna, model 221, and
then automatically transmits or receives the mobile radio signals or data for the relevant vehicle-related services
via the following route:
Direct line
Emergency call system antenna splitter (A2/25)
Direct line
Emergency call system left backup antenna
Emergency call system right backup antenna
function 216 97CAA
Model PE82.95-P-2062-
221 97SAA
Emergency call system control unit, component description N123/4 GF82.95-P-3212LEU
SELECTING TELEPHONE ANTENNA, FUNCTION - GF82.95-P-3001SXR
MODEL 221.0 /1 as of 1.1.06 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Under normal circumstances, the telephone connections are handled over the frequency switchover control unit
(N96) and, on model 221, over the telephone and GPS roof antenna (A2/49) on the roof or, on model 216, over
the telephone and GPS antenna (A2/49) in the trunk lid.
In the event of a defect of the telephone and GPS roof antenna (model 221) or of the telephone and GPS
antenna (model 216), e.g. due to a rollover or poor reception, 2 backup antennas are available in the rear
bumper of the vehicle, which are designated as emergency call system left backup antenna (A2/54) and
emergency call system right backup antenna (A2/55).
The emergency call system control unit on model 221 detects a failure or poor reception of the telephone and
GPS roof antenna and on model 216 of the telephone and GPS antenna and then automatically actuates over the
emergency call system antenna splitter (A2/25) the emergency call system left backup antenna and the
emergency call system right backup antenna.
GPS antenna splitter, component GF82.62-P-
description 3129SXU
Telephone and GPS roof antenna Model 221.0/1 as of 1.1.06 up to 31.8.06 with code GF82.62-P-
component description (494) USA version 4119SXR
Model 221.0/1 as of 1.9.06 with code (494) USA
version
Model 221.0/1 with code (389) Mobile phone GF82.62-P-
preinstallation with universal interface, USA/ 4119SXX
Canada
Model 216.3
Frequency switchover control unit, GF82.62-P-
component description 4204SXU
Emergency call system control GF82.95-P-
unit, component description 3212SXR
Emergency call antenna splitter GF82.95-P-
component description 4001SXU
antennas component description 4002SXU
RESTRAINT SYSTEM CONTROL UNIT DATA, FUNCTION - GF82.95-P-3005LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 09/YoM 08
Function requirements
Status "Circuit 15R ON"
Proper communication with restrain systems control unit (N2/7)
Automatic crash recognition including crash level by restraint systems control unit
General
In the event of an accident with airbag actuation, an automatic emergency call (E-Call) is transmitted
immediately. An emergency call is sent out regardless of the severity of the accident.
Function sequence
The emergency call system control unit (N123/4) receives the crash data from the restraint systems control unit,
on the one hand via a direct line as a digital crash signal and, on the other hand, it also receives the data
(redundantly) including the crash level via the following route:
Chassis CAN
Central gateway control unit (N93)
Diagnostic CAN
The restraint systems control unit sends a LIFE signal (the LIFE signal is the "life sign" from the restraint
systems control unit) every t = 500 ms over the same path as the crash information including crash level. This
allows the emergency call system control unit to permanently monitor communication with the restraint systems
control unit and proper function of the crash recognition.
Electrical function diagram for data from restraint systems Model PE82.95-P-2063-
control unit, function 216 97CAA
Model PE82.95-P-2063-
221 97SAA
Restraint systems control unit, component description N2/7 GF91.60-P-4048LE
Central gateway control unit, component description N93 GF54.21-P-4170LE
GF82.95-P-
Emergency call system control unit, component description N123/4
3212LEU
RESTRAINT SYSTEM CONTROL UNIT DATA, FUNCTION - GF82.95-P-3005SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
The emergency call system control unit (N123/4) receives the messages listed in the following via a discrete
line as a digital crash signal from the restraint systems control unit (N2/7) and additionally (redundantly) via the
diagnostic CAN from the central gateway control unit (N93). The central gateway control unit receives the
message via the chassis CAN from the restraint systems control unit.
Crash data on chassis CAN and diagnostic CAN Byte no. 1
CRASH DATA ON CHASSIS CAN AND DIAGNOSTIC CAN
Byte no. 1
Bit no. Crash level Type of accident
Bit 0 CRASH_A Head-on collision 1
Bit 1 CRASH_B Rear end collision 1
Bit 2 CRASH_C Head-on collision 5
Bit 3 CRASH_D Side impact 1
Bit 4 CRASH_E Rear end collision 2
Bit 5 CRASH_F Head-on collision 2
Bit 6 CRASH_G Rollover 1
Bit 7 CRASH_Tgl Confirmation bit
Byte no. 2
Bit no. Crash level Type of accident
Bit 0 CRASH_H Rollover 2
Bit 1 CRASH_I Rollover 3
Bit 2 CRASH_K Rear end collision 3
Bit 3 CRASH_L Side impact 2
Bit 4 CRASH_M Unassigned
Bit 5 CRASH_N Unassigned
Bit 6 CRASH_O Unassigned
Bit 7 CRASH_X Unassigned
A vehicle crash is automatically detected by the restraint systems control unit. The emergency call system
control unit receives the crash information as a digital crash signal from the restraint systems control unit via a
discrete line, and additionally (redundantly) via the chassis CAN from the central gateway control unit. In the
event of an accident, an emergency call is automatically sent out immediately. An emergency call is sent out
regardless of the severity of the accident.
Error messages
The restraint systems control unit sends a signal every 500 ms. This indicates to the emergency call system
control unit that the crash recognition feature is operating properly.
The restraint systems control unit performs a self-test cyclically. Any lighting of the red light emitting diode
(LED) in the SOS pushbutton switch (S93/3) in normal mode indicates a fault in the Telematic Alarm
Identification on Demand (emergency call system) (TELE AID). The corresponding error message is then
shown on the COMAND display (A40/8) and in the multifunction display (A1p13) of the instrument cluster
(A1). The red LED in the SOS pushbutton switch is illuminated until circuit 15 is switched off or the fault has
been rectified. The SOS pushbutton switch is monitored. A stuck SOS pushbutton switch is detected. The fault
signal is ignored and TELE AID remains operational.
SOS switch, component GF82.95-P-
description 3210SXU
Emergency call system control Model 221.0/1 up to 31.12.05 with code (494) USA GF82.95-P-
unit, component description version 3212SXU
Model 221.0/1 as of 1.1.06 with code (494) USA
version
GF82.95-P-
Model 221.0/1 with code (389) Mobile phone
3212SXR
preinstallation with universal interface, USA/ Canada
Model 216.3
Restraint systems control unit, GF91.60-P-
component description 4048SX
SOS SWITCH, COMPONENT DESCRIPTION - GF82.95-P-3210SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Illustrated on model 221
Location
The SOS pushbutton switch is integrated in the overhead control panel control unit (N70).
Fig. 42: Locating SOS Pushbutton Switch
Courtesy of MERCEDES-BENZ USA
Task
The following are the primary tasks of the SOS pushbutton switch:
Actuation of a manual Telematic Alarm Identification on Demand (emergency call system) (TELE AID)
emergency call
Visual feedback signal of the TELE AID operating conditions in the event of a manual as well as an
automatic emergency call
Design
The SOS pushbutton switch is designed primarily as follows:
Switch contact
A control resistor in parallel to the switch contact
Cap with inscription "SOS"
Integrated light-emitting diodes (LED) for night illumination (circuit 58d) and to indicate operating
condition
Function
In the park position, electric current flows through the control resistor installed in the SOS pushbutton switch
(parallel to switch contact). When current is flowing through the resistor, the emergency call system control unit
(N123/4) knows that the voltage supply line and the ground line are functioning properly. When pressing the
SOS pushbutton switch, the control resistor is bridged by a switch contact. The SOS pushbutton switch is read
in by the emergency call system control unit over a discreet line. When the SOS button is pressed, a manual
emergency call is recognized by the emergency call system control unit and then transmitted.
COMPONENT DESCRIPTION FOR EMERGENCY CALL SYSTEM CONTROL UNIT - GF82.95-P-
3212LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 2009 /YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 2009 /YoM 08
Shown on model 221
Fig. 43: Locating Emergency Call System Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The emergency call system control unit is located in the trunk at the left front at the rear wall.
Task
Realization of vehicle-related services
Regulation of priorities over integrated priority management
Communication management between vehicle and service center
Forwarding vehicle position and identification as well as other required data to the service center
Audio management
Display management
Fault handling
Receive signals
Transmit signals
Realization of vehicle-related services
Realization of following vehicle-related services:
Authorization (provisioning)
Emergency call (E-Call) manual or automatic, including police emergency call number "911"
MB-Info call
Breakdown assistance (Roadside Assistance)
Vehicle tracking
Vehicle remote door unlock
Vehicle remote door lock
Regulation of priorities over integrated priority management
Priority Service
1. Automatic emergency call
2. Manual emergency call
3. Vehicle tracking
4. Roadside assistance
5. MB information call
6. Authorization
7. Vehicle remote unlocking 7 Vehicle remote locking
Communication management between vehicle and service center
Communication management between the vehicle and Service Center over the integrated communication
module and the mobile telephone network as well as forwarding information to the customer when
required
Forwarding vehicle position and identification as well as other required data to the service center
Forwarding vehicle position and identification as well as other required data to the service center after
activation by the following actions:
Crash signal from restraint systems control unit (N2/7), for automatic emergency call
Actuation of SOS pushbutton switch (S93/3), for manual emergency call
Actuation of MB-Info button (S93/6s1), for MB-Info call
Actuation of Telediagnosis button (S93/6s2), for breakdown assistance
Call to Service Center and operation of trunk lid external operation switch (S88/8), for vehicle
remote door unlock and lock
Call to Service Center and reporting of theft for vehicle tracking
Audio management
Output of audio signals on the center cockpit speaker (Centerfill) (H4/27)
Fault handling
After activation of circuit 15R, the emergency call system control unit performs a self-test (for approx. t = 3.5
s). If the self-test is successful, the emergency call system is then ready for operation.
Display management
Display management on COMAND display (A40/8), in the instrument cluster (A1), in the SOS push
button, in the MB-Info button or the telediagnosis button
In the event of a fault, a fault message is displayed on the instrument cluster, depending on the type of fault, and
the two red light-emitting diodes (LEDs) in the SOS pushbutton switch are actuated continuously. Depending
on the fault type, the fault is also stored in the emergency call system control unit's memory.
Receive signals
Direct lines
Controller Area Network (data bus/CAN bus) (CAN)
Direct lines
Power supply over circuit 30 and circuit 31 over one direct line each
Status signal for circuit 15R over a direct line
SOS pushbutton switch over discrete line
MB-Info button signal over discrete line
Telediagnosis button signal over discrete line
Digital crash signal from restraint systems control unit over a direct line
Signals from hands-free system microphone group (A67b1) over the voice control system control unit
(VCS [SBS]) (N41/3) (up to 31.5.09) or from the COMAND controller unit (A40/3) (as of 1.6.09) over
direct lines
Mobile radio signals or data from the emergency call antenna (A2/52) over a coaxial cable, model 216
Mobile phone signals or data from telephone and GPS roof antenna (A2/49) over the frequency
switchover control unit (N96) (with code (389) Mobile phone preinstallation with universal interface
USA/Canada) and a coaxial cable, model 221
GPS signals from the GPS antenna (A2/49a2) over the antenna splitter (A2/5) and a coaxial cable, model
216
GPS signals from the telephone and GPS roof antenna over the antenna splitter and a coaxial cable, model
221
Mobile phone signals or data from the left emergency call system backup antenna (A2/54) and the right
emergency call system backup antenna (A2/55) over the emergency call system antenna splitter (A2/25)
and a coaxial cable
The emergency call antenna on model 216 is integrated into the GPS antenna.
CAN
Diagnostic CAN (CAN D) low
Diagnostic CAN high
The emergency call system control unit is a diagnostic CAN subscriber. The emergency call system control unit
receives the crash information from the restraint systems control unit redundantly including the crash level as
follows:
Chassis CAN (CAN-E)
Central gateway control unit (N93)
Diagnostic CAN
Transmit signals
Direct lines
Voice output on center cockpit speaker (Centerfill) over discrete line
Actuation signal for LEDs in SOS pushbutton over direct line
Actuation signal for LED in MB-Info button switch over discrete line
Actuation signal for LED in Telediagnosis button switch over discrete line
Audio mute (MUTE) over a direct line to the audio tuner control unit (N93/1) or to the digital sound
processor (A2/69) (model 221 as of 1.9.10 with code (811) Advanced Sound System)
Mobile phone signals or data to the telephone and GPS roof antenna over the frequency switchover
control unit (with code (389) Mobile phone preinstallation with universal interface USA/Canada) and a
coaxial cable, model 221
Mobile radio signals or data to the emergency call antenna over a coaxial cable, model 216
Mobile phone signals or data to the emergency call system left backup antenna and to the emergency call
system right backup antenna
Wake-up signal to COMAND controller unit
The emergency call antenna on model 216 is integrated into the GPS antenna.
Design
Integrated communication module
Integrated locating module
Integrated Global Positioning System (GPS) receiver for position finding (Date, time, history and last
known location) for listed vehicle-related services
Memory for vehicle-specific data
Function
The emergency call system control unit has its own microprocessor. A differentiation is made between the 2
subareas of the communication module and the locating module. The emergency call system control unit
centrally processes all the vital data for the listed vehicle-related services.
The emergency call system control unit uses the installed locating module to calculate the vehicle position and
generates a data telegram in the form of a Short Message Service (SMS) message, if one of the following
vehicle-related services is activated:
Manual or automatic emergency call, including police emergency call number "911"
MB-Info call
Breakdown assistance
Vehicle remote door unlock
communication module
The communication module integrated into the emergency call system control unit is a mobile phone
transceiver enabling voice and data communication with the service center over mobile phone frequencies.
Other functions of the communication module are:
day transmission and reception capability, as soon as an SMS is received, the emergency call system
control unit is activated (wake-up); after 4 days the emergency call system reverts to the "sleep mode"
Following activation a self-diagnosis is performed and the result sent to the "controller"
If the telephone and GPS roof antenna malfunctions, model 221, or the emergency call antenna, model
216, (e.g. defective through rollover) the emergency call system control unit sends and receives the mobile
radio signals or mobile radio data as follows to transmit the mobile radio signals or mobile radio data:
Direct line
Emergency call system antenna splitter
Direct line
Emergency call system left backup antenna
Emergency call system right backup antenna
The emergency call antenna on model 216 is integrated into the GPS antenna.
Wiring diagram for emergency call system control unit Model 216 PE82.95-P-2101-97CAA
Model 221 PE82.95-P-2101-97SAA
EMERGENCY CALL SYSTEM CONTROL UNIT, COMPONENT DESCRIPTION - GF82.95-P-
3212SXR
MODEL 221.0 /1 as of 1.1.06 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Illustrated on model 221
Fig. 44: Locating Emergency Call System Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The emergency call system control unit is located in the luggage compartment at the left front at the rear wall.
Task
The emergency call system control unit is responsible for the following functions:
Integrated telephone module for Telematic Alarm Identification on Demand (emergency call system)
(TELE AID) emergency call, MB-Info call and telediagnosis call
Independent position sensing
Acquiring and storing vehicle-specific data (e.g. circuit status)
Actuation of telephone and GPS roof antenna (A2/49) (on model 221) or of the telephone and GPS
antenna (A2/49) (on model 216), over the frequency switchover control unit (N96), or actuation of the
backup antennas, consisting of the emergency call system left backup antenna (A2/54) and the emergency
call system right backup antenna (A2/55), over the emergency call system antenna splitter (A2/25)
Input of crash data from the restraint systems control unit (N2/7) via a discrete line
Vehicle remote door unlocking
Vehicle remote door locking
Reading in the SOS pushbutton switch (S93/3) and MB-Info and telediagnosis button group (S93/6) over
2 separate and discreet lines
Satellite data from the telephone and GPS roof antenna (on model 221) or from the telephone and GPS
antenna (on model 216), over the antenna splitter
Generating and keeping an SMS ready
Muting other audio signals (e.g. radio, navigation)
Design
The emergency call system control unit is designed primarily as follows:
Integrated telephone module
Integrated navigation module
Integrated additional battery
Memory for vehicle-specific data
Screened metal housing
Function
The emergency call system control unit has its own microprocessor. It also has 2 sub-units, a telephone module
and a navigation module. All the relevant data for a TELE AID emergency call are processed centrally in the
emergency call system control unit. The emergency call system control unit calculates the vehicle position with
the aid of the installed navigation module and generates a TELE AID emergency call telegram in the form of an
SMS in the event of a TELE AID emergency call.
The crash data are received from the restraint systems control unit via a discrete serial interface.
The emergency call system control unit can be diagnosed over a diagnosis CAN through the central
gateway control unit (N93) using STAR DIAGNOSIS.
EMERGENCY CALL SYSTEM CONTROL UNIT, COMPONENT DESCRIPTION - GF82.95-P-
3212SXU
MODEL 221.0 /1 up to 31.12.05 with CODE (494) USA version
Fig. 45: Locating Emergency Call System Control Unit
Courtesy of MERCEDES-BENZ USA
Location
The emergency call system control unit is located in the luggage compartment at the left front at the rear wall.
Task
The emergency call system control unit is responsible for the following functions:
Integrated telephone module for Telematic Alarm Identification on Demand (emergency call system)
(TELE AID) emergency call, MB-Info call and telediagnosis call
Independent position sensing
Acquiring and storing vehicle-specific data (e.g. circuit status)
Actuation of the emergency call antenna (A2/52) or of the backup antennas, consisting of the emergency
call system left backup antenna (A2/54) and the emergency call system right backup antenna (A2/55),
over the emergency call system antenna splitter (A2/25)
Voice output over the center cockpit center speaker (centerfill) (H4/27)
Input of crash data from the restraint systems control unit (N2/7) via a discrete line
Vehicle remote door unlocking
Vehicle remote door locking
Reading in the SOS pushbutton switch (S93/3) and MB-Info and telediagnosis button group (S93/6) over
2 separate and discreet lines
Satellite data from telephone and GPS roof antenna (A2/49) over the antenna splitter (A2/5)
Generating and keeping an SMS ready
Muting other audio signals (e.g. radio, navigation)
Design
The emergency call system control unit is designed primarily as follows:
Integrated telephone module
Integrated navigation module
Integrated additional battery
Memory for vehicle-specific data
Screened metal housing
Function
The emergency call system control unit has its own microprocessor. It also has 2 sub-units, a telephone module
and a navigation module. All the relevant data for a TELE AID emergency call are processed centrally in the
emergency call system control unit. The emergency call system control unit calculates the vehicle position with
the aid of the installed navigation module and generates a TELE AID emergency call telegram in the form of an
SMS in the event of a TELE AID emergency call.
The crash data are received from the restraint systems control unit via a discrete serial interface.
The emergency call system control unit can be diagnosed over a diagnosis CAN through the central
gateway control unit (N93) using STAR DIAGNOSIS.
MB-INFO AND TELEDIAGNOSIS BUTTON GROUP, COMPONENT DESCRIPTION - GF82.95-P-
3213SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Illustrated on model 221
Fig. 46: Locating MB-Info And Telediagnosis Button Group
Courtesy of MERCEDES-BENZ USA
Location
The MB-Info and telediagnosis button group with the integrated MB-Info button and the integrated
telediagnosis button is located in the center console at the right of the UPCI [UHI] portable CTEL holder
(Universal Handy Interface) (A34/15).
Design
Basically, the MB-Info and telediagnosis button group with the integrated MB-Info button and the integrated
telediagnosis button consists of the following:
integrated light emitting diodes (LED) for the night illumination (circuit 58d)
integrated LEDs for display of the operating conditions (telediagnosis and MB-Info)
The MB-Info button and the telediagnosis button are each equipped with a control resistor connected in
parallel to the switch contact
Task
The MB-Info and telediagnosis button group with the integrated MB-Info button and the integrated
telediagnosis button can be used - depending on the direction of actuation - to trigger either a telediagnosis call
or an MB-Info call. In addition, the respective operating condition is indicated to the driver by means of the 2
integrated LEDs.
Function
In quiescent position, an electrical current flows over the control resistors installed in the MB-Info and
telediagnosis button group with the integrated MB-Info button and the integrated telediagnosis button
(connected in parallel to the switch contact). The emergency call system control unit (N123/4) thus knows that
the voltage supply lines and the ground line are OK. When the MB-Info button or the telediagnosis button is
pressed, the respective control resistance is bridged by the respective switch contact. The MB-Info and
telediagnosis button group with the integrated MB-Info button and the integrated telediagnosis button is read in
over 4 discrete lines by the emergency call system control unit. When the MB-Info button or the telediagnosis
button is pressed, the emergency call system control unit transmits the corresponding request. The emergency
call system control unit then actuates the respective LED for the triggered function to provide the driver with a
visual feedback.
EMERGENCY CALL ANTENNA SPLITTER COMPONENT DESCRIPTION - GF82.95-P-4001SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Illustrated on model 221
Fig. 47: Locating Emergency Call System Antenna Splitter
Courtesy of MERCEDES-BENZ USA
Location
The emergency call system antenna splitter is installed in the front of the trunk on the left-hand side.
Task and function
The emergency call system antenna splitter connects the emergency call system left backup antenna (A2/54)
and the emergency call system right backup antenna (A2/55). The emergency call system left backup antenna
and the emergency call system right backup antenna are used on model 221 up to 31.12.05 by the telephone
module for Telematic Alarm Identification on Demand (emergency call system) (TELE AID) in case of failure
of the emergency call antenna (A2/52) or in case of poor reception or transmission quality of the emergency call
antenna over the emergency call system antenna splitter.
On model 221 as of 1.1.06 and on model 216, the emergency call system left backup antenna and the
emergency call system right backup antenna are used by the TELE AID in case of failure or poor reception or
transmission quality of the telephone and GPS roof antenna (A2/49) (model 221) or telephone and GPS antenna
(A2/49) (model 216) over the emergency call system antenna splitter.
EMERGENCY CALL SYSTEM BACKUP ANTENNAS COMPONENT DESCRIPTION - GF82.95-P-
4002SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
Shown on left-hand side of model 221
Fig. 48: Locating Emergency Call System Left Backup Antenna
Courtesy of MERCEDES-BENZ USA
Location
The emergency call system left backup antenna is installed at the left rear and the emergency call system right
backup antenna (A2/55) at the right rear behind the bumper. The emergency call system left backup antenna and
the emergency call system right backup antenna are accessible from the trunk.
Task and function
On model 221 up to 31.12.05, the emergency call system left backup antenna and the emergency call system
right backup antenna receive and transmit - in the event of a failure of the emergency call antenna (A2/52) - the
mobile phone network data over the emergency call system antenna splitter (A2/25) from and to the emergency
call system control unit (N123/4).
On model 221 as of 1.1.06 and on model 216 as of 1.1.06, the emergency call system left backup antenna and
the emergency call system right backup antenna receive and transmit - in the event of a failure of the telephone
and GPS roof antenna (A2/49) (model 221) or of the telephone and GPS antenna (A2/49) (model 216) - the
mobile phone network data over the emergency call system antenna splitter from and to the emergency call
system control unit.
OVERVIEW OF EMERGENCY CALL SYSTEM COMPONENTS - GF82.95-P-9995LEU
MODEL 216 with CODE (359) TELE AID emergency call system as of model year 2009/YoM 08
MODEL 221 with CODE (359) TELE AID emergency call system as of model year 2009/YoM 08
GF54.30-P-
Component description for instrument cluster A1
6000LE
A2/69
Digital sound processor, component GF82.62-P-
Model 221 as of YoM 10 with code
description 5011LE
(811) Advanced Sound System
Component description for COMAND GF82.85-P-
A40/3
controller unit 3136LEU
GF54.30-P-
COMAND display, component description A40/8
6110LE
Component description for restraint systems GF91.60-P-
N2/7
control unit 4048LE
Component description for rear SAM control GF54.21-P-
N10/2
unit with fuse and relay module 6030LE
N41/3
Component description for voice control GF82.70-P-
Up to 31.5.09 with code (813) Voice
system (VCS [SBS]) control unit 4300LE
control system (VCS [SBS])
GF42.45-P-
Component description for ESP control unit N47-5
5118LE
GF80.57-P-
EZS control unit, component description N73
6003LE
Component description for central gateway GF54.21-P-
N93
control unit 4170LE
N93/1
description 3132LES
Component description for emergency call GF82.95-P-
N123/4
system control unit 3212LEU
Table of contents for function description of GF82.95-P-
emergency call system 0996LEU
OVERVIEW OF SYSTEM COMPONENTS FOR THE TELE AID EMERGENCY CALL SYSTEM,
COMPONENT DESCRIPTION - GF82.95-P-9997SXU
MODEL 221.0 /1 with CODE (494) USA version up to Model Year 8
MODEL 221.0 /1 with CODE (389) Mobile phone preinstallation with universal interface, USA/Canada
up to Model Year 8
MODEL 216.3 with CODE (494) USA version up to Model Year 8
GPS antenna splitter, component GF82.62-P-
description 3129SXU
Telephone and GPS roof antenna Model 221.0/1 up to 31.12.05 with code (494) USA GF82.62-P-
component description version 4119SX
Model 221.0/1 as of 1.1.06 up to 31.8.06 with code GF82.62-P-
(494) USA version 4119SXR
Model 221.0/1 as of 1.9.06 with code (494) USA
version
Model 221.0/1 with code (389) Mobile phone GF82.62-P-
preinstallation with universal interface, USA/ 4119SXX
Canada
Model 216.3
Model 221.0/1 as of 1.1.06 with code (494) USA
version
Frequency switchover control unit, Model 221.0/1 with code (389) Mobile phone GF82.62-P-
component description preinstallation with universal interface, USA/ 4204SXU
Canada
Model 216.3
Speaker system, component GF82.62-P-
description 4220SXS
GF82.95-P-
SOS switch, component description
3210SXU
Emergency call system control Model 221.0/1 up to 31.12.05 with code (494) USA GF82.95-P-
unit, component description version 3212SXU
Model 221.0/1 as of 1.1.06 with code (494) USA
version GF82.95-P-
Model 221.0/1 with code (389) Mobile phone 3212SXR
preinstallation with universal interface, USA/
Model 216.3
MB-Info and telediagnosis button GF82.95-P-
group, component description 3213SXU
Emergency call antenna component Model 221.0/1 up to 31.12.05 with code (494) USA GF82.95-P-
description version 4000SXU
Emergency call antenna splitter GF82.95-P-
component description 4001SXU
Emergency call system backup GF82.95-P-
antennas component description 4002SXU
Restraint systems control unit, GF91.60-P-
component description 4048SX
Contents, function description of GF82.95-P-
TELE AID 0999SXU
ENGINE
Engine Cooling System - General Information - S-Class (221)
GENERAL INFORMATION
NOTES ON COOLANT - AH20.00-N-2080-01A
All engines
Coolant composition
Passenger car and commercial vehicle engines (normally): 50% water by volume and 50%
anticorrosion/antifreeze agent by volume.
Different coolant composition for CV engines, refer to MB Specifications for Operating Fluids .
Tasks of anticorrosion/antifreeze agent
Corrosion and cavitation protection for all components in cooling system
Antifreeze protection (frost protection)
Increase the boiling point so that coolant does not evaporate so rapidly. Avoiding ejection of coolant at
high coolant temperatures.
Antifreeze protection
50% anticorrosion/antifreeze agent by volume provides antifreeze protection down to approx. -37°C. A higher
concentration is only necessary if the ambient temperatures are even lower. 55% anticorrosion/antifreeze agent
by volume provides antifreeze protection down to approx. -45°C.
A concentration of more than 55% anticorrosion/antifreeze agent by volume should not be used as the
maximum antifreeze protection is already reached at this concentration. An even higher concentration once
reduces antifreeze protection and impairs heat dissipation. Reduced heat dissipation can result in damage to
components of the cooling system and to the engine.
Water
Use water which is clean and not too hard. Drinking water often satisfies requirements, but not always The
amount of dissolved substances in the water may be of significance for the occurrence of corrosion. If in doubt,
analyze the water.
For fresh water specifications refer to MB Specifications for Operating Fluids.
Period of use
The maximum permissible period of use of the coolant is given in the maintenance booklet, the applicable
"Service/Maintenance Sheet" or the MB-Specifications for Operating Fluids.
For the period of use for a varying coolant composition for CV engines, refer to MB Specifications for
Operating Fluids.
Before pouring in fresh coolant, flush the used coolant out of the cooling system. In the case of severe
fouling by dirt or oil, clean the cooling system otherwise components of the cooling system can be damaged.
If the drained coolant is reused, it is essential that the coolant be filtered before it is filled into the cooling
system. No dirt particles may enter the cooling system, otherwise components of the cooling system may be
damaged.
Disposing of coolants
Observe the legal provisions and local waste water regulations. The following brochures are available about
disposing of waste products in auto repair trade for the location Federal Republic of Germany:
"Environmental protection manual for motor vehicle repair operations"
Publisher: Verband der Automobilindustrie e.V. (VDA) 60325 Frankfurt am Main, Westendstrabe 61 to be
ordered under: Tel no.:069/97507-0 or at www.vda.de
or
"The new waste laws"
Publisher: Zentralverband Deutsches Kraftfahrzeuggewerbe e. V. (ZDK)
53129 Bonn, Franz-Lohe-Strabe 21 to be ordered under:
Tel. no.:0261/8059-584, Fax no. 0261/8059-585 or at www.kfzgewerbe.de
NOTES ON COOLANT LEVEL - AH20.00-P-1142-01V
Engine 273 in MODEL 211, 216, 219, 221, 230
ENGINE 157 in MODEL 216, 221, 231
ENGINE 275 in MODEL 215, 216, 220, 221, 230
ENGINE 156 in MODEL 211, 216, 219, 221, 230
Model 216 with engine 156, 157, 273, 278,
model 221 with engine 156, 157, 272, 273, 276, 278, 629, 642, 651,
Model 216, 221 with engine 275, main circuit
When the engine is cold, the engine coolant level must reach up to the marking (arrow) in the coolant expansion
reservoir.
When the coolant is warm: approx. 1 cm above this scribe mark.
Fig. 1: Locating Engine Coolant Level Marking On Coolant Expansion Reservoir
Courtesy of MERCEDES-BENZ USA
Model 215, 216, 220, 221, 230 with engine 275, low temperature circuit
Model 240 with engine 285, low temperature circuit
The engine coolant level must be placed, when coolant is warm or cold, in the cross-hatched illustrated area of
filler neck.
Fig. 2: Locating Engine Coolant Level
Courtesy of MERCEDES-BENZ USA
MODEL all
General information on the ENGINE 111, 112, 113, 119, 166, 271, 602, 603, 604,
AH20.00-P-
coolant preheater 605, 606, 611, 612, 613, 668... 1001-01A
Notes on application of sealant AH20.10-P-
ENGINE 113...
to coolant pump housing 0001-02RVK
AH20.00-N-
Notes on coolant ENGINE all
2080-01A
ENGINE 156, 157, 159, 271, 272, 273, 276, 278, 642, AH20.00-P-
Notes on coolant level
646, 651... 1142-01CW
AH20.00-P-
Notes on coolant level ENGINE 642
1142-01TI
ENGINE 112, 113, 137, 156, 157, 271, 272, 273, 275, AH20.00-P-
Notes on coolant level
276, 278, 285, 612, 628, 629, 642, 651... 1142-01V
MODEL 124, 129, 140, 163, 168, 170, 202, 208, 210, AH20.00-P-
Notes on coolant level
211, 219, 220... 1142-01A
ENGINE 111, 112, 113, 271, 272, 273, 611, 612, AH20.00-P-
Notes on coolant level
646... 1142-01P
ENGINE 266.9, 640.9 in MODEL 169.0 /3, 245.2
AH20.00-P-
Notes on coolant level (except, 245.286) ENGINE 780.992 in MODEL
1142-01AK
169.090
ENGINE 272, 642 in MODEL 203 ENGINE 156, 272, AH20.00-P-
Notes on coolant level
273, 642 in MODEL 209 1142-01PI
AH20.00-P-
Notes on coolant level ENGINE 642, 629 in MODEL 221
1142-01SXI
AH20.00-P-
Notes on coolant level ENGINE 155 in MODEL 199
1142-01SLR
AH20.00-P-
Notes on coolant level ENGINE 629 in MODEL 211
1142-01TJ
AH20.00-P-
Notes on coolant level ENGINE 642.940 in MODEL 164.120 /122
1142-01GZD
ENGINE 113, 156, 272, 273, 629, 642 in MODEL 164 AH20.00-P-
Notes on coolant level
ENGINE 113, 156, 272, 273, 642 in MODEL 251 1142-01GZB
AH20.00-P-
Notes on engine coolant level ENGINE 111, 112, 113 in MODEL 163
1142-01GH
AH20.40-P-
Notes on viscous fan clutch ENGINE 120
0001-01AO
TESTING & REPAIR
INSPECT COOLING SYSTEM FOR LEAKS - AR20.00-P-1010HN
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Low-temperature circuit
ENGINE 285 in MODEL 240 Low temperature circuit
Shown on engine 285
Fig. 3: Inspecting Cooling System For Leaks
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift support
toppling off the lifting platform. 0010-01A
points specified by vehicle
manufacturer.
AR01.10-P-
Engine 275.95, 285
2405LA
1 Remove engine cover.
AR01.10-P-
Engine 275.98
2405IM
Only open cap (1) at a coolant
temperature below 40°C otherwise
coolant can flow out.
2 Remove cap (1) of filler neck (2) If coolant has flowed out, the low
temperature circuit must be bled: ?
AR20.00-P-
Bleed low temperature circuit
1145H
Checking
Check engine coolant level and antifreeze *BF20.00-P-
3
1001-04A
circuit, correct if required
AH20.00-N-
Notes on coolant
2080-01A
AH20.00-P-
1142-01V
In case of inadequate
antifreeze content: Replace coolant
of low temperature circuit: ?
Notes on coolant level
Drain/fill in coolant
AR20.00-P-
Model 215, 216, 220, 221, 230
1142HM
AR20.00-P-
Model 240
1142HN
4 Mount test cap (01) on filler neck (2) Fig. 5
5 Connect testing unit (02) at test cap (01) Fig. 4
Test pressure approx. 1.4
6 Apply pressure to low temperature circuit
bar.
Check condition and coolant loss of coolant
In the engine
7 lines and hoses as well as connecting points;
compartment.
replace coolant lines and hoses if required
Check condition and seating of the clamps;
8 remove clamp with hose clamp pliers if
necessary and replace
AR61.20-P-
Model 215, 220
1105M
Model 216, model 221 without AR61.20-P-
code (Z07) Top protection 1105SX
Model 221 with code (Z07) Top AR61.20-P-
protection 1105SXS
9 Remove bottom engine compartment paneling
Model 230 without code (P99) AR61.20-P-
"AMG Black Series" 1105R
Model 230 with code (P99) Special AR61.20-P-
model "AMG Black Series" 1105RBS
AR61.20-P-
Model 240
1105H
Check condition and coolant loss of low
temperature circuit radiator, coolant lines and
10 hoses as well as connecting points; replace If vehicle is raised.
low temperature circuit radiator, as well as
coolant lines and hoses if required
If no water loss can be determined
from outside: ?
AR09.41-P-
Remove engine induction air ducts
8623H
coolers.
Check left and right charge air
cooler at air inlet using a flexible
endoscope, cylinder illumination AR09.41-P-
unit and inspection mirror for inner 6800-01H
leaktightness.
In the event of leaks: ?
Replace left and/or right-side
charge air cooler. AR09.41-P-
If no water loss is determined at the 6817HH
Check condition and seating of the clamps; side of the air inlet: ?
11 remove clamp with hose clamp pliers if
necessary and replace Leaving coolant lines connected,
AR09.41-P-
remove left and right-side charge
6817HH
air coolers from engine.
Check left and right charge air
cooler at air outlet using a flexible
endoscope, cylinder illumination AR09.41-P-
unit and inspection mirror for inner 6800-01HH
leaktightness.
In the event of leaks: ?
Replace left and/or right-side AR09.41-P-
charge air cooler. 6817HH
12 Install in the reverse order
13 Pour in coolant After installation of new parts
AR20.00-P-
14 Bleed low temperature circuit After installation of new parts
1145H
MIXTURE RATIO FOR COOLANT
Number Designation ENGINE all
Up to -37°
50/50
C
Antifreeze/water
up to -45°
55/45
BF20.00-P-1001- Mixture ratio for C
04A coolant BB00.40-P-0310-
Sheet
Specifications for service 01A
products BB00.40-P-0325-
Sheet
00A
Fig. 4: Identifying Pressure Pump (124 589 24 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 5: Identifying Test Cap (124 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
INSPECT COOLING SYSTEM FOR LEAKS - AR20.00-P-1010SX
ENGINES 156, 157, 272, 273, 275, 276, 278, 642, 651 in MODEL 221
ENGINES 156, 157, 273, 275, 278 in MODEL 216
Shown on engine 273
Fig. 6: Inspecting Cooling System For Leaks
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury to skin and
Do not open cooling system unless coolant temperature
eyes caused by scalding
is below 90°C. Open cap slowly and release the pressure.
from contact with hot AS20.00-Z-
Do not pour coolant into beverage containers.
coolant spray. Risk of 0001-01A
Wear protective gloves, protective clothing and safety
poisoning caused by
glasses.
swallowing coolant.
AH20.00-
Notes on coolant N-2080-
01A
1 Switch on ignition
Adjust heater to maximum
2
heat output
Unscrew cap (1) slowly at
3 expansion reservoir (2)
and relieve overpressure
Check coolant level and Correct if necessary. *BF20.00-
4
antifreeze content coolant Mixture ratio for coolant P-1001-04A
Screw on test cap (3) at
5 Tester cap Fig. 7
the expansion reservoir (2)
Connect pressure pump
6 Pressure pump Fig. 4
(4) at test cap (3)
Apply test pressure to To prevent damage to cooling system, do not exceed *BE20.30-
7
cooling system stated test pressure. P-1005-01A
Checking
Check condition and coolant loss for all coolant
carrying components and connections. The coolant
leaktightness if there is no external coolant loss. There is
the possibility, for example, that coolant can find its way
over a defective cylinder head gasket into the
Perform visual inspection combustion chamber or over a defective water heat
8 of coolant carrying exchanger into the oil circuits.
components
Check condition and seating of the Henn coupling;
replace catch springs as required in order to avoid AR09.41-P-
coolant loss. 1311-01AL
Install
Release overpressure over
valve on pressure pump
9 Pressure pump Fig. 4
(4) and remove pressure
pump (4)
Unscrew test cap (3) at the
10 Tester cap Fig. 7
expansion reservoir (2)
11 Switch off ignition
Check coolant level and *BF20.00-
12 Mixture ratio for coolant
antifreeze content coolant P-1001-04A
AH20.00-
Notes on coolant level P-1142-
01V
Screw cap (1) onto
13
expansion reservoir (2)
CAP FOR RADIATOR OR EXPANSION RESERVOIR
Number Designation 2-stage cap
BE20.30-P-1005-01A Test pressure for bar gage 1.4
pressure-testing cooling
system
MIXTURE RATIO FOR COOLANT
Number Designation ENGINE all
BF20.00-P-1001- Mixture ratio for Antifreeze/water up to -37°C 50/50
04A coolant up to -45°C 55/45
Specifications for Sheet BB00.40-P-0310-01A
service products Sheet BB00.40-P-0325-00A
Fig. 7: Identifying Test Cap (210 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 8: Identifying Pressure Pump (124 589 24 21 00)
Courtesy of MERCEDES-BENZ USA
POUR IN COOLANT AND BLEED COOLING SYSTEM - AR20.00-P-1142-04A
ENGINE 111, 112, 113, 137, 152, 156, 157, 166, 270, 271, 274, 275
ENGINE 273 in MODEL 164, 207, 211, 212, 216, 219, 221, 230, 251
Fig. 9: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
Special tool The vacuum-type cooling system filler is needed.
Only vent cooling system for a cold engine.
1. Unscrew cooling system closure cap (10) and screw on test cap (2) at coolant expansion reservoir (1).
2. Attach control unit (3) to test cap (2).
3. Attach venturi nozzle (9) to control unit (3).
4. Close drain valve (8) and feed valve (7).
Fig. 10: Bleeding Cooling System
Courtesy of MERCEDES-BENZ USA
5. Attach feed hose (4) of coolant to coolant container (4a)
To avoid suctioning in of air put at least 2 l more coolant in the coolant reservoir (4a) than the
maximum filling capacity of the cooling system.
6. Guide waste air hose (5) into an empty container (5a).
7. Connect compressed-air hose (6) to venturi nozzle (9) and apply pressure.
The overpressure in the compressed air supply must be at least about 8 bar so that sufficient
vacuum can be generated through the Venturi nozzle (9).
8. Open drain valve (8).
A vacuum is created in cooling system.
9. Open feed valve (7) until feed hose (4) has filled with coolant.
10. Close drain valve (8) if display of the control unit (3) is in the green area.
11. Detach compressed air hose (6) from the venturi nozzle (9) and monitor whether vacuum remains stable
for 30 seconds.
If this is not the case, check hoses and connections and if necessary, repair and create a new
vacuum.
12. Open feed valve (7).
The cooling system is filled.
13. Open drain valve (8) if coolant is no longer suctioned.
14. Remove control unit (3) along with all connections and test cap (2).
15. Fill coolant up to bottom edge of filler neck of coolant expansion reservoir (1).
16. Screw cooling system closure cap (10) onto coolant expansion reservoir (1).
DRAIN/POUR IN COOLANT - AR20.00-P-1142H
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Main circuit
ENGINE 285 in MODEL 240 Main circuit
Fig. 11: Locating Drain Screw
Courtesy of MERCEDES-BENZ USA
Drain
Do not open cooling system unless
Risk of injury to skin and eyes caused by coolant temperature is below 90°C. AS20.00-Z-
scalding from contact with hot coolant Open cap slowly and release the 0001-01A
swallowing coolant. beverage containers.
Wear protective gloves, protective
clothing and safety glasses.
AH20.00-N-
Notes on coolant
2080-01A
Only when draining coolant at
crankcase, right.
Do not connect quiescent
current retention unit.
AR54.10-P-
Model 215, 220
0003I
Remove ground line(s) from battery AR54.10-P-
1 Model 216, 221
(batteries) 0003SX
Model 230 without code (P99) AR54.10-P-
Special model "AMG Black Series" 0003R
Model 230 with code (P99) Special AR54.10-P-
model "AMG Black Series" 0003RBS
AR54.10-P-
Model 240
0003H
Turn cooling system cap (1)
Unscrew cooling system cap (1) at coolant 1/2 one revolution until the pressure is
2
expansion reservoir (2) releases then unscrew cooling system
cap (1).
Only the front and center
engine compartment paneling.
AR61.20-P-
Model 215, 220
1105M
Model 216, Model 221 without (Z07) AR61.20-P-
Highest protection 1105SX
Remove lower engine compartment MODEL 221 with CODE (Z07) Top AR61.20-P-
3
paneling protection 1105SXS
Model 230 without code (P99) AR61.20-P-
Special model "AMG Black Series" 1105R
Model 230 with code (P99) Special AR61.20-P-
model "AMG Black Series" 1105RBS
AR61.20-P-
Model 240
1105H
Drain coolant from radiator
Push siphon hose (3) onto left fitting (4) at
4
radiator
Slacken siphon hose (5) at radiator and Catch coolant in a suitable
5
drain coolant vessel.
Tighten drain plug (5) and detach drain
6
hose (3) from fitting (4)
Drain coolant at crankcase on the right
Detach drain plug (6) near alternator and
7 Model 230, 240
slide drain hose (3) onto drain plug (6)
Model 230, 240
8 Open drain plug (6) and drain off coolant Catch coolant in a suitable
vessel.
Model 230, 240
Detach drain hose (3) and tighten drain
9 *BA20.00-
plug (6)
P-1002-02D
Detach drain plug (8) and slide drain hose
10 Model 215, 216, 220, 221
(3) onto drain plug (8)
Model 215, 216, 220, 221
11 Open drain plug (8) and drain off coolant Catch coolant in a suitable
vessel.
Model 215, 216, 220, 221
Detach drain hose (3) and tighten drain
12 *BA20.00-
plug (8)
P-1001-02D
Drain coolant at crankcase. left
Detach drain plug (7) and place drain hose
13 Model 216, 220, 221, 240
(3) on drain plug (7)
Model 216, 220, 221, 240
14 Open drain plug (7) and drain off coolant Catch coolant in a suitable
vessel.
Model 216, 220, 221, 240
Detach drain hose (3) and tighten drain
15 *BA20.00-
plug (7)
P-1001-02D
16 Lower vehicle
Filling
AR20.00-P-
Use clean coolant again. 1142-04A
17 Pour in coolant and bleed cooling system Fig. 7
Fig. 9
BB00.40-P-
Coolant specifications Sheet 310.1
0310-01A
Anticorrosion/antifreeze agents (Sheet BB00.40-P-
Sheet 325.0
325.0) 0325-00A
AH20.00-P-
1142-01V
Notes on coolant level
*BF20.00-P-
1001-04A
AR20.00-P-
Model 215, 220, 230, 240
1010HA
18 Inspecting cooling system for leaks
Model 216, 221
1010SX
AR61.20-P-
Model 215, 220
1105M
Model 216, Model 221 without code AR61.20-P-
(Z07) Top protection 1105SX
MODEL 221 with CODE (Z07) Top AR61.20-P-
protection 1105SXS
19 Install lower engine compartment paneling
Model 230 without code (P99) AR61.20-P-
Special model "AMG Black Series" 1105R
Model 230 with code (P99) Special AR61.20-P-
model "AMG Black Series" 1105RBS
AR61.20-P-
Model 240
1105H
Only when coolant has been drained
at crankcase on the right.
AR54.10-P-
Model 215, 220
0003I
AR54.10-P-
Model 216, 221
0003SX
20 Attach ground line(s) to battery(ies)
Model 230 without code (P99) AR54.10-P-
Special model "AMG Black Series" 0003R
Model 230 with code (P99) Special AR54.10-P-
model "AMG Black Series" 0003RBS
AR54.10-P-
Model 240
0003H
Connect STAR DIAGNOSIS, read and
21
erase diagnostic trouble code memory Only if ground line (a) on the battery
Connect STAR DIAGNOSIS and read out (ies) were removed. AD00.00-P-
fault memory 2000-04A
ENGINE COOLING, GENERAL
Engine 275.950/951/952/980/981, Engine 275.953/954
Number Designation
285.950 982/983/, 285.980
BA20.00-P- Coolant drain plug
Nm 14 14
1001-02D on crankcase
BA20.00-P- Coolant drain plug
Nm 12 -
1002-02D on alternator
MIXTURE RATIO FOR COOLANT
Number Designation ENGINE all
Up to -37°
50/50
C
Antifreeze/water
up to -45°
55/45
C
04A coolant BB00.40-P-0310-
Sheet
Specifications for service 01A
products BB00.40-P-0325-
Sheet
00A
Fig. 12: Identifying Test Cap (210 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 13: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
DRAIN/FILL IN COOLANT - AR20.00-P-1142HM
ENGINES 275 in MODEL 215, 216, 220, 221, 230 Low-temperature circuit
Fig. 14: Identifying Charge Air Cooler Circulation Pump, Coolant Hose And Cap
Courtesy of MERCEDES-BENZ USA
Drain
Do not open cooling system unless coolant
Risk of injury to skin and eyes caused temperature is below 90°C. Open cap slowly
by scalding from contact with hot and release the pressure. Do not pour coolant AS20.00-Z-
coolant spray. Risk of poisoning into beverage containers. 0001-01A
caused by swallowing coolant. Wear protective gloves, protective clothing and
safety glasses.
AH20.00-N-
Notes on coolant
2080-01A
AR01.10-P-
Engine 275.95
2405LA
1 Remove engine trim panel
AR01.10-P-
Engine 275.98
2405IM
Unscrew cap (1) slowly and until
2 Unscrew cap (1).
excess pressure escapes.
Model 230: Only remove right engine
compartment paneling under bumper.
AR61.20-P-
Model 215, 220
1105M
Remove lower engine compartment Model 216, Model 221 without code (Z07) AR61.20-P-
3 Top protection 1105SX
paneling
AR61.20-P-
Model 221 with code (Z07) Top protection
1105SXS
Model 230 without code (P99) Special model AR61.20-P-
"AMG Black Series" 1105R
Model 230 with code (P99) Special model AR61.20-P-
"AMG Black Series" 1105RBS
Model 215, 216, 220, 221, model 230 without
code (P99) Special Model "AMG Black
Remove coolant hose (2) to charge air Series"
4.1
cooler circulation pump (M44) Collect coolant in a container.
Follow regulations for disposal of
coolant.
Model 230 with code (P99) Special model
"AMG Black Series"
See "Remove/install radiator for low
Remove drain screw on right low-
4.2 temperature water circuit"
temperature cooler AR09.41-P-
Collect coolant in a container.
6935RBS
Follow regulations for disposal of
coolant.
Filling
Connect coolant hose (2) to charge air Check coolant hose (2) and hose
5
cooler circulation pump (M44) clamp for damage, replace if required.
*BF20.00-P-
6 Pour in coolant
1001-04A
AR20.00-P-
7 Bleed low temperature circuit
1145H
AR20.00-P-
8 Inspect cooling system for leaks
1010HN
AR61.20-P-
Model 215, 220
1105M
Model 216, model 221 without code (Z07) Top AR61.20-P-
protection 1105SX
Install lower engine compartment AR61.20-P-
9 Model 221 with code (Z07) Top protection
paneling 1105SXS
Model 230 without code (P99) Special model AR61.20-P-
"AMG Black Series" 1105R
Model 230 with code (P99) Special model AR61.20-P-
"AMG Black Series" 1105RBS
MIXTURE RATIO FOR COOLANT
Number Designation ENGINE all
Up to -37°
50/50
C
Antifreeze/water
up to -45°
BF20.00-P-1001- Mixture ratio for 55/45
C
04A coolant BB00.40-P-0310-
Specifications for service Sheet
01A
products
Sheet 00A
DRAIN/FILL IN COOLANT - AR20.00-P-1142SMG
ENGINE 156 in MODEL 216, 221
Fig. 15: Identifying Drain Plug Of Radiator And Cylinder Crankcase Drain Screws
Courtesy of MERCEDES-BENZ USA
Drain
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk lids, clear of moving parts. 0011-01A
liftgates or sliding roof
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift support
toppling off the lifting platform. 0010-01A
points specified by vehicle
manufacturer.
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant spray. AS20.00-Z-
pressure. Do not pour coolant into
Risk of poisoning caused by swallowing 0001-01A
beverage containers. Wear
coolant.
protective gloves, protective
clothing and safety glasses.
Risk of explosion caused by oxyhydrogen gas.
Risk of poisoning and caustic burns caused No fire, sparks, open flames or
caused by burns to skin and eyes from battery gloves, clothing and glasses. Only 0001-01A
acid or when handling damaged lead-acid pour battery acid into suitable and
batteries appropriately marked containers.
When draining coolant at AR54.10-P-
1 Disconnect ground line from battery the right drain plug (3) on the 0003SX
crankcase.
AH54.10-
Notes on battery All models P-0001-
01A
2 Open engine hood
Unscrew cap slowly and
3 Open cap on coolant expansion reservoir release excess pressure, then screw
down cap.
AR00.60-P-
4 Raise vehicle with vehicle lift
1000SX
AR61.20-P-
5 Remove bottom engine compartment paneling
1105SX
Drain coolant from radiator
Slide collector siphon hose onto fitting on The fitting is located at the
6
radiator bottom left on the radiator.
Catch coolant in a suitable
Open siphon hose (1) on radiator and drain
7 vessel. Observe regulations for
coolant
disposal of coolant.
Drain coolant from radiator
Only loosen drain plug
Loosen crankcase drain plug on the left (2)
8 from crankcase until it can be
and crankcase drain plug on the right (3)
turned by hand.
9 Push drain hose onto crankcase drain screws
Catch coolant in a suitable
Continue to loosen crankcase drain screws by
10 vessel. Observe regulations for
hand and drain of coolant
disposal of coolant.
Filling
Tighten drain plug (1) at radiator and detach After coolant is drained at
11
siphon hose from fitting the radiator.
Detach drain hose from crankcase drain After coolant is drained at
12
screws the radiator.
Tighten crankcase drain plug on the left (2) *BA03.20-
13
and crankcase drain plug on the right (3) P-1009-01J
AR20.00-P-
14 Pour in coolant and bleed cooling system Use clean coolant again. 1142-04A
AH20.00-
Notes on coolant N-2080-
All engines 01A
P-1142-
Notes on coolant level
01V
BB00.40-P-
Coolant specifications Sheet 310.1
0310-01A
BB00.40-P-
Sheet 325.0
0325-00A
*BF20.00-
Cooling system P-1001-02U
Anticorrosion/antifreeze agents (Sheet 325.0)
Tester cap Fig. 7
Pressure pump Fig. 4
Cooler vacuum filling device Fig. 9
AR20.00-P-
15 Inspecting cooling system for leaks
1010SX
AR61.20-P-
16 Install engine compartment paneling
1105SX
17 Lower vehicle
18 Screw cap onto coolant expansion reservoir
After fully tightening the AR54.10-P-
19 Connect ground cable to battery crankcase drain plug on the right
0003SX
(3).
Only if ground lead of
20 Perform basic programming
battery has been disconnected.
21 Close engine hood
CRANKSHAFT BEARING CAP
Number Designation Engine 156
BA03.20-P-1009-01J Drain screw for coolant Nm 15
COOLING SYSTEM
Engine 156 in model
Number Designation
216, 221
Total filling capacity approx.Liters 10
Up to -37°C 50/50
BF20.00-P-1001- Cooling Antifreeze/water
up to -45°C 55/45
02U system
Specifications for Operating Sheet BB00.40-P-0310-01A
Fluids Sheet BB00.40-P-0325-00A
Fig. 16: Identifying Test Cap (210 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 17: Identifying Pressure Pump (124 589 24 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 18: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
DRAIN/FILL IN COOLANT - AR20.00-P-1142SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 19: Identifying Cylinder Crankcase Drain Screws, Drain Plug On Radiator And Drain Hose
Courtesy of MERCEDES-BENZ USA
Drain
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant AS20.00-Z-
pressure. Do not pour coolant into
spray. Risk of poisoning caused by 0001-01A
beverage containers.
swallowing coolant.
Wear protective gloves, protective
clothing and safety glasses.
Align vehicle between columns of
Risk of death caused by vehicle slipping or vehicle lift and position four support AS00.00-Z-
toppling off the lifting platform. plates at vehicle lift support points 0010-01A
specified by vehicle manufacturer.
AH20.00-N-
Notes on coolant
2080-01A
Turn cooling system cap
Unscrew cooling system cap at coolant
1 slowly and release excess pressure,
expansion reservoir
then unscrew cooling system cap.
Drain coolant from radiator
Slide drain hose on to left fitting (3) at
2
radiator
Open radiator drain plug (4) and drain Follow regulations for
3
coolant disposal of coolant.
Model 221.095 / 195
4 Turn key for about 5 s in ignition lock in Repeat process twice after a
position 0 order to empty the low-temperature
water circuit.
Drain coolant at crankcase
Except model 221.095 /195
Vehicles with 4MATIC:
Before draining the coolant at the left
Detach ground line(s) from AR54.10-P-
5 drain screw (5).
battery/batteries 0003SX
Vehicles without 4MATIC:
Before draining the coolant at the right
drain screw (6).
Model 221.095/ 195:
Remove power electronics from cylinder AR08.10-P-
6 Before draining the coolant at the right
crankcase 0011SXH
drain screw (6).
Loosen the left or right drain plug (5, 6) at
7 the crankcase until it can be turned
manually
Push drain hose (3) onto left (5) or right (6)
8
drain screw
Continue to manually loosen left or right Follow regulations for
9
drain plug (5, 6) and drain coolant disposal of coolant.
Filling
Tighten drain plug (4) at radiator and
10.1 After coolant is drained at radiator
detach siphon hose from fitting (3)
After draining the coolant at the
Detach drain hose (3) and tighten crankcase crankcase *BA20.00-
10.2
drain plug at left and right (5, 6) P-1001-02E
Model 221.095/ 195:
Mount power electronics on cylinder AR08.10-P-
11 After draining the coolant at the right
crankcase 0011SXH
drain screw (6).
Except model 221.095 /195
Vehicles with 4MATIC: after
draining the coolant at LH drain screw
AR54.10-P-
12 Attach ground line(s) for battery (batteries) (5).
0003SX
Vehicles without 4MATIC:
after draining the coolant at RH drain
screw (6).
Except model 221.095 /195 AR20.00-P-
13.1 Pour in coolant and bleed cooling system
Reuse clean coolant. 1142-04A
BB00.40-P-
Coolant specifications Sheet 310.1
0310-01A
Anticorrosion/antifreeze agents (Sheet BB00.40-P-
Sheet 325.0
325.0) 0325-00A
*BF20.00-P-
1001-02U
Fig. 7
Fig. 9
AH20.00-P-
Notes on coolant level
1142-01V
Model 221.095 / 195
Add coolant, bleed cooling system and turn Repeat process twice after a AR20.00-P-
13.2 key for about 5 s in ignition lock in position waiting time of about 30 seconds in
1142-04A
1 and then turn key again into position 0 order to charge and purge the low-
temperature water circuit.
AR20.00-P-
14 Inspect cooling system for leaks
1010SX
Except model 221.095 /195:
Connect STAR DIAGNOSIS, read out
15 After detaching the ground line(s) for
fault memory and erase if necessary
battery(batteries).
Connect STAR DIAGNOSIS and read out AD00.00-P-
fault memory 2000-04A
ENGINE COOLING, GENERAL
Number Designation Engine 272 Engine 273
BA20.00-P-1001- Coolant drain plug Nm 12 12
02E on crankcase
COOLING SYSTEM
Engine 272 in
model 221
Engine 272.985 Engine 273 in
Number Designation in model 219 model 216, 221
BF20.00-P- Cooling system Total filling Liters 8 8.5
1001-02U capacity
Antifreeze/water up to -37°C 50/50 50/50
up to -45°C 55/45 55/45
Specifications for Sheet BB00.40-P- BB00.40-P-
Operating Fluids 0310-01A 0310-01A
Sheet BB00.40-P- BB00.40-P-
0325-00A 0325-00A
Fig. 20: Identifying Test Cap (210 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 21: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
PREPARE THE LOW TEMPERATURE CIRCUIT FOR THE BLEEDING PROCESS - AR20.00-P-
1145-02R
1. Connect the connections (A, B) to the service connections of the charge air cooler.
Fig. 22: Identifying Charge Air Cooler Connections
Courtesy of MERCEDES-BENZ USA
2. Close all the valves (C, D, H, HA, O, P) on the control unit, the Y-fitting and the vacuum box.
Fig. 23: Identifying Valves On Control Unit, Y-Fitting And Vacuum Box
Courtesy of MERCEDES-BENZ USA
All the connections described in steps 3 to 5 will be maintained throughout the bleeding process.
Interchanging the hoses (E, J, S) will damage the bleeding devices.
3. Connect the coolant feed (J) to connection (N).
4. Connect the coolant drain (E) to connection (F).
5. Lay down the waste air hose (S) in the receptacle.
Fig. 24: Identifying Connections For Bleeding Process
Courtesy of MERCEDES-BENZ USA
Fig. 25: Identifying Connections Of Control Unit And Venturi Nozzle
Courtesy of MERCEDES-BENZ USA
6. Connect the control unit (5) to the test connection - connection (L) to the test connection.
7. Connect the venturi nozzle (6) to the control unit (5) - connection (U) to connection (T).
8. Connect the compressed air (Z) to the venturi nozzle (6) - compressed air (Z) to connection (M).
An audible air discharge is normal.
9. Generate a vacuum in the control unit (5) - open valve (P).
10. By regulating the valve (O) (arrow), draw in the coolant up to the control unit (5) by suction. Then again
close valve (O).
Fig. 26: Identifying Control Unit And Valve
Courtesy of MERCEDES-BENZ USA
11. Test the low temperature circuit for leaks - close valve (P).
The unchanged display (arrow) of the pressure gauge shows that the vacuum has been
maintained, thereby indicating the leak tightness of the low temperature circuit.
Fig. 27: Testing Low Temperature Circuit For Leaks
Courtesy of MERCEDES-BENZ USA
Fig. 28: Identifying Venturi Nozzle And Control Unit
Courtesy of MERCEDES-BENZ USA
12. Detach the venturi nozzle (6) from the control unit (5).
The display of the pressure gauge (arrow) must continue to show a vacuum even after the
preparatory tasks have been completed.
CARRYING OUT THE BLEEDING PROCESS FOR THE LOW TEMPERATURE CIRCUIT -
AR20.00-P-1145-03R
Fig. 29: Identifying Connections Of Venturi Nozzle With Vacuum Box
Courtesy of MERCEDES-BENZ USA
1. Connect venturi nozzle (6) with vacuum box (1) connection (U) to connection (G).
2. Generate vacuum in vacuum box (1) - open valve (H).
3.1 Model 215, 220, 230, 240:
Actuate circulation pump for low-temperature circuit. Switch on switch on relay slot.
3.2 Model 216, 221:
Actuate circulation pump for low temperature circuit via STAR DIAGNOSIS.
4 Generate vacuum in low temperature circuit - open valves (C, D) and wait for 15 seconds.
5 Start venting process - open valve (O) for at least 5 minutes.
The air in the coolant is removed by flushing the low temperature circuit.
6 Observe coolant flow in the area of the Y-fitting (arrow) during the flushing process. If the coolant is
flowing free of bubbles after 5 minutes then the low temperature circuit has been bled.
Fig. 30: Flushing Low Temperature Circuit
Courtesy of MERCEDES-BENZ USA
7 Stop coolant flow by first closing valve (O), switching off the switch for the circulation pump, actuating
STAR DIAGNOSIS and then closing valves (C, D).
8 Remove vacuum - disconnect compressed air (Z) from venturi nozzle (6) connection (M).
9 Decouple connection (L) to test cap.
Fig. 31: View Of Bleeding Process For Low Temperature Circuit
Courtesy of MERCEDES-BENZ USA
VENTING AIR FROM LOW TEMPERATURE CIRCUIT - AR20.00-P-1145H
ENGINE 275, 285
Fig. 32: Identifying Venturi Nozzle, Pressure Tube And Connections
Courtesy of MERCEDES-BENZ USA
Vacuum-type cooling system filler with low-temperature circuit (NTKL) adaptation
Fig. 33: Identifying Bleeding System Components
Courtesy of MERCEDES-BENZ USA
Prepare for bleeding: line routing Illustrated on model 230
Fig. 34: Routing Line For Bleeding Cooling System
Courtesy of MERCEDES-BENZ USA
Perform bleeding: line routing Illustrated on model 230
Fig. 35: Bleeding Cooling System
Courtesy of MERCEDES-BENZ USA
Do not open cooling system unless coolant
Risk of injury to skin and eyes
temperature is below 90°C. Open cap slowly and
caused by scalding from contact
release the pressure. Do not pour coolant into AS20.00-Z-
with hot coolant spray. Risk of
beverage containers. 0001-01A
poisoning caused by swallowing
Wear protective gloves, protective clothing and
coolant.
safety glasses.
AH20.00-
Notes on coolant All engines N-2080-
01A
Only conduct ventilation
procedure on a cold engine
Vacuum-type cooling system
Fig. 9
filler
NTKL adapter Fig. 38
Attach STAR DIAGNOSIS in
order to actuate the circulation
1.1
pump for the low-temperature
circuit Model 216, 221
Connect STAR DIAGNOSIS
AD00.00-
and read out fault memory
04A
AR20.00-P-
Model 215, 220
1145-01M
Preparing for actuation of the
AR20.00-P-
1.2 circulation pump on the low Model 230
1145-01R
temperature circuit
AR20.00-P-
Model 240
1145-01H
The venturi nozzle (6) will lose its
function if used without the pressure tube (7). The
venturi nozzle (6) does not generate a vacuum but
Screw on connection (M) at creates excess pressure at connection (U) if the
2 pressure tube (7) of the venturi compressed air is connected without the pressure
nozzle (6) tube (7).
When first assembling the venturi nozzle (6)
connection (M) on the workshop equipment
compressed air system must be closed.
Fill coolant reservoir (4) with
3 20 liter
coolant
Open low temperature circuit at
4 Tester cap Fig. 5
filler neck and screw on test cap
5 Empty vacuum box (1)
AR20.00-
Prepare low temperature circuit
6 P-1145-
for bleeding and check for leaks
02R
Bleed low temperature circuit AR20.00-
7 using circulation pump and P-1145-
vacuum 03R
Close cooler vacuum filling Close connections (A, B) and close
8
device diagnostic sockets for low temperature circuit.
Screw on test cap and close low
9
temperature circuit
Replace switch (2) for manual
10 actuation of the circulation pump
against a relay
Fig. 36: Identifying Test Cap (124 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 37: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 38: Identifying NTKL Adapter (285 589 01 21 00)
Courtesy of MERCEDES-BENZ USA
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE COOLING SYSTEM - AR20.00-Z-
9156AB
ENGINE 156
AR20.00-P-
Drain/fill in coolant ENGINES 156 in MODEL 204, 212
1142CMG
AR20.00-P-
Drain/fill in coolant ENGINE 156 in MODEL 164, 251
1142GZS
AR20.00-P-
Drain/fill in coolant ENGINE 156 in MODEL 230
1142RMG
AR20.00-P-
Drain/fill in coolant ENGINE 156 in MODEL 216, 221
1142SMG
ENGINE 156.982 in MODEL 209.377 /477 AR20.00-P-
Drain/fill in coolant
ENGINE 156.983 in MODEL 211.077 /277, 219.377 1142TMG
ENGINE 156 in MODEL 164, 251
for leaks 1010GZS
Inspect cooling system AR20.00-P-
ENGINE 156, 157, 272, 273, 275, 276, 278, 642, 651...
for leaks 1010SX
Inspect cooling system ENGINE 156.982 in MODELS 209.377 /477 AR20.00-P-
for leaks ENGINE 156.983 in MODELS 211.077 /277, 219.377 1010TMG
Inspecting cooling AR20.00-P-
ENGINES 156 in MODEL 204, 212
system for leaks 1010CMG
Inspecting cooling AR20.00-P-
ENGINE 156 in MODEL 230
system for leaks 1010RMG
Remove/install coolant ENGINE 272, 642 in MODEL 203 AR20.30-P-
level switch ENGINE 156, 272, 273, 642 in MODEL 209 4392PI
Remove/install coolant AR20.10-P-
ENGINE 156 in MODEL 204, 212
pump 1271CMG
Remove/install coolant AR20.10-P-
ENGINE 156 in MODEL 164, 251
pump 1271GZS
Remove/install coolant AR20.10-P-
ENGINE 156 in MODEL 230.470
pump 1271RMG
Remove/install coolant AR20.10-P-
ENGINE 156 in MODEL 216, 221
pump 1271SMG
Remove/install coolant ENGINE 156.982 in MODEL 209.377 /477 AR20.10-P-
pump ENGINE 156.983 in MODEL 211.077 /277, 219.377 1271TMG
Remove/install coolant AR20.10-P-
ENGINE 156 in MODEL 204, 212
thermostat 2460CMG
Remove/install coolant AR20.10-P-
ENGINE 156 in MODEL 164, 251
thermostat 2460GZS
Remove/install coolant AR20.10-P-
ENGINE 156 in MODEL 230.470
thermostat 2460RMG
Remove/install coolant AR20.10-P-
ENGINE 156 in MODEL 216, 221
thermostat 2460SMG
Remove/install coolant ENGINE 156.982 in MODEL 209.377 /477 AR20.10-P-
thermostat ENGINE 156.983 in MODEL 211.077 /277, 219.377 2460TMG
Remove/install electric AR20.40-P-
ENGINE 156 in MODEL 164, 251
fan 5000GZS
Remove/install electric AR20.40-P-
ENGINE 156, 272, 273...
fan 5000QB
Remove/install electric AR20.40-P-
ENGINE 156 in MODEL 216, 221
fan 5000SMG
Remove/install expansion AR20.30-P-
ENGINE 156 in MODEL 204, 212
reservoir 4950CMG
Remove/install expansion AR20.30-P-
ENGINE 156 in MODEL 164
reservoir 4950GZS
Remove/install expansion ENGINE 272, 642 in MODEL 203 AR20.30-P-
reservoir ENGINE 156, 272, 642 in MODEL 209 4950PI
reservoir ENGINES 113, 156, 272, 273, 276, 642 in MODEL 251 4950RT
Remove/install expansion AR20.30-P-
ENGINE 156, 157, 272, 273, 275, 276, 278...
reservoir 4950SX
Remove/install expansion ENGINE 272, 273 in MODELS 211, 219 AR20.30-P-
reservoir ENGINE 156 in MODEL 211 4950TS
ENGINE 113.967 in MODEL 219.375
Remove/install expansion AR20.30-P-
ENGINE 113.990 in MODEL 219.376
reservoir 4950TY
ENGINE 156.983 in MODEL 219.377
Remove/install fan ENGINES 113.990 in MODEL 211.076 /276 AR20.40-P-
shroud ENGINES 156.983 in MODEL 211.077 /277 6800TC
Remove/install fan ENGINE 113.990 in MODEL 219.376 AR20.40-P-
shroud ENGINE 156.983 in MODEL 219.377 6800TZ
AR20.40-P-
Remove/install fan unit ENGINE 156, 271, 272, 273, 276, 278, 642, 646, 651...
5050CW
ENGINE 156, 271, 272, 273, 642, 651 in MODEL 212 AR20.40-P-
Remove/install fan unit
ENGINE 642, 651 in MODEL 218 5050EW
ENGINE 156.982 in MODEL 209.377 with CODE (P98) AR20.40-P-
Remove/install fan unit
Black Series With electrical radiator fan 5050QBS
AR20.40-P-
Remove/install fan unit ENGINE 156 in MODEL 230.470
5050RMG
AR20.20-P-
Remove/install radiator ENGINES 156 in MODEL 204
3865CMG
AR20.20-P-
Remove/install radiator ENGINES 156 in MODEL 164, 251
3865GZS
ENGINES 156.982 in MODEL 209.377 with CODE (P98) AR20.20-P-
Remove/install radiator
Black Series 3865QBS
AR20.20-P-
Remove/install radiator ENGINES 156 in MODEL 230.470
3865RMG
ENGINE 156, 272, 273 in MODEL 221 AR20.20-P-
Remove/install radiator
ENGINE 156, 273 in MODEL 216 3865SX
AR20.20-P-
Remove/install radiator ENGINE 156...
3865TMG
AR20.30-P-
Test coolant gage ENGINE 111, 112, 113, 156...
4460A
ENGINE 156, 272 in MODEL 204 ENGINE 272, 273 in AR20.10-P-
Test coolant thermostat
MODEL 207 ENGINE 156 in MODEL 212 2455CV
AR20.10-P-
Test coolant thermostat ENGINE 156 in MODEL 164, 251
2455GZS
AR20.10-P-
Test coolant thermostat ENGINE 156 in MODEL 230.470
2455RMG
AR20.10-P-
Test coolant thermostat ENGINE 156 in MODEL 216, 221
2455SMG
ENGINE 156.982 in MODELS 209.377 /477 AR20.10-P-
Test coolant thermostat
ENGINE 156.983 in MODELS 211.077 /277, 219.377 2455TMG
AR20.30-P-
Test cooling system cap ENGINE 156 in MODEL 164, 251
4300GZS
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE COOLING SYSTEM - AR20.00-Z-
9273AB
ENGINE 273
AR20.00-P-
Drain, fill coolant ENGINE 272, 273 in MODEL 211, 219
1142TS
AR20.00-P-
Drain/fill in coolant ENGINE 271, 272, 273, 642, 646, 651...
1142CW
AR20.00-P-
Drain/fill in coolant ENGINES 272, 273 in MODEL 212
1142EWS
AR20.00-P-
Drain/fill in coolant ENGINE 272, 273 in MODEL 164, 251
1142GZC
AR20.00-P-
Drain/fill in coolant ENGINE 272, 273...
1142QB
AR20.00-P-
Drain/fill in coolant ENGINES 272, 273 in MODEL 230
1142RX
ENGINE 272, 273 in MODEL 221 ENGINE 273 in MODEL AR20.00-P-
Drain/fill in coolant
216 1142SX
Inspect cooling system AR20.00-P-
ENGINE 271, 272, 273, 642, 646, 651...
for leaks 1010CW
Inspect cooling system AR20.00-P-
ENGINE 272, 273...
for leaks 1010QB
Inspect cooling system AR20.00-P-
ENGINE 272, 273 in MODEL 230
for leaks 1010RX
Inspect cooling system AR20.00-P-
ENGINE 156, 157, 272, 273, 275, 276, 278, 642, 651...
for leaks 1010SX
Inspect cooling system AR20.00-P-
ENGINE 272, 273 in MODEL 211, 219
for leaks 1010TS
Inspecting cooling AR20.00-P-
ENGINES 272, 273 in MODEL 212
system for leaks 1010EW
ENGINES 272, 273 in MODEL 164, 251
Inspecting cooling AR20.00-P-
ENGINES 273 in MODEL 463 ENGINES 276 in MODEL
system for leaks 1010GZC
251
Remove, install coolant AR20.10-P-
ENGINE 272, 273...
pump 1271QB
Remove, install coolant AR20.10-P-
ENGINE 272, 273 in MODEL 211, 219
pump 1271TS
Remove, install coolant AR20.10-P-
ENGINE 272, 273 in MODEL 211, 219
thermostat 2460TS
level switch 642 in MODEL 209 4392PI
Remove/install coolant ENGINES 157, 272, 273, 275, 276, 278, 642, 629 in AR20.30-P-
level switch MODEL 221 ENGINES 157, 275, 278 in MODEL 216 4392SXI
Remove/install coolant ENGINE 272 in MODEL 204 ENGINE 272, 273 in MODEL AR20.10-P-
pump 207 1271CV
Remove/install coolant AR20.10-P-
ENGINE 272, 273 in MODEL 212
pump 1271EW
Remove/install coolant AR20.10-P-
ENGINE 272, 273 in MODEL 164, 251
pump 1271GZA
Remove/install coolant AR20.10-P-
ENGINES 272, 273 in MODEL 230
pump 1271RX
Remove/install coolant ENGINE 272, 273 in MODEL 221 ENGINE 273 in MODEL AR20.10-P-
pump 216 1271SX
Remove/install coolant ENGINE 272 in MODEL 204 ENGINE 272, 273 in MODEL AR20.10-P-
thermostat 207 2460CV
Remove/install coolant AR20.10-P-
ENGINE 272, 273 in MODEL 212
thermostat 2460EW
Remove/install coolant ENGINE 272, 273 in MODEL 164, 251 AR20.10-P-
thermostat ENGINE 273 in MODEL 463 2460GZA
Remove/install coolant AR20.10-P-
ENGINE 272, 273...
thermostat 2460QB
Remove/install coolant AR20.10-P-
ENGINES 272, 273 in MODEL 230
thermostat 2460RX
Remove/install coolant ENGINE 272, 273 in MODEL 221 ENGINE 273 in MODEL AR20.10-P-
thermostat 216 2460SX
Remove/install electric AR20.40-P-
ENGINE 272, 273 in MODEL 164
fan 5000GZA
Remove/install electric AR20.40-P-
ENGINE 156, 272, 273...
fan 5000QB
Remove/install electric AR20.40-P-
ENGINE 272, 273 in MODEL 251
fan 5000RTA
Remove/install electric ENGINE 272, 273 in MODEL 221 ENGINE 273 in MODEL AR20.40-P-
fan 216 5000SX
Remove/install AR20.30-P-
ENGINES 272, 273 in MODEL 212
expansion reservoir 4950EW
Remove/install AR20.30-P-
ENGINE 113, 272, 273 in MODEL 164
expansion reservoir 4950GZ
Remove/install AR20.30-P-
ENGINES 113, 156, 272, 273, 276, 642 in MODEL 251
expansion reservoir 4950RT
Remove/install AR20.30-P-
ENGINE 272, 273 in MODEL 230
expansion reservoir 4950RX
Remove/install AR20.30-P-
ENGINE 156, 157, 272, 273, 275, 276, 278...
expansion reservoir 4950SX
expansion reservoir ENGINE 156 in MODEL 211 4950TS
Remove/install fan AR20.40-P-
ENGINES 272, 273 in MODEL 230
shroud 6800RX
Remove/install fan ENGINE 272, 273 in MODEL 221 ENGINE 273 in MODEL AR20.40-P-
shroud 216 6800SX
Remove/install fan AR20.40-P-
ENGINE 272, 273 in MODEL 211, 219
shroud 6800TS
AR20.40-P-
Remove/install fan unit ENGINE 156, 271, 272, 273, 276, 278, 642, 646, 651...
5050CW
ENGINE 156, 271, 272, 273, 642, 651 in MODEL 212 AR20.40-P-
Remove/install fan unit
ENGINE 642, 651 in MODEL 218 5050EW
AR20.20-P-
Remove/install radiator ENGINE 271, 272, 273, 276, 642, 646, 651...
3865CW
AR20.20-P-
Remove/install radiator ENGINE 272, 273 in MODEL 212
3865EWS
AR20.20-P-
Remove/install radiator ENGINE 272, 273 (except 272.973) in MODEL 164
3865GZA
AR20.20-P-
Remove/install radiator ENGINE 272, 273...
3865QB
AR20.20-P-
Remove/install radiator ENGINES 272, 273 in MODEL 251
3865RTC
AR20.20-P-
Remove/install radiator ENGINES 272, 273 in MODEL 230
3865RX
ENGINE 156, 272, 273 in MODEL 221 AR20.20-P-
Remove/install radiator
ENGINE 156, 273 in MODEL 216 3865SX
AR20.20-P-
Remove/install radiator ENGINES 272, 273 in MODEL 211, 219
3865TS
ENGINE 156, 272 in MODEL 204 ENGINE 272, 273 in AR20.10-P-
Test coolant thermostat
MODEL 207 ENGINE 156 in MODEL 212 2455CV
AR20.10-P-
Test coolant thermostat ENGINE 272, 273 in MODEL 212
2455EW
ENGINE 272, 273 in MODEL 164, 251 AR20.10-P-
Test coolant thermostat
ENGINE 273 in MODEL 463 2455GZA
AR20.10-P-
Test coolant thermostat ENGINE 272, 273...
2455QB
ENGINE 272, 273 in MODEL 221 ENGINE 273 in MODEL AR20.10-P-
Test coolant thermostat
216 2455SX
AR20.10-P-
Test coolant thermostat ENGINE 272, 273 in MODEL 211, 219
2455TS
Testing coolant AR20.10-P-
ENGINE 272, 273 in MODEL 230
thermostat 2455RX
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE COOLING SYSTEM - AR20.00-Z-
9275AB
ENGINE 275
ENGINES 275 in MODEL 215, 216, 220, 221, 230 Low- AR20.00-P-
Drain/fill in coolant
temperature circuit 1142HM
ENGINE 275 in MODEL 215, 216, 220, 221, 230 Main AR20.00-P-
Drain/pour in coolant
circuit ENGINE 285 in MODEL 240 Main circuit 1142H
ENGINE 111, 112, 113, 120, 137, 271, 275, 285, 601,
Inspect cooling system for AR20.00-P-
602, 603, 604, 605, 606, 611, 612, 613, 628, 646, 647,
leaks 1010HA
648...
Inspect cooling system for AR20.00-P-
ENGINE 275, 285...
leaks 1010HN
Inspect cooling system for AR20.00-P-
ENGINE 156, 157, 272, 273, 275, 276, 278, 642, 651...
leaks 1010SX
Remove, install coolant AR20.10-P-
ENGINE 275 in MODEL 215, 216, 220, 221, 230
thermostat housing 2710M
Remove/install additional AR20.20-P-
ENGINE 275...
radiator 3866RMB
Remove/install additional AR20.20-P-
ENGINE 275.982 in MODEL 221.179, 216.379
radiator 3866SX
Remove/install center cooling ENGINE 275 in MODEL 230 with CODE (P99) "AMG AR20.20-P-
duct Black Series" special model 0200RBS
Remove/install coolant level ENGINES 157, 272, 273, 275, 276, 278, 642, 629 in AR20.30-P-
switch MODEL 221 ENGINES 157, 275, 278 in MODEL 216 4392SXI
AR20.10-P-
Remove/install coolant pump ENGINES 275 in MODELS 215, 216, 220, 221, 230
1271MC
Remove/install coolant ENGINES 275 in MODEL 215, 216, 220, 221, 230 AR20.10-P-
thermostat ENGINES 285 in MODEL 240 2460H
Remove/install expansion AR20.30-P-
ENGINE 156, 157, 272, 273, 275, 276, 278...
reservoir 4950SX
AR20.40-P-
Remove/install fan shroud ENGINE 137, 275...
6800AC
AR20.40-P-
Remove/install fan shroud ENGINE 275.980 in MODEL 215.379, 220.179
6800IM
AR20.40-P-
Remove/install fan shroud ENGINE 275.982 in MODEL 216.379, 221.179
6800SXM
AR20.40-P-
Remove/install fan shroud ENGINE 275 (except 275.982) in MODEL 216, 221
6800SZ
ENGINE 275 in MODEL 230 with CODE (P99) "AMG AR20.40-P-
Remove/install fan unit
Black Series" special model 5050RBS
ENGINE 275.950 in MODEL 220.176 ENGINE 137.970 AR20.20-P-
Remove/install radiator
in MODEL 215.378, 220.178 /878 3865MC
AR20.20-P-
Remove/install radiator ENGINE 112, 113, 275...
3865R
Remove/install radiator Black Series" special model 3865RBS
AR20.20-P-
Remove/install radiator ENGINE 275.981 in MODEL 230.479
3865RM
AR20.20-P-
Remove/install radiator ENGINE 275.982 in MODEL 216.379, 221.179
3865SXM
AR20.20-P-
Remove/install radiator ENGINE 275 (except 275.982) in MODEL 216, 221
3865SZ
AR20.20-P-
Remove/install radiator unit ENGINE 275.980 in MODEL 215.379, 220.179
3871IM
Removing and installing AR20.20-P-
ENGINE 275.980 in MODEL 215.379, 220.179
radiator 3865IM
Removing/installing AR20.20-P-
Engine 275.980 in model 215.379 up to 29.2.04, 220.179
additional radiator 3866IM
Venting air from low AR20.00-P-
ENGINE 275, 285
temperature circuit 1145H
BOLT PLAN FOR COOLANT PUMP - AR20.10-P-1271-03L
ENGINE 137.970, 275.950 /951 /953 /954 /980 /981 /982 /983, 285
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engine 137, 275 Engine 285
BA20.10-P-1004-01C Coolant pump on timing case M7 Nm 14 14
1 to 9: Bolts for fastening coolant pump at timing case cover and simultaneously fastening timing case
cover to crankcase. 10 and 11: Bolts for fastening coolant pump to timing case cover.
1. Screw in bolts according to the tightening sequence.
Item number corresponding to tightening sequence.
Fig. 39: Tightening Sequence Of Coolant Pump Bolts
Courtesy of MERCEDES-BENZ USA
BOLT PLAN FOR COOLANT PUMP - AR20.10-P-1271-03VA
ENGINE 272, 273
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engine 272 Engine 273
BA20.10-P- Self-tapping bolt M7 Nm 25 25
1001-01U connecting
coolant pump to
timing case cover
BA20.10-P- Bolt, coolant M8 Nm 20 20
1002-01U pump to
crankcase
Bolt assignments for coolant pump
Bolts A: Coolant pump to timing case cover.
Bolts B and C: Coolant pump on crankcase.
The tightening sequence given in the following table must be followed to ensure that there are no leaks in the
coolant pump.
Fig. 40: Identifying Coolant Pump Bolts
Courtesy of MERCEDES-BENZ USA
TIGHTENING SEQUENCE AND BOLT LENGTH
Tightening sequence Bolts
1 1A to 8A (M7 x28), tighten in numerically ascending order
2 B (M8x75)
3 C (M8x110)
REMOVE/INSTALL COOLANT PUMP - AR20.10-P-1271MC
ENGINES 275 in MODELS 215, 216, 220, 221, 230
Fig. 41: Identifying Coolant Pump Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant spray. AS20.00-Z-
pressure. Do not pour coolant into
Risk of poisoning caused by swallowing 0001-01A
beverage containers.
coolant.
Wear protective gloves, protective
clothing and safety glasses.
AR20.00-P-
1 Drain coolant at radiator
1142H
AH20.00-N-
Notes on coolant
2080-01A
Model 216, 221 except 216.379, AR20.40-P-
221.179 6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
2.1 Remove fan shroud Model 215.376, 220.176, 230
AR20.40-P-
without code (P99) Special model
6800AC
"AMG Black Series"
AR20.40-P-
Model 215.379, 220.179
6800IM
2.2 Remove fan unit model "AMG Black Series" 5050RBS
Slacken bolts (1) for the pulley (2) at coolant *BA20.10-
3
pump (3) P-1002-01C
AR13.22-P-
Model 215, 220, 230
1202L
4 Remove poly-V belt
AR13.20-P-
Model 216, 221
0001SZ
5 Detach belt pulley (2) from coolant pump (3)
Inspect condition of coolant
Remove coolant hoses (4, 5) from coolant hoses (4, 5) and hose clamps.
6
pump (3) Installation: Replace if
required.
AR03.30-P-
7 Remove belt pulley/vibration damper (9)
1600L
*BA01.30-
8 Detach guide pulley (6) from front cover.
P-1002-01G
*BA01.40-
9 Detach guide pulley (10)
P-1006-01C
Installation: Install new
seal (8).
Installation: Observe
length of bolts and tightening
Remove bolts (7) and take off coolant pump
10 sequence:
(3)
AR20.10-P-
Bolt plan for coolant pump (3)
1271-03L
*BA20.10-
P-1004-01C
11 Install in the reverse order
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting work
0005-01A
starting procedure or when working near the clothes.
engine as it is running Do not touch hot or rotating parts.
AR20.00-P-
Model 215, 220, 230
1010HA
12 Inspect cooling system for leaks
AR20.00-P-
Model 216, 221
1010SX
CYLINDER HEAD
Number Designation Engine 275
BA01.30-P-1002-01G Bolt, guide pulley to front cover on right M8 Nm 35
CRANKCASE, TIMING CASE COVER, END COVER
Number Designation Engine 275, 285
BA01.40-P-1006-01C Bolt, pulley to timing case cover Nm 35
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engines 137, 275
BA20.10-P-1002-01C Belt pulley on coolant pump Nm 8
BA20.10-P-1004-01C Coolant pump on timing case M7 Nm 14
REMOVE/INSTALL COOLANT PUMP - AR20.10-P-1271SMG
ENGINE 156 in MODEL 216, 221
Shown on engine 156.980
Fig. 42: Identifying Coolant Pump Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value modified: Guide pulley on coolant pump housing (between power *BA13.25-P-
7.8.09
steering pump and guide pulley with grooved channel profile) 1003-01U
Remove/install
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear of AS00.00-Z-
removing, installing or aligning hoods,
moving parts. 0011-01A
doors, trunk lids, tailgates or sliding
roof.
Risk of death caused by vehicle lift and position four support plates at
AS00.00-Z-
slipping or toppling off the lifting vehicle lift support points specified by
0010-01A
platform. vehicle manufacturer.
Do not open cooling system unless coolant
Risk of injury to skin and eyes caused temperature is below 90°C. Open cap
by scalding from contact with hot slowly and release the pressure. Do not AS20.00-Z-
coolant spray. Risk of poisoning pour coolant into beverage containers. 0001-01A
caused by swallowing coolant. Wear protective gloves, protective clothing
and safety glasses.
On vehicles with code 889,
Keyless Go: Press Keyless Go start/stop
Switch ignition off, remove ignition button repeatedly until ignition is switched
1
key (transmitter key). off. Remove keyless go transmitter card or
transmitter key from vehicle and store
outside of transmission range (min. 2 m)
2 Open engine hood
Do not tilt front engine cover, but lift
3 Remove front engine cover upwards vertically otherwise retaining lugs
can break off.
AR00.60-P-
4 Raise vehicle with lifting platform
1000SX
Remove bottom engine compartment Installation : Only install lower AR61.20-P-
5 engine compartment paneling after leak
paneling 1105SX
test.
AR20.00-P-
6 Drain coolant from radiator
1142SMG
AH20.00-
All engines N-2080-
01A
Notes on coolant *BF20.00-
Coolant
P-1001-02U
Test cap Fig. 7
Cooler vacuum filling device Fig. 9
AR20.40-P-
7 Remove electric fan
5000SMG
Attach guard plate for radiator /
8
condenser
WF58.50-
Radiator guard plate/ condenser
P-0110-01A
*BA13.25-
9 Loosen bolts for belt pulley (2)
P-1002-01U
AR13.22-P-
10 Remove poly-V belt (3)
1202SMG
11
pump (1) by hand, do not tighten.
*BA13.25-
Remove guide pulley (4, 5) from P-1003-01U
12
coolant pump (1) *BA13.25-
P-1004-01U
Remove guide pulley (6) from timing *BA13.25-
13
case cover P-1005-01U
Inspect condition of coolant hoses
Dismount coolant hose (9) on coolant and hose clamps, replace if necessary.
14
pump (1)
Set of stop plugs Fig. 46
*BA20.10-
15 Remove bolts (7)
P-1001-01V
*BA20.10-
16 Remove bolts (8)
P-1001-01V
Detach and remove coolant pump (1)
17 Installation : Install new gasket
from timing case cover
Installation : Clean sealing
Clean sealing surface on timing case
18 surface with clean rags otherwise leakage
cover
can occur.
Clean sealing surface on coolant pump Only when reusing coolant pump
19
(1) (1).
20 Install in the reverse order
AR20.00-P-
1010SX
21 Inspect cooling system for leaks
Pressure Pump Fig. 4
Tester cap Fig. 7
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving
running. Risk of injury caused by by itself.
contusions and burns during starting Wear closed and snug-fitting work clothes.
procedure or when working near the Do not touch hot or rotating parts. AS00.00-Z-
engine as it is running 0005-01A
In the event of oil loss determine and
Conduct engine test run and check the eliminate cause, otherwise malfunctions,
22
engine for leaks transmission damage, and serious
environmental pollution may occur.
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engine 156
M6x30 Nm 9
M6x80 Nm 9
BA20.10-P-1001-01V Bolt, coolant pump to timing case cover and crankcase
M8x80 Nm 20
M8x100 Nm 20
BELT TENSIONING DEVICE
Engine 156,
Number Designation
159
BA13.25-P-
Bolt, pulley to coolant pump M6 Nm 8.5
1002-01U
BA13.25-P- Guide pulley on coolant pump housing (between power steering pump
Nm 30
1003-01U and guide pulley with grooved channel profile)
BA13.25-P- Guide pulley to coolant pump housing (between alternator and smooth
Nm 20
1004-01U guide pulley)
BA13.25-P- Guide pulley (between poly-V belt tensioning device and coolant
Nm 20
1005-01U pump)
COOLING SYSTEM
Engine 156 in model
Number Designation
216, 221
Total filling capacity approx.Liters 10
Up to -37°C 50/50
BF20.00-P-1001- Cooling Antifreeze/water
Up to -45°C 55/45
02U system
Specifications for Operating Sheet BB00.40-P-0310-01A
Fluids Sheet BB00.40-P-0325-00A
Fig. 43: Identifying Test Cap (210 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 44: Identifying Pressure Pump (124 589 24 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 45: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 46: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL COOLANT PUMP - AR20.10-P-1271SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 47: Identifying Coolant Pump Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Switch off ignition
AR20.00-P-
2 Drain coolant at radiator
1142SX
AH20.00-N-
Notes on coolant
2080-01A
Except model AR13.20-P-
3.1 Remove poly-V belt (1) and guide pulley (2, 3)
221.095 /195 0001SX
AR13.22-P-
3.2 Remove both V-belts Model 221.095 / 195
1202SXH
AR15.40-P-
4 Remove alternator Model 221.095 / 195
5032SXH
Remove alternator bracket from timing case cover and Model 221.095 / 195 *BA15.40-P-
5
coolant pump (5) 1010-01F
Pry off electrical feed line retaining clamp (4) from Except model
6
coolant pump (5) 221.095 /195
Installation:
7 Detach coolant hose (6) from coolant pump (5) Replace sealing ring on
coolant hose (6).
Installation: AR20.10-P-
Remove bolts and coolant pump (5) from timing case
8 Replace gasket and note
cover 1271-03VA
bolting plan.
*BA20.10-P-
1001-01U
*BA20.10-P-
1002-01U
Clean
Clean sealing surfaces on coolant pump (5) and timing
9
case cover with a rag
10 Install in the reverse order
AR20.00-P-
11 Inspecting cooling system for leaks
1010SX
Secure vehicle to
prevent it from moving
Risk of accident caused by vehicle starting off by itself
by itself.
when engine is running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-
contusions and burns during starting procedure or when 0005-01A
fitting work clothes.
working near the engine as it is running
Do not touch hot or
rotating parts.
Conduct engine test run and check coolant pump (5) for
12
leaks
ALTERNATOR
Number Designation Engine 272
BA15.40-P-1010-01F Bolt, alternator bracket to Nm 20
timing case cover/coolant
pump
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engine 272 Engine 273
BA20.10-P- Self-tapping bolt M7 Nm 25 25
1001-01U connecting
coolant pump to
timing case cover
BA20.10-P- Bolt, coolant M8 Nm 20 20
1002-01U pump to
crankcase
TEST COOLANT THERMOSTAT - AR20.10-P-2455SMG
ENGINE 156 in MODEL 216, 221
Fig. 48: Testing Coolant Thermostat
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant AS20.00-Z-
pressure. Do not pour coolant into
spray. Risk of poisoning caused by 0001-01A
beverage containers.
swallowing coolant.
Wear protective gloves, protective
clothing and safety glasses.
Installation : Install new
sealing ring.
The coolant thermostat (1)
must not be removed from the housing. AR20.10-P-
1 Remove coolant thermostat (1)
Otherwise it will be destroyed. The 2460SMG
housing is supplied together with a
coolant thermostat (1) for repair
purposes.
Checking
Suspend coolant thermostat (1)
from a wire in a vessel filled with water
and heat water.
2 Heat coolant thermostat (1) For heating up under no
circumstance use a welding torch or a
soldering torch, otherwise sudden heat
penetration modifies the metal
structure!
The heating-up rate should be
not more than 1 to 2°C / minute from
about 8°C below start of opening of the
3 Measure temperature of water
coolant thermostat (1).
Digital temperature measuring
unit
achieved, replace coolant thermostat
(1).
Heat water to the fully open temperature of
*BE20.10-
4 thermostat (2) and then measure the stroke Start of opening
P-1001-02D
of the valve (2)
*BE20.10-
Minimum stroke
P-1002-02D
5 Install in the reverse order
AR20.00-P-
6 Inspect cooling system for leaks
1010SX
Risk of accident caused by vehicle
Secure vehicle to prevent it from
starting off by itself when engine is
moving by itself.
running. Risk of injury caused by
Wear closed and snug-fitting work
contusions and burns during starting
clothes. Do not touch hot or rotating
procedure or when working near the
parts. AS00.00-Z-
engine as it is running
0005-01A
In the event of oil loss determine and
eliminate cause, otherwise
Conduct engine test run and check the
7 malfunctions, transmission damage, and
engine for leaks
serious environmental pollution may
occur.
COOLANT THERMOSTAT
Number Designation Engine 156
conventional °C 98 to 102
BE20.10-P-1001-02D Start of opening
electrical °C 65
conventional °C 115
electrical °C 100
BE20.10-P-1002-02D Minimum stroke
conventional mm 5
electrical mm 8
TEST COOLANT THERMOSTAT - AR20.10-P-2455SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 49: Testing Coolant Thermostat
Courtesy of MERCEDES-BENZ USA
Remove/install
AR13.20-P-
1 Remove poly-V belt Except model 221.095 /195
0001SX
Disconnect electrical connector (4) at
2
three disc thermostat valve (Y110)
Measure
Connect multimeter (3) with adapter Digital multimeter (DMM)
3 cable (1) to three disc thermostat valve Automotive gotis://E_15/54_06.1 Fig. 50
(Y110)
If the measured value lies *BE20.10-P-
4 Measure resistance
outside the specified scatter: ? 1003-02C
AR20.10-P-
Replace coolant thermostat.
2460SX
5 Install in the reverse order
CHECK VALUES FOR COOLANT THERMOSTAT
Number Designation Engine 272 Engine 273
BE20.10-P-1003-02C Resistor at 20°C ohms 15.2 (±1.5) 15.2 (±1.5)
Fig. 50: Identifying Adapter Line (220 589 00 99 01)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL COOLANT THERMOSTAT - AR20.10-P-2460H
ENGINES 275 in MODEL 215, 216, 220, 221, 230
ENGINES 285 in MODEL 240
Fig. 51: Identifying Coolant Thermostat Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury to skin and eyes caused by
scalding from contact with hot coolant spray. Do not open cooling system unless AS20.00-Z-
Risk of poisoning caused by swallowing coolant temperature is below 90°C. 0001-01A
coolant. Open cap slowly and release the
1 Drain coolant at radiator beverage containers. 1142H
Wear protective gloves, protective AH20.00-N-
Notes on coolant clothing and safety glasses. 2080-01A
AR14.30-P-
2 Remove air shutoff valve
7200H
Installation: Install new
seal ring (2).
Remove coolant line (1) from housing top *BA20.10-
3
section (6) and place to one side P-1005-01C
*BA20.10-
P-1006-01C
Installation: Replace
Screw out bolt (4), remove temperature probe
sealing ring (3).
4 for coolant (B11/4) with holder from upper
part of housing (6) and lay it to one side *BA20.10-
P-1003-01C
Installation: Replace seal
Remove bolts (5) and remove upper part of (7).
5
housing (6) *BA20.10-
P-1003-01C
Remove coolant thermostat (8) from housing
6
top section (6)
7 Install in the reverse order
Checking
AR20.00-P-
Model 215, 220, 230, 240
1010HA
8 Inspecting cooling system for leaks
AR20.00-P-
Model 216, 221
1010SX
Risk of accident caused by vehicle starting
off by itself when engine is running. Risk of Secure vehicle to prevent it from
injury caused by contusions and burns during moving by itself.
starting procedure or when working near the Wear closed and snug-fitting work AS00.00-Z-
engine as it is running 0005-01A
clothes.
Conduct engine test run and check engine for Do not touch hot or rotating parts.
9
leaks
COOLANT PUMP, COOLANT THERMOSTAT
Engine 137, Engine
Number Designation
275 285
BA20.10-P-1003-
Bolt for coolant thermostat housing M6 Nm 15 15
01C
BA20.10-P-1005- Bolt, coolant line to coolant thermostat
M6 Nm 8 8
01C housing
BA20.10-P-1006-
Bolt connecting coolant line to cylinder head M6 Nm 8 8
01C
REMOVE/INSTALL COOLANT THERMOSTAT - AR20.10-P-2460SMG
ENGINE 156 in MODEL 216, 221 Shown on engine 156.980
Fig. 52: Identifying Coolant Thermostat Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant AS20.00-Z-
pressure. Do not pour coolant into
spray. Risk of poisoning caused by 0001-01A
beverage containers.
swallowing coolant.
Wear protective gloves, protective
clothing and safety glasses.
Align vehicle between columns of
Risk of death caused by vehicle slipping vehicle lift and position four support AS00.00-Z-
or toppling off the lifting platform. plates at vehicle lift support points 0010-01A
specified by vehicle manufacturer.
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear of AS00.00-Z-
installing or aligning hoods, doors, trunk moving parts. 0011-01A
lids, tailgates or sliding roof.
AH20.00-N-
Notes on coolant All engines
2080-01A
Notes on avoiding damage to electronic AH54.00-P-
All models
components due to electrostatic discharge 0001-01A
On vehicles with code 889,
1 Turn key in ignition switch to position "0". Keyless Go: Press keyless go start/stop
button repeatedly until ignition is
switched off
2 Open engine hood
Do not tilt front engine cover, but lift
3 Remove front engine cover upwards vertically otherwise the
retaining lugs can break off.
4 Remove right and left intake air duct
AR14.30-P-
5 Remove switchover valve
7255SMG
AR00.60-P-
6 Raise vehicle with lifting platform
1000SX
Remove lower engine compartment AR61.20-P-
7
paneling 1105SX
AR20.00-P-
8 Drain coolant from radiator
1142SMG
Detach upper coolant hose (1) from
Installation : Install new O-
9 coolant thermostat housing (2) and place it
ring.
to one side
Remove overflow line from coolant
10 thermostat housing (2) to coolant
expansion reservoir and set aside
Unlatch electrical connector at three-disk Also disconnect connector on
11
thermostat valve (Y110) and disconnect underside of thermostat housing.
*BA20.10-
12 Remove bolts (2a)
P-1002-01V
The coolant thermostat and coolant
thermostat housing (2) are a single unit.
Pull out coolant thermostat housing (2) The coolant thermostat must not be
13 with coolant thermostat from timing case taken out of coolant thermostat housing
cover (2) as it can get damaged in the process.
Installation : Install new O-
ring and seal.
14 Install in the reverse order
AR20.00-P-
15 Inspect cooling system for leaks
1010SX
Checking
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from
running. Risk of injury caused by moving by itself.
contusions and burns during starting AS00.00-Z-
Wear closed and snug-fitting work
procedure or when working near the 0005-01A
clothes. Do not touch hot or rotating
engine as it is running parts.
16 Carry out engine test run
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engine 156
M6x25 Nm 8.5
BA20.10-P-1002-01V Bolt, thermostat on timing case cover
M8x80 Nm 20
REMOVE/INSTALL COOLANT THERMOSTAT - AR20.10-P-2460SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 53: Identifying Coolant Thermostat Components
Courtesy of MERCEDES-BENZ USA
Shown on engine 273
Remove/install
1 Switch off ignition
AR20.00-P-
2 Drain coolant at radiator
1142SX
AH20.00-N-
Notes on coolant
2080-01A
Remove left engine intake air duct and front AR09.10-P-
3 See Remove air filter housing.
engine cover 1150SX
Vehicles without 4MATIC
Detach top coolant hose (1) from coolant
4.1 Replace O-ring
thermostat housing (2) and place it on the side
(1a).
Vehicles with 4MATIC
AR46.25-P-
4.2 Remove coolant pipe See "Removing power steering
1000SX
expansion reservoir".
AR13.20-P-
5 Remove poly-V belt and guide pulley (3) Except model 221.095 /195
0001SX
Unlatch electrical connector at three-disk
6
thermostat valve (Y110) and disconnect
*BA20.10-
7 Remove bolts (2a, 2 pieces)
P-1003-01U
The coolant thermostat must
not be taken out of the coolant
Pull out coolant thermostat housing (2) with thermostat housing (2) as it can
8
coolant thermostat from timing case cover get damaged in the process.
Installation: Replace
gasket (2b) and O-ring (2c).
9 Install in the reverse order
Checking
Secure vehicle to prevent it from
Risk of accident caused by vehicle starting off
moving by itself.
by itself when engine is running. Risk of injury
Wear closed and snug-fitting AS00.00-Z-
caused by contusions and burns during starting
work clothes. 0005-01A
procedure or when working near the engine as it
Do not touch hot or rotating
is running
parts.
Conduct engine test run and check engine for
10
leaks
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engine 272 Engine 273
BA20.10-P-1003- Bolt, coolant Nm 25 25
01U thermostat housing
to timing case cover
REMOVE, INSTALL COOLANT THERMOSTAT HOUSING - AR20.10-P-2710M
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Shown on model 220
Fig. 54: Identifying Coolant Thermostat Housing Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not open cooling system unless
Risk of injury to skin and eyes caused coolant temperature is below 90°C. Open
by scalding from contact with hot cap slowly and release the pressure. Do AS20.00-Z-
coolant spray. Risk of poisoning not pour coolant into beverage containers. 0001-01A
caused by swallowing coolant. Wear protective gloves, protective
clothing and safety glasses.
AR20.00-P-
1 Drain coolant from radiator
1142H
AH20.00-N-
Notes on coolant All engines
2080-01A
AR01.10-P-
Engine 275.95
2405LA
2 Remove front engine cover
AR01.10-P-
Engine 275.98
2405IM
Installation: replace O-ring (2).
*BA20.10-P-
Dismount coolant line (1) and place to
3 1005-01C
the side
*BA20.10-P-
1006-01C
4
coolant temperature sensor (B11/4)
Dismount pneumatic line (3) and air
5
hose (4) from aspirator shutoff valve (5)
Inspect condition of coolant hose and
Dismount coolant hose of coolant pump
6 hose clamp.
at coolant thermostat housing (6)
Installation: Replace if required.
Installation: Clean sealing
surfaces, replace O-ring (9) and gasket
Remove bolts (7, 8) and coolant
7 (10).
thermostat housing (6) upwards
*BA20.10-P-
1007-01C
8 Install in the reverse order
AR20.00-P-
Model 215, 220, 230
1010HA
9 Inspect cooling system for leaks
AR20.00-P-
Model 216, 221
1010SX
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engine 137, 275
BA20.10-P-1005-01C Bolt, coolant line to coolant thermostat housing M6 Nm 8
BA20.10-P-1006-01C Bolt connecting coolant line to cylinder head M6 Nm 8
BA20.10-P-1007-01C Bolt, coolant thermostat housing to cylinder head M6 Nm 8
REMOVE/INSTALL RADIATOR - AR20.20-P-3865SX
ENGINE 156, 272, 273 in MODEL 221
ENGINE 156, 273 in MODEL 216
Fig. 55: Identifying Radiator Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on engine 273
Fig. 56: Identifying Radiator Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on engine 273
Remove/install
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off of the lifting platform. 0010-01A
support points specified by
vehicle manufacturer.
AR61.20-P-
1 Remove bottom engine compartment paneling
1105SX
AR20.00-P-
2 Drain coolant at radiator Engine 272, 273
1142SX
AR20.00-P-
Engine 156
1142SMG
AH20.00-N-
Notes on coolant
2080-01A
AR83.30-P-
3 Discharge air conditioning system Model 221 with engine 156
1760SX
Close off connections using AR27.10-P-
4 Remove oil lines (1) on radiator (2) stop plugs to avoid ingress of 0501-03SX
contaminants.
Fig. 46
AR09.41-P-
5 Remove coolant hoses (3a, 3b) on radiator (2)
1311-01AL
6 Remove coolant hose (3c) on radiator (2) Fig. 58
AR09.41-P-
7 Take off coolant hose (3d) at radiator (2) Engine 272
1311-01AL
Engine 272, 273 AR20.40-P-
8 Remove fan shroud
Engine 156 6800SX
9 Remove bolt (4)
10 Remove radiator (2) bracket (5)
11 Remove upper radiator crossmember Model 221 with engine 156
12 Remove air ductings (6)
Remove radiator for low temperature water AR09.41-P-
13 Model 221 with engine 272.974
circuit 6935SXH
*BA62.30-
14 Remove bolts (7a)
P-1001-04B
15 Disconnect AC line on condenser (8) Model 221 with engine 156
Unclip condenser (8) using needle nose pliers
16
(01) on left and right from radiator (2)
Installation: Check correct
Remove bolts (7b, 7c) and take off radiator *BA62.30-
17 seating of rubber mount (2a) in
support (7) downwards P-1001-04B
radiator (2) and radiator support
18 Remove bottom air ducting (9)
19 Unhook condenser (8) below out of radiator (2)
Hook guard plate onto radiator (2) and remove
20
radiator (2) upwards
WF58.50-P-
Guard plate for radiator/condenser
0110-01A
21 Install in the reverse order
Check fluid level in automatic transmission and AR27.00-P-
22 Vehicles without 4MATIC
adjust to correct level 0270W
AR27.00-P-
Vehicles with 4MATIC
0270SYZ
Risk of accident caused by vehicle starting off Secure vehicle to prevent it from
by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting
0005-01A
starting procedure or when working near the work clothes.
engine as it is running Do not touch hot or rotating parts.
Perform engine test run and check connections
23
for oil lines (1) for leaks
RADIATOR SUPPORT
Number Designation Model 216 Model 221
BA62.30-P- Bolt, radiator M6 Nm 10 10
1001-04B support to
longitudinal M12 Nm 120 120
member
Fig. 57: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 58: Identifying Hose Clamp Pliers (003 589 03 37 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL RADIATOR - AR20.20-P-3865SXM
ENGINE 275.982 in MODEL 216.379, 221.179
Fig. 59: Identifying Radiator Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 60: Identifying Radiator Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
support points specified by vehicle
manufacturer.
AR01.10-P-
1 Remove engine trim panel
2405IM
2 Remove engine intake air duct
3 Remove radiator trim Model 216
AR62.30-P-
4 Dismount radiator crossmember (11)
2300SXM
Take out fan shroud AR20.40-P-
5 Remove fan shroud
upwards. 6800SXM
6 Hook guard plate onto radiator (2)
WF58.50-P-
Guard plate for radiator / condenser
0110-01A
Remove front section of lower engine AR61.20-P-
7
compartment paneling 1105SX
AR20.00-P-
8 Drain coolant at radiator (2)
1142H
Remove oil cooler (5) for Active Body Control AR32.50-P-
9
(ABC) on condenser (8) 0020SX
10 Remove air ductings (6)
AR09.41-P-
11 Remove circulation pump (M44)
6925LA
Remove bracket (12) for circulation pump
12
(M44)
13 Remove right front fanfare horn
14 Remove oil lines (1) on radiator (2) Close off connections to avoid AR27.10-P-
ingress of contaminants. 0501-03SX
Fig. 46
15 Remove coolant hose (3c) on radiator (2) Fig. 58
Detach coolant hoses (3a, 3b, 3f) on radiator AR09.41-P-
16
(2) 1311-01AL
Installation: Check correct
seating of rubber mount (2a) in
Unscrew bolts (7a, 7b, 7c) and take off *BA62.30-
17 radiator (2) and radiator support
radiator support (14) downwards P-1001-04B
(14).
Remove rubber strips (2b, 2c) from cooler (2)
18
upwards
19 Unclip oil lines on bracket (15)
Unclip low-temperature cooler with condenser AR09.41-P-
20
(8) from radiator (2) 6935SXM
Detach coolant line holder for air conditioning
21
on radiator (2) by removing bolt (7)
Detach engine oil cooler (13) and secure with AR18.30-P-
22
a cable tie 1000SX
23 Take out radiator (2) in an upward direction
24 Install in the reverse order
Check oil level in automatic transmission, AR27.00-P-
25
correct if necessary 0100AC
AR88.40-P-
26 Adjust engine hood
3020SX
Risk of accident caused by vehicle starting off Secure vehicle to prevent it from
by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting work
0005-01A
starting procedure or when working near the clothes.
engine as it is running Do not touch hot or rotating parts.
Perform engine test run and check connections
27
for oil lines (1) for leaks
RADIATOR SUPPORT
Number Designation Model 216 Model 221
BA62.30-P-1001-04B Bolt, radiator support to longitudinal member M6 Nm 10 10
M12 Nm 120 120
Fig. 61: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 62: Identifying Hose Clamp Pliers (003 589 03 37 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL RADIATOR - AR20.20-P-3865SZ
ENGINE 275 (except 275.982) in MODEL 216, 221
Fig. 63: Identifying Radiator Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 64: Identifying Radiator Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
support points specified by vehicle
manufacturer.
AR01.10-P-
Engine 275.95
2405LA
1 Remove engine trim panel
AR01.10-P-
Engine 275.98
2405IM
2 Remove engine intake air duct
3 Remove expansion clip (5) from radiator (2)
Model 216
4 Remove radiator grille from bumper Installation: First install
radiator paneling in bumper.
5 Remove bottom air ducting (9)
See Completely replace front end
with reinforcement.
Installation: For vehicles AR62.30-P-
with code 219 Distronic (DTR) or 1570SX
6 Dismount radiator crossmember (11)
code 233 Distronic Plus :
?
Check / adjust sensor setting of AR30.30-P-
Distronic. 1000R
Take out fan shroud AR20.40-P-
7 Remove fan shroud
upwards. 6800SZ
8 Hook guard plate onto radiator (2)
WF58.50-P-
Guard plate for radiator / condenser
0110-01A
AR61.20-P-
Vehicles without top protection
Remove front section of lower engine 1105SX
9
compartment paneling Vehicles with code Z07 Top AR61.20-P-
protection 1105SXS
AR20.00-P-
10 Drain coolant at radiator (2)
1142H
11 Undo clip (10) on oil lines (12)
Unclip condenser (8) using needle nose pliers
12
(01) on left and right from radiator (2)
Remove front section of fender liner in right
13
front fender
14 Remove air ductings (6)
Close off connections using
stop plugs to avoid ingress of
15 Remove oil lines (1) on radiator (2) contaminants.
Fig. 46
AR09.41-P-
16 Remove coolant hoses (3a, 3b) on radiator (2) See Open and close Henn coupling.
1311-01AL
17 Remove coolant hose (3c) on radiator (2) Fig. 58
AR18.30-P-
18 Detach oil cooler and secure with cable tie Model 221.176, 216.376
1000SZ
*BA62.30-
19 Remove bolts (7a)
P-1001-04B
AR09.41-P-
20 Take off coolant hose (3d) at radiator (2)
1311-01AL
21 Unscrew bolt (4)
Installation: Check correct
seating of rubber mount (2a) in
Unscrew bolts (7b, 7c) and take off radiator radiator (2) and radiator support
22
support (7) downwards (7).
*BA62.30-
P-1001-04B
Unclip low-temperature cooler from radiator AR09.41-P-
23
(2) 6935SZ
Unhook condenser (8) below out of radiator
24
(2)
25 Take out radiator (2) in an upward direction
26 Install in the reverse order
Check oil level in automatic transmission, AR27.00-P-
27
correct if necessary 0100AC
AR88.40-P-
28 Adjust engine hood
3020SX
Risk of accident caused by vehicle starting
off by itself when engine is running. Risk of Secure vehicle to prevent it from
injury caused by contusions and burns during moving by itself.
starting procedure or when working near the Wear closed and snug-fitting work AS00.00-Z-
engine as it is running 0005-01A
clothes.
Perform engine test run and check connections Do not touch hot or rotating parts.
29
for oil lines (1) for leaks
RADIATOR SUPPORT
Number Designation Model 216 Model 221
M6 Nm 10 10
BA62.30-P-1001-04B Bolt, radiator support to longitudinal member
M12 Nm 120 120
Fig. 65: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 66: Identifying Hose Clamp Pliers (003 589 03 37 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ADDITIONAL RADIATOR - AR20.20-P-3866SX
ENGINE 275.982 in MODEL 221.179, 216.379
Fig. 67: Identifying Additional Radiator Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Turn steering to the right and detach key
1
from ignition lock
AR20.00-P-
2 Drain coolant at radiator
1142H
3 Remove front right fender liner (1)
Pry off additional fan connector (A) from
4 left bracket (2) on mounting frame for
additional radiator (3) and disconnect
Unlock additional fan relay (K9) and
5
detach upwards from bracket
Remove bolts (2a), unscrew nuts (2b) and Installation: Check for correct
6 remove left bracket (2) on mounting seating of the additional radiator (3) in
frame for additional radiator (3) the four rubber supports (3a).
Installation: Check for correct
Remove additional radiator (3) seating of the four rubber supports (3a)
7
downwards in the mounting frame for additional
radiator (3).
Catch escaping coolant in a
container.
Open retaining clamp (4a) and remove
8 Installation: Check coolant lines (4)
coolant lines (4) at additional radiator (3)
and spring-loaded band-type clamps for
damage; replace if necessary.
for coolant (M4/2) from additional
9 If necessary
radiator (3)
10 Install in the reverse order
REMOVE/INSTALL COOLANT LEVEL SWITCH - AR20.30-P-4392SXI
ENGINES 157, 272, 273, 275, 276, 278, 642, 629 in MODEL 221
ENGINES 157, 275, 278 in MODEL 216
Shown on ENGINE 272 in MODEL 221
Fig. 68: Identifying Coolant Level Switch Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant spray. AS20.00-Z-
pressure. Do not pour coolant into
Risk of poisoning caused by swallowing 0001-01A
beverage containers.
coolant.
Wear protective gloves, protective
clothing and safety glasses.
1 Switch off ignition
Slowly open cap (1) on expansion reservoir The coolant temperature
2
(2) and remove should be approx. 40°C.
3
pliers of 60 mm
4 Suction coolant out of expansion reservoir (2) Hand pump Fig. 69
5 Disconnect electrical connector (4)
Release locks (5a) and lift out coolant lines Install new O-rings
6
(5) from expansion reservoir (2) (5b).
Unscrew nut (6) and lift expansion reservoir
7
(2)
Remove coolant hose (3) on expansion
8 Hose clamp pliers Fig. 58
reservoir (2)
The coolant level switch is
9 Remove expansion reservoir (2) integrated in expansion reservoir (2)
and cannot be replaced as a separate
item.
10 Install in the reverse order
Checking
11 Check coolant level and correct if necessary
AH20.00-
Notes on coolant level N-2080-
01A
AR20.00-P-
12 Inspect cooling system for leaks Engine 629
1010SXD
Engine 157, 272, 273, 275, 276, 278, AR20.00-
642 P-1010SX
Engine 275 with low temperature AR20.00-
circuit P-1010HN
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting work
0005-01A
starting procedure or when working near the clothes.
engine as it is running Do not touch hot or rotating parts.
Conduct engine test run and check engine for
13
leaks
Fig. 69: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
Fig. 70: Identifying Hose Clamp Pliers (003 589 03 37 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL EXPANSION RESERVOIR - AR20.30-P-4950SX
ENGINES 156, 157, 272, 273, 275, 276, 278 in MODEL 221
ENGINES 156, 157, 273, 275, 278 in MODEL 216
Fig. 71: Identifying Expansion Reservoir Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not open cooling system unless
coolant temperature is below 90°C.
scalding from contact with hot coolant spray. pressure. Do not pour coolant into
Risk of poisoning caused by swallowing beverage containers. AS20.00-Z-
coolant. Wear protective gloves, protective 0001-01A
clothing and safety glasses.
1 Switch off ignition
Slowly open cap (1) on expansion reservoir The coolant temperature
2
(2) and remove should be approx. 40°C.
Clamp off coolant hose (3) using a suitable
3
tool
4 Suction coolant out of expansion reservoir (2) Fig. 69
5 Disconnect electrical connector (4)
Release lock (5a) and pull out coolant lines Install new O-rings
6
(5) from expansion reservoir (2) (5b).
Unscrew nut (6) and lift expansion reservoir
7
(2)
Remove coolant hose (3) on expansion
8 Fig. 58
reservoir (2)
9 Install in the reverse order
Checking
10 Check coolant level and correct if necessary
AH20.00-
Notes on coolant level P-1142-
01V
AR20.00-
11 Inspect cooling system for leaks
P-1010SX
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting work
0005-01A
starting procedure or when working near the clothes.
engine as it is running Do not touch hot or rotating parts.
Conduct engine test run and check engine for
12
leaks
Fig. 72: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
Fig. 73: Identifying Hose Clamp Pliers (003 589 03 37 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ELECTRIC FAN - AR20.40-P-5000SMG
ENGINE 156 in MODEL 216, 221
Fig. 74: Identifying Electric Fan Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
AS00.00-
pinched or crushed when removing, installing Keep body parts and limbs well
Z-0011-
or aligning hoods, doors, trunk lids, tailgates or clear of moving parts.
01A
sliding roof.
Align vehicle between columns of
vehicle lift and position four AS00.00-
Risk of death caused by vehicle slipping or
support plates at vehicle lift support Z-0010-
toppling off the lifting platform.
points specified by vehicle 01A
manufacturer.
Risk of explosion caused by oxyhydrogen gas.
No fire, sparks, open flames or
Risk of poisoning and caustic burns caused
smoking. Wear acid-resistant AS54.10-
by swallowing battery acid. Risk of injury
gloves, clothing and glasses. Only Z-0001-
caused by burns to skin and eyes from battery
pour battery acid into suitable and 01A
acid or when handling damaged lead-acid
appropriately marked containers.
batteries
AR54.10-
1 Disconnect ground line from battery
P-0003SX
AH54.10-
Notes on battery All models P-0001-
01A
2 Open engine hood
Remove engine intake air duct and front engine
3
cover
Remove edge stripping in the area of the
4
radiator crossmember
5 Unplug electrical connector (6) on electrical fan
Remove clamps (7a) on the left and right on fan
6
shroud (7)
AR00.60-
7 Raise vehicle
P-1000SX
Unscrew engine oil line to the underside of the
8
fan shroud (7)
9 Take out fan shroud (7) towards top
10 Install in the reverse order
REMOVE/INSTALL ELECTRIC FAN - AR20.40-P-5000SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 75: Identifying Electric Fan Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR20.40-P-
1 Remove fan shroud (1)
6800SX
Remove electrical connector (2) By unlatching locks using a
2
from fan shroud (1) screwdriver in the direction of the arrow.
3 Expose electrical feed line (3)
4 Remove bolts (4)
Remove electrical suction fan
5
(M4/7)
6 Install in the reverse order
REMOVE/INSTALL FAN SHROUD - AR20.40-P-6800SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 76: Identifying Fan Shroud Components
Courtesy of MERCEDES-BENZ USA
Shown on engine 273
Remove/install
1 Switch off ignition
Remove bottom engine compartment AR61.20-P-
2 Engine 273
paneling 1105SX
AR20.00-P-
3 Drain coolant at radiator Engine 273
1142SX
Remove engine intake air duct and front AR09.10-P-
4 See "Remove/install air filter housing".
engine cover 1150SX
Model 221 with engine 273 without
5 Remove engine oil dipstick (1)
4MATIC
Model 221 with engine 273 without
6.1 Remove hose (2)
4MATIC
Model 221 with engine 273 with
AR46.25-P-
6.2 Remove coolant pipe 4MATIC See Remove/install power
1000SX
steering expansion reservoir.
Vehicles with engine 273 and 4MATIC
AR62.30-P-
7 Remove upper radiator crossmember See Completely replace front end with
1570SX
reinforcement.
8 the radiator crossmember (4)
Detach hose (5) from radiator and
AR09.41-P-
9 temperature control switch housing and Engine 273
1311-01AL
place to the side with bracket (5a)
Disconnect electrical connector (6) on
10
electrical suction fan
Remove feed line for electrical suction
11
fan from fan shroud (7) (arrow)
Remove clamps (7a) on the left and right
12
on fan shroud (7)
13 Take out fan shroud (7) towards top
14 Install in the reverse order
REMOVE/INSTALL FAN SHROUD - AR20.40-P-6800SXM
ENGINE 275.982 in MODEL 216.379, 221.179
Fig. 77: Identifying Fan Shroud Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 78: Identifying Fan Shroud Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
AR01.10-P-
1 Remove front engine cover
2405IM
2 Remove engine intake air duct
3 Remove radiator trim Model 216
AR62.30-P-
4 Dismount radiator crossmember (5)
2300SXM
Remove bolts (9) and upper coolant
5
pipe (4)
Remove front and center section of AR61.20-P-
6
engine compartment paneling 1105SX
Remove bolt (8) and unclip lower
7
coolant pipe (7)
Unclip coolant hose (6) on upper right
8
on radiator from bracket
Disconnect electrical connector (2s)
9
on electrical suction fan
Detach clamps (2k) on the left and
10 right from fan shroud (2) brackets
(2h)
Lift fan shroud (2) until brackets
(2n) have moved out of the radiator
mounts.
11 Unhook fan shroud (2) on radiator
Installation: Check for correct
seating of brackets (2n) in the radiator
frame.
Take out the fan shroud (2) in the
12
upward direction.
13 Install in the reverse order
REMOVE/INSTALL FAN SHROUD - AR20.40-P-6800SZ
ENGINE 275 (except 275.982) in MODEL 216, 221
Fig. 79: Identifying Fan Shroud Components
Courtesy of MERCEDES-BENZ USA
Fig. 80: Identifying Fan Shroud And Brackets
Courtesy of MERCEDES-BENZ USA
Remove/install
AR01.10-P-
Engine 275.95
2405LA
1 Remove front engine cover
AR01.10-P-
Engine 275.98
2405IM
2 Remove engine intake air duct
3 Unclip bracket (1)
Disconnect electrical connector (2s)
4
on electrical suction fan
Unclip coolant hose (6) on upper right
5
on radiator from bracket
Detach edge stripping (3) in area of
6
the radiator crossmember (5)
Detach clamps (2k) on the left and
7 right from fan shroud (2) brackets
(2h)
Pull our ventilation hose (4) between
8 fan shroud (2) and radiator
crossmember (5)
Vehicles without code (Z07) Top AR61.20-P-
Remove front and center section of protection 1105SX
9
engine compartment paneling AR61.20-P-
Vehicles with code(Z07) Top protection
1105SXS
Lift fan shroud (2) until brackets
(2n) have moved out of the radiator
mounts.
10 Unhook fan shroud (2) out of radiator
Installation: Check for correct
seating of fan shroud (2) brackets (2n) in
the radiator mounts.
11 Remove fan shroud (2) downwards
12 Install in the reverse order
SAFETY PRECAUTIONS
RISK OF INJURY TO SKIN AND EYES SUFFERING SCALDING FROM CONTACT WITH HOT
COOLANT SPRAY. RISK OF POISONING FROM SWALLOWING COOLANT. - AS20.00-Z-0001-
01A
Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the
pressure. Do not pour coolant into beverage bottles.
Wear protective gloves, protective clothing and eye protection.
Possible hazards
Risk of injury
When the engine is warm, the cooling system is pressurized. If the cooling system is opened suddenly, there is a
risk of scalding from hot coolant which splashes out.
Danger of poisoning
If coolant is swallowed, this can result in manifestations of poisoning such as headaches, dizziness, stomach
pain, respiratory paralysis, unconsciousness, vomiting and cramps.
Safety precautions/instructions
Allow cooling system to cool down to a coolant temperature of less than 90 °C.
Open cap of cooling system slowly; turn a conventional coolant cap as far as the first detent and turn a
screwed coolant cap approx. 1/ 2 turn and release the pressure.
Wear protective gloves, protective clothing and eye protection. Do not pour coolant into beverage bottles.
First aid measures
Rinse affected skin with large quantities of cold water and cover with sterile bandages.
Allow the person affected to drink plenty of water with the addition of medicinal charcoal.
If the person has suffered severe burns or has swallowed coolant, contact a doctor.
SAFETY INFORMATION: ENGINE COOLING SYSTEM - AS20.00-Z-9999ZZ
MODEL all
Risk of injury to skin and eyes suffering scalding from contact with ENGINE AS20.00-Z-
Danger!
hot coolant spray. Risk of poisoning from swallowing coolant. all 0001-01A
TORQUE SPECIFICATIONS
ENGINE COOLING, GENERAL - BA20.00-P-1000-02D
Engine 275, 285
ENGINE COOLING, GENERAL
Engine Engine
Number Designation 275.950/951/952/980/981, 275.953/954/982/983,
285.950 285.980
BA20.00-P- Coolant drain plug
Nm 14 14
1001-02D to crankcase
BA20.00-P- Coolant drain plug
Nm 12 -
1002-02D to alternator
ENGINE COOLING, GENERAL - BA20.00-P-1000-02E
Engine 272, 273
ENGINE COOLING, GENERAL
Number Designation Engine 272 Engine 273
BA20.00-P-1001- Coolant drain plug Nm 12 12
02E to crankcase
TIGHTENING TORQUES: PASSENGER CARS: ENGINE COOLING SYSTEM - BA20.00-Z-9999AZ
MODEL all
BA20.00-P-
Coolant preheater ENGINE 602, 603, 604, 605, 606, 611, 612, 613
1000-01B
BA20.00-P-
Coolant preheater ENGINE 111, 112 /, 113 /, 119, 155.980, 271
1000-01A
Coolant pump, coolant BA20.10-P-
ENGINE 601, 602, 603, 604, 605, 606, 611, 612, 613, 647...
thermostat 1000-01A
Coolant pump, coolant BA20.10-P-
ENGINE 780 in MODEL 169
thermostat 1000-01AB
Coolant pump, coolant BA20.10-P-
ENGINE 157, 278
thermostat 1000-01W
Coolant pump, coolant BA20.10-P-
ENGINE 276
thermostat 1000-01AA
Coolant pump, coolant BA20.10-P-
ENGINE 651
thermostat 1000-01X
Coolant pump, coolant BA20.10-P-
ENGINE 112...
thermostat 1000-01M
Coolant pump, coolant BA20.10-P-
ENGINE 272, 273 /
thermostat 1000-01U
Coolant pump, coolant BA20.10-P-
ENGINE 159
thermostat 1000-01Y
Coolant pump, coolant BA20.10-P-
ENGINE 266
thermostat 1000-01P
Coolant pump, coolant BA20.10-P-
ENGINE 628.960 /961 /962 /963, 629
thermostat 1000-01F
Coolant pump, coolant BA20.10-P-
ENGINE 642 /
thermostat 1000-01S
Coolant pump, coolant BA20.10-P-
ENGINE 646.951 /8 /961 /962 /963 /966, 647, 648
thermostat 1000-01G
Coolant pump, coolant BA20.10-P-
ENGINE 113, 137, 155, 275, 285...
thermostat 1000-01C
Coolant pump, coolant BA20.10-P-
ENGINE 668.914 /940 /941 /942
thermostat 1000-01E
Coolant pump, coolant BA20.10-P-
ENGINE 166.940 /960 /961 /990 /991 /995
thermostat 1000-01D
thermostat ENGINE 103 /, 104 /, 111, 119, 120 1000-01B
Coolant pump, coolant BA20.10-P-
ENGINE 156
thermostat 1000-01V
Coolant pump, coolant BA20.10-P-
ENGINE 113.987 /988 /989 /990 /991, 155
thermostat 1000-01L
Coolant pump, coolant BA20.10-P-
ENGINE 271
thermostat 1000-01I
Coolant pump, coolant BA20.10-P-
ENGINE 640
thermostat 1000-01Q
Engine coolant pump, BA20.10-N-
ENGINE 601 /, 602 / /982 /983
engine coolant thermostat 1000-01B
BA20.00-P-
Engine cooling, general ENGINE 611, 612, 613, 628, 646, 647, 648, 651...
1000-02A
BA20.00-P-
Engine cooling, general ENGINE 272, 273 /
1000-02E
BA20.00-P-
Engine cooling, general ENGINE 111, 112, 113, 155...
1000-02B
BA20.00-P-
Engine cooling, general ENGINE 640
1000-02F
BA20.00-P-
Engine cooling, general ENGINE 271
1000-02C
ENGINE 275.950 /951 /952 /953 /954 /980 /981 /982 /983, BA20.00-P-
Engine cooling, general
285.950 /980 1000-02D
BA20.40-P-
Fan, fan clutch ENGINE 112, 113, 155...
1000-01B
ENGINE 103, 104, 111, 119, 120, 601, 602, 603, 604, 605, BA20.40-P-
Fan, fan clutch
606, 612, 613... 1000-01A
BA20.40-P-
Fan shroud ENGINE 113.967 /990 in MODEL 219
1000-03C
BA20.40-P-
Fan shroud ENGINE 111, 112, 113, 271, 272, 273, 611, 612, 646...
1000-03B
BA20.40-P-
Fan shroud ENGINE 285.950
1000-03A
ENGINE 103, 111, 112, 113, 119, 137, 155, 272, 273, 275, BA20.20-P-
Radiator, coolant hoses
285... 1000-01A
BA20.20-N-
Radiator, coolant hoses ENGINE 272, 601, 602, 642, 646, 651, 780...
1000-01B
BA20.20-P-
Radiator, coolant hoses ENGINE 266
1000-01M
BA20.20-P-
Radiator, coolant hoses ENGINES 668.914 /940 /941 /942
1000-01G
BA20.20-P-
Radiator, coolant hoses ENGINE 271
1000-01K
Radiator, coolant hoses ENGINE 628.963 /961 1000-01I
ENGINE 612.963 in MODEL 163.113 BA20.20-P-
Radiator, coolant hoses
ENGINE 628.963 in MODEL 163.128 1000-01L
BA20.20-P-
Radiator, coolant hoses ENGINE 640
1000-01N
BA20.20-P-
Radiator, coolant hoses ENGINE 166.940 /960 /961 /990 /991 /995
1000-01C
BA20.20-P-
Radiator, radiator hoses ENGINE 601, 602, 603, 604, 605, 606, 613
1000-01H
BA20.20-P-
Radiator, radiator hoses ENGINE 120
1000-01F
BA20.20-P-
Radiator, radiator hoses ENGINE 611.960 /961
1000-01D
COOLANT PUMP, COOLANT THERMOSTAT - BA20.10-P-1000-01C
Engines 113, 137, 155, 275, 285
COOLANT PUMP, COOLANT THERMOSTAT
Engines
Number Designation 113.940/941/942/943/944/945/946/948/960/961/962/963/965/966/967/968/969
993/995
Thread
not
M6 Nm 14
pre-
Self- tapped
tapping Thread
screw not
BA20.10- for M8 Nm
pre-
P-1001- coolant tapped
01C pump
to Thread
timing pre- M6 Nm 10
case tapped
Thread
pre- M8 Nm 25
tapped
BA20.10-
Belt pulley to
P-1002- Nm 10
coolant pump
01C
Bolt for
BA20.10-
coolant
P-1003- M6 Nm 10
thermostat
01C
housing
BA20.10- Coolant pump M7 Nm 10
01C case
Bolt, coolant
BA20.10-
line to housing
P-1005- M6 Nm -
of coolant
01C
thermostat
BA20.10- Bolt, coolant
P-1006- line to M6 Nm -
01C cylinder head
Bolt, coolant
BA20.10-
thermostat
P-1007- M6 Nm -
housing to
01C
cylinder head
Bolt, guide
BA20.10-
pulley to
P-1008- M8 Nm -
coolant pump
01C
housing
COOLANT PUMP, COOLANT THERMOSTAT
Engine Engine
Number Designation
155 285
Thread not pre-
M6 Nm - -
tapped
Thread not pre-
M8 Nm --
BA20.10-P-1001- Self-tapping screw for coolant pump tapped
01C to timing case Thread pre-
M6 Nm - -
tapped
Thread pre-
M8 Nm - -
tapped
BA20.10-P-1002-
Belt pulley to coolant pump Nm - 8
01C
BA20.10-P-1003-
Bolt for coolant thermostat housing M6 Nm 9 15
01C
BA20.10-P-1004-
Coolant pump at the timing case M7 Nm - 14
01C
BA20.10-P-1005-
Bolt, coolant line to housing of coolant thermostat M6 Nm - 8
01C
BA20.10-P-1006-
Bolt, coolant line to cylinder head M6 Nm - 8
01C
BA20.10-P-1007-
Bolt, coolant thermostat housing to cylinder head M6 Nm - -
01C
BA20.10-P-1008-
Bolt, guide pulley to coolant pump housing M8 Nm - -
01C
COOLANT PUMP, COOLANT THERMOSTAT - BA20.10-P-1000-01U
Engine 272, 273
COOLANT PUMP, COOLANT THERMOSTAT
Number Designation Engine 272 Engine 273
BA20.10-P- Self-tapping M7 Nm 25 25
1001-01U bolt connecting
coolant pump
to timing case
cover
BA20.10-P- Bolt, coolant M8 Nm 20 20
1002-01U pump to
crankcase
BA20.10-P- Bolt, coolant Nm 25 25
1003-01U thermostat
housing to
timing case
cover
BA20.10-P- Bolt, guide Initial Nm 35 35
1004-01U pulley between installation
water pump
and belt Follow-up Nm 25 25
tensioner operations
BA20.10-P- Bolt Nm - 9
1005-01U connecting
coolant pipe to
coolant
thermostat
housing
BA20.10-P- Bolt Nm - 9
1006-01U connecting
coolant pipe to
cylinder head
front cover
BA20.10-P- Bolt, guide Nm 35 35
1007-01U pulley between
power steering
pump and
alternator
COOLANT PUMP, COOLANT THERMOSTAT - BA20.10-P-1000-01V
Engine 156
MODIFICATION NOTES
6.2.07 Bolt, coolant pump to timing case cover and crankcase Engine 156
COOLANT PUMP, COOLANT THERMOSTAT
Engine
Number Designation
156
M6x30 Nm 9
BA20.10-P-1001- M6x80 Nm 9
Bolt, coolant pump to timing case cover and crankcase
01V M8x80 Nm 20
M8x100 Nm 20
BA20.10-P-1002- M6x25 Nm 8.5
Bolt, thermostat to timing case cover
01V M8x80 Nm 20
BA20.10-P-1003-
Bolt, shutoff valve to cylinder head at the right rear M6x16 Nm 8.5
01V
BA20.10-P-1004- Heating water pipe to crankcase for shutoff valve for hot
M8x12 Nm 20
01V water hose
BA20.10-P-1005-
Bolt, preheater M6x40 Nm 10
01V
FAN SHROUD - BA20.40-P-1000-03B
Engine 111, 112, 113, 271, 272, 273, 611, 612, 646
FAN SHROUD
Engine 272 in Engine 272 in Engine 272, 273
Number Designation model 209 model 251 in model 221
BA20.40-P- Bolt, fan wheel Nm 6 6 6
1001-03B to fan motor
BA20.40-P- Bolt, fan wheel Nm - - -
1002-03B to notch
BA20.40-P- Bolt, electronics Nm - 8 -
1003-03B to notch
BA20.40-P- Bolt, fan motor Nm 8 - 8
1004-03B to fan shroud
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ENGINE COOLING SYSTEM - BE20.00-
Z-9999AZ
MODEL all
ENGINE 601, 602.91 /96, 603.91 /96 /97, 604, BE20.10-P-1000-
Coolant thermostat
605 02B
Coolant thermostat 271... 02A
BE20.10-P-1000-
Coolant thermostat ENGINE 157, 272, 273 /, 276, 278
02C
BE20.10-P-1000-
Coolant thermostat ENGINE 156, 159
02D
BE20.40-P-1000-
Fan, fan clutch ENGINE 120
01A
BE20.20-P-1000-
Fan/fan shroud ENGINE 104, 119, 120, 603
01C
BE20.20-P-1000-
Fan/fan shroud ENGINE 111, 604, 605, 606
01A
BE20.20-P-1000-
Fan/fan shroud ENGINE 103, 104, 119
01B
Test values for cooling system BE20.30-P-1000-
ENGINE all
cap 01A
COOLANT THERMOSTAT - BE20.10-P-1000-02C
Engine 157, 272, 273, 276, 278
CHECK VALUES FOR COOLANT THERMOSTAT
Number Designation Engine 272 Engine 273
BE20.10-P- Start of opening Main plate °C 65 65
1001-02C Locking plate °C 40 -
BE20.10-P- Minimum stroke Main plate °C 100 100
1002-02C Locking plate °C - -
mm 8 8
BE20.10-P- Resistor at 20°C ohms 15.2 (±1.5) 15.2 (±1.5)
1003-02C
CHECK VALUES FOR COOLANT THERMOSTAT
Engines 157,
Number Designation Engine 276 278
BE20.10-P- Start of opening Main plate °C 60 60
1001-02C Locking plate °C 15 15
BE20.10-P- Minimum stroke Main plate °C 90 90
1002-02C Locking plate °C - -
mm 8 to 12 8 to 12
BE20.10-P- Resistor at 20°C ohms 15.2 (±2) 15.2 (±2)
1003-02C
COOLANT THERMOSTAT - BE20.10-P-1000-02D
Engine 156, 159
COOLANT THERMOSTAT
Number Designation Engine 156 Engine 159
Conventional ° 98 to 102 98 to 102
BE20.10-P-1001-02D Start of opening
Electrical ° 65 65
Conventional ° 115 115
Electrical ° 100 100
BE20.10-P-1002-02D Minimum stroke
Conventional mm 5 5
Electrical mm 8 8
BE20.10-P-1003-02D Resistor at 20°C ohms 15.2 (±1.5) 15.2 (±1.5)
TEST VALUES FOR COOLING SYSTEM CAP - BE20.30-P-1000-01A
All engines
CAP OF RADIATOR OR EXPANSION RESERVOIR
1-stage cap
Number Designation Cap 2-stage cap on model 163
BE20.30-P- Cap code number 140 140/200 -
1001-01A
BE20.30-P- Pressure relief New bar overpressure 1.4 (+0.1) - 1.4 (+0.1)
1002-01A valve opens Used bar overpressure 1.4 (-0.1) - 1.4 (+0.1)
BE20.30-P- Vacuum valve bar vacuum 0.1 0.1 0.5
1003-01A opens (reference
value)
BE20.30-P- Pressure relief Stage 1 bar overpressure - 1.4 (±1) -
1004-01A valve opens Coolant temp. - > or =130/134 -
Stage 2 bar overpressure - 2.0 (±1) -
Coolant temp. - > or =137/143 -
BE20.30-P- Test pressure for bar overpressure 1.4 1.4 -
1005-01A pressure-testing
cooling system
CAPACITIES & SPECIFICATIONS
COOLING SYSTEM - BF20.00-P-1000-02Q
Engines 275, 285
MODIFICATION NOTES
Cooling system Engine 275.950 in model 215/220
Cooling system Engine 275.951/954 in model 230
Cooling system Engine 275.953 in model 221
1.12.05 Cooling system Engine 275.980 in model 215
Cooling system Engine 275.980 in model 220
Cooling system Engine 275.981 in model 230
Cooling system Engine 285.950/980 in model 240
COOLING SYSTEM
Engine 275.953 in
Number Designation model 216, 221
BF20.00-P- Cooling Total filling capacity Main circuit Liters approx.8.8
1001-02Q system Low temperature Liters approx.1.5
circuit
Filling capacity of Main circuit Liters approx.4.4
anticorrosion and
antifreeze down to -37 Low temperature Liters approx.0.75
°C circuit
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
COOLING SYSTEM
Engine
Engine 275.982 in
Number Designation 285.950/980 in
model 216, 221
model 240
Main circuit Liters approx.11.8 approx.10.3
Total filling Low
capacity temperature Liters approx.2.1 approx.1.6
circuit
Filling capacity of
Main circuit Liters approx.5.9 approx.5.15
anticorrosion and
BF20.00-P- Cooling
1001-02Q system Low
antifreeze down to -
temperature Liters approx.1 approx.0.8
37 °C
circuit
BB00.40-P-0310- BB00.40-P-0310-
Sheet
01A 01A
Specifications for Operating Fluids
BB00.40-P-0325- BB00.40-P-0325-
Sheet
00A 00A
COOLING SYSTEM - BF20.00-P-1000-02U
Engine 156, 159, 272, 273
MODIFICATION NOTES
6.3.06 Cooling system Engine 272, 273
COOLING SYSTEM
Engine 156 in
Engine 156 in model 209, 211,
Number Designation model 216, 221 219
BF20.00-P- Cooling system Total filling Liters 10 8
1001-02U capacity
Antifreeze/water Up to -37°C 50/50 50/50
up to -45°C 55/45 55/45
Specifications for Sheet BB00.40-P- BB00.40-P-
Operating Fluids 0310-01A 0310-01A
Sheet BB00.40-P- BB00.40-P-
0325-00A 0325-00A
COOLING SYSTEM
Engine 273 in Engine 273 in
Number Designation model 216, 221 model 463
BF20.00-P- Cooling system Total filling Liters 8.5 6
1001-02U capacity
Antifreeze/water Up to -37°C 50/50 50/50
up to -45°C 55/45 55/45
Specifications for Sheet BB00.40-P- BB00.40-P-
Operating Fluids 0310-01A 0310-01A
Sheet BB00.40-P- BB00.40-P-
0325-00A 0325-00A
MIXTURE RATIO FOR COOLANT - BF20.00-P-1000-04A
Engine all
MIXTURE RATIO FOR COOLANT
Number Designation Engine all
Up to -37°
50/50
C
Antifreeze/water
Up to -45°
55/45
BF20.00-P-1001- Mixture ratio for C
04A coolant BB00.40-P-0310-
Sheet
Specifications for Operating 01A
Fluids BB00.40-P-0325-
Sheet
CAPACITIES: PASSENGER CARS: ENGINE COOLING SYSTEM - BF20.00-Z-9999AZ
MODEL all
BF20.00-P-1000-
Cooling system ENGINE 266, 640...
02V
BF20.00-P-1000-
Cooling system ENGINE 275, 285...
02Q
BF20.00-P-1000-
Cooling system ENGINE 104...
02A
BF20.00-P-1000-
Cooling system ENGINE 112, 113...
02K
BF20.00-P-1000-
Cooling system ENGINE 271
02P
ENGINE 642 in MODEL 164, 203, 204, 209, 211, 212, 219, 221, BF20.00-P-1000-
Cooling system
251 ENGINE 642 in MODEL 461, 463 02W
BF20.00-P-1000-
Cooling system ENGINE 629 in MODEL 164, 221, 211
02Y
BF20.00-P-1000-
Cooling system ENGINE 155.980
02S
BF20.00-P-1000-
Cooling system ENGINE 604, 605, 606, 611, 612, 613, 628, 647, 648...
02E
BF20.00-P-1000-
Cooling system ENGINE 120
02C
BF20.00-P-1000-
Cooling system ENGINE 119
02B
BF20.00-P-1000-
Cooling system ENGINE 111...
02F
BF20.00-P-1000-
Cooling system ENGINE 601, 602, 603
02D
BF20.00-P-1000-
Cooling system ENGINE 668...
02N
BF20.00-P-1000-
Cooling system ENGINE 156, 159, 272, 273...
02U
BF20.00-P-1000-
Cooling system ENGINE 137.970
02M
BF20.00-P-1000-
Cooling system ENGINE 166...
02L
BF20.00-P-1000-
Cooling system MODEL 251 with ENGINE 113
02X
ENGINE 646 in MODEL 203, 204, 209 ENGINE 651 in MODEL BF20.00-P-1000-
Cooling system
204, 207, 212, 221 02AA
Mixture ratio for BF20.00-P-1000-
ENGINE all
coolant 04A
BASIC KNOWLEDGE
HEATING SYSTEM SHUTOFF VALVE, COMPONENT DESCRIPTION - GF20.00-P-2200AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211, 219
ENGINE 156.984 in MODEL 216, 221 up to Model Year 8
Location
Fig. 81: Locating Heating System Shutoff Valve
Courtesy of MERCEDES-BENZ USA
The shutoff valve is located at the rear on the right cylinder head.
Task
To warm up the engine quickly following a cold start, the shutoff valve can close off the coolant circuit to the
heating system.
Design
The shutoff valve consists of a solenoid with a coil resistance of around 12 ohms at 25 °C.
Function
The heating system shutoff valve is actuated by the ME-SFI control unit (N3/10) via a ground signal if required.
The shutoff valve is opened without a current.
If the vehicle heater is switched on, the shutoff valve is always open (not actuated).
COMPONENT DESCRIPTION FOR THE HEATING SYSTEM SHUTOFF VALVE - GF20.00-P-
2200V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.960 in MODEL 203 up to Model Year 8
ENGINE 272.964 in MODEL 211, 219
ENGINE 272.965 in MODEL 221 up to Model Year 8
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.970 in MODEL 203 up to Model Year 8
ENGINE 272.972 in MODEL 211
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 272.985 in MODEL 211, 219
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.923 in MODEL 164 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Fig. 82: Identifying Heating System Shutoff Valve
Courtesy of MERCEDES-BENZ USA
Location
The heating system shutoff valve is located behind the left cylinder bank at the coolant outlet of the engine.
Fig. 83: Locating Heating System Shutoff Valve
Courtesy of MERCEDES-BENZ USA
Task
To rapidly warm up the engine following a cold start, locks the coolant circuit to the heat exchangers. When the
vehicle heater is switched on, the valve is always open.
Function
The heating system shutoff valve is actuated by the ME control unit via a ground signal. The valve is opened
without a current. The coil resistance at room temperature is approx. 12.
COMPONENT DESCRIPTION FOR THE THREE-DISK THERMOSTAT VALVE - GF20.10-P-3160V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.942 in MODEL 171 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.960 in MODEL 203 up to Model Year 8
ENGINE 272.963 in MODEL 171 up to Model Year 8
ENGINE 272.964 in MODEL 211, 219
ENGINE 272.965 in MODEL 221 up to Model Year 8
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.970 in MODEL 203 up to Model Year 8
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 272.985 in MODEL 211, 219
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.923 in MODEL 164 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Fig. 84: Locating Three-Disk Thermostat Valve
Courtesy of MERCEDES-BENZ USA
Location
The three-disk thermostat valve is located at the front of the engine.
Task
independently of the control.
Function
Voltage supply to terminal 87, actuation of the heating element on the ground side of the ME control unit. The
opening cross-section is set via the operating time.
COMPONENT DESCRIPTION FOR THE TWO DISC THERMOSTAT HEATER ELEMENT -
GF20.10-P-3161AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211, 219
ENGINE 156.984 in MODEL 216, 221 up to Model Year 8
Location
Fig. 85: Identifying Two-Disk Thermostat And Two-Disk Thermostat Heating Element
Courtesy of MERCEDES-BENZ USA
The heating element is located on two-disk thermostat housing.
Task
The heating element regulates the engine coolant temperature within the range from approx. 85°C to 105°C.
From a coolant temperature of about 105°C the coolant thermostat opens independently of actuation (limp-
home function).
By regulating the coolant temperature the following benefits result:
Operating temperature is reached faster
Reducing exhaust gas emissions
Improved heat comfort.
Function
Actuation of the heating element takes via a PWM signal (pulse width modulated signal) from the ME-SFI
[ME] control unit (N3/10). The voltage is supplied through "terminal 87 M2e".
The open cross-section of the two-disk thermostat is determined via the duty cycle (frequency of the PWM
signal).
The limp-home function ensures that the two-disk thermostat is completely opened above around 105 °C,
irrespective of actuation.
Function of two-disk thermostat, schematic
Fig. 86: Two-Disk Thermostat Function Diagram
Courtesy of MERCEDES-BENZ USA
Short-circuit operation position (A)
Heating element de-energized Coolant temperature < 100°C
Heating element energized Coolant temperature < 60°C
Mixed fuel operation position (C)
Heating element de-energized Coolant temperature 100 to115 °C
Heating element energized Coolant temperature 60 to 100°C
Radiator operation position (C)
Heating element de-energized Coolant temperature > 115°C
Heating element energized Coolant temperature > 100°C
Above about a 115°C coolant temperature the two-disk thermostat is fully open independently of energizing
(limp-home function).
COMPONENT DESCRIPTION FOR THE ENGINE COOLANT CIRCULATION PUMP - GF20.10-P-
3200AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8 ENGINE 156.984 in MODEL 216, 221 up to
Model Year 8
Location for model 164
Fig. 87: Locating Engine Coolant Circulation Pump (Model 164)
Courtesy of MERCEDES-BENZ USA
The engine coolant circulation pump is located on the right next to the engine radiator.
Location on model 251
The engine coolant circulation pump is located on the outer right behind the bumper.
Location on model 216, 221
Fig. 88: Locating Engine Coolant Circulation Pump (Model 216, 221)
Courtesy of MERCEDES-BENZ USA
The engine coolant circulation pump is located on the lower right next to the engine radiator.
Task
The engine coolant circulation pump ensures circulation of coolant through the engine oil heat exchanger.
Actuation for model 164, 251 (shown is the engine compartment at the right)
Fig. 89: Identifying Engine Compartment Fuse And Relay Box Fuses & Relays
Courtesy of MERCEDES-BENZ USA
The engine coolant circulation pump is actuated for an excessively high engine oil temperature by the ME-SFI
[ME] control unit (N3/10) via the coolant circulation pump relay.
Actuation for model 216, 221 (shown is the engine compartment at the front middle)
Fig. 90: Identifying Rear SAM Control Unit With Fuse And Relay Module, Fuse 116 And Circulation
Pump Relay
Courtesy of MERCEDES-BENZ USA
The engine coolant circulation pump is actuated for an excessively high engine oil temperature by the ME-SFI
[ME] control unit (N3/10) via the circulation pump relay.
WIRING DIAGRAMS
ELECTRIC WIRING DIAGRAMS: PASSENGER CARS: ENGINE COOLING SYSTEM - PE20.00-Z-
9999AZ
MODEL all
Wiring diagram for engine cooling ENGINE 156, 157, 272, 273, 276, PE20.40-P-2000-97SAA
system (fan) 278 in MODEL 221
ENGINE 275 in MODEL 221.1
WIRING DIAGRAM FOR ENGINE COOLING SYSTEM (FAN) - PE20.40-P-2000-97SAA
ENGINES 156, 157, 272, 273, 276, 278, 642, 651 in MODEL 221.0 /1 ENGINES 275 in MODEL 221.1
Code: Designation: Position:
AO Color code key 40L
F32 Front prefuse 2L
F32/3 Engine compartment prefuse box 4L
F32/3f5 Fuse 5 4K
F32f6 Fuse 6 2K
M4/7 Engine and AC electric suction fan with integrated 4A
control
M4/7 Engine and AC electric suction fan with integrated 12A
control
M4/7 Engine and AC electric suction fan with integrated 20A
control
M4/7 Engine and AC electric suction fan with integrated 26A
control
N10/1 Front SAM control unit with fuse and relay module 6L
N10/1 Front SAM control unit with fuse and relay module 4A
N10/2 Rear SAM control unit with fuse and relay module 13A
N10/2 Rear SAM control unit with fuse and relay module 11L
N3/10 ME-SFI [ME] control unit 22C
N3/10 ME-SFI [ME] control unit 25L
N3/10 ME-SFI [ME] control unit 30L
N3/10 ME-SFI [ME] control unit 34L
N3/9 CDI control unit 21L
N82/1 Vehicle power supply control unit 2L
R15 Electric suction fan series resistor 27L
R15 Electric suction fan series resistor 36L
U1018 Valid for gasoline engine 276 13G
U1018 Valid for gasoline engine 276 26F
U1018 Valid for gasoline engine 276 9F
U1019 Valid for engine 278 13G
U1019 Valid for engine 278 28F
U1019 Valid for engine 278 9F
U1028 Valid for engine 157 23F
U1028 Valid for engine 157 13H
U1028 Valid for engine 157 9F
U152 Valid for engine 156 23E
U152 Valid for engine 156 9E
U484 Valid for M273 ME 13F
U484 Valid for M273 ME 15F
U484 Valid for M273 ME 5E
U779 Valid for engine 275 13G
U779 Valid for engine 275 9F
U819 Valid for engine 272 15E
U819 Valid for engine 272 13F
U819 Valid for engine 272 5F
U880 Valid for engine 642 19E
U880 Valid for engine 642 13F
U880 Valid for engine 642 5F
U932 Valid for engine 642 BLUETEC 5F
U932 Valid for engine 642 BLUETEC 13G
U932 Valid for engine 642 BLUETEC 19F
U948 Valid for diesel engine 651 9G
U948 Valid for diesel engine 651 13F
U948 Valid for diesel engine 651 19F
U966 Valid for engine 275.953 28E
U967 Valid for engine 275.982 33E
U968 Valid for mild hybrid drive 15F
Valid for mild hybrid drive 13E
W2 Ground (right front, at lamp unit) 14L
W9 Ground (left front, at lamp unit) 14L
Z7/48 Circuit 87 D2 connector sleeve 10H
Z7/5 Circuit 87 connector sleeve 10G
Z7/5 Circuit 87 connector sleeve 6G
Z7/5 Circuit 87 connector sleeve 6H
Z7/75 Circuit 87 D3 connector sleeve 6H
Fig. 91: Engine Cooling System Fan Wiring Diagram (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 92: Engine Cooling System Fan Wiring Diagram (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 93: Engine Cooling System Fan Wiring Diagram (3 Of 3)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS
119 589 00 03 00 BOX WRENCH BIT - WS20.00-P-0010C
FG 20/Set C
ENGINE 102.92 /93 /96 /97 /98 /99, 103, 104, 110.92 /98 /99, 115.97, 116, 117, 119, 120, 272, 273, 601,
602.91 /93 /94 /96, 603.91 /93 /96 /97, 612.965 /966, 615, 616, 617.91 /93 /95, 113.962 /942 /965, 112.942 /970
Use:
Open box wrench bit,
46 mm, 1/2" square for removing and installing coolant preheater
Fig. 94: Identifying Box Wrench Bit (119 589 00 03 00)
Courtesy of MERCEDES-BENZ USA
124 589 24 21 02 PRESSURE HOSE - WS20.00-P-0016-01B
FG 09/20/Set B
MODEL all
MODIFICATION NOTES
12.12.94 Replacement for: 124 589 15 21 02
Use:
Pressure hose with quick coupling.
Fig. 95: Identifying Pressure Hose (124 589 24 21 02)
Courtesy of MERCEDES-BENZ USA
124 589 24 21 00 PRESSURE PUMP - WS20.00-P-0016B
FG 20/Set B
MODEL all
MODIFICATION NOTES
29.11.94 Replacement for: 124 589 15 21 00
Part 124 589 24 21 02 Pressure hose FG 20/Set B WS20.00-P-0016-01B
Use:
0 to 2.5 bar testing unit for cooling system, consisting of pressure pump with pressure gage and pressure hose
with quick-coupling.
Test caps for cooling system:
124 589 00 91 00 (System Renk)
163 589 01 91 00 (ML-class)
168 589 02 91 00 (A-class)
210 589 00 91 00 (E-Class, S-Class, G-Class)
639 589 01 91 00 (Vito, Sprinter)
NOTE: For model 639 with code MA0 (E-CELL 60 kw) in combination with 450 589 07 21
07 adapter.
Fig. 96: Identifying Pressure Pump (124 589 24 21 00)
Courtesy of MERCEDES-BENZ USA
210 589 00 91 00 TEST CAP - WS20.00-P-0017B
FG 01/20/Set B
MODEL 124, 129, 140, 163, 164, 166, 170, 171, 172, 197, 199, 202, 203, 204, 207, 208, 209, 210, 211, 212,
215, 216, 218, 219, 220, 221, 230, 240, 251, 461, 463 with screw cap on expansion reservoir
MODEL 639 with ENGINE 112, 272, 642, 646 with screw cap on expansion reservoir
MODEL 636 with ENGINE 646 with screw cap on expansion reservoir
Use:
Test connection with thread for coolant expansion reservoir to testing unit 124 589 24 21 00 and filling device
285 589 00 21 00.
Fig. 97: Identifying Test Cap (210 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
124 589 00 91 00 TEST CAP - WS20.00-P-0018B
FG 20/Set B
MODEL 107, 123, 124, 126, 129, 140, 170, 201, 202, 210, 211, 215, 216, 219, 220, 221, 230, 240, 461, 463,
901, 902, 903, 904 mit Renk-Verschluss am Ausgleichbehalter
MODEL XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7, WD1, WD2,
WD3, WD6, WD7 mit Renk-Verschluss am Ausgleichbehalter
MODEL 220 with ENGINE 648.960 mit Renk-Verschluss am Ausgleichbehalter
MODEL 221 mit Renk-Verschluss am Ausgleichbehalter
MODEL 668, 670 with ENGINE 900.9 mit Renk-Verschluss am Ausgleichbehalter
MODIFICATION NOTES
2.12.94 Replacement for: 124 589 15 21 02
Use:
57 mm tester cap (System Renk) for coolant expansion tank in combination with test equipment 124 589 24 21
00 and filling device.
Fig. 98: Identifying Test Cap (124 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
285 589 01 21 00 NTKL ADAPTATION - WS20.00-P-0029B
FG 20/Set B
ENGINE 275, 285
ENGINE 155 in MODEL 199
Use:
For filling and bleeding LT circuit.
NOTE: Only for use in combination with 285 589 00 21 00.
Fig. 99: Identifying NTKL Adaptation (285 589 01 21 00)
Courtesy of MERCEDES-BENZ USA
285 589 00 21 00 COOLER VACUUM FILLING DEVICE - WS20.00-P-0030B
FG 01/08/20/54/Set B
MODEL all
Use:
Vacuum-type cooling system filler for cooling circuits (bubble-free), with integrated leak test.
NOTE: On model 639 with code MA0 (E-CELL 60 kW) in combination with 450 589 07 21
07 Adapter and 639 589 00 91 00 Tester cap
Fig. 100: Identifying Cooler Vacuum Filling Device (285 589 00 21 00)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS: PASSENGER CARS: ENGINE COOLING SYSTEM - WS20.00-Z-9999AZ
MODEL all
WS00.00-P-
000 589 40 37 00 Clamp FG 00/01/07/18/20/ 47/82/88
0005Z
FG 00/01/07/08/13/ 14/18/20/22/28/33/ WS00.00-P-
000 589 54 37 00 Clamp
46/47/54/82/83/Set B 0006Z
WS20.00-P-
000 589 77 63 00 Adapter FG 20/Set B
0002B
001 589 73 21 00 Hand WS00.00-P-
FG 00/01/07/09/14/15/ 20/30
vacuum pump 0018Z
001 589 81 09 00 Set of WS00.00-P-
FG 00/01/07/09/14/15/ 20/Set B
flexible head wrenches 0251B
003 589 03 37 00 Hose clamp WS01.00-P-
FG 01/07/09/18/20/ 46/54/ set B
pliers 0113B
003 589 03 37 00 Hose clamp WS46.00-P-
FG 01/20/46/Set B
pliers 0096B
WS20.00-P-
103 589 00 40 00 Bracing tool FG 20/Set B
0004B
103 589 01 09 00 Screwdriver WS20.00-P-
FG 20/Set B
bit 0005B
WS20.00-P-
104 589 00 33 00 Puller FG 20/Set C
0006C
111 589 00 40 00 WS20.00-N-
FG 20/Set B
Counterholder 0007B
111 589 02 01 00 Open wrench WS20.00-N-
FG 20/Set B
socket 0008B
113 589 00 01 00 Open wrench WS20.00-P-
FG 20/Set B
socket 0026B
113 589 00 40 00 WS20.00-P-
FG 20/Set B
Counterholder 0027B
WS20.00-P-
117 589 00 90 00 Flushing pipe FG 20/Set C
0009C
119 589 00 03 00 Box wrench WS20.00-P-
FG 20/Set C
bit 0010C
WS20.00-P-
119 589 00 09 00 Socket FG 20/Set C
0011C
119 589 02 40 00 WS20.00-P-
FG 20/Set B
Counterholder 0020B
120 589 02 01 00 Open-end WS20.00-P-
FG 20/Set B
wrench 0012B
WS20.00-P-
120 589 14 07 00 Screwdriver FG 20/Set B
0013B
WS20.00-P-
124 589 00 91 00 Test cap FG 20/Set B
0018B
WS15.00-N-
124 589 09 63 00 Ohm decade FG 09/15/20/Set C
0009C
WS20.00-N-
124 589 15 21 00 Tester FG 20/Set A
0014A
124 589 15 21 01 Pressure WS20.00-N-
FG20/Set A
pump 0014-01A
WS20.00-N-
124 589 15 21 02 Radiator cap FG20/Set A
0014-02A
124 589 24 21 00 Pressure WS20.00-P-
FG 20/Set B
pump 0016B
WS20.00-P-
124 589 24 21 02 Pressure hose FG 09/20/Set B
0016-01B
126 589 00 01 00 Open-end WS20.00-P-
FG 20/Set B
wrench 0059B
FG 00/Set Z FG 01/05/06/07/09/14/ 15/18/20/22/25/26/ WS00.00-P-
129 589 00 91 00 Record plug
27/29/32/33/35/42/ 46/47/68/82/83/88/ 91/Set B 0255Z
WS20.00-P-
163 589 01 91 00 Test cap FG 20/Set B
0023B
WS20.00-P-
163 589 02 91 00 Test cap FG 20/Set B
0044B
168 589 02 62 00 WS20.00-P-
FG 20/Set B
Removal/installation device 0047B
WS20.00-P-
168 589 02 91 00 Test cap FG 20/Set B
0024B
WS20.00-P-
168 589 03 91 00 Adapter FG 20/Set B
0046B
WS20.00-P-
168 589 04 91 00 Adapter FG 20/Set B
0045B
WS20.00-P-
169 589 00 40 00 Bracket set FG 20/01/32/33 /Set B
0055B
WS20.00-P-
169 589 00 91 00 Test cap FG 20/Set B
0056B
199 589 00 01 00 Open-end WS20.00-P-
FG 20/Set B
wrench 0048B
WS20.00-P-
199 589 00 21 00 Adaptation FG 20/Set A
0053A
WS20.00-P-
199 589 01 01 00 Open wrench FG 20/Set B
0049B
WS00.00-P-
210 589 00 71 00 Hand pump FG 00/01/07/09/20/25/ 27/32/33/43/46/88
0280Z
WS20.00-P-
210 589 00 91 00 Test cap FG 01/20/Set B
0017B
WS20.00-P-
210 589 03 63 00 Adapter FG 20/Set B
0019B
220 589 00 99 00 Electrical WS54.00-P-
FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B
connection kit 0050B
WS54.00-P-
220 589 00 99 20 Test cable FG 15/20/25/42/43/54/ Set B
0050-14B
220 589 00 99 35 Adapter WS54.00-P-
FG 00/09/20/42/43/54/Set B
cable 0050-24B
220 589 05 99 00 Electrical WS00.00-P-
FG 00/01/09/13/15/ 20/25/42/43/47/54/ 72/ Set B
connection kit 0279Z
285 589 00 21 00 Cooler WS20.00-P-
FG 01/08/20/54/Set B
vacuum filling device 0030B
285 589 01 21 00 NTKL WS20.00-P-
FG 20/Set B
Adaption 0029B
603 589 00 40 00 WS20.00-P-
FG 20/01/46/Set B
Counterholder 0015B
WS15.00-N-
611 589 00 37 00 Pliers FG 01/15/20/Set B
3033B
611 589 00 40 00 WS20.00-N-
FG 01/03/20/46/ Set B
Counterholder 3032B
613 589 01 40 00 WS20.00-P-
FG 20/Set B
Counterholder 0025B
WS20.00-N-
639 589 00 91 00 Test cap FG 20/54/Set B
3035B
WS20.00-N-
639 589 01 91 00 Test cap FG 20/Set B
3036B
763 589 00 01 00 Open-end WS20.00-P-
FG 20/Set B
wrench 0058B
ENGINE
Electrical System - Engine - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE - AH15.00-Z-9999AZ
MODEL all
General notes on contactless AH15.10-P-
ENGINE 112, 113...
high voltage distribution 1002-01WA
General notes on contactless AH15.10-P-
ENGINE 119, 120...
high voltage distribution 1002-01WE
General notes on contactless AH15.10-P-
ENGINE 104, 111...
high voltage distribution 1002-01WD
General notes on testing
AH15.10-P-
contactless high voltage ENGINE 104, 111, 112, 113, 119, 120...
1003-01W
distribution
Information on avoiding damage AH15.10-P-
ENGINE 137, 275, 285
to ignition system 0002-01L
AH15.20-P-
Notes for ceramic glow plugs ENGINE 640, 646.8, 642 /, 651
0001-01A
Notes on avoiding damage to AH15.10-P-
ENGINE 159
ignition system 0002-01RQ
Notes on avoiding damage to ENGINE 104, 111, 112 /, 113, 119, 120, 156, 271, AH15.10-P-
ignition system 272 mit Benzin-Einspritz-und Zundsystem ME 0002-01D
Notes on avoiding damage to AH15.10-P-
ENGINE 272, 273, 157, 276, 278
ignition system 0002-01V
Notes on avoiding damage to ENGINE 266.920 /940 /960 /980 in MODEL AH15.10-P-
ignition system 169.0 /3, 245.2 0002-01AK
Notes on avoiding damage to the ENGINE 104, 111 mit Benzin-Einspritz-und AH15.10-P-
ignition system Zundsystem HFM 0002-01C
Notes on avoiding damage to the ENGINE 104, 119, 120 mit Benzin-Einspritzanlage AH15.10-P-
ignition system LH 0002-01F
Notes on avoiding damage to the ENGINE 103, 104, 119 mit Benzin-Einspritzanlage AH15.10-P-
ignition system KE 0002-01E
Notes on avoiding damage to the ENGINE 166 mit Benzin-Einspritz-und Zundsystem AH15.10-P-
ignition system MSM 0002-01G
Notes on avoiding damage to the ENGINE 111 mit Benzin-Einspritz-und Zundsystem AH15.10-P-
ignition system PMS 0002-01B
Notes on ignition coil
AH15.10-P-
characteristics of ignition ENGINE 104, 111, 112, 113, 119, 120...
1001-01A
systems
NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002-01D
Engine 104, 111, 112, 113, 119, 120, 156, 271, 272 with ME-SFI gasoline injection and ignition system
To avoid damage to control unit, only connect and disconnect the two connectors on control unit when
ignition is switched off.
Terminal 1 of ignition coils must not be short-circuited to GND, e.g. as antitheft protection.
Only install 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 k ohms (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 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 injection / ignition systems.
Use of testing units
Only connect and disconnect secondary measuring sensor to corresponding ignition cables when vertical
engine and ignition are switched off.
If the short-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.
INFORMATION ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002-01L
Engine 137, 275, 285
Engine 137, 275, 285 with ignition system ECI
It is not possible to test the ignition sparks for example during a roadside assistance on this ignition system.
It is only possible to determine faults in the ignition system through read out of diagnostic trouble code memory
by means of STAR DIAGNOSIS.
The separation of electrical connectors at components of ignition system can only take place after switching off
the ignition.
To avoid damage, the ignition must not be switched on without ground supply at power supply unit ECI (N91).
A sufficient ground supply can only be assured, if the power supply unit ECI (N91) is bolted to the intake
manifold (1).
Shown on Engine 137
Fig. 1: Identifying Intake Manifold And ECI Power Supply Unit
Courtesy of MERCEDES-BENZ USA
NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002-01V
Engine 157, 272, 273, 276, 278
Before disconnecting the connector (R) at the ME-SFI [ME] control unit (N3/10), turn the key in the
ignition switch (EIS [EZS] control unit) to the "0" position.
Disconnect the battery before disconnecting the connector (L) at the ME-SFI [ME] control unit (N3/10).
Only install original ignition system components.
Shown on engine 272
Fig. 2: Identifying ME-SFI [ME] Control Unit & Connectors
Courtesy of MERCEDES-BENZ USA
Fig. 3: Identifying Ignition Coil And Spark Plug Connector
Courtesy of MERCEDES-BENZ USA
Do not run the ignition system without fully connected lines or without the spark plug connector (a).
Do not disconnect the connectors at the ignition coils (T1/1 to T1/8) at starting speed or when the engine
is running.
Do not take off the ignition coils (T1/1 to T1/8) from the spark plugs at starting speed or when the engine
is running.
Before working at starting speed, for example, check the compression pressure, turn the key in the EIS
[EZS] control unit to the "0" position.
MAINTENANCE
REPLACE SPARK PLUGS - AP15.10-P-1580SX
ENGINE 157, 273, 278 in MODEL 216
ENGINE 157, 272, 273, 276, 278 in MODEL 221
Shown on ENGINE 272
Fig. 4: Removing Spark Plug
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of death due to Do not touch parts which AS15.10-Z-0001-01A
contact with high-voltage conduct high voltages.
conductive parts Persons who wear
electronic implants (e.g.
heart pacemakers) should
never perform any work
on the ignition system
Risk of injury to skin Wear safety gloves, AS00.00-Z-0002-01A
and eyes caused by protective clothing and
handling hot or glowing safety glasses, if
objects. necessary.
Notes on avoiding damage AH15.10-P-0002-01V
to ignition system
Notes on avoiding damage AH00.00-P-5000-01A
through contamination
and foreign objects
1 Switch off ignition
2 Remove ignition coils Engine 272, 273 AR15.12-P-2003SX
Engine 157, 276, 278 AR15.12-P-2003MM
Checking
3 Check spark plug Check for damage,
connectors, ignition coil deformation and crack
connectors and ignition formation, replace if
lines necessary.
4 Remove spark plugs (R4) *BA15.10-P-1001-01C
from the cylinder heads
using a spark plug
wrench (01)
Engine 272, 273 Fig. 5
Engine 157, 276, 278 Fig. 6
5 Install in the reverse order
SPARK PLUGS
Engine Engine Engine Engine Engine
Number Designation
157 272 273 276 278
BA15.10-P-1001- Spark plug on cylinder
Nm 23 23 23 23 23
01C head
Fig. 5: Identifying Spark Plug Wrench (112 589 01 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 6: Identifying Spark Plug Wrench (278 589 00 09 00)
Courtesy of MERCEDES-BENZ USA
REPLACE SPARK PLUGS - AP15.10-P-1580SZ
ENGINES 275.953 in MODEL 216.376, 221.176
ENGINES 275.982 in MODEL 216.379, 221.179
Fig. 7: Identifying Spark Plugs And ECI Ignition Modules
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
26.2.07 Notes on avoiding damage through contamination and foreign objects, added
Remove/install and replacing
Do not touch parts which conduct high
voltages. Persons who wear electronic
Risk of death due to contact with AS15.10-Z-
implants (e.g. heart pacemakers) should
high-voltage conductive parts 0001-01A
never perform any work on the ignition
system
Risk of injury to skin and eyes
Wear safety gloves, protective clothing AS00.00-Z-
caused by handling hot or glowing
and safety glasses, if necessary. 0002-01A
objects.
Notes on avoiding damage to ignition AH15.10-P-
system 0002-01L
Notes on avoiding damage through AH00.00-P-
contamination and foreign objects 5000-01A
1 Switch off ignition
Remove ECI [energy controlled
ignition], ignition module, right
2 cylinder bank (N92/1) and ECI
ignition module, left cylinder bank
(N92/2)
AR15.12-P-
Remove/install ignition coil module
1100LA
Remove spark plugs (R4) from the Spark plug to cylinder *BA15.10-
3 cylinder heads using spark plug head P-1001-01C
wrench Spark plug wrench Fig. 5
4 Install in the reverse order
SPARK PLUGS
Number Designation Engine 275, 285
BA15.10-P-1001-01C Spark plug on cylinder head Nm 25
Fig. 8: Identifying Spark Plug Wrench (112 589 01 09 00)
Courtesy of MERCEDES-BENZ USA
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE -
AR15.00-Z-9156AB
ENGINE 156
Check regulator and AR15.40-P-
ENGINE 156, 271, 272, 273, 642, 646, 651...
alternator 5000CW
Checking regulator and AR15.40-P-
ENGINES 156, 272, 273 in MODEL 230
alternator 5000RX
Checking regulator and ENGINE 156, 272, 273, 275, 629, 642 in MODEL 221 AR15.40-P-
alternator ENGINE 156, 273, 275 in MODEL 216 5000SX
Checking the alternator and AR15.40-P-
ENGINE 156, 271, 272, 273, 629, 642, 646, 648...
regulator 5000T
Prerequisites for testing AR15.40-P-
ENGINE 156 in MODEL 164, 251
Alternator 5009GZS
AR15.40-P-
Remove/install alternator ENGINES 156 in MODEL 204, 212
5032CMG
AR15.40-P-
Remove/install alternator ENGINE 156 in MODEL 164, 251
5032GZS
Remove/install alternator ENGINE 156 in MODEL 230.470 5032RMG
AR15.40-P-
Remove/install alternator ENGINE 156 in MODEL 216, 221
5032SMG
ENGINE 156.982 in MODEL 209.377 /477 ENGINE AR15.40-P-
Remove/install alternator
156.983 in MODEL 211.077 /277, 219.377 5032TMG
Remove/install camshaft AR15.10-P-
ENGINE 156 in MODEL 204, 212
Hall sensor 2000CMG
Remove/install camshaft AR15.10-P-
ENGINE 156 in MODEL 164, 251
Hall sensor 2000GZS
Remove/install camshaft AR15.10-P-
ENGINE 156 in MODEL 230.470
Hall sensor 2000RMG
Remove/install camshaft AR15.10-P-
ENGINE 156 in MODEL 221, 216
Hall sensor 2000SMG
Remove/install camshaft ENGINE 156.983 in MODEL 211.077 /277, 219.377 AR15.10-P-
Hall sensor ENGINE 156.982 in MODEL 209.377 /477 2000TMG
Remove/install crankshaft AR15.12-P-
ENGINES 156 in MODEL 204
position sensor 2133CMG
Remove/install crankshaft AR15.12-P-
ENGINES 156 in MODEL 212
position sensor 2133EMG
Remove/install crankshaft AR15.12-P-
ENGINE 156 in MODEL 164, 251
position sensor 2133GZS
Remove/install crankshaft AR15.12-P-
ENGINE 156.982 in MODELS 209.377 /477
position sensor 2133QMG
Remove/install crankshaft AR15.12-P-
ENGINE 156 in MODEL 230.470
position sensor 2133RMG
Remove/install crankshaft AR15.12-P-
ENGINE 156 in MODEL 221, 216
position sensor 2133SMG
Remove/install crankshaft AR15.12-P-
ENGINE 156.983 in MODELS 211.077 /277, 219.377
position sensor 2133TMG
Remove/install ignition AR15.12-P-
ENGINES 156 in MODEL 204, 212
coils 2003CMG
Remove/install ignition AR15.12-P-
ENGINE 156 in MODEL 164, 251
coils 2003GZS
Remove/install ignition AR15.12-P-
ENGINE 156 in MODEL 230
coils 2003RMG
Remove/install ignition AR15.12-P-
ENGINE 156 in MODEL 216, 221
coils 2003SMG
Remove/install ignition ENGINE 156.983 in MODEL 211.077 /277, 219.377 AR15.12-P-
coils ENGINE 156.982 in MODEL 209.377 /477 2003TMG
Remove/install knock AR15.12-P-
ENGINES 156 in MODEL 204, 212
sensors 2184CMG
Remove/install knock AR15.12-P-
ENGINES 156 in MODEL 164, 251
sensors 2184GZS
sensors ENGINE 156 in MODEL 230.470 2184RMG
Remove/install knock AR15.12-P-
ENGINE 156 in MODEL 216, 221
sensors 2184SMG
Remove/install knock ENGINE 156.982 in MODEL 209.377 /477 ENGINE AR15.12-P-
sensors 156.983 in MODEL 211.077 /277, 219.377 2184TMG
Remove/install regulator for AR15.40-P-
ENGINES 156 in MODEL 204, 212
alternator 5760CMG
Remove/install regulator for AR15.40-P-
ENGINE 156 in MODEL 164, 251
alternator 5760GZS
Remove/install regulator for AR15.40-P-
ENGINE 156 in MODEL 230.470
alternator 5760RMG
Remove/install regulator for AR15.40-P-
ENGINE 156 in MODEL 216, 221
alternator 5760SMG
Remove/install regulator for ENGINE 156.982 in MODELS 209.377 /477 ENGINE AR15.40-P-
alternator 156.983 in MODELS 211.077 /277, 219.377 5760TMG
AR15.12-P-
Remove/install spark plugs ENGINES 156 in MODEL 204, 212
1010CMG
AR15.12-P-
Remove/install spark plugs ENGINES 156 in MODEL 164, 251
1010GZS
AR15.12-P-
Remove/install spark plugs ENGINES 156 in MODEL 230.470
1010RMG
AR15.12-P-
Remove/install spark plugs ENGINES 156 in MODEL 221, 216
1010SMG
ENGINES 156.983 in MODEL 211.077 /277, 219.377 AR15.12-P-
Remove/install spark plugs
ENGINES 156.982 in MODEL 209.377 /477 1010TMG
AR15.30-P-
Remove/install starter ENGINES 156 in MODEL 204, 212
7100CMG
AR15.30-P-
Remove/install starter ENGINES 156 in MODEL 164, 251
7100GZS
AR15.30-P-
Remove/install starter ENGINE 156.982 in MODEL 209.377 /477
7100QMG
AR15.30-P-
Remove/install starter ENGINE 156 in MODEL 230.470
7100RMG
AR15.30-P-
Remove/install starter ENGINE 156 in MODEL 216, 221
7100SMG
AR15.30-P-
Remove/install starter ENGINE 156.983 in MODEL 211.077 /277, 219.377
7100TMG
Remove/install temperature AR15.60-P-
ENGINE 156 in MODEL 204, 212
sensor 3000CMG
Remove/install temperature AR15.60-P-
ENGINE 156 in MODEL 164, 251
sensor 3000GZS
Remove/install temperature AR15.60-P-
ENGINE 156 in MODEL 230.470
sensor 3000RMG
sensor ENGINES 156 in MODEL 216, 221 3000SMG
Remove/install temperature ENGINE 156.982 in MODEL 209.377 /477 ENGINE AR15.60-P-
sensor 156.983 in MODEL 211.077 /277, 219.377 3000TMG
Test alternator charging AR15.40-P-
ENGINE 156, 271, 272, 273, 642, 646, 651...
current 5011CW
Test alternator charging AR15.40-P-
ENGINES 156 in MODEL 164, 251
current 5011GZS
Test alternator charging AR15.40-P-
ENGINES 156.982 in MODEL 209.377 /477
current 5011QMG
Test alternator charging AR15.40-P-
ENGINES 156, 272, 273 in MODEL 230
current 5011RX
Test alternator charging ENGINE 156, 157, 272, 273, 275, 276, 278, 629, 642, AR15.40-P-
current 651... 5011SX
Test alternator charging AR15.40-P-
ENGINE 156, 271, 272, 273, 629, 642, 646, 648...
current 5011TS
AR15.40-P-
Test alternator fuse ENGINES 156 in MODEL 204
5012CMG
AR15.40-P-
Test alternator fuse ENGINE 156, 272, 273...
5012QB
AR15.40-P-
Test alternator fuse ENGINE 156 in MODEL 230.470
5012RMG
Testing backup fuse of AR15.40-P-
ENGINE 156, 272, 273 in MODEL 211, 219
alternator 5012TS
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE -
AR15.00-Z-9273AB
ENGINE 273
Check regulator and AR15.40-P-
ENGINE 156, 271, 272, 273, 642, 646, 651...
alternator 5000CW
Checking regulator and AR15.40-P-
ENGINES 272, 273, 642, 651 in MODEL 212
alternator 5000EW
Checking regulator and ENGINE 272, 273, 642 in MODEL 164 ENGINE 272, 273, AR15.40-P-
alternator 642 in MODEL 251 ENGINE 629 in MODEL 164 5000GZ
Checking regulator and AR15.40-P-
ENGINES 156, 272, 273 in MODEL 230
alternator 5000RX
Checking regulator and ENGINE 156, 272, 273, 275, 629, 642 in MODEL 221 AR15.40-P-
alternator ENGINE 156, 273, 275 in MODEL 216 5000SX
Checking the alternator AR15.40-P-
ENGINE 156, 271, 272, 273, 629, 642, 646, 648...
and regulator 5000T
AR15.40-P-
Remove, install alternator ENGINE 272, 273 in MODEL 211, 219
5032TS
belt pulley ENGINE 272, 273 in MODEL 211, 219 5710TS
Remove, install camshaft AR15.10-P-
ENGINE 272, 273 in MODEL 211, 219
Hall sensor 2000TS
Remove, install crankshaft AR15.12-P-
ENGINE 272, 273 in MODEL 211, 219
position sensor 2133TS
Remove, install ignition AR15.12-P-
ENGINE 272, 273 in MODEL 211, 219
coils 2003TS
Remove, install knock AR15.12-P-
ENGINE 272, 273 in MODEL 211, 219
sensors 2184TS
ENGINE 273 in MODEL 219 ENGINE 273 (except AR15.30-P-
Remove, install starter
273.962) in MODEL 211 7100TX
Remove, install ENGINE 272 273 in MODEL 211, 219 Coolant temperature AR15.60-P-
temperature sensor sensor 3000TS
ENGINE 272 in MODEL 204 ENGINE 272, 273 in AR15.40-P-
Remove/install alternator
MODEL 207 5032CV
AR15.40-P-
Remove/install alternator ENGINES 272, 273 in MODEL 212
5032EW
AR15.40-P-
Remove/install alternator ENGINE 272, 273 (except 272.973) in MODEL 164
5032GZA
AR15.40-P-
Remove/install alternator ENGINE 272, 273...
5032QB
AR15.40-P-
Remove/install alternator ENGINE 272, 273 in MODEL 251
5032RTA
AR15.40-P-
Remove/install alternator ENGINE 272, 273 in MODEL 230
5032RX
ENGINE 272.946 /965 /975 in MODEL 221 ENGINE 273 AR15.40-P-
Remove/install alternator
in MODEL 216, 221 5032SX
Remove/install alternator AR15.40-P-
ENGINE 271, 272, 273, 642, 646, 651...
belt pulley 5710CW
Remove/install alternator AR15.40-P-
ENGINES 272, 273 in MODEL 212
belt pulley 5710EW
Remove/install alternator ENGINE 272, 273 in MODEL 164, 251 ENGINE 273 in AR15.40-P-
belt pulley MODEL 463 5710GZA
Remove/install alternator AR15.40-P-
ENGINE 272, 273...
belt pulley 5710QB
Remove/install alternator AR15.40-P-
ENGINE 272, 273 in MODEL 230
belt pulley 5710RX
Remove/install alternator ENGINES 157, 272, 273, 276, 278 in MODEL 221 AR15.40-P-
belt pulley ENGINES 157, 273, 278 in MODEL 216 5710SX
Remove/install camshaft AR15.10-P-
ENGINES 272, 273 in MODEL 212
Hall sensor 2000EW
Remove/install camshaft ENGINES 272, 273 in MODEL 164, 251 ENGINES 273 in AR15.10-P-
Hall sensor MODEL 463 2000GZA
Hall sensor ENGINE 272, 273... 2000QB
Remove/install camshaft AR15.10-P-
ENGINE 272, 273 in MODEL 230
Hall sensor 2000RX
Remove/install camshaft ENGINE 272, 273 in MODEL 221 ENGINE 273 in AR15.10-P-
Hall sensor MODEL 216 2000SX
Remove/install crankshaft ENGINES 272 in MODEL 204 ENGINES 272, 273 in AR15.12-P-
Hall sensor MODEL 207 2136CV
Remove/install crankshaft AR15.12-P-
ENGINES 272, 273 in MODEL 212
Hall sensor 2136EW
Remove/install crankshaft ENGINE 272, 273 in MODEL 164 ENGINE 273 in AR15.12-P-
position sensor MODEL 463 2133GZA
Remove/install crankshaft AR15.12-P-
ENGINE 272, 273...
position sensor 2133QB
Remove/install crankshaft AR15.12-P-
ENGINES 272, 273 in MODEL 251
position sensor 2133RTA
Remove/install crankshaft AR15.12-P-
ENGINE 272, 273 in MODEL 230
position sensor 2133RX
Remove/install crankshaft ENGINE 272, 273 in MODEL 221 ENGINE 273 in AR15.12-P-
position sensor MODEL 216 2133SX
Remove/install ignition ENGINES 272 in MODEL 204 ENGINES 272, 273 in AR15.12-P-
coils MODEL 207 2003CV
Remove/install ignition AR15.12-P-
ENGINES 272, 273 in MODEL 212
coils 2003EW
Remove/install ignition ENGINES 272, 273 in MODEL 164, 251 ENGINES 273 in AR15.12-P-
coils MODEL 463 2003GZA
Remove/install ignition AR15.12-P-
ENGINE 272, 273...
coils 2003QB
Remove/install ignition AR15.12-P-
ENGINE 272, 273 in MODEL 230
coils 2003RX
Remove/install ignition ENGINE 272, 273 in MODEL 221 ENGINE 273 in AR15.12-P-
coils MODEL 216 2003SX
Remove/install knock ENGINES 272 in MODEL 204 ENGINES 272, 273 in AR15.12-P-
sensors MODEL 207 2184CV
Remove/install knock AR15.12-P-
ENGINES 272, 273 in MODEL 212
sensors 2184EW
Remove/install knock ENGINE 272, 273 in MODEL 164, 251 ENGINE 273 in AR15.12-P-
sensors MODEL 463 2184GZA
Remove/install knock AR15.12-P-
ENGINE 272, 273...
sensors 2184QB
Remove/install knock AR15.12-P-
ENGINE 272, 273 in MODEL 230
sensors 2184RX
Remove/install knock ENGINE 272, 273 in MODEL 221 ENGINE 273 in AR15.12-P-
sensors MODEL 216 2184SX
for alternator MODEL 207 5760CV
Remove/install regulator AR15.40-P-
ENGINES 272, 273, 642 in MODEL 212
for alternator 5760EW
Remove/install regulator ENGINES 272, 273 in MODEL 164, 251 ENGINES 273 in AR15.40-P-
for alternator MODEL 463 5760GZA
Remove/install regulator AR15.40-P-
ENGINE 272, 273...
for alternator 5760QB
Remove/install regulator AR15.40-P-
ENGINES 272, 273 in MODEL 230
for alternator 5760RX
Remove/install regulator AR15.40-P-
ENGINES 273 in MODEL 216, 221
for alternator 5760SX
Remove/install regulator AR15.40-P-
ENGINES 272, 273 in MODEL 211, 219
for alternator 5760TS
ENGINE 272 in MODEL 204 ENGINE 272, 273 in AR15.30-P-
Remove/install starter
MODEL 207 7100CV
AR15.30-P-
Remove/install starter ENGINES 272, 273 in MODEL 212
7100EW
AR15.30-P-
Remove/install starter ENGINE 272, 273 in MODEL 164
7100GZA
AR15.30-P-
Remove/install starter ENGINE 112, 113, 272, 273...
7100PW
AR15.30-P-
Remove/install starter ENGINE 272, 273...
7100QB
AR15.30-P-
Remove/install starter ENGINE 272, 273 in MODEL 251
7100RTA
AR15.30-P-
Remove/install starter ENGINE 272, 273 in MODEL 230
7100RX
ENGINE 272.946 /965 /975 in MODEL 221 ENGINE 273 AR15.30-P-
Remove/install starter
in MODEL 216, 221 7100SX
Remove/install ENGINE 272 in MODEL 204 ENGINE 272, 273 in AR15.60-P-
temperature sensor MODEL 207 3000CV
Remove/install AR15.60-P-
ENGINES 272, 273 in MODEL 212
temperature sensor 3000EW
Remove/install AR15.60-P-
ENGINE 272, 273...
temperature sensor 3000GZA
Remove/install AR15.60-P-
ENGINE 272, 273...
temperature sensor 3000QB
Remove/install ENGINES 272, 273 in MODEL 251 Coolant temperature AR15.60-P-
temperature sensor sensor 3000RTA
Remove/install ENGINE 272, 273 in MODEL 230 Coolant temperature AR15.60-P-
temperature sensor sensor 3000RX
Remove/install AR15.60-P-
ENGINE 272, 273...
temperature sensor 3000SX
regulator 273 in MODEL 209 5000P
Test alternator charging AR15.40-P-
ENGINE 156, 271, 272, 273, 642, 646, 651...
current 5011CW
Test alternator charging AR15.40-P-
ENGINES 156, 272, 273 in MODEL 230
current 5011RX
Test alternator charging AR15.40-P-
ENGINE 156, 157, 272, 273, 275, 276, 278, 629, 642, 651...
current 5011SX
Test alternator charging AR15.40-P-
ENGINE 156, 271, 272, 273, 629, 642, 646, 648...
current 5011TS
AR15.40-P-
Test alternator fuse ENGINES 272, 273, 642, 651 in MODEL 212
5012EW
AR15.40-P-
Test alternator fuse ENGINE 156, 272, 273...
5012QB
Test charging current for ENGINE 272, 273, 642, 629 in MODEL 164 AR15.40-P-
alternator ENGINE 272, 273, 642 in MODEL 251 5011GA
Test charging current for ENGINE 271, 272, 642, 646 in MODEL 203, 209 ENGINE AR15.40-P-
alternator 273 in MODEL 209 5011PI
Testing backup fuse of AR15.40-P-
ENGINE 156, 272, 273 in MODEL 211, 219
alternator 5012TS
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE -
AR15.00-Z-9275AB
ENGINE 275
Check regulation voltage of AR15.40-P-
ENGINE 112, 113, 275 in MODEL 230
alternator 5010R
Checking charging current of AR15.40-P-
ENGINE 112, 113, 137, 275...
alternator 5011I
Checking regulation voltage of AR15.40-P-
ENGINE 112, 113, 137, 275...
alternator 5010I
Checking regulator and ENGINE 156, 272, 273, 275, 629, 642 in MODEL AR15.40-P-
alternator 221 ENGINE 156, 273, 275 in MODEL 216 5000SX
Prerequisites for testing AR15.40-P-
ENGINE 112, 113, 137, 275...
Alternator 5009I
Prerequisites for testing the AR15.40-P-
ENGINE 112, 113, 275 in MODEL 230
alternator 5009R
AR15.40-P-
Remove and install alternator ENGINE 275 in MODEL 215, 220
5032LA
ENGINES 275 in MODEL 230 except CODE (P99) AR15.40-P-
Remove/install alternator
Special model "AMG Black Series" 5032RA
ENGINE 275 in MODEL 230 with CODE (P99) AR15.40-P-
Remove/install alternator
"AMG Black Series" special model 5032RBS
Remove/install alternator ENGINE 275.982 in MODEL 216.379, 221.179 5032SXM
AR15.40-P-
Remove/install alternator ENGINE 275 (except 275.982) in MODEL 216, 221
5032SZ
Remove/install alternator belt ENGINES 275 in MODEL 230 except CODE (P99) AR15.40-P-
pulley Special model "AMG Black Series" 5710RM
Remove/install camshaft Hall AR15.10-P-
ENGINE 275 in MODEL 215, 216, 220, 221, 230
sensor 2000M
Remove/install crankshaft ENGINES 275 in MODELS 215, 216, 220, 221, 230 AR15.12-P-
position sensor ENGINES 285 in MODEL 240 2133H
Remove/install ECI ignition ENGINE 275 in MODEL 215, 216, 220, 221, 230 AR15.15-P-
system power pack ENGINE 285 in MODEL 240 2093H
Remove/install ignition coil AR15.12-P-
ENGINES 275 in MODELS 215, 216, 220, 221, 230
module 1100LA
AR15.12-P-
Remove/install knock sensors ENGINES 275 in MODELS 215, 216, 220, 221, 230
2184R
ENGINES 275 in MODEL 215, 220, 230 ENGINES AR15.30-P-
Remove/install starter
285 in MODEL 240 7100H
AR15.30-P-
Remove/install starter ENGINE 275 in MODEL 216, 221
7100SZ
ENGINE 156, 157, 272, 273, 275, 276, 278, 629, 642, AR15.40-P-
Test alternator charging current
651... 5011SX
Test Charging current for AR15.40-P-
ENGINE 112, 113, 275 in MODEL 230
alternator 5011R
REMOVE/INSTALL CAMSHAFT HALL SENSOR - AR15.10-P-2000M
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Illustrated on model 220
Fig. 9: Identifying Camshaft Hall Sensors And Charge Air Cooler
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being pinched or Keep body parts and
AS00.00-Z-
crushed when removing, installing or aligning hoods, limbs well clear of
0011-01A
doors, trunk lids, tailgates or sliding roof. moving parts.
Remove right charge air cooler (1) from engine and
Do not open low AR09.41-P-
1 connect with connected coolant hoses to the engine
temperature circuit. 6817HH
hood
2 Pull out the plug (arrow)
Installation:
Remove camshaft Hall sensor, left cylinder bank Check sealing ring;
3 (B6/2) and camshaft Hall sensor, right cylinder bank replace if necessary.
(B6/3) *BA15.10-P-
1002-03D
4 Install in the reverse order
Secure vehicle to
Risk of accident caused by vehicle starting off by prevent it from
itself when engine is running. Risk of injury caused moving by itself.
by contusions and burns during starting procedure or Wear closed and AS00.00-Z-
when working near the engine as it is running snug-fitting work 0005-01A
clothes.
Do not touch hot or
5 Run engine and inspect for oil leaks rotating parts.
*WH58.30-Z-
6 Read out fault memory and erase if required
1048-13A
Connect STAR DIAGNOSIS and read out fault AD00.00-P-
memory 2000-04A
POSITION SENSOR
Number Designation Engine 271, 275, 285
BA15.10-P-1002-03D Camshaft position sensor to cylinder head cover Nm 8
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
REMOVE/INSTALL CAMSHAFT HALL SENSOR - AR15.10-P-2000SMG
ENGINE 156 in MODEL 221, 216
Fig. 10: Identifying Camshaft Hall Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, installing
or aligning hoods, doors, trunk lids, tailgates or Keep body parts and limbs AS00.00-Z-
sliding roof. well clear of moving parts. 0011-01A
1 Open engine hood and raise to vertical position
Depending on which Hall
2 Remove left or right suction fan duct
sensor must be removed
Remove air pump hose at power steering pump only when removing right
3.1
expansion reservoir Hall sensor.
Unhook power steering pump feed line from Only when removing left
3.2
oil filter housing Hall sensor.
4 When disconnecting upper
camshaft Hall sensor tie must be disconnected at
lower camshaft Hall sensor.
Installation: Replace
Undo bolt (1) and remove respective camshaft sealing ring.
5
Hall sensor from front cover on cylinder head *BA15.10-
P-1001-02C
6 Install in the reverse order
Risk of accident caused by vehicle starting off
by itself when engine is running. Risk of Secure vehicle to prevent it
injury caused by contusions and burns during from moving by itself.
starting procedure or when working near the AS00.00-Z-
Wear closed and snug-fitting
engine as it is running 0005-01A
work clothes. Do not touch hot
Conduct engine test run and check engine for or rotating parts.
7
leaks
KNOCK SENSORS
Number Designation Engine 156, 159
BA15.10-P-1001-02C Bolt, knock sensor to crankcase Nm 20
REMOVE/INSTALL CAMSHAFT HALL SENSOR - AR15.10-P-2000SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Shown on vehicle with Airmatic
Fig. 11: Identifying Camshaft Hall Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 engine air intake duct (1) housing. 1150SX
Vehicles with 4MATIC,
when removing exhaust
camshaft Hall sensor, left
Detach coolant pipe and lay to one side with AR46.25-P-
2 (B6/6)
attached hoses 1000SX
See "Removing power
steering expansion
reservoir".
3 Disconnect plug from each camshaft Hall sensor.
Replace
Undo bolt (3) and remove each camshaft Hall *BA15.10-P-
4 sealing ring.
sensor from front cover on cylinder head 1002-03E
5 Install in the reverse order
6 Read out fault memory and erase if necessary
Connect STAR DIAGNOSIS and read out fault AD00.00-P-
memory 2000-04A
Secure vehicle to prevent
Risk of accident caused by vehicle starting off by
it from moving by itself.
itself when engine is running. Risk of injury
Wear closed and snug- AS00.00-Z-
caused by contusions and burns during starting
fitting work clothes. 0005-01A
procedure or when working near the engine as it is
Do not touch hot or
running
rotating parts.
Conduct engine test run and check the engine for
7
leaks while it is running
POSITION SENSOR
Engine Engine
Number Designation
272 273
BA15.10-P-1002- Bolt, camshaft Hall sensor to front cover on cylinder
Nm 8 8
03E head
REMOVE/INSTALL SPARK PLUGS - AR15.12-P-1010SMG
ENGINES 156 in MODEL 221, 216
Shown on right cylinder bank
Fig. 12: Locating Spark Plugs
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not touch parts which conduct
high voltages. Persons who wear
Risk of death caused by contact with parts AS15.10-Z-
electronic implants (e.g. heart
conducting high voltages. 0001-01A
pacemakers) should never perform
any work on the ignition system
Wear safety gloves, protective
Risk of injury to skin and eyes caused by AS00.00-Z-
clothing and safety glasses, if
handling hot or glowing objects. 0002-01A
necessary.
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic All models
0001-01A
discharge
Notes on avoiding damage to ignition AH15.10-P-
system 0002-01D
Risk of injury caused by fingers being
pinched or crushed when removing,
installing or aligning hoods, doors, trunk Keep body parts and limbs well AS00.00-Z-
lids, liftgates or sliding roof clear of moving parts. 0011-01A
Open engine hood and raise to vertical
1
position
AR09.10-P-
2 Remove air filter housing
1150SMG
AR15.12-P-
2003SMG
3 Remove ignition coils
*BA15.10-
P-1001-04B
4
heads 02 01.0 P-1001-01H
5 Install in the reverse order
Checking
Risk of accident caused by vehicle starting
off by itself when engine is running. Risk Secure vehicle to prevent it from
of injury caused by contusions and burns moving by itself. AS00.00-Z-
during starting procedure or when working Wear closed and snug-fitting work 0005-01A
near the engine as it is running clothes.
Do not touch hot or rotating parts.
6 Carry out engine test run
IGNITION COIL
Number Designation Engine 156, 159
BA15.10-P-1001-04B Bolt, ignition coil to cylinder head cover Nm 10
SPARK PLUGS
Number Designation Engine 156, 159
BA15.10-P-1001-01H Spark plug on cylinder head Nm 22
REMOVE/INSTALL IGNITION COIL MODULE - AR15.12-P-1100LA
ENGINES 275 in MODELS 215, 216, 220, 221, 230
Fig. 13: Identifying Ignition Coil Module Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on model 220.176
Fig. 14: Identifying Ignition Coil Module Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on model 220.176
Remove/install
Do not touch parts which conduct
high voltages. Persons who wear
Risk of death caused by contact with parts AS15.10-Z-
electronic implants (e.g. heart
conducting high voltages. 0001-01A
pacemakers) should never perform
any work on the ignition system
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk clear of moving parts. 0011-01A
lids, liftgates or sliding roof
Notes on avoiding damage to ignition AH15.10-P-
system 0002-01L
AR01.10-P-
1 Remove engine trim panel Engine 275.95
2405LA
AR01.10-P-
Engine 275.98
2405IM
Model 215, 216, 220, 221, 230
AR09.10-P-
2 Remove left or right air filter housing (1) without code (P99) Special Model
1150LA
"AMG Black Series"
Remove left or right charge air duct (2)
*BA09.41-
3 upstream of charge air cooler (3) on
P-1001-02B
turbocharger
Remove charge air duct (4) downstream
AR09.50-P-
4 charge air cooler (3) at left or right charge
8680H
air cooler (3)
Slacken left or right charge air cooler (3), *BA09.41-
5
to do so unscrew bolts (6) P-1001-03A
When removing the ECI ignition
module, right cylinder bank
Disconnect pneumatic line (5a) on charge (N92/1).
6
air cooler (3). Installation: Check pneumatic
line (5a) and hose clamp for
damage and replace if required.
When removing the ECI ignition
module, right cylinder bank
Remove pneumatic line (5c) at charge air
7 (N92/1).
cooler (3).
Installation: Install new cable
ties.
When removing ECI ignition
module, right cylinder bank
(N92/1).
Disconnect electrical connector at pressure
The pneumatic line (5b) is
8 sensor upstream of throttle valve actuator
bonded with the support to charge
(B28/6) and remove
air cooler (3). This combination
must not be separated, otherwise
leakage may occur.
Unclip connector of left O2 sensor
upstream of catalytic converter (G3/3x1)
9 or connector of right O2 sensor upstream
of catalytic converter (G3/4x1) from rear
retaining spring at charge air cooler (3)
Close air outlet at turbocharger,
Fold left or right charge air cooler (3) to
otherwise parts could fall in and
10 the top and hang with hooks onto engine
lead to engine damage.
hood
Installation: Install new O-ring.
Detach left bracket (9) or right bracket *BA15.12-
11
(11) P-1002-01D
Remove switchover valve (14) and detach When removing the ECI ignition
12
bracket (13)
(N92/1).
Disconnect electrical connector (7 or 10)
from ECI ignition module, left cylinder
13
bank (N92/2) or from ECI ignition
module, right cylinder bank (N92/1)
Remove bolt (8 or 12) for ECI ignition
module, left cylinder bank (N92/2) or for *BA15.12-
14
ECI ignition module, right cylinder bank P-1001-01D
(N92/1)
Position special tool on two
points and carefully pry off ECI
Remove ECI ignition module, left cylinder ignition module, left cylinder bank
15 bank (N92/2) or ECI ignition module, right (N92/2) or ECI ignition module,
cylinder bank (N92/1) with a special tool right cylinder bank (N92/1).
Fig. 16
Fig. 15
16 Install in the reverse order
Read out fault memory with STAR
17
DIAGNOSIS and erase if necessary
Connect STAR DIAGNOSIS and read out AD00.00-P-
fault memory 2000-04A
CHARGE AIR DUCT
Engine 275,
Number Designation
285
BA09.41-P-1001- Bolt, charge air channel before charge air cooler to
Nm 8
02B turbocharger
CHARGE AIR COOLER
Number Designation Engine 275, 285
BA09.41-P-1001-03A Bolt, charge air cooler to cylinder head cover Nm 8
ECI IGNITION SYSTEM
Number Designation Engine 275, 285
BA15.12-P-1001-01D Bolt, ignition coil module to cylinder head Nm 8
BA15.12-P-1002-01D Bolt, bracket to ignition coil module Nm 8
Fig. 15: Identifying Puller (137 589 00 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 16: Identifying Support (285 589 00 34 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL IGNITION COILS - AR15.12-P-2003SMG
ENGINE 156 in MODEL 216, 221
Fig. 17: Identifying Ignition Coil Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
6.8.09 Value changed: Bolt, ignition coil to cylinder head cover *BA15.10-P-1001-04B
Remove/install
Do not come into contact with parts
that are under high voltage. Persons
Risk of death caused by contact with who wear electronic implants (e.g. AS15.10-Z-
parts conducting high voltages. heart pacemakers) should never 0001-01A
perform any work on the ignition
system.
Wear safety gloves, protective
Risk of injury to skin and eyes caused by AS00.00-Z-
clothing and safety glasses, if
handling hot or glowing objects. 0002-01A
necessary.
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic All models
0001-01A
discharge
Notes on avoiding damage to ignition AH15.10-P-
All models
system 0002-01D
Risk of injury caused by fingers being
pinched or crushed when removing,
installing or aligning hoods, doors, trunk Keep body parts and limbs well clear AS00.00-Z-
lids, liftgates or sliding roof of moving parts. 0011-01A
Open engine hood and raise to vertical
1
position
AR09.10-P-
2 Remove air filter housing
1150SMG
Detach electrical feed lines from cylinder
3 1 ignition coil to cylinder 8 ignition coil Install: Install new cable ties.
(T1/1 to T1/8) at ignition coil
Unlock electrical connectors (2) for
4 cylinder 1 ignition coil to cylinder 8
ignition coil (T1/1 to T1/8) and detach
*BA15.10-
5 Remove bolt (3)
P-1001-04B
Remove cylinder 1 ignition coil to
6
cylinder 8 ignition coils (T1/1 to T1/8)
7 Install in the reverse order
Risk of accident caused by vehicle
starting off by itself when engine is
running. Risk of injury caused by Secure vehicle to prevent it from
contusions and burns during starting moving by itself. Wear closed and AS00.00-Z-
procedure or when working near the snug-fitting work clothes. Do not 0005-01A
engine as it is running touch hot or rotating parts.
IGNITION COIL
Number Designation Engine 156, 159
BA15.10-P-1001-04B Bolt, ignition coil to cylinder head cover Nm 10
REMOVE/INSTALL IGNITION COILS - AR15.12-P-2003MM
ENGINES 157, 278 in MODEL 216
ENGINES 157, 276, 278 in MODEL 221
Fig. 18: Identifying Ignition Coil Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of death caused by Do not touch parts which AS15.10-Z-0001-01A
contact with parts conduct high voltages.
conducting high voltages. Persons who wear
electronic implants (e.g.
heart pacemakers) should
never perform any work
on the ignition system
Risk of injury to skin and Wear safety gloves, AS00.00-Z-0002-01A
eyes caused by handling protective clothing and
hot or glowing objects. safety glasses, if
necessary.
Notes on avoiding damage AH15.10-P-0002-01V
to ignition system
The ignition coil (T1/1 to
T1/6 or T1/1 to T1/8) and
spark plug connector (a)
create a unit and can
therefore only be
removed and replaced
together.
1 Switch off ignition
2 Detach connector from the
ignition coils (T1/1 or
T1/6 or T1/1 up to T1/8)
3 Remove bolts (1) of *BA15.10-P-1001-04A
ignition coils (T1/1 to
T1/6 and T1/1 to T1/8)
4 Pull ignition coils (T1/1 to
T1/6 and T1/1 to T1/8)
with spark plug
connectors (a) upwards
and out
Checking
5 Check ignition coils (T1/1
to T1/6 and T1/1 to T1/8)
and spark plug connector
(a) for damage and
replace if necessary
6 Install in the reverse order
7 Read out fault memory AD00.00-P-2000-04A
with STAR DIAGNOSIS
and erase if necessary
IGNITION COIL
Number Designation Engine 157
BA15.10-P-1001-04A Bolt, ignition coil to cylinder head Nm 9
cover
REMOVE/INSTALL IGNITION COILS - AR15.12-P-2003SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Shown on engine 273.961
Fig. 19: Identifying Ignition Coils, Spark Plug Connector & Screw
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of death caused by Do not touch parts which AS15.10-Z-0001-01A
contact with parts conduct high voltages.
conducting high voltages. Persons who wear
electronic implants (e.g.
heart pacemakers) should
never perform any work
on the ignition system
Risk of injury to skin and Wear safety gloves, AS00.00-Z-0002-01A
eyes caused by handling protective clothing and
hot or glowing objects. safety glasses, if
necessary.
Notes on avoiding damage AH15.10-P-0002-01V
to ignition system
1 Switch off ignition
2 Remove air filter housing AR09.10-P-1150SX
3 Detach connector from the
ignition coils (T1/1 or
T1/6 or T1/1 up to T1/8)
4 Remove bolts (1) of *BA15.10-P-1001-04A
ignition coils (T1/1 to
T1/6 and T1/1 to T1/8)
5 Pull ignition coils (T1/1 to
T1/6 and T1/1 to T1/8)
with spark plug
and out
6 Install in the reverse order
7 Read out fault memory AD00.00-P-2000-04A
with STAR DIAGNOSIS
and erase if necessary
IGNITION COIL
Number Designation Engine 272 Engine 273
BA15.10-P-1001-04A Bolt, ignition coil to cylinder head cover Nm 9 9
REMOVE/INSTALL CRANKSHAFT POSITION SENSOR - AR15.12-P-2133H
ENGINES 275 in MODELS 215, 216, 220, 221, 230
ENGINES 285 in MODEL 240
Shown on engine 285
Fig. 20: Identifying Crankshaft Position Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear AS00.00-Z-
removing, installing or aligning hoods,
of moving parts. 0011-01A
doors, trunk lids, lift gates or sliding
roof
AR01.10-P-
Engine 275.98
2405IM
1 Remove/install engine cover
AR01.10-P-
Engines 275.95, 285
2405LA
Model 215, 216, 220, 221, 230 without
AR09.10-P-
code (P99) Special Model "AMG
1150LA
2 Remove right air filter housing Black Series"
AR09.10-P-
Model 240
1150H
Tighten hose clamps (1, 3) using
prescribed torque so that charge air
duct (6) can disconnect from engine
Loosen hose clamps (1, 3) at charge charge air ducts (4) in the event of an
3 air hose (2) and at charge air duct (4) accident.
downstream of charge air cooler (6) *BA09.41-
P-1002-02B
*BA09.41-
P-1003-02B
Do not remove coolant hoses to
charge air cooler (6).
4 Remove bolts (5)
*BA09.41-
P-1001-03A
Lift charge air cooler (6) from charge
air hose (2) and remove from charge Do not damage coolant hoses
5
air duct (4) downstream of charge air running to charge air coolers (6).
cooler (6)
Unplug connector (arrow) from
6
crankshaft position sensor (L5)
If the crankshaft position sensor
(L5) is replaced, an initialization must
be conducted with STAR DIAGNOSIS
Remove crankshaft position sensor
7 in the menu item of the control unit
(L5)
adaptation.
*BA15.10-
P-1001-03D
8 Install in the reverse order
Read out fault memory with STAR
9
DIAGNOSIS and erase if necessary
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
CHARGE AIR DUCT
Engine 275,
Number Designation
285
BA09.41-P- Hose clamp, charge air hose to ENGINE charge air channel and to
Nm 3
1002-02B charge air cooler
BA09.41-P- Hose clamp, charge air channel as required charge air cooler to charge
Nm 3
1003-02B air cooler and to electronic accelerator actuator
CHARGE AIR COOLER
Number Designation Engine 275, 285
BA09.41-P-1001-03A Bolt, charge air cooler to cylinder head cover Nm 8
POSITION SENSOR
Number Designation Engine 271, 275, 285
BA15.10-P-1001-03D Crankshaft position sensor to engine block Nm 8
REMOVE/INSTALL CRANKSHAFT POSITION SENSOR - AR15.12-P-2133SMG
ENGINE 156 in MODEL 221, 216
Fig. 21: Identifying Crankshaft Position Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being pinched or
crushed when removing, installing or aligning Keep body parts and
AS00.00-Z-
hoods, doors, trunk lids, tailgates or sliding roof. limbs well clear of
0011-01A
moving parts.
1 Open engine hood
2 Remove air filter housing (1).
1150SMG
Push shielding (2)
3 Push shielding (2) upwards upwards until the
electrical connector (3) is
accessible.
Disconnect electrical connector (3) from crankshaft
4
position sensor (L5)
*BA15.12-P-
5 Unscrew bolt (4)
1001-01K
6 Remove crankshaft position sensor (L5)
7 Install in the reverse order
STAR DIAGNOSIS
8 Read out fault memory and erase if necessary
diagnosis system
Connect STAR DIAGNOSIS and read out fault AD00.00-P-
memory 2000-04A
Risk of accident caused by vehicle starting off by Secure vehicle to prevent
itself when engine is running. Risk of injury it from moving by itself.
caused by contusions and burns during starting Wear closed and snug- AS00.00-Z-
procedure or when working near the engine as it is fitting work clothes. Do 0005-01A
running not touch hot or rotating
9 Carry out engine test run parts.
ECI IGNITION SYSTEM
Number Designation Engine 156, 159
BA15.12-P-1001-01K Crankshaft position sensor on crankshaft housing M6 Nm 8
REMOVE/INSTALL CRANKSHAFT POSITION SENSOR - AR15.12-P-2133SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Shown on engine 273
Fig. 22: Identifying Crankshaft Hall Sensor And Bolt
Courtesy of MERCEDES-BENZ USA
Engine 272.974
Fig. 23: Identifying Crankshaft Hall Sensor, Intermediate Housing And Bolts
Courtesy of MERCEDES-BENZ USA
Remove/install
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Except model AR09.10-P-
2 Remove air filter housing
221.095 /195 1150SX
Release and disconnect electrical connector at
3
crankshaft Hall sensor (B70)
Except model *BA15.10-P-
4 Remove bolt (1)
221.095 /195 1001-03E
Model *BA15.10-P-
221.095 / 195 1004-03E
Remove crankshaft Hall sensor (B70) from the
5
cylinder crankcase or intermediate housing (4)
6 Install in the reverse order
Carry out first initialization and then sensor
7 Only when replacing
rotor adaptation using STAR DIAGNOSIS
Menu guidance:
Engine control
module
Adaptations
Learning processes
Connect STAR DIAGNOSIS and read out AD00.00-P-
fault memory 2000-04A
POSITION SENSOR
Number Designation Engine 272 Engine 273
BA15.10-P-1001-03E Bolt, crankshaft Hall sensor to crankcase Nm 8 8
BA15.10-P-1004-03E Bolt, crankshaft Hall sensor to intermediate housing Nm 8 -
REMOVE/INSTALL KNOCK SENSORS - AR15.12-P-2184R
ENGINES 275 in MODELS 215, 216, 220, 221, 230
Fig. 24: Identifying Knock Sensors, Heat Shield & Bolts
Courtesy of MERCEDES-BENZ USA
Illustrated on model 230.476
Fig. 25: Identifying Heat Shield
Courtesy of MERCEDES-BENZ USA
Remove/install
Vehicles with code (889)
Turn key in electronic ignition switch Keyless Go: Press the start/stop
1
control unit to position "0" button repeatedly until the ignition
is switched off.
AR61.20-P-
Model 215, 220
1105M
Model 216,
AR61.20-P-
Model 221 without code (Z07)
1105SX
Top protection
Model 221 with code (Z07) Top AR61.20-P-
2 Remove lower engine compartment paneling
protection 1105SXS
Model 230 except special model AR61.20-P-
"AMG Black Series" 1105R
Model 230 with code (P99)
AR61.20-P-
Special model "AMG Black
1105RBS
Series"
Left front knock sensor
Disconnect electrical connector for front
3
knock sensor (left side of engine) (A29/1)
Remove bolt (2) and remove front knock *BA15.10-
4
sensor (left side of engine) (A29/1) P-1001-02B
Left rear knock sensor
AR49.10-P-
5 Remove complete exhaust system Model 230
7000RB
6 Remove heat shield (22) Model 230
Model 230
Remove bolts (1a) and take out heat shield
7 *BA15.10-
(1).
P-1002-02B
Disconnect electrical connector for rear
8
knock sensor (left side of engine) (A29/2)
Remove bolt (2) and remove rear knock *BA15.10-
9
sensor (left side of engine) (A29/2) P-1001-02B
Right front knock sensor
AR22.10-P-
Model 215, 220
4320IX
AR22.10-P-
10 Remove right engine support Model 216, 221
1260SZ
AR22.10-P-
Model 230
1260R
Disconnect electrical connector for front
11
knock sensor (right side of engine) (A30/1)
12 sensor (left side of engine) (A30/1) P-1001-02B
Right rear knock sensor
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant
caused by swallowing battery acid. Risk of AS54.10-Z-
gloves, clothing and glasses. Only
injury caused by burns to skin and eyes 0001-01A
pour battery acid into suitable and
from battery acid or when handling damaged
appropriately marked containers.
lead-acid batteries
AR54.10-P-
Model 215, 220
0003I
AR54.10-P-
Model 216, 221
0003SX
13 Disconnect ground line(s) at battery(ies) Model 230 without code (P99) AR54.10-P-
"AMG Black Series" 0003R
Model 230 with code (P99)
AR54.10-P-
Special model "AMG Black
0003RBS
Series"
AR49.10-P-
14.1 Remove complete exhaust system Model 230
7000RB
AR49.10-P-
14.2 Remove right catalytic converter Model 215, 220
5500M
Model 216, 221
14.3 Remove heat shield from starter AR15.30-P-
See Remove/install starter.
7100SZ
Disconnect electrical connector for rear
15
knock sensor (right side of engine) (A30/2)
Remove bolt (2) and remove rear knock *BA15.10-
16
sensor (right side of engine) (A30/2) P-1001-02B
17 Install in the reverse order
Read out fault memory and erase if Faults which may have been
18 caused by disconnecting wires or
necessary
by a simulation must be erased in
Connect STAR DIAGNOSIS and read out the fault memory after completing AD00.00-P-
fault memory the work. 2000-04A
KNOCK SENSORS
Number Designation Engine 275, 285
BA15.10-P-1001-02B Bolt, knock sensor to crankcase Nm 20
BA15.10-P-1002-02B Bolt connecting heat shield of knock sensor to crankcase Nm 8
REMOVE/INSTALL KNOCK SENSORS - AR15.12-P-2184SMG
ENGINE 156 in MODEL 216, 221
Fig. 26: Identifying Knock Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear of AS00.00-Z-
removing, installing or aligning
moving parts. 0011-01A
hoods, doors, trunk lids, tailgates or
sliding roof.
Align vehicle between columns of vehicle
Risk of death caused by vehicle
lift and position four support plates at AS00.00-Z-
slipping or toppling off the lifting
vehicle lift support points specified by 0010-01A
platform.
vehicle manufacturer.
Notes on avoiding damage to AH54.00-
electronic components due to All models P-0001-
electrostatic discharge 01A
Risk of explosion caused by
oxyhydrogen gas. Risk of
poisoning and caustic burns No fire, sparks, open flames or smoking.
caused by swallowing battery acid. Wear acid-resistant gloves, clothing and AS54.10-Z-
Risk of injury caused by burns to glasses. Only pour battery acid into suitable 0001-01A
skin and eyes from battery acid or and appropriately marked containers.
when handling damaged lead-acid
batteries
AR54.10-
1.1 Disconnect ground line from battery Only when removing right knock sensor
1 (A16/1) is necessary. P-0003SX
All models Of) Insulate ground line clamp
of dismounted ground line with ground
point of battery.
AH54.10-
Vehicles with code 889, Keyless Go:
Notes on battery P-0001-
Switch engine off, remove Keyless-Go 01A
cards from the vehicle and store outside of
transmitter range.
2 Open engine hood
3 Remove both intake air ducts
Do not tilt front engine cover, but lift AR09.10-
4 Remove air filter housing upwards vertically otherwise the retaining P-
lugs can break off. 1150SMG
Engine supporting frame basic frame
5 Mount the engine hoist side piece (M/S-class) see GOTIS
http://gotis.aftersales.mercedes-benz.com
AR00.60-
6 Raise vehicle with lifting platform
P-1000SX
Remove lower engine compartment AR61.20-
7
paneling P-1105SX
Remove engine mount with front
Depending on which knock sensor, on AR22.10-
8 engine support on the appropriate
the right or left, should be removed. P-1260SX
side
Unlock and remove the electrical Depending on which knock sensor, on
9
connector (1, 3). the right or left, should be removed.
Depending on which knock sensor, on
the right or left, should be removed.
10 Undo bolt (2, 4)
*BA15.10-
P-1001-02C
Remove right knock sensor 1,
11 (A16/1) or left knock sensor 2
(A16/2)
12 Install in the reverse order
13 Perform basic programming
Read out fault memory and erase if
14 STAR DIAGNOSIS diagnosis system
necessary
AD00.00-
Connect STAR DIAGNOSIS and
P-2000-
read out fault memory
04A
Risk of accident caused by vehicle
starting off by itself when engine is
running. Risk of injury caused by Secure vehicle to prevent it from moving by
contusions and burns during starting itself. AS00.00-Z-
procedure or when working near the Wear closed and snug-fitting work clothes. 0005-01A
engine as it is running Do not touch hot or rotating parts.
15 Carry out engine test run
KNOCK SENSORS
Number Designation Engine 156, 159
BA15.10-P-1001-02C Bolt, knock sensor to crankcase Nm 20
REMOVE/INSTALL KNOCK SENSORS - AR15.12-P-2184SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Shown on engine 272.965
Fig. 27: Identifying Knock Sensors & Bolt
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Switch off ignition
2 Remove air filter housing AR09.10-P-1150SX
3 Remove resonance intake manifold AR09.20-P-1961SX
4 Disconnect plug from knock sensor (A16/1) or (A16/2)
Unscrew bolt (1) and remove knock sensor (A16/1) *BA15.10-P-1001-
5
or (A16/2) 02B
6 Install in the reverse order
7 Read out fault memory with STAR DIAGNOSIS
KNOCK SENSORS
Number Designation Engine 272 Engine 273
BA15.10-P-1001-02B Bolt, knock sensor to crankcase Nm 20 20
REMOVE/INSTALL ECI IGNITION SYSTEM POWER PACK - AR15.15-P-2093H
ENGINE 275 in MODEL 215, 216, 220, 221, 230
ENGINE 285 in MODEL 240
Illustrated on model 240
Fig. 28: Identifying ECI Ignition System Power Pack Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
15.7.06 Hazard note added. 3rd stage
Removing
Do not touch parts which conduct high voltages.
Risk of death caused by
Persons who wear electronic implants (e.g. heart AS15.10-Z-
contact with parts conducting
pacemakers) should never perform any work on 0001-01A
high voltages.
the ignition system
Notes on avoiding damage to
AH54.00-P-
electronic components due to
0001-01A
electrostatic discharge
AR01.10-P-
Engines 275.95, 285
2405LA
1 Remove engine trim panel
AR01.10-P-
Engine 275.98
2405IM
Pull out locking bar (1) to the
2
side
Risk of death when touching
parts conducting high voltage
when the ignition is switched After ignition is turned OFF, only disconnect the
AS15.15-Z-
off plug on the ECI power pack after first waiting
0001-01A
for 3 minutes.
3 Disconnect electrical connector
power pack (N91).
Unscrew bolts (3) and place *BA15.15-P-
4
bracket (4) to the side 1003-01A
Unscrew bolts (5) and place *BA15.15-P-
5
ground line (6) to the side 1003-01A
Take out ECI ignition system
6
mains unit (N91)
7 Install in the reverse order
Read out fault memory and *WH58.30-Z-
8
erase if required 1048-13A
Connect STAR DIAGNOSIS AD00.00-P-
and read out fault memory 2000-04A
IGNITION SYSTEM ECI
Number Designation Engine 275, 285
BA15.15-P-1003-01A Bolt, ECI ignition system power pack to bracket Nm 8
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
REMOVE/INSTALL STARTER - AR15.30-P-7100MMB
ENGINE 157, 278 in MODEL 216, 221
Fig. 29: Identifying Starter Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Notes on self-locking nuts and bolts AH00.00-N-0001-01A
For vehicles with 4MATIC the starter (M1) is installed on the left
engine side and for vehicles without 4MATIC it is installed on the
right engine side
1 Deactivate easy Vehicles with 4MATIC AR54.30-P-1000-02ESX
entry/exit function with code (275) Memory
package (driver seat,
steering column, mirrors)
2 Turn front wheels to Vehicles with 4MATIC
straight-ahead position
and secure steering The steering wheel must not
wheel with holding be turned when the steering
device coupling is detached,
otherwise the clock spring
contact will be destroyed Fig. 31
3 Detach ground line AR54.10-P-0003SX
from battery
Notes on battery AH54.10-P-0001-01A
4 Remove bottom engine AR61.20-P-1105SX
compartment paneling
5 Remove steering Vehicle with 4MATIC AR46.10-P-8000SX
coupling
6 Remove electrical Vehicles with 4MATIC
connection on SPS
solenoid valve and set
aside
7 Remove shield over
starter (M1)
8 Detach protection *BA15.30-P-1001-01J
against accidental
contact (3) and detach
electrical line circuit 30
at starter (M1)
9 Disconnect electrical *BA15.30-P-1002-01J
line of circuit 50 (4) at
starter (M1)
10 Unclip electrical line
(2) at starter (M1) and
cylinder crankcase
11 Remove Bolts (5) of *BA15.30-P-1003-01J
starter (M1)
12 Remove starter (M1)
from below
Checking
13 Check ring gear at the When replacing the starter
drive plate for wear (M1)
and damage Rotate engine at the center
bolt of crankshaft in the
direction of rotation Fig. 30
14 Install in the reverse
order
STARTER
Number Designation Engine 157 Engine 278
BA15.30-P-1001- Nut, connection for Nm 15 15
01J circuit 30
BA15.30-P-1002- Nut, connection for Nm 6 6
01J circuit 50
BA15.30-P-1003- Bolt connecting Nm 40 40
01J starter to crankcase
Fig. 30: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 31: Identifying Holding Device (129 589 01 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL STARTER - AR15.30-P-7100SMG
ENGINE 156 in MODEL 216, 221
Fig. 32: Identifying Starter Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk clear of moving parts. 0011-01A
lids, tailgates or sliding roof.
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
support points specified by
vehicle manufacturer.
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant
caused by swallowing battery acid. Risk of AS54.10-Z-
gloves, clothing and glasses. Only
injury caused by burns to skin and eyes from 0001-01A
pour battery acid into suitable and
battery acid or when handling damaged lead-
appropriately marked containers.
acid batteries
Insulate ground line clamp as a
protection against unintentional AR54.10-P-
1 Disconnect ground line from battery
contact of dismounted ground line 0003SX
with ground point of battery.
AH54.10-P-
Notes on battery All models
0001-01A
2 Open engine hood
AR00.60-P-
3 Raise vehicle with lifting platform
Remove bottom engine compartment Vehicles without code (Z07) Top AR61.20-P-
4
paneling protection 1105SX
Remove protection against accidental contact
5 for electrical line for circuit 30 (1) on starter
(M1)
Dismount electrical line for circuit 30 (1) at *BA15.30-
6
starter (M1) P-1001-01O
Remove circuit 50 (2) electrical line on *BA15.30-
7
starter (M1) P-1002-01O
*BA15.30-
8 Unscrew bolts (7) of starter (M1)
P-1003-01O
9 Lead starter (M1) down and out
When replacing starter (M1)
Check ring gear on the drive plate for wear Rotate engine at center bolt of
10
and damage crankshaft in the direction of
rotation.
11 Install in the reverse order
12 Perform basic programming
STARTER
Number Designation Engine 156
BA15.30-P-1001-01O Nut, connection for circuit 30 Nm 15
BA15.30-P-1002-01O Nut, connection for circuit 50 Nm 8
BA15.30-P-1003-01O Bolt connecting starter to crankcase Nm 40
REMOVE/INSTALL STARTER - AR15.30-P-7100SX
ENGINE 272.946 /965 /975 in MODEL 221
ENGINE 273 in MODEL 216, 221
Shown on engine 272
Fig. 33: Identifying Starter Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of vehicle
Risk of death caused by
lift and position four support plates at vehicle AS00.00-Z-
vehicle slipping or toppling off
lift support points specified by vehicle 0010-01A
the lifting platform.
manufacturer.
Notes on self-locking nuts and AH00.00-N-
bolts 0001-01A
Detach ground lines from AR54.10-P-
1
batteries 0003SX
Remove center and rear engine AR61.20-P-
2
compartment paneling 1105SX
Vehicles with 4-MATIC
Dismount steering coupling at AR46.10-P-
3 For vehicles with 4-MATIC the starter
the steering shaft 8000SX
(M1) is located on the left side.
Pull out protective cap (1) and
*BA15.30-P-
4 remove electrical connections
1001-01J
(2, 3) at starter (M1)
*BA15.30-P-
1002-01J
Dismount cable holder (1a)
5
from starter (M1)
Unscrew bolts (4) of starter *BA15.30-P-
6
(M1) 1003-01J
7 Take starter (M1) down and out
Checking
When replacing the starter (M1)
Check starter ring gear at drive
8 Rotate engine at center bolt of crankshaft
plate for wear and damage
in the direction of rotation.
9 Install in the reverse order
STARTER
Number Designation Engine 272, 273
BA15.30-P-1001-01J Nut, connection for circuit 30 Nm 15
BA15.30-P-1002-01J Nut, connection for circuit 50 Nm 8
BA15.30-P-1003-01J Bolt connecting starter to crankcase Nm 40
REMOVE/INSTALL STARTER - AR15.30-P-7100SZ
ENGINE 275 in MODEL 216, 221
Fig. 34: Identifying Starter Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
AR54.10-P-
1 Disconnect ground lines from batteries
0003SX
Vehicles without code (Z07) Top AR61.20-P-
Remove lower engine compartment protection 1105SX
2
paneling Vehicles with code (Z07) Top AR61.20-P-
protection 1105SXS
*BA15.30-P-
3 Remove bolt (1) from starter (M1)
1003-01G
Unscrew nuts (2), remove bolt (4) and *BA15.30-P-
4
remove heat shield (3) 1004-01G
Pull out protective cap (5) and dismantle
*BA15.30-P-
5 electrical connection circuit 30 (6) at
1001-01G
starter (M1)
Remove electrical connection terminal *BA15.30-P-
6
50 (7) at starter (M1) 1002-01G
*BA15.30-P-
7 Remove bolt (8) from starter (M1)
1003-01G
8 Take starter (M1) down and out
Checking
When replacing the starter (M1)
Check starter ring gear at drive plate for Rotate engine at center bolt
9
wear and damage for crankshaft in the direction of
rotation.
10 Install in the reverse order
STARTER
Number Designation Engine 275
BA15.30-P-1001-01G Nut for connection of circuit 30 Nm 14
BA15.30-P-1002-01G Nut for connection for circuit 50 Nm 6
BA15.30-P-1003-01G Bolt connecting starter to crankcase Nm 42
BA15.30-P-1004-01G Bolt heat shield to crankcase Nm 8
REMOVE/INSTALL INTEGRATED STARTER ALTERNATOR - AR15.40-P-0003SXH
ENGINE 272.974 in MODEL 221.095 /195
Fig. 35: Identifying Integrated Starter Alternator Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 36: Identifying Integrated Starter Alternator Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
The high voltage lines should not be
detached from the power distributor or
from the power module. Non-observation
electronics with power distributor.
Work on a high-voltage system or on
hybrid components may only be
performed by skilled workshop
personnel.
In the case of damage to the high
voltage lines the power electronics with
power distributor must be completely
replaced.
Only use new or clean protective
covers to cover the electrical
connections.
Do not touch components and open lines
of the high-voltage on-board electrical
Risk of death when touching system. Persons who are carriers of
AS54.00-Z-
components on vehicles with high- electronic implants (e.g. cardiac
0001-01A
voltage on-board electrical system pacemakers), must not carry out any
work on high-voltage on-board electrical
systems.
After completing the work attach
Perform disable for the high-voltage AR54.10-P-
1 initial startup event log and the disable
on-board electrical system 1150SXH
power event log to the vehicle file.
Note on high-voltage on-board AH54.00-P-
electrical system 0010-01A
AR27.10-P-
2 Remove transmission
0500SX
Remove O2 left sensor downstream AR07.52-P-
3
of catalytic converter 5303SX
Detach both coolant hoses from the To prevent damage to the power AR08.10-P-
4 electronics, detach the front coolant hose 0011SXH
power electronics
first.
Detach power electronics with power
distributor from the cylinder AR08.10-P-
5
crankcase (12) and set aside with 0011SXH
attached electrical lines
Disconnect electrical connectors on
crankshaft Hall sensor and on the AR15.12-P-
6 Crankshaft Hall sensor
rotor position sensor and set aside 2133SX
outside the working area
AR15.12-P-
Rotor position sensor
2139SXH
Do not damage connecting point (7)
Remove bolts (4, 6) and remove *BA01.40-
7 in the process!
intermediate housing (5) P-1013-01G
bolt of the crankshaft in direction of
Bring integrated starter alternator engine rotation until the rotor dowel pin
8
(A79) into assembly position (2) is in the 12 o'clock position (see
picture).
Loosen bolts (9) from stator on *BA08.10-
9
cylinder crankcase (12) P-1001-01A
*BA03.30-
Loosen bolts (3) from rotor on
10 P-1004-
crankshaft
01M
The fit bolts M8 (1P) must be
Prefix integrated starter alternator tightened in 2 stages. After tightening,
11 (A79) in the assembly position with the head of the fit bolt M8 (1P) does not
fit bolts M8 (1P) touch the integrated starter alternator
(A79).
*BA08.10-
P-1002-01A
Fig. 37
Screw in assembly bolts M6 (1M) in
The assembly bolts M6 (1M) must be
integrated starter alternator (A79), *BA08.10-
12 tightened in 2 stages.
place in position by hand and tighten P-1003-01A
in 2 stages
Fig. 37
Remove two opposing bolts (3) for
13 the rotor on crankshaft and screw in Fig. 37
assembly bolts by hand
Remove bolts (3) from rotor on
14
crankshaft
Lay bolts (9) in position
15 Remove bolts (9)
by hand.
Disconnect electrical plug connection
16 (8) on integrated starter alternator
(A79)
Do not damage any cable o
connectors.
Do not bring starter-alternator
(A79) into contact
Remove integrated starter alternator with battery acid since
17
(A79) downwards it will be attacked and destroyed.
The user interface corrosion protection
on the component will also be damaged
by hypoid gear oil, brake fluid and diesel
fuel.
Checking
18
(11) for leaks Replace front crankshaft radial seal (11) 3063SXH
If necessary: AR01.40-P-
19 Check end cover (10) for leaks
Remove/install and seal end cover (10). 8913SXH
20 Install in the reverse order
Carry out commissioning of the
21 integrated starter alternator (A79)
using STAR DIAGNOSIS
Connect STAR DIAGNOSIS and AD00.00-P-
read out fault memory 2000-04A
Checking
AR20.00-P-
22 Inspect cooling system for leaks
1010SX
Risk of accident caused by vehicle
Secure vehicle to prevent it from moving
starting off by itself when engine is
by itself.
running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-fitting work
contusions and burns during starting 0005-01A
clothes.
procedure or when working near the
Do not touch hot or rotating parts.
engine as it is running
Carry out engine test run and check
23
engine for leaks and proper operation
CRANKCASE, TIMING CASE COVER, END COVER
Number Designation Engine 272
BA01.40-P-1013- Bolt, intermediate housing to M6 Nm 8
01G crankcase/oil pan M10 Nm 38
ELECTRIC MOTOR
Number Designation Engine 272.974
BA08.10-P-1001- Bolt, stator to crankcase Nm 20
01A
BA08.10-P-1002- Fit bolt on starter-alternator Stage 1 Nm 5
01A Stage 2 Nm 12
BA08.10-P-1003- Assembly bolts on starter-alternator Stage 1 Nm 5
01A Stage 2 Nm 12
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR
Number Designation Engine 272
BA03.30-P-1004-01M Bolt, starter ring gear/starter-alternator Stage 1 Nm 20
to crankshaft Stage 2 Nm 45
Stage 3 <° 90
Fig. 37: Identifying Removal And Installation Tool (272 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
CHECKING REGULATOR AND ALTERNATOR - AR15.40-P-5000SX
ENGINE 156, 272, 273, 275, 629, 642 in MODEL 221
ENGINE 156, 273, 275 in MODEL 216
Fig. 38: Connecting STAR DIAGNOSIS
Courtesy of MERCEDES-BENZ USA
Checking
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant gloves, AS54.10-
caused by swallowing battery acid. Risk of
clothing and glasses. Only pour Z-0001-
injury caused by burns to skin and eyes from
battery acid into suitable and 01A
battery acid or when handling damaged lead-
appropriately marked containers.
acid batteries
AH54.00-
Notes on avoiding damage to electronic
P-0001-
components due to electrostatic discharge
01A
AH54.10-
Notes on battery P-0001-
01A
Determine findings and replace AR54.10-
1 Check battery status
faulty battery if necessary. P-1129SX
Connect up STAR DIAGNOSIS (0100) to
2 STAR DIAGNOSIS diagnosis system
data link connector (X11/4).
AD00.00-
Connect STAR DIAGNOSIS P-2000-
04A
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself. AS00.00-
injury caused by contusions and burns Wear closed and snug-fitting work Z-0005-
during starting procedure or when working clothes. 01A
near the engine as it is running Do not touch hot or rotating parts.
Only perform tests when engine at
its normal operating temperature.
Tests are menu-assisted:
Check alternator using STAR DIAGNOSIS
3
(0100) Engine control unit
Actuations
Alternator diagnosis
4 Disconnect STAR DIAGNOSIS (0100).
TEST ALTERNATOR CHARGING CURRENT - AR15.40-P-5011SX
ENGINES 156, 157, 272, 273, 275, 276, 278, 629, 642, 651 in MODEL 221
ENGINES 156, 157, 273, 275, 278 in MODEL 216
Connection scheme
Fig. 39: Testing Alternator Charging Current
Courtesy of MERCEDES-BENZ USA
Checking
No fire, sparks, open flames or
Risk of explosion caused by oxyhydrogen gas.
smoking.
Risk of poisoning and caustic burns caused by
Wear acid-resistant gloves, AS54.10-Z-
swallowing battery acid. Risk of injury caused by
clothing and goggles. Only pour 0001-01A
burns to skin and eyes from battery acid or when
battery acid into suitable and
handling damaged lead-acid batteries
appropriately marked containers.
1 Check tension of poly-V belt
Engine 156, 157, 272, 273, 276, AP13.22-P-
2 Check poly-V belt for wear
278 1352SX
Engine 275 AP13.22-P-1352SZ
AP13.22-P-
ENGINES 629, 642, 651
1352SXI
Check electrical lines to on-board electrical
system battery (G1), alternator (G2) and on-board
3
electrical system battery (N82/1) for tight seating
and a perfect condition
Check freewheel of the belt pulley for alternator Only for diesel engines and for
4
mechanically engine 157.
Open front prefuse box (F32) and check alternator
5
fuse
AR61.20-P-
6 Remove lower engine compartment paneling
1105SX
Check ground strap between engine and body for
7
tight seating and proper condition
Connect up volt ampere tester (079) with current
8
clamp (065) according to connection diagram
Secure vehicle to prevent it from
Risk of accident caused by vehicle starting off by
moving by itself.
itself when engine is running. Risk of injury
Wear closed and snug-fitting AS00.00-Z-
caused by contusions and burns during starting
work clothes. 0005-01A
procedure or when working near the engine as it is
Do not touch hot or rotating
running
parts.
For vehicles as of 1.6.10 open
the driver door so that the
9 Start engine
alternator management changes
over into workshop mode.
Vary load resistance until the
maximum load current is
Test charge current at fast engine revs; apply load achieved; in doing so, the
*BE15.40-P-
10 to on-board electrical system battery (G1) for this regulation voltage must not fall
below 12.7 V. 1001-01I
step using volt-ampere tester (079)
Alternator charging current (G2)
Engine 156, 157, 272, 273, 275,
276, 278
*BE15.40-P-
Engine 642, 651
1001-01H
*BE15.40-P-
Engine 629
1001-01J
If the charging current lies
under the specified value the
diode for the alternator (G2) AR15.40-P-
needs checking. 9301-02SX
See
Test alternator diodes (G2).
The alternator (G2) must be
replaced if the diodes are
defective, see: AR15.40-P-
See 5032SMG
Replace alternator (G2):
Engine 156
AR15.40-P-
Engine 272.946/965/ 975, 273
5032SX
AR15.40-P-
Engine 272.974
5032SXH
AR15.40-P-
Engine 275 (except 275.982)
5032SZ
AR15.40-P-
Engine 275.982
5032SXM
AR15.40-P-
Engine 276
AR15.40-P-
Engine 157, 278
5032MMB
AR15.40-P-
Engine 629
5032SXD
AR15.40-P-
Engine 642
5032SXI
AR15.40-P-
Engine 651
5032CD
11 Turn off engine
Unclamp volt ampere tester (079) with current
12
clamp (065)
AR61.20-P-
13 Install lower engine compartment paneling
1105SX
CHECK VALUES FOR ALTERNATOR
Engine 272 in
model 164,
211, 219, 230,
251 Engine
Engine 156 in Engine 157 in 272 in model
model 216, model 216, 221 without
Number Designation 221 221 code 910
BE15.40-P- Charge current for max. A 220 220 180
1001-01I alternator min. A 170 170 140
Engine speed RPM 2000 2000 2000
Ratio i= 2.93 2.93 2.93
CHECK VALUES FOR ALTERNATOR
Engine 273 in
model 164,
209, 211, 219,
230, 251, 463
engine 273 in Engine 273 in
Engine 272 in model 216, model 216,
model 221 221 without 221 with code
Number Designation with code 910 code 910 910
BE15.40-P- Charge current for max. A 220 180 220
1001-01I alternator min. A 170 140 170
Engine speed RPM 2000 2000 2000
Ratio i= 2.93 2.93 2.93
CHECK VALUES FOR ALTERNATOR
Engine 276 in
without code Engine 276 in
Engine 275 in 910/B03, model 221
models 216, engine 276 in with code
Number Designation 221, Bosch model 251 910/ B03
BE15.40-P- Charge current for max. A 220 180 220
1001-01I alternator min. A 170 140 170
Engine speed RPM 2000 2000 2000
Ratio i= 2.93 2.93 2.93
REMOVE/INSTALL ALTERNATOR - AR15.40-P-5032SMG
ENGINE 156 in MODEL 216, 221
Fig. 40: Identifying Alternator Components
Courtesy of MERCEDES-BENZ USA
Fig. 41: Identifying Bolts & Bracket
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk clear of moving parts. 0011-01A
lids, tailgates or sliding roof.
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
support points specified by
vehicle manufacturer.
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant
caused by swallowing battery acid. Risk of AS54.10-Z-
gloves, clothing and glasses. Only
injury caused by burns to skin and eyes from 0001-01A
pour battery acid into suitable and
battery acid or when handling damaged lead-
appropriately marked containers.
acid batteries
Insulate ground line clamp as a
protection against unintentional
contact of dismounted ground line
with ground point of battery.
AR54.10-P-
1 Disconnect ground line from battery Vehicles with code 889, 0003SX
Keyless Go: Switch engine off,
remove Keyless-Go cards from
vehicle and store outside of
transmitter range.
AH54.10-P-
Notes on battery
0001-01A
2 Open engine hood
Do not tilt front engine cover,
but lift upwards vertically
3 Remove front engine cover
otherwise the retaining lugs can
break off.
4 Remove right and left intake air duct
AR20.40-P-
5 Remove electric fan
5000SMG
Only on model 221.
Removal: During removal
from alternator (G2) press holder
6 Unscrew bolts (6) on bracket (7)
(7) to the side.
*BA46.30-
P-1003-01O
Unclip engine wiring harness clip on
7
alternator (G2)
AR00.60-P-
8 Raise vehicle with lifting platform
1000SX
AR61.20-P-
9 Remove lower engine compartment paneling
1105SX
AR13.22-P-
10 Remove poly-V belt
1202SMG
11 Detach clamp on transmission oil lines Only on model 221.
Then lower vehicle using the
12 Unscrew bottom bolts (5) for alternator
vehicle lift.
Remove cap (1) and disconnect circuit 30
*BA15.40-
13 electrical line (B+) (3) at alternator (G2) by
P-1002-01P
unscrewing nut (2)
Remove electrical line plug of tml. 61 (D+)
14
(4) from alternator (G2)
15 Unscrew top bolts (5) for alternator (G2) *BA15.40-
P-1001-01P
16 Take alternator (G2) down and out
17 Install in the reverse order
18 Perform basic programming
ALTERNATOR
Number Designation Engine 156
BA15.40-P-1001-01P Bolt, alternator to timing case M8x90 Nm 20
BA15.40-P-1002-01P Nut, circuit B+ to alternator Nm 18
POWER STEERING PUMP
Engine 156 in model 216,
Number Designation
221
BA46.30-P-1003- Bolt, expansion reservoir to front lifting
M6x13 Nm 8.5
01O eye
REMOVE/INSTALL ALTERNATOR - AR15.40-P-5032SX
ENGINE 272.946 /965 /975 in MODEL 221
ENGINE 273 in MODEL 216, 221
Shown on engine 273
Fig. 42: Identifying Alternator Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
12.4.06 Bolt, oil cooler line double clamp to bracket *BA27.55-P-1005-01D
Remove/install
Align vehicle between columns of vehicle
Risk of death caused by
lift and position four support plates at AS00.00-Z-
vehicle slipping or toppling off
vehicle lift support points specified by 0010-01A
the lifting platform.
vehicle manufacturer.
Remove front and center engine AR61.20-P-
1
compartment paneling 1105SX
2.1 Remove double hose clamp (7) Vehicles without 4MATIC
*BA27.55-P-
1005-01D
Remove hydraulic line for
2.2 power steering from alternator Vehicles with 4-MATIC
(G2) holder
Unscrew lower bolts (6) for *BA15.40-P-
3
alternator (G2) 1001-01F
Detach ground lines from AR54.10-P-
4
batteries 0003SX
Remove engine intake air duct
5
and front engine cover
AR20.40-P-
6 Remove fan shroud Except engine 272 with 4-MATIC
6800SX
7 Attach radiator guard plate Except engine 272 with 4-MATIC
WF58.50-P-
Radiator guard plate/ condenser
0110-01A
AR13.20-P-
8 Remove poly-V belt
0001SX
Unclip switchover valve (Y32)
Model 221 with engine 273 without 4-
9 and remove bolts from bracket
MATIC
(8)
*BA01.30-P-
1009-01O
10 Release plug (4) and disconnect
Detach cap (1), unscrew nut (2)
*BA15.40-P-
11 and remove electrical line (3)
1002-01F
from alternator (G2)
Vehicles with engine 273 with 4-MATIC
Remove upper bolts (5) and
12 pull alternator (G2) upwards Lead along alternator on radiator until
middle of engine then remove vertically
and out
upwards.
*BA15.40-P-
1001-01F
13 Install in the reverse order
CYLINDER HEAD
Number Designation Engine 273
BA01.30-P-1009-01O Bolt, switchover valve bracket to cylinder head M6 Nm 9
ALTERNATOR
Number Designation Engine 272 Engine 273
BA15.40-P-1001-01F Bolt, alternator to timing case Nm 20 20
BA15.40-P-1002-01F Nut, circuit B+ to alternator Nm 15 15
TRANSMISSION, OIL COOLER
Number Designation Transmission 722.9
BA27.55-P-1005-01D Bolt, oil cooler line double clamp to bracket Nm 8
REMOVE/INSTALL ALTERNATOR - AR15.40-P-5032SXM
ENGINE 275.982 in MODEL 216.379, 221.179
Fig. 43: Identifying Alternator Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 44: Identifying Alternator Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
AR54.10-P-
1 Detach ground lines from batteries
0003SX
AR09.10-P-
2 Remove right air filter housing.
1150LA
3 Remove radiator grille Model 216
AR62.30-P-
4 Remove radiator crossmember
2300SXM
AR20.40-P-
5 Remove fan shroud
6800SXM
6 Mount guard plate on radiator
WF58.50-P-
Radiator guard plate/ condenser
0110-01A
AR13.20-P-
7 Remove poly-V belt
0001SZ
AR14.30-P-
8 Remove air pump
7251SZ
*BA14.30-P-
9 Remove bolts (3) and bracket (4)
1003-01B
Remove retaining clamp for alternator electrical line
10
(G2)
Detach cap (1), unscrew nut (2) and remove *BA15.40-P-
11
electrical line 30 (B+) from alternator (G2) 1001-01I
Unlock electrical line connector for circuit 61 (D+)
12
at alternator (G2) and detach
*BA15.40-P-
13 Remove bolts (5) and bracket (6)
1013-01I
*BA01.30-P-
14 Unscrew bolt (14) and remove guide pulley (21)
1002-01G
Remove bolt (13) from oil dipstick guide tube on *BA01.45-P-
15
cylinder crankcase 1010-01B
AR22.10-P-
16 Detach front engine mount
1260SZ
AR33.10-P-
17 Mount engine hoist
0105SX
*BA46.30-P-
Model 221 1014-01N
18 Remove bolts (16) and hydraulic line (15)
*BA46.30-P-
Model 216 1013-01Q
*BA18.30-P-
19 Remove screw (12)
1014-01B
Remove bolts (11) and take off retaining clamp (18)
20
with automatic oil lines (19)
*BA15.40-P-
21 Remove bolts (10)
1013-01I
Unscrew bolts (8) and remove holder (7) from *BA15.40-P-
22
23 Take alternator (G2) down and out
24 Install in the reverse order
AIR PUMP
Number Designation Engine 275
BA14.30-P-1003-01B Bolt, air pump holder to cylinder head Nm 8
OIL COOLING SYSTEM
Engine 275.980/ 981/982/
Number Designation
983
BA18.30-P-1014- Crankcase engine oil line retaining clamp to engine
Nm 8
01B oil cooler
ALTERNATOR
Engine 275.982 in model 221.179,
Number Designation
216.379
BA15.40-P-1001-
Nut, circuit B+ to alternator Nm 12
01I
BA15.40-P-1012-
Bolt, alternator to bracket Nm 20
01I
BA15.40-P-1013- Bolt connecting alternator bracket to
Nm 20
01I crankcase bracket
CYLINDER HEAD
Number Designation Engine 275
BA01.30-P-1002-01G Bolt, guide pulley to front cover on right M8 Nm 35
OIL PAN
Number Designation Engine 275, 285
M6 Nm 8
BA01.45-P-1010-01B Mounting screw, oil dipstick guide tube to crankcase
M8 Nm -
POWER STEERING PUMP
Model 221 with code
Number Designation
487
BA46.30-P-1014- Bolt, high pressure line of power steering to alternator
Nm 8
01N bracket
REMOVE/INSTALL ALTERNATOR - AR15.40-P-5032SZ
ENGINE 275 (except 275.982) in MODEL 216, 221
Fig. 45: Identifying Alternator Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 46: Identifying Alternator Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 47: Identifying Engine Oil Line Retaining Clamps
Courtesy of MERCEDES-BENZ USA
Fig. 48: Identifying Retaining Clamp And Electrical Line
Courtesy of MERCEDES-BENZ USA
Remove/install
Detach ground lines from AR54.10-P-
1
batteries 0003SX
Model 216
Remove radiator grille from
2 Installation: First install radiator
bumper
paneling in bumper.
See Completely replace front end with
reinforcement.
AR62.30-P-
Installation: For vehicles with code
Remove upper radiator 1570SX
3 219 Distronic (DTR) or code 233
crossmember
Distronic Plus :
AR30.30-P-
Check / adjust sensor setting of Distronic.
1000R
Detach expansion reservoir for
AR20.30-P-
4 coolant and lay to the side with
4950SX
attached coolant lines
AR20.40-P-
5 Remove fan shroud
6800SZ
6 Mount guard plate on radiator
WF58.50-P-
Radiator guard plate/ condenser
0110-01A
AR13.20-P-
7 Remove poly-V belt
0001SZ
AR14.30-P-
8 Remove air pump
7251SZ
Remove bolts (3) and air pump *BA14.30-P-
9
bracket (4) 1003-01B
*BA09.41-P-
Remove bolts (15) and bracket 1007-01G
10 (19) from cylinder head cover
(18) and connecting pipe (16) *BA09.41-P-
1008-01G
Remove retaining clamp (13) for
11 electrical line (14) on alternator
(G2)
Detach cap (1), unscrew nut (2)
*BA15.40-P-
12 and remove electrical line 30 (B+)
1001-01I
from alternator (G2)
Unlock electrical line connector
13 for circuit 61 (D+) at alternator
(G2) and detach
*BA18.30-P-
14 Remove retaining clamps (11, 12)
1014-01B
AR22.10-P-
15 Detach front engine mount
1260SZ
Pay attention when lifting out engine
16 Lift engine using a load regulator that no cables and lines are damaged and
that engine does not lean against the
bulkhead.
Remove bolts (8, 9) and detach *BA15.40-P-
17
bolts (10) 1012-01I
*BA15.40-P-
18 Remove bolts (5) and bracket (6)
1013-01I
Take alternator (G2) down and
19
out
20 Install in the reverse order
AIR PUMP
Number Designation Engine 275
BA14.30-P-1003-01B Bolt, air pump holder to cylinder head Nm 8
CHARGE AIR PIPE/CHARGE AIR COOLING
Engine 275,
Number Designation
285
BA09.41-P- Bolt, low temperature water circuit connecting pipe bracket to
Nm 8
1007-01G cylinder head cover
BA09.41-P- Bolt, low temperature water circuit connecting pipe bracket to low
Nm 8
1008-01G temperature water circuit connecting pipe
OIL COOLING SYSTEM
Engine 275.950/ 951/953/
Number Designation
954, 285
BA18.30-P-1014- Crankcase engine oil line retaining clamp to
Nm 8
01B engine oil cooler
ALTERNATOR
Engine 275.953 in model 221.176,
Number Designation
216.376
BA15.40-P-1001-
Nut, circuit B+ to alternator Nm 12
01I
BA15.40-P-1012-
Bolt, alternator to bracket Nm 20
01I
BA15.40-P-1013- Bolt connecting alternator bracket to
Nm 20
01I crankcase bracket
REMOVE/INSTALL ALTERNATOR BELT PULLEY - AR15.40-P-5710SX
ENGINES 157, 272, 273, 276, 278 in MODEL 221
ENGINES 157, 273, 278 in MODEL 216
Shown on engine 273.961
Fig. 49: Identifying Belt Pulley Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk clear of moving parts. 0011-01A
lids, liftgates or sliding roof
1 Open engine hood
Remove front engine cover (1) and
2
engine air intake ducts (2)
AR13.20-P-
3 Remove poly-V belt (3) Engine 272, 273 except 272.974
0001SX
AR13.22-P-
Engine 272.974
1202SXH
AR13.20-P-
Engine 276
0001MMA
AR13.20-P-
Engine 157, 278
0001MMB
Counterhold the alternator shaft
using a serrated socket or Torx
socket and socket wrench.
4 Detach belt pulley (4). During repairs to the
alternator, the belt pulley (4) must
always be replaced for a mileage of
more than 100.000 km.
Fig. 50
*BA15.40-P-
1004-01F
5 Install in the reverse order
ALTERNATOR
Number Designation Engine 272 Engine 273
BA15.40-P-1004- Collar nut, connecting belt pulley Nm 80 80
01F to alternator
ALTERNATOR
Number Designation Engine 157 Engine 276 Engine 278
BA15.40-P- Collar nut, connecting belt Nm 75 75 75
1004-01F pulley to alternator
Fig. 50: Identifying Socket Wrench (602 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL REGULATOR (GOVERNOR) FOR ALTERNATOR - AR15.40-P-5760SMG
ENGINE 156 in MODEL 216, 221
Fig. 51: Identifying Alternator, Governor & Bolts
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk clear of moving parts. 0011-01A
lids, tailgates or sliding roof.
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off the lifting platform. 0010-01A
support points specified by
vehicle manufacturer.
Risk of explosion caused by oxyhydrogen
No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns
smoking. Wear acid-resistant
caused by swallowing battery acid. Risk of AS54.10-Z-
gloves, clothing and glasses. Only
injury caused by burns to skin and eyes from 0001-01A
pour battery acid into suitable and
battery acid or when handling damaged lead-
appropriately marked containers.
acid batteries
AR54.10-P-
1 Disconnect ground line from battery
0003SX
AH54.10-P-
Notes on battery All models
0001-01A
2 Open engine hood
AR00.60-P-
3 Raise vehicle with lifting platform
1000SX
4 Remove lower engine compartment paneling
1105SX
*BA15.40-
5 Unscrew bolts (4) at regulator (5)
P-1006-01P
Installation: When
assembling the regulator (5)
6 Take out regulator (5)
ensure that the carbon brushes are
not damaged!
7 Install in the reverse order
8 Perform basic programming
Risk of accident caused by vehicle starting
off by itself when engine is running. Risk of Secure vehicle to prevent it from
injury caused by contusions and burns moving by itself.
AS00.00-Z-
during starting procedure or when working Wear closed and snug-fitting
0005-01A
near the engine as it is running work clothes. Do not touch hot or
rotating parts.
9 Carry out engine test run
ALTERNATOR
Number Designation Engine 156
- Nm 2.8
BA15.40-P-1006-01P Bolt connecting regulator to alternator M4X13 Nm 1.2
M4X19 Nm 2.5
REMOVE/INSTALL REGULATOR (GOVERNOR) FOR ALTERNATOR - AR15.40-P-5760SX
ENGINES 273 in MODEL 216, 221
Shown on vehicle without 4-MATIC
Fig. 52: Identifying Alternator Governor Components (Without 4-Matic)
Courtesy of MERCEDES-BENZ USA
Vehicle with 4MATIC
Fig. 53: Identifying Alternator Components (With 4Matic)
Courtesy of MERCEDES-BENZ USA
Fig. 54: Identifying Governor And Screw
Courtesy of MERCEDES-BENZ USA
Remove/install
Disconnect ground lines from AR54.10-P-
1
batteries 0003SX
Remove oil dipstick guide tube AR18.40-P-
2 Vehicles without 4MATIC
(1). 3510SX
Remove electrical line (2) from *BA15.40-P-
3
alternator (G2) 1002-01F
Unplug plug (3) from alternator
4
(G2)
Remove bolt (8) and pressure line
5 Vehicles with 4MATIC
(9) from holder (10)
Remove the bolt/nut (4) and take *BA15.40-P-
6
off cover (5) 1008-01F
Remove bolts (6) and remove the Do not damage sliding
7
regulator (7) brushes during installation!
*BA15.40-P-
1005-01F
8 Install in the reverse order
ALTERNATOR
Number Designation Engine 273
BA15.40-P-1002- Nut, circuit B+ to alternator Nm 15
01F
BA15.40-P-1005- Bolt, regulator to alternator M4x19 Nm 3
01F M4x13 Nm 2
BA15.40-P-1008- Bolt/nut, cover to alternator Nm 3
01F
TEST ALTERNATOR DIODES - AR15.40-P-9301-02SX
Connection diagram shown for model 230
Fig. 55: Alternator Diodes Connection Diagram
Courtesy of MERCEDES-BENZ USA
1. Connect engine tester with oscilloscope (030) with current clamp (065) according to the connection
diagram.
2. Start engine.
3. Switch on low beams.
4. Assess diode harmonics at 3000 RPM (engine speed).
Example: Diode harmonics in order (voltage spikes possible, but not significant)
Fig. 56: Screen Display - Diode Harmonics In Order
Courtesy of MERCEDES-BENZ USA
Example: Zero line, if the alternator fuse is defective.
Fig. 57: Screen Display - Zero Line
Courtesy of MERCEDES-BENZ USA
Example: Harmonics, if a positive diode is defective.
Fig. 58: Screen Display - Harmonics (Positive Diode Is Defective)
Courtesy of MERCEDES-BENZ USA
Fig. 59: Screen Display - Harmonics (Minus Diode Is Defective)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL TEMPERATURE SENSOR - AR15.60-P-3000SMG
ENGINES 156 in MODEL 216, 221
Fig. 60: Identifying Temperature Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not open cooling system unless coolant
Risk of injury to skin and eyes
temperature is below 90°C. Open cap slowly
caused by scalding from contact
and release the pressure. Do not pour coolant AS20.00-Z-
with hot coolant spray. Risk of
into beverage containers. 0001-01A
poisoning caused by swallowing
Wear protective gloves, protective clothing
coolant.
and safety glasses.
being pinched or crushed when
removing, installing or aligning Keep body parts and limbs well clear of AS00.00-Z-
hoods, doors, trunk lids, liftgates moving parts. 0011-01A
or sliding roof
Align vehicle between columns of vehicle
Risk of death caused by vehicle
lift and position four support plates at AS00.00-Z-
slipping or toppling off of the
vehicle lift support points specified by 0010-01A
lifting platform.
vehicle manufacturer.
Information on preventing
AH54.00-P-
damage to electronic components All models
0001-01A
due to electrostatic discharge
On vehicles with Keyless Go, code 889:
Press keyless go start/stop button repeatedly
Switch ignition off, remove until ignition is switched off. Remove
1
ignition key (transmitter key). keyless go transmitter card or transmitter key
from vehicle and store outside of
transmission range (min. 2 m)
2 Open engine hood
Remove left and right intake air
3
duct
Do not tilt front engine cover, but lift
4 Remove front engine cover upwards vertically otherwise the retaining
lugs can break off.
Detach air hose (3) from air
5
shutoff valves
Unclip air hose (3) and place to
6
one side
7 Remove poly-V belt (4)
Remove guide pulley (5) from *BA13.25-
8
coolant pump P-1004-01U
AR00.60-P-
9 Raise vehicle with vehicle lift
1000SX
Vehicles without code (Z07) Top protection
Remove bottom engine AR61.20-P-
10 Installation: Only install lower engine 1105SX
compartment paneling
compartment paneling after leak test.
AR20.00-P-
11 Drain coolant at radiator
1142SMG
AH20.00-N-
Notes on coolant All engines
2080-01A
*BF20.00-
Coolant
P-1001-02U
Unlock and disconnect electrical
12 connector (6) on coolant
temperature sensor (B11/4)
Remove coolant temperature Installation: Replace sealing ring.
13 sensor (B11/4) from cylinder *BA15.60-
head P-1002-01C
14 Install in the reverse order
Pour in coolant and bleed cooling AR20.00-P-
15
system 1142SMG
Conduct engine test run and
16
check engine for leaks
TEMPERATURE SENSOR
Number Designation Engine 156, 159
BA15.60-P-1002-01C Coolant temperature, temperature sensor on cylinder head Nm 21
BELT TENSIONING DEVICE
Engine 156,
Number Designation
159
BA13.25-P-1004- Guide pulley to coolant pump housing (between alternator and
Nm 20
01U smooth guide pulley)
COOLING SYSTEM
Engine 156 in model
Number Designation 216, 221
BF20.00-P-1001- Cooling system Total filling capacity approx.Liters 10
02U Antifreeze/water Up to -37°C 50/50
up to -45°C 55/45
Specifications for Operating Sheet BB00.40-P-0310-01A
Fluids Sheet BB00.40-P-0325-00A
REMOVE/INSTALL TEMPERATURE SENSOR - AR15.60-P-3000SX
ENGINES 272, 273 in MODEL 221 Coolant temperature sensor
ENGINES 273 in MODEL 216 Coolant temperature sensor
Fig. 61: Identifying Temperature Sensor Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
Risk of death caused by vehicle
vehicle lift and position four support AS00.00-Z-
slipping or toppling off of the lifting
plates at vehicle lift support points 0010-01A
platform.
specified by vehicle manufacturer.
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes
Open cap slowly and release the
caused by scalding from contact with AS20.00-Z-
pressure. Do not pour coolant into
hot coolant spray. Risk of poisoning 0001-01A
beverage containers.
caused by swallowing coolant.
Wear protective gloves, protective
clothing and safety glasses.
Information on preventing damage to
AH54.00-P-
electronic components due to
0001-01A
electrostatic discharge
1 Switch off ignition
Prior to installation, clean AR61.20-P-
Remove rear section of lower engine
2 escaped coolant off the engine and
compartment paneling 1105SX
transmission.
AR09.10-P-
3 Remove air filter housing (1).
1150SX
Reduce pressure in cooling system by
The coolant temperature should be
slowly opening cap (2) on the
4 approx. 40°C.
expansion reservoir (3) for the
coolant and closing it again Do not drain off coolant!
5 crankshaft Hall sensor (B70)
Disconnect electrical connector at
6
coolant temperature sensor (B11/4)
Remove bolt (4) and remove *BA15.60-P-
7
clamping plate (5) 1001-01A
Fit new O-ring (6) to new coolant
8
temperature sensor (B11/4)
Pull coolant temperature sensor
(B11/4) out of cylinder head and
9
immediately insert new coolant
temperature sensor (B11/4)
10 Install in the reverse order
Pour in coolant and bleed cooling AR20.00-P-
11
system 1142SX
Read out fault memory with STAR
12
DIAGNOSIS and erase if necessary
Connect STAR DIAGNOSIS and AD00.00-P-
read out fault memory 2000-04A
TEMPERATURE SENSOR
Number Designation Engine 272 Engine 273
BA15.60-P-1001- Bolt, clamping plate for coolant Nm 8 8
01A temperature sensor to cylinder
head
SAFETY PRECAUTIONS
SAFETY INFORMATION: ELECTRICAL SYSTEM - ENGINE - AS15.00-Z-9999ZZ
MODEL all
Risk of death caused by coming
into contact with high-voltage AS15.15-Z-
Danger! ENGINE 137 ENGINE 275 ENGINE 285
parts although ignition is turned 0001-01A
off.
ENGINE 103, 104, 111, 112, 113, 119, 120, 122,
Risk of death caused by contact
132, 134, 135, 137, 155, 156, 157, 159, 160, 166, AS15.10-Z-
Danger! with parts conducting high
266, 271, 272, 273, 275, 276, 278, 285, 613, 628, 0001-01A
voltages.
629, 642, 646, 648, 902, 906...
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) should never perform any work on the ignition system
Risk of death caused by high voltages in the ignition system
Electronic ignition systems operate within a hazardous power range both at 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. 62: High Voltages Caution
Courtesy of MERCEDES-BENZ USA
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.
First aid measures
Switch off current, bring injured person to safety.
Immediately notify an emergency physician.
Perform mouth to mouth respiration, if necessary.
Perform cardiopulmonary resuscitation, if necessary.
RISK OF DEATH CAUSED BY COMING INTO CONTACT WITH HIGH-VOLTAGE PARTS
ALTHOUGH IGNITION IS TURNED OFF. - AS15.15-Z-0001-01A
After ignition is turned OFF, only disconnect the plug on the ECI power pack after first waiting for 3
minutes.
Fig. 63: ECI Ignition System Power Pack Connector Assignment
Courtesy of MERCEDES-BENZ USA
After ignition is OFF there is still a voltage of more than 48 V at plugs 9 and 16 on the ECI ignition
system power pack. Remove plug from ECI power pack unit only after first waiting for 3 minutes. The
voltage is then no longer dangerous because the capacitor has had time to discharge.
For safety reasons the 180 V may only be measured with the corresponding insulated measuring
equipment and lines.
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE - BA15.00-Z-
9999AZ
MODEL all
BA15.40-P-
Alternator ENGINE 275, 285...
1000-01I
ENGINE 113.964 in MODEL 164.1 ENGINE 113.971 in BA15.40-P-
Alternator
MODEL 251.075 /175 1000-01N
BA15.40-P-
Alternator ENGINE 113.967 /990 in MODEL 219
1000-01M
BA15.40-P-
Alternator ENGINE 266, 640
1000-01K
Alternator ENGINE 601, 602, 603, 604, 605, 606, 612.966 /965
1000-01E
BA15.40-P-
Alternator ENGINE 157, 271, 272, 273 /, 276, 278
1000-01F
BA15.12-P-
DI ignition system ENGINE 120
1000-01C
Distributor ignition (DI BA15.12-P-
ENGINE 156, 159
[EZL]) system 1000-01K
Distributor ignition (DI BA15.12-P-
ENGINE 271
[EZL]) system 1000-01F
Distributor ignition (DI BA15.12-P-
ENGINE 166.940 /960 /961 /990 /991 /995
[EZL]) system 1000-01A
Distributor ignition (DI BA15.12-P-
ENGINE 266
[EZL]) system 1000-01J
Distributor ignition (DI BA15.12-P-
ENGINE 137, 275, 285
[EZL]) system 1000-01D
Distributor ignition (DI BA15.12-P-
ENGINE 111.951 /955 /981
[EZL]) system 1000-01E
BA15.12-P-
ECI ignition system ENGINE 668.914 /940 /941 /942
1000-01B
BA15.15-P-
ECI ignition system ENGINE 275, 285
1000-01A
BA15.18-P-
Engine wiring harness ENGINE 628.960 /961, 629
1000-01A
BA15.18-P-
Engine wiring harness ENGINE 640, 642, 646.8, 651
1000-01C
BA15.18-P-
Engine wiring harness ENGINE 272, 273 /
1000-01B
BA15.40-P-
Generator ENGINE 103, 104, 111, 112, 113, 119, 120, 137, 155...
1000-01A
BA15.40-P-
Generator ENGINE 156, 159
1000-01P
BA15.40-P-
Generator ENGINE 166.940 /960 /961 /990 /991 /995
1000-01B
BA15.40-P-
Generator ENGINE 651
1000-01Q
ENGINE 611 / /, 612 /, 613, 628 /, 629, 642 /, 646, BA15.40-P-
Generator
647.961 /981, 648 1000-01D
BA15.40-N-
Generator ENGINE 601.942 /943 /970, 602.980 /982 /984 /985
1000-01I
BA15.40-P-
Generator ENGINE 668 /
1000-01C
BA15.10-P-
Ground strap ENGINE 266
1000-05B
Ground strap MODEL 163 with ENGINE 111, 112, 113, 612, 628 1000-05A
BA15.10-P-
Ground strap MODEL 204, 197, 207, 212, 218, 221
1000-05C
BA15.10-P-
Ignition coil ENGINE 112 / /, 113 /, 155, 157, 270, 272, 273 /, 276, 278
1000-04A
BA15.10-P-
Ignition coil ENGINE 156, 159
1000-04B
BA15.10-P-
Ignition system ENGINE 266
1000-01F
ENGINE 102, 103, 104, 110, 111, 112, 113, 115, 117, 119, BA15.10-P-
Ignition system
120, 137, 155, 166... 1000-01A
BA15.10-P-
Ignition system ENGINE 113.971 in MODEL 251
1000-01G
BA15.10-P-
Ignition system ENGINE 157, 270, 271, 272, 273 /, 275, 276, 278, 285
1000-01C
BA15.10-P-
Ignition system ENGINE 156, 159
1000-01H
BA15.10-P-
Knock sensors ENGINE 111, 112, 113, 119, 120, 271...
1000-02A
BA15.10-P-
Knock sensors ENGINE 156, 159
1000-02C
BA15.10-P-
Knock sensors ENGINE 157, 272, 273 /, 275, 276, 278, 285
1000-02B
BA15.10-P-
Knock sensors ENGINE 646.8
1000-02D
BA15.10-P-
Knock sensors ENGINE 651
1000-02E
ENGINE 612.962 /963 /965 /966 /967 /990, 628, 629, 646, BA15.10-P-
Position sensor
647.961 /981, 648 1000-03C
BA15.10-P-
Position sensor ENGINE 157, 272, 273 /, 276, 278
1000-03E
BA15.10-P-
Position sensor ENGINE 640
1000-03F
BA15.10-P-
Position sensor ENGINE 642 /
1000-03G
BA15.10-P-
Position sensor ENGINE 271, 275, 285
1000-03D
BA15.10-P-
Position sensor ENGINE 651
1000-03H
BA15.10-P-
Position sensor ENGINE 137
1000-03B
BA15.10-P-
Position sensor ENGINE 111, 112, 113, 155...
1000-03A
Preglow system ENGINE 640 1000-01E
BA15.20-P-
Preglow system ENGINE 668.914 /940 /941 /942
1000-01B
ENGINE 601, 602, 603, 604, 605, 606, 611, 612, 613, 628, BA15.20-P-
Preglow system
629, 646, 647, 648, 651... 1000-01A
BA15.20-P-
Preglow system ENGINE 642 /
1000-01F
BA15.30-P-
Starter ENGINE 157, 272, 273 /, 276, 278
1000-01J
BA15.30-P-
Starter ENGINE 103, 104, 111, 112, 113, 119, 120, 271...
1000-01A
BA15.30-P-
Starter ENGINE 642 in MODEL 463, 461 ENGINE 642
1000-01N
BA15.30-P-
Starter ENGINE 651
1000-01P
BA15.30-P-
Starter ENGINE 668.914 /940 /941 /942
1000-01D
BA15.30-P-
Starter ENGINE 166.940 /960 /961 /990 /995 /991
1000-01B
BA15.30-P-
Starter ENGINE 113 in MODEL 219
1000-01M
BA15.30-P-
Starter ENGINE 156
1000-01O
BA15.30-P-
Starter ENGINE 159
1000-01Q
BA15.30-N-
Starter ENGINE 611, 612, 613, 642, 646, 647, 648, 651...
1000-01G
BA15.30-P-
Starter ENGINE 137, 275, 285
1000-01G
BA15.30-P-
Starter ENGINE 266
1000-01L
BA15.30-P-
Starter ENGINE 640
1000-01K
BA15.30-P-
Starter ENGINE 155.980
1000-01H
BA15.30-P-
Starter ENGINE 601, 602, 604, 605, 606, 611, 628, 629...
1000-01C
BA15.60-P-
Temperature sensor ENGINE 272, 273 /
1000-01A
BA15.60-P-
Temperature sensor ENGINE 651
1000-01D
BA15.60-P-
Temperature sensor ENGINE 156, 159
1000-01C
IGNITION SYSTEM - BA15.10-P-1000-01C
ENGINE 157, 270, 271, 272, 273, 275, 276, 278, 285
SPARK PLUGS
Engine Engine Engine Engine Engine
Number Designation
157 270 271.8 271.9 272
BA15.10-P-1001- Spark plug on cylinder
Nm 23 23 23 28 23
01C head
SPARK PLUGS
Engine Engine 275, Engine Engine
Number Designation
273 285 276 278
BA15.10-P-1001- Spark plug on cylinder
Nm 23 25 23 23
01C head
IGNITION SYSTEM - BA15.10-P-1000-01H
Engine 156, 159
MODIFICATION NOTES
7.8.09 Value modified: Spark plug to cylinder head
SPARK PLUGS
Number Designation Engine 156, 159
BA15.10-P-1001-01H Spark plug to cylinder head Nm 22
KNOCK SENSORS - BA15.10-P-1000-02B
Engine 157, 272, 273, 275, 276, 278, 285
KNOCK SENSORS
Number Designation Engine 272 Engine 273 Engine 275, 285
BA15.10-P- Bolt, knock sensor to Nm 20 20 20
1001-02B cylinder crankcase
BA15.10-P- Bolt connecting heat Nm - - 8
1002-02B shield of knock sensor to
crankcase
KNOCK SENSORS
Number Designation Engine 276 Engine 278 Engine 157
BA15.10-P- Bolt, knock sensor to Nm 20 20 20
1001-02B cylinder crankcase
BA15.10-P- Bolt connecting heat Nm - - -
1002-02B shield of knock sensor to
crankcase
KNOCK SENSORS - BA15.10-P-1000-02C
Engine 156, 159
KNOCK SENSORS
Number Designation Engine 156, 159
BA15.10-P-1001-02C Bolt of knock sensor to crankcase Nm 20
BA15.10-P-1002-02C Bolt heat shield of knock sensor to crankcase Nm 20
POSITION SENSOR - BA15.10-P-1000-03D
Engines 271, 275, 285
MODIFICATION NOTES
21.10.05 Camshaft position sensor to cylinder head cover Engines 271, 285
POSITION SENSOR
Number Designation Engines 271, 275, 285
BA15.10-P-1001-03D Crankshaft position sensor to engine block Nm 8
BA15.10-P-1002-03D Camshaft position sensor to cylinder head cover Nm 8
POSITION SENSOR - BA15.10-P-1000-03E
Engine 157, 272, 273, 276, 278
POSITION SENSOR
Number Designation Engine 157 Engine 272 Engine 273
BA15.10-P- Bolt, crankshaft Hall Nm 8 8 8
1001-03E sensor to crankcase
BA15.10-P- Bolt, camshaft Hall sensor Nm - 8 8
1002-03E to front cover on cylinder
head
BA15.10-P- Bolt, camshaft solenoid to Nm - 8 8
1003-03E front cover at cylinder
head
BA15.10-P- Bolt, crankshaft Hall Nm - 8 -
1004-03E sensor to intermediate
housing
BA15.10-P- Bolt, rotor position sensor Nm - 8 -
1005-03E to intermediate housing
BA15.10-P- Bolt, camshaft Hall sensor Nm 8 - -
1006-03E to cylinder head cover
POSITION SENSOR
Number Designation Engine 276 Engine 278
BA15.10-P-1001- Bolt, crankshaft Hall sensor to Nm 8 8
03E crankcase
BA15.10-P-1002- Bolt, camshaft Hall sensor to Nm - -
03E front cover on cylinder head
BA15.10-P-1003- Bolt, camshaft solenoid to front Nm - -
03E cover at cylinder head
BA15.10-P-1004- Bolt, crankshaft Hall sensor to Nm - -
03E intermediate housing
BA15.10-P-1005- Bolt, rotor position sensor to Nm - -
03E intermediate housing
BA15.10-P-1006- Bolt, camshaft Hall sensor to Nm 9 8
03E cylinder head cover
IGNITION COIL - BA15.10-P-1000-04A
Engine 112, 113, 155, 157, 270, 272, 273, 276, 278
IGNITION COIL
Engines 112,
Number Designation 113 Engine 155 Engine 157
BA15.10-P- Bolt, ignition coil to Nm 8 8 9
1001-04A cylinder head cover
IGNITION COIL
Number Designation Engine 270 Engine 272 Engine 273
BA15.10-P- Bolt, ignition coil to Nm 9 9 9
1001-04A cylinder head cover
IGNITION COIL
Number Designation Engine 276 Engine 278
BA15.10-P-1001- Bolt, ignition coil to cylinder Nm 9 9
04A head cover
IGNITION COIL - BA15.10-P-1000-04B
Engine 156, 159
MODIFICATION NOTES
7.8.09 Value modified: Bolt for ignition coil on cylinder head cover
IGNITION COIL
Number Designation Engine 156, 159
BA15.10-P-1001-04B Bolt for ignition coil on cylinder head cover Nm 10
GROUND STRAP - BA15.10-P-1000-05C
Model 221
GROUND STRAP
Model 221
except Model
Number Designation 221.094/194 221.094/194
BA15.10-P- Bolt, ground strap to body Nm 20 20
1001-05C
BA15.10-P- Bolt, ground strap to M8 Nm - -
1002-05C transmission M10 Nm 39 39
BA15.10-P- Bolt, engine ground strap from Nm 10 -
1003-05C power steering pump to body
BA15.10-P- Nut, ground strap to oil tank Nm - -
1004-05C
BA15.10-P- Bolt, ground strap to engine Nm - -
1005-05C block
DISTRIBUTOR IGNITION (DI [EZL]) SYSTEM - BA15.12-P-1000-01D
ENGINES 137, 275, 285
ECI IGNITION SYSTEM
Engine Engines 275,
Number Designation
137 285
BA15.12-P-1001-
Bolt, ignition coil module to cylinder head Nm 8 8
01D
BA15.12-P-1002-
Bolt, bracket to ignition coil module Nm 8 8
01D
BA15.12-P-1003- Bolt, ignition coil module bracket to cylinder
Nm 8 8
01D head
DISTRIBUTOR IGNITION (DI [EZL]) SYSTEM - BA15.12-P-1000-01K
Engine 156, 159
ECI IGNITION SYSTEM
Number Designation Engine 156, 159
BA15.12-P-1001-01K Crankshaft position sensor on crankshaft housing M6 Nm 8
ECI IGNITION SYSTEM - BA15.15-P-1000-01A
Engines 275, 285
IGNITION SYSTEM ECI
Engine 275,
Number Designation
285
BA15.15-P-1001-
Bolt of ignition coil module to cylinder head Nm 8
01A
BA15.15-P-1002-
Bolt of bracket to ignition coil module Nm 8
01A
BA15.15-P-1003-
Bolt ECI ignition system power pack to bracket Nm 8
01A
BA15.15-P-1004- Bolt bracket for ECI ignition system power pack to charge air
Nm 8
01A distribution pipe
BA15.15-P-1005- Bolt bracket of purge line to bracket for ECI ignition system
Nm 8
01A power pack
ENGINE WIRING HARNESS - BA15.18-P-1000-01B
Engine 272, 273
ENGINE WIRING HARNESS
Number Designation Engine 272 Engine 273
BA15.18-P-1001- Bolt of supply cable to resonance Nm 8 8
01B intake manifold
BA15.18-P-1002- Bolt of feed line duct to cylinder Nm 8 8
01B head cover
BA15.18-P-1003- Bolt of feed line duct to motor Nm 8 8
01B suspension lug
STARTER - BA15.30-P-1000-01G
ENGINES 137, 275, 285
STARTER
Number Designation Engine 137 Engine 275 Engine 285
BA15.30-P-1001-01G Nut for connection on circuit 30 Nm 14 14 14
BA15.30-P-1002-01G Nut for connection on circuit 50 Nm 6 6 6
BA15.30-P-1003-01G Bolt for starter on crankcase Nm 42 42 38
BA15.30-P-1004-01G Bolt for heat shield on crankcase Nm - 8 8
STARTER - BA15.30-P-1000-01J
Engines 157, 272, 273, 276, 278
STARTER
Engine 272,
Number Designation Engine 157 273 Engine 276 Engine 278
BA15.30-P- Nut, connection for Nm 15 15 15 15
1001-01J circuit 30
BA15.30-P- Nut, connection for Nm 6 8 6 6
1002-01J circuit 50
BA15.30-P- Bolt connecting Nm 40 40 40 40
1003-01J starter to crankcase
STARTER - BA15.30-P-1000-01O
Engine 156
STARTER
Number Designation Engine 156
BA15.30-P-1001-01O Nut for connection of circuit 30 Nm 15
BA15.30-P-1002-01O Nut for connection of circuit 50 Nm 8
BA15.30-P-1003-01O Bolt connecting starter to crankcase Nm 40
BA15.30-P-1004-01O Bracket on starter M6 Nm 9
BA15.30-P-1005-01O Shield on bracket M6 Nm 9
ALTERNATOR - BA15.40-P-1000-01F
Engine 157, 271, 272, 273, 276, 278
ALTERNATOR
Number Designation Engine 157 Engine 271 Engine 272 Engine 273
BA15.40-P- Bolt, alternator to Nm 20 20 20 20
1001-01F timing case
BA15.40-P- Nut, circuit B+ to Nm 15 15 15 15
1002-01F alternator
BA15.40-P- Nut, circuit D+ to Nm - 4 - -
1003-01F alternator
BA15.40-P- Collar nut, Nm 75 80 80 80
1004-01F connecting belt
pulley to alternator
BA15.40-P- Bolt, regulator to M4x19 Nm 3 3 3 3
1005-01F alternator M4x13 Nm 2 2 2 2
BA15.40-P- Collar nut, cover to Nm 30 30 30 30
1007-01F alternator
BA15.40-P- Bolt/nut, cover to Nm 3 3 3 3
1008-01F alternator
BA15.40-P- Bolt, regulator to Nm 3 3 3 3
1009-01F alternator
BA15.40-P- Bolt, alternator Nm - - 20 -
1010-01F bracket to timing
case cover/coolant
pump
BA15.40-P- Bolt, alternator to Nm - - 20 -
1011-01F bracket
ALTERNATOR - BA15.40-P-1000-01I
Engine 275, 285
ALTERNATOR
Engine 275.950 in Engine 275.951 in model
Number Designation model 215.376, 230.476, Engine 275.954 in
220.176 model 230.477
BA15.40-P-
Nut, circuit B+ to alternator Nm 12 12
1001-01I
BA15.40-P- Collar nut on poly V-belt
Nm - 125
1002-01I pulley
BA15.40-P- Bolt, cooler housing of M7 Nm 14 14
1003-01I alternator to crankcase M8 Nm 20 20
BA15.40-P- Bolt, cable bracket of
Nm 8 -
1004-01I electrical lines B+ to alternator
BA15.40-P- Bolt, cable bracket of ATF
Nm - -
1005-01I line to alternator
Bolt, cable bracket of oil
BA15.40-P-
dipstick guide tube to Nm 8 -
1006-01I
alternator
BA15.40-P- Coolant drain plug at
Nm - 12
1007-01I alternator
BA15.40-P-
Bolt, guide pulley to alternator Nm - 50
1008-01I
Bolt, cable bracket of oil
BA15.40-P-
dipstick guide tube to timing Nm 8 -
1009-01I
case
BA15.40-P- Bolt, ABC cable bracket to
Nm - 10
1010-01I rear alternator
BA15.40-P- Bolt, ABC cable bracket to
Nm - 10
1011-01I front alternator
BA15.40-P-
Bolt, alternator to bracket Nm - -
1012-01I
BA15.40-P- Bolt connecting alternator
Nm - -
1013-01I bracket to crankcase bracket
ALTERNATOR
Engine 275.980 in
Engine 285 Engine 275.981
Number Designation model 215.379,
in model 240 in model 230.479
220.179
BA15.40-P-
Nut, circuit B+ to alternator Nm 12 12 12
1001-01I
BA15.40-P- Collar nut on poly-V belt
Nm - 125 80
1002-01I pulley
BA15.40-P- Bolt, cooler housing of M7 Nm 14 14 14
1003-01I alternator to crankcase M8 Nm 20 20 20
Bolt, cable bracket of
BA15.40-P-
electrical lines B+ to Nm 8 8 8
1004-01I
alternator
BA15.40-P- Bolt, cable bracket of ATF
Nm - 8 -
1005-01I line to alternator
Bolt, cable bracket of oil
BA15.40-P-
dipstick guide tube to Nm 8 8 8
1006-01I
alternator
BA15.40-P- Coolant drain plug at
Nm - 12 -
1007-01I alternator
BA15.40-P-
Bolt, guide pulley to alternator Nm - 50 -
1008-01I
Bolt, cable bracket of oil
BA15.40-P-
dipstick guide tube to timing Nm 8 - 8
1009-01I
case
BA15.40-P- Bolt, ABC cable bracket to
Nm - - -
1010-01I rear alternator
BA15.40-P- Bolt, ABC cable bracket to
Nm - - -
1011-01I front alternator
BA15.40-P-
Bolt, alternator to bracket Nm - - -
1012-01I
BA15.40-P- Bolt connecting alternator
Nm - - -
1013-01I bracket to crankcase bracket
ALTERNATOR
Engine 275.953 in Engine 275.982 in Engine 275.983
Number Designation model 221.176, model 221.179, in model
216.376 216.379 230.479
BA15.40-P-
Nut, circuit B+ to alternator Nm 12 12 12
1001-01I
1002-01I pulley Nm -- -
BA15.40-P- Bolt, cooler housing of M7 Nm - - -
1003-01I alternator to crankcase M8 Nm -- -
Bolt, cable bracket of
BA15.40-P-
electrical lines B+ to Nm - - -
1004-01I
alternator
BA15.40-P- Bolt, cable bracket of ATF
Nm - - -
1005-01I line to alternator
Bolt, cable bracket of oil
BA15.40-P-
dipstick guide tube to Nm - - -
1006-01I
alternator
BA15.40-P- Coolant drain plug on
Nm - - -
1007-01I alternator
BA15.40-P- Bolt, guide pulley to
Nm - - -
1008-01I alternator
Bolt, cable bracket of oil
BA15.40-P-
dipstick guide tube to Nm - - -
1009-01I
timing case
BA15.40-P- Bolt, ABC cable bracket to
Nm - - -
1010-01I rear alternator
BA15.40-P- Bolt, ABC cable bracket to
Nm - - -
1011-01I front alternator
BA15.40-P-
Bolt, alternator to bracket Nm 20 20 20
1012-01I
BA15.40-P- Bolt connecting alternator
Nm 20 20 20
1013-01I bracket to crankcase bracket
GENERATOR - BA15.40-P-1000-01P
Engine 156, 159
MODIFICATION NOTES
6.10.09 Value modified: Nut of circuit B+ to alternator Engine 159
ALTERNATOR
Number Designation Engine 156 Engine 159
BA15.40-P-1001-01P Bolt, alternator to timing case M8X90 Nm 20 20
BA15.40-P-1002-01P Nut of circuit B+ to alternator Nm 18 20
BA15.40-P-1003-01P Nut, circuit D+ to alternator Nm 5 6
BA15.40-P-1004-01P Nut connecting cover to alternator Nm 12 16
BA15.40-P-1005-01P Collar nut connecting cover to alternator Nm 30 -
- Nm 2.8 -
BA15.40-P-1006-01P Bolt connecting regulator to alternator M4X13 Nm 1.2 -
M4X19 Nm 2.5 -
TEMPERATURE SENSOR - BA15.60-P-1000-01A
Engine 272, 273
TEMPERATURE SENSOR
Number Designation Engine 272 Engine 273
BA15.60-P-1001- Bolt of clamping plate for coolant Nm 8 8
01A temperature sensor to cylinder
head
TEMPERATURE SENSOR - BA15.60-P-1000-01C
Engine 156, 159
TEMPERATURE SENSOR
Number Designation Engine 156, 159
BA15.60-P-1001-01C Oil temperature sensor on crankcase Nm 21
BA15.60-P-1002-01C Coolant temperature sensor on cylinder head Nm 21
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE -
BE15.00-Z-9999AZ
MODEL all
Check values for BE15.40-P-
ENGINE 628, 629, 640, 646, 647, 648...
alternator 1000-01J
Check values for ENGINE 156, 157, 159, 266, 271, 272, 273, 275, 276, 278, BE15.40-P-
alternator 285... 1000-01I
Check values for BE15.40-P-
ENGINE 156, 157, 271, 272, 273, 276, 278, 642, 646, 651...
alternator 1000-01L
Check values for BE15.40-P-
ENGINE 642, 651...
alternator 1000-01H
Check values for ENGINE 104, 111, 113, 119, 137, 155, 601, 602, 604, 605, BE15.40-P-
alternator 606, 611, 612, 613... 1000-01A
Coolant temperature BE15.60-P-
ENGINE 103 /, 104 /, 119, 120
sensor 1000-01A
Coolant temperature BE15.60-P-
ENGINE 111, 271
sensor 1000-01B
ENGINE 103, 104, 111, 112, 113, 119, 120, 137, 155, 166 /, BE15.40-P-
Governor
275 1000-02A
ENGINE 601, 602, 603, 604, 605, 606, 611, 612 /, 613, 628 /, BE15.40-P-
Governor
642, 646, 647, 668 / 1000-02C
BE15.12-P-
Ignition angle ENGINE 103.985 in MODEL 124
1000-01A
BE15.12-P-
Ignition angle ENGINE 104.990, 119.97, 120
1000-01B
Intake air temperature BE15.60-P-
ENGINE 111, 271
sensor 1000-02B
Intake air temperature BE15.60-P-
ENGINE 103, 104, 119, 120
sensor 1000-02A
BE15.10-P-
Position sensor ENGINE 104 /, 111
1000-04A
BE15.10-P-
Spark plugs ENGINE all
1000-01A
Test values for BE15.40-P-
ENGINE 112, 113
alternator 1000-01K
Test values for BE15.40-P-
ENGINES 668.914 /940 /941 /942
generator 1000-01E
Test values for BE15.40-P-
ENGINE 104, 119, 120, 603 in MODEL 140
generator 1000-01C
Test values for BE15.40-P-
ENGINE 103, 104, 119, 120 in MODEL 129
generator 1000-01B
Test values for BE15.40-P-
ENGINES 166.940 /960 /961 /990 /991 /995
generator 1000-01D
SPARK PLUGS - BE15.10-P-1000-01A
TEST VALUES OF SPARK PLUGS
Number Designation All engines
BE15.10-P-1001-01A Electrode gap mm 0.8
CHECK VALUES FOR ALTERNATOR - BE15.40-P-1000-01I
Engine 156, 157, 159, 266, 271, 272, 273, 275, 276, 278, 285
MODIFICATION NOTES
21.6.06 Charge current for alternator Engine 156 in model 164, 204,
209, 211, 219, 230, 251
Charge current for alternator Engine 156 in model 216, 221
10.8.06 Charging current for alternator, Engine 271 in model 171, 203,
engine speed and gear ratio 209 Valeo
CHECK VALUES FOR ALTERNATOR
Engine 156 in
model 164, 209,
211, 219, 230, Engine 156 in
Number Designation 251 model 216, 221
BE15.40-P- Charge current max. A 180 220
1001-01I for alternator min. A 140 170
Engine speed RPM 2000 2000
Ratio i= 2.93 2.93
CHECK VALUES FOR ALTERNATOR
Engine 157 in Engine 159 in
Number Designation model 216, 221 model 197
BE15.40-P- Charge current max. A 220 185
1001-01I for alternator min. A 170 115
Engine speed RPM 2000 2000
Ratio i= 2.93 2.82
CHECK VALUES FOR ALTERNATOR
Engine Engine
266.920/940 266.920/940 with
without code code 910 engine
910 in model 266.960/980 in
Number Designation 169, 245 model 169, 245
BE15.40-P- Charge current max. A 90 115
1001-01I for alternator min. A 70 90
Engine speed RPM 2000 2000
Ratio i= 2.77 2.77
CHECK VALUES FOR ALTERNATOR
Engine 273 in
model 164, 209,
211, 219, 230,
251, 463 engine
273 in model
216, 221 Engine 273 in
without code model 216, 221
Number Designation 910 with code 910
BE15.40-P- Charge current max. A 180 220
1001-01I for alternator min. A 140 170
Engine speed RPM 2000 2000
Ratio i= 2.93 2.93
CHECK VALUES FOR ALTERNATOR
Engine 275 in Engine 275 in
models 216, model 215, 220,
Number Designation 221, Bosch 230, Bosch
BE15.40-P- Charge current max. A 220 180
1001-01I for alternator min. A 170 140
Engine speed RPM 2000 2000
Ratio i= 2.93 2.93
CHECK VALUES FOR ALTERNATOR
Engine 276 in
model 221
without code
910/B03, engine Engine 276 in
276 in model model 221 with
Number Designation 251 Code 910/ B03
BE15.40-P- Charge current max. A 180 220
1001-01I for alternator min. A 140 170
Engine speed RPM 2000 2000
Ratio i= 2.93 2.93
GOVERNOR - BE15.40-P-1000-02A
Engines 103, 104, 111, 112, 113, 119, 120, 137, 155, 166, 275
CHECK VALUES FOR REGULATOR
Engines 103, 104, 111, 112, 113,
Number Designation
119, 120, 137, 155, 166, 275
Loading: only on
V 13 to 15
BE15.40-P- Regulating voltage permanent consumer
1001-02A (at battery) Engine speed RPM 3000
measured after min approx.2
BASIC KNOWLEDGE
COMPONENT DESCRIPTION FOR SPARK PLUGS - GF15.10-P-2000AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211, 219
ENGINE 156.984 in MODEL 216, 221 up to Model Year 8
Location
Fig. 64: Locating Spark Plugs
Courtesy of MERCEDES-BENZ USA
On each cylinder, a spark plug is inserted from the top of the cylinder head to centrally in the combustion
chamber.
Task
The spark plugs ignite the suctioned and compressed fuel-air mixture due to arcing between the electrodes.
Function
The ignition voltage flows from the ignition lines of the directly plugged in ignition coils to the spark plugs and
causes arcing in the air gap between the central electrode and ground electrode.
All the spark plug characteristics are defined by the type symbols provided by the manufacturer (e.g. heat
rating, seat shape, thread, width across flats, electrode material, spark position).
COMPONENT DESCRIPTION FOR SPARK PLUGS - GF15.10-P-2000V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.942 in MODEL 171 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.960 in MODEL 203 up to Model Year 8
ENGINE 272.963 in MODEL 171 up to Model Year 8
ENGINE 272.964 in MODEL 211, 219
ENGINE 272.965 in MODEL 221 up to Model Year 8
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.970 in MODEL 203 up to Model Year 8
ENGINE 272.972 in MODEL 211
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.923 in MODEL 164 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Location
In the cylinder head, each cylinder has a spark plug located in the center between the engine valves.
Task
The compressed fuel-air mixture is combusted by sparks between the electrodes according to the actuation from
the ME control unit.
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).
Fig. 65: Identifying Spark Plug
Courtesy of MERCEDES-BENZ USA
Function
The ignition voltage flows from the ignition lines of the directly plugged in ignition coils to the spark plugs and
causes arcing in the air gap between the central electrode and ground electrode.
Spark plug table, see IS, Group 15.
IGNITION COIL, COMPONENT DESCRIPTION - GF15.10-P-2100AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211, 219
ENGINE 156.984 in MODEL 216, 221 up to Model Year 8
Location
Fig. 66: Locating Ignition Coils
Courtesy of MERCEDES-BENZ USA
A dedicated ignition coil is plugged straight onto the spark plug (R4) for each cylinder.
Task
The ignition coils provide sufficient ignition energy under all operating conditions for the respective ignition
circuit.
Design (ignition coil with integrated output stage)
Fig. 67: Design Of Ignition Coil With Integrated Output Stage
Function
An output stage is located in each ignition coil for the ignition coil primary circuit. The ME-SFI control unit
(N3/10) actuates the ignition coil primary circuit between connection (2) and (4). The current flow in the
primary coil (P) causes a magnetic field to form. The dwell angle control determines the operating time of the
ignition coil primary circuit and thus the magnetic saturation of the ferrous core of the ignition coil.
The primary current flow is interrupted at the moment of ignition timing point. The sudden collapse of the
magnetic field generates the ignition voltage in the secondary coil (S), which is fed directly to the spark plugs
(R4).
The diode (D) is fitted to suppress an additional ignition spark when the primary current is switched on.
Because of the diode it is not possible to measure the resistance of the secondary coil.
For diagnosis of the ignition coils, the primary current is measured. The capacitive tap is used to connect
measuring equipment.
COMPONENT DESCRIPTION FOR AN IGNITION COIL - GF15.10-P-2100V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.942 in MODEL 171 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.960 in MODEL 203 up to Model Year 8
ENGINE 272.963 in MODEL 171 up to Model Year 8
ENGINE 272.964 in MODEL 211, 219
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.970 in MODEL 203 up to Model Year 8
ENGINE 272.972 in MODEL 211
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.923 in MODEL 164 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Shown on ENGINE 272
Fig. 68: Identifying Ignition Coil & Connector Terminals
Courtesy of MERCEDES-BENZ USA
Location
For each cylinder, a dedicated ignition coil is plugged directly onto the spark plugs.
Task
Supplying adequate ignition energy in all operating conditions for the particular ignition circuit.
Shown on engine 272
Fig. 69: Locating Ignition Coils - Engine 272
Courtesy of MERCEDES-BENZ USA
Shown on engine 273
Fig. 70: Locating Ignition Coils - Engine 273
Courtesy of MERCEDES-BENZ USA
Design
Shown on engine 272
Fig. 71: Design Of Ignition Coil
Courtesy of MERCEDES-BENZ USA
The ignition output stages are integrated in the ignition coils.
Internal circuitry of ignition coils with integral output stage Shown on engine 272
Fig. 72: Internal Circuitry Of Ignition Coils With Integral Output Stage
Courtesy of MERCEDES-BENZ USA
Function
An output stage is located in each ignition coil for the primary circuit. The ME control unit actuated the ignition
coil primary circuit between terminals 2 and 4. The current flow in the primary coil (L1) causes a magnetic field
to form. The dwell angle control determines the operating time of the ignition coil primary circuit and thus the
magnetic saturation of the ferrous core of the ignition coil.
The primary current flow is interrupted at the moment of ignition timing point. The sudden collapse of the
magnetic field generates the ignition voltage in the secondary coil (L2) which is fed directly to the spark plugs.
The voltage supply of the ignition coils is protected at circuit 87 M1
A diode is integrated in each ignition coil for suppressing additional ignition sparks when the output stage is
switched off.
Because of the diodes, it is not possible to measure the resistance in the secondary windings. For diagnosis
of the ignition coils, the primary current is measured. The capacitive tap is used to connect measuring
equipment.
SPARK PLUGS, LOCATION/TASK/DESIGN/FUNCTION - GF15.10-P-3101M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 73: Identifying Spark Plug
Courtesy of MERCEDES-BENZ USA
Spark plugs,
Two spark plugs per cylinder are fitted in the cylinder head
location
Spark plugs, Ignite the compressed fuel-air mixture through sparks between the electrodes according
task to actuation of the ECI ignition system. Detects the ion current.
In the manufacturer's specific type symbols, all spark plug features are assigned (e. g.
Spark plugs,
heat rating, shape of seating, thread, width across flats, electrode material, spark
design
position).
The ignition voltage flows from the directly-inserted ignition coils in the ECI ignition
Spark plugs,
modules (N92/1, N92/2) to the spark plugs and causes arcing in the gap between the
function
central electrode and ground electrode.
ME-SFI IGNITION SYSTEM SIGNAL ASSIGNMENT - GF15.12-P-0001-02M
Fig. 74: ME-SFI Ignition System Signal Assignment
Courtesy of MERCEDES-BENZ USA
ME-SFI IGNITION SYSTEM, FUNCTION - GF15.12-P-0001M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
Fig. 75: ME-SFI Ignition System Function Diagram
Courtesy of MERCEDES-BENZ USA
When the crankshaft is rotating, an alternating voltage is generated in the crankshaft position sensor by the teeth
of the drive plate.
During this operation, each tooth generates an alternating voltage signal. No voltage is generated as a result of
the gap created by 2 missing teeth. The ME-SFI [ME] control unit detects the TDC position of cylinders 1 and 7
via the 2nd negative signal edge after the gap:
If the signal from the camshaft Hall sensor of the respective cylinder bank is at 0 V ("Low") at this moment, the
ME-SFI [ME] control unit processes this to detect ignition TDC for cylinder 1 and, with the ME-SFI 2.7.1,
additionally for cylinder 7. This is used to actuate the ignition modules and the fuel injection valves.
The high voltage distribution is performed statically and directly from the ECI ignition modules to the spark
plugs.
1. Determining the ignition angle in line with the input signals and actuating the ECI ignition modules
For determining the ignition angle, the ME-SFI control unit essentially analyzes the signals of the
following sensors:
Pressure sensor downstream of throttle valve actuator (engine load)
Crankshaft position sensor
Camshaft Hall sensor
Coolant temperature sensor
Charge air temperature sensor
The ME-SFI [ME] control unit actuates the output stages in the ECI ignition modules. The output stages
generate the high voltage from an AC voltage for each spark plug.
The ignition angles can be checked using the DAS.
2. Ignition angle adaptations
2.1 Catalytic converter heating up (warming-up phase)
The ignition angle is continuously retarded for about 20 seconds in order to warm up the catalytic
converter more rapidly to its operating temperature, if:
coolant temperature at start > 15°C and < 40°C
Selector lever position P or N
At the same time idle speed is increased by the idle speed control.
2.2 No-load speed
To assist idle speed control, the ignition angle can be retarded briefly by as much as 36° crank angle or
advanced by as much as 20° crank angle.
The control by altering the ignition angle reacts more rapidly than altering the position of the throttle
valve (idle speed control).
2.3 Deceleration fuel shutoff
When combustion is restored (actuation of the fuel injectors), the ignition angle is briefly retarded in
order to prevent a sudden increase in torque.
2.4 Overheating and pinging protection
The ignition angle is retarded under load, as a function of the charge air temperature and coolant
temperature, in order to prevent any knocking tendency at high charge air and coolant temperatures.
2.5 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 [ME] control unit is supplied with a signal from the ETC [EGS] control unit
for this purpose via the CAN.
2.6 ESP 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 unit over the CAN data bus to the ME-
SFI control unit.
2.7 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".
2.8 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 combustion misfires.
Detection of combustion misfires is performed through a smooth running analysis and at high RPM, in
addition through the evaluation of the ion current. The size of the ion current is detected by the ECI
ignition module and is transmitted to the ME-SFI control unit.
2.9 Double ignition
Two spark plugs for each cylinder are beneficial on the basis of the valve arrangement for achieving
optimal exhaust emission levels and smooth engine running.
Each spark plug is actuated via its own ignition coil in the ECI ignition modules separately by the ME-
SFI control unit.
In the lower part load range up to approx. 2000 RPM both ignition sparks of a cylinder are triggered
simultaneously. At medium and high loads, ignition is offset by up to 10° crank angle.
The order of actuation is constantly varied in this case in order to ensure uniform wear of both spark plugs and
to avoid deposits on one side of the combustion chamber. The signals for ignition circuit change and ignition
offset are transmitted by the ME-SFI control unit to the respective ECI ignition module.
ME-SFI ignition system signal assignment GF15.12-P-0001-02M
ME-SFI [ME] control unit, location/task/ design/function GF07.61-P-5000M
Crankshaft position sensor, location/task/ design/function GF07.04-P-4116M
Camshaft Hall sensor, location/task/design/ function GF07.04-P-4117M
Spark plugs, location/task/design/function GF15.10-P-3101M
Charge air temperature sensor, location/task/ function GF07.04-P-5038M
Pressure sensor downstream of throttle valve actuator, location/task/function GF07.04-P-5049M
Coolant temperature sensor, location/task/ design/function GF07.04-P-5026M
ME-SFI IGNITION SYSTEM, FUNCTION - GF15.12-P-0001V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.942 in MODEL 171 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.960 in MODEL 203 up to Model Year 8
ENGINE 272.963 in MODEL 171 up to Model Year 8
ENGINE 272.964 in MODEL 211, 219
ENGINE 272.965 in MODEL 221 up to Model Year 8
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.970 in MODEL 203 up to Model Year 8
ENGINE 272.972 in MODEL 211
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Shown on engine 272 in model 171
Fig. 76: ME-SFI Ignition System, Function Diagram
Courtesy of MERCEDES-BENZ USA
Cylinder arrangement and ignition firing order
Fig. 77: Cylinder Arrangement And Ignition Firing Order (Engine 272)
Courtesy of MERCEDES-BENZ USA
Fig. 78: Cylinder Arrangement And Ignition Firing Order (Engine 273)
Courtesy of MERCEDES-BENZ USA
The ME-SFI control unit essentially analyzes the following signals for determining the ignition angle:
Air mass
Position and RPM of crankshaft
Positions of intake camshafts
Positions of exhaust camshafts
Coolant temperature
Intake air temperature
Knock sensor signals
Intake manifold air pressure
Engine torque requests
The ME-SFI [ME] control unit interrupts the respective ignition coil at the moment of the ignition timing of the
primary circuit to "terminal 1".
Ignition angle adaptation
For the following partial functions an ignition angle adjustment in the direction "retarded" or "advanced" can
take place:
Catalytic converter heating-up
Idle speed control
Overheating / knock protection
Deceleration fuel shutoff
Transmission overload protection (with automatic transmission 722.9)
Anti-knock control [AKC]
Engine torque requests
The ignition angle can only be checked using the DAS.
Component description for the ME-SFI [ME] control unit GF07.61-P-6000V
Component description for the knock sensor GF07.04-P-6030V
Component description for the pressure sensor GF07.04-P-6060V
Component description for the crankshaft Hall sensor GF07.04-P-6220V
Component description for the camshaft Hall sensor GF07.04-P-6020V
Component description for the coolant temperature sensor GF07.04-P-6040V
Component description for the hot film mass air flow sensor GF07.07-P-6000V
Component description for spark plugs GF15.10-P-2000V
Component description for ignition coils GF15.10-P-2100V
Component description for the accelerator pedal sensor GF30.20-P-2010V
Component description for the throttle valve actuator GF30.20-P-2020V
ANTI-KNOCK CONTROL FUNCTION - GF15.12-P-4024M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 79: Anti-Knock Control Function Diagram
Courtesy of MERCEDES-BENZ USA
The task of the anti-knock control AKC is to ensure knock-free operation of the engine with different fuels and
in all operating conditions from idling speed up to maximum engine speed.
For this purpose, if uncontrolled combustion (knocking) occurs, the ignition angle at the relevant cylinder or
cylinders is retarded. The anti-knock control (AKC) function is integrated in the ME-SFI [ME] control unit
(N3/10).
Input signals:
Engine speed (crankshaft position sensor)
Camshaft position (camshaft Hall sensor)
Recognition of knocking over 4 knocking sensors
Engine temperature (coolant temperature sensor)
Engine load (pressure sensor downstream of throttle valve actuator)
Accelerator pedal position (accelerator pedal sensor)
Precontrol by means of automatic RON switch (internal)
RON correction with STAR DIAGNOSIS.
Output signals:
Ignition angle correction for specific cylinder to the map value
calculated by the alternator control unit
Ignition angle emergency mode if fault identified.
Anti-knock control is active from a coolant temperature of 70°C. If cylinder knocking is recognized above an
engine load of about 40%, its ignition angle is retarded by approx. 3.0° crank angle after the next ignition. If
knocking continues to be detected, the ignition angle is continuously retarded in 3° crank angle increments until
the maximum retardation is reached (approx. a 10 - 15° crank angle, depending on the engine speed). The
automatic RON switch also influences the maximum retardation of ignition timing - the higher the selected
RON stage, the less the maximum retardation of ignition timing.
If knocking-free combustion exists, retardation is reduced in approx. 0.75° crank angle increments after a few
ignitions (depending on the engine speed) until the performance map value is achieved, or knocking occurs
again.
Adaptation of anti-knock control
Adaptation of anti-knock control is active from a coolant temperature of approx. 75°C. Any corrections required
to the ignition angle due to 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 angles so that each
cylinder is immediately operated with the optimal ignition angle.
During abrupt acceleration, no values are stored for about 2 seconds to avoid any incorrect adaptation values.
Faults in knocking detection
If no signals are received from the knock sensors or from ionic current measurement, the ignition angle of all
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 STAR DIAGNOSIS, 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 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 performed via STAR DIAGNOSIS is active at first.
The engines are designed to run with RON 98 fuel. If only fuel with RON 91 is available, the RON correction
must be carried out immediately using STAR DIAGNOSIS, otherwise engine damage is possible.
Crankshaft position sensor, location/task/ design/function GF07.04-P-4116M
Camshaft Hall sensor, location/task/design/ function GF07.04-P-4117M
Knock sensors, location/task/design/function GF15.12-P-4101M
Coolant temperature sensor, location/task/ design/function GF07.04-P-5026M
Pressure sensor downstream of throttle valve actuator, location/task/function GF07.04-P-5049M
Accelerator pedal sensor, location/task/ design/function GF30.20-P-4010M
ME-SFI control unit, location/task/design/ function GF07.61-P-5000M
ME-SFI synchronization of fuel injection and firing order, function GF07.61-P-4009M
THE ANTI-KNOCK CONTROL FUNCTION - GF15.12-P-4024V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.942 in MODEL 171 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.960 in MODEL 203 up to Model Year 8
ENGINE 272.963 in MODEL 171 up to Model Year 8
ENGINE 272.964 in MODEL 211, 219
ENGINE 272.965 in MODEL 221 up to Model Year 8
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.970 in MODEL 203 up to Model Year 8
ENGINE 272.972 in MODEL 211
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.923 in MODEL 164 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Shown on engine 272.963 in model 171
Fig. 80: Anti-Knock Control Function Diagram
Courtesy of MERCEDES-BENZ USA
The task of the anti-knock control AKC is to ensure knock-free operation of the engine with different fuels and
in all operating conditions from idling speed up to maximum engine speed. For this purpose, if uncontrolled
combustion (knocking) occurs, the ignition angle at the knocking cylinders is retarded. The anti-knock control
(AKP) is integrated in the ME-SFI [ME] control unit.
Input signals:
Motor speed (crankshaft Hall sensor)
Camshaft position (camshaft Hall sensor)
Recognition of knocking over 2 knocking sensors
Engine temperature (coolant temperature sensor)
Engine load (hot film mass air flow sensor)
Accelerator pedal position (accelerator pedal sensor)
Precontrol by means of automatic RON switch (internal)
RON correction with STAR DIAGNOSIS.
Output signals:
Ignition angle correction for specific cylinder to the map value calculated by the ME control unit
Ignition angle emergency mode if fault identified.
The anti-knock control is active from a coolant temperature of 40°C. If cylinder knocking is recognized above
an engine load of about 40%, its ignition angle is adjusted to retarded by about a 3.0° crank angle after the next
ignition. If knocking continues to be detected, the ignition angle is continuously retarded in steps of a 3° crank
angle until the maximum retardation is reached (approx. a 10 -15° crank angle, depending on the engine speed).
The automatic RON switch also 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 the engine speed) until the map value is achieved, or knocking occurs again.
Adaptation of anti-knock control
The adaptation of the anti-knock control is active from a coolant temperature of approx. 75°C. 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 angles so that each cylinder is
immediately operated with the optimal ignition angle.
During abrupt acceleration, no values are stored for about 2 seconds in order to avoid any incorrect adaptation
values.
Faults if knocking is detected
If no signals are received from the knock sensors, the ignition angle of all cylinders is retarded by as much as a
11° crank angle for safety reasons, 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 STAR DIAGNOSIS, 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 STAR DIAGNOSIS is at first
active.
Component description for the ME-SFI [ME] control unit GF07.61-P-6000V
Component description for a knock sensor GF07.04-P-6030V
Component description for the crankshaft Hall sensor GF07.04-P-6220V
Component description for the camshaft Hall sensor GF07.04-P-6020V
Component description for the coolant temperature sensor GF07.04-P-6040V
Component description for the hot film MAF sensor GF07.07-P-6000V
Component description for the accelerator pedal sensor GF30.20-P-2010V
ME-SFI synchronization of fuel injection and firing order function GF07.61-P-4009V
KNOCK SENSORS, LOCATION - GF15.12-P-4101-01M
Fig. 81: Locating Knock Sensors And Generator
Courtesy of MERCEDES-BENZ USA
KNOCK SENSORS, FUNCTION - GF15.12-P-4101-02M
Fig. 82: Knock Sensors Circuit And Signal Pattern
Courtesy of MERCEDES-BENZ USA
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.
KNOCK SENSORS, LOCATION/TASK/DESIGN/FUNCTION - GF15.12-P-4101M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 83: Identifying Knock Sensors
Courtesy of MERCEDES-BENZ USA
Knock sensors, GF15.12-P-
location 4101-01M
Knock sensors,
The knock sensor detects vibrations at the crankcase.
task
Knock sensors, The knock sensor is a self-contained system. Inside the sensor are piezo
design crystals. The screened cable is fitted directly onto the knock sensor.
Knock sensors, GF15.12-P-
function 4101-02M
ECI IGNITION SYSTEM, FUNCTION - GF15.15-P-3000M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 84: ECI Ignition System Function Diagram
Courtesy of MERCEDES-BENZ USA
ECI ignition module, left ME-SFI control unit ECI ignition module, right
cylinder bank (N92/2) (N3/10), coupling 3 cylinder bank (N92/1)
ion current signal Pin 6 --> Pin 32 Pin 33 <-- Pin 6 ion current signal
cylinders 7 to 9 cylinders 1 to 3
ion current signal Pin 7 --> Pin 45 Pin 46 <-- Pin 7 ion current signal
cylinders 10 to 12 cylinders 4 to 6
Ground, ion Pin 5 -- Pin 44 Pin 47 -- Pin 5 Ground, ion current
current signals signals
Ignition trigger Pin 1 <-- Pin 37 Pin 49 --> Pin 1 Ignition trigger
signal, cylinder 7 signal, cylinder 1
Ignition trigger Pin 2 <-- Pin 2 Pin 1 --> Pin 2 Ignition trigger
signal, cylinder 8 signal, cylinder 2
Ignition trigger Pin 3 <-- Pin 35 Pin 24 --> Pin 3 Ignition trigger
signal, cylinder 9 signal, cylinder 3
Ignition trigger Pin 4 <-- Pin 14 Pin 28 --> Pin 4 Ignition trigger
signal, cylinder signal, cylinder 4
10
Ignition trigger Pin 13 <-- Pin 38 Pin 50 --> Pin 13 Ignition trigger
signal, cylinder signal, cylinder 5
11
Ignition trigger Pin 12 <-- Pin 36 Pin 51 --> Pin 12 Ignition trigger
signal, cylinder signal, cylinder 6
12
Ignition offset Pin 10 <-- Pin 29 Pin 15 --> Pin 10 Ignition offset
cylinders 7 to 12 cylinders 1 to 6
Ignition change Pin 11 <-- Pin 30 Pin 43 --> Pin 11 Ignition change
(ignition circuit (ignition circuit a/b)
a/b)
ECI ignition system
power pack (N91)
Battery voltage, Pin 15 <-- Pin 13 Pin 12 --> Pin 15 Battery voltage,
terminal 87 terminal 87
Ground Pin 8 -- Pin 14 Pin 11 -- Pin 8 Ground
Auxiliary voltage Pin 14 <-- Pin 8 Pin 7 --> Pin 14 Auxiliary voltage
approx. 23 approx. 23 V
Voltage approx. Pin 16 <-- Pin 16 Pin 9 --> Pin 16 Voltage approx. 180
180 V V
Voltage supply
Voltage supply --> Pin 4
Circuit 87 --> Pin 5
The short name for the AC ignition system ECI means:
E = Energy (energy)
C = Controlled (controlled)
I = Ignition (ignition system)
The ignition system ECI must initiate combustion by creating a spark at the spark plugs. This requires an
adequately high voltage for generating a spark at the end of the spark plug and the sparks must also have
sufficient energy to ensure guaranteed combustion of the fuel / air mixture.
The ignition system must be insensible to carbon fouled spark plugs and guarantee a high spark plug working
life.
The ignition system ECI consists of:
The ignition module ECI for the right cylinder bank
The ignition module ECI for the left cylinder bank
ECI ignition system mains unit
Evaluation circuit for the ion current in the ME control unit
Actuation of the ignition system ECI by the ME control unit
Ignition map in the ME control unit.
The ignition system ECI has the following sub-functions:
1. Generation of the ignition voltage (AC voltage).
There is an output stage for each spark plug in the ignition modules. The ignition coils are arranged in the
spark plug connectors. The output stages with oscillating circuit generate the ignition voltage from an
input of about 180 V.
The ME control unit produces the following actuation impulses:
Triggering of the ignition spark according to the ignition angle
Permanent control of the ignition process
Change of ignition
Ignition offset
2. Measurement of the ion current.
There is a switchover to ion current measurement at the end of the ignition spark phase and the ion
current on the spark plug is measured with the help of an auxiliary voltage of about 23 V. Evaluation of
the ion current signals takes place in the ME control unit. The signals are used for detection of
combustion misfires at high RPM.
3. The power pack generates the required voltages of two times about 180 volts and two times about 23
volts.
Fig. 85: Ignition Voltage Generation Circuit (AC Voltage)
Courtesy of MERCEDES-BENZ USA
Generation of the ignition voltage (AC voltage)
The ignition voltage is generated in two steps:
1. Transistor (T R) closed - the voltage U 180 is transferred to the secondary side.
2. Transistor (T R) opened - the negative half wave of the AC voltage develops and is also transferred to the
secondary side.
Control of the transistor can theoretically allow generation of an AC voltage of any desired duration and energy
level.
The maximum spark burning period is, however, limited by the rated output of the power pack ECI of two times
55 watts depending on the engine speed to about 0.15 to 1.5 msecs. A spark burning period of about 0.1 msecs
is usually quite adequate for guaranteed combustion of the fuel / air mixture.
The rapid increase in ignition voltage makes the ignition system ECI insensible to carbon fouled spark plugs
e.g. due to frequent cold starts.
Permanent control of the ignition process
Adjustment of the spark energy over the spark duration to the actually required ignition energy of the fuel / air
mixture occurs controlled by the ME control unit according to the performance map.
The spark plugs enjoy 4 times their usual working life due to spark duration control. Combining this at the same
time with the use of spark plugs with platinum electrodes allows the working life to be extended even further.
Ignition offset and ignition change
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.
Here the order of actuation is changed each 720° crank angle in order to achieve even wear of both spark plugs
in a cylinder and to prevent one-sided accumulation of deposits in the combustion chamber.
Ion current measurement
Ions are created in the flame front during combustion (particles which have various different electrical charges)
which balance each other out again in the burnt mixture. The application of a relatively small measuring voltage
to the end of the spark plug allows one to measure this ion current through the flame. The measuring voltage is
applied to the primary side of the ignition coils (auxiliary voltage of about 23 volts). This gives an AC voltage
on the secondary side of about 1 kV with about 65 kHz on the spark plug electrodes. The ion current modulates
this voltage. Decoupling and filtering allows one to obtain an ion current signal. The ion current signal gives
information about the rate of cylinder pressure with a degree of accuracy, which allows the detection of
combustion misfirings.
The ion current signal is transferred to the control unit ME for every 3 cylinders. The cylinder concerned in
each case is allocated in the control unit ME with the help of measuring windows.
The chemical formula for the creation of ions in the flame is:
CH + O --> CHO+ + e -
CHO+ + H2 O--> H3 O+ + CO
H3 O+ + e- --> H2 O + H
Fig. 86: View Of Ions In Flame
Courtesy of MERCEDES-BENZ USA
Ion current measurement at the spark plug delivers a signal directly from the combustion chamber without the
use of any additional components such as combustion chamber pressure sensors.
The measurement is taken after ignition has been initiated by both spark plugs and
The profiles of the ion current signal and cylinder pressure are the same during combustion.
Through this behavior, the evaluated ion current signal is used to detect combustion misfires reliably in all
operating conditions and at all engine speeds. This is used for actuating the spark duration, for spark plugs
diagnosis, for diagnosis according to OBD or EURO4 and for cylinder specific fuel cut-off.
a short waiting time. The measurement is only taken on the spark plug which first sparked. The distance
between the electrodes does not have any effect on the ion current signal.
Fig. 87: Behavior Pattern Of Ion Current Signal And Cylinder Pressure
Courtesy of MERCEDES-BENZ USA
ECI ignition system power pack location/task/design/function GF15.15-P-3100M
Ignition module, location/task/design/function GF15.15-P-3101M
ME-SFI control unit, location/task/design/function GF07.61-P-5000M
ECI IGNITION SYSTEM, FUNCTION - GF15.15-P-3000MOS
ENGINE 275.953 in MODEL 216.376, 221.176 as of Model Year 09 /AEJ 08
ENGINE 275.982 in MODEL 216.379, 221.179 as of Model Year 09 /AEJ 08
Function requirements for the ignition system, general points
Circuit 87M ON (engine control ON)
Ignition system, general points
The short name for the AC ignition system ECI means:
E = E nergy
C = C ontrolled
I = I gnition
The ECI ignition system initiates combustion by generating sparks at the spark plug (R4). To do this, it must
provide a sufficiently high voltage to cross the spark gap and sufficient energy to ignite the fuel-air mixture.
The ignition system is impervious to spark plug carbon fouling and ensures long service life for the spark plugs.
The ignition system ECI consists of:
ECI ignition system power pack (N91)
ECI ignition module, RH cylinder bank (N92/1)
ECI ignition module, LH cylinder bank (N92/2)
ME-SFI control unit (N3/10) (for evaluation of ionic current, actuation at "tml. 1", ignition maps)
Spark plugs
No spark tests can be carried out on the ECI ignition system.
ECI ignition system function sequence
The ECI ignition system is divided into the following subfunctions:
Ignition voltage generation function sequence
Ignition spark control function sequence
Ionic current measurement function sequence
Ignition voltage generation function sequence
The power pack generates the required ignition voltages (AC voltages) of 2 x 180 V approx. and the auxiliary
voltages of 2 X 23 V approx. for ionic current measurement.
One output stage per spark plug is provided in the ignition modules. The ignition coils are integrated in the
spark plug connectors. The output stages generate the ignition voltage from about 180 V.
The ignition voltage is generated in two steps:
1. Transistor closed in the ECI power pack - 180 V voltage transferred to the secondary side.
2. Transistor open in the ECI power pack - the negative half-wave of the AC voltage is generated and is also
transferred to the secondary side.
Control of the transistor can theoretically allow generation of an AC voltage of any desired duration and energy
level.
However, the maximum spark duration is limited by the rated output of the ECI power pack (2 x 55 W) to
between about 0.15 and 1.5 ms, depending on RPM. A spark duration of about 0.1 ms is sufficient to ignite the
mixture.
The rapid increase in ignition voltage makes the
The ECI ignition system is impervious to carbon fouling of the spark plugs, for example due to frequent cold
starts.
Ignition spark control function sequence
The ignition sparks are triggered by the ME-SFI control unit according to the ignition map.
Spark duration control
Adaptation of the spark energy by spark duration to the actual energy requirement for ignition of the fuel-air
mixture is map-controlled by ME-SFI control unit.
The spark plugs enjoy 4 times their usual working life due to spark duration control. Combining this at the same
time with the use of spark plugs with platinum electrodes allows the working life to be extended even further.
Ignition offset and ignition change
In the lower part load range up to approx. 2000 RPM both ignition sparks of a cylinder are triggered
simultaneously. At medium and high loads ignition is displaced by up to 10° CKA (C rank A ngle).
The actuation sequence is changed every 720° crank angle, to ensure even wear on the two spark plugs in the
cylinder and prevent single-sided deposits in the combustion chamber.
Ionic current measurement function sequence
When the ignition spark has ended, ionic current measurement is started and the ionic current at the spark plug
is measured with the auxiliary voltage of about 23 V. Evaluation of the ionic current signals takes place in the
ME control unit. The signals are used for detection of combustion misfires at high RPM.
ionic current measurement at the spark plug delivers a signal directly from the combustion chamber without the
use of any additional components such as combustion chamber pressure sensors.
The measurement is taken after a successful ignition at both spark plugs and a brief waiting time. The
measurement is only taken on the spark plug which first sparked. The electrode gap has no effect on the ionic
current signal.
During combustion, ions are created at the flame front (particles with different electrical charges), which are
balanced out again in the burnt fuel-air mixture.
By applying a relative low measurement voltage to the spark plug (about 23 V) after the spark has ended, the
ionic current can be measured through the flame.
The measurement voltage is applied to the primary side of the ignition coils. On the secondary side, this
produces an AC voltage of about 1 kV at 65 kHz at the spark plug electrodes. The ionic current modulates this
voltage.
Decoupling and filtering allows one to obtain an ionic current signal. The ionic current signal gives information
about cylinder pressure characteristics, with some accuracy, and can therefore be used to detect combustion
misfires.
The ionic current signal is transferred to the control unit ME for every 3 cylinders. The cylinder concerned in
each case is allocated in the control unit ME with the help of measuring windows.
Ionic current signal and cylinder pressure
The characteristics of the ionic current signal and cylinder pressure are the same during combustion.
The ionic current can thus be used to securely detect combustion misfires in all operating conditions and at all
engine speeds.
The ionic current signal is also used to control spark duration, and for spark plug diagnosis, diagnosis (as in on-
board diagnosis (OBD) or EURO4) and cylinder-specific fuel shutoff.
Fig. 88: Ionic Current Signal And Cylinder Pressure Behavior Patterns
Courtesy of MERCEDES-BENZ USA
ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MOS
ECI IGNITION SYSTEM POWER PACK, LOCATION - GF15.15-P-3100-01M
Fig. 89: Locating ECI Ignition System Power Pack
Courtesy of MERCEDES-BENZ USA
ECI IGNITION SYSTEM POWER PACK DESIGN - GF15.15-P-3100-02M
Fig. 90: Identifying ECI Ignition System Mains Unit
Courtesy of MERCEDES-BENZ USA
Electrical structure:
The DC converter is built discretely out of condensers, coils, transistors etc.. The DC voltages so generated
have a load dependent duty cycle of about 10 to 90%, while the frequency is about 20 kHz (180 volts) and 65
kHz (23 volts).
The ECI ignition system power pack is fitted with an electronic overload protection for the voltages 180 volts
and 23 volts. The outputs are switched off if a short-circuit or overload situation arises. They will remain locked
out until the ignition is switched on again.
Protection of the battery voltage which is looped to the ignition modules takes place on the vehicle side.
Mechanical structure:
An aluminum die cast housing with plastic cover.
The ignition must not be switched on without an earth connection to the power pack for the ignition system ECI
is order to avoid any damage occurring. The earth connection is achieved over the housing.
ECI IGNITION SYSTEM POWER PACK LOCATION/TASK/DESIGN/FUNCTION - GF15.15-P-
3100M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 91: ECI Ignition System Mains Unit Connector Assignment
Courtesy of MERCEDES-BENZ USA
Risk of death when touching
parts conducting high voltage After ignition OFF only disconnect the plug on the AS15.15-Z-
when the ignition is switched ECI ignition system power pack after 3 minutes. 0001-01A
off
ECI ignition system power pack GF15.15-P-
location 3100-01M
The ECI ignition system power pack generates:
23 volts as an auxiliary voltage for ion
task about 180 volts for generating the ignition
voltage.
Terminal 87 is also looped to each ignition module.
ECI ignition system power pack GF15.15-P-
design 3100-02M
DC voltage converter with two separate channels
ECI ignition system power pack
each with 55 watts for the ignition module on the
function
right and on the left. All outputs are protected.
LOCATION OF THE IGNITION MODULE - GF15.15-P-3101-01M
Fig. 92: Locating ECI Ignition Module (Right Cylinder Bank)
Courtesy of MERCEDES-BENZ USA
Fig. 93: Locating ECI Ignition Module (Left Cylinder Bank)
Courtesy of MERCEDES-BENZ USA
STRUCTURE OF AN IGNITION MODULE - GF15.15-P-3101-02M
Mechanical structure:
An aluminum die cast housing with plastic cover. One ignition module per cylinder bank with 12 ignition coils
integrated into the spark plug sockets.
Electrical structure:
Printed circuit board with discrete components (condensers, resistances etc.), microchip and ion current
evaluation filter. Oscillating circuit with control and regulating circuit for the ignition output stages.
Switching-over between the 180 volt main voltage and the auxiliary voltage (about 23 volts).
Fig. 94: Identifying ECI Ignition Modules
Courtesy of MERCEDES-BENZ USA
There are seals in the spark plug socket (1) to protect the ignition coils.
The seals (1) must be replaced for each removal/installation of ignition modules.
Fig. 95: Identifying Spark Plug Socket Seal
Courtesy of MERCEDES-BENZ USA
FUNCTION OF THE IGNITION MODULE - GF15.15-P-3101-03M
Fig. 96: Ignition Module Schematic
Courtesy of MERCEDES-BENZ USA
An L/C/R coil/condenser/resistance) - oscillating circuit with control and regulating circuit generates a 180 volt
AC voltage (primary voltage) for every spark plug. This is then stepped up in the ignition coils above in the
spark plug sockets to create the ignition voltage (secondary voltage).
Once ignition has taken place there is then a switch-over to the auxiliary voltage of about 23 volts. This is used
to measure the ion currents at the spark plugs.
The ion current signal is decoupled in the ignition module, filtered and then transferred over a screened cable to
the ME control unit.
IGNITION MODULE LOCATION/TASK/DESIGN/FUNCTION - GF15.15-P-3101M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Fig. 97: ECI Ignition Module Connector Assignment
Courtesy of MERCEDES-BENZ USA
Location of the GF15.15-P-
ignition module 3101-01M
Generation of ignition voltage (AC voltage) for each spark
plug.
Execute the ignition angle, spark period control, ignition offset
Ignition module
task and ignition change according to the signals from the ME
control unit
Detect the ion current signals, filter and transfer to the ME
control unit.
The spark plug connectors cannot be removed.
Structure of an GF15.15-P-
ignition module Only remove and install strictly according to manufacturer's 3101-02M
instructions in order to avoid damage to the die cast housing!
Function of the GF15.15-P-
ignition module 3101-03M
STARTER CONTROL, FUNCTION - GF15.30-P-3000AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211, 219
ENGINE 156.984 in MODEL 216, 221 up to Model Year 8
Fig. 98: Starter Control CAN Function Diagram
Courtesy of MERCEDES-BENZ USA
The starter control which is integrated in the ME control unit takes over the actuation of the starter and the
deactivation of the starter after reaching the engine starting speed.
Starting prerequisites
Actuation of the starter only takes place for "start enable" (drive authorization) from EIS [EZS] control unit and
by recognition of engaged drive position "P" or "N" by the electronic selector lever module control unit (for
model 209, 211, 219) or by the intelligent servo module for DIRECT SELECT (for model 164, 216, 221, 251).
Starting
Through actuation of ignition in the start position, the ME control unit receives the "tml. 50 signal" from the
EIS control unit via the CAN data bus. Start control is carried out automatically by the ME control unit (touch
start). It actuates the starter relay with a ground signal. The power contact on the starter relay closes and the
starter solenoid switch is supplied at "terminal 50" with voltage from "terminal 15 unfused".
Ending start
(dependent on the coolant temperature), the ME control unit interrupts the negative activation to the starter relay
and therefore ends the starting procedure.
Once the start operation is initiated, switching off "Terminal 50" (ignition/starter switch) has no further
influence on the starting procedure.
Component description for the coolant temperature sensor, component GF07.04-P-
B11/4
description 6040AMG
GF07.04-P-
Component description for the crankshaft Hall sensor B70
6220AMG
GF07.61-P-
Component description for the ME-SFI [ME] control unit N3/10
6000AMG
STARTER CONTROL, FUNCTION - GF15.30-P-3000M
ENGINE 275.950 in MODEL 215, 220
ENGINE 275.951 in MODEL 230 up to Model Year 8
ENGINE 275.953 in MODEL 216, 221 up to Model Year 8
ENGINE 275.954 in MODEL 230 up to Model Year 8
ENGINE 275.980 in MODEL 215, 220
ENGINE 275.981 in MODEL 230 up to Model Year 8
ENGINE 275.982 in MODEL 216, 221 up to Model Year 8
ENGINE 285.950 in MODEL 240
ENGINE 285.980 in MODEL 240
Illustrated model 215, 220, 230, 240
Fig. 99: Starter Control Function Diagram
Courtesy of MERCEDES-BENZ USA
The starter control takes over the actuation of the starter (M1) and interrupts the circuit (circuit 50) to the
solenoid switch of the starter (starter deactivation) after reaching the engine cranking speed.
By actuating the ignition starter switch at the electronic ignition switch control unit (N73), from position
"2" (ignition ON) in position "3" (START), starter detection is performed by the ME control unit (N3/10).
The solenoid switch of the starter is actuated by the ME control unit via the starter relay.
The voltage supply of the starter relay (coil) is supplied through circuit 87. The starter relay is actuated by the
ME control unit with a ground signal.
If the starting procedure has started, the actuation of the ignition starter switch from position "3" back into
position "2" no longer has any influence (touch start).
When reaching the engine cranking speed of 400 up to 700 RPM or a starting time of approx. 5 to 40 seconds
(dependent on the engine temperature), the ME control unit interrupts the negative activation to the starter relay
and therefore ends the starting procedure.
ME-SFI control unit, GF07.61-P-
location/task/design/ function 5000M
GF07.61-P-
Model 215, 220, 240
5001M
Voltage supply of ME-SFI control unit, GF07.61-P-
Model 216, 221
function 5001MS
GF07.61-P-
Model 230
5001R
Crankshaft position sensor, GF07.04-P-
location/task/design/function 4116M
Coolant temperature sensor, GF07.04-P-
location/task/design/function 5026M
Selector lever position information P/N and GF27.19-P-
ETC control unit, location/task
driving position engaged. Transmission 722.6 4012G
STARTER CONTROL, FUNCTION - GF15.30-P-3000MAS
ENGINE 156.984 in MODEL 216.377, 221.077 /177 as of Model Year 09 /AEJ 08
Function requirements for starter control general points
Circuit 87M ON (engine control ON)
Engine OFF
Drive authorization system 3 (DAS 3) start enable
Engaged gear range "P" or "N"
Starter control general points
Starter control which is integrated in the ME-SFI [ME] control unit (N3/10) takes over actuation and shutoff of
the starter (M1).
The ME-SFI control unit manages the starter control according to the following sensors and signals:
Coolant temperature sensor (B11/4)
Crankshaft Hall sensor (B70), motor speed
EIS control unit (N73), tml. 50 signal over the chassis CAN (CAN E)
Electric controller unit (VGS) (Y3/8), gear range over the drive train CAN (CAN C)
Starter control function sequence
The function sequence is subdivided into the following steps:
Start function sequence
End of start function sequence
Start function sequence
When the transmitter key (A8/1) is moved to the start position, the ME-SFI control unit receives the "tml. 50
signal" from the EIS control unit over the chassis CAN.
It then actuates terminal 50 starter relay (N10/1kH) with a ground signal. The power contact on the starter relay
closes and the starter solenoid switch is supplied at "circuit 50" with voltage from "circuit 30".
End of start function sequence
Start control is carried out automatically by the ME-SFI [ME] control unit (touch start). This means that if the
start process is initiated switching off of "circuit 50" has no further influence on the start process.
When the engine cranking speed of 400 to 700 RPM is reached, or after a starting time of about 5 to 40 s
(depending on coolant temperature), the ME-SFI control unit breaks off the negative activation of terminal 50
relay (starter) and thus terminates the start procedure.
The start sequence can only be aborted by switching off the ignition.
Model 216 PE15.30-P-2051-97CAC
Electrical function schematic for starter control
Model 221 PE15.30-P-2051-97SAC
ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MAS
STARTER CONTROL, FUNCTION - GF15.30-P-3000MIS
ENGINE 272.9 (except 272.974) in MODEL 221.0 /1 (except 221.095 /195) as of model year 2009 /AEJ 08
ENGINE 273.9 in MODEL 216.3, 221.0 /1 as of model year 2009 / AEJ 08
Function requirements for starter control, general points
Circuit 87M ON (engine control ON)
Engine OFF
Drive authorization system 3 (DAS 3) start enable
Engaged gear range "P" or "N"
Starter control, general points
Starter control which is integrated in the ME-SFI [ME] control unit (N3/10) takes over actuation and shutoff of
the starter (M1). For the starter control, the ME-SFI [ME] control unit reads the following sensors and signals:
Coolant temperature sensor (B11/4)
Crankshaft Hall sensor (B70), engine speed
EIS control unit (N73), circuit 50 signal via the chassis CAN (CAN E)
Electric controller unit (VGS) (Y3/8), gear range via the drive train CAN (CAN C)
Starter control function sequence
The function sequence is subdivided into the following steps:
Start function sequence
End of start function sequence
Start function sequence
The ME-SFI [ME] control unit receives the "circuit 50 signal" from the EIS [EZS] control unit via the chassis
CAN by actuating the transmitter key (A8/1) in the start position.
This control unit actuates the circuit 50 starter relay (N10/1kH) with a ground signal. The power contact on the
starter relay closes and the starter solenoid switch is supplied at "circuit 50" with voltage from "circuit 30".
End of start function sequence
Start control is carried out automatically by the ME-SFI [ME] control unit (touch start). This means that if the
start process is initiated switching off of "circuit 50" has no further influence on the start process.
When engine cranking speed has reached 400 to 700 RPM, or after a starting time of 5 to 40 s (depending on
coolant temperature), the ME-SFI [ME] control unit interrupts the negative activation of the circuit 50 starter
relay and thus terminates the start sequence.
The start sequence can only be aborted by switching off the ignition.
Electrical function schematic for Model 216 PE15.30-P-2051-97CAB
starter control Model 221 PE15.30-P-2051-97SAB
Component description for ME-SFI N3/10 Engine 272 GF07.61-P-6000MIS
[ME] control unit N3/10 Engine 273 GF07.61-P-6000MLS
STARTER CONTROL, FUNCTION - GF15.30-P-3000MOS
ENGINE 275.953 in MODEL 216.376, 221.176 as of Model Year 09 /AEJ 08
ENGINE 275.982 in MODEL 216.379, 221.179 as of Model Year 09 /AEJ 08
Function requirements for starter control, general points
Circuit 87M ON (engine control ON)
Engine OFF
Drive authorization system 3 (DAS 3) start enable
Engaged gear range "P" or "N"
Starter control, general points
Starter control which is integrated in the ME-SFI [ME] control unit (N3/10) takes over actuation and shutoff of
the starter (M1).
For the starter control, the ME-SFI control unit reads the following sensors and signals:
Coolant temperature sensor (B11/4)
Crankshaft position sensor (L5), motor speed
EIS control unit (N73), tml. 50 signal over the chassis CAN (CAN E)
ETC control unit (N15/3), gear range over the drive train CAN (CAN C)
Starter control function sequence
The function sequence is subdivided into the following steps:
Start function sequence
End of start function sequence
Start function sequence
When the transmitter key (A8/1) is moved to the start position, the ME-SFI control unit receives the "tml. 50
signal" from the EIS control unit over the chassis CAN.
It then actuates terminal 50 starter relay (N10/1kH) with a ground signal. The power contact on the starter relay
closes and the starter solenoid switch is supplied at "circuit 50" with voltage from "circuit 30".
End of start function sequence
Start control is carried out automatically by the ME-SFI [ME] control unit (touch start). This means that if the
start process is initiated switching off of "circuit 50" has no further influence on the start process.
When the engine cranking speed of 400 to 700 RPM is reached, or after a starting time of about 5 to 40 s
(depending on coolant temperature), the ME-SFI control unit breaks off the negative activation of terminal 50
relay (starter) and thus terminates the start procedure.
The start sequence can only be aborted by switching off the ignition.
Electrical function Model 216 PE15.30-P-2051-97CAA
schematic for starter
Model 221 PE15.30-P-2051-97SAA
control
ME-SFI [ME] control N3/10 GF07.61-P-6000MOS
unit, component
description
STARTER CONTROL, FUNCTION - GF15.30-P-3000VA
ENGINE 272.920 in MODEL 203 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.922 in MODEL 211 with automatic transmission 722.9
ENGINE 272.940 in MODEL 203 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.941 in MODEL 203 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.942 in MODEL 171 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.943 in MODEL 211, 219 with automatic transmission 722.9
ENGINE 272.944 in MODEL 211 with automatic transmission 722.9
ENGINE 272.945 in MODEL 251 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.946 in MODEL 221 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.960 in MODEL 203 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.963 in MODEL 171 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.964 in MODEL 211, 219 with automatic transmission 722.9
ENGINE 272.965 in MODEL 221 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.966 in MODEL 230 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.970 in MODEL 203 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.972 in MODEL 211 with automatic transmission 722.9
ENGINE 272.975 in MODEL 221 up to Model Year 8 with automatic transmission 722.9
ENGINE 273.922 in MODEL 221 up to Model Year 8 with automatic transmission 722.9
ENGINE 273.923 in MODEL 164 up to Model Year 8 with automatic transmission 722.9
ENGINE 273.924 in MODEL 221 up to Model Year 8 with automatic transmission 722.9
ENGINE 273.960 in MODEL 211, 219 with automatic transmission 722.9
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8 with automatic transmission 722.9
ENGINE 273.962 in MODEL 211 with automatic transmission 722.9
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8 with automatic transmission 722.9
ENGINE 273.965 in MODEL 230 up to Model Year 8 with automatic transmission 722.9
ENGINE 273.967 in MODEL 209 with automatic transmission 722.9
ENGINE 273.968 in MODEL 221 up to Model Year 8 with automatic transmission 722.9
ENGINE 272.940 in MODEL 209 with automatic transmission 722.9
ENGINE 272.960 in MODEL 209 with automatic transmission 722.9
Shown on Engine 272.963 in Model 171
Fig. 100: Starter Control Function Diagram
Courtesy of MERCEDES-BENZ USA
Starter control actuates the starter and provides the circuit (terminal 50) when the engine speed is achieved to
the starter solenoid switch (starter disconnection).
By operating the ignition start switch on the EIS control unit, from position "2" (ignition ON) to position
"3" (START), the ME control unit detects the start
The solenoid switch of the starter is actuated by the ME-SFI control unit via the starter relay.
The voltage supply of the starter relay (coil) is supplied through circuit 87. The starter relay is actuated by the
ME-SFI control unit with a ground signal.
If the starting procedure has started, the actuation of the ignition starter switch from position "3" back into
position "2" no longer has any influence (touch start).
When reaching the engine cranking speed of 400 up to 700 RPM or a starting time of approx. 5 to 40 seconds
(dependent on the engine temperature), the ME control unit interrupts the negative activation to the starter relay
Component description for the ME-SFI [ME] control unit GF07.61-P-6000V
Voltage supply of ME-SFI control unit, function Model 171, 211, 219 GF07.61-P-5001V
Model 164, 251 GF07.61-P-5001VA
Model 203, 209 GF07.61-P-5001VB
Model 216, 221 GF07.61-P-5001VC
Model 230 GF07.61-P-5001VD
Component description for the crankshaft Hall sensor GF07.04-P-6220V
Component description for the coolant temperature sensor GF07.04-P-6040V
POWER SUPPLY FOR ON-BOARD ELECTRICAL SYSTEM, LOCATION OF COMPONENTS -
GF15.40-P-0001-02AA
Shown on model 211 with 642
Fig. 101: Locating On-Board Electrical System Power Supply Components
Courtesy of MERCEDES-BENZ USA
ON-BOARD ELECTRICAL SYSTEM POWER SUPPLY, FUNCTION - GF15.40-P-0001B
ENGINES 271 in MODEL 171, 203 up to Model Year 08 /Modification Year 07 valid with engine control
unit variant SIM 4 only
ENGINES 275 in MODEL 221, 216, 230 up to Model Year 08 /Modification Year 07 valid with engine
control unit variant ME 2.7.1 only
ENGINES 285 in MODEL 240 only valid with engine control unit variant ME 2.7.1
ENGINES 628 in MODEL 163, 211, 220 only valid with engine control unit variant CDI V1
ENGINES 646 in MODEL 203 up to Model Year 08 /Modification Year 07 valid with engine control unit
variant CDI 3 (UP) only
ENGINES 648 in MODEL 211, 220 only valid with engine control unit variant CDI 3 (UP)
ENGINES 271 in MODEL 209, 211 valid with engine control unit variant SIM 4 only
ENGINES 646 in MODEL 209, 211 valid with engine control unit variant CDI 3 (UP) only
Shown on model 211 with engine 271
Networking
Fig. 102: On-Board Electrical System Power Supply Networking Of Components - (Model 211 With
Engine 271)
Courtesy of MERCEDES-BENZ USA
Shown on model 211 with engine 648
Networking
Fig. 103: On-Board Electrical System Power Supply Networking Of Components - (Model 211 With
Engine 648)
Courtesy of MERCEDES-BENZ USA
General
When the engine is running, the alternator supplies the on-board electrical system with electrical energy and
charges the battery. For this purpose, the alternator generates three-phase current which is rectified. A bit
synchronous data interface is used as the alternator interface between the ME-SFI [ME] control unit or CDI
control unit and the alternator. The data rate between the engine control unit and alternator is up to 1250 bit/s.
Function and task
Messages between the engine control unit and the alternator are exchanged via the alternator interface. This
follows the master-slave principle. The engine control unit is the master and the alternator acts as the slave. The
alternator only sends when it is requested to do so by the master. The following tasks are performed:
Switching on of the alternator after the engine has been started, and regulation of the alternator according
to the information stored in the engine control unit. To do this, the control voltage is preset by the engine
control unit.
Protecting the alternator against overheating.
Delayed adaptation of the regulation voltage in the case of a major change in alternator load.
Generation of terminal 61 (information "alternator is turning") in the engine control unit.
The alternator constantly performs self-diagnosis and sends the results when requested to the engine control
unit. The engine control unit compares them with other signals (e.g. engine speed, battery voltage and time after
engine start) and detects the following faults:
Electrical and mechanical faults at the alternator (regulator or diodes defective, stator interruption or short
circuit, exciter interruption, regulation voltage and charging current may not be achieved, regulation
voltage too high, cracked or loose poly-V belt).
Short circuit or open circuit at output terminal 61 of engine control unit.
Line for the alternator interface interrupted between engine control unit and alternator. With this fault, the
alternator operates using its fixed parameters. A regulation voltage of approx. 14.3 V is predefined.
The DFM connection outputs a signal which indicates the capacity utilization of the alternator.
This signal is used for electrical control of the engine heater booster. In model series 211, the AAC [KLA]
control and operating unit evaluates the signal and regulates the heater booster according to the alternator load
condition.
Networking
The engine control unit uses the alternator interface to control the control response of the alternator in order to
reduce, in idle, the generator torque which is produced at a high power output. As a result of the reduced engine
load, less fuel is injected and the exhaust characteristics are optimized.
Terminal 61 is simulated in the control unit using the information which the ME-SFI [ME] engine control unit
or CDI engine control unit receives via the alternator interface. This information is supplied to the driver-side
SAM control unit with fuse and relay module via Controller Area Network bus class C or via a signal line.
The driver-side SAM control unit with fuse and relay module conditions the signal and makes it available to the
instrument cluster via Controller Area Network bus class B.
The upper limit value of the regulation voltage can be up to approx. 15 V.
Engine speed
Depending on the variant, the pulses from the Hall sensor or position sensor on the crankshaft are read in by the
ME-SFI [ME] control unit or CDI control unit.
The control unit relays the "engine speed" (in RPM) message onto the CAN-C.
Diagnosis
The following faults are detected after "ignition ON" and may be stored as a fault entry in the ME-SFI [ME]
engine control unit or CDI engine control unit:
Alternator interface defective
Line interruption (circuit 30)
The following faults are detected after "engine start" and may be stored as a fault entry in the ME-SFI [ME]
engine control unit or CDI engine control unit:
Electrical fault at alternator
Mechanical fault at alternator
Line interruption (circuit 30)
Undervoltage and defective alternator interface
The "battery symbol" and the "Visit workshop" message also appear in the multifunction display in the
instrument cluster.
This fault message in the multifunction display in the instrument cluster can also be triggered by information
from the following control units:
Battery control unit (N82)
EIS [EZS] control unit (N73)
If malfunctions occur, always perform an alternator diagnosis using the diagnosis assistance system (DAS).
Emergency running
If the communication between the alternator and engine control unit is interrupted, the alternator continues to
run at its fixed default parameters during normal engine operation.
The test prerequisites for the alternator test are listed in the DAS and must always be observed. The test itself is
a test routine and is menu-assisted.
Emergency start
The alternator has an emergency start function. If the communication between the alternator and engine control
unit is interrupted, the alternator can, depending on the rotational speed, generate a voltage from the residual
magnetism.
If, on the basis of the voltage and frequency, the regulator detects that the alternator is rotating, it automatically
begins energizing of the field and enters regulation mode.
Limitations:
The "regulation OFF" command from the control unit interrupts this emergency running state.
Precise specification of the starting speed for the emergency start function is not possible.
On-board electrical system power supply Location of components GF15.40-P-0001-02AA
Component description for the alternator GF15.40-P-2000A
ON-BOARD ELECTRICAL SYSTEM POWER SUPPLY, FUNCTION - GF15.40-P-0001C
ENGINES 266 in MODEL 169, 245 up to Model Year 08 /Modification Year 07 valid with engine control
unit variant SIM 266 only
ENGINES 272 in MODEL 230, 171, 203, 221, 164, 251 up to Model Year 08 /Modification Year 07 valid
with engine control unit variant ME 9.7 only
ENGINES 273 in MODEL 221, 230 up to Model Year 08 /Modification Year 07 valid with engine control
unit variant ME 9.7 only
ENGINES 275 in MODEL 221, 216, 230 up to Model Year 08 /Modification Year 07 valid with engine
control unit variant ME 2.7.2 only
ENGINES 629 in MODEL 164, 221 up to Model Year 08 /Modification Year 07 valid with engine control
unit variant CDI 5 only
ENGINES 640 in MODEL 169, 245 up to Model Year 08 /Modification Year 07 valid with engine control
unit variant CDI A only
ENGINES 642 in MODEL 164, 203, 221, 251 up to Model Year 08 /Modification Year 07 valid with
engine control unit variant CDI 4 only
ENGINES 646 in MODEL 211 only valid with engine control unit variant CDI D
ENGINES 642 in MODEL 463 only valid with engine control unit variant CDI 4
ENGINES 272 in MODEL 209, 211, 219 valid with engine control unit variant ME 9.7 only
ENGINES 273 in MODEL 211, 219 valid with engine control unit variant ME 9.7 only
ENGINES 629 in MODEL 211 valid with engine control unit variant CDI 5 only
ENGINES 642 in MODEL 209, 211, 219 valid with engine control unit variant CDI 4 only
Shown on model 211 with engine 272
Networking
Fig. 104: On-Board Electrical System Power Supply Networking Of Components - Model 211 With
Engine 272
Courtesy of MERCEDES-BENZ USA
Shown on model 211 with engine 642
Networking
Fig. 105: On-Board Electrical System Power Supply Networking Of Components - Model 211 With
Engine 642
Courtesy of MERCEDES-BENZ USA
General
When the engine is running, the alternator supplies the on-board electrical system with electrical energy and
charges the battery. For this purpose, the alternator generates three-phase current which is rectified. A local
interconnect network is used as the alternator interface between the engine control unit and the alternator. The
LIN bus is a bidirectional single-wire interface with a maximum transfer rate of 20 kbit/s.
Function and task
Messages between the engine control unit and the alternator are exchanged via the alternator interface. This
follows the master-slave principle. The engine control unit is the master and the alternator acts as the slave. The
alternator only sends when it is requested to do so by the master. The following tasks are performed:
Switching on of the alternator after the engine has been started, and regulation of the alternator according
to the information stored in the engine control unit. To do this, the control voltage is preset by the engine
control unit.
Delayed adaptation of the regulation voltage in the case of a major change in alternator load.
Protecting the alternator against overheating.
Generation of terminal 61 (information "alternator is turning") in the engine control unit.
unit. The engine control unit compares them with other signals (e.g. engine speed, battery voltage and time after
engine start) and detects the following faults:
Electrical and mechanical faults at the alternator (regulator or diodes defective, stator interruption or short
circuit, exciter interruption, regulation voltage and charging current may not be achieved, regulation
voltage too high, cracked or loose poly-V belt).
Line for the alternator interface interrupted between engine control unit and alternator. With this fault, the
alternator operates using its fixed parameters. A regulation voltage of approx. 14.3 V is predefined.
Short circuit or open circuit at output terminal 61 of engine control unit.
Networking
The engine control unit uses the alternator interface to control the control response of the alternator in order to
reduce, in idle, the generator torque which is produced at a high power output. As a result of the reduced engine
load, less fuel is injected and the exhaust characteristics are optimized.
Terminal 61 in the engine control unit is simulated using information which the engine control unit receives via
the alternator interface. This information is supplied to the driver-side SAM control unit with fuse and relay
module via Controller Area Network bus class C or via a signal line.
The driver-side SAM control unit with fuse and relay module conditions the signal and makes it available to the
instrument cluster via Controller Area Network bus class B.
The upper limit value of the regulation voltage can be up to approx. 15 V.
Engine speed
Pulses from the Hall sensor or position sensor to the crankshaft are read in by the engine control unit.
The engine control unit sends the motor speed (in RPM) message to the Controller Area Network bus Class C.
Diagnosis
The following faults are detected after "ignition ON" and may be stored as a fault entry in the engine control
unit:
Alternator interface defective
Line interruption (circuit 30)
The following faults are detected after "Engine start" and may be stored as a fault entry in the engine control
unit:
Electrical fault at alternator
Mechanical fault at alternator
Line interruption (circuit 30)
Undervoltage and defective alternator interface.
The "battery symbol" and the "Visit workshop" message also appear in the multifunction display in the
instrument cluster. This fault message in the multifunction display in the instrument cluster can also be
triggered by information from the following control units:
Battery control module
EIS [EZS] control unit
Test prerequisites for the alternator test are listed in the diagnosis assistance system (DAS) and must always
be observed. The test itself is a test routine and is menu-assisted.
Emergency running
If communication between the alternator and engine control unit is interrupted, the alternator continues to run at
its fixed default parameters during normal engine operation
Emergency start
The alternator has an emergency start function. If the communication between the alternator and engine control
unit is interrupted, the alternator can build up a voltage via the residual magnetism depending on the rotational
speed. If, on the basis of the voltage and frequency, the regulator detects that the alternator is rotating, it
automatically begins energizing of the field and enters regulation mode.
Limitations:
The command "Regulation Off" from the engine control unit interrupts this limp-home.
Precise specification of the starting speed for the emergency start function is not possible.
Engine 272 in model 171, 203, 209, 211, 219, 221, 230 only
valid with engine control unit variant ME 9.7
Engine 273 in model 211, 219, 221, 230 only valid with
engine control unit variant ME 9.7
On-board electrical system Engine 275 in model 216, 221, 230 only valid with engine
GF15.40-P-
power supply Location of control unit variants ME 2.7.1, ME 2.7.2
0001-02AA
components Engine 629 in model 211, 221 valid with engine control unit
variant CDI 5 only Engine 642 in model 203, 209, 211, 219,
221 only valid with engine control unit variants CDI 4
Engine 646 in model 211, only valid with engine control
unit variant CDI D
Engine 272 in model 164, 251 valid with engine control unit
variant ME 9.7 only Engine 629 in model 164, only valid
with engine control unit variant CDI 5 GF15.40-P-
Engine 642 in model 164, 251 only valid with engine 0001-02AB
control unit variant CDI 4
variant CDI 4 only
Engine 266 in model 169, 245 only valid with engine
control unit variant SIM 266 GF15.40-P-
Engine 640 in model 169, 245 only valid with engine 0001-02AC
control unit variant CDI A
Component description for GF15.40-P-
the alternator 2000A
TABLE OF CONTENTS FOR FUNCTION DESCRIPTION ON-BOARD ELECTRICAL SYSTEM
POWER SUPPLY - GF15.40-P-0999A
ENGINE 112, 113 in MODEL 203, 209, 211, 220, 230 only valid with engine control unit variant ME 2.8
ENGINE 113 in MODEL 164, 171, 215, 219, 251 only valid with engine control unit variant ME 2.8
ENGINE 155 in MODEL 199 only valid with engine control unit variant ME 2.8
ENGINE 266 in MODEL 169, 245 only valid with engine control unit variant SIM 266
ENGINE 271 in MODEL 171, 203, 209, 211 only valid with engine control unit variant SIM 4
ENGINE 272 in MODEL 164, 171, 203, 209, 211, 219, 221, 230, 251 only valid with engine control unit
variant ME 9.7
ENGINE 273 in MODEL 211, 219, 221, 230 only valid with engine control unit variant ME 9.7
ENGINE 275 in MODEL 216, 221, 230 only valid with engine control unit variant ME 2.7.1, ME 2.7.2
ENGINE 285 in MODEL 240 only valid with engine control unit variant ME 2.7.1
ENGINE 628 in MODEL 163, 211, 220 only valid with engine control unit variant CDI V1
ENGINE 629 in MODEL 164, 211, 221 only valid with engine control unit variant CDI 5
ENGINE 640 in MODEL 169, 245 only valid with engine control unit variant CDI A
ENGINE 642 in MODEL 164, 203, 209, 211, 219, 221, 251 only valid with engine control unit variant CDI
4
ENGINE 646 in MODEL 203, 209, 211 only valid with engine control unit variant CDI 3, CDI 3 (UP),
CDI D
ENGINE 647 in MODEL 211 only valid with engine control unit variant CDI 3
ENGINE 648 in MODEL 211, 220 only valid with engine control unit variant CDI 3, CDI 3 (UP)
ENGINE 642 in MODEL 463 only valid with engine control unit variant CDI 4
Alternator with multifunction regulator (MFR) without
interface:
Engine 112, 113 in model 203, 209, 211, 220, 230 only
valid with engine control unit variant ME 2.8
Engine 113 in model 164, 171, 215, 219, 251 only valid
with engine control unit variants CDI 2.8
On-board electrical system Engine 155 in model 199, only valid with engine control GF15.40-P-
power supply, function unit variant CDI 2.8 0001A
Engine 646 in model 211, only valid with engine control
unit variant CDI 3
Engine 647 in model 211, only valid with engine control
unit variant CDI 3
Engine 648 in model 211, 220 only valid with engine
control unit variant CDI 3
GF15.40-P-
Alternator with bit synchronous data interface (BSS)
0001B
Engine 271 in model 171, 211, 203, 209 only valid with
engine control unit variant SIM 4
Engine 275 in model 216, 221, 230 only valid with engine
control unit variant ME 2.7.1
Engine 285 in model 240, only valid with engine control
unit variant ME 2.7.1
Engine 628 in model 163, 211, 220 only valid with engine
control unit variant CDI V1
Engine 646 in model 203, 209, 211 only valid with engine
control unit variant CDI 3 (UP) Engine 648 in model 211,
220 only valid with engine control unit variant CDI 3 (UP)
Alternators with local interconnect network (LIN)
interface:
Engine 266 in model 169, 245 only valid with engine
control unit variant SIM 266
Engine 272 in model 164, 171, 203, 209, 211, 219, 221,
230, 251 only valid with engine control unit variant ME 9.7
Engine 273 in model 211, 219, 221, 230 only valid with
engine control unit variant ME 9.7
Engine 275 in model 216, 221, 230 only valid with engine GF15.40-P-
control unit variant ME 2.7.2 0001C
Engine 629 in model 164, 211, 221 only valid with engine
control unit variant CDI 5
Engine 640 in model 169, 245 only valid with engine
control unit variant CDI A
Engine 642 in model 164, 203, 209, 211, 219, 221, 251
only valid with engine control unit variant CDI 4
Engine 646 in model 211, only valid with engine control
Engine 642 in model 463, only valid with engine control
unit variant CDI 4
Engine 112, 113 in model 203, 209, 211, 220, 230
Engine 113 in model 171, 215, 219
Engine 155 in model 199
Engine 271 in model 171, 203, 209, 211
Engine 272 in model 171, 203, 209, 211, 219, 221, 230
Engine 273 in model 211, 219, 221, 230
On-board electrical system
Engine 275 in model 216, 221, 230 GF15.40-P-
power supply Location of
Engine 285 in model 240 0001-02AA
components
Engine 628 in model 163, 211, 220
Engine 629 in model 211, 221
Engine 642 in model 203, 209, 211, 219, 221
Engine 646 in model 203, 209, 211
Engine 647 in model 211
Engine 648 in model 211, 220
Engine 113 in model 164, 251 only valid with engine
control unit variant ME 2.8
Engine 272 in model 164, 251 only valid with engine
control unit variant ME 9.7
Engine 629 in model 164, only valid with engine control GF15.40-P-
unit variant CDI 5 0001-02AB
Engine 642 in model 164, 251 only valid with engine
control unit variant CDI 4
Engine 642 in model 463, only valid with engine control
unit variant CDI 4
Engine 266 in model 169, 245 only valid with engine
control unit variant SIM 266 GF15.40-P-
Engine 640 in model 169, 245 only valid with engine 0001-02AC
control unit variant CDI A
Overview of system
components On-board GF15.40-P-
electrical system power 9999A
supply
COMPONENT DESCRIPTION FOR THE ALTERNATOR - GF15.40-P-2000A
ENGINE 112, 113 in MODEL 203, 209, 211, 220, 230 only valid with engine control unit variant ME 2.8
ENGINE 113 in MODEL 164, 171, 215, 219, 251 only valid with engine control unit variant ME 2.8
ENGINE 155 in MODEL 199 only valid with engine control unit variant ME 2.8
ENGINE 266 in MODEL 169, 245 only valid with engine control unit variant SIM 266
ENGINE 271 in MODEL 203, 209, 211, 171 only valid with engine control unit variant SIM 4
ENGINE 272 in MODEL 164, 171, 203, 209, 211, 219, 221, 230, 251 only valid with engine control unit
variant ME 9.7
ENGINE 273 in MODEL 211, 219, 221, 230 only valid with engine control unit variant ME 9.7
ENGINE 275 in MODEL 216, 221, 230 only valid with engine control unit variant ME 2.7.1, ME 2.7.2
ENGINE 285 in MODEL 240 only valid with engine control unit variant ME 2.7.1
ENGINE 628 in MODEL 163, 211, 220 only valid with engine control unit variant CDI V1
ENGINE 629 in MODEL 164, 211, 221 only valid with engine control unit variant CDI 5
ENGINE 640 in MODEL 169, 245 only valid with engine control unit variant CDI A
ENGINE 642 in MODEL 164, 203, 209, 211, 219, 221, 251 only valid with engine control unit variant CDI
4
ENGINE 646 in MODEL 203, 209, 211 only valid with engine control unit variant CDI 3, CDI 3 (UP),
CDI D
ENGINE 647 in MODEL 211 only valid with engine control unit variant CDI 3
ENGINE 648 in MODEL 211, 220 only valid with engine control unit variant CDI 3, CDI 3 (UP)
ENGINE 642 in MODEL 463 only valid with engine control unit variant CDI 4
Fig. 106: Identifying Alternator Components
Courtesy of MERCEDES-BENZ USA
Assignment of connection for signal lines
Connector on alternator, pin 1:
Alternator with multifunction regulator without interface: Connection for alternator (G2) to driver-side
SAM control unit with fuse and relay module (N10/1)
Alternators with bit synchronous data interface (BSS): Connection for alternator to engine control unit
ME (N3/10) or CDI (N3/9)
Alternators with local interconnect network interface (LIN): Connection for alternator to engine control
unit ME or CDI
Connector on alternator, pin 2:
This is a Dynamo Field Monitor (DFM) signal. It provides information about the load condition of the
alternator. This signal is used for electrical control of the engine heater booster. In model series 211 the
AAC [KLA] control and operating unit (N22) evaluates the signal and regulates the heater booster
(R22/3) depending on the alternator load.
Pre-excitation power circuit
Alternators receive the pre-or excitation current directly from the battery (G1), via circuit B+ at the alternator.
The switch-on signal at Pin 1 of the alternator takes place:
for multifunction regulator without interface with a discrete signal from the driver-side SAM control unit
with fuse and relay module
for BSS or LIN interface with a valid message from the engine control unit
Excitation power circuit
Alternator are self-exciting power generators. The excitation current builds up the magnetic field in the
excitation coil of the rotor. It is branched off from the current flowing in the three-phase AC winding.
Charge power circuit
The charge power circuit supplies the on-board electrical system with electrical energy.
Control
Regulation of alternator with multifunction regulator takes place by integral electronics depending on the
rotational speed and on-board power supply voltage.
For alternators with BSS or a LIN interface the engine management intervenes in the regulation.
Overview of system components On-board electrical system power supply GF15.40-P-9999A
OVERVIEW OF SYSTEM COMPONENTS ON-BOARD ELECTRICAL SYSTEM POWER SUPPLY -
GF15.40-P-9999A
ENGINE 112, 113 in MODEL 203, 209, 211, 220, 230 only valid with engine control variant ME 2.8
ENGINE 113 in MODEL 164, 171, 215, 219, 251 only valid with engine control variant ME 2.8
ENGINE 155 in MODEL 199 only valid with engine control variant ME 2.8
ENGINE 266 in MODEL 169, 245 only valid with engine control variant SIM 266
ENGINE 271 in MODEL 203, 209, 211, 171 only valid with engine control variant SIM 4
ENGINE 272 in MODEL 164, 171, 203, 209, 211, 219, 221, 230, 251 only valid with engine control variant
ME 9.7
ENGINE 273 in MODEL 211, 219, 221, 230 only valid with engine control variant ME 9.7
ENGINE 275 in MODEL 216, 221, 230 only valid with engine control variant ME 2.7.1, ME 2.7.2
ENGINE 285 in MODEL 240 only valid with engine control variant ME 2.7.1
ENGINE 628 in MODEL 163, 211, 220 only valid with engine control variant CDI V1
ENGINE 629 in MODEL 164, 211, 221 only valid with engine control variant CDI 5
ENGINE 640 in MODEL 169, 245 only valid with engine control variant CDI A
ENGINE 642 in MODEL 164, 203, 209, 211, 219, 221, 251 only valid with engine control variant CDI 4
ENGINE 646 in MODEL 203, 209, 211 only valid with engine control variant CDI 3, CDI 3 (UP), CDI D
ENGINE 647 in MODEL 211 only valid with engine control variant CDI 3
ENGINE 648 in MODEL 211, 220 only valid with engine control variant CDI 3, CDI 3 (UP)
ENGINE 642 in MODEL 463
Component description for the alternator GF15.40-P-2000A
Table of contents for function description On-board electrical system power supply GF15.40-P-0999A
WIRING DIAGRAMS
OVERVIEW OF WIRING DIAGRAMS FOR ELECTRICAL SYSTEM, ENGINE - PE15.00-P-
1100SAA
ENGINES 629, 642, 651, 156, 157, 272, 273, 275, 276, 278 in MODEL 221
Wiring diagram for starter, ENGINE 629, 642, 156, 272, 273 PE15.00-P-2000-97SAA
alternator in MODEL 221.0/1 up to model
ENGINE 275 in MODEL 221.1 up
to model year 2009 /AEJ08
Wiring diagram for starter, ENGINE 629, 642, 156, 272, 273 PE15.00-P-2000-97SAB
alternator in MODEL 221.0/1 as of model
year 2009 /AEJ08
ENGINE 275 in MODEL 221.1 as
of model year 2009 /AEJ08
Wiring diagram for starter, ENGINE 157, 276, 278, 642.8, PE15.00-P-2101-97SAA
alternator, battery 651 in MODEL 221.0/1
Wiring diagram for engine ENGINE 157, 276, 278, 651 in PE15.00-P-2103-97SAA
Start/Stop MODEL 221.0/1 with CODE
(B03) ECO start/stop function
WIRING DIAGRAM FOR STARTER, ALTERNATOR - PE15.00-P-2000-97SAA
ENGINE 629, 642, 156, 272, 273 in MODEL 221.0 /1 up to model year 08 /AEJ 07
ENGINE 275 in MODEL 221.1 up to model year 08 /
Code: Designation: Position:
A0 Color code key 56L
F32 Front prefuse 39L
F32 Front prefuse 45L
F32 Front prefuse 53L
F32 Front prefuse 3L
F32 Front prefuse 15L
F32 Front prefuse 9L
F32f1 Fuse 1 45K
F32f10 Fuse 10 3H
F32f2 Fuse 2 39K
F32f2 Fuse 2 46K
F32f6 Fuse 6 14J
F32f9 Fuse 9 52K
F32k1 Battery coupling relay 4L
G1 On-board electrical system battery 2L
G1/4 Starter battery 16L
G2 Alternator 50L
M1 Starter 43L
N10/1 Front SAM control unit with fuse 28A
and relay module
N10/1 Front SAM control unit with fuse 36A
and relay module
N10/1 Front SAM control unit with fuse 45A
and relay module
N10/1 Front SAM control unit with fuse 20A
and relay module
N10/1 Front SAM control unit with fuse 54A
and relay module
N10/1 Front SAM control unit with fuse 14A
and relay module
N10/1f21 Fuse 21 24B
N10/1kC Circuit 87 relay, engine 23A
N10/1kH Circuit 50 relay, starter 41A
N10/1kJ Circuit 15 relay, starter 51A
N14/3 Glow time output stage 34L
N3/10 ME-SFI [ME] control unit 19L
N3/10 ME-SFI [ME] control unit 23L
N3/9 CDI control unit 28L
N82/1 Vehicle power supply control unit 4A
N82/1 Vehicle power supply control unit 9A
N82/1b1 On-board electrical network line 10A
pyrofuse temperature sensor
N82/1f1 On-board electrical network line 5B
pyrofuse
N82/1k1 Quiescent current cutout relay 8A
R9 Glow plugs 34F
U12 Valid for left-hand drive vehicles 12D
U13 Valid for right-hand drive vehicles 12D
U152 Valid for engine 156 40F
U152 Valid for engine 156 40E
U152 Valid for engine 156 53B
U484 Valid for M273 ME 40F
U484 Valid for M273 ME 52A
U484 Valid for M273 ME 53A
U779 Valid for engine 275 21F
U779 Valid for engine 275 44H
U779 Valid for engine 275 41F
U779 Valid for engine 275 53C
U819 Valid for engine 272 17F
U819 Valid for engine 272 40F
U819 Valid for engine 272 52A
U880 Valid for engine 642 26F
U880 Valid for engine 642 41F
U880 Valid for engine 642 49E
U880 Valid for engine 642 52B
U882 Valid for engine 629 38H
U882 Valid for engine 629 41F
U882 Valid for engine 629 52B
U882 Valid for engine 629 36J
U882 Valid for engine 629 42F
U968 Valid for mild hybrid drive 52B
W10 Ground (battery) 16G
W10/4 Ground (2nd battery) 2G
W11 Ground (engine - electrical line 36F
connected)
W3/1 Ground (right front wheelhouse) 12E
W3/2 Ground (left front wheelhouse) 12E
X26 Interior and engine wiring harness 40H
connector
X4/1 Terminal block (circuit 30, 49F
interior)
Z7 Tml. 30 connector sleeve 32H
Z7/5 Circuit 87 connector sleeve 32G
Z9 Connector sleeve 1 31L
Fig. 107: Starter, Alternator - Wiring Diagram (1 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 108: Starter, Alternator - Wiring Diagram (2 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 109: Starter, Alternator - Wiring Diagram (3 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 110: Starter, Alternator - Wiring Diagram (4 Of 4)
Courtesy of MERCEDES-BENZ USA
WIRING DIAGRAM FOR STARTER, ALTERNATOR - PE15.00-P-2000-97SAB
ENGINE 629, 642, 156, 272, 273 in MODEL 221.0 /1 as of model year 09 /AEJ08
ENGINE 275 in MODEL 221.1 as of model year 09 /AEJ 08
Code: Designation: Position:
A0 Color code key 48L
F32/3 Engine compartment prefuse box 26L
F32/3 Engine compartment prefuse box 3L
F32/3 Engine compartment prefuse box 45L
F32/3 Engine compartment prefuse box 38L
F32/3f2 Fuse 2 26K
F32/3f2 Fuse 2 39K
F32/4 Interior prefuse box 34L
G1 On-board electrical system battery 32L
G2 Alternator 41L
M1 Starter 31L
N10/1 Front SAM control unit with fuse and relay module 12A
N10/1 Front SAM control unit with fuse and relay module 21A
N10/1 Front SAM control unit with fuse and relay module 27A
N10/1 Front SAM control unit with fuse and relay module 36A
N10/1 Front SAM control unit with fuse and relay module 4A
N10/1 Front SAM control unit with fuse and relay module 46A
N10/1f21 Fuse 21 12B
N10/1kC Circuit 87 relay, engine 10A
N10/1kH Circuit 50 relay, starter 28A
N10/1kJ Circuit 15 relay, starter 43A
N14/3 Glow time output stage 22L
N14/3 Glow time output stage 25L
N3/10 ME-SFI [ME] control unit 7L
N3/10 ME-SFI [ME] control unit 11L
N3/9 CDI control unit 16L
R9 Glow plugs 22F
U152 Valid for engine 156 9F
U152 Valid for engine 156 29G
U152 Valid for engine 156 44B
U484 Valid for M273 ME 5F
U484 Valid for M273 ME 27F
U484 Valid for M273 ME 44A
U779 Valid for engine 275 9F
U779 Valid for engine 275 29F
U779 Valid for engine 275 44C
U819 Valid for engine 272 5F
U819 Valid for engine 272 27F
U819 Valid for engine 272 44A
U880 Valid for engine 642 14F
U880 Valid for engine 642 29F
U880 Valid for engine 642 40E
U880 Valid for engine 642 25G
U880 Valid for engine 642 44B
U882 Valid for engine 629 13F
U882 Valid for engine 629 26H
U882 Valid for engine 629 23J
U882 Valid for engine 629 23J
U882 Valid for engine 629 29F
U882 Valid for engine 629 44B
U968 Valid for mild hybrid drive 44B
W11 Ground (engine - electrical line connected) 24F
X26 Interior and engine wiring harness connector 28H
X4/1 Terminal block (circuit 30, interior) 41F
Z7 Tml. 30 connector sleeve 20H
Z7/5 Circuit 87 connector sleeve 20G
Z9 Connector sleeve 1 18L
Fig. 111: Starter, Alternator - Wiring Diagram (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 112: Starter, Alternator - Wiring Diagram (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 113: Starter, Alternator - Wiring Diagram (3 Of 3)
Courtesy of MERCEDES-BENZ USA
WIRING DIAGRAM FOR STARTER, ALTERNATOR - PE15.00-P-2000-99SAA
ENGINE 629, 642, 156, 272, 273 in MODEL 221.0 /1 up to model year 08 /AEJ 07
ENGINE 275 in MODEL 221.1 up to model year 08 /AEJ 07
Code: Designation: Position:
A0 Explanation of color codes 56 A
F32 Front prefuse 5L
F32 Front prefuse 12 L
F32 Front prefuse 39 L
F32 Front prefuse 46 L
F32 Front prefuse 53 L
F32f1 Fuse 1 45 K
F32f10 Fuse 10 5H
F32f2 Fuse 2 39 K
F32f2 Fuse 2 46 K
F32f6 Fuse 6 16 J
F32f9 Fuse 9 52 K
F32k1 Battery coupling relay 6L
G1 On-board electrical system battery 1L
G1/4 Starter battery 3L
G2 Generator 50 L
M1 Starter 43 L
N10/1 Front SAM control module with fuse and relay module 20 A
N10/1 Front SAM control module with fuse and relay module 28 A
N10/1 Front SAM control module with fuse and relay module 36 A
N10/1 Front SAM control module with fuse and relay module 44 A
N10/1 Front SAM control module with fuse and relay module 51 A
N10/1f21 Fuse 21 24 B
N10/1kC Circuit 87 relay, engine 22 A
N10/1kH Circuit 50 relay, starter 40 A
N10/1kJ Circuit 15 relay, starter 52 A
N14/3 Glow time output stage 34 L
N3/10 ME-SFI [ME] control module 19 L
N3/10 ME-SFI [ME] control module 23 L
N3/9 CDI control module 28 L
N82/1 Vehicle power supply control unit 4A
N82/1 Vehicle power supply control unit 12 A
N82/1b1 On-board electrical network line pyrofuse temperature sensor 13 A
N82/1f1 On-board electrical network line pyrofuse 7B
N82/1k1 Quiescent current cutout relay 12 A
R9 Glow plugs 34 F
U12 Valid for left-hand steering 8D
U13 Valid for right-hand steering 8D
U152 Valid for engine 156 21 F
U152 Valid for engine 156 40 F
U484 Valid for M273 ME 17 F
U484 Valid for M273 ME 40 F
U779 Valid for engine 275 21 F
U779 Valid for engine 275 41 F
U779 Valid for engine 275 44 H
Valid for engine 272 17 F
U819 Valid for engine 272 40 F
U880 Valid for engine 642 26 F
U880 Valid for engine 642 37 G
U880 Valid for engine 642 41 F
U880 Valid for engine 642 49 E
U882 Valid for engine 629 26 F
U882 Valid for engine 629 35 J
U882 Valid for engine 629 36 J
U882 Valid for engine 629 38 H
U882 Valid for engine 629 41 F
W10 Ground (battery) 2G
W10/4 Ground (2nd battery) 2G
W11 Ground (engine - connection point for ground wires) 36 F
W3/1 Ground (right front wheelhousing) 8E
W3/2 Ground (left front wheelhousing) 8E
X26 Interior and engine wiring harness connector 40 H
X4/1 Terminal block (circuit 30, interior) 49 F
Z7 Circuit 30 connector sleeve 32 H
Z7/5 Circuit 87 connector sleeve 32 H
Z9 Connector sleeve 1 30 L
Fig. 114: Starter, Alternator - Wiring Diagram (1 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 115: Starter, Alternator - Wiring Diagram (2 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 116: Starter, Alternator - Wiring Diagram (3 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 117: Starter, Alternator - Wiring Diagram (4 Of 4)
Courtesy of MERCEDES-BENZ USA
WIRING DIAGRAM FOR STARTER, ALTERNATOR - PE15.00-P-2000-99SAB
ENGINE 629, 642, 156, 272, 273 in MODEL 221.0 /1 as of model year 09 /AEJ08
ENGINE 275 in MODEL 221.1 as of model year 09 /AEJ08
Fig. 118: Starter, Alternator - Wiring Diagram (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 119: Starter, Alternator - Wiring Diagram (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 120: Starter, Alternator - Wiring Diagram (3 Of 3)
Courtesy of MERCEDES-BENZ USA
WIRING DIAGRAM FOR STARTER, ALTERNATOR, BATTERY - PE15.00-P-2101-97SAA
Code: Designation: Position:
A0 Color code key 72L
B76/1 Condensation sensor for fuel filter with heating element 19L
B76/1 Condensation sensor for fuel filter with heating element 35L
F32/3 Engine compartment prefuse box 3L
F32/3 Engine compartment prefuse box 64L
F32/3 Engine compartment prefuse box 57L
F32/3f2 Fuse 2 58K
F32/4 Interior prefuse box 54L
G1 On-board electrical system battery 51L
G2 Alternator 61L
M1 Starter 50L
N10/1 Front SAM control unit with fuse and relay module 4A
N10/1 Front SAM control unit with fuse and relay module 12A
N10/1 Front SAM control unit with fuse and relay module 20A
N10/1 Front SAM control unit with fuse and relay module 28A
N10/1 Front SAM control unit with fuse and relay module 36A
N10/1 Front SAM control unit with fuse and relay module 44A
N10/1 Front SAM control unit with fuse and relay module 53A
N10/1 Front SAM control unit with fuse and relay module 61A
N10/1 Front SAM control unit with fuse and relay module 65A
N10/1f21 Fuse 21 13B
N10/1kC Circuit 87 relay, engine 11A
N10/1kH Circuit 50 relay, starter 47A
N10/1kJ Circuit 15 relay, starter 62A
N14/3 Glow time output stage 24L
N14/3 Glow time output stage 40L
N3/10 ME-SFI [ME] control unit 7L
N3/10 ME-SFI [ME] control unit 11L
N3/9 CDI control unit 15L
N3/9 CDI control unit 31L
R9/1 Cylinder 1 glow plug 28L
R9/1 Cylinder 1 glow plug 44L
R9/2 Cylinder 2 glow plug 28L
R9/2 Cylinder 2 glow plug 44L
R9/3 Cylinder 3 glow plug 28L
R9/3 Cylinder 3 glow plug 45L
R9/4 Cylinder 4 glow plug 29L
R9/4 Cylinder 4 glow plug 45L
R9/5 Cylinder 5 glow plug 45L
R9/6 Cylinder 6 glow plug 46L
U1018 Valid for gasoline engine 276 5F
U1018 Valid for gasoline engine 276 48F
U1018 Valid for gasoline engine 276 64A
U1019 Valid for engine 278 5F
U1019 Valid for engine 278 64B
U1019 Valid for engine 278 48F
U1028 Valid for engine 157 9F
Valid for engine 157 64B
U1028 Valid for engine 157 48G
U932 Valid for engine 642 BLUETEC 30F
U932 Valid for engine 642 BLUETEC 64A
U932 Valid for engine 642 BLUETEC 46F
U948 Valid for diesel engine 651 13F
U948 Valid for diesel engine 651 48F
U948 Valid for diesel engine 651 64B
W11 Ground (engine - electrical line connected) 19H
W11 Ground (engine - electrical line connected) 23G
W11 Ground (engine - electrical line connected) 42G
W12 Ground point for fuel filter with heating element 35H
X214 Glow plug electrical connector 27H
X26 Interior and engine wiring harness connector 48H
Z203/3 Alternator LIN signal connector sleeve 12G
Z7/5 Circuit 87 connector sleeve 23G
Z7/5z3 Circuit 87 connector sleeve 37G
Z9 Connector sleeve 1 17L
Z9 Connector sleeve 1 34L
Fig. 121: Starter, Alternator And Battery Wiring Diagram (1 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 122: Starter, Alternator And Battery Wiring Diagram (2 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 123: Starter, Alternator And Battery Wiring Diagram (3 Of 4)
Courtesy of MERCEDES-BENZ USA
Fig. 124: Starter, Alternator And Battery Wiring Diagram (4 Of 4)
Courtesy of MERCEDES-BENZ USA
ELECTRIC WIRING DIAGRAMS: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE -
PE15.00-Z-9999AZ
MODEL all
Survey of wiring diagrams ENGINE 104, 111, 112, 113, 119, 602, 604, 605, PE15.00-P-
electrical system, engine 606, 611, 612, 613 in MODEL 210 1100A
Survey of wiring diagrams of PE15.00-P-
ENGINE 111, 112, 113, 604, 605, 611...
electric system - engine 1100D
Survey of wiring diagrams of PE15.00-P-
ENGINE 111, 112 in MODEL 170
electrical system - engine 1100B
Overview of wiring diagrams for ENGINE 112, 113, 156, 271, 272, 273, 628, 629, PE15.00-P-
electrical system, engine 642, 646, 647, 648... 1100DA
Overview of wiring diagrams for ENGINE 112, 113, 156, 271, 272, 273, 612, 642, PE15.00-P-
electrical system, engine 646... 1100BA
Survey of wiring diagrams, ENGINE 112, 113, 137, 275, 613, 628, 648 in PE15.00-P-
electrical system, engine MODEL 220 1100SA
Overview of wiring diagrams for ENGINE 112, 113, 156, 272, 273, 275 in MODEL PE15.00-P-
electrical system, engine 230 wiring diagrams, block diagrams 1100KA
ENGINE 113, 156, 272, 273, 642...
electrical system, engine 1100RAB
Survey of wiring diagrams, ENGINE 113, 137, 275 in MODEL 220 with CODE PE15.00-P-
electrical system, engine (979) Special protection version 1100SB
Overview of wiring diagrams for PE15.00-P-
ENGINE 113, 156, 272, 273, 642 in MODEL 219
electrical system, engine 1100XA
Overview of wiring diagrams for PE15.00-P-
ENGINE 155 in MODEL 199
electrical system, engine 1100LA
Overview of wiring diagrams for PE15.00-P-
ENGINE 156, 272, 273, 275...
electrical system, engine 1100KB
Survey of wiring diagrams PE15.00-P-
ENGINE 166, 668 in MODEL 168
electrical system, engine 1100GC
Survey of wiring diagrams, PE15.00-P-
ENGINE 285 in MODEL 240
electrical system, engine 1100HA
Overview of wiring diagrams for ENGINE 111, 112, 113, 271, 272, 611, 612, 642, PE15.00-P-
electrical system, engine 646... 1100FA
Overview of wiring diagrams for PE15.00-P-
ENGINES 111, 112, 113, 612, 628 in MODEL 163
electrical system, engine 1100E
Survey of wiring diagrams, PE15.00-P-
ENGINES 113, 137, 275 in MODEL 215
electrical system, engine 1100CA
Overview of wiring diagrams for ENGINES 156, 157, 271, 272, 273, 276, 278, PE15.00-P-
electrical system, engine 642, 651 in MODEL 212 1100DAA
Overview of wiring diagrams for ENGINES 156, 271/8, 272, 276, 272.98, 642.9/8, PE15.00-P-
electrical system, engine 646.8, 651 in MODEL 204 1100FAA
Overview of wiring diagrams for ENGINES 156.984, 157, 273, 275.953/982, 278 in PE15.00-P-
electrical system, engine MODEL 216 1100CAA
Overview of wiring diagrams for PE15.00-P-
ENGINES 157, 276, 278, 642, 651 in MODEL 218
electrical system, engine 1100XAA
Overview of wiring diagrams for ENGINES 157.9, 276.9, 278.9, 642.8, 651.9 in PE15.00-P-
electrical system, engine MODEL 166 1100NAA
Overview of wiring diagrams for PE15.00-P-
ENGINES 159.980 in MODEL 197
electrical system, engine 1100HAA
Overview of wiring diagrams for PE15.00-P-
ENGINE 266, 640...
electrical system, engine 1100QB
Overview of wiring diagrams for ENGINES 266, 640 in MODEL 245 with PE15.00-P-
electrical system, engine TRANSMISSION 722, 711, 716 1100BAA
Overview of wiring diagrams for PE15.00-P-
ENGINES 270, 651 in MODEL 246
electrical system, engine 1100IAA
Overview of wiring diagrams for ENGINES 271, 272, 273, 276, 278, 642, 651 in PE15.00-P-
electrical system, engine MODEL 207 1100EAA
Overview of wiring diagrams for PE15.00-P-
ENGINES 271.8, 276.9, 651.9 in MODEL 172.4
electrical system, engine 1100TAA
Overview of wiring diagrams for ENGINES 629, 642, 651, 156, 157, 272, 273, 275, PE15.00-P-
electrical system, engine 276, 278 in MODEL 221 1100SAA
ELECTRICAL FUNCTION SCHEMATIC FOR IGNITION SYSTEM - PE15.12-P-2050-97SAA
MODEL 221 with ENGINE 275 as of model year 09/AEJ 08
Code: Designation: Position:
A29/1 Front knock sensor (left side of 1E
engine)
A29/2 Rear knock sensor (left side of 1E
engine)
A30/1 Front knock sensor (right side of 1F
engine)
A30/2 Rear knock sensor (right side of 1F
engine)
B11/4 Coolant temperature sensor 2C
B17/8 Charge air temperature sensor 2D
B28/7 Pressure sensor downstream of 5K
throttle valve actuator
B6/3 Camshaft Hall sensor, right 2G
cylinder bank
L5 Crankshaft position sensor 5B
N3/10 ME-SFI [ME] control unit 5E
N92/1 ECI ignition module, right cylinder 3J
bank
N92/2 ECI ignition module, left cylinder 3J
bank
R4 Spark plugs 1J
Fig. 125: Ignition System - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR IGNITION SYSTEM - PE15.12-P-2050-97SAB
MODEL 221 with ENGINE 272, 273 as of model year 09 / AEJ 08
Code: Designation: Position:
A16/1 Right knock sensor 1 1E
A16/2 Left knock sensor 2 1F
B11/4 Coolant temperature sensor 2C
B2/5 Hot film mass air flow sensor 4B
B2/5b1 Intake air temperature sensor 4B
B28 Pressure sensor 4K
B6/4 Left intake camshaft Hall sensor 2G
B6/5 Right intake camshaft Hall sensor 2G
B6/6 Left exhaust camshaft Hall sensor 2G
B6/7 Right exhaust camshaft Hall sensor 2G
B70 Crankshaft Hall sensor 7F
N3/10 ME-SFI [ME] control unit 4E
R4 Spark plugs 1J
T1/1 Cylinder 1 ignition coil 3J
T1/2 Cylinder 2 ignition coil 3J
T1/3 Cylinder 3 ignition coil 3J
T1/4 Cylinder 4 ignition coil 3K
T1/5 Cylinder 5 ignition coil 3K
T1/6 Cylinder 6 ignition coil 3K
T1/7 Cylinder 7 ignition coil 3L
T1/8 Cylinder 8 ignition coil 3L
U484 Valid for M273 ME 3K
U484 Valid for M273 ME 3D
U819 Valid for engine 272 3D
Fig. 126: Ignition System - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR IGNITION SYSTEM - PE15.12-P-2050-97SAC
MODEL 221 with ENGINE 156 as of model year 09/AEJ 08
Code: Designation: Position:
A16/1 Right knock sensor 1 1F
A16/2 Left knock sensor 2 1F
B11/4 Coolant temperature sensor 1C
B17 Intake air temperature sensor 7E
B2/6 Left hot film MAF sensor 4B
B2/7 Right hot film MAF sensor 4B
B28 Pressure sensor 6K
B6/4 Left intake camshaft Hall sensor 2G
B6/5 Right intake camshaft Hall sensor 2G
B6/6 Left exhaust camshaft Hall sensor 2H
B6/7 Right exhaust camshaft Hall sensor 2H
B70 Crankshaft Hall sensor 7B
N3/10 ME-SFI [ME] control unit 4E
R4 Spark plugs 1J
T1/1 Cylinder 1 ignition coil 3J
T1/2 Cylinder 2 ignition coil 3J
T1/3 Cylinder 3 ignition coil 3J
T1/4 Cylinder 4 ignition coil 3K
T1/5 Cylinder 5 ignition coil 3K
T1/6 Cylinder 6 ignition coil 3K
T1/7 Cylinder 7 ignition coil 3K
T1/8 Cylinder 8 ignition coil 3L
Fig. 127: Ignition System Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR STARTER CONTROL - PE15.30-P-2051-97SAA
MODEL 221 with ENGINE 275 as of model year 09/ AEJ 08
Code: Designation: Position:
1 Circuit 50, status 4D
2 Gear range, status 6E
3 Starter circuit 50 relay, actuation 4J
4 Starter, actuation 6J
A8/1 Transmitter key 4B
B11/4 Coolant temperature sensor 1F
CAN C Drive train CAN 7F
CAN E Chassis CAN 4C
L5 Crankshaft position sensor 2J
M1 Starter 7J
N10/1kH Circuit 50 relay, starter 4J
N15/3 ETC [EGS] control unit 9E
N3/10 ME-SFI [ME] control unit 3E
N73 EIS [EZS] control unit 3A
Fig. 128: Starter Control - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR STARTER CONTROL - PE15.30-P-2051-97SAB
MODEL 221 with ENGINE 272, 273 as of model year 09 / AEJ 08
Code: Designation: Position:
1 Circuit 50, status 4D
2 Gear range, status 6E
3 Starter circuit 50 relay, actuation 4J
4 Starter, actuation 6J
A8/1 Transmitter key 5A
B11/4 Coolant temperature sensor 1F
B70 Crankshaft Hall sensor 2J
CAN C Drive train CAN 4C
CAN C Drive train CAN 7F
M1 Starter 7J
N10/1kH Circuit 50 relay, starter 4K
N3/10 ME-SFI [ME] control unit 3E
N73 EIS [EZS] control unit 3A
U484 Valid for M273 ME 3D
U819 Valid for engine 272 3D
Y3/8 Electric control unit (VGS) 9E
Fig. 129: Starter Control - Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
ELECTRICAL FUNCTION SCHEMATIC FOR STARTER CONTROL - PE15.30-P-2051-97SAC
MODEL 221 with ENGINE 156 as of model year 09/AEJ 08
Code: Designation: Position:
1 Circuit 50, status 4E
2 DAS [FBS] start enable, status 4D
3 Shift stage, status 6F
4 Starter circuit 50 relay, actuation 4J
5 Starter, actuation 6J
A8/1 Transmitter key 5B
B11/4 Coolant temperature sensor 1E
B70 Crankshaft Hall sensor 2J
CAN C Drive train CAN 7F
CAN E Chassis CAN 4D
M1 Starter 7J
N10/1kH Circuit 50 relay, starter 4J
N3/10 ME-SFI [ME] control unit 4E
N73 EIS [EZS] control unit 3B
Y3/8 Electric control unit (VGS) 9E
Fig. 130: Starter Control Electrical Function Schematic
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS
124 589 09 63 00 OHM DECADE - WS15.00-N-0009C
FG 09/15/20/Set C
ENGINE all
Further use FG 43/54/Set C WS54.00-N-3000C
Use:
Decade resistor for simulation of resistors
Fig. 131: Identifying Ohm Decade (124 589 09 63 00)
Courtesy of MERCEDES-BENZ USA
201 589 00 99 00 ELECTRICAL CONNECTION KIT - WS15.00-N-0014C
FG 15/54/Set C
ENGINES all
MODIFICATION NOTES
28.4.11 Replaced by 220 589 00 99 00 WS42.00-N-3062B
Use:
Electrical connection kit for electrical connection during voltage, current and resistance measurements.
Fig. 132: Identifying Electrical Connection Kit (201 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
124 589 09 63 00 OHM DECADE - WS15.00-P-0009C
FG 15/54/Set C
ENGINE all
Use/specification:
Ohm decade for simulation of resistances
Fig. 133: Identifying Ohm Decade (124 589 09 63 00)
Courtesy of MERCEDES-BENZ USA
602 589 00 10 00 SOCKET WRENCH - WS15.00-P-0015B
FG 15/Set B
ENGINE all
Use:
Serrated socket wrench 17 20 mm (to DIN 5481 / SW 17 mm) for assembly of alternator belt pulley with
freewheel in combination with screwdriver bit 601 589 00 10 00 for counterholding alternator drive shaft.
Fig. 134: Identifying Socket Wrench (602 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
112 589 01 09 00 SPARK PLUG WRENCH - WS15.00-P-0016A
FG 05/15/Set A
ENGINE 112, 113, 137, 155, 166, 266, 271, 272, 273, 275, 902, 906
Use:
Spark plug wrench 5/8 (15.8 mm) with retaining spring and joint, 3/8 square drive, outer diameter 21.4 mm,
length 97 mm
Also required for M112/113 commercially available extension 3/8 length 74 mm, e.g. Hazet 8821-3.
Fig. 135: Identifying Spark Plug Wrench (112 589 01 09 00)
Courtesy of MERCEDES-BENZ USA
137 589 00 33 00 PULLER - WS15.00-P-0019B
FG 15/Set B
ENGINE 137.970, 275, 285
Use:
Puller for pulling off ignition rail (changing spark plug)
Fig. 136: Identifying Puller (137 589 00 33 00)
Courtesy of MERCEDES-BENZ USA
137 589 01 33 00 PULLER - WS15.00-P-0021B
FG 15/Set B
ENGINE 137.970, 275, 285
Use:
Puller for pulling off rubber seal of spark plugs (A) or for pulling out of ignition rail (B) and for installing
rubber seal in ignition rail (C).
Fig. 137: Identifying Puller (137 589 01 33 00)
Courtesy of MERCEDES-BENZ USA
285 589 00 34 00 SUPPORT - WS15.00-P-0022B
FG 15/Set B
ENGINE 275, 285
Use:
Use support only in combination with 137 589 00 33 00.
Fig. 138: Identifying Support (285 589 00 34 00)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE - WS15.00-Z-9999AZ
MODEL all
000 589 25 33 00 Internal WS00.00-P-
FG 00/15/26
extractor 0050Z
000 589 55 37 00 Cable WS15.00-P-
FG 15/Set B
pliers 0001B
001 589 01 91 00 Set of WS01.00-P-
FG 01/08/09/14/15/ 54/83/ Set B
protective covers 0111B
001 589 73 21 00 Hand WS00.00-P-
FG 00/01/07/09/14/15/ 20/30
vacuum pump 0018Z
001 589 78 09 00 Socket WS15.00-P-
FG 01/15/Set B
wrench 0018B
001 589 80 09 00 Wrench WS15.00-P-
FG 01/15/Set B
socket 0043B
001 589 81 09 00 Set of WS00.00-P-
FG 00/01/07/09/14/15/ 20/Set B
flexible head wrenches 0251B
102 589 01 09 00 Spark WS15.00-P-
FG 15/Set A
plug wrench 0002A
WS15.00-P-
103 589 00 37 00 Pliers FG 15/Set A
0003A
110 589 01 01 00 Double WS15.00-P-
FG 15/Set B
open-ended wrench 0017B
112 589 01 09 00 Spark WS15.00-P-
FG 05/15/Set A
plug wrench 0016A
117 589 00 09 00 Spark WS15.00-P-
FG 15/Set A
plug wrench 0004A
117 589 01 21 00
WS15.00-P-
Diagnosis cable FG 15/Set C
0005C
DIS/AKC
119 589 02 09 00 Spark WS15.00-P-
FG 15/Set A
plug wrench 0007A
120 589 02 09 00 Spark WS15.00-P-
FG 15/Set A
plug wrench 0008A
124 589 09 63 00 Ohm WS15.00-N-
FG 09/15/20/Set C
decade 0009C
124 589 09 63 00 Ohm WS15.00-P-
FG 15/54/Set C
decade 0009C
WS15.00-P-
126 589 00 40 00 Bracket FG 15/Set B
0011B
plug 27/29/32/33/35/42/46/47/68/82/83/88/ 91/Set B 0255Z
129 589 05 63 00 22-pin WS15.00-P-
FG 15/Set B
test cable 0012B
WS15.00-P-
137 589 00 33 00 Puller FG 15/Set B
0019B
WS15.00-P-
137 589 01 33 00 Puller FG 15/Set B
0021B
140 589 10 63 00 Test WS15.00-P-
FG 15/Set B
cable 0013B
164 589 06 63 00 Safety WS15.00-P-
FG 15/Set B
plug 0062B
166 589 00 33 00 WS15.00-P-
FG 15/Set B
Expanding clamp 0020B
201 589 00 99 00 WS15.00-N-
FG 15/54/Set C
Electrical connection kit 0014C
210 589 00 40 00 WS05.00-P-
FG 05/15/Set B
Magnetic pin 0155B
WS15.00-P-
211 589 00 37 00 Pliers FG 15/Set K
0048K
211 589 09 63 00 Blade WS15.00-P-
FG 15/Set B
holder with blade 0038B
211 589 09 63 01 WS15.00-P-
FG15/Set B
Replacement blade 0038-01B
220 589 00 99 00 WS54.00-P-
FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B
Electrical connection kit 0050B
220 589 00 99 07 WS54.00-P-
FG 15/25/42/43/54/Set B
Adapter line 0050-07B
220 589 00 99 08 WS54.00-P-
FG 15/42/43/54 / Set B
Adapter line 0050-08B
220 589 00 99 09 WS54.00-P-
FG 15/42/43/54/Set B
Adapter line 0050-09B
220 589 00 99 10 WS54.00-P-
FG 15/42/43/54/Set B
Adapter line 0050-10B
220 589 00 99 11 WS54.00-P-
FG 00/09/15/42/43/54/ Set B
Adapter line 0050-11B
220 589 00 99 12 WS54.00-P-
FG 15/42/43/54/ Set B
Adapter line 0050-12B
220 589 00 99 13 WS54.00-P-
FG 15/42/43/54 / Set B
Adapter line 0050-13B
220 589 00 99 20 Test WS54.00-P-
FG 15/20/25/42/43/54/ Set B
cable 0050-14B
220 589 00 99 21 WS54.00-P-
FG 15/42/43/54/ Set B
Alligator clip 0050-15B
clamp FG 15/25/42/43/54/Set B 0050-16B
220 589 00 99 23 Clamp WS54.00-P-
FG 15/42/43/54 / Set B
test probe 0050-17B
220 589 00 99 37 WS54.00-P-
FG54/15/Set B
Adapter cable 0050-37B
220 589 05 99 00 WS00.00-P-
FG 00/01/09/13/15/ 20/25/42/43/47/54/ 72/ Set B
Electrical connection kit 0279Z
221 589 01 62 00 Eyebolt WS15.00-P-
FG 15/54/Set B
set 0059B
221 589 05 63 00 safety WS15.00-P-
FG 15/Set B
plug 0060B
266 589 01 61 00 WS15.00-P-
FG 15/Set A
Removal tool 0049A
WS15.00-P-
272 589 01 33 00 Puller FG 15/Set B
0054B
278 589 00 09 00 Spark WS15.00-P-
FG 15/Set B
plug wrench 0065B
WS15.00-P-
285 589 00 34 00 Support FG 15/Set B
0022B
WS42.00-N-
352 589 02 37 00 Pliers FG 42/15/82/Set C Set B
3022C
WS15.00-P-
451 589 00 15 00 Socket FG 15/Set B
0064B
601 589 00 10 00 WS01.00-P-
FG 01/15/Set B
Screwdriver bit 0033B
602 589 00 10 00 Socket WS15.00-P-
FG 15/Set B
wrench 0015B
WS15.00-N-
611 589 00 37 00 Pliers FG 01/15/20/Set B
3033B
611 589 00 68 00 Round WS01.00-P-
FG 01/07/15/Set B
brush 0059B
611 589 00 68 10 Round WS01.00-P-
FG 01/05/07/15/Set B
brushes (3 x) 0059-01B
611 589 00 91 00 Record WS15.00-P-
FG 15/Set B
plug 0039B
611 589 00 99 00 Glow WS15.00-P-
FG 15/Set B
plug repair set 0037B
611 589 00 99 03 Drill WS15.00-P-
FG15/Set B
bit 0037-01B
611 589 00 99 04 Depth WS15.00-P-
FG15/Set B
stop 0037-02B
611 589 00 99 07 Drill WS15.00-P-
FG15/Set B
bit 0037-03B
stop FG15/Set B 0037-04B
WS15.00-P-
611 589 00 99 10 Tap FG15/Set B
0037-05B
611 589 00 99 11 Depth WS15.00-P-
FG15/Set B
stop 0037-06B
611 589 00 99 13 Impact WS15.00-P-
FG15/Set B
adapter 0037-07B
611 589 00 99 15 Drill WS15.00-P-
FG15/Set B
bit 0037-08B
611 589 00 99 16 Depth WS15.00-P-
FG15/Set B
stop 0037-09B
WS15.00-P-
611 589 00 99 18 Tap FG15/Set B
0037-10B
611 589 00 99 19 Depth WS15.00-P-
FG15/Set B
stop 0037-11B
611 589 00 99 21 Impact WS15.00-P-
FG15/Set B
adapter 0037-12B
611 589 00 99 22 Thread WS15.00-P-
FG15/Set B
cutter 0037-13B
611 589 00 99 23 WS15.00-P-
FG15/Set B
Threaded awl 0037-14B
WS15.00-P-
611 589 00 99 24 Tap FG15/Set B
0037-15B
611 589 00 99 25 WS15.00-P-
FG15/Set B
Threaded insert 0037-16B
611 589 00 99 27 Wire WS15.00-P-
FG15/Set B
brush 0037-17B
611 589 01 99 00 Glow WS15.00-P-
FG 15/Set C
plug repair kit, M10 0057C
611 589 01 99 01 WS15.00-P-
FG15/Set C
Drilling-out sleeve 0057-01C
611 589 01 99 02 WS15.00-P-
FG15/Set C
Drilling-out sleeve 0057-02C
WS15.00-P-
611 589 01 99 03 Tap FG15/Set C
0057-03C
611 589 01 99 04 WS15.00-P-
FG15/Set C
Graduated drill 0057-04C
611 589 01 99 05 WS15.00-P-
FG15/Set C
Threaded insert 0057-05C
WS15.00-P-
611 589 01 99 06 Tap FG15/Set C
0057-06C
611 589 05 21 00 DRV WS15.00-P-
FG 15/Set B
module 0044B
Adapter cable FG 15/Set B 0046B
640 589 04 63 00 WS15.00-P-
FG 15/Set C
Baseplate 0061C
642 589 00 99 00 Glow WS15.00-P-
FG 15/Set C
plug repair kit, M8 0058C
WS15.00-P-
642 589 00 99 01 Tap FG15/Set C
0058-01C
WS15.00-P-
642 589 00 99 02 Tap FG15/Set C
0058-02C
642 589 00 99 03 WS15.00-P-
FG15/Set C
Drilling-out sleeve 0058-03C
642 589 00 99 04 Twist WS15.00-P-
FG15/Set C
drill bit 0058-04C
642 589 00 99 05 WS15.00-P-
FG15/Set C
Graduated drill 0058-05C
642 589 00 99 06 Pullout WS15.00-P-
FG15/Set C
spindle 0058-06C
646 589 00 63 00 3-pin WS15.00-P-
FG 15/Set B
adapter cable 0050B
646 589 01 63 00 6-pin WS15.00-P-
FG 15/Set B
adapter cable 0051B
646 589 02 63 00 4-pin WS15.00-P-
FG 15/Set B
adapter cable 0052B
646 589 03 63 00 WS15.00-P-
FG 15/Set B
Adapter cable, 2-pin 0053B
651 589 00 63 00 5-pin WS15.00-P-
FG 15/Set B
adapter cable 0056B
651 589 01 63 00 3-pin WS15.00-P-
FG 15/Set B
adapter cable 0055B
668 589 01 59 00 WS05.00-P-
FG 05/15/27/Set C
Insertion plate 0190C
ENGINE
Complete Engine - General Information - S-Class (221)
GENERAL INFORMATION
DETERMINE LOSS OF PRESSURE AT CYLINDER - AH01.00-N-1300-02A
All engines
If an increased pressure loss was found with the cylinder leaktightness tester, inspect engine by listening at
cylinder head gasket, air intake area, exhaust, oil filler opening and prechamber or spark plug bores of the
adjacent cylinder or cylinders.
Check the coolant in the coolant expansion reservoir for the formation of air bubbles.
Possible causes for the pressure loss are:
1. Outlet of air through prechamber or spark plug bore of adjacent cylinder or cylinders, air bubbles
in coolant expansion reservoir:
pressure loss at cylinder head gasket
2. Outlet of air through air intake area: For inspecting by listening, open throttle valve
pressure loss at inlet valve(s)
3. Outlet of air through exhaust:
pressure loss at exhaust valve(s)
4. Outlet of air through oil filler opening:
pressure loss through pistons and piston rings
It is possible to pinpoint the pressure loss of the relevant cylinder by spraying with engine oil. Engine oil seals
off the gap between piston and cylinder briefly.
If a reduced pressure loss now occurs for a short time, the cause is very likely to be at the pistons, piston rings
or cylinder contact surface of the relevant cylinder.
Determining the cause can be falsified by the position of the piston ring joints. If suspicion exists that the loss of
pressure is caused by the piston ring joints being positioned directly one above the other, fit parts to engine and
repeat test after running engine for a short time.
NOTES ON POSITION OF ENGINE NUMBER - AH01.00-P-0001-01D
Engine 112, 113, 120, 137, 271, 272, 273, 275, 285, 628, 629, 642, 651
Shown on engine 275
Fig. 1: Locating Engine Number
Courtesy of MERCEDES-BENZ USA
The engine number is located on the upper right transmission flange.
With OM 642 the engine number is located on the left front on the cylinder crankcase below the vacuum
pump
With OM 651 the engine number is located on the left side on the cylinder crankcase below the vacuum
pump
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01AMG
1. Pressure gloss marks, smooth spots
Individual blank points, e.g. in middle of cylinder or in area of cylinder head bolts.
Reuse crankcase.
Fig. 2: Identifying Pressure Gloss Marks, Smooth Spots On Cylinder Wall
Courtesy of MERCEDES-BENZ USA
2. Visible mottling, friction marks
Starting from first piston ring, tapering to an end after about 30 mm. Traces of dry friction marks which
cannot be felt, caused by oil film being washed off by fuel, e.g. during frequent cold starts associated with
short-distance driving. These traces of friction marks which occur principally in area of cylinder head
bolts and on pressure side are not a problem provided they are smoothed. The piston rings are not
damaged.
Reuse crankcase.
Fig. 3: Identifying Visible Mottling, Friction Marks On Cylinder Wall
Courtesy of MERCEDES-BENZ USA
3. Ring shaped imprints
Visible imprints in the upper and lower piston ring reversal range are not a reason for complaint.
Reuse crankcase.
Fig. 4: Identifying Ring Shaped Imprints
Courtesy of MERCEDES-BENZ USA
4. Rotary bright, specular, polished upper surfaces of cylinder
Usually starting from the first piston ring, in the upper area of cylinder, with measurable partial cylinder
wear.
Cylinder wall unusable.
Fig. 5: Identifying Rotary Bright, Specular, Polished Upper Surfaces Of Cylinder
Courtesy of MERCEDES-BENZ USA
5. Roughened mottling, friction scoring
Starting from first and second piston ring, tapering to an end only in bottom part of cylinder. Traces of
rubbing as described in item 2, which have advanced to signs of seizure. Piston rings may be damaged.
If damage can be felt, cylinder wall unusable.
Fig. 6: Identifying Roughened Mottling, Friction Scoring On Cylinder Wall
Courtesy of MERCEDES-BENZ USA
6. Continuous individual traces of scratch
Caused by contamination, e.g. through reverse pulsation of soot particles out of exhaust.
Reuse crankcase.
7. Piston seizure
Most of cylinder wall perceptibly roughened over the entire length. Material deposits and perceptible
scoring marks on cylinder wall and at piston skirt.
Cylinder wall unusable.
8. Brown coloring of cylinder upper surface.
Oil varnish is over large areas of cylinder contact surface and indicates, that engine was driven at high
temperature level. Reuse crankcase provided no impermissible cylinder distortion is present. Oil varnish
above piston ring zone is normal and is not a reason for complaint.
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01VA
General note
If a complaint is made about an engine, for example because of noises, overheating, oil consumption etc.,
perform a visual inspection of the mounted cylinder head by inspecting with light probe with an endoscope. The
following notes should be helpful in assessing the cylinder barrels to allow a professional decision to be made
about the condition and further use of the crankcase. If this can cannot be assessed with sufficient security
through inspecting with an endoscope then the work "Check compression pressure" and "Check cylinder
leakage" must be performed before removal of the cylinder head as described in the Workshop Information
System (WIS).
The results of checking should be documented on a repair order. For deviations from the prescribed wear and
tolerance values one should particularly determine the direction of the leakage while checking the leaktightness
of the cylinder (in the direction valve or in the direction of the crankcase).
In the case of deviating compression pressure values, in particular when not achieving the installation
tolerance/new values (measured with a compression recorder), one should check for indications of a fluid lock
(e.g. wet piston crown, wet air filter, water-oil-glycol residues).
Ideal condition
A matt gray user interface, no honing pattern, a dry cylinder barrel, without polished sections or mirror polished
flats.
It is also possible that irregularities can occur which should be individually assessed.
Fig. 7: Identifying Ideal Condition
Courtesy of MERCEDES-BENZ USA
Individual score marks up fields of score marks
converter or the exhaust system.
Continue to use crankcase.
Fig. 8: Locating Individual Score Marks & Fields Of Score Marks
Courtesy of MERCEDES-BENZ USA
Ring shaped imprints
Visible in the upper and lower reversal range of piston rings, are not a reason for complaint.
Continue to use crankcase.
Fig. 9: Locating Ring Shaped Imprints
Courtesy of MERCEDES-BENZ USA
Brown coloring of cylinder upper surface.
Brown coloration (oil varnish) over large areas of the cylinder barrel indicates that the engine has been driven at
a high temperature level. This is normal and not a cause for complaint.
Continue to use crankcase.
Fig. 10: Identifying Brown Coloring Of Cylinder Upper Surface
Courtesy of MERCEDES-BENZ USA
Pressure gloss marks, smooth spots
Individual blank points, e.g. in middle of cylinder or in area of cylinder head bolts. An all-round impression at
the piston ring reversing point above and below.
Continue to use crankcase.
Fig. 11: Identifying Pressure Gloss Marks, Smooth Spots
Courtesy of MERCEDES-BENZ USA
Optical stripes, friction marks
Starting from the first, second or third piston ring, run out after approx. 30 mm. Traces of dry friction marks
which cannot be felt, caused by soot particles and oil film being washed off by fuel, e.g. from frequent cold
starts associated with short-distance driving. These traces of friction marks which occur principally in area of
cylinder head bolts and on pressure side are not a problem provided they are smoothed.
Continue to use crankcase.
Fig. 12: Locating Optical Stripes, Friction Marks
Courtesy of MERCEDES-BENZ USA
Imprint on valve cooling bore for an 8 and 12 cylinder engine
The cooling bore in the crankcase shows a different coloration to the cylinder barrel.
Continue to use crankcase.
Fig. 13: Identifying Imprint On Valve Cooling Bore
Courtesy of MERCEDES-BENZ USA
Corrugated wear of the cylinder barrel
A washboard type surface structure of the cylinder barrel, partially or all around.
Do not use the crankcase anymore.
Fig. 14: Identifying Corrugated Wear Of Cylinder Barrel
Courtesy of MERCEDES-BENZ USA
Roughened mottling, friction scoring
Starting from first, second or third piston ring, tapering to an end only in bottom part of cylinder. Friction marks
as described under "Optical streaks, friction marks", in an advanced for becoming friction eroded areas.
If friction eroded areas are perceptible the cylinder barrel is unusable.
Do not use the crankcase anymore.
Fig. 15: Identifying Roughened Mottling, Friction Scoring
Courtesy of MERCEDES-BENZ USA
Piston seizure, eroded areas on the ring
Most of cylinder wall perceptibly roughened over the entire length.
Material deposits and perceptible scoring marks on cylinder wall and at piston skirt.
Cylinder barrel unusable.
Do not use the crankcase anymore.
Fig. 16: Identifying Piston Seizure, Eroded Areas On Ring
Courtesy of MERCEDES-BENZ USA
GENERAL NOTES: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE VENTILATION,
CYLINDER HEAD, CRANKCASE - AH01.00-Z-9999AZ
MODEL all
Bolt diagram cylinder head AH01.20-P-
ENGINE 120
cover 5014-04AO
Determine loss of pressure at AH01.00-N-
ENGINE all
cylinder 1300-02A
Determining pressure loss of AH01.00-P-
ENGINE 640
cylinders 1300-02AL
AH01.00-N-
Firing order ENGINE 111 /, 601 /, 602
0100-01A
General information on AH01.00-P-
ENGINE 112, 113, 137, 166, 272, 273, 275, 285
inspecting cylinder walls 0300-01VA
General information on AH01.00-N-
ENGINE 111, 601, 604, 605, 606, 611, 612, 647, 668...
inspecting cylinder walls 0300-01A
General information on ENGINE 112, 122, 134, 135, 166, 271, 272, 611, 612, 613, AH01.00-P-
inspecting cylinder walls 628, 629, 639, 642, 646, 647, 648, 651... 0300-01A
General information on AH01.00-P-
ENGINE 266.920 /940 /960 /980 in MODEL 169.0 /3, 245.2
inspecting cylinder walls 0300-01AK
General information on AH01.00-P-
ENGINE 155
inspecting cylinder walls 0300-01SLR
AH01.00-P-
General information on
ENGINE 156 0300-
inspecting cylinder walls
01AMG
General information on AH01.00-P-
ENGINE 640
inspecting cylinder walls 0300-01AL
Information for assigning AH01.30-P-
ENGINE 642 in MODEL 219.322, 221
cylinder head gaskets 1000-06TQ
Information for assigning the AH01.30-P-
ENGINE 112 ENGINE 113
cylinder head gaskets 1000-06V
Information for assigning the ENGINE 642 in MODEL 164, 203, 209, 251.0 /1 ENGINE AH01.30-P-
cylinder head gaskets 642 in MODEL 461, 463 1000-06PI
Information on application
AH01.40-P-
of sealant to bottom part of ENGINE 628...
1000-03B
crankcase
Information on application
AH01.40-P-
of sealant to bottom part of ENGINE 629
1000-03TJ
crankcase
Information on application
AH01.40-P-
of sealant to crankcase ENGINE 137.970, 275, 285
1000-03A
bottom section
Information on application
AH01.40-P-
of sealant to crankcase ENGINE 159
1000-03RQ
bottom section
Information on application AH01.40-P-
of sealant to crankcase ENGINE 156 1000-
bottom section 03AMG
Information on application
AH01.40-P-
of sealant to end cover of ENGINE 628...
1000-04C
crankcase
Information on application
AH01.40-P-
of sealant to end cover of ENGINE 137.970, 275
1000-04A
crankcase
Information on application
AH01.40-P-
of sealant to end cover of ENGINE 628...
1000-04B
crankcase
Information on application
AH01.40-P-
of sealant to end cover of ENGINE 651
1000-04CD
crankcase
Information on application
AH01.40-P-
of sealant to end cover of ENGINE 629 am Motor vorn
1000-04TJT
crankcase
Information on application AH01.45-P-
ENGINE 628.960 /961 /962 /963
of sealant to oil pan 0001-01MA
Information on application AH01.45-P-
ENGINE 160.921 /922 /923 in MODEL 452.3 /4
of sealant to oil pan 0001-01RR
Information on application AH01.45-P-
ENGINE 628.961 in MODEL 211.028
of sealant to oil pan 0001-01TD
Information on application
AH01.40-P-
of sealant to timing case ENGINE 137.970, 275
1000-01C
cover
Information on applying
ENGINE 112 ENGINE 113 ENGINE 112.951 ENGINE AH01.30-P-
sealant to a cylinder head
112.976 1000-04VA
gasket
Information on applying
AH01.30-P-
sealant to cylinder head ENGINE 272, 273
1000-04RX
gasket
Information on cylinder head AH01.30-P-
ENGINE 112, 113, 112.951 /976, 157, 272, 273, 276, 278
contact surface 1000-05A
Notes application of sealant
AH01.40-P-
to end cover with radial shaft ENGINE 642 in MODEL 219.322
1000-06TQ
seal
Notes application of sealant
AH01.40-P-
to end cover with radial shaft ENGINE 266, 640 in MODEL 169.0 /3, 245.2
1000-06AK
seal
Notes application of sealant
AH01.40-P-
to end cover with radial shaft ENGINE 112, 113
1000-06A
seal
Notes application of sealant AH01.40-P-
to end cover with radial shaft ENGINE 132.9 in MODEL 451.3 /4 1000-
seal 06MCC
Notes application of sealing
AH01.40-P-
compound to end cover with ENGINE 134.9, 135.9 in MODEL 454.0
1000-06FF
radial shaft seal
Notes concerning application
AH01.40-P-
of sealant to an end cover ENGINE 642 in MODEL 203, 209
1000-06PI
with radial shaft seal
Notes for evaluation of a ENGINE 160.9 in MODEL 450.3 /4, 452.3 /4 ENGINE AH01.40-P-
cylinder barrel 132.9, 660.9 in MODEL 451.3 /4 0001-03SM
Notes for position of engine AH01.00-P-
ENGINE 166, 266, 640, 668
number 0001-01B
Notes for position of engine AH01.00-P-
ENGINE 155
number 0001-01A
Notes for position of engine AH01.00-P-
ENGINE 601, 602, 603, 604, 605, 606
number 0001-01E
Notes for position of engine AH01.00-P-
ENGINE 611, 612, 613, 646, 647, 648
number 0001-01C
Notes on application of AH01.45-P-
ENGINE 113.940 /943 /944 /961 /980 /984
sealant oil pan 0001-01D
Notes on application of AH01.45-P-
ENGINE 112.912 /946
Notes on application of AH01.45-P-
ENGINE 112
sealant oil pan 0001-01C
Notes on application of AH01.40-P-
ENGINE 112, 113
sealant timing case cover 1000-01B
Notes on application of
AH01.40-P-
sealant to a timing case ENGINE 642 in MODEL 164, 203, 204, 209, 251.0 /1
1000-01PI
cover
Notes on application of AH01.40-P-
ENGINE 137.970
sealant to crankcase cover 1000-05A
Notes on application of
AH01.30-P-
sealant to cylinder head ENGINE 272
1000-08V
cover
Notes on application of
AH01.30-P-
sealant to cylinder head ENGINE 113
1000-04V
gasket
Notes on application of
AH01.30-P-
sealant to cylinder shutoff oil ENGINE 137.970
1000-01A
pump
Notes on application of
ENGINE 642 in MODEL AH01.40-P-
sealant to end cover with
211.020 /022 /084 /089 /220 /222 /284 /289 1000-06TI
radial shaft seal
Notes on application of
AH01.30-P-
sealant to front cover at ENGINE 275
1000-02C
cylinder head
Notes on application of
AH01.30-P-
sealant to front cover at ENGINE 668.914 /940 /941 /942
1000-02A
cylinder head
Notes on application of
AH01.30-P-
sealant to front cover of ENGINE 629
1000-02TJ
cylinder head
Notes on application of
AH01.30-P-
sealant to front cover of the ENGINE 640 in MODEL 169, 245
1000-02AL
cylinder head
Notes on application of AH01.45-P-
ENGINE 137.970, 275
sealant to oil pan 0001-01A
Notes on application of AH01.45-P-
ENGINE 629
sealant to oil pan 0001-01TJ
AH01.45-P-
Notes on application of
ENGINE 272 in MODEL 164, 251 0001-
sealant to oil pan
01GZA
Notes on application of ENGINE AH01.45-P-
sealant to oil pan 113.963 /967 /968 /987 /988 /989 /990 /991 /992 /995 0001-01R
Notes on application of AH01.45-P-
ENGINE 273
sealant to oil pan 0001-01SX
sealant to oil pan ENGINE 628.960 /962 /963 0001-01M
Notes on application of AH01.45-P-
ENGINE 134.9, 135.9 in MODEL 454.0
sealant to oil pan 0001-01FF
Notes on application of ENGINE 166.940 /960 /961 /990 /991 /995, AH01.45-P-
sealant to oil pan 668.914 /940 /941 /942 0001-01F
Notes on application of AH01.45-P-
ENGINE 155 in MODEL 199
sealant to oil pan 0001-01SLR
Notes on application of AH01.45-P-
ENGINE 160, 660...
sealant to oil pan 0001-01SM
Notes on application of AH01.45-P-
ENGINE 285
sealant to oil pan 0001-01H
Notes on application of AH01.45-P-
ENGINE 112...
sealant to oil pan 0001-01PV
Notes on application of AH01.45-P-
ENGINE 122.9 in MODEL 454.0
sealant to oil pan 0001-01FB
Notes on application of AH01.45-P-
ENGINE 113, 156...
sealant to oil pan 0001-01GZ
Notes on application of AH01.45-P-
ENGINE 640 in MODEL 169, 245
sealant to oil pan 0001-01AL
Notes on application of AH01.45-P-
ENGINE 266.920 /940 /960 /980 in MODEL 169.0 /3, 245.2
sealant to oil pan 0001-01AK
AH01.45-P-
Notes on application of
ENGINE 156... 0001-
sealant to oil pan
01AMG
Notes on application of AH01.45-P-
ENGINE 272, 273...
sealant to oil pan 0001-01TZ
Notes on application of AH01.45-P-
ENGINE 271
sealant to oil pan 0001-01T
Notes on application of AH01.45-P-
ENGINE 272
sealant to oil pan 0001-01VB
Notes on application of ENGINE 272 in MODEL 203.08 /28 /09 /29, AH01.45-P-
sealant to oil pan 211.08 /28 /09 /29 ENGINE 273 in MODEL 211.09 /29 0001-01TW
Notes on application of
AH01.30-P-
sealant to rear cover at ENGINE 668.914 /940 /941 /942
1000-03A
cylinder head
Notes on application of
AH01.40-P-
sealant to right-hand ENGINE 137.970
1000-02A
crankcase
Notes on application of
AH01.40-P-
sealant to the timing case ENGINE 266.920 /940 /960 /980 in MODEL 169.0 /3, 245.2
1000-01AK
cover
Notes on application of
AH01.40-P-
sealant to the timing case ENGINE 611, 612, 613, 646, 647, 648...
1000-01E
cover
Notes on application of ENGINE 166.940 /960 /961 /990 /991, AH01.40-P-
sealant to timing case cover 668.914 /940 /941 /942 1000-01D
Notes on application of AH01.40-P-
ENGINE 640
sealant to timing case cover 1000-01AL
Notes on application of AH01.40-P-
ENGINE 137.970
sealant to timing case cover 1000-01A
Notes on application of ENGINE 642 in MODEL AH01.40-P-
sealant to timing case cover 211.020 /022 /084 /089 /220 /222 /284 /289 /620 1000-01TI
Notes on application of AH01.40-P-
ENGINE 642 in MODEL 219.322
sealant to timing case cover 1000-01TQ
Notes on application of AH01.40-P-
ENGINE 134.9, 135.9 in MODEL 454.0
sealant to timing case cover 1000-01FF
AH01.40-P-
Notes on application of
ENGINE 156 1000-
sealant to timing case cover
01AMG
Notes on application of
AH01.30-P-
sealing compound to front ENGINE 275
1000-02D
cover at cylinder head
Notes on application of AH01.45-P-
ENGINE 113.941 /942 /960 /962 /965 /981 /982 /993
sealing compound to oil pan 0001-01E
Notes on application of
AH01.30-P-
sealing compound to rear ENGINE 640 in MODEL 169
1000-03AL
cover at cylinder head
Notes on application of
AH01.40-P-
sealing compound to timing ENGINE 639.939 in MODEL 454.0
1000-01FG
case cover
Notes on assigning the AH01.30-P-
ENGINE 642
cylinder head gaskets 1000-06TI
Notes on position of engine AH01.00-P-
MODEL 450.3 /4, 452.3 /4, 454.0
number 0001-01FF
AH01.00-P-
Notes on position of engine
ENGINE 132.9, 660.9 in MODEL 451.3 /4 0001-
number
01MCC
Notes on position of engine ENGINE 112, 113, 120, 137, 271, 272, 273, 275, 285, 628, AH01.00-P-
number 629, 642, 651 0001-01D
Notes on sealant path for a AH01.40-P-
ENGINE 157, 276, 278
cylinder crankcase 1000-08MM
Notes on sealant path for AH01.30-P-
ENGINE 642 in MODEL 207, 212, 218, 221
cylinder head cover 1000-08SXI
Notes on sealant path for AH01.30-P-
ENGINE 157, 276, 278
cylinder head cover 1000-08MM
Notes on sealant path for ENGINE 642.970 in MODEL 463 ENGINE 642.975 /884 in AH01.30-P-
cylinder head cover MODEL 461 1000-08GY
ENGINE 611, 612, 613, 628, 646, 647, 648...
front cover to cylinder head 1000-02B
Notes on sealant path for AH01.30-P-
ENGINE 272, 273
front cover to cylinder head 1000-02V
Notes on sealant path for
AH01.30-P-
front cover to cylinder head ENGINE 157, 276, 278
1000-02MM
xxx
Notes on sealant path for oil AH01.45-P-
ENGINE 273
pan 0001-01SY
AH01.45-P-
Notes on sealant path for oil
ENGINE 156 in MODEL 230.470 0001-
pan
01RMG
AH01.45-P-
Notes on sealant path for oil
ENGINE 276 0001-
pan
01MMA
AH01.45-P-
Notes on sealant path for oil
ENGINE 157, 278 0001-
pan
01MMB
Notes on sealant path for oil AH01.45-P-
ENGINE 272
pan 0001-01VA
AH01.45-P-
Notes on sealant path for oil
ENGINE 132.9 in MODEL 451.3 /4 0001-
pan
01MCC
Notes on sealant path for oil AH01.45-P-
ENGINE 651 in MODEL 204, 207, 212, 218, 221
pan 0001-01CD
Notes on sealant path for oil AH01.45-P-
ENGINE 642
pan 0001-01OM
AH01.45-P-
Notes on sealant path for oil
ENGINE 156 in MODEL 204.077 /277 0001-
pan
01CMG
AH01.40-P-
Notes on sealant path for
ENGINE 132.9 in MODEL 451.3 /4 1000-
timing case cover
01MCC
Notes on sealant path for AH01.40-P-
ENGINE 159
timing case cover 1000-01RQ
AH01.40-P-
Notes on sealant path for
ENGINE 276 1000-
timing case cover
01MMA
Notes on sealant path for AH01.40-P-
ENGINE 271 ENGINE 271.951 in MODEL 906
timing case cover 1000-01TK
AH01.40-P-
Notes on sealant path for
ENGINE 660.9 in MODEL 451.3 /4 1000-
timing case cover
01MCD
Notes on sealant path for AH01.40-P-
ENGINE 272, 273
timing case cover 1000-01VA
Notes on sealant path for AH01.40-P-
ENGINE 651
timing case cover 1000-01CD
Notes on sealant path for ENGINE 642.970 in MODEL 463 ENGINE 642.975 /884 in AH01.40-P-
timing case cover MODEL 461 1000-01GY
Notes on sealant path for AH01.40-P-
ENGINE 642 in MODEL 207, 212, 218, 221
timing case cover 1000-01SXI
AH01.40-P-
Notes on sealant path for
ENGINE 157, 278 1000-
timing case cover
01MMB
Notes on the application of
AH01.30-P-
sealant to the cylinder head ENGINE 122.9 in MODEL 454.0
1000-08FB
cover
Notes on the application of
AH01.30-P-
sealing compound to the ENGINE 273
1000-08SX
cylinder head cover
Notes on the application of
AH01.30-P-
sealing compound to the ENGINE 642 in MODEL 219.322
1000-08TQ
cylinder head cover
Notes on the application of
AH01.30-P-
sealing compound to the ENGINE 642 in MODEL 164, 203, 209, 251.0 /1
1000-08PI
cylinder head cover
Notes on the application of
AH01.30-P-
sealing compound to the ENGINE 266.980 in MODEL 169.0 /3, 245.2
1000-08BK
cylinder head cover
Notes on the application of
AH01.30-P-
sealing compound to the ENGINE 266.920 /940 /960 in MODEL 169.0 /3, 245.2
1000-08AK
cylinder head cover
Notes on the application of
AH01.30-P-
sealing compound to the ENGINE 642
1000-08TI
cylinder head cover
Notes on the sealant process
ENGINE 166.940 /960 /961 /990 /995 /991, AH01.40-P-
for the end cover with radial
668.914 /940 /941 /942 1000-06C
shaft seal
Use of engine no. when
installing reconditioned
AH01.10-P-
engines and factory-new ENGINE all
0001-01A
replacement engines or
crankcases
Use of unleaded fuel in AH01.10-P-
ENGINE 102, 110, 115, 116, 117...
reconditioned engines 1000-01A
USE OF ENGINE NO. WHEN INSTALLING RECONDITIONED ENGINES AND FACTORY-NEW
REPLACEMENT ENGINES OR CRANKCASES - AH01.10-P-0001-01A
All engines
The engine number has a different legal significance in individual countries. In the Federal Republic of
Germany, for example, it has been classified by the legislative authorities since mid-1972 as "insignificant in
terms of traffic legislation". It is therefore no longer included in the vehicle title document and vehicle
registration document.
Practically all other countries continue to require the indication of the engine number on motor vehicles which
are registered in such countries. In dealing with international traffic, the authorities proceed on the basis of the
provisions of the country in which the vehicle is registered.
In order to avoid any problems on the occasion of vehicle checks or when crossing international frontiers as a
result of the lack of or incorrect engine number, the following directives have to be observed when carrying out
repairs.
1. Directives for vehicles which are registered in the Federal Republic of Germany
a. In the case of vehicles for which no engine number is indicated in the vehicle registration
document (first registration after approx. mid-1972), it is not necessary to stamp or revise an
engine number if a replacement engine or crankcase of the same type is fitted.
b. If an engine number is indicated in the vehicle registration document , it is possible, if an
engine of the same type is fitted, to transfer the number of the removed component to the new
engine, or the appropriate authority (vehicle inspection authority, vehicle registration authority)
should be requested to delete the engine number in the vehicle title document or registration
document. The German Federal Minister of Transport has issued appropriate ministerial orders in
Transport Gazette 1973, p. 66.
2. Vehicles which are registered outside of the Federal Republic of Germany
If a reconditioned engine or factory-new replacement engine or crankcase is fitted and this is of the
identical type, it is then necessary to adopt the engine number of the engine removed and to transfer it to
the new engine or crankcase.
NOTE: It is possible in the case of various engines only to stamp the engine
number in place when the engine is removed.
For this reason, pay attention to the particular directives stated in Para 3 for the installation of
reconditioned engines, crankcases and shortblocks.
3. Special directives
3.1 Installation of factory-new replacement engine of identical type
a. If a factory-new engine is installed and an engine number is required (e.g. vehicle registered
outside of the Federal Republic of Germany), the number of the factory-new engine must be ground
off and the number of the originally installed engine of identical type stamped in its place.
b. If the factory-new engine is fitted with an engine type plate (older car engines) and it is necessary
to indicate an engine number in the vehicle documents, in this case take the engine type plate off
the engine removed and affix it at the same point on the engine of identical type to be installed.
3.2 Installation of reconditioned engine of identical type
a. The reconditioned engine plate must not be removed either from the reconditioned engine to be
installed, nor from the engine removed, if the latter was a reconditioned engine.
b. If the engine removed is fitted with an engine type plate (older car engines) and it is necessary to
indicate an engine number in the vehicle documents, the engine type plate then has to be taken off
the engine removed and affixed at the same point to the reconditioned engine to be installed. This
plate should be affixed in addition to the reconditioned engine plate.
In the event that a vehicle owner has problems on the occasion of vehicle checks or when crossing
international frontiers because of the lack of an engine number, the workshop in question may in certain
circumstances be held liable.
After replacing an engine, the engine number has to be altered in the vehicle maintenance booklet and on
the vehicle data cards as well as in the repair customer file. These documents should clearly show which
engine is installed in the vehicle in order to ensure smooth parts service.
In addition, the copy of the vehicle data card which is held at the Parts Department of the relevant Branch
or Importer should also be altered.
3.3 Model designation identification of crankcases and shortblocks
Crankcases and shortblocks available in the parts sector are not provided with an engine model designation
identification and also not with an engine number.
To make it possible to identify the engine on the occasion of vehicle inspections (e.g. by an inspection authority
when a vehicle is taken out of service or at the Customs on the occasion of importation of vehicle), the
workshop carrying out the repairs has to stamp the engine model designation in the crankcase or the shortblock
in the space provided for the engine number.
Example:
Type Engine model designation 201.024 102.962
Extract from Transport Gazette 1973 p. 66
(applies only to the Federal Republic of Germany)
Official Gazette of the Federal Minister of Transport
Directive in respect of vehicle title document (VkBI 1972 p. 354)
Bonn, 28 December 1972 StV 2/36.15.17
Pursuant to the directive relating to the vehicle title document dated 20 June 1972, Part C. No. 9.1, a dash
should be inserted at the relevant point in the place of data which are no longer required in future (e.g. in the
case of the "factory number of engine") in those instances where the older type of title documents are used for
the preparation of the vehicle title document.
The question which is now posed is what procedure should be adopted in respect of the vehicle title document
or the vehicle registration document in the event that the factory number of the engine from the past is still
entered in the older type of title documents and a replacement engine with a new number is now installed in the
vehicle in question. Following consultation with the competent authorities in the regions, I now provide the
following instructions:
I. In view of the fact that the factory number of the engine is regarded as insignificant in respect of traffic
legislation, no change requires to be made to the vehicle documents. This also does not conflict with 27
Para 1 StVZO pursuant to which the data in the vehicle title and registration documents constantly have
to reflect actual circumstances. This requirement namely covers only those particulars relating to actual
circumstances which are of significance in terms of traffic legislation. This is no longer the case,
however, in respect of the factory number of the engine.
II. In order to spare the relevant vehicle owner any misunderstandings or indeed possible disadvantages (e.g.
on the occasion of checks when abroad), I recommend proceeding as follows:
In the event that the replacement engine installed has a different number than that entered in the title and
registration document, the figures in the column "engine factory number" shall be deleted and the following
endorsement made at a suitable point both in the title as well as in the registration document:
"Entry of engine factory number no longer necessary".
If the endorsement is made close to the deletion, it is sufficient to state:
"Entry no longer required".
The Federal Minister of Transport
Ip. p.
Wagner
USE OF UNLEADED FUEL IN RECONDITIONED ENGINES - AH01.10-P-1000-01A
Engine 102, 110.92, 110.98, 110.99, 115.954, 116.96, 116.98, 117.96, 117.98
Permanent operation with unleaded fuel requires installation of harder valve seat inserts.
The above reconditioned engines are equipped with these harder valve seat inserts and therefore can be operated
permanently with unleaded fuel without limitation.
Engine model designation Engine end no. as of Production period as of
102 736672 1.1.87
110.92 736672 1.1.87
110.98 736672 1.1.87
110.99 736672 1.1.87
115.954 736672 1.1.87
116.96 815427 1.2.88
116.98 815427 1.2.88
117.96 815427 1.2.88
117.98 815427 1.2.88
NOTES ON APPLICATION OF SEALANT TO FRONT COVER AT CYLINDER HEAD - AH01.30-P-
1000-02C
Engine 275
Application of sealing compound to front cover at right cylinder head
The line (F ) marks the application of the sealing compound.
The sealant must be applied only to the specified surfaces with a bead of 2.0 mm 0.5 mm.
The sealing compound must be applied within 10 minutes
The sealing compound bead must not be spread. Only the approved sealing compound must be used.
Fig. 17: Identifying Sealant Applying Surface On Front Cover Of Right Cylinder Head
Courtesy of MERCEDES-BENZ USA
NOTES ON APPLICATION OF SEALING COMPOUND TO FRONT COVER AT CYLINDER HEAD
- AH01.30-P-1000-02D
Engine 275
Application of sealing compound to front cover at left cylinder head
The line (F ) marks the application of the sealing compound.
The sealant must be applied only to the specified surfaces with a bead of 2.0 mm 0.5 mm.
The sealing compound must be applied within 10 minutes
The sealing compound bead must not be spread. Only the approved sealing compound must be used.
Fig. 18: Identifying Sealant Applying Surface On Front Cover Of Left Cylinder Head
Courtesy of MERCEDES-BENZ USA
NOTES ON SEALANT PATH FOR FRONT COVER TO CYLINDER HEAD - AH01.30-P-1000-02V
Engine 272, 273
Application of sealant to the right front cover
The line (A) identifies the sealant run.
The sealing compound must only be applied along the line (A) in the form of a bead with a height and width
of 1.0 mm (+0.5 mm).
The sealing compound must be applied within 10 min.
The sealant bead must not be spread. Only the approved sealant may be used.
Fig. 19: Identifying Sealant On Right Front Cover
Courtesy of MERCEDES-BENZ USA
Application of sealant to the left front cover
Fig. 20: Identifying Sealant On Left Front Cover
Courtesy of MERCEDES-BENZ USA
INFORMATION ON APPLYING SEALANT TO CYLINDER HEAD GASKET - AH01.30-P-1000-
04RX
Engine 272, 273
Before mounting the cylinder heads, apply sealant around the timing case cover on the cylinder crankcase.
Repair information
The sealing surface must be cleaned.
Sealant should be applied only to the specified surface, in the form of a bead 2.0 mm (±0.5 mm) in height and
width (see picture).
The sealant remains workable for 10 min.
The bead should not be spread.
Fig. 21: Identifying Sealant On Cylinder Crankcase
Courtesy of MERCEDES-BENZ USA
INFORMATION ON CYLINDER HEAD CONTACT SURFACE - AH01.30-P-1000-05A
The cylinder head contact surface should only be machined if there is mechanical damage.
It should not be machined (by face grinding) if the contact surface of the cylinder head is uneven (warped) in
the longitudinal and transverse directions.
When the cylinder head is mounted again, surface warping will be evened out when the cylinder head bolts are
tightened.
Stock removal from the cylinder head and cylinder crankcase of an engine should together be no more than 0.3
mm If the cylinder head contact surface is machined, the valve seats must be reset.
NOTES ON THE APPLICATION OF SEALING COMPOUND TO THE CYLINDER HEAD COVER -
AH01.30-P-1000-08SX
Sealing compound beads on the right cylinder head cover
The lines (A) identify the sealing compound beads.
The sealing surface must be cleaned.
The sealing compound must only be applied to the specified surface in the form of a bead and a height and
width of 1.0 mm (±0.2 mm).
The sealing compound must be applied within 10 minutes.
The sealing compound bead must not be spread. Only the approved sealant may be used.
Fig. 22: Identifying Sealing Compound Bead On Right Cylinder Head Cover
Courtesy of MERCEDES-BENZ USA
Sealing compound beads on the left cylinder head cover
Fig. 23: Identifying Sealing Compound Bead On Left Cylinder Head Cover
Courtesy of MERCEDES-BENZ USA
NOTES ON APPLICATION OF SEALANT TO TIMING CASE COVER - AH01.40-P-1000-01AMG
The lines (1) identify the application of the sealant.
The sealing surface must be cleaned. The sealant must only be applied to the specified surface in the form of
a bead and to a height and width of 1.5 mm (±0.5 mm). The sealant must be applied within 10 min. The sealant
bead must not be spread. Use only sealant listed in the Repair Products.
Fig. 24: Identifying Sealant Application Area On Timing Case Cover
Courtesy of MERCEDES-BENZ USA
INFORMATION ON APPLICATION OF SEALANT TO TIMING CASE COVER - AH01.40-P-1000-
01C
Engine 137.970, 275
Application of sealant to timing case cover
The line (F ) marks the application of the sealing compound.
The sealant must be applied only to the specified surfaces with a bead of 2.0 mm 0.5 mm.
The sealing compound must be applied within 10 minutes
The sealing compound bead must not be spread. Only the approved sealing compound must be used.
Fig. 25: Identifying Timing Case Cover Sealant Application Areas
Courtesy of MERCEDES-BENZ USA
NOTES ON SEALANT PATH FOR TIMING CASE COVER - AH01.40-P-1000-01VA
Engine 272, 273
The lines (1) identify the application of the sealant.
The sealing surface must be cleaned. Sealant should be applied only to the specified surface, in the form of a
bead of height and width 1.5 mm ±0.5 mm. The sealing compound must be applied within 10 min. The sealing
compound bead must not be spread. Use only the sealant indicated in Repair Materials.
Fig. 26: Identifying Sealant Application Area On Timing Case Cover
Courtesy of MERCEDES-BENZ USA
INFORMATION ON APPLICATION OF SEALANT TO CRANKCASE BOTTOM SECTION -
AH01.40-P-1000-03A
Sealing agent flow
The line drawn in (F) identifies the sealing compound application.
The sealant must be applied only to the specified surfaces with a bead of 2.0 mm 0.5 mm. The sealing
compound must be applied within 10 min. The bead should not be spread. Only the approved silicone sealant
may be used.
Fig. 27: Identifying Sealant Applying Areas On Crankcase Bottom Section
Courtesy of MERCEDES-BENZ USA
INFORMATION ON APPLICATION OF SEALANT TO CRANKCASE BOTTOM SECTION -
AH01.40-P-1000-03AMG
Engine 156
Sealing agent flow
The line drawn in (F) identifies the sealant application.
The sealant must be applied only to specified surfaces with a bead of 2.0 mm ±0.5 mm. The sealant must be
applied within 10 min. The silicone bead must not be spread. Only use released sealant listed in the Repair
Products.
Fig. 28: Identifying Sealant Application Areas On Crankcase Bottom Section
Courtesy of MERCEDES-BENZ USA
INFORMATION ON APPLICATION OF SEALANT TO END COVER OF CRANKCASE - AH01.40-
P-1000-04A
The line (G) identifies the sealant run.
The sealant must only be applied to the specified surfaces with a bead of 2.0 mm 0.5 mm.
The sealing compound must be applied within 10 min.
The bead should not be spread. Only the approved sealant may be used.
Courtesy of MERCEDES-BENZ USA
NOTES ON APPLICATION OF SEALANT TO OIL PAN - AH01.45-P-0001-01A
The line (F) identifies the sealing compound flow.
The sealant must only be applied to the specified surfaces with a bead of 2.0 mm 0.5 mm.
The sealing compound must be worked on within 10 minutes.
The bead should not be spread. Only the approved sealant may be used.
Fig. 30: Identifying Sealant Application Areas On Oil Pan
Courtesy of MERCEDES-BENZ USA
NOTES ON APPLICATION OF SEALANT TO OIL PAN - AH01.45-P-0001-01AMG
Application off sealant to oil pan top section on an engine with a front sump
The line (1) identifies the sealant run
The sealing surface must be cleaned.
The sealing compound must only be applied to the specified surface in the form of a bead and a height and
width of 2.0 mm (±0.5 mm).
The sealing compound must be applied within 10 min.
The sealant bead must not be spread. Only the sealing compound listed in the Repair Products may be used.
Fig. 31: Identifying Sealant Application Areas On Oil Pan Top Section On Engine With Front Sump
Courtesy of MERCEDES-BENZ USA
Application off sealant to oil pan bottom section on an engine with a front sump
The line (1) identifies the sealant run
The sealing surface must be cleaned.
The sealing compound must only be applied to the specified surface in the form of a bead and a height and
width of 2.0 mm (±0.5 mm).
The sealing compound must be applied within 10 min.
The sealant bead must not be spread. Only the sealing compound listed in the Repair Products may be used.
Fig. 32: Identifying Sealant Application Areas On Oil Pan Bottom Section On An Engine With Front
Sump
Courtesy of MERCEDES-BENZ USA
Application off sealant to oil pan top section on an engine with a rear sump
The line (1) identifies the sealant run
The sealing surface must be cleaned.
The sealing compound must only be applied to the specified surface in the form of a bead and a height and
width of 2.0 mm (±0.5 mm).
The sealing compound must be applied within 10 min.
The sealant bead must not be spread. Only the sealing compound listed in the Repair Products may be used.
Fig. 33: Identifying Sealant Application Areas On Oil Pan Top Section On Engine With Rear Sump
Courtesy of MERCEDES-BENZ USA
Application of sealant to oil pan bottom section at rear for engine with rear sump
The line (1) identifies the sealant run
The sealing surface must be cleaned. The sealing compound must only be applied to the specified surface in
the form of a bead and a height and width of 2.0 mm (±0.5 mm).
The sealing compound must be applied within 10 min.
The sealant bead must not be spread. Only the sealing compound listed in the Repair Products may be used.
Fig. 34: Identifying Sealant Application Areas On Oil Pan Bottom Section At Rear For Engine With Rear
Sump
Courtesy of MERCEDES-BENZ USA
Application of sealant to oil pan bottom section at front for engine with rear sump
The line (1) identifies the sealant run
The sealing surface must be cleaned. The sealing compound must only be applied to the specified surface in
the form of a bead and a height and width of 2.0 mm (±0.5 mm).
The sealing compound must be applied within 10 min.
The sealant bead must not be spread. Only the sealing compound listed in the Repair Products may be used.
Fig. 35: Identifying Sealant Application Areas On Oil Pan Bottom Section At Front For Engine With
Rear Sump
Courtesy of MERCEDES-BENZ USA
NOTES ON APPLICATION OF SEALANT TO OIL PAN - AH01.45-P-0001-01SX
MODIFICATION NOTES
28.2.06 Sealant path for adapted to specifications of the Development Department Engine 273
Oil pan with front sump
The line (A) identifies the sealant run.
The sealing surface must be cleaned. The sealant must only be applied to the specified surface in the form of
a bead and a height and width of 2.0 mm (±0.5 mm). The sealant must be applied within 10 min. The sealant
bead must not be spread. Only the sealant listed in the Repair Products may be used.
Fig. 36: Identifying Sealant Application Areas On Oil Pan With Front Sump
Courtesy of MERCEDES-BENZ USA
Oil pan with rear sump
Fig. 37: Identifying Sealant Application Areas On Oil Pan With Rear Sump
Courtesy of MERCEDES-BENZ USA
Oil pan with middle sump
Fig. 38: Identifying Sealant Application Areas On Oil Pan With Middle Sump
Courtesy of MERCEDES-BENZ USA
NOTES ON SEALANT PATH FOR OIL PAN - AH01.45-P-0001-01SY
Application of sealant to oil pan bottom section for engine with front sump
The line (1) identifies the sealant run.
The sealing surface must be cleaned. The sealant must only be applied to the specified surface in the form of
a bead and a height and width of 2.0 mm (±0.5 mm).
The sealant must be applied within 10 min. The sealant bead must not be spread. Only sealant listed in the
Repair Products may be used.
Fig. 39: Identifying Sealant Application Areas On Oil Pan Bottom Section For Engine With Front Sump
Courtesy of MERCEDES-BENZ USA
Application of sealant to oil pan bottom section for engine with middle sump
Fig. 40: Identifying Sealant Application Areas On Oil Pan Bottom Section For Engine With Middle Sump
Courtesy of MERCEDES-BENZ USA
Application of sealant to oil pan bottom section for engine with rear sump
Fig. 41: Identifying Sealant Application Areas On Oil Pan Bottom Section For Engine With Rear Sump
Courtesy of MERCEDES-BENZ USA
REMOVE SEALANT - AR01.00-P-0050-01A
REPAIR MATERIALS
Number Designation Order number
Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925
BR00.45-Z-
Loctite 7200 Munchen Germany Tel. +49 899268-0 Fax + 49 899101978
1038-04A
www.Loctite.de
BR00.45-Z- Loctite 7063 cleaning
A 001 986 71 71 10
1046-04A spray (150 ml)
1. Wipe off operating fluids and other soiling from sealing surface using rags.
2. Spray Loctite 7200 onto sealing surfaces and leave to work for about 10 to 20 minutes.
Observe manufacturer's processing instructions!
3. Remove loosened silicone sealant with a scraper from sealing surfaces and wipe off with rags.
Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces.
The sealing surfaces must feel even after treatment. The sealing surfaces must not be metallic bright; a
thin layer of firmly adhering silicone sealant must remain (see picture).
4. Absolutely be sure to thoroughly clean the sealing surface with cleaning spray Loctite 7063 and blow
off using compressed air.
Fully blow off the cleaning spray Loctite 7063 before applying the new silicone sealant otherwise
leaks can occur.
Fig. 42: View Of Sealing Surfaces
Courtesy of MERCEDES-BENZ USA
ENGINE
Engine Suspension - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: ENGINE SUSPENSION - AH22.00-Z-9999AZ
MODEL all
Notes on rear engine mounts ENGINE 601, 602, 603 AH22.10-P-0001-01A
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE SUSPENSION - AR22.00-Z-9156AB
ENGINE 156
ENGINE 113.990 in MODEL 219.376
AR22.10-P-
Remove/install engine mount ENGINE 156.983 in MODEL
1100TZ
211.077 /277, 219.377
Remove/install engine mount or engine AR22.10-P-
ENGINES 156 in MODEL 204, 212
crossmember at the rear 1180CMG
Remove/install engine mount or engine AR22.10-P-
ENGINE 156 in MODEL 230.470
crossmember at the rear 1180RMG
Remove/install engine mount or engine ENGINE 156, 157, 272, 273, 275, 276, AR22.10-P-
crossmember at the rear 278, 629, 642... 1180SX
Remove/install front engine mounts and/or AR22.10-P-
ENGINES 156 in MODEL 204, 212
engine support 1260CMG
Remove/install front engine mounts and/or AR22.10-P-
ENGINES 156 in MODEL 164, 251
engine support 1260GZS
Remove/install front engine mounts and/or ENGINE 156.982 in MODEL AR22.10-P-
engine support 209.377 /477 1260QMG
Remove/install front engine mounts and/or AR22.10-P-
ENGINES 156 in MODEL 230.470
engine support 1260RMG
Remove/install front engine mounts and/or AR22.10-P-
ENGINE 156, 272, 273...
engine support 1260SX
AR22.10-P-
Remove/install left engine support ENGINE 113, 156...
4350TY
AR22.10-P-
Remove/install rear engine cross member ENGINES 156 in MODEL 164, 251
1170GZS
AR22.10-P-
Remove/install rear engine mount ENGINE 156 in MODEL 164, 251
1160GZS
Remove/install rear engine mount ENGINE 156, 272, 273...
1160QB
ENGINES 156.983 in MODEL AR22.10-P-
Remove/install rear engine mount
211.077 /277 1160TS
AR22.10-P-
Remove/install rear engine mount ENGINE 156.983 in MODEL 219.377
1160TX
AR22.10-P-
Remove/install right engine support ENGINE 113, 156...
4340TY
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE SUSPENSION - AR22.00-Z-9273AB
ENGINE 273
ENGINES 273 in MODEL 212 Vehicle with AR22.10-P-
Remove/install engine mount
4MATIC 1100EWX
AR22.10-P-
Remove/install engine mount ENGINE 272, 273...
1100QB
AR22.10-P-
Remove/install engine mount ENGINE 112, 113, 272, 273...
1100VM
Remove/install engine mount or ENGINE 157, 271, 272, 273, 276, 278, 642, 646, AR22.10-P-
engine crossmember at the rear 651... 1180CW
Remove/install engine mount or ENGINES 272, 273, 629, 642 in MODEL 164 AR22.10-P-
engine crossmember at the rear ENGINES 272, 273, 642 in MODEL 251 1180GZD
Remove/install engine mount or AR22.10-P-
ENGINES 272, 273 in MODEL 230
engine crossmember at the rear 1180RX
Remove/install engine mount or AR22.10-P-
ENGINE 272, 273, 276, 278, 642...
engine crossmember at the rear 1180SW
Remove/install engine mount or ENGINE 156, 157, 272, 273, 275, 276, 278, 629, AR22.10-P-
engine crossmember at the rear 642... 1180SX
ENGINES 272, 273 (except 272.972 /944, 273.962)
Remove/install engine mount or AR22.10-P-
in MODEL 211 ENGINES 272, 273 in MODEL
engine crossmember at the rear 1180TS
219
AR22.10-P-
Remove/install engine support ENGINE 272, 273...
1200QB
Remove/install front engine AR22.10-P-
ENGINE 272, 273...
mounts and/or engine support 1260CV
Remove/install front engine AR22.10-P-
ENGINES 272, 273 in MODEL 212
mounts and/or engine support 1260EWS
Remove/install front engine ENGINES 273 in MODEL 164 ENGINES 272.973 AR22.10-P-
mounts and/or engine support in MODEL 164 1260GZA
Remove/install front engine AR22.10-P-
ENGINES 272, 273 in MODEL 251
mounts and/or engine support 1260RTC
Remove/install front engine AR22.10-P-
ENGINES 272, 273 in MODEL 230
mounts and/or engine support 1260RX
mounts and/or engine support ENGINES 273 in MODEL 216.38 1260SW
Remove/install front engine AR22.10-P-
ENGINE 156, 272, 273...
mounts and/or engine support 1260SX
Remove/install front engine ENGINES 273 (except 273.962) in MODEL 211 AR22.10-P-
mounts and/or engine support ENGINES 273 in MODEL 219 1260TS
AR22.10-P-
Remove/install left engine support ENGINE 112, 113, 272, 273...
4350TW
AR22.10-P-
Remove/install rear engine mount ENGINE 156, 272, 273...
1160QB
AR22.10-P-
Remove/install rear engine mount ENGINE 112, 113, 272, 273...
1160TW
Remove/install right engine AR22.10-P-
ENGINE 112, 113, 272, 273...
support 4340TW
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE SUSPENSION - AR22.00-Z-9275AB
ENGINE 275
Remove/install engine mount or ENGINE 156, 157, 272, 273, 275, 276, 278, 629,
AR22.10-P-
engine crossmember at the rear 642... 1180SX
ENGINE 275.950 in MODEL 215.376, 220.176 AR22.10-P-
Remove/install front engine mount
ENGINE 275.980 in MODEL 215.379, 220.179 4330IX
Remove/install front engine mounts AR22.10-P-
ENGINES 275 in MODEL 230
and/or engine support 1260R
Remove/install front engine mounts AR22.10-P-
ENGINES 275 in MODEL 216, 221
and/or engine support 1260SZ
ENGINES 275.950 in MODEL 215.376, 220.176 AR22.10-P-
Remove/install front engine supports
ENGINES 275.980 in MODEL 215.379, 220.179 4320IX
Remove/install rear engine cross AR22.10-P-
ENGINE 275, 628...
member 1170M
AR22.10-P-
Remove/install rear engine mount ENGINE 112, 113, 137, 275, 613, 628...
1160AB
REMOVE/INSTALL ENGINE MOUNT OR ENGINE CROSSMEMBER AT THE REAR - AR22.10-P-
1180SW
ENGINES 272, 273, 276, 642 in MODEL 221.08 /18
ENGINES 273 in MODEL 216.38
ENGINES 278 in MODEL 221.094 /194, 216.39
Fig. 1: Identifying Rear Engine Crossmember, Rear Engine Mount, Transfer Case And Bolts
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
29.5.08 Value changed: Bolt for rear engine crossmember to body *BA22.10-P-1007-03D
REMOVE/INSTALL ENGINE MOUNT OR ENGINE CROSSMEMBER AT THE REAR - AR22.10-P-
1180SX
ENGINES 156, 157, 272, 273, 275, 276, 278, 642, 629 in MODEL 221 (except 221.08 /18 /094 /194)
ENGINES 156, 157, 273, 275, 278 in MODEL 216 (except 216.38 /39)
Fig. 2: Identifying Rear Engine Mount, Engine Crossmember, Bracket & Bolts
Courtesy of MERCEDES-BENZ USA
Remove/install
AH00.00-P-
Notes on bolted connections with self tapping screws
0007-01SF
AR00.60-P-
1 Secure vehicle on vehicle lift
0100SX
AR61.20-P-
Remove rear part section of engine compartment 1105SX
2
paneling Vehicles without code (Z07) Top protection Vehicles with code AR61.20-P-
(Z07) Top protection 1105SXS
*BA22.10-P-
Model 221 1005-03D
3 Remove bolts (1a)
*BA22.10-P-
Model 216
1005-03C
Raise transmission with a transmission jack by about 10
4
mm
*BA22.10-P-
Model 221 1007-03D
5 Remove bolts (2s) and take off engine crossmember (2)
*BA22.10-P-
Model 216 1007-03C
*BA22.10-P-
Model 221
Remove bolts (1b) and rear engine mount (1) from 1004-03D
6
holder (3) on transmission *BA22.10-P-
Model 216 1004-03C
7 Install in the reverse order
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
221.02/05/07/095/12/15/17/195
BA22.10-P-1004- Bolt connecting rear engine mount to
Nm 50
03D transmission bracket
BA22.10-P-1005- Bolt, rear engine mount to rear engine
Nm 28
03D crossmember
BA22.10-P-1007-
Bolt, rear engine crossmember to body Nm 45
03D
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
216.371/373/374 /376/377/379
BA22.10-P-1004- Bolt connecting rear engine mount to
Nm 50
03C transmission bracket
BA22.10-P-1005- Bolt, rear engine mount to rear engine
Nm 28
03C crossmember
BA22.10-P-1007-
Bolt, rear engine crossmember to body Nm 45
03C
REMOVE/INSTALL FRONT ENGINE MOUNTS AND/OR ENGINE SUPPORT - AR22.10-P-1260SW
ENGINES 273.924 /968 in MODEL 221.08 /18
ENGINES 273 in MODEL 216.38
Fig. 3: Identifying Front Engine Mounts & Engine Support Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Disable entry/exit support replaced by detach ground line(s) from battery
Step 1
(batteries)
17.3.08
Operation step
Remove heat shield from engine mount added
4
Remove/install
Both engine mounts
General information Engine mounts (8) must be replaced in pairs.
Remove ground line(s) from AR54.10-P-
1
battery (batteries) 0003SX
The steering wheel must not be turned when
Move front wheels to straight- the steering coupling is detached, otherwise the
2 ahead position and secure clock spring contact will be destroyed.
steering wheel.
Fig. 4
AR09.10-P-
3 Remove air filter housing
1150SX
4 mounts (8)
Fig. 5
*BA22.10-P-
1001-03D
*BA22.10-P-
5 Remove bolts (5, 7) 1002-03D
*BA22.10-P-
1001-03C
*BA22.10-P-
1002-03C
No not apply tension to or damage lines or
Attach engine hoist and raise hoses. AR33.10-P-
6
engine Attach shackle to front engine suspension lug 0105SX
only .
Remove bottom engine AR61.20-P-
7
compartment paneling 1105SX
Detach steering coupling at AR46.10-P-
8
steering shaft 8000SX
Installation: Align anti-twist lock on engine
mount (8) to cutout on engine support (6).
Remove left engine mount (8) to
9 Pay attention to environmental protection
the rear and down
regulations for disposal of engine mounts (8).
Dispose engine mounts (8) into mixed scrap.
Detach power steering oil line (4)
10
from holder (2)
Remove holder (2) from
*BA15.40-P-
11 alternator (G2) by removing bolts
1001-01F
(1)
Remove engine mount (8) between front axle
carrier (9) and fan shroud.
Installation: Align anti-twist lock on engine
Remove right engine mount (8)
12 mount (8) to cutout on engine support (6).
to the front and down
Pay attention to environmental protection
regulations for disposal of engine mounts (8).
Dispose engine mounts (8) into mixed scrap.
Left engine support
AR49.10-P-
13 Remove left catalytic converter
7100SX
Remove refrigerant compressor *BA83.55-P-
14
bolt on engine support (6) 1001-01M
Remove engine support (6) from
*BA22.10-P-
15 cylinder crankcase by removing
1001-02A
bolts (6S)
16 rear and down
Right engine support
AR49.10-P-
17 Remove right catalytic converter
7100SX
AR14.10-P-
18 Remove right exhaust manifold
3915SX
Remove bolt from engine support *BA33.30-P-
19
(6) to front axle transmission 1007-03G
*BA22.10-P-
20 Remove bolts (6S)
1001-02A
Remove engine support (6) to the
21
rear and down
22 Install in the reverse order
ALTERNATOR
Number Designation Engine 273
BA15.40-P-1001-01F Bolt, alternator to timing case Nm 20
ENGINE SUPPORT (ENGINE SIDE)
Number Designation Engine 273
Stage 1 Nm 20
BA22.10-P-1001-02A Bolt, engine support to cylinder crankcase
Stage 2 Angle° 90
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
216.386/394
BA22.10-P-1001-
Bolt, front engine mount to front axle carrier Nm 28
03C
M10 Nm 50
Stage
BA22.10-P-1002- Bolt connecting front engine mount to engine M12 Nm 85
1
03C support
Stage
Angle° 90
2
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
221.08/094/18/194
BA22.10-P-1001-
Bolt, front engine mount to front axle carrier Nm 30
03D
M10 Nm 50
BA22.10-P-1002- Bolt connecting front engine mount to Stage
M12 Nm 85
03D engine support 1
2 Angle° 90
FRONT AXLE TRANSMISSION
Model Model
Number Designation
216 221
Stage
Nm 5 5
1
BA33.30-P-1007- Collar bolt, front axle transmission to engine Stage
Nm 50 50
03G support 2
Stage
Angle° 95 95
3
REFRIGERANT COMPRESSOR
Engine
Number Designation
273
BA83.55-P-1001- Bolt, refrigerant compressor to timing case/crankcase/engine
Nm 20
01M support
Fig. 4: Identifying Holding Device (129 589 01 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 5: Identifying Set Of Engine Bearing Wrenches (001 589 01 16 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL FRONT ENGINE MOUNTS AND/OR ENGINE SUPPORT - AR22.10-P-1260SX
ENGINES 156, 272.946 /965 in MODEL 221
ENGINES 273.922 /961 in MODEL 221
ENGINES 156, 273.961 in MODEL 216
Shown on engine 273
Fig. 6: Identifying Front Engine Mounts & Engine Support Components
Courtesy of MERCEDES-BENZ USA
Remove/install
General information Engine mounts must be replaced in pairs.
Vehicles with code 275, Memory package (driver
AR54.30-P-
1 Deactivate easy entry/exit seat, steering column, mirrors) for removal of left
1000-02ESX
engine mount (8) on engine 273
For removal of left engine mount (8) for engine
273
Move front wheels to straight- The steering wheel must not be turned
2 ahead position and secure steering when the steering coupling is detached, otherwise
wheel. the clock spring contact will be destroyed.
Holding device Fig. 4
Set of engine bearing wrenches Fig. 5
*BA22.10-P-
3 Remove bolts (7) Model 221 1001-03D
*BA22.10-P-
Model 216 1001-03C
Attach engine hoist and raise No not apply tension to or damage lines or AR33.10-P-
4
engine hoses. 0105SX
Remove bottom engine AR61.20-P-
5
compartment paneling 1105SX
Detach steering coupling at the For removal of left engine mount (8) for engine AR46.10-P-
6
steering shaft 273 8000SX
Installation: Align anti-twist lock on engine
mount (8) and heat shield (9) to cutout and raised
point on engine support (6).
Pay attention to environmental protection
Undo bolt (10) and remove engine regulations for disposal of engine mounts (8).
7 mount (8) with heat shield (9)
Dispose engine mounts (8) into mixed scrap.
from the bottom
*BA22.10-P-
Model 221 1002-03D
*BA22.10-P-
Model 216 1002-03C
Left engine support
*BA83.55-P-
Engine 272, 273
Remove refrigerant compressor 1001-01M
8
bolt on engine support (6) *BA83.55-P-
Engine 156
1001-01T
Remove engine support (6) from *BA22.10-P-
9
crankcase by removing bolts (65) 1001-02A
Remove engine support (6) to the
10
rear and down
Right engine support
Disconnect ground lines from AR54.10-P-
11
batteries 0003SX
Loosen alternator and lay down to AR15.40-P-
12 Engine 272
the side with connected feed lines 5032SX
AR18.40-P-
13 Remove oil dipstick guide tube Engine 272
3510SX
Remove bolt (4) for ground line
14
(5) at engine support (6)
Remove bolts (65) at engine *BA22.10-P-
15
support (6) 1001-02A
Remove engine support (6) to the
16
rear and down
17 Install in the reverse order
ENGINE SUPPORT (ENGINE SIDE)
Engine Engine Engine
Number Designation
272 273 156
1 Nm 20 20 20
BA22.10-P-1001- Bolt, engine support to cylinder
02A crankcase Stage
Angle° 90 90 90
2
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model 221.02/05/07/
Number Designation
095/12/15/17/ 195
BA22.10-P-
Bolt, front engine mount to front axle carrier Nm 35
1001-03D
M10 Nm 50
Stage
BA22.10-P- Bolt connecting front engine mount M12 Nm 85
1
1002-03D to engine support
Stage
Angle° 90
2
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
216.371/373/374 /376/377/379
BA22.10-P-
Bolt, front engine mount to front axle carrier Nm 35
1001-03C
M10 Nm 50
Stage
BA22.10-P- Bolt connecting front engine M12 Nm 85
1
1002-03C mount to engine support
Stage
Angle° 90
2
REFRIGERANT COMPRESSOR
Engine Engine
Number Designation
272 273
BA83.55-P-1001- Bolt, refrigerant compressor to timing case/
Nm 20 20
01M crankcase/engine support
REFRIGERANT COMPRESSOR
Engine 156 in model 204, 209,
Number Designation
211, 212, 216, 219, 221, 230
BA83.55-P- Bolt, refrigerant compressor to timing case/
Nm 20
1001-01T crankcase/and/or engine support
Fig. 7: Identifying Set Of Engine Bearing Wrenches (001 589 01 16 00)
Courtesy of MERCEDES-BENZ USA
Fig. 8: Identifying Holding Device (129 589 01 21 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL FRONT ENGINE MOUNTS AND/OR ENGINE SUPPORT - AR22.10-P-1260SZ
ENGINES 275 in MODEL 216, 221
Fig. 9: Identifying Front Engine Mount Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 10: Identifying Front Engine Mount Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Remove/install
General information Engine mounts must be replaced in pairs.
Remove/install left and right engine Only perform steps 1 through to 9 for
mount (1) remove/install of engine mount (1).
Remove rear and center section of lower AR61.20-P-
1
engine compartment paneling 1105SX
Detach steering coupling at the steering AR46.10-P-
2
shaft 8000SX
*BA22.10-P-
Model 216
1001-03C
3 Remove bolts (1s)
*BA22.10-P-
Model 221
1001-03D
AR01.10-P-
Engine 275.95
2405LA
4 Remove engine trim panel
AR01.10-P-
Engine 275.98
2405IM
No not apply tension to or damage
lines or hoses.
Attach mount engine lifting device and Model 221 with maximum protection, code
5
raise engine. Z07
Model 216, 221 without top protection 0105SX
*BA22.10-P-
6 Remove bolts (4S) 1002-02A
Fig. 11
Remove engine mounts (1) with carrier
7 plate (2) and heat shield (3) to bottom
rear
When replacing engine mounts (1).
Pay attention to environmental
protection regulations for disposal of
engine mounts (1).
Remove bolts (2s) and engine mounts Dispose engine mounts (1) into mixed
8 scrap.
(1) from carrier plate (2)
*BA22.10-P-
Model 216 1003-03C
*BA22.10-P-
Model 221 1003-03D
9 Install in the reverse order
Install left and right engine support Only perform steps 10 through to 14 for
(6) remove/install of engine mount (6).
AR01.10-P-
10 Remove engine with front axle carrier
2500SZ
AR01.10-P-
11 Detach engine from front axle carrier
2510SX
Remove screws (4s) from front engine
12
support (6)
Remove bolts (1a) and engine support *BA22.10-P-
13
(6) from crankcase 1001-02A
14 Install in the reverse order
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
216.371/373/374/376/377/379
BA22.10-P-1001- Bolt, front engine mount to front axle
Nm 35
03C carrier
BA22.10-P-1003-
Bolt, front engine mount to carrier plate Nm -
03C
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
221.02/05/07/095/12/15/17/195
BA22.10-P-1001- Bolt, front engine mount to front axle
Nm 35
03D carrier
03D Bolt, front engine mount to carrier plate Nm 25
ENGINE SUPPORT (ENGINE SIDE)
Engine
Number Designation
275
Stage
Nm 20
BA22.10-P-1001- 1
Bolt, engine support to cylinder crankcase
02A Stage
Angle° 90
2
Stage
Nm 20
BA22.10-P-1002- Bolt, engine mount carrier plate at front on engine 1
02A support Stage
Angle° 90
2
Fig. 11: Identifying Flexible Head Wrench Set (001 589 81 09 00)
Courtesy of MERCEDES-BENZ USA
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: ENGINE SUSPENSION - BA22.00-Z-9999AZ
MODEL all
Engine mount, engine BA22.10-P-
ENGINE 155 in MODEL 199
support 1000-01W
Engine mount, engine BA22.10-P-
MODEL 230
support (engine side) 1000-03H
Engine mount, engine BA22.10-P-
MODEL 197
support (engine side) 1000-03I
Engine mount, engine BA22.10-P-
MODEL 209
support (engine side) 1000-03B
Engine mount, engine BA22.10-P-
MODEL 164, 166
support (engine side) 1000-03G
MODEL 216
support (engine side) 1000-03C
Engine mount, engine BA22.10-P-
MODEL 172, 204, 207, 212, 218
support (engine side) 1000-03E
Engine mount, engine BA22.10-P-
MODEL 221
support (engine side) 1000-03D
Engine mount, engine BA22.10-P-
MODEL 211, 220
support (engine side) 1000-03A
Engine mount, engine BA22.10-P-
MODEL 251
support (engine side) 1000-03F
Engine mounts, engine BA22.10-P-
ENGINE 601, 602, 603
brackets 1000-01J
Engine mounts, engine BA22.10-P-
ENGINE 120
brackets 1000-01B
Engine mounts, engine BA22.10-P-
ENGINE 103
brackets 1000-01C
Engine mounts, engine BA22.10-P-
ENGINE 104, 111, 119
supports 1000-01A
Engine mounts, engine BA22.10-P-
ENGINE 266, 640 in MODEL 169, 245
supports 1000-01T
Engine mounts, engine ENGINE 166.940 /960 /990 /995 in MODEL 168 ENGINE BA22.10-P-
supports 166.961 /991 in MODEL 414 1000-01G
Engine mounts, engine ENGINE 668.940 /941 /942 in MODEL 168 ENGINE 668.914 BA22.10-P-
supports in MODEL 414 1000-01I
Engine mounts, engine ENGINE 604, 605, 606, 611, 612, 613, 628, 629, 642, 646, BA22.10-P-
supports 647... 1000-01D
Engine mounts, engine BA22.10-P-
ENGINE 112, 113, 137, 275...
supports 1000-01L
Engine mounts, engine BA22.10-P-
ENGINE 113, 156, 272, 273...
supports 1000-01S
Engine mounts, engine BA22.10-P-
ENGINE 112.916 /953 /912 /946 /961 in MODEL 203
supports 1000-01R
Engine mounts, engine BA22.10-P-
MODEL 240
supports 1000-01P
Engine mounts, engine ENGINE 271 in MODEL 171, 203 ENGINE 272 in MODEL BA22.10-P-
supports 171 ENGINE 272 in MODEL 164 1000-01O
Engine mounts, engine BA22.10-P-
ENGINE 780 in MODEL 169
supports 1000-01U
Engine support (engine ENGINE 112, 113, 137, 156, 157, 159, 271, 272, 273, 275, BA22.10-P-
side) 276, 278, 628, 629, 642, 646, 647, 648, 651... 1000-02A
ENGINE SUPPORT (ENGINE SIDE) - BA22.10-P-1000-02A
Engine 112, 113, 137, 156, 157, 159, 271, 272, 273, 275, 276, 278, 285, 628, 629, 642, 646, 651
MODIFICATION NOTES
29.6.10 Value modified: Bolt, shield to engine support Engine 278
ENGINE SUPPORT (ENGINE SIDE)
Engine 112 except Engine Engine
Number Designation
112.916/953 112.916/953 113
Stage
Nm 20 20 20
BA22.10-P- Bolt, engine support to 1
1001-02A cylinder crankcase Stage
Angle° 90 60 90
2
Stage
Bolt, engine mount carrier Nm - - -
BA22.10-P- 1
plate at front on engine
1002-02A Stage
support Angle° -- -
2
BA22.10-P-
Bolt, shield to engine support Nm - - -
1003-02A
ENGINE SUPPORT (ENGINE SIDE)
Engine Engine Engine
Number Designation
137 156 157
Stage
Nm 20 20 20
BA22.10-P- Bolt, engine support to cylinder 1
1001-02A crankcase Stage
Angle° 90 90 90
2
Stage
Nm 20 - -
BA22.10-P- Bolt, engine mount carrier plate at front 1
1002-02A on engine support Stage
Angle° 90 - -
2
BA22.10-P-
Bolt, shield to engine support Nm - 9 9
1003-02A
ENGINE SUPPORT (ENGINE SIDE)
Engine Engine Engine
Number Designation
159 271 272
Stage
Nm 20 20 20
BA22.10-P- Bolt, engine support to cylinder 1
1001-02A crankcase Stage
Angle° 90 90 90
2
Stage
Nm - - -
BA22.10-P- Bolt, engine mount carrier plate at front 1
1002-02A on engine support Stage
Angle° -- -
2
BA22.10-P-
Bolt, shield to engine support Nm - - 9
1003-02A
ENGINE SUPPORT (ENGINE SIDE)
Engine Engine Engine
Number Designation
273 275 276
Stage
Nm 20 20 20
BA22.10-P- Bolt, engine support to cylinder 1
1001-02A crankcase Stage
Angle° 90 90 90
2
Stage
Nm - 20 -
BA22.10-P- Bolt, engine mount carrier plate at front 1
1002-02A on engine support Stage
Angle° - 90 -
2
BA22.10-P-
Bolt, shield to engine support Nm 9 - 13
1003-02A
ENGINE SUPPORT (ENGINE SIDE)
Engine Engine Engine
Number Designation
278 285 628
Stage
Nm 20 20 20
BA22.10-P- Bolt, engine support to cylinder 1
1001-02A crankcase Stage
Angle° 90 90 90
2
Stage
Nm - 20 -
BA22.10-P- Bolt, engine mount carrier plate at front 1
1002-02A on engine support Stage
Angle° - 90 -
2
BA22.10-P-
Bolt, shield to engine support Nm 13 - -
1003-02A
ENGINE SUPPORT (ENGINE SIDE)
Engine Engine Engine
Number Designation
629 642 646
Stage
Nm 20 20 20
BA22.10-P- Bolt, engine support to cylinder 1
1001-02A crankcase Stage
Angle° 90 90 -
2
Stage
Nm - - -
BA22.10-P- Bolt, engine mount carrier plate at front 1
1002-02A on engine support Stage
Angle° -- -
2
BA22.10-P-
Bolt, shield to engine support Nm 9 - -
1003-02A
ENGINE SUPPORT (ENGINE SIDE)
Number Designation 647 648 651
Stage
Nm 20 20 20
BA22.10-P- Bolt, engine support to cylinder 1
1001-02A crankcase Stage
Angle° -- 90
2
Stage
Nm - - -
BA22.10-P- Bolt, engine mount carrier plate at front 1
1002-02A on engine support Stage
Angle° -- -
2
BA22.10-P-
Bolt, shield to engine support Nm - - 9
1003-02A
ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE) - BA22.10-P-1000-03D
Model 221
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model Model
Number Designation
221.02/05/07/095/12/15/17/195 221.08/094/18/194
BA22.10-P- Bolt, front engine mount to
Nm 35 30
1001-03D front axle carrier
M10 Nm 50 50
Bolt connecting Stage
BA22.10-P- M12 Nm 85 85
front engine mount 1
1002-03D
to engine support Stage
Angle° 90 90
2
BA22.10-P- Bolt, front engine mount to
Nm 25 -
1003-03D carrier plate
BA22.10-P- Bolt connecting rear engine
Nm 50 28
1004-03D mount to transmission bracket
BA22.10-P- Bolt, rear engine mount to rear
Nm 28 28
1005-03D engine crossmember
BA22.10-P- Bolt, rear engine crossmember
Nm 45 45
1007-03D to body
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
221.003/103
BA22.10-P-1001-
Bolt, front engine mount to front axle carrier Nm 30
03D
M10 Nm 50
BA22.10-P-1002- Bolt connecting front engine mount to engine M12 Stage Nm -
03D support 1
2 Angle° -
BA22.10-P-1003-
Bolt, front engine mount to carrier plate Nm -
03D
BA22.10-P-1004-
Bolt connecting rear engine mount to transmission bracket Nm 50
03D
BA22.10-P-1005-
Bolt, rear engine mount to rear engine crossmember Nm 28
03D
BA22.10-P-1007-
Bolt, rear engine crossmember to body Nm 45
03D
SPECIAL TOOLS
112 589 00 16 00 VERBINDUNGSSTUCK - WS22.00-P-0003C
FG 22/Satz C
ENGINE 112, 113, 272, 273
Verwendung:
Verbindungsstuck Lange 60 mm mit durchgehendem Innenrechteckprofil 14x18 mm fur Einsteckwerkzeuge.
z.B.
Vierkantantrieb 1/2" z.B. Hazet Nr. 6414
Ringschlussel 17 mm z.B. Hazet Nr.6630d-17
Verlangerung 1/2" z.B. Hazet Nr. 918-10
Zum Losen und Anziehen der oberen Verschraubungen der Motorlager mit Drehmoment.
Fig. 12: Identifying Verbindungsstuck (112 589 00 16 00)
Courtesy of MERCEDES-BENZ USA
210 589 00 16 00 CONNECTION PIECE - WS22.00-P-0005B
FG 22/Set B
ENGINE 111, 112, 113, 137, 272, 273, 611, 612, 613, 628, 629, 642, 647, 648, 651, 642
Use:
14 x 18 mm connection piece to loosen and tighten the mounting screw for the engine mount to the engine
support (along with a four-point drive 210 589 01 16 00)
Fig. 13: Identifying Connection Piece (210 589 00 16 00)
Courtesy of MERCEDES-BENZ USA
210 589 01 16 00 FOUR-POINT DRIVE - WS22.00-P-0006B
FG 22/05/Set B
ENGINE 111, 112, 113, 137, 272, 273, 275, 611, 612 /965 /966, 613, 628, 629, 642, 646, 647, 648, 651
Use:
Four-point drive to remove the chain tensioner.
Fig. 14: Identifying Four-Point Drive (210 589 01 16 00)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 01 PLUG-IN ADAPTER - WS22.00-P-0008-01B
FG22/07/09/28/Set B
MODEL 163, 164, 171, 203, 204, 210, 211, 215, 219, 220, 221, 230, 251
Use:
Insert adapter 9x12 on 3/8 from set of engine mount wrenches 001 589 01 16 00
Fig. 15: Identifying Plug-In Adapter (001 589 01 16 01)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 02 BOX WRENCH BIT - WS22.00-P-0008-02B
FG22/09/28/Set B
MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251
Use:
Box wrench bit SW16 from set of engine mount wrenches 001 589 01 16 00
Fig. 16: Identifying Box Wrench Bit (001 589 01 16 02)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 03 BOX WRENCH - WS22.00-P-0008-03B
FG22/09/28/Set B
MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251, 451
Use:
Box wrench SW16 from set of engine mount wrenches 001 589 01 16 00.
Fig. 17: Identifying Box Wrench (001 589 01 16 03)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 04 WRENCH SOCKET - WS22.00-P-0008-04B
FG22/09/28/Set B
MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251
Use:
Socket from set of engine mount wrenches 001 589 01 16 00
Fig. 18: Identifying Wrench Socket (001 589 01 16 04)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 05 WRENCH SOCKET - WS22.00-P-0008-05B
FG22/07/09/28/Set B
MODEL 163, 164, 171, 203, 204, 210, 211, 215, 219, 220, 221, 230, 251
Use:
Socket from set of engine mount wrenches 001 589 01 16 00
Fig. 19: Identifying Wrench Socket (001 589 01 16 05)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 06 WRENCH SOCKET - WS22.00-P-0008-06B
FG22/09/28/Set B
MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251
Use:
Socket from set of engine mount wrenches 001 589 01 16 00
Fig. 20: Identifying Wrench Socket (001 589 01 16 06)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 07 ANGLED PIECE - WS22.00-P-0008-07B
FG22/09/28/91/Set B
MODEL 163, 164, 171, 172, 203, 210, 211, 215, 219, 220, 221, 230, 251
Use:
Angular piece 9x12 on 3/8 from set of engine mount wrenches 001 589 01 16 00.
For model 172, also for tightening and loosening the bolts on the airbag control unit with torque.
Fig. 21: Identifying Angled Piece (001 589 01 16 07)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 09 BOX WRENCH BIT - WS22.00-P-0008-09B
FG22/09/28/Set B
MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251, 451
Use:
Box wrench bit SW17 from set of engine mount wrenches 001 589 01 16 00
Fig. 22: Identifying Box Wrench Bit (001 589 01 16 09)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 08 PLUG-IN JOINT ADAPTER - WS22.00-P-0008-10B
FG22/09/28/Set B
MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251
Use:
Plug-in joint adapter from the set of engine mounting keys 001 589 01 16 00.
Fig. 23: Identifying Plug-In Joint Adapter (001 589 01 16 08)
Courtesy of MERCEDES-BENZ USA
001 589 01 16 00 ENGINE MOUNT WRENCH SET - WS22.00-P-0008B
FG 01/22/07/09/28/61/ Set B
MODEL all
Further use 001 589 01 16 00 Engine mount wrench set WS09.00-P-0010B
Further use 001 589 01 16 00 Engine mount wrench set WS28.00-P-0088B
Separate part FG22/Set B 001 589 01 16 01 Plug-in adapter WS22.00-P-0008-01B
Separate part FG22/Set B 001 589 01 16 02 Box wrench bit WS22.00-P-0008-02B
Separate part FG22/Set B 001 589 01 16 03 Box wrench WS22.00-P-0008-03B
Separate part FG22/Set B 001 589 01 16 04 Wrench socket WS22.00-P-0008-04B
Separate part FG22/Set B 001 589 01 16 05 Wrench socket WS22.00-P-0008-05B
Separate part FG22/Set B 001 589 01 16 06 Wrench socket WS22.00-P-0008-06B
Separate part FG22/Set B 001 589 01 16 07 Angled piece WS22.00-P-0008-07B
Separate part FG22/Set B 001 589 01 16 09 Box wrench bit WS22.00-P-0008-09B
Separate part FG22/Set B 001 589 01 16 08 Plug-in joint adapter WS22.00-P-0008-10B
Use:
Set of engine mount wrenches for removing/installing the engine mount and diagonal struts.
Fig. 24: Identifying Engine Mount Wrench Set (001 589 01 16 00)
Courtesy of MERCEDES-BENZ USA
SPECIAL TOOLS: PASSENGER CARS: ENGINE SUSPENSION - WS22.00-Z-9999AZ
MODEL all
WS00.00-P-
000 589 54 37 00 Clamp FG 00/01/07/08/13/ 14/18/20/22/28/33/46/47/54/82/83/Set B
0006Z
001 589 01 16 00 Engine WS22.00-P-
FG 01/22/07/09/28/61/ Set B
mount wrench set 0008B
001 589 01 16 01 Plug-in WS22.00-P-
FG22/07/09/28/Set B
adapter 0008-01B
001 589 01 16 02 Box WS22.00-P-
FG22/09/28/Set B
wrench bit 0008-02B
001 589 01 16 03 box WS22.00-P-
FG22/09/28/Set B
wrench 0008-03B
001 589 01 16 04 Wrench WS22.00-P-
FG22/09/28/Set B
socket 0008-04B
001 589 01 16 05 Wrench WS22.00-P-
FG22/07/09/28/Set B
socket 0008-05B
001 589 01 16 06 Wrench WS22.00-P-
FG22/09/28/Set B
socket 0008-06B
FG22/09/28/91/Set B
piece 0008-07B
001 589 01 16 08 Plug-in WS22.00-P-
FG22/09/28/Set B
joint adapter 0008-10B
001 589 01 16 09 Box WS22.00-P-
FG22/09/28/Set B
wrench bit 0008-09B
112 589 00 16 00 WS22.00-P-
FG 22/Satz C
Verbindungsstuck 0003C
WS01.00-P-
112 589 00 62 00 Bracket FG 01/09/22/Set B
0062B
129 589 00 91 00 Record FG 00/Set Z FG 01/05/06/07/09/14/15/18/20/22/25/26/ WS00.00-P-
plug 27/29/32/33/35/42/46/47/68/82/83/88/ 91/Set B 0255Z
210 589 00 16 00 WS22.00-P-
FG 22/Set B
Connection piece 0005B
210 589 01 16 00 Four- WS22.00-P-
FG 22/05/Set B
point drive 0006B
240 589 00 32 00 WS01.00-P-
AEJ 01/22/27/33/60/ Set B
Adaptation plates 0150B
240 589 01 31 00 Adapter WS01.00-P-
FG 01/22/27/33/60/ Set B
kit 0085B
240 589 01 32 00 WS01.00-P-
FG 01/22/27/33/60/ Set B
Adaptation plates 0156B
240 589 01 32 00 WS01.00-P-
FG 01/22/60/Set C
Adaptation plates 0156C
246 589 00 62 00 Support WS01.00-P-
FG 01/22/26/27/33/46/ Set B
fixture 0159B
ENGINE
Engine Timing - General Information - S-Class (221)
GENERAL INFORMATION
GENERAL NOTES: PASSENGER CARS: ENGINE TIMING - AH05.00-Z-9999AZ
MODEL all
AH05.20-P-
Camshaft code number and assignment ENGINE 120
0100-01AO
AH05.20-P-
Camshaft code number and assignment ENGINE 111
0100-01AG
AH05.20-N-
Camshaft code number and assignment ENGINE 111.948 /978, 112, 113
0100-01A
AH05.20-P-
Camshaft, code numbers and allocation ENGINE 601, 602, 603
6992-03HB
AH05.10-P-
General notes on timing, markings ENGINE 112, 113, 112.951/976
1000-01A
AH05.20-N-
Identification of camshaft bearing caps ENGINE 111 /948 /978
6992-01A
Information on application of sealant to ENGINE 271 ENGINE 271.951 in MODEL AH05.20-P-
bottom part of camshaft housing 906 6995-01QK
Loosening and tightening regulation for ENGINE 160.921 /922 /923 in MODEL AH05.20-P-
camshaft bearing caps 452.3/4 0300-01RR
Loosening and tightening regulation for AH05.20-P-
ENGINE 160, 660...
camshaft bearing caps 0300-01SM
Loosening and tightening regulation for ENGINE 601.943, AH05.20-N-
camshaft bearing caps 602.980 /983 /981 /984/985, 601.942 /970 0300-01B
AH05.20-P-
Marking of camshaft bearing caps ENGINE 668.914 /940 /941 /942
6992-01GD
AH05.20-P-
Marking of camshaft bearing caps ENGINE 613, 648
6992-04HD
AH05.20-P-
Marking of camshaft bearing caps ENGINE 612 /965 /966, 647.961
6992-04HC
AH05.20-P-
Marking of camshaft bearing caps ENGINE 628, 629...
6992-04HE
AH05.20-P-
Marking of camshaft bearing caps ENGINE 120
6992-01AO
AH05.20-P-
Marking of camshaft bearing caps ENGINE 166
6992-01GF
AH05.20-P-
Marking of camshaft bearing caps ENGINE 266.920 /940 /960 /980
6992-01AK
ENGINE 611, AH05.20-P-
Marking on camshaft bearing caps
646.8 /951 /961 /962 /963/966 6992-04HB
Note concerning adjusting the valve seat AH05.30-P-
ENGINE 160 in MODEL 450.3 /4, 452.3 /4
cutter 4520-01A
AH05.30-P-
Note concerning valve seat machining ENGINE 160 in MODEL 450.3 /4, 452.3 /4
4520-02A
ENGINE 113.960 with CODE (479) AH05.20-P-
Notes on coupling rocker arm
Cylinder shutoff 3000-01AV
Notes on installing camshaft bearing ENGINE 113.960 with CODE (479) AH05.20-P-
bridge Cylinder shutoff 2000-01BV
Notes on installing camshaft bearing AH05.20-P-
ENGINE 112, 113...
bridge 2000-01AV
Notes on the application of sealing ENGINE 266.980 in MODEL 169.0 /3, AH05.20-P-
compound of the camshaft case 245.2 6995-02BK
Slackening and tightening instructions AH05.20-P-
ENGINE 275
for the camshaft bearing caps 0300-01A
SLACKENING AND TIGHTENING INSTRUCTIONS FOR THE CAMSHAFT BEARING CAPS -
AH05.20-P-0300-01A
Engine 275
Fig. 1: Tightening Sequence Of Left Camshaft Bearing Cap Screws
Courtesy of MERCEDES-BENZ USA
Tightening instructions for left cylinder head
1. Tighten screws stepwise according to the specified sequence.
At the same time the bearing caps must not tilt.
Slackening instructions for left cylinder head
The slackening of the screws is performed in the reverse order.
Fig. 2: Tightening Sequence Of Right Camshaft Bearing Cap Screws
Courtesy of MERCEDES-BENZ USA
Tightening instructions for right cylinder head
1. Tighten screws stepwise according to the specified sequence.
At the same time the bearing caps must not tilt.
Slackening instructions for right cylinder head
The slackening of the screws is performed in the reverse order.
TESTING & REPAIR
CHECK HYDRAULIC VALVE CLEARANCE COMPENSATING ELEMENTS - AR05.00-P-2010AMG
ENGINES 156
Fig. 3: Identifying Drift
Courtesy of MERCEDES-BENZ USA
Checking
Risk of accident caused by vehicle starting off Secure vehicle to prevent it from
by itself when engine is running. Risk of injury moving by itself.
AS00.00-Z-
caused by contusions and burns during starting Wear closed and snug-fitting work
0005-01A
procedure or when working near the engine as it clothes.
is running Do not touch hot or rotating parts.
Risk of injury caused by fingers being
pinched or crushed when removing, installing Keep body parts and limbs well clear AS00.00-Z-
or aligning hoods, doors, trunk lids, liftgates or of moving parts. 0011-01A
sliding roof
1 Check engine oil level, correct if necessary
Start engine, bring to normal operating Coolant temperature 60 to 80°
2
temperature and switch off C.
AR62.30-P-
3 Remove partition wall between wheel wells Model 251 only
2400RT
Only if it is not possible to
crank engine due to high compression.
AR15.12-P-
Model 164, 251
1010GZS
AR15.12-P-
Model 204, 212
1010CMG
4 Remove spark plugs
AR15.12-P-
Model 209, 211, 219
1010TMG
AR15.12-P-
Model 216, 221
1010SMG
AR15.12-P-
Model 230
1010RMG
Rotate engine at crankshaft in
Rotate engine at crankshaft center bolt in running direction until scribe mark 40°
5 direction of rotation of the engine to a 40° on pulley/ vibration damper
crankshaft angle after top dead center (TDC) corresponds with scribe mark on
timing case.
AR01.20-P-
Model 164, 251
5014GZS
AR01.20-P-
Model 204, 212
5014CMG
AR01.20-P-
6 Remove cylinder head covers Model 209, 211, 219
5014TMG
AR01.20-P-
Model 216, 221
5014SMG
AR01.20-P-
Model 230
5014RMG
Never use a steel tool to avoid
The compensating element
should be pressed together very slowly
with the normal force of the hand. Do
not apply strong pressure.
Press down the compensating element with a If compensating element
7
drift (1) drops too strongly: ?
Replace compensation element
If several compensation AR05.00-P-
elements are defective, check pressure 2011AMG
oil supply to the cylinder head.
8 Install in the reverse order
Conduct engine test run and check engine for
9
leaks
INSPECT HYDRAULIC VALVE CLEARANCE COMPENSATING ELEMENTS - AR05.00-P-2010SX
ENGINE 273 in MODEL 216
ENGINE 272, 273 in MODEL 221
Fig. 4: Identifying Drift & Roller Drag Lever
Courtesy of MERCEDES-BENZ USA
Checking
1 Check engine oil level, correct if necessary
Start engine, bring to normal operating Coolant temperature 60 to 80
2
temperature and switch off °C
AR01.20-P-
Right cylinder head cover
5014SY
3 Remove cylinder head covers
AR01.20-P-
Left cylinder head cover
Do not turn the engine
against the direction of engine
Rotate the engine at the crankshaft until the cam rotation. If a roller-type cam follower
4 on the valve clearance compensating element (1) is not attached at the cam:
stands on the cam base circle ?
AR05.00-P-
Replace the compensating element
2011SX
Never use a steel tool to avoid
damaging the surfaces.
The compensating element
should be pressed together very
slowly with the normal force of the
hand. Do not apply strong pressure.
Compress the compensating element, to do this,
If the compensating element
5 depress the roller-type cam follower (1) using a
drops too strongly:
suitable drift (01)
?
Replace the compensating element
If more than one
AR05.00-P-
compensating element is faulty, check
2011SX
the pressure oil supply to the cylinder
head.
6 Install in the reverse order
Risk of accident caused by vehicle starting off by Secure vehicle to prevent it from
itself when engine is running. Risk of injury moving by itself.
AS00.00-Z-
caused by contusions and burns during starting Wear closed and snug-fitting work
0005-01A
procedure or when working near the engine as it is clothes. Do not touch hot or rotating
running parts.
Carry out an engine test run and check the engine
7
for leaks
REMOVE/INSTALL HYDRAULIC VALVE CLEARANCE COMPENSATING ELEMENTS -
AR05.00-P-2011AMG
ENGINES 156
Fig. 5: Identifying Sucker & Compensating Element
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being pinched
Keep body parts and limbs well AS00.00-Z-
or crushed when removing, installing or aligning
clear of moving parts. 0011-01A
hoods, doors, trunk lids, liftgates or sliding roof
AR05.20-P-
Up to engine number 001177
6992ANG
1 Remove camshafts
AR05.20-P-
from engine number 001178
6992AMG
Do not use a magnet!
The friction surface of the
compensating element would
otherwise be magnetized.
This may cause minute iron
Remove the compensating element (2) of the
2 swarf to gather which can result
respective cylinder using a sucker (1)
in damage to the compensating
element and cam.
Reinstall compensation
elements at the same place if
they have not been replaced.
Check the surface of
the basic bore for score marks
and damage; replace the
cylinder head if necessary: ?
Remove cylinder head
AR01.30-P-
Model 164, 251
5800GZS
Check the basic bore of compensation elements
3 AR01.30-P-
(2) Model 204, 212
5800CMG
AR01.30-P-
Model 209, 211, 219
5800TMG
AR01.30-P-
Model 216, 221
5800SMG
AR01.30-P-
Model 230
5800RMG
4 Install in the reverse order
Risk of accident caused by vehicle starting off by Secure vehicle to prevent it
itself when engine is running. Risk of injury from moving by itself.
caused by contusions and burns during starting Wear closed and snug-fitting AS00.00-Z-
procedure or when working near the engine as it work clothes. 0005-01A
is running Do not touch hot or rotating
5 Do an engine test run and check for leaks parts.
REMOVING/INSTALLING THE HYDRAULIC VALVE CLEARANCE COMPENSATION
ELEMENTS - AR05.00-P-2011SX
ENGINE 273 in MODEL 216
ENGINE 272, 273 in MODEL 221
Fig. 6: Identifying Roller Drag Lever, Compensating Element And Clamp
Courtesy of MERCEDES-BENZ USA
Removing/installing
AR09.10-
1 Remove air filter housing
P-1150SX
AR01.20-
The right hand cylinder head cover
P-5014SY
2 Remove cylinder head covers
AR01.20-
Left cylinder head cover
P-5014SX
AR05.20-
3 Remove camshafts
P-6992SX
If removing more than one
compensation elements, ensure that
the cam followers and compensation
elements not being replaced are
Take out cam follower (1) with reinstalled at their previous location.
4
compensation element (2) Mark the cam follower for the
corresponding compensation element
is necessary.
Installation: Oil the cam follower
and compensation element.
Dismount clamp (3) by hand and remove
5 compensation element (2) from cam follower
(1)
Checking
together by hand only; do not use steel
tools as these can damage the surface
of the compensation element.
The compensation element
should be pressed together very
Check compensation element (2) for proper
6 slowly with the normal force of the
function, replace if required.
hand. Do not apply strong pressure.
If several compensation
elements are defective, check the
pressure oil supply to the cylinder
head.
7 Install in reverse order
Risk of accident caused by vehicle starting
Secure vehicle to prevent it from
off by itself when engine is running. Risk of AS00.00-
moving. Wear closed and snug-fitting
injury caused by contusions and burns Z-0005-
work clothes. Do not grasp hot or
during starting procedure or when working 01A
rotating parts.
near engine
Carry out an engine test run and check the
8
engine for leaks
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE TIMING - AR05.00-Z-9156AB
ENGINE 156
ENGINES 156 Basic position of camshafts for a 40° AR05.20-P-
Check basic position of camshafts
crank angle after top dead center 6010AMG
Check hydraulic valve clearance AR05.00-P-
ENGINES 156
compensating elements 2010AMG
Remove and install tensioning rail AR05.10-P-
ENGINE 156 in MODEL 164, 251
and slide rail in timing case cover 8500GZS
ENGINE 156.983 in MODEL 211.077 /277, timing
Remove, install tensioning rail and AR05.10-P-
case cover 219.377 ENGINE 156.982 in MODEL
slide rail in 8500TMG
209.377 /477
AR05.20-P-
Remove/install camshaft adjusters ENGINES 156.### ## as of 001178
7201AMG
AR05.20-P-
Remove/install camshafts ENGINES 156.### ## as of 001178
6992AMG
AR05.20-P-
Remove/install camshafts ENGINE 156.### ## up to 001177
6992ANG
AR05.20-P-
Remove/install camshafts ENGINE 156.### ## up to 001177
7201ANG
AR05.10-P-
Remove/install chain tensioner ENGINE 156 in MODEL 204, 212
7800CMG
AR05.10-P-
Remove/install chain tensioner ENGINE 156 in MODEL 164, 251
7800GZS
AR05.10-P-
Remove/install chain tensioner ENGINE 156 in MODEL 230.470
7800RMG
AR05.10-P-
Remove/install chain tensioner ENGINE 156 in MODEL 216, 221
7800SMG
ENGINE 156.982 in MODEL 209.377 /477
AR05.10-P-
Remove/install chain tensioner ENGINE 156.983 in MODEL 211.077 /277,
7800TMG
219.377
Remove/install hydraulic valve AR05.00-P-
ENGINES 156
clearance compensating elements 2011AMG
Remove/install tensioning rail and AR05.10-P-
ENGINES 156 in MODEL 204, 212
slide rail in timing case cover 8500CMG
Remove/install tensioning rail and AR05.10-P-
ENGINE 156 in MODEL 230.470
slide rail in timing case cover 8500RMG
Remove/install tensioning rail and AR05.10-P-
ENGINE 156 in MODEL 221, 216
slide rail in timing case cover 8500SMG
Remove/install valve springs AR05.30-P-
ENGINES 156
and/or valve stem seals 3500AMG
AR05.30-P-
Remove/install valves ENGINES 156
3511AMG
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE TIMING - AR05.00-Z-9273AB
ENGINE 273
ENGINE 272 in MODEL 204 ENGINE 272, AR05.20-P-
Check basic position of camshafts
273 in MODEL 207 6010CV
AR05.20-P-
Check basic position of camshafts ENGINES 272, 273 in MODEL 212
6010EW
ENGINES 272, 273 in MODEL 164, 251 AR05.20-P-
Check basic position of camshafts
ENGINES 273 in MODEL 463 6010GZA
AR05.20-P-
Check basic position of camshafts ENGINE 272, 273...
6010QB
AR05.20-P-
Check basic position of camshafts ENGINE 272, 273...
6010SX
AR05.20-P-
Check basic position of camshafts ENGINE 272, 273...
6010TS
Check hydraulic valve clearance ENGINE 272 in MODEL 204 ENGINE 272, AR05.00-P-
compensating elements 273 in MODEL 207 2010CV
Check hydraulic valve clearance AR05.00-P-
ENGINES 272, 273 in MODEL 212
compensating elements 2010EW
Check hydraulic valve clearance AR05.00-P-
ENGINE 272, 273 in MODEL 211, 219
compensating elements 2010TS
AR05.20-P-
Checking basic position of camshafts ENGINE 272, 273...
6010RX
Inspect hydraulic valve clearance AR05.00-P-
ENGINE 272, 273 in MODEL 164, 251
compensating elements 2010GZA
Inspect hydraulic valve clearance AR05.00-P-
ENGINE 272, 273...
compensating elements 2010QB
Inspect hydraulic valve clearance ENGINE 273 in MODEL 216 ENGINE 272, AR05.00-P-
compensating elements 273 in MODEL 221 2010SX
Inspecting hydraulic valve clearance AR05.00-P-
ENGINE 272, 273 in MODEL 230
compensation elements 2010RX
ENGINES 272 in MODEL 204 ENGINES AR05.20-P-
Remove/install camshafts
272, 273 in MODEL 207 6992CV
AR05.20-P-
Remove/install camshafts ENGINES 272, 273 in MODEL 212
6992EW
AR05.20-P-
Remove/install camshafts ENGINES 272, 273 in MODEL 164, 251
6992GZA
AR05.20-P-
Remove/install camshafts ENGINE 272, 273...
6992QB
AR05.20-P-
Remove/install camshafts ENGINES 272, 273 in MODEL 230
6992RX
ENGINES 273 in MODEL 216 ENGINES AR05.20-P-
Remove/install camshafts
272, 273 in MODEL 221 6992SX
AR05.20-P-
Remove/install camshafts ENGINES 272, 273 in MODEL 211, 219
6992TS
ENGINE 272 in MODEL 204 On exhaust
camshafts AR05.20-P-
Remove/install camshafts
ENGINE 272, 273 in MODEL 207 On 7201CVA
exhaust camshafts
ENGINE 272 in MODEL 204 To intake
camshaft AR05.20-P-
Remove/install camshafts
ENGINE 272, 273 in MODEL 207 On intake 7201CVE
camshafts
ENGINES 272, 273 in MODEL 212 on AR05.20-P-
Remove/install camshafts
exhaust camshafts 7201EWA
ENGINE 272, 273 in MODEL 212 On intake AR05.20-P-
Remove/install camshafts
camshafts 7201EWE
ENGINES 272, 273 in MODEL 164, 251 AR05.20-P-
Remove/install camshafts
Camshaft adjuster for exhaust camshafts 7201GZA
ENGINE 272, 273 in MODEL 164, 251 AR05.20-P-
Remove/install camshafts
Camshaft adjuster for intake camshafts 7201GZC
AR05.20-P-
Remove/install camshafts ENGINE 272, 273...
7201QB
AR05.20-P-
Remove/install camshafts ENGINE 272, 273...
7201QC
ENGINE 272, 273 in MODEL 230 Camshaft AR05.20-P-
Remove/install camshafts
adjuster for intake camshafts 7201RX
ENGINES 272, 273 in MODEL 230 AR05.20-P-
Remove/install camshafts
Camshaft adjuster for exhaust camshafts 7201RY
AR05.20-P-
Remove/install camshafts ENGINE 272, 273...
7201SX
AR05.20-P-
Remove/install camshafts ENGINE 272, 273...
7201SY
ENGINE 272, 273 in MODEL 211, 219 AR05.20-P-
Remove/install camshafts
Camshaft adjuster for intake camshafts 7201TS
ENGINES 272, 273 in MODEL 211, 219 AR05.20-P-
Remove/install camshafts
Camshaft adjuster for exhaust camshafts 7201TT
ENGINES 272 in MODEL 204 ENGINES AR05.10-P-
Remove/install chain tensioner
272, 273 in MODEL 207 7800CV
AR05.10-P-
Remove/install chain tensioner ENGINES 272, 273 in MODEL 212
7800EW
AR05.10-P-
Remove/install chain tensioner ENGINE 272, 273...
7800GZG
ENGINES 272 in MODEL 203, 209 M22 1.5 AR05.10-P-
Remove/install chain tensioner
ENGINES 273 in MODEL 209 M22 1.5 7800QC
AR05.10-P-
Remove/install chain tensioner ENGINE 272, 273 in MODEL 230
7800RX
ENGINE 273 in MODEL 216 ENGINE 272, AR05.10-P-
Remove/install chain tensioner
273 in MODEL 221 7800SX
ENGINES 272 in MODEL 171 M22X1.5
AR05.10-P-
Remove/install chain tensioner ENGINES 272, 273 in MODEL 211, 219
7800VB
M22 X 1.5
Remove/install guide wheel for timing AR05.10-P-
ENGINES 273
chain 7760A
Remove/install hydraulic valve clearance ENGINE 272 in MODEL 204 ENGINE 272, AR05.00-P-
compensating elements 273 in MODEL 207 2011CV
Remove/install hydraulic valve clearance AR05.00-P-
ENGINES 272, 273 in MODEL 212
compensating elements 2011EW
Remove/install hydraulic valve clearance AR05.00-P-
ENGINE 272, 273 in MODEL 164, 251
compensating elements 2011GZA
Remove/install hydraulic valve clearance AR05.00-P-
ENGINE 272, 273 in MODEL 211, 219
compensating elements 2011TS
Remove/install hydraulic valve clearance AR05.00-P-
ENGINES 272, 273 in MODEL 230
compensation elements 2011RX
Remove/install slide rail in timing case ENGINE 272 in MODEL 204 ENGINE 272, AR05.10-P-
cover 273 in MODEL 207 8484CV
Remove/install slide rail in timing case AR05.10-P-
ENGINES 272, 273 in MODEL 212
cover 8484EW
ENGINES 272.### ## as of 013489 in
Remove/install slide rail in timing case AR05.10-P-
MODEL 164, 251 ENGINES 273 in
cover 8484GZZ
MODEL 164, 251
Remove/install slide rail in timing case ENGINE 272 in MODEL 203 ENGINE 272, AR05.10-P-
cover 273 in MODEL 209 8484QB
Remove/install slide rail in timing case AR05.10-P-
ENGINE 272, 273 in MODEL 230
cover 8484RX
Remove/install slide rail in timing case ENGINE 273 in MODEL 216 ENGINE 272, AR05.10-P-
cover 273 in MODEL 221 8484SX
ENGINE 272.### ## as of 013489 in
Remove/install slide rail in timing case AR05.10-P-
MODEL 171, 211, 219 ENGINE 273 in
cover 8484TS
MODEL 211, 219
ENGINE 272 in MODEL 204 LH cylinder
head AR05.20-P-
Remove/install solenoid camshaft
ENGINE 272, 273 in MODEL 207 Left 7295CVL
cylinder head
ENGINE 272 in MODEL 204 RH cylinder
head AR05.20-P-
Remove/install solenoid camshaft
ENGINE 272, 273 in MODEL 207 Right 7295CVR
cylinder head
ENGINE 272, 273 in MODEL 212 Left AR05.20-P-
Remove/install solenoid camshaft
cylinder head 7295EWL
ENGINE 272, 273 in MODEL 212 Right AR05.20-P-
Remove/install solenoid camshaft
cylinder head 7295EWR
ENGINE 272, 273 in MODEL 164 Left AR05.20-P-
Remove/install solenoid camshaft
cylinder head 7295GZA
ENGINE 272, 273 in MODEL 164, 251 AR05.20-P-
Remove/install solenoid camshaft
Right cylinder head 7295GZB
ENGINE 272 in MODEL 203, 209 Left
cylinder head AR05.20-P-
Remove/install solenoid camshaft
ENGINE 273 in MODEL 209 Left cylinder 7295QB
head
ENGINE 272 in MODEL 203, 209 Right
cylinder head AR05.20-P-
Remove/install solenoid camshaft
ENGINE 273 in MODEL 209 Right cylinder 7295QC
head
ENGINES 272, 273 in MODEL 230 Left AR05.20-P-
Remove/install solenoid camshaft
cylinder head 7295RX
ENGINE 272, 273 in MODEL 230 Right AR05.20-P-
Remove/install solenoid camshaft
cylinder head 7295RY
ENGINES 273 in MODEL 216 LH cylinder
head AR05.20-P-
Remove/install solenoid camshaft
ENGINES 272, 273 in MODEL 221 Left 7295SX
cylinder head
ENGINE 273 in MODEL 216 Right cylinder
head AR05.20-P-
Remove/install solenoid camshaft
ENGINE 272, 273 in MODEL 221 Right 7295SY
cylinder head
ENGINES 272, 273 in MODEL 211, 219 AR05.20-P-
Remove/install solenoid camshaft
Left cylinder head 7295TS
ENGINE 272, 273 in MODEL 211, 219 AR05.20-P-
Remove/install solenoid camshaft
Right cylinder head 7295TT
ENGINE 272 in MODEL 204 ENGINE 272, AR05.10-P-
Remove/install tensioning rail
273 in MODEL 207 8127CV
AR05.10-P-
Remove/install tensioning rail ENGINES 272, 273 in MODEL 212
8127EW
AR05.10-P-
Remove/install tensioning rail ENGINES 272, 273 in MODEL 164, 251
8127GZA
AR05.10-P-
Remove/install tensioning rail ENGINE 272, 273...
8127QB
AR05.10-P-
Remove/install tensioning rail ENGINES 272, 273 in MODEL 230
8127RX
ENGINES 273 in MODEL 216 ENGINES AR05.10-P-
Remove/install tensioning rail
272, 273 in MODEL 221 8127SX
AR05.10-P-
Remove/install tensioning rail ENGINES 272, 273 in MODEL 211, 219
8127TT
Remove/install valve springs and / or ENGINE 272 in MODEL 203, 209 ENGINE AR05.30-P-
valve stem seals 273 in MODEL 209 3500QB
Remove/install valve springs and / or AR05.30-P-
ENGINE 272, 273 in MODEL 230
valve stem seals 3500RX
Remove/install valve springs and/or valve ENGINE 272 in MODEL 204 ENGINE 272, AR05.30-P-
stem seals 273 in MODEL 207 3500CV
Remove/install valve springs and/or valve AR05.30-P-
ENGINES 272, 273 in MODEL 212
stem seals 3500EW
Remove/install valve springs and/or valve AR05.30-P-
ENGINE 272, 273 in MODEL 164, 251
stem seals 3500GZA
Remove/install valve springs and/or valve ENGINE 272, 273 in MODEL 221 ENGINE AR05.30-P-
stem seals 273 in MODEL 216 3500SX
Remove/install valve springs and/or valve AR05.30-P-
ENGINE 272, 273 in MODEL 211, 219
stem seals 3500TS
Removing/installing hydraulic valve AR05.00-P-
ENGINE 272, 273...
clearance compensation elements 2011QB
Removing/installing the hydraulic valve ENGINE 273 in MODEL 216 ENGINE 272, AR05.00-P-
clearance compensation elements 273 in MODEL 221 2011SX
AR05.30-P-
Removing/installing valves ENGINE 272, 273 Cylinder head removed
3511SX
ENGINE 272 in MODEL 204 ENGINE 272, AR05.10-P-
Replace timing chain
273 in MODEL 207 7601CV
AR05.10-P-
Replace timing chain ENGINES 272, 273 in MODEL 212
7601EW
AR05.10-P-
Replace timing chain ENGINE 272, 273 in MODEL 164, 251
7601GZA
AR05.10-P-
Replace timing chain ENGINE 272, 273...
7601QB
ENGINE 273 in MODEL 216 ENGINE 272, AR05.10-P-
Replace timing chain
273 in MODEL 221 7601SX
AR05.10-P-
Replace timing chain ENGINE 272, 273 in MODELS 211, 219
7601TS
AR05.10-P-
Replacing timing chain ENGINE 272, 273 in MODEL 230
7601RX
ENGINE 272 in MODEL 204 ENGINE 272, AR05.20-P-
Set basic position of camshafts
273 in MODEL 207 6020CV
AR05.20-P-
Set basic position of camshafts ENGINES 272, 273 in MODEL 212
6020EW
AR05.20-P-
Set basic position of camshafts ENGINES 272, 273 in MODEL 164, 251
6020GZA
ENGINES 272 in MODEL 203, 209 AR05.20-P-
Set basic position of camshafts
ENGINES 273 in MODEL 209 6020QB
AR05.20-P-
Set basic position of camshafts ENGINES 272, 273 in MODEL 230
6020RX
ENGINES 273 in MODEL 216 ENGINES AR05.20-P-
Set basic position of camshafts
272, 273 in MODEL 221 6020SX
AR05.20-P-
Set basic position of camshafts ENGINES 272, 273 in MODEL 211, 219
6020TS
TESTING AND REPAIR WORK: PASSENGER CARS: ENGINE TIMING - AR05.00-Z-9275AB
ENGINE 275
ENGINE 275 in MODEL 215, 216, 220, 221, AR05.20-P-
Check basic position of camshafts
230 6010MC
Remove and install tensioning rail and AR05.10-P-
ENGINE 275
slide rail in timing case cover 8500M
ENGINE 275 in MODEL 215, 216, 220, 221, AR05.20-P-
Remove/install camshafts
230 6992MC
ENGINE 275.950 in MODEL 215.376, 220.176 AR05.10-P-
Remove/install chain tensioner
ENGINE 275.980 in MODEL 215.379, 220.179 7800M
AR05.10-P-
Remove/install chain tensioner ENGINE 275 in MODEL 230
7800R
AR05.10-P-
Remove/install chain tensioner ENGINE 275 in MODEL 216, 221
7800SZ
ENGINE 275 in MODEL 215, 216, 220, 221, AR05.10-P-
Replace timing chain
230 7601R
ENGINE 275 in MODEL 215, 216, 220, 221, AR05.20-P-
Set basic position of camshafts
230 6020M
SEPARATE TIMING CHAIN - AR05.10-P-7601-01R
Fig. 7: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 8: Identifying Chain Separating Tool (602 589 02 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 9: Identifying Thrust Pins (602 589 05 63 01)
Courtesy of MERCEDES-BENZ USA
Fig. 10: Identifying Thrust Spindle (602 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
1. Assemble chain separating tool (1) and thrust spindle (2).
Fig. 11: Identifying Chain Separating Tool And Thrust Spindle
Courtesy of MERCEDES-BENZ USA
2. Cover crankcase with clean rags.
3. Use chain separating tool (1) and turn the guide sleeve (3) up to the chain link system.
Ensure that the guide sleeve sits above the bolts on the timing chain.4
4. Screw in pressure screw (2) and separate timing chain (4).
Do not allow pushed out bolts and links to fall into the crankcase. Parts which have dropped into
the crankcase, must be removed.
5. Unscrew thrust spindle (2) and take off chain separating tool (1).
Fig. 12: Separating Timing Chain
Courtesy of MERCEDES-BENZ USA
SEPARATE TIMING CHAIN - AR05.10-P-7601-01VA
Fig. 13: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 14: Identifying Chain Separating Tool (602 589 02 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 15: Identifying Thrust Spindle (602 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 16: Identifying Pressure Pins (602 589 05 63 01)
Courtesy of MERCEDES-BENZ USA
1. Cover over timing case recess with a clean cloth.
The timing case recess must be secured against parts falling down. Parts that have fallen into the
timing case recess must be removed.
2. Assemble the chain separating tool (01) and the pressure screw (02) together.
4. Ensure that the pressure pin (03) lies at the pin (arrow) of a timing chain link.
Fig. 17: Separating Timing Chain
Courtesy of MERCEDES-BENZ USA
5. Screw in the pressure screw (02) and separate the timing chain (1).
6. Do not let the pins that have been pushed out fall into the timing case recess.
7. Remove the pressure screw (02) and take off the chain separating tool (01).
RIVET TIMING CHAIN - AR05.10-P-7601-02R
Fig. 18: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 19: Identifying Riveting Tool (602 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
Fig. 20: Identifying Assembly Inserts (112 589 09 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 21: Identifying Assembly Inserts (602 589 02 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 22: Identifying Thrust Spindle (602 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
1. Cover timing case recess and cylinder head with clean rag.
Parts which have fallen into the timing case recess or in the cylinder head must be removed.
2. Insert new riveted link (7.1) and new middle plate (7.2) together with centering fork (3) into the ends of
the new timing chain (2). Fix center plate (7.2) with new riveted link (7.1).
Fig. 23: Inserting Riveting Tool Onto Timing Chain
Courtesy of MERCEDES-BENZ USA
3. Place assembly insert (6) with the digit F5 into the rivet press tool (5) and fix with mounting screw.
4. Place assembly insert (7) with the digit D9 into the riveting tool (5).
The assembly insert (7) is able to move on the pressure screw and is loosely mounted.
5. Press in new riveted link (7.1) as far as the stop with the riveting tool (5).
Ensure that the riveted link and the riveting tool (5) are aligned. Do not allow the centering
fork (3) which is pressed out to drop into the timing case recess.
6. Remove assembly inserts (6, 7) from rivet press tool (5). Dismount riveting tool (5).
Fig. 24: Identifying Assembly Insert And Rivet Press Tool
Courtesy of MERCEDES-BENZ USA
7. Place assembly insert (1) with the digit F1 into the rivet press tool (5) and fix with mounting screw.
Fig. 25: Placing Assembly Insert Into Rivet Press Tool
Courtesy of MERCEDES-BENZ USA
8. Place movable assembly insert (4) with the digit D5 into the riveting tool (5).
Fig. 26: Placing Assembly Insert Into Riveting Tool
Courtesy of MERCEDES-BENZ USA
9. Insert new outer plate (15) into the movable assembly insert (4).
The outer plate (15) is held by a magnet.
Fig. 27: Identifying Outer Plate On Assembly Insert
Courtesy of MERCEDES-BENZ USA
10. Fit on rivet press tool (5)
The guide spacers must lie on the control chain rollers (2). Ensure that riveted link (7.1) and
outer plate (15) are aligned.
11. Screw in pressure screw (5a) at rivet press tool (5) until solid resistance is felt.
While turning the pressure screw (5a), ensure that the pin in rivet link (7.1) is inserted in the
holes in external mounting link (15).
12. Take off riveting tool (5).
Fig. 28: Identifying Rivet Press Tool And Pressure Screw
Courtesy of MERCEDES-BENZ USA
13. Turn over movable assembly insert (4) to the riveting section (arrow).
14. Fit rivet press tool (5) at the center onto one of both timing chain pins of the riveted link (7.1).
15. Tighten thrust spindle (5a) of rivet press tool (5) and rivet first control chain bolt of riveted link
(7.1).
16. Release thrust spindle (5a) and fit rivet press tool (5) on second control chain bolt of riveted link
(7.1).
17. Tighten thrust spindle (5a) of rivet press tool (5) and rivet second control chain bolt.
Fig. 29: Riveting Control Chain Bolts
Courtesy of MERCEDES-BENZ USA
18. Release thrust spindle (5a) and remove rivet press tool (5).
19. Check both rivets (arrows), re-rivet if required.
20. Remove rag from timing case recess and cylinder head.
Fig. 30: Locating Rivets
Courtesy of MERCEDES-BENZ USA
RIVETING THE TIMING CHAIN - AR05.10-P-7601-02VA
TIMING CHAIN, CHAIN TENSIONER
Engine Engine
Number Designation
272 273
BA05.10-P-1007- Bolt for rivet element in timing chain (reference
Nm 32 32
01B value)
Fig. 31: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 32: Identifying Riveting Tool (272 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
Fig. 33: Identifying Assembly Inserts (272 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 34: Identifying Guide (272 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 35: Identifying Assembly Inserts (271 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
When carrying out work on the timing case recess, safeguard this with a clean cloth to prevent items
dropping down. Parts which have fallen into the timing case recess, must be removed.
Press the riveted link into the press-fit center plate
1. Place the assembly insert (F11) in the rivet press tool (01) and fix in place with the mounting
screw.
2. Place the assembly insert (D12) in the rivet press tool (01).
Fig. 36: Placing Assembly Insert On Rivet Press Tool
Courtesy of MERCEDES-BENZ USA
3. Insert the riveted link (1), the centering fork (03) and the press-fit center plate (2) into the ends of the
timing chain (4), and press the pins of the centering fork (03) into the holes of the press-fit center plate (2)
and center the press-fit center plate (2).
Insert riveted link (1) from the rear.
Fig. 37: Identifying Riveted Link, Centering Fork And Timing Chain
Courtesy of MERCEDES-BENZ USA
4. Screw in the pressure screw (02) at the rivet press tool (01), and press the riveted link (1) into the
press-fit center plate (2) all the way to the backstop.
Ensure that the riveted link (1) and the rivet press tool (01) are aligned. While screwing in the
pressure screw (02) ensure that the pins of the riveted link (1) are pressed into the holes of the press-fit
center plate (2), and that the centering fork (03) that has been squeezed out does not fall into the timing
case recess.
5. Remove the pressure screw (02) and take off the rivet press tool (01).
Press the outer plate on the riveted link
Fig. 38: Identifying Pressure Screw At Rivet Press Tool
Courtesy of MERCEDES-BENZ USA
6. Place the assembly insert (F401) in the rivet press tool (01) and fix in place with the mounting
screw.
Fig. 39: Placing Assembly Insert In Rivet Press Tool
Courtesy of MERCEDES-BENZ USA
8. Insert the outer plate (3) into the assembly insert (D3).
The outer plate (3) is held magnetically.
Fig. 40: Identifying Outer Plate On Assembly Insert
Courtesy of MERCEDES-BENZ USA
9. Place the rivet press tool (01) in such a way that the spacer webs of the assembly insert (F4) lies on
the rolls of the timing chain (4).
Ensure that the riveted link (1) and the outer plate (3) are aligned.
10. Screw in the pressure screw (02) at the rivet press tool (01) until there is solid resistance.
While turning the pressure screw (02), ensure that the pins of the riveted link (1) are pressed
into the outer plate (3).
Fig. 41: Pressing Pins Of Riveted Link Into Outer Plate
Courtesy of MERCEDES-BENZ USA
Rivet timing chain
12. Shift the assembly insert (D3) on the riveted section (arrow).
Fig. 42: Identifying Assembly Insert
Courtesy of MERCEDES-BENZ USA
13. Place the rivet press tool (01) in the center of a riveted link (1) pin.
Rivet the pins of the riveted link (1) individually.
14. Tighten the pressure screw (02) at the rivet press tool (01).
Tightening torque of the pressure screw (02): reference value 32 Nm.
15. Remove rivet press tool (01).
Fig. 43: Riveting Timing Chain
Courtesy of MERCEDES-BENZ USA
16. Inspect riveting (arrows), re-rivet if necessary.
Fig. 44: Locating Riveting
Courtesy of MERCEDES-BENZ USA
DRAWING IN TIMING CHAIN - AR05.10-P-7601-04VA
Fig. 45: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 46: Identifying Assembly Link (272 589 03 63 00)
Courtesy of MERCEDES-BENZ USA
1. Cover over timing case recess with a clean cloth.
The timing case recess must be secured against parts falling down. Parts that have fallen into the
timing case recess must be removed.
2. Connect the new timing chain (2) and the old timing chain (1) with the assembly link (01).
Fit the lock of the assembly link (01) in the direction opposite to that in which the timing
chain is drawn; otherwise it could get jammed on the slide rails and come off when the timing chain is
drawn.
Fig. 47: Connecting New And Old Timing Chain
Courtesy of MERCEDES-BENZ USA
3. Remove the rags from the timing case recess.
Otherwise, they could get pulled into the timing case recess when the engine is cranked.
4. Turn the crankshaft slowly in the engine's direction of rotation (arrow) and draw in the new timing chain
(2) until the ends of the new timing chain (2) can be connected.
As the new timing chain (2) is being drawn in (arrows), pull out the end of the old timing chain
(1) evenly as it becomes free.
5. Cover over timing case recess with a clean cloth.
The timing case recess must be secured against parts falling down. Parts that have fallen into the timing
case recess must be removed.
6. Detach the assembly link (01), and separate the old timing chain (1) from the new timing chain (2).
The assembly link (01) must be removed. The assembly link is only an aid for assembly and is
not suitable for engine operation.
Fig. 48: Drawing In New Timing Chain
Courtesy of MERCEDES-BENZ USA
REPLACE TIMING CHAIN - AR05.10-P-7601R
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Fig. 49: Replacing Timing Chain
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
22.1.08 Value changed from 20 to 30 degrees Step 11
Removing
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear AS00.00-Z-
installing or aligning hoods, doors, trunk lids, of moving parts. 0011-01A
liftgates or sliding roof
AH15.10-P-
Notes on avoiding damage to ignition system
0002-01L
Vehicles with code 889
1 Turn key in ignition lock to position "0" Keyless-Go: press Start/Stop button
repeatedly until ignition is switched
off.
AR54.10-P-
Model 215, 220
0003I
AR54.10-P-
2 Remove ground line(s) at battery(ies) Model 216, 221
0003SX
AR54.10-P-
Model 230
0003R
AH54.10-P-
Notes on battery
0001-01A
AR01.10-P-
Engine 275.95
2405LA
3 Remove engine trim panel
AR01.10-P-
Engine 275.98
2405IM
4 Remove left and right air filter housing
1150LA
AR15.12-P-
5 Remove left and right ignition coil module
1100LA
AR01.20-P-
6 Remove cylinder head covers
5014H
Turn and remove one spark plug from each So that engine turns more
7
cylinder easily.
AP15.10-P-
Replace spark plugs Model 215, 220, 230
1580L
AP15.10-P-
Model 216, 221
1580SZ
Detach coolant expansion reservoir and place
8.1 Model 230
to one side with lines connected
AR82.35-P-
Model 215, 220
6000M
Remove washer fluid reservoir of windscreen Model 216, 221 without top AR82.35-P-
8.2
washer system protection 6000SY
Model 221 with code Z07 Top AR82.35-P-
protection 6000SX
AR14.30-P-
Model 215, 220
7251L
AR14.30-P-
9 Remove air pump Model 216, 221
7251SZ
AR14.30-P-
Model 230
7251R
AR20.40-P-
Model 215.376, 220.176, 230
6800AC
AR20.40-P-
Model 215.379, 220.179
6800IM
10 Remove fan shroud
Model 216, 221 except 216.379, AR20.40-P-
221.179 6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
Turn engine at crankshaft in
the direction of rotation of the
engine until the marking 30° CA
after TDC at the belt pulley/
Position engine to a 30° crank angle after top
11 vibration damper is reached.
dead center
The engine must not be turned
back, otherwise timing chain can
skip and this can result in engine
damage.
AR05.10-P-
Model 215, 220
7800M
Model 216, 221 7800SZ
12 Remove chain tensioner AR05.10-P-
Model 230
7800R
13 Remove air shutoff valve (1) hose
Mount retainer (10) onto right cylinder
14 Holding device Fig. 51
head
AR05.10-P-
7601-01R
Case Fig. 7
15 Disconnect old timing chain
Chain separating tool Fig. 8
Thrust spindle Fig. 10
Pressure pins Fig. 9
Install
AR05.10-P-
7601-04R
16 Draw in new timing chain Holding device Fig. 51
Case Fig. 7
Assembly links Fig. 50
AR05.10-P-
7601-02R
Case Fig. 7
17 Rivet new timing chain Riveting tool Fig. 19
Thrust spindle Fig. 10
Assembly inserts Fig. 20
Assembly inserts Fig. 21
AR05.20-P-
18 Check basic position of camshafts
6010MC
Remove retainer (10) from right cylinder
19 Holding device Fig. 51
head
20 Mount air shutoff valve (1) hose
AR05.10-P-
Model 215, 220
7800M
AR05.10-P-
21 Install chain tensioner Model 216, 221
7800SZ
AR05.10-P-
Model 230
7800R
AR20.40-P-
Model 215.376, 220.176, 230
6800AC
AR20.40-P-
22 Install fan shroud Model 215.379, 220.179
6800IM
Model 216, 221 except 216.379, AR20.40-P-
221.179 6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
AR14.30-P-
Model 215, 220
7251L
AR14.30-P-
23 Install air pump Model 216, 221
7251SZ
AR14.30-P-
Model 230
7251R
AR82.35-P-
Model 215, 220
6000M
Install washer fluid reservoir of windshield Model 216, 221 without top AR82.35-P-
24.1
washer system protection 6000SY
Model 221 with code Z07 Top AR82.35-P-
protection 6000SX
24.2 Mount coolant expansion reservoir Model 230
25 Install spark plugs
AP15.10-P-
Replace spark plugs Model 215, 220, 230
1580L
AP15.10-P-
Model 216, 221
1580SZ
AR01.20-P-
26 Install cylinder head covers
5014H
AR15.12-P-
27 Install left and right ignition coil module
1100LA
AR09.10-P-
28 Install left and right air filter housing
1150LA
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns Wear closed and snug-fitting work
0005-01A
during starting procedure or when working clothes.
near the engine as it is running Do not touch hot or rotating parts.
Carry out engine test run, check for oil
29
leakage
AR01.10-P-
Engine 275.95
2405LA
30 Fit engine cover
AR01.10-P-
Engine 275.98
2405IM
AR54.10-P-
Model 215, 220
0003I
AR54.10-P-
31 Attach ground line(s) to battery(ies) Model 216, 221
0003SX
AR54.10-P-
Model 230
0003R
Fig. 50: Identifying Assembly Links (602 589 02 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 51: Identifying Holding Device (285 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 52: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 53: Identifying Chain Separating Tool (602 589 02 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 54: Identifying Thrust Spindle (602 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 55: Identifying Thrust Pins (602 589 05 63 01)
Courtesy of MERCEDES-BENZ USA
Fig. 56: Identifying Assembly Inserts (112 589 09 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 57: Identifying Riveting Tool (602 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
Fig. 58: Identifying Assembly Inserts (602 589 02 63 00)
Courtesy of MERCEDES-BENZ USA
REPLACE TIMING CHAIN - AR05.10-P-7601SX
ENGINE 273 in MODEL 216
ENGINE 272, 273 in MODEL 221
Fig. 59: Identifying Camshafts, Old & New Timing Chains And Pulse Wheel Markings
Courtesy of MERCEDES-BENZ USA
Fig. 60: Identifying Markings On Camshaft Adjuster
Courtesy of MERCEDES-BENZ USA
Removing
Do not touch components and open lines of
the high-voltage on-board electrical
Risk of death when touching system. Persons who are carriers of
AS54.00-Z-
components on vehicles with high- electronic implants (e.g. cardiac
0001-01A
voltage on-board electrical system pacemakers), must not carry out any work
on high-voltage on-board electrical
systems.
Perform disable for high-voltage on- AR54.10-P-
1 Model 221.095 / 195
board electrical system 1150SXH
Include initial startup event log
together with the disable power event log
in the vehicle file after conclusion of the
work.
Note on high-voltage on-board AH54.00-P-
electrical system 0010-01A
Remove ground line(s) for battery AR54.10-P-
2
(batteries) 0003SX
AH54.10-P-
Notes on battery
0001-01A
3 Remove spark plugs
AP15.10-P-
Replace spark plugs
1580SX
Remove exhaust and intake camshafts AR05.20-P-
4
(1, 2) at right cylinder head 6992SX
AR05.10-P-
7601-01VA
Fig. 7
5 Disconnect old timing chain (3) Fig. 8
Fig. 10
Fig. 9
Install
AR05.10-P-
7601-04VA
6 Draw in new timing chain (4) Fig. 7
Fig. 46
AR05.10-P-
7601-02VA
*BA05.10-
P-1007-01B
7 Rivet new timing chain (4) Fig. 7
Fig. 32
Fig. 33
Fig. 34
Fig. 35
See "CHECK BASIC POSITION OF
CAMSHAFTS with front cover installed at
cylinder head at a 55° crankshaft angle
before ignition TDC ".
Markings on pulse wheels (5) of
Crank engine at crankshaft in direction intake and exhaust camshafts at left
of rotation of engine to a 55° crank cylinder head must be located centrally in AR05.20-P-
8
angle before ignition TDC on first bores of camshaft Hall sensors. 6010SX
cylinder (305° marking on belt pulley) If markings (5) on pulse wheels of
intake and exhaust camshafts at the left
cylinder head cannot be seen through the
bores of the camshaft Hall sensors, rotate
engine at crankshaft in the engine's
direction of rotation by another revolution.
Crank engine at crankshaft in its
direction of rotation through a 95°
9
crank angle to a 40° crank angle after
ignition TDC on first cylinder
Markings (6) point upwards and AR05.20-P-
markings (7) align with contact surfaces on
6992SX
Install intake camshaft (1) and exhaust the cylinder head covers.
10 camshaft (2) on right cylinder head in See "CHECK BASIC POSITION OF
the basic position CAMSHAFTS with front cover removed at AR05.20-P-
the cylinder head at 40° crankshaft angle 6010-01VB
after ignition TDC ".
Crank engine at the crankshaft in the
direction of rotation of the engine and
check basic position of camshafts for Markings (5) on pulse wheels of
AR05.20-P-
11 an installed front cover on the cylinder intake and exhaust camshafts (1, 2) must
be located centrally in bores for camshaft 6010SX
head at a 55° crank angle before
ignition TDC (305° marking on the Hall sensors.
12 Install spark plugs
AP15.10-P-
Replace spark plugs
1580SX
Attach ground line(s) for battery AR54.10-P-
13
(batteries) 0003SX
Perform initial startup of high-voltage AR54.10-P-
14 Model 221.095 / 195
on-board electrical system 1150SXH
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving
running. Risk of injury caused by by itself. AS00.00-Z-
contusions and burns during starting Wear closed and snug-fitting work clothes. 0005-01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
Carry out an engine test run and check
15
engine for leaks
TIMING CHAIN, CHAIN TENSIONER
Number Designation Engine 272 Engine 273
BA05.10-P-1007-01B Bolt for timing chain rivet element (reference value) Nm 32 32
Fig. 61: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 62: Identifying Chain Separating Tool (602 589 02 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 63: Identifying Thrust Spindle (602 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 64: Identifying Thrust Pins (602 589 05 63 01)
Courtesy of MERCEDES-BENZ USA
Fig. 65: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
Fig. 66: Identifying Riveting Tool (272 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
Fig. 67: Identifying Assembly Inserts (272 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 68: Identifying Guide (272 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 69: Identifying Assembly Inserts (271 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 70: Identifying Assembly Link (272 589 03 63 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL GUIDE WHEEL FOR TIMING CHAIN - AR05.10-P-7760A
ENGINES 273
Fig. 71: Identifying Bearing Bushing, Guide Wheel And Bolts
Courtesy of MERCEDES-BENZ USA
Figure item,
Work instructions
etc.
AR01.40-P-
Model 164, 251
8000GZA
AR01.40-P-
Model 209
8000QB
AR01.40-P-
Model 211, 219
Remove/install timing case 8000TS
cover AR01.40-P-
Model 212
8000EWS
AR01.40-P-
Model 216, 221
8000SX
AR01.40-P-
Model 230
8000RX
Left-hand thread! Observe the
loosening direction.
1 Screw
*BA05.10-P-1006-
01B
TIMING CHAIN, CHAIN TENSIONER
Number Designation Engine 273
BA05.10-P-1006-01B Guide pulley to crankcase Nm 55
INSTALLING CHAIN TENSIONER - AR05.10-P-7800-02VA
MODIFICATION NOTES
8.2.05 Chain tensioner housing in timing case cover Engine 272 *BA05.10-P-1002-01B
TIMING CHAIN, CHAIN TENSIONER
Number Designation Engine 272
BA05.10-P-1001-01B End piece of chain tensioner Nm 50
BA05.10-P-1002-01B Chain tensioner housing in timing case cover Nm 70
TIMING CHAIN, CHAIN TENSIONER
Number Designation Engines 275, 285
BA05.10-P-1002-01H End piece of chain tensioner Nm 80
BA05.10-P-1003-01H Chain tensioner housing in timing case cover Nm 120
1. Press out the bolt (8) and detent spring (9) from chain tensioner housing (5) (arrowed).
Fig. 72: Pressing Out Bolt And Detent Spring From Chain Tensioner Housing
Courtesy of MERCEDES-BENZ USA
2. Insert the bolt (8) and detent spring (9) in chain tensioner housing (5) (arrowed).
Insert the bolt (8) and detent spring (9) so that the detent springs (9) sit in the first notch (10).
The bolt (8) must remain in this position.
Fig. 73: Inserting Bolt And Detent Spring
Courtesy of MERCEDES-BENZ USA
3. Screw in the chain tensioner housing (5) with bolt (8), detent spring (9) and new sealing ring (7) into the
timing case cover, and tighten .
Fig. 74: Identifying Bolt, Chain Tensioner Housing & Sealing Ring
Courtesy of MERCEDES-BENZ USA
4. Insert the push spring (3) and filler pin (4) in chain tensioner housing (5).
5. Screw in the end piece (1) with new sealing ring (2) into chain tensioner housing (5), and tighten .
When the push spring (3), filler pin (4) and end piece (1) are installed, bolt (8) is moved into the
correct position in chain tensioner housing (5).
Fig. 75: Identifying Chain Tensioner Components
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CHAIN TENSIONER - AR05.10-P-7800SMG
ENGINE 156 in MODEL 216, 221
Fig. 76: Identifying Chain Tensioner, Poly-V Belt & Alternator
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
4.9.08 Replace sealing ring by replacing chain tensioner-replaced Operation step 7
Remove/install
Risk of injury caused by fingers being pinched
Keep body parts and limbs AS00.00-Z-
or crushed when removing, installing or aligning
well clear of moving parts. 0011-01A
hoods, doors, trunk lids, liftgates or sliding roof
No fire, sparks, open flames or
Risk of explosion caused by oxyhydrogen gas. smoking.
Risk of poisoning and caustic burns caused by Wear acid-resistant gloves,
AS54.10-Z-
swallowing battery acid. Risk of injury caused by clothing and glasses. Only
0001-01A
burns to skin and eyes from battery acid or when pour battery acid into suitable
handling damaged lead-acid batteries and appropriately marked
containers.
Insulate clamping device of
the ground line in order to
AR54.10-P-
1 Detach ground line from battery prevent inadvertent contact
0003SX
with the ground point of the
battery.
AH54.10-P-
Notes on battery All models
0001-01A
2 Open engine hood and raise to vertical position
3 Remove left and right intake air duct
Do not tilt front
engine cover, but lift upwards
4 Remove front engine cover
vertically otherwise the
retaining lugs can break off.
The poly-V belt (3) AR13.22-P-
5 Partially remove poly-V belt (3) must be removed from the 1202SMG
alternator belt pulley (G2).
AR15.40-P-
5032SMG
Loosen alternator (G2) and lay down to side with
6 *BA15.40-
connected lines P-1001-01P
External torx set Fig. 77
Installation: Replace
chain tensioner (1).
7 Remove chain tensioner (1) from timing case cover
*BA05.10-
P-1008-01B
8 Install in the reverse order
9 Perform basic programming
Checking
Risk of accident caused by vehicle starting off by
itself when engine is running. Risk of injury Secure vehicle to prevent it AS00.00-Z-
caused by contusions and burns during starting from moving by itself. 0005-01A
running work clothes. Do not touch hot
10 Check for leaks with engine running or rotating parts.
ALTERNATOR
Number Designation Engine 156
BA15.40-P-1001-01P Bolt, alternator to timing case M8x90 Nm 20
TIMING CHAIN, CHAIN TENSIONER
Number Designation Engine 156
BA05.10-P-1008-01B Chain tensioner to timing case M22x1.5 Nm 75
Fig. 77: Identifying External Torx Set (001 589 76 09 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CHAIN TENSIONER - AR05.10-P-7800SX
ENGINE 273 in MODEL 216
ENGINE 272, 273 in MODEL 221
Fig. 78: Identifying Chain Tensioner, Pressure Pin And Timing Case Cover
Fig. 79: Identifying Left Exhaust Camshaft And Cap
Courtesy of MERCEDES-BENZ USA
Removing
Remove ground line(s) for battery AR54.10-P-
1
(batteries) 0003SX
AH54.10-P-
Notes on battery
0001-01A
Rotate engine at crankshaft center
bolt in direction of rotation of engine
2 Fig. 80
to a 40° crankshaft angle after
ignition TDC
Except model 221.095 /195
Detach connector for circuit 61 (D+)
The alternator remains with its AR15.40-P-
3.1 from alternator and remove alternator
attached line for circuit 30 (B+) in the engine 5032SX
from timing case cover (2)
compartment.
AR15.40-P-
3.2 Remove alternator Model 221.095 / 195
5032SXH
Remove chain tensioner (1) from
4
timing case cover (2)
Install
Replace chain tensioner (1) . The
previously installed chain tensioner must not
be reinstalled since, on removal of pressure
Screw new chain tensioner (1) into bolt (1a), it is pressed into the end position
5 timing case cover (2) and tightened and the locking device of the pressure bolt
to prescribed torque prevents its return stroke. This would
overstretch the timing chain on reinstalling.
*BA05.10-
P-1008-01B
6 Remove end cover (3)
Turn engine at center bolt on the This unlocks the chain tensioner (1).
crankshaft with prescribed torque *BA05.10-
against direction of engine rotation P-1009-01B
7
(arrow) while counterholding left
Fig. 81
exhaust camshaft (4) at rear with a
Torx wrench Fig. 82
Rotate engine at center bolt for The thrust pin (1a) for chain
8 crankshaft in its direction of tensioner (1) will be pushed out and tensions
rotation by a 90° crank angle the timing chain.
9 Install end cover (3)
Attach connector for circuit 61 (D+)
AR15.40-P-
10.1 and mount alternator on timing case Except model 221.095 /195
5032SX
cover (2)
AR15.40-P-
10.2 Install alternator Model 221.095 / 195
5032SXH
Mount ground line(s) for battery AR54.10-P-
11
(batteries) 0003SX
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving by
running. Risk of injury caused by itself. AS00.00-Z-
contusions and burns during starting Wear closed and snug-fitting work clothes. 0005-01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
Carry out an engine test run and
12
check engine for leaks
TIMING CHAIN, CHAIN TENSIONER
Number Designation Engine 272 Engine 273
BA05.10-P-1008-01B Chain tensioner on timing case M22X1.5 Nm 70 70
BA05.10-P-1009-01B Torque to unlock chain tensioner Nm 70 70
Fig. 80: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 81: Identifying Bracket (000 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 82: Identifying Torx Screwdriver Bit T60 (272 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CHAIN TENSIONER - AR05.10-P-7800SZ
ENGINE 275 in MODEL 216, 221
Fig. 83: Identifying Chain Tensioner Components
Courtesy of MERCEDES-BENZ USA
Removing
AR14.30-P-
1 Remove electric air pump (M33)
7251SZ
Remove air pump bracket See AR09.40-P-
2
Remove/install deceleration air valve. 3001SZ
Model 216, 221 except 216.379, AR20.40-P-
221.179 6800SZ
3 Remove fan shroud
AR20.40-P-
Model 216.379, 221.179
6800SXM
Rotate engine at the
crankshaft in running direction until
scribe mark for a 20° crank angle on
Position piston of cylinder 1 at a 20° crank pulley/ vibration damper corresponds
4
angle after TDC with scribe mark on timing case.
The engine must not be turned back,
otherwise timing chain can skip and
this can result in engine damage.
Unscrew end piece (1) from chain tensioner *BA05.10-
5
housing (5) and remove sealing ring (2) P-1002-01H
Pull push spring (4) and filler pin (3) out of
6
chain tensioner housing (5)
Remove chain tensioner housing (5) from *BA05.10-
7
timing case cover P-1003-01H
Install
It is essential to follow chain
tensioner installation sequence, AR05.10-P-
otherwise the chain tensioner may not 7800-02VA
function correctly. Renew seals (2, 6).
8 Installing chain tensioner
*BA05.10-
P-1002-01H
*BA05.10-
P-1003-01H
Model 216, 221 except 216.379, AR20.40-P-
221.179 6800SZ
9 Install fan shroud
AR20.40-P-
Model 216.379, 221.179
6800SXM
See Remove/install deceleration air AR09.40-P-
10 Install air pump bracket
valve. 3001SZ
AR14.30-P-
11 Install electric air pump (M33)
7251SZ
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk moving by itself. AS00.00-Z-
of injury caused by contusions and burns Wear closed and snug-fitting work 0005-01A
near the engine as it is running Do not touch hot or rotating parts.
Conduct engine test run and check the
12
engine for leaks
TORQUE SPECIFICATION
Number Designation Engine 275, 285
BA05.10-P-1002-01H End piece of chain tensioner Nm 80
BA05.10-P-1003-01H Chain tensioner housing in timing case cover Nm 120
REMOVE/INSTALL TENSIONING RAIL - AR05.10-P-8127SX
ENGINES 273 in MODEL 216
ENGINES 272, 273 in MODEL 221
Shown on engine 273
Fig. 84: Identifying Tensioning Rail Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 85: Identifying Tensioning Rail Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 86: Identifying Tensioning Rail Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Open engine hood
2 Remove air filter housing AR09.10-P-1150SX
Do not touch components and open lines of
Risk of death when the high-voltage on-board electrical system.
touching components on Persons who are carriers of electronic
AS54.00-Z-0001-01A
vehicles with high-voltage implants (e.g. cardiac pacemakers), must
on-board electrical system not carry out any work on high-voltage on-
board electrical systems.
Model 221.095 / 195
Perform disable for the high-
3 voltage on-board electrical After completing the work, attach AR54.10-P-1150SXH
system initial startup event log together with the
disconnection log to the vehicle file.
Note on high-voltage on-
AH54.00-P-0010-01A
board electrical system
Remove front covers from Front cover on the right AR01.30-P-5700SY
4
cylinder heads Front cover on the left AR01.30-P-5700SX
5 Remove centrifuge AR01.20-P-2100SX
Crank engine at crankshaft AR05.20-P-6010-
01VB
rotation of engine to a 40°
crankshaft angle after
6 Fig. 80
ignition TDC and check
position of camshafts
Lock gear backlash
compensation for camshaft AR05.20-P-7201-
7
adjuster (13) at right exhaust 05VA
camshaft (1)
AR05.20-P-7201-
Observe loosening direction. 06VA
Loosen center valve (5) on
8 *BA05.20-P-1009-
right exhaust camshaft (1) 02A
Fig. 82
Remove the right cylinder
9 AR01.20-P-5014SY
head cover
Installation: Always replace pulse
wheel (9). When tightening center valve Check dowel pin (18)
(5), there is a risk that dowel pin (18) or pin and pin (19). If dowel
Remove center valve (5) for (19) on pulse wheel (9) may shear off. pin (18) or pin (19)
10 right exhaust camshaft (1) Before assembling, lubricate the center has sheared off, it
and remove pulse wheel (9) valve (5) at the contact surface with pulse must be removed from
wheel (9). camshaft adjuster
Installation: Align dowel pin (18) on (13).
pulse wheel (9) with bore (20) in the
camshaft adjuster (13).
Counterhold the right
Installation: Align dowel pin (21) in
exhaust camshaft (1) at the
camshaft adjuster (13) to fitted bore (22) in Fig. 82
rear and pull off the
11 exhaust camshaft (1) and install camshaft
camshaft adjuster (13) from
adjuster (13) in its basic position:
the right exhaust camshaft
(1) in the forward direction See "CHECK BASIC POSITION OF AR05.20-P-6010-
CAMSHAFTS". 01VB
Remove auxiliary bearing
cap (17) on right exhaust *BA05.20-P-1010-
12
camshaft (1) and take out 02A
exhaust camshaft (1)
Installation: Install new chain
tensioner . The previously installed chain
tensioner must not be reinstalled because
13 Remove chain tensioner during removal, its pressure pin is pressed AR05.10-P-7800SX
into the end position. The thrust pin latch
prevents this return stroke. This would
overstretch the timing chain on reinstalling.
AR01.30-P-5800-04V
tensioning rail bolts (23) before assembly.
Fig. 90
Remove tensioning rail bolt
14 Fig. 89
(23)
*BR00.45-Z-1013-
Loctite 5970 sealant
01A
Pull tensioning rail (24) up
15
and out of timing case
16 Install in the reverse order
CAMSHAFT, CAMSHAFT ADJUSTMENT
Number Designation Engine 272 Engine 273
BA05.20-P- Center valve for pulse Nm 145 145
1009-02A wheel/camshaft adjuster to
camshaft
BA05.20-P- Bolt, auxiliary Stage 1 Nm 8 8
1010-02A bearing cap to
cylinder head Stage 2 Angle° - -
Fig. 87: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 88: Identifying Torx Screwdriver Bit T60 (272 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
Fig. 89: Identifying Impact Extractor (116 589 20 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 90: Identifying Threaded Stud (116 589 01 34 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
REMOVE/INSTALL SLIDE RAIL IN TIMING CASE COVER - AR05.10-P-8484SX
ENGINE 273 in MODEL 216
ENGINE 272, 273 in MODEL 221
Fig. 91: Identifying Tensioning Rail And Slide Rails
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not touch components and open lines
of the high-voltage on-board electrical
Risk of death when touching system. Persons who are carriers of AS54.00-
components on vehicles with high- electronic implants (e.g. cardiac Z-0001-
voltage on-board electrical system pacemakers), must not carry out any work 01A
on high-voltage on-board electrical
systems.
Model 221.095 / 195
Include initial startup event log AR54.10-
Perform disable for high-voltage on-
1 together with the disable power event log P-
board electrical system
in the vehicle file after conclusion of the 1150SXH
work.
AH54.00-
Note on high-voltage on-board electrical
P-0010-
system
01A
AR01.30-
2 Remove right cylinder head
P-5800SY
AR01.30-
3 Remove left cylinder head
P-5800SX
Since cylinder heads have already
4 Remove timing case cover been removed, it is no longer necessary to AR01.40-
detach the oil pan in order to remove the P-8000SX
timing case cover.
5 Remove tensioning rail (1a)
6 Detach slide rails (1b) from guide pins
7 Install in the reverse order
8 Check engine oil level
AP18.00-
Engine oil and filter change
P-0101SX
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving
AS00.00-
running. Risk of injury caused by by itself.
Z-0005-
contusions and burns during starting Wear closed and snug-fitting work clothes.
01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
Carry out an engine test run and check
9
engine for leaks
AR20.00-
10 Inspect cooling system for leaks
P-1010SX
REMOVE AND INSTALL TENSIONING RAIL AND SLIDE RAIL IN TIMING CASE COVER -
AR05.10-P-8500M
ENGINE 275
Fig. 92: Identifying Slide Rail Short, Slide Rail Long, Tensioning Rail, Crankshaft And Guide Wheel
Courtesy of MERCEDES-BENZ USA
Remove/install
AR01.40-P-
1 Remove timing case cover
8000M
Detach slide rail short (1) and slide rail long (2) Installation:
2
to the front from guide pins Lubricate guide pins.
Detach tensioning rail (3) to front from guide Installation:
3
pin. Lubricate guide pin.
4 Install in the reverse order
REMOVE/INSTALL TENSIONING RAIL AND SLIDE RAIL IN TIMING CASE COVER - AR05.10-
P-8500SMG
ENGINE 156 in MODEL 221, 216
Fig. 93: Identifying Tensioning Rail And Slide Rail Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
Risk of death caused by vehicle slipping or vehicle lift and position four support AS00.00-Z-
toppling off the lifting platform. plates at vehicle lift support points 0010-01A
specified by vehicle manufacturer.
No fire, sparks, open flames or
Risk of explosion caused by fuel igniting, smoking.
risk of poisoning caused by inhaling and Only pour fuels into suitable and AS47.00-Z-
swallowing fuel and risk of injury to eyes appropriately marked containers. 0001-01A
and skin caused by contact with fuel Wear protective clothing when
handling fuel.
AH00.00-N-
Notes on self-locking nuts and bolts All models
0001-01A
AR01.10-P-
1 Remove engine
2400SMG
Remove automatic transmission from the AR27.10-P-
2
engine 0500SX
3 Mount engine onto assembly stand
AR01.40-P-
4 Remove timing case cover
8000AMG
AR01.30-P-
5800-
Pull out tensioning rail pins (4) and slide 04AMG
5
rail pins (5) at cylinder head Fig. 89
Impact extractor
Threaded stud Fig. 90
Remove tensioning rail (1), short slide rail
6
(2) and long slide rail (3) from below
7 Install in the reverse order
Fig. 94: Identifying Impact Extractor (116 589 20 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 95: Identifying Threaded Stud (116 589 01 34 00)
Courtesy of MERCEDES-BENZ USA
INSPECT BASIC POSITION OF CAMSHAFT - AR05.20-P-6010-01AMG
Shown on the right cylinder head
Fig. 96: Identifying Retainer And Straightedge
Courtesy of MERCEDES-BENZ USA
1. Turn engine at crankshaft in direction of engine rotation to a 40° crank angle after ignition TDC.
The 40° marking on the belt pulley must be aligned with the positioning edge on the timing case
cover.
2. Fix camshaft with straightedge to the rear side. The retaining device must allow itself to pushed over the
camshaft afterwards.
INSPECT BASIC POSITION OF CAMSHAFT - AR05.20-P-6010-01VB
Shown without pulse wheels on the camshaft adjusters
1. Crank the engine at the crankshaft in Turn the direction of engine rotation (arrow) to 40° crank angle after
ignition TDC.
The 40° marking (1) on the belt pulley must be aligned with the positioning edge (2) on the
timing case cover.
The markings (3) on the camshaft adjusters face upward, and the markings (4) align with the contact
surfaces on the cylinder head covers.
Fig. 97: Aligning Belt Pulley With Positioning Edge
Courtesy of MERCEDES-BENZ USA
CHECK BASIC POSITION OF CAMSHAFTS - AR05.20-P-6010AMG
ENGINES 156 Basic position of camshafts for a 40° crank angle after top dead center
Fig. 98: Identifying Timing Case Cover Marking
Courtesy of MERCEDES-BENZ USA
Shown on right cylinder head
Fig. 99: Identifying Holding Device And Straightedge
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of explosion caused by fuel No fire, sparks, open flames or smoking.
igniting, risk of poisoning caused by Pour fuels only into suitable and
AS47.00-Z-
inhaling and swallowing fuel and risk appropriately marked containers.
0001-01A
of injury to eyes and skin caused by Wear protective clothing when handling
contact with fuel fuel.
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear of AS00.00-Z-
removing, installing or aligning
moving parts. 0011-01A
hoods, doors, trunk lids, liftgates or
sliding roof
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
1 Switch off ignition
2 Open engine hood
Remove partition wall between wheel AR62.30-P-
3 Model 251
wells 2400RT
AR09.10-P-
Model 164, 251
1150GZS
AR09.10-P-
Model 204, 212
1150CMG
AR09.10-P-
4 Remove air filter housing Model 209, 211, 219
1150TMG
AR09.10-P-
Model 216, 221
1150SMG
AR09.10-P-
Model 230
1150RMG
Only if it is not possible to crank
engine due to high compression.
Model 164, 251
1010GZS
AR15.12-P-
Model 204, 212
1010CMG
AR15.12-P-
Model 209, 211, 219
5 Remove spark plugs 1010TMG
AR15.12-P-
Model 216, 221
1010SMG
AR15.12-P-
Model 230
1010RMG
AR13.22-P-
Model 209 with code P98 Black Series
1202TMG
AR13.20-P-
6 Remove poly-V belt Model 204, 212
0001CMG
AR13.20-P-
Model 230
0001RMG
Model 209 with code P98 Black Series
AR13.20-P-
Model 204, 212
0001CMG
Detach the guide pulley above
7 AR13.20-P-
crankshaft belt pulley (12) Model 230
0001RMG
*BA13.25-
P-1005-01U
Turn the engine on the crankshaft
The TDC marking on belt pulley
center bolt in the direction of engine
8
rotation to 40° crank angle ATDC of (12) must align with marking on timing case
cover (arrow).
cylinder 1
AR01.20-P-
Model 164, 251
5014GZS
AR01.20-P-
Model 204, 212
5014CMG
AR01.20-P-
9 Remove cylinder head covers Model 209, 211, 219
5014TMG
AR01.20-P-
Model 216, 221
5014SMG
AR01.20-P-
Model 230
5014RMG
Fix camshafts in place with a
10 Fig. 100
straightedge (04) on the rear side
The holding device (01) must be
able to move over the camshaft. If this is not
the case, the timing must be set: ?
Remove/install camshaft adjusters
AR05.20-P-
Up to engine number 001177
7201ANG
left cylinder head The holding device (01) is
constructed symmetrically. To check the
camshafts in the LH cylinder head, the AR05.20-P-
11 holding device (01) and straightedge (04) 7201AMG
are mounted in the same way as for the RH
side.
Fig. 100
12 Install in the reverse order
BELT TENSIONING DEVICE
Engine 156,
Number Designation
159
BA13.25-P-1005- Guide pulley (between poly-V belt tensioning device and
Nm 20
01U coolant pump)
Fig. 100: Identifying Holding Device (156 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
CHECK BASIC POSITION OF CAMSHAFTS - AR05.20-P-6010MC
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Fig. 101: Identifying Camshaft Components
Courtesy of MERCEDES-BENZ USA
Shown on model 220
Remove/install
Remove cylinder head AR01.20-P-
1
covers (1) 5014H
Model 215.376, 220.176, 230 without code (P99) Special AR20.40-P-
model "AMG Black Series" 6800AC
AR20.40-P-
Model 215.379, 220.179
6800IM
2.1 Remove fan shroud (2).
AR20.40-P-
Model 216, 221 except 216.379, 221.179
6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
Model 230 with code (P99) Special model "AMG Black AR20.40-P-
2.2 Remove fan unit
Series" 5050RBS
Checking
Rotate engine at crankshaft in direction of engine
Position engine to a 30°
rotation until marking for a 30° crank angle on the belt
3 crank angle after ignition
pulley/vibration damper (12) coincides with marking on
TDC of cylinder 1
the timing case cover (arrow).
timing chain can skip and this can result in engine
damage.
The basic position of the camshafts is only
correct if both holding devices (3) can be mounted free of
tension on left and right cylinder head. The scribe marks
(A) of the camshaft bearing caps (4) must align with
Check basic position of scribe marks (B) on camshafts (5).
4 Fig. 103
camshafts Retainer (left camshaft)
Retainer (right camshaft) Fig. 102
If this is not possible: ?
AR05.20-P-
Set basic position of camshafts.
6020M
Install in the reverse
5
order
Fig. 102: Identifying Holding Device (137 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 103: Identifying Holding Device (285 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
CHECK BASIC POSITION OF CAMSHAFTS - AR05.20-P-6010SX
ENGINE 273 in MODEL 216 Basic position of camshaft for installed front cover on cylinder head at a
55° crank angle BTDC
ENGINE 272, 273 in MODEL 221 Basic position of camshaft for installed front cover on cylinder head at
a 55° crank angle BTDC
Fig. 104: Identifying Belt Pulley Marking, Pulse Wheel Markings And Positioning Edge On Timing Case
Cover
Courtesy of MERCEDES-BENZ USA
Remove/install
AR09.10-
1 Remove front engine cover See Remove air filter housing.
P-1150SX
AR15.10-
2 Remove Hall sensor on camshafts
P-2000SX
Checking
The 305° marking (1) on belt
pulley must be aligned with positioning
Turn engine at crankshaft in direction of
edge (2) on timing case cover and
rotation of engine (arrow) to a 55°Crank
markings (3) on pulse wheels must be
3 before ignition TDC (305° marking on
located in center of sensor bores for Hall
belt pulley) and check basic position of
sensors. If necessary: ?
camshafts
AR05.20-
Set basic position of camshafts.
P-6020SX
4 Install in the reverse order
Risk of accident caused by vehicle
Secure vehicle to prevent it from moving
starting off by itself when engine is
by itself. AS00.00-
running. Risk of injury caused by
Wear closed and snug-fitting work Z-0005-
contusions and burns during starting
clothes. Do not touch hot or rotating 01A
procedure or when working near the
parts.
engine as it is running
Carry out an engine test run and check
5
engine for leaks
SET BASIC POSITION OF CAMSHAFTS - AR05.20-P-6020M
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Fig. 105: Identifying Camshaft Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on model 220
Fig. 106: Identifying Camshaft Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury caused by
fingers being pinched or
crushed when removing, AS00.00-Z-
Keep body parts and limbs well clear of moving parts.
installing or aligning hoods, 0011-01A
doors, trunk lids, liftgates or
sliding roof
AR20.00-P-
1 Drain coolant at radiator
1142H
AH20.00-
Notes on coolant N-2080-
01A
Remove coolant thermostat AR20.10-P-
2
housing 2710M
AR14.30-P-
Model 215, 220
7251L
AR14.30-P-
3 Remove air pump Model 216, 221
7251SZ
AR14.30-P-
Model 230
7251R
Model 215.376, 220.176, 230 without code (P99) AR20.40-P-
Special model "AMG Black Series" 6800AC
AR20.40-P-
Model 215.379, 220.179
6800IM
4.1 Remove fan shroud (1)
AR20.40-P-
Model 216, 221 except 216.379, 221.179
6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
Model 230 with code (P99) Special model "AMG AR20.40-P-
4.2 Remove fan unit
Black Series" 5050RBS
Remove cylinder head AR01.20-P-
5
covers (2) 5014H
Remove front cover at left AR01.30-P-
6
cylinder head 5700ML
Remove front cover at the AR01.30-P-
7
right cylinder head 5700MR
Check basic position of AR05.20-P-
8
camshafts (11) 6010MC
Remove circlip (4) of left
9 camshaft sprocket (5) and Installation: Install new O-ring (8).
remove centrifuge (7)
To loosen bolts (9), turn camshafts (11) in
such a way that holding devices (3) can be mounted
Loosen bolts (9) for free of tension at cylinder heads.
10
camshaft sprockets (5, 6)
Retainer (left camshaft) Fig. 103
Retainer (right camshaft) Fig. 102
11 Detach retainers (3)
Rotate engine at crankshaft in direction of
engine rotation until marking for a 30° crank angle on
the belt pulley/vibration damper (12) coincides with
Position piston of cylinder a marking on the timing case cover (arrow). The
12 1 to 30° crank angle after marking (A) of the camshaft bearing cap (10) must be
ignition TDC aligned with the marking (B) of the camshaft (11).
The engine must not be turned back, otherwise
timing chain can skip and this can result in engine
damage.
AR05.10-P-
Model 215, 220
7800M
AR05.10-P-
13 Remove chain tensioner Model 216, 221
7800SZ
AR05.10-P-
Model 230
7800R
Remove camshaft sprockets Mark camshaft sprockets (5, 6) and timing
14
(5, 6) chain relative to each other.
Install
The basic position of camshaft (11) is only
correct if retaining device (3) can be installed free of
stress at the left cylinder head. The marking (A) of the
camshaft bearing cap (10) must be aligned with the
Turn left camshaft (11) to marking (B) of the camshaft (11).
15 At a 30° crank angle after ignition TDC of cylinder
basic position
1 it is possible to rotate camshaft (11) without valves
coming into contact with the pistons.
Fig. 109
Fig. 103
The basic position of right camshaft (11) is
only correct if retaining device (3) can be installed free
of stress at the right cylinder head. The marking (A) of
the camshaft bearing cap (10) must be aligned with the
Turn right camshaft (11) to marking (B) of the camshaft (11).
16 At a 30° crank angle after ignition TDC of cylinder
basic position
1 it is possible to rotate camshaft (11) without valves
coming into contact with the pistons.
Fig. 109
Fig. 102
Install camshaft sprockets *BA05.20-
17
(5, 6) P-1001-02I
18 Detach retainers (3)
Model 215, 220 7800M
AR05.10-P-
Model 216, 221
19 Install chain tensioner 7800SZ
AR05.10-P-
Model 230
7800R
Check basic position of AR05.20-P-
20
camshafts (11) 6010MC
Install front cover on right AR01.30-P-
21
cylinder head 5700MR
Install front cover on left AR01.30-P-
22
cylinder head 5700ML
Install cylinder head covers AR01.20-P-
23
(2) 5014H
Model 215.376, 220.176, 230 without code (P99) AR20.40-P-
Special model "AMG Black Series" 6800AC
AR20.40-P-
Model 215.379, 220.179
6800IM
24.1 Install fan shroud (1)
AR20.40-P-
Model 216, 221 except 216.379, 221.179
6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
Model 230 with code (P99) Special model "AMG AR20.40-P-
24.2 Install fan unit
Black Series" 5050RBS
AR14.30-P-
Model 215, 220
7251L
AR14.30-P-
25 Install air pump Model 216, 221
7251SZ
AR14.30-P-
Model 230
7251R
Install coolant thermostat AR20.10-P-
26
housing 2710M
AR20.00-P-
27 Pour in coolant
1142H
AR20.00-P-
Model 215, 220, 230
Inspect cooling system for 1010HA
28
leaks AR20.00-P-
Model 216, 221
1010SX
CAMSHAFT
Number Designation Engine 275, 285
Stage 1 Nm 20
BA05.20-P-1001-02I Camshaft sprocket bolt M8x16
Stage 2 Angle° 90
Fig. 107: Identifying Holding Device (137 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 108: Identifying Holding Device (285 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 109: Identifying Open-End Wrench, Double (104 589 01 01 00)
Courtesy of MERCEDES-BENZ USA
SET BASIC POSITION OF CAMSHAFTS - AR05.20-P-6020SX
ENGINES 273 in MODEL 216
ENGINES 272, 273 in MODEL 221
Fig. 110: Identifying Camshaft Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 111: Identifying Camshaft Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 112: Identifying Camshaft Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Switch off ignition
AR09.10-P-
2 Remove air filter housing
1150SX
Do not touch components and open lines of the
high-voltage on-board electrical system.
Risk of death when touching
Persons who are carriers of electronic implants AS54.00-Z-
components on vehicles with high-
(e.g. cardiac pacemakers), must not carry out 0001-01A
voltage on-board electrical system
any work on high-voltage on-board electrical
systems.
Model 221.095 / 195
Perform disable for the high- After completing the work, attach AR54.10-P-
3
voltage on-board electrical system initial startup event log together with the 1150SXH
disconnection log to the vehicle file.
Note on high-voltage on-board AH54.00-P-
electrical system 0010-01A
AR01.30-P-
Left cylinder head
Remove front covers from cylinder 5700SX
4
heads AR01.30-P-
Right cylinder head
5700SY
5 Remove centrifuge 2100SX
Rotate engine at center bolt on
crankshaft in direction of rotation AR05.20-P-
6 of engine to a 40° crank angle after 6010-01VB
ignition TDC and then check
position of camshafts Fig. 80
Lock gear backlash compensation AR05.20-P-
7
for camshaft adjusters (13, 14) 7201-05VA
AR05.20-P-
Observe loosening direction. 7201-06VA
8 Detach center valves (5, 6, 7) *BA05.20-
P-1009-02A
Fig. 82
AR01.20-P-
Left cylinder head cover
5014SX
9 Remove cylinder head covers
AR01.20-P-
Right cylinder head cover
5014SY
Check dowel pins (18) and pins (19). If a
dowel pin (18) or pin (19) is sheared off, this
must be removed from camshaft adjuster (13,
14).
Installation: Always replace pulse wheels
Remove center valves (5, 6) of (9, 10). When tightening central valve (5, 6)
10 camshaft adjuster (13, 14) and there is the risk of a dowel pin (18) or pin (19)
remove pulse wheel (9, 10) shearing off at pulse wheels (9, 10). Lubricate
central valves (5, 6) for assembly on contact
surfaces to pulse wheels (9, 10).
Installation: Align pulse wheels (9,
10) dowel pin (18) to fitted bores (20) in
camshaft adjusters (13, 14).
Installation: Before assembly of
camshaft adjusters (13, 14) lubricate contact
surfaces on exhaust camshaft (1, 2) and
Counterhold exhaust camshafts (1,
camshaft adjusters (13, 14). Align dowel pins Fig. 82
2) at the rear and pull off camshaft
11 (21) in camshaft adjusters (13, 14) to fitted
adjusters (13, 14) from the exhaust
holes (22) in exhaust camshafts (1, 2) and
camshafts (1, 2) towards the front
install camshaft adjusters (13, 14) in their basic
position:
See "CHECK BASIC POSITION OF AR05.20-P-
CAMSHAFTS". 6010-01VB
Remove auxiliary bearing cap (17) *BA05.20-
12
and exhaust camshaft (1) P-1010-02A
Installation: Install new chain
tensioner must not be reinstalled because during
removal, its pressure pin is pressed into the end
AR05.10-P-
13 Remove chain tensioner position. The thrust pin latch prevents this
7800SX
return stroke. This would overstretch the timing
chain on reinstalling.
Installation: Apply sealant to AR01.30-P-
tensioning rail bolts (23) before assembly. 5800-04V
Fig. 89
14 Remove tensioning rail bolt (23)
Fig. 90
*BR00.45-
Loctite 5970 sealant
Z-1013-01A
Pull tensioning rail (24) up and out
15
of timing case
Check dowel pin (18) and pin (19). If a
dowel pin (18) or pin (19) is sheared off then
this must be removed from camshaft adjuster
(15).
Installation: Always replace pulse wheel
Remove center valve (7) on (11). When tightening center valve (7) there is a
16 camshaft adjuster (15) and pulse risk that dowel pin (18) or pin (19) may shear
wheel (11) off at pulse wheel (11). Before assembling,
lubricate center valve (7) at contact surface to
pulse wheel (11).
Installation: Align dowel pin (18) for pulse
wheel (11) with fitted bore (20) in camshaft
adjuster (15).
Installation: Lubricate contact
surfaces on intake camshaft (3) and camshaft
adjuster (15) before assembling camshaft
Remove timing chain from
adjuster (15). Align dowel pin (21) in camshaft
camshaft adjuster (15) and detach
17 adjuster (15) to fitted bore (22) in intake
camshaft adjuster (15) forwards
camshaft (3) and install camshaft adjuster (15)
from intake camshaft (3)
in its basic position:
See "CHECK BASIC POSITION OF AR05.20-P-
CAMSHAFTS". 6010-01VB
Remove timing chain from
camshaft adjuster (16) and turn See "CHECK BASIC POSITION OF AR05.20-P-
18
camshaft adjuster (16) in basic CAMSHAFTS". 6010-01VB
position
19 Install in the reverse order
Checking
Risk of accident caused by vehicle
starting off by itself when engine is
running. Risk of injury caused by Secure vehicle to prevent it from moving by
starting procedure or when Wear closed and snug-fitting work clothes. 0005-01A
working near the engine as it is Do not touch hot or rotating parts.
running
Conduct engine test run and check
20
engine for leaks
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine
Number Designation
272 273
BA05.20-P-1009- Center valve for pulse wheel/camshaft adjuster to
Nm 145 145
02A camshaft
BA05.20-P-1010- Stage 1 Nm 8 8
Bolt, auxiliary bearing cap to cylinder head
02A Stage 2 Angle° - -
Fig. 113: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 114: Identifying Torx Screwdriver Bit T60 (272 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
Fig. 115: Identifying Impact Extractor (116 589 20 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 116: Identifying Threaded Stud (116 589 01 34 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
DETACH, ATTACH CAMSHAFTS AT CYLINDER HEAD - AR05.20-P-6992-09AMG
CYLINDER HEAD
Number Designation Engine 156
BA01.30-P-1001-01U Bolt of camshaft bearing cap/bearing bridge M6 Nm 10
Courtesy of MERCEDES-BENZ USA
Remove camshafts:
1. Turn the exhaust and intake camshaft only until the base circles of the cams abut the cup tappets as much
as possible.
The camshafts (4) are highly sensitive to fracturing. When removing and installing the camshafts,
make sure that the base circles of the cams abut the cup tappets as much as possible. The camshafts (4)
are thus mainly free from tension in the bearing points.
If the camshafts (4) and camshaft bearing caps (3) have no identification markings, these must be
marked. Interchanged bearing caps can lead to engine damage.
2. Unscrew the bolts (2) and remove the camshaft bearing caps (3)
3. Remove the camshafts (4).
Install the camshafts:
4. Lubricate the cup tappets and camshaft bearing points.
5. Place the exhaust and intake camshafts into the camshaft bearing points so that the base circles of the
cams abut the cup tappets as much as possible.
When installing the camshaft bearing caps (3), pay attention to the identification markings and
install the camshaft bearing caps (3) in the same locations.
6. Attach the assigned camshaft bearing caps (3) with bolts (2).
7. Tighten the bolts (2) evenly.
Pay attention to the tightening torque and tightening diagram.
REMOVE/INSTALL CAMSHAFTS - AR05.20-P-6992AMG
ENGINES 156.### ## as of 001178
Shown on right cylinder head
Fig. 118: Identifying Camshaft Components
Courtesy of MERCEDES-BENZ USA
Tightening sequence on right cylinder head
Fig. 119: Identifying Right Cylinder Head Bolts Tightening Sequence
Courtesy of MERCEDES-BENZ USA
Tightening sequence on left cylinder head
Fig. 120: Identifying Left Cylinder Head Bolts Tightening Sequence
Courtesy of MERCEDES-BENZ USA
Removing
No fire, sparks, open flames or
Risk of explosion caused by fuel igniting, smoking. Pour fuels only into
risk of poisoning caused by inhaling and suitable and appropriately marked AS47.00-Z-
swallowing fuel and risk of injury to eyes containers. 0001-01A
and skin caused by contact with fuel Wear protective clothing when
handling fuel.
pinched or crushed when removing,
Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk lids,
clear of moving parts. 0011-01A
liftgates or sliding roof
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
Risk of explosion caused by oxyhydrogen No fire, sparks, open flames or
gas. Risk of poisoning and caustic burns smoking.
caused by swallowing battery acid. Risk of Wear acid-resistant gloves, clothing AS54.10-Z-
injury caused by burns to skin and eyes from and glasses. Only pour battery acid 0001-01A
battery acid or when handling damaged lead- into suitable and appropriately
acid batteries marked containers.
1 Switch off ignition
AR62.30-P-
2 Remove partition wall between wheel wells Model 251
2400RT
AR09.10-P-
Model 164, 251
1150GZS
AR09.10-P-
Model 204, 212
1150CMG
AR09.10-P-
3 Remove air filter housing Model 209, 211, 219
1150TMG
AR09.10-P-
Model 216, 221
1150SMG
AR09.10-P-
Model 230
1150RMG
Only if it is not possible to
crank engine due to high
compression.
AR15.12-P-
Model 164, 251
1010GZS
AR15.12-P-
Model 204, 212
4 Remove spark plugs 1010CMG
AR15.12-P-
Model 209, 211, 219
1010TMG
AR15.12-P-
Model 216, 221
1010SMG
AR15.12-P-
Model 230
1010RMG
Rotate engine at crankshaft
Rotate engine at crankshaft center bolt in
direction of rotation of engine to a 40° in running direction until scribe
5
crankshaft angle after top dead center (TDC) mark 40° on pulley/ vibration
on cylinder 1 damper corresponds with scribe
mark on timing case.
AR01.20-P-
Model 164, 251
5014GZS
Model 204, 212 5014CMG
AR01.20-P-
Model 209, 211, 219
5014TMG
6 Remove cylinder head covers AR01.20-P-
Model 216, 221
5014SMG
AR01.20-P-
Model 230
5014RMG
AR05.20-P-
7 Remove all camshaft adjusters (1)
7201AMG
If camshaft bearing caps (3) have
no identification markings, the AR05.20-P-
8 Remove bolts (2) for camshaft bearing cap (3) original position must be marked. 6992-
Interchanged bearing caps can lead 09AMG
to engine damage.
Identify the position of
camshafts (4) in the cylinder head.
If the camshafts (4) have no
9 Remove camshafts (4)
identification markings for the
intake and exhaust side, these must
be marked.
Checking
Check camshafts (4) and camshaft bearing
10
caps (3) for galling and score marks
Install
Follow the camshaft
markings. Oil the bearing surfaces!
11 Insert the camshafts (4)
Camshafts (4) must not be replaced
individually for tolerance reasons.
AR05.20-P-
Observe tightening 6992-
procedure!
12 Install camshaft bearing caps (3) 09AMG
*BA01.30-P-
1001-01U
Lock camshafts (4) using
13 Turn camshafts (4) into basic position holding device and straightedge.
Fig. 100
AR05.20-P-
14 Install all camshaft adjusters (1)
7201AMG
AR01.20-P-
Model 164, 251
5014GZS
AR01.20-P-
15 Install cylinder head covers Model 204, 212
5014CMG
AR01.20-P-
Model 209, 211, 219
5014TMG
AR01.20-P-
Model 216, 221
5014SMG
AR01.20-P-
Model 230
5014RMG
If necessary
AR15.12-P-
Model 164, 251
1010GZS
AR15.12-P-
Model 204, 212
1010CMG
16 Install spark plugs AR15.12-P-
Model 209, 211, 219
1010TMG
AR15.12-P-
Model 216, 221
1010SMG
AR15.12-P-
Model 230
1010RMG
AR62.30-P-
17 Remove/install between the wheel well liners Model 251
2400RT
AR09.10-P-
Model 164, 251
1150GZS
AR09.10-P-
Model 204, 212
1150CMG
AR09.10-P-
18 Install air filter housing Model 209, 211, 219
1150TMG
AR09.10-P-
Model 216, 221
1150SMG
AR09.10-P-
Model 230
1150RMG
Risk of accident caused by vehicle starting
off by itself when engine is running. Risk of Secure vehicle to prevent it from
injury caused by contusions and burns during moving by itself.
AS00.00-Z-
starting procedure or when working near the Wear closed and snug-fitting work
0005-01A
engine as it is running clothes.
Do not touch hot or rotating parts.
19 Carry out engine test run
CYLINDER HEAD
Number Designation Engine 156
BA01.30-P-1001-01U Bolt, camshaft bearing cap/bearing bridge M6 Nm 10
Fig. 121: Identifying Holding Device (156 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CAMSHAFTS - AR05.20-P-6992MC
ENGINE 275 in MODEL 215, 216, 220, 221, 230
Fig. 122: Identifying Camshaft Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Shown on model 220
Fig. 123: Identifying Camshaft Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Removing
Risk of injury caused by
fingers being pinched or
crushed when removing, Keep body parts and limbs well clear of moving AS00.00-Z-
installing or aligning hoods, parts. 0011-01A
doors, trunk lids, liftgates or
sliding roof
AR20.00-P-
1 Drain coolant at radiator
1142H
AH20.00-
Notes on coolant
N-2080-01A
Remove coolant thermostat AR20.10-P-
2
housing 2710M
AR14.30-P-
Model 215, 220
7251L
AR14.30-P-
3 Remove air pump Model 216, 221
7251SZ
AR14.30-P-
Model 230
7251R
Model 215.376, 220.176, 230 without code (P99) AR20.40-P-
Special model "AMG Black Series" 6800AC
4.1 Remove fan shroud (2). AR20.40-P-
Model 215.379, 220.179
6800IM
AR20.40-P-
Model 216, 221 except 216.379, 221.179
6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
Model 230 with code (P99) Special model "AMG AR20.40-P-
4.2 Remove fan unit
Black Series" 5050RBS
Remove cylinder head covers AR01.20-P-
5
(1) 5014H
Remove front cover at left AR01.30-P-
6
cylinder head 5700ML
Remove front cover at the AR01.30-P-
7
right cylinder head 5700MR
Rotate engine at crankshaft in direction of
engine rotation until marking for a 30° crank angle
on the belt pulley/vibration damper (12) coincides
Position piston of cylinder a 1 with marking on the timing case cover (arrow).
8 to 30° crank angle after Marking (A) of camshaft bearing cap (4) must be
ignition TDC aligned with marking (B) on camshaft (5).
The engine must not be turned back, otherwise
timing chain can skip and this can result in engine
damage.
AR05.10-P-
Model 215, 220
7800M
AR05.10-P-
9 Remove chain tensioner Model 216, 221
7800SZ
AR05.10-P-
Model 230
7800R
Remove circlip (6) of left
10 camshaft sprocket (7) and
remove centrifuge (8)
Marl camshaft sprocket and timing chain
relative to each other.
Turn camshafts (5) in such a way that
Remove camshaft sprockets holding devices (3) can be mounted free of tension
11
(7) on the cylinder heads.
Retainer (left camshaft) Fig. 103
Retainer (right camshaft) Fig. 102
Remove camshaft bearing Observe loosening instructions for camshaft bearing
12
caps (4) cap: ?
Loosening, tightening
AH05.20-P-
instructions for camshaft
0300-01A
bearing cap
13 Remove camshafts (5)
Install
14 Install camshafts (5) Lubricate cams and bearing points.
Install camshaft bearing caps Observe camshaft bearing cap tightening
15
(4) instructions: ?
Loosening, tightening
AH05.20-P-
instructions for camshaft
0300-01A
bearing cap
*BA05.20-
Bolt (10) for camshaft bearing cap
P-1002-02I
Adjust basic position of AR05.20-P-
16
camshafts (5) 6020M
*BA05.20-
Camshaft sprocket bolt (11)
P-1001-02I
17 Install camshaft sprockets (7)
Retainer (left camshaft) Fig. 103
Retainer (right camshaft) Fig. 102
Mount centrifuge (8) with
18 circlip (6) on left camshaft Replace O-ring (9).
sprocket (7)
AR05.10-P-
Model 215, 220
7800M
AR05.10-P-
19 Install chain tensioner Model 216, 221
7800SZ
AR05.10-P-
Model 230
7800R
Check basic position of AR05.20-P-
20
camshafts (5) 6010MC
Install front cover on right AR01.30-P-
21
cylinder head 5700MR
Install front cover on left AR01.30-P-
22
cylinder head 5700ML
Install cylinder head covers AR01.20-P-
23
(1) 5014H
Model 215.376, 220.176, 230 without code (P99) AR20.40-P-
Special model "AMG Black Series" 6800AC
AR20.40-P-
Model 215.379, 220.179
6800IM
24.1 Install fan shroud (2)
AR20.40-P-
Model 216, 221 except 216.379, 221.179
6800SZ
AR20.40-P-
Model 216.379, 221.179
6800SXM
Model 230 with code (P99) Special model "AMG AR20.40-P-
24.2 Install fan unit
Black Series" 5050RBS
AR14.30-P-
Model 215, 220
7251L
Model 216, 221 7251SZ
25 Install air pump AR14.30-P-
Model 230
7251R
Install coolant thermostat AR20.10-P-
26
housing 2710M
AR20.00-P-
27 Pour in coolant
1142H
AR20.00-P-
Model 215, 220, 230
Inspecting cooling system for 1010HA
28
leaks AR20.00-P-
Model 216, 221
1010SX
CAMSHAFT
Engine 275,
Number Designation
285
Stage
Nm 20
BA05.20-P-1001- 1
Camshaft sprocket bolt M8x16
02I Stage
Angle° 90
2
Stage
Nm 14
BA05.20-P-1002- Bolt connecting camshaft bearing cap to 1
M7x85
02I cylinder head Stage
Angle° -
2
Fig. 124: Identifying Holding Device (137 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 125: Identifying Holding Device (285 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CAMSHAFTS - AR05.20-P-6992SX
ENGINES 273 in MODEL 216
ENGINES 272, 273 in MODEL 221
Shown on engine 273
Fig. 126: Identifying Camshaft Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Intake camshafts
AR05.20-P-
1 Remove respective camshaft adjusters (1)
7201SX
*BA05.20-P-
2 Remove auxiliary bearing cap (2) and intake camshaft (3)
1010-02A
Exhaust camshaft
AR05.20-P-
3 Remove respective camshaft adjusters
7201SY
Left cylinder head AR01.20-P-
cover 5014SX
4 Remove respective cylinder head cover
Right cylinder head AR01.20-P-
cover 5014SY
Take off auxiliary bearing cap (4) and remove exhaust *BA05.20-P-
5
camshaft (5) 1010-02A
6 Install in the reverse order
Checking
Secure vehicle to
prevent it from moving
Risk of accident caused by vehicle starting off by itself
by itself.
when engine is running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-
contusions and burns during starting procedure or when 0005-01A
fitting work clothes. Do
working near the engine as it is running
not touch hot or
rotating parts.
7 Conduct engine test run and check engine for leaks
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine
Number Designation
272 273
Stage
Nm 8 8
BA05.20-P-1010- Bolt, auxiliary bearing cap to cylinder 1
02A head Stage
Angle° - -
2
LOCK THE GEAR BACKLASH COMPENSATION - AR05.20-P-7201-05AMG
Fig. 127: Identifying Compressing Tool (156 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
The tooth flanks (2a, 2b) are pressed against one another under spring tension. Ensure that the tooth
backlash compensation is arrested before installing the camshaft adjuster.
1. Insert retaining bolt (01b) for tensioning tool (01) in to camshaft adjuster (2).
The tensioning tool (01) should make even contact with the camshaft adjuster (2).
2. Screw in bolt (01s) as far as possible.
This causes the quadrant (01z) to arrest the tooth flanks (2a, 2b) on the camshaft adjuster (2) in
relation to one another.
Fig. 128: Locking Gear Backlash Compensation
Courtesy of MERCEDES-BENZ USA
LOCK THE GEAR BACKLASH COMPENSATION - AR05.20-P-7201-05VA
The tooth flanks (1, 2) are held against each other by spring pressure and should not be skewed, otherwise
the camshaft adjuster will be irreparably damaged
1. Insert the drift (3, diameter 3mm) into the bore (4) of the cover plate and lock the tooth flanks (1, 2) with
each other.
Push the drift (3) through to the end of tooth flank (2).
To allow the drift (3) to be inserted more easily, align the tooth flanks with each other (in the direction of
the arrows).
Shown on camshaft adjuster, engine 273.965
Fig. 129: Inserting Drift Into Bore Of Cover Plate
Courtesy of MERCEDES-BENZ USA
LOOSEN/TIGHTEN THE CENTER VALVES - AR05.20-P-7201-06VA
MODIFICATION NOTES
14.9.07 Use the Torx screwdriver bit T60 to counterhold camshafts, added
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine
Number Designation
272 273
BA05.20-P-1009- Center valve for pulse wheel/camshaft adjuster to
Nm 145 145
02A camshaft
Fig. 130: Identifying Torx Screwdriver Bit T60 (272 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
Counterhold camshafts at the rear with a Torx screwdriver bit T60 to unfasten and fasten the center
valves. Before installing, the center valves must be lubricated with oil on the contact surfaces with the pulse
wheels.
Center valves of right cylinder head
1. Loosen the center valves in the direction of the arrow.
2. Tighten the center valves against the direction of the arrow.
Fig. 131: Loosening/Tightening Center Valves Of Right Cylinder Head
Courtesy of MERCEDES-BENZ USA
Center valves of left cylinder head
3. Loosen the center valves in the direction of the arrow.
4. Tighten the center valves against the direction of the arrow.
Fig. 132: Loosening/Tightening Center Valves Of Left Cylinder Head
Courtesy of MERCEDES-BENZ USA
REMOVE CAMSHAFT PINION PINS - AR05.20-P-7201-07AMG
Engine 156
CAMSHAFT, CAMSHAFT ADJUSTMENT
Number Designation Engine 156
BA05.20-P-1003- Bolt connecting bearing pin of camshaft drive gear to
M6 Nm 9
02J crankcase
Fig. 133: Identifying Threaded Stud (19 156 589 00 34 00)
Courtesy of MERCEDES-BENZ USA
Fig. 134: Identifying Impact Extractor (116 589 20 33 00)
Courtesy of MERCEDES-BENZ USA
1. Remove locking bolt (17).
2. Screw threaded stud (03) into camshaft pinion pin (8).
3. Attach impact extractor (02).
4. Knock out pinion pin (8).
Fig. 135: Removing Camshaft Pinion Pin
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CAMSHAFT ADJUSTERS - AR05.20-P-7201AMG
ENGINES 156.### ## as of 001178
Shown on RH cylinder head model 211
Fig. 136: Identifying Camshaft Adjuster Components
Courtesy of MERCEDES-BENZ USA
Right-hand cylinder head
Left-hand cylinder head
Fig. 137: Identifying Center Valves With Segment Plates
Courtesy of MERCEDES-BENZ USA
Fig. 138: Identifying Camshaft Adjuster Components
Courtesy of MERCEDES-BENZ USA
Fig. 139: Identifying Timing Case Cover Marking
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Step AR05.20-P-7201-
7.12.09 "Arrest gear backlash" added
12.2 05AMG
Value changed: bolt, camshaft adjuster on camshaft, 1st
*BA05.20-P-1001-02J
stage
6.8.09
Value changed: bolt, camshaft adjuster cover on cylinder
*BA05.20-P-1002-02J
head
Removing
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear of AS00.00-Z-
removing, installing or aligning
moving parts. 0011-01A
hoods, doors, trunk lids, liftgates or
sliding roof
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
1 Switch off ignition
Remove partition wall between AR62.30-P-
2 Model 251
wheel wells 2400RT
AR09.10-P-
Model 164, 251
1150GZS
AR09.10-P-
Model 204, 212
1150CMG
AR09.10-P-
3 Remove air filter housing Model 209, 211, 219
1150TMG
AR09.10-P-
Model 216, 221
1150SMG
AR09.10-P-
Model 230
Only if it is not possible to crank engine due
to high compression.
AR15.12-P-
Model 164, 251
1010GZS
AR15.12-P-
Model 204, 212
1010CMG
4 Remove spark plugs
AR15.12-P-
Model 209, 211, 219
1010TMG
AR15.12-P-
Model 216, 221
1010SMG
AR15.12-P-
Model 230
1010RMG
Rotate engine at crankshaft center
bolt in direction of rotation of the The 40° marking (12) on belt pulley
5 must be aligned with marking on the timing
engine to a 40° crankshaft angle
after top dead center (TDC) case cover (arrow).
When removing camshaft adjuster (4) on the
right.
AR18.40-P-
Model 164, 251
3510GZS
AR18.40-P-
Model 204, 212
Loosen oil dipstick guide tubes (11) 3510CMG
6
on cylinder head and turn to the side AR18.40-P-
Model 209, 211, 219
3510TMG
AR18.40-P-
Model 216, 221
3510SMG
AR18.40-P-
Model 230
3510RMG
AR01.20-P-
Model 164, 251
5014GZS
AR01.20-P-
Model 204, 212
5014CMG
AR01.20-P-
7 Remove cylinder head covers (1) Model 209, 211, 219
5014TMG
AR01.20-P-
Model 216, 221
5014SMG
AR01.20-P-
Model 230
5014RMG
See "CHECK BASIC POSITION OF AR05.20-P-
Insert holding device (01) at CAMSHAFTS". 6010AMG
8
camshafts (2)
Fig. 100
When removing camshaft adjuster (4) on the
9.1 Disconnect electrical connectors (3a, left.
3b) on left camshaft intake solenoid Mark electrical connectors (3b) with
solenoid (Y49/6) connectors during installation.
When removing camshaft adjuster (4) on the
Disconnect electrical connectors (3a, right.
3b) on right camshaft intake
9.2 Mark electrical connectors (3b) with
solenoid (Y49/5) and right camshaft
different colors to avoid mixing up the
exhaust solenoid (Y49/7)
connectors during installation.
Remove bolt from ground strap (5)
10
at caps (7, 8)
11 Remove bolts (6) on cap (7, 8)
Insert safety screws in the bores (4b) The safety screws are required for
12.1 on the rear of the camshaft adjuster locking the gear backlash adjustment (4a) of
(4) the camshaft adjuster (4).
AR05.20-P-
On camshaft adjusters (4) without
Arrest gear backlash compensation 7201-
12.2 thread in bore (4b).
(4a) on camshaft adjuster (4) 05AMG
Compressing tool Fig. 127
13 Remove bolts (9)
Observe identification for intake and
Remove camshaft adjuster (4) and exhaust camshaft adjusters. Mark central
14
center valve with segment plate (10) valve with segment plates (10) relative to
intake and exhaust camshaft adjusters.
Install
Camshaft adjuster (4) can be
Insert camshaft adjuster (4) and
15 inserted at any desired position. Insert washer
center valve with segment plate (10)
(12a) before inserting camshaft adjuster (4).
Only screw in bolts (9) so that center
16 Screw in bolts (9)
valve with segment plates (10) can be turned.
Remove securing screws at rear of
17.1
the camshaft adjuster (4)
AR05.20-P-
Remove tensioning tool for arresting On camshaft adjusters (4) without 7201-
17.2 tooth backlash compensation (4a) on thread in bore (4b). 05AMG
camshaft adjuster (4)
Compressing tool Fig. 127
Check basic position of camshafts Check camshaft position on both AR05.20-P-
18
(2) cylinder heads. 6010AMG
Bring central valve with segment
19 plates (10) on left cylinder head into See picture L
the installation position
Bring central valve with segment
20 plates (10) on right cylinder head See picture R
into the installation position
Observe respective side of locating
plate (05). Turn center valve with segment
(13) of locating plate (05) engages in cutouts
on segment plates (10). Then tighten bolts (9)
Place locating plate (05) on front and remove locating plate (05).
21 *BA05.20-
side of cylinder head
P-1001-02J
Fig. 141
22
*BA05.20-
P-1002-02J
23 Screw bolts (6) into cap (7, 8)
*BR00.45-
Loctite sealant 5970
Z-1013-01A
*BA05.20-
24 Mount ground strap (5) on cap (7, 8)
P-1004-02J
Contact intake camshaft solenoid,
left (Y49/4) and exhaust camshaft
solenoid, left (Y49/6) or intake
25
camshaft solenoid, right (Y49/5) and
exhaust camshaft solenoid, right
(Y49/7)
Remove holding device (01) on
26 Fig. 100
camshafts (2)
AR01.20-P-
Model 164, 251
5014GZS
AR01.20-P-
Model 204, 212
5014CMG
AR01.20-P-
27 Install cylinder head covers (1) Model 209, 211, 219
5014TMG
AR01.20-P-
Model 216, 221
5014SMG
AR01.20-P-
Model 230
5014RMG
If camshaft adjuster (4) on the right side was
removed.
AR18.40-P-
Model 164, 251
3510GZS
AR18.40-P-
Model 204, 212
3510CMG
28 Install oil dipstick guide tube (11)
AR18.40-P-
Model 209, 211, 219
3510TMG
AR18.40-P-
Model 216, 221
3510SMG
AR18.40-P-
Model 230
3510RMG
If it is not possible to crank engine due to
AR15.12-P-
Model 164, 251
1010GZS
AR15.12-P-
Model 204, 212
1010CMG
AR15.12-P-
29 Install spark plugs Model 209, 211, 219
1010TMG
AR15.12-P-
Model 216, 221
1010SMG
AR15.12-P-
Model 230
1010RMG
Remove partition wall between AR62.30-P-
30 Model 251
wheel wells 2400RT
AR09.10-P-
Model 164, 251
1150GZS
AR09.10-P-
Model 204, 212
1150CMG
AR09.10-P-
31 Install air filter housing Model 209, 211, 219
1150TMG
AR09.10-P-
Model 216, 221
1150SMG
AR09.10-P-
Model 230
1150RMG
Checking
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving by
running. Risk of injury caused by itself.
contusions and burns during starting Wear closed and snug-fitting work clothes. AS00.00-Z-
procedure or when working near the Do not touch hot or rotating parts. 0005-01A
engine as it is running
32 Carry out engine test run Inspect engine for leaks.
Conduct new calibration of sensor
33 rotor of camshaft adjustor (4) using
STAR DIAGNOSIS When removing camshaft adjuster
(4) new calibration is always necessary.
Connect STAR DIAGNOSIS and AD00.00-P-
read out fault memory 2000-04A
CAMSHAFT, CAMSHAFT ADJUSTMENT
Number Designation Engine 156
Stage 1 Nm 45
BA05.20-P-1001-02J Bolt, camshaft adjuster to camshaft M12
Stage 2 Angle° 90
BA05.20-P-1002-02J Bolt, camshaft adjuster cover to cylinder head M6 Nm 10
BA05.20-P-1004-02J Bolt, engine wiring harness ground to camshaft adjuster cover Nm 9
Fig. 140: Identifying Holding Device (156 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
Fig. 141: Identifying Locating Plate (156 589 00 32 00)
Courtesy of MERCEDES-BENZ USA
Fig. 142: Identifying Compressing Tool (156 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS
Number Designation Order number
BR00.45-Z-1013-01A Loctite sealant 5970 A 003 989 98 20
REMOVE/INSTALL CAMSHAFTS - AR05.20-P-7201SX
ENGINE 273 in MODEL 216 Camshaft adjuster for intake camshafts
Fig. 143: Identifying Camshaft Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 144: Identifying Camshaft Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 145: Identifying Camshaft Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Use the Torx screwdriver bit T60 to counterhold camshafts, AR05.20-P-7201-
14.9.07
added 06VA
Step
26.11.07 Installation note on install new chain tensioner, added
3
Remove/install
1 Switch off ignition
AR09.10-P-
2 Remove air filter housing
1150SX
Installation: Install new chain
tensioner . The previously installed chain
tensioner must not be reinstalled because AR05.10-P-
3 Remove chain tensioner during removal, its pressure pin is pressed into 7800SX
the end position. The pressure pin latch
prevents this return stroke. This would
overstretch the timing chain on reinstalling.
Right-hand side
Remove camshaft adjuster for right AR05.20-P-
4
exhaust camshaft (1) 7201SY
5 Remove cap (26)
Observe loosening direction.
Installation: The center valve (7) may AR05.20-P-
only be tightened when chain tensioner is 7201-06VA
removed, otherwise this can lead to
6 Detach center valve (7) malfunctioning of camshaft adjustment.
*BA05.20-
P-1009-02A
Fig. 82
Remove the right cylinder head AR01.20-P-
7
cover 5014SY
Engine positioned at 40° crankshaft
Mark timing chain relative to the angle after ignition TDC.
8 camshaft adjuster (15) using color Installation: Check position of
codes (25) intake camshaft (3) based on color coding
(25).
AR05.10-P-
9 Remove tensioning rail (24)
8127SX
Check dowel pin (18) and pin (19). If a
dowel pin (18) or pin (19) is sheared off then
this must be removed from camshaft adjuster
(15).
(11). When tightening center valve (7) there is
a risk that dowel pin (18) or pin (19) may
shear off at pulse wheel (11).
Installation: Lubricate center valve
Remove center valve (7) and pulse
10 (7) at contact surface with pulse wheel (11)
wheel (11)
before assembly.
Installation: Align dowel pin (18) on
pulse wheel (11) with bore (20) in camshaft
adjuster (15).
Installation: Lubricate contact
surfaces to intake camshaft (3) and camshaft
adjuster (15) before mounting camshaft
Remove timing chain from camshaft
adjuster (15).
adjuster (15) and detach camshaft
11 Installation: Align color coding (25)
adjuster (15) forwards from intake
camshaft (3) on camshaft adjuster (15) and timing chain
with each other. Align the dowel pin (21) in
the camshaft adjuster (15) with fitted bore (22)
in intake camshaft (3).
Left-hand side
Remove camshaft adjuster for the AR05.20-P-
12
left exhaust camshaft (2) 7201SY
13 Remove cap (27)
Observe loosening direction.
Installation: The center valve (8) may AR05.20-P-
only be tightened when chain tensioner is 7201-06VA
removed, otherwise this can lead to
14 Detach center valve (8) malfunctioning of camshaft adjustment.
*BA05.20-
P-1009-02A
Fig. 82
AR01.20-P-
15 Remove left cylinder head cover
5014SX
Engine positioned at 40° crankshaft
Mark timing chain relative to the angle after ignition TDC.
16 camshaft adjuster (16) using color Installation: Check position of
codes (25) intake camshaft (4) based on color coding
(25).
Check dowel pin (18) and pin (19). If a
dowel pin (18) or pin (19) is sheared off then
this must be removed from camshaft adjuster
Remove center valve (8) and pulse (16).
17
wheel (12) Installation: Always replace pulse wheel
(12). When tightening center valve (8) there is
a risk that dowel pin (18) or pin (19) may
Installation: Lubricate center valve
(8) at contact surface with pulse wheel (12)
before assembly.
Installation: Align dowel pin (18)
for pulse wheel (12) with fitted bore (20) in
camshaft adjuster (16).
Installation: Lubricate contact
surfaces to intake camshaft (4) and camshaft
adjuster (16) before the mounting camshaft
Remove timing chain from camshaft
adjuster (16).
adjuster (16) and detach camshaft
18 Installation: Align color coding (25)
adjuster (16) towards the front from
intake camshaft (4) on camshaft adjuster (16) and timing chain
with each other. Align the dowel pin (21) in
the camshaft adjuster (16) with fitted bore (22)
in intake camshaft (4).
19 Install in the reverse order
Checking
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving by
running. Risk of injury caused by itself. AS00.00-Z-
contusions and burns during starting Wear closed and snug-fitting work clothes. 0005-01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
Conduct engine test run and check
20
engine for leaks
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine
Number Designation
272 273
BA05.20-P-1009- Center valve for pulse wheel/camshaft adjuster to
Nm 145 145
02A camshaft
Fig. 146: Identifying Torx Screwdriver Bit T60 (272 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL CAMSHAFTS - AR05.20-P-7201SY
ENGINES 272, 273 in MODEL 221 Camshaft adjuster for exhaust camshafts
ENGINES 273 in MODEL 216 Camshaft adjuster for exhaust camshafts
Fig. 147: Identifying Camshaft Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 148: Identifying Camshaft Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 149: Identifying Camshaft Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
14.9.07 Use the Torx screwdriver bit T60 to counterhold camshafts, added AR05.20-P-7201-06VA
Remove/install
1 Switch off ignition
AR09.10-P-
2 Remove air filter housing
1150SX
AR01.30-P-
Left cylinder head
Remove front cover at respective 5700SX
3
cylinder head AR01.30-P-
Right cylinder head
5700SY
When removing from right camshaft adjuster AR01.20-P-
4.1 Remove centrifuge
(13). 2100SX
When removing from left camshaft adjuster
4.2 Remove cap (26)
(14).
Turn engine at crankshaft center bolt
in direction of engine rotation to a AR05.20-P-
5
40° crank angle after ignition TDC 6010-01VB
and check position of camshafts
Lock gear backlash compensation
AR05.20-P-
6 for respective camshaft adjuster (13
7201-05VA
or 14)
AR05.20-P-
Observe loosening direction.
Detach center valve (5 or 6) for 7201-06VA
7 respective camshaft adjuster (13 or *BA05.20-
14) P-1009-02A
Fig. 82
Check dowel pin (18) and pin (19). If a
dowel pin (18) or pin (19) is sheared off then
this must be removed from respective
Installation: Always replace pulse wheel
(9 or 10). When tightening the center valve (5
or 6) there is a risk that dowel pin (18) or pin
Remove center valve (5 or 6) for (19) may shear at the pulse wheel (9 or 10).
respective camshaft adjuster (13 or Lubricate center valve (5 or 6) at contact
8
14) and remove pulse wheel (9 or surface with pulse wheel (9 or 10) before
10) assembling.
Installation: Align dowel pin (18)
for pulse wheel (9 or 10) with the fitted bore
(20) in the camshaft adjuster (13 or 14).
Installation: Lubricate contact
surfaces on exhaust camshaft (2) and
Counterhold the respective exhaust camshaft adjuster (13 or 14) before
camshaft (2) at the rear and pull off assembling camshaft adjuster (13 or 14). Fig. 82
9 the camshaft adjuster (13 or 14) Installation: Align dowel pin (21) in
from the exhaust camshaft (2) camshaft adjuster (13 or 14) to fitted bore (22)
towards the front in exhaust camshaft (2) and install camshaft
adjuster (13 or 14) in its basic position:
See "CHECK BASIC POSITION OF AR05.20-P-
CAMSHAFTS". 6010-01VB
10 Install in the reverse order
Checking
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving by
running. Risk of injury caused by itself. AS00.00-Z-
contusions and burns during starting Wear closed and snug-fitting work clothes. 0005-01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
Conduct engine test run and check
11
engine for leaks
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine
Number Designation
272 273
BA05.20-P-1009- Center valve for pulse wheel/camshaft adjuster to
Nm 145 145
02A camshaft
Fig. 150: Identifying Torx Screwdriver Bit T60 (272 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL SOLENOID CAMSHAFT - AR05.20-P-7295SX
ENGINES 273 in MODEL 216 LH cylinder head
ENGINES 272, 273 in MODEL 221 Left cylinder head
Fig. 151: Identifying Camshaft Solenoid Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
27.10.08 Remove Hall sensor for intake camshaft - added Step 5.2
Remove/install
Remove left engine intake air duct and front engine
1
Removal Intake camshaft solenoid (Y49/4)
*BA15.10-P-
2 Remove intake camshaft Hall sensor (B6/4)
1002-03E
Release and disconnect electrical connector on
3
solenoid (Y49/4)
Installation:
Replace sealing ring.
Installation:
Remove bolts (1) and solenoid (Y49/4) from front Tightening to indicated
4
cover torque using an insert box
wrench Hazet 6609 c-E8 .
*BA15.10-P-
1003-03E
Removal of exhaust camshaft solenoid (Y49/6)
Vehicles up to and including
31.01.2006 without code AR46.25-P-
5.1 Remove power steering expansion reservoir (3)
(487) Active Body Control 1000SX
(ABC)
Vehicles as of 01.02.2006
without code (487) Active
Remove intake camshaft Hall sensor (B6/4) and Body Control (ABC)
5.2
exhaust camshaft Hall sensor (B6/6)
*BA15.10-P-
1002-03E
Release and disconnect electrical connector on
6
solenoid (Y49/6)
Installation:
Replace sealing ring.
Installation:
Remove bolts (2) and solenoid (Y49/6) from front Tightening to indicated
7
cover torque using an insert box
wrench Hazet 6609 c-E8 .
*BA15.10-P-
1003-03E
8 Install in the reverse order
Checking
Secure vehicle to prevent it
Risk of accident caused by vehicle starting off by from moving by itself.
itself when engine is running. Risk of injury caused Wear closed and snug-fitting AS00.00-Z-
by contusions and burns during starting procedure work clothes. 0005-01A
or when working near the engine as it is running Do not touch hot or rotating
parts.
9 Conduct engine test run and check engine for leaks
POSITION SENSOR
Engine Engine
Number Designation
272 273
BA15.10-P-1002- Bolt, camshaft Hall sensor to front cover on cylinder
Nm 8 8
03E head
BA15.10-P-1003-
Bolt, camshaft solenoid to front cover to cylinder head Nm 8 8
03E
REMOVE/INSTALL SOLENOID CAMSHAFT - AR05.20-P-7295SY
ENGINE 273 in MODEL 216 Right cylinder head
ENGINE 272, 273 in MODEL 221 Right cylinder head
Fig. 152: Identifying Solenoid Camshaft Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove right engine intake air duct and front engine cover
Removal Intake camshaft solenoid, right (Y49/5)
Remove bolts (4), detach bracket (3) with switchover valve *BA01.30-P-
2
(Y32) and lay with attached lines to one side 1009-01O
Release and disconnect electrical connector on solenoid
3
(Y49/5)
Installation:
Replace sealing ring.
4 Remove bolts (2) and solenoid (Y49/5) from the front cover
*BA15.10-P-
1003-03E
Removal of exhaust camshaft solenoid, right (Y49/7)
Release and disconnect electrical connector on solenoid
5
(Y49/7)
Installation:
Replace sealing ring.
6 Remove bolts (1) and solenoid (Y49/7) from the front cover
*BA15.10-P-
1003-03E
7 Install in the reverse order
Checking
Secure vehicle to
prevent it from
Risk of accident caused by vehicle starting off by itself moving by itself.
when engine is running. Risk of injury caused by Wear closed and AS00.00-Z-
contusions and burns during starting procedure or when snug-fitting work 0005-01A
working near the engine as it is running clothes.
Do not touch hot or
rotating parts.
8 Conduct engine test run and check engine for leaks
CYLINDER HEAD
Number Designation Engine 272 Engine 273
BA01.30-P-1009-01O Bolt, switchover valve bracket to cylinder head M6 Nm 9 9
POSITION SENSOR
Number Designation Engine 272 Engine 273
BA15.10-P-1003-03E Bolt, camshaft solenoid to front cover to cylinder head Nm 8 8
REPLACE VALVE STEM SEALS - AR05.30-P-3500-02VA
Fig. 153: Identifying Pliers (606 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
Fig. 154: Identifying Drift (604 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
1. Use pliers (01) to pull off valve stem seals (1 )
2. Check surface of valve stems for roughness and ridging.
Replace valves with a rough stem surface or formation of burrs.
Shown on engine 273
Fig. 155: Pulling Valve Stem Seal
Courtesy of MERCEDES-BENZ USA
3. Fit protective sleeve (02) onto valve stem.
4. Oil valve stem seals (1).
5. Press on the valve stem seals (1) with) drift (03).
6. Pull protective sleeve (02) off the valve stem.
Shown on engine 273
Fig. 156: Pressing On Valve Stem Seal
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL VALVE SPRINGS AND/OR VALVE STEM SEALS - AR05.30-P-3500AMG
ENGINES 156
Fig. 157: Identifying Valve Spring Components
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off of the
support points specified by vehicle 0010-01A
lifting platform.
manufacturer.
AR01.20-P-
Model 164, 251
5014GZS
AR01.20-P-
Model 204, 212
5014CMG
AR01.20-P-
1 Remove cylinder head covers Model 209, 211, 219
5014TMG
AR01.20-P-
Model 216, 221
5014SMG
AR01.20-P-
Model 230
5014RMG
AR05.20-P-
Up to engine number 001177
6992ANG
2 Remove camshafts
AR05.20-P-
from engine number 001178
6992AMG
Remove hydraulic valve clearance AR05.00-P-
3
compensation elements (2) 2011AMG
Rotate piston of the cylinder to be Installation: Before installing the
4 camshaft sprockets, turn the crankshaft back
worked on to TDC
TDC at cylinder 1.
Screw connection hose for cylinder AR01.00-P-
Connect cylinder leakage tester leakage testing unit (1) into relevant spark 1300-01VA
5 plug bore.
(1)
Fig. 160
Pressurize the compression
6 The pressure should be around 5 bar.
chamber
Screw retaining fork and detent
7 with hinged bearing into cylinder Fig. 158
head
Position thrust piece vertically at
Attach detent depressor with lever upper valve spring retainer (3) and align
8 handle and thrust piece into detent parallel to grid with joint bearing.
with hinged bearing, align
Fig. 158
Depress valve spring (4) and Remove valve keepers (5) using
9 remove split valve spring retainer tweezers or magnetic finger.
locks (5) Fig. 159
Do not allow valves to come into contact
with piston crowns, otherwise they will be
Remove upper valve spring
10 bent.
retainer (3) and valve spring (4)
The valve springs of the intake and
exhaust valves are identical.
Installation: Replace valve stem seal AR05.30-P-
(6) after inspecting lower valve spring retainer 3500-02VA
11 Remove valve stem seal (6) (7).
Fig. 153
Fig. 154
Remove lower valve spring
12
retainer (7)
Checking
Visual inspection or with nail probe.
Replace valves with a rough stem surface or
Inspect surface of valve stems for
13 formation of ridging: ?
roughness and ridging
AR05.30-P-
Remove valves.
3511AMG
Check upper and lower valve inspect the valve spring retainer for
14
spring retainers (3, 7) burrs, replace if necessary.
15 Install in the reverse order
Fig. 158: Identifying Case For Valve Installation Tools (111 589 25 61 00)
Courtesy of MERCEDES-BENZ USA
Fig. 159: Identifying Magnetic Finger (116 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 160: Identifying Threaded Adapter (272 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 161: Identifying Pliers (606 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
Fig. 162: Identifying Drift (604 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL VALVE SPRINGS AND/OR VALVE STEM SEALS - AR05.30-P-3500SX
ENGINE 272, 273 in MODEL 221
ENGINE 273 in MODEL 216
Fig. 163: Removing/Installing Valve Springs And Valve Stem Seals
Courtesy of MERCEDES-BENZ USA
Fig. 164: Identifying Valve Stem Components
Courtesy of MERCEDES-BENZ USA
Remove/install
AR09.10-
1 Remove air filter housing
P-1150SX
AR01.20-
Right cylinder head cover
P-5014SY
2 Remove cylinder head covers
AR01.20-
Left cylinder head cover
P-5014SX
AR05.20-
3 Remove camshafts
P-6992SX
Remove hydraulic valve clearance AR05.00-
4
compensation elements P-2011SX
5 Remove spark plugs
AP15.10-P-
Replace spark plugs
1580SX
Crank crankshaft at center bolt
for the belt pulley, at the same time
hold up the timing chain, so that it does
not jam when cranking.
Crank engine at crankshaft in direction of
Installation: Before installing
6 rotation until piston on cylinder to be
camshafts turn engine again at
machined is positioned at TDC
crankshaft in direction of engine
rotation in starting position to a 40°
crank angle after ignition TDC.
Fig. 80
P-1300-
7 Connect cylinder leakage testing unit 01VA
Fig. 160
Pressurize compression chamber to about 5
8
bar
9 Mount counterholder (01) on cylinder head Fig. 158
Place depressor (03) on upper
Mount assembly lever (02) with depressor valve spring retainer (1) vertically.
10
(03) on counterholder (01) and align Fig. 158
Fig. 166
When pressing together the valve
spring (2) ensure that the depressor (03)
does not slip otherwise the surface of
the valve stem can be damaged.
Do not allow valves to touch piston
crowns otherwise they will be
Remove upper valve spring retainer (1) damaged.
11
and valve spring (2) Compress valve spring (2).
Remove split valve spring retainer
locks (3) with magnetic finger (04),
magnet pit or tweezers.
Fig. 159
Fig. 168
12 Take out lower valve spring retainer (4).
Check surface of valve stem
for roughness and formation of ridging AR05.30-
(visual inspection or with nail). P-3500-
Replace valves with a rough stem 02VA
13 Replace valve stem seal (5) surface or formation of ridging: ?
AR05.30-
Remove/install valves.
P-3511SX
Fig. 153
Fig. 154
Checking
Check valve spring retainer (1, 4) for
14
pitting; replace as required
If a retaining lock for
Perform machining of other cylinders in crankshaft/starter ring gear was
15
the same way installed, it must be removed before
turning engine.
16 Install in the reverse order
17 Check engine oil level using the engine oil The vehicle must be on a level
the engine at operating temperature; will occur.
correct if necessary
AP18.00-P-
Engine oil and filter change
0101SX
Risk of accident caused by vehicle
Secure vehicle to prevent it from
starting off by itself when engine is
moving by itself.
running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-fitting work
contusions and burns during starting 0005-01A
clothes.
procedure or when working near the
Do not touch hot or rotating parts.
engine as it is running
Carry out an engine test run and check
18
engine for leaks
AR20.00-
19 Inspect cooling system for leaks
P-1010SX
Fig. 165: Identifying Case For Valve Installation Tools (111 589 25 61 00)
Courtesy of MERCEDES-BENZ USA
Fig. 166: Identifying Depressor (273 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
Fig. 167: Identifying Magnetic Finger (116 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 168: Identifying Magnetic Pin (210 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 169: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 170: Identifying Threaded Adapter (272 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 171: Identifying Pliers (606 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
Fig. 172: Identifying Drift (604 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL VALVES - AR05.30-P-3511AMG
ENGINES 156
Fig. 173: Identifying Valve Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
8.9.09 Value changed: valve disk- ø *BE05.30-P-1001-01E
Value changed: valve disk height *BE05.30-P-1002-01E
Value changed: valve stem- ø *BE05.30-P-1004-01E
Value changed: valve length *BE05.30-P-1005-01E
Remove/install
Align vehicle between columns of
Risk of death caused by vehicle slipping vehicle lift and position four support AS00.00-Z-
or toppling off the lifting platform. plates at vehicle lift support points 0010-01A
specified by vehicle manufacturer.
AR01.30-P-
Model 164, 251
5800GZS
AR01.30-P-
Model 204, 212
5800CMG
AR01.30-P-
1 Remove cylinder head (1) Model 209, 211, 219
5800TMG
AR01.30-P-
Model 216, 221
5800SMG
AR01.30-P-
Model 230
5800RMG
Mount cylinder head (1) onto assembly
2 Fig. 178
device
head (1) and set vertically to the upper from the valve assembly tool case.
3 valve spring retainer (2) Fig. 158
Remove hydraulic valve clearance
AR05.00-P-
4 compensation elements using a suction
2011AMG
cup
Depress valve spring with assembly tool
5 (7) and remove split valve spring retainer Fig. 159
locks (4)
Check for pitting and replace if
necessary.
Remove upper and lower valve spring The intake valve has 2 valve
6 springs.
retainers (2, 3)
Fig. 168
Fig. 177
Installation: Fit protective
sleeve for valve stem seal (5) onto valve
stem. Lubricate valve stem seal (5) and
7 Use pliers to remove valve stem seal (5) press on with drift. Pull off protective
sleeve for valve stem seal (5) again.
Fig. 153
Fig. 154
Remove cylinder head (1) from assembly
8
device
Risk of explosion and poisoning caused
by the melting down or improper
Do not open sodium-filled valves. Wear
handling of sodium-filled valves. Risk of
protective gloves and safety glasses
injury caused by skin contact with
when handling damaged valves.
sodium resulting in heat or chemical
burns. AS05.30-Z-
Installation: Check surface of 0001-01A
valve stems for roughness and
formation of ridging (visual inspection
9 Remove valve (6)
or with a nail). Replace valves (6) with
a rough stem surface or formation of
burrs.
The intake and exhaust valves must
not be worked otherwise there is the
risk that the valve (6) may not be sealed AR05.30-P-
correctly. 4201-01SLR
If the specified tolerances are not met,
10 Inspect valve (6)
valve (6) must be replaced.
*BE05.30-P-
1001-01E
1002-01E
*BE05.30-P-
1003-01E
*BE05.30-P-
1004-01E
*BE05.30-P-
1005-01E
OS05.30-P-
Disposal of sodium-filled valves Exhaust valves with sodium filling
0001-01A
11 Install in the reverse order
CHECK VALUES FOR VALVES
Number Designation Engine 156/159
Exhaust mm 33.35 (±0.1)
BE05.30-P-1001-01E Valve disk dia.
Intake mm 40 (±0.1)
Exhaust when new mm 1.75 (±0.1)
BE05.30-P-1002-01E Valve disk height
Intake when new mm 1.48 (±0.1)
Exhaust Angle° 45 (±15')
BE05.30-P-1003-01E Valve seat angle (a)
Intake Angle° 45 (±15')
Exhaust mm 5.97 (-0.015)
BE05.30-P-1004-01E Valve stem dia.
Intake mm 5.98 (-0.015)
Exhaust mm 103.55 (±0.015)
BE05.30-P-1005-01E Valve length
Intake mm 106.67 (±0.2)
Fig. 174: Identifying Magnetic Finger (116 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 175: Identifying Magnetic Pin (210 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
Fig. 176: Identifying Case For Valve Installation Tools (111 589 25 61 00)
Courtesy of MERCEDES-BENZ USA
Fig. 177: Identifying Thrust Piece (119 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 178: Identifying Assembly Tool (271 589 00 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 179: Identifying Pliers (606 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
Fig. 180: Identifying Drift (604 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
REMOVING/INSTALLING VALVES - AR05.30-P-3511SX
ENGINE 272, 273 Cylinder head removed
Fig. 181: Identifying Valve Removing/Installing Components (1 Of 2)
Courtesy of MERCEDES-BENZ USA
Fig. 182: Identifying Valve Removing/Installing Components (2 Of 2)
Courtesy of MERCEDES-BENZ USA
Removing/installing
Assembly tool Fig. 178
Valve assembly tool case Fig. 158
Compressor Fig. 185
Before startup of assembly device (01),
check that the counterholders (02) are correctly
that the cylinder head (1) is pressed to the top
out of the assembly device (01), because the
air bellows of the assembly device (01) in
Mount cylinder head (1) onto the combustion chamber of the cylinder head
1
assembly device (01) (1) are pressed onto the valve disk.
Observe owner's manual of assembly
device manufacturer (01).
Mount assembly lever (03) Position depressor (04) vertically at
2 with depressor (04) onto sliding upper valve spring plate (2) and align to sliding
piece (05) piece (05).
Ensure, that the air bellows of the assembly
Move the air bellows of the
device (01) are correctly matched with a
assembly device (01) with a combustion chamber and pressed in centrally,
3 lever (06) in such a way that the air otherwise the air bellows can press laterally out
bellows are matched with the of the combustion chamber.
combustion chamber of the
Observe owner's manual of assembly
respective valves
device manufacturer (01).
Press the air bellows of the assembly
Connect compressed air to device (01) in the combustion chamber onto
4 assembly device (01) and open the valve disks.
compressed air valve Observe owner's manual of assembly
device manufacturer (01).
Compress valve spring (3). Remove
split valve spring retainer locks (4) with
magnetic rod (07) , magnetic pin or
tweezers.
Fig. 159
Remove upper valve spring plate
5 Fig. 168
(2) and valve spring (3)
*WH58.30-
Z-1040-02A
Installation: Before mounting the AR05.30-P-
upper valve spring plates (2) and valve springs
3500-02VA
(3), replace valve stem seals.
Take out lower valve spring plate
6
(5).
Close compressed air valve and
7 compressed air connection for
assembly device (01)
Dismount cylinder head (1)
8 from assembly device (01) and
take out valves (6)
Checking
9
pitting; replace if required
If the specified tolerances are below the
limit, the valve must be replaced, in order to
assure the function.
Check surface of valve stems for AR05.30-P-
10 Check valves (6) roughness and burrs (visual inspection or with 4201-01VA
nail).
Replace valves (6) with a rough stem surface or
formation of burrs.
The valves must not be machined.
11 Install in reverse order
Fig. 183: Identifying Assembly Tool (271 589 00 59 00)
Courtesy of MERCEDES-BENZ USA
Fig. 184: Identifying Valve Assembly Tool Case (111 589 25 61 00)
Courtesy of MERCEDES-BENZ USA
Fig. 185: Identifying Compressor (272 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
Fig. 186: Identifying Magnet Finger (116 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 187: Identifying Magnet Pin (210 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1040-02A Tweezers, straight 160 mm with rounded tips
CHECK VALVES - AR05.30-P-4201-01SLR
Value changed: valve disk dia. Engine 156/159 *BE05.30-P-1001-01E
Value changed: valve disk height Engine 156/159 *BE05.30-P-1002-01E
8.9.09
Value changed: valve stem dia. Engine 156/159 *BE05.30-P-1004-01E
Value changed: valve length Engine 156/159 *BE05.30-P-1005-01E
CHECK VALUES FOR VALVES
Number Designation Engine 155 Engine 156/159
Exhaust mm 43 (0.1) 33.35 (0.1)
BE05.30-P-1001-01E Valve disk dia.
Intake mm 38 (0.1) 40 (0.1)
Exhaust when new mm 2.1 (±0.1) 1.75 (0.1)
BE05.30-P-1002-01E Valve disk height
Intake when new mm 1.7 (0.1) 1.48 (0.1)
Exhaust Angle° 45 (±15') 45 (±15')
BE05.30-P-1003-01E Valve seat angle (a)
Intake Angle° 45 (±15') 45 (±15')
Exhaust mm 6.97 (-0.02) 5.97 (-0.015)
BE05.30-P-1004-01E Valve stem dia.
Intake mm 6.975 (-0.015) 5.98 (-0.015)
Exhaust mm 121.80 (±0.2) 103.55 (±0.015)
BE05.30-P-1005-01E Valve length
Intake mm 119.10 (±0.2) 106.67 (±0.2)
Fig. 188: Identifying Valve Dimensions
Courtesy of MERCEDES-BENZ USA
CHECK VALVES - AR05.30-P-4201-01VA
CHECK VALUES FOR VALVES
Engine
Number Designation Engine 273.92 273.96/97
BE05.30-P-1001- Valve disk dia. Exhaust mm 30 (± 0.1) 32 (± 0.1)
01E Intake mm 39.5 (± 0.1) 42 (± 0.1)
BE05.30-P-1002- Valve disk height Exhaust when new mm 1.8 (± 0.1) 1.8 (± 0.1)
01E Intake when new mm 1.6 (± 0.1) 1.6 (± 0.1)
BE05.30-P-1003- Valve seat angle (a) Exhaust Angle° 45° 30' (± 10') 45 (± 15')
01E Intake Angle° 45 (± 15') 45 (± 15')
BE05.30-P-1004- Valve stem dia. Exhaust mm 5.955 to 5.970 5.955 to 5.970
01E Intake mm 5.960 to 5.975 5.960 to 5.975
BE05.30-P-1005- Valve length Exhaust mm 107.3 (± 0.2) 107.2 (± 0.2)
01E Intake mm 108.8 (± 0.2) 107.8 (± 0.2)
1. Check dimensions (A. B, C, D,) on valve.
Fig. 189: Identifying Dimensions Of Valve
Courtesy of MERCEDES-BENZ USA
SAFETY PRECAUTIONS
SAFETY INFORMATION: ENGINE TIMING - AS05.00-Z-9999ZZ
MODEL all
Risk of explosion and poisoning ENGINE 111, 112, 113, 137, 155, AS05.30-Z-0001-01A
caused by the melting down or 156, 159, 166, 266, 646, 647,
improper handling of sodium- 648...
filled valves. Risk of injury caused
by skin contact with sodium
resulting in heat or chemical
burns.
RISK OF EXPLOSION AND POISONING CAUSED BY THE MELTING DOWN OR IMPROPER
HANDLING OF SODIUM-FILLED VALVES. RISK OF INJURY CAUSED BY SKIN CONTACT
WITH SODIUM RESULTING IN HEAT OR CHEMICAL BURNS. - AS05.30-Z-0001-01A
Risk of explosion and poisoning Do not open sodium-filled valves.
caused by the melting down or Wear protective gloves and safety
improper handling of sodium-filled glasses when handling damaged
valves. Risk of injury caused by valves.
skin contact with sodium resulting
in heat or chemical burns.
Potential risks
Risk of explosion
Explosion may occur when melting down sodium-filled valves.
Sodium has a very low self-ignition temperature (121 °C) and may spontaneously ignite in moist air.
Improper disposal may lead to fires due to moisture in scrap containers.
Risk of poisoning
The inhalation of toxic vapors causes severe irritation, shortness of breath, headaches, nausea and vomiting.
Risk of injury
Leaked sodium that comes into contact with moist body tissue (perspiration on hands, tears) may undergo a
severe, explosive reaction and generate heat. This may lead to skin irritation and burns, and to corneal damage
with possible blinding.
Safety instructions/precautions
Keep water and sources of heat and ignition away from sodium.
When handling damaged, sodium-filled valves, wear suitable protective gloves and safety glasses, if
necessary.
Never machine sodium-filled valves.
Do not open sodium-filled valves.
Observe all additional safety requirements and regulations in your country.
First aid measures
Skin and eye contact
Remove sodium, treat the injured area with an oily solution, e.g. Biseptol and consult a physician.
Ingestion
Do not give the affected person anything to drink, consult a physician.
Vapor inhalation
Move the victim out of the risk area.
If victim has the urge to vomit, give him/her oxygen.
In the event of respiratory failure, administer artificial respiration and notify a physician.
TORQUE SPECIFICATIONS
TIGHTENING TORQUES: PASSENGER CARS: ENGINE TIMING - BA05.00-Z-9999AZ
MODEL all
BA05.20-N-
Camshaft ENGINE 601, 602 /982 /983
1000-01F
BA05.20-P-
Camshaft ENGINE 266
1000-01K
BA05.20-P-
Camshaft ENGINE 611, 612, 613, 628, 629, 646, 647, 648...
1000-01F
BA05.20-P-
Camshaft ENGINE 668.914 /940 /941 /942
1000-01D
BA05.20-P-
Camshaft ENGINE 166.940 /960 /961 /990 /991 /995
1000-01C
ENGINE 601, 602 /, 603 /, 604, 605, 606 / (except, BA05.20-P-
Camshaft
602.98 /98) 1000-01A
BA05.20-P-
Camshaft ENGINE 640
1000-01J
BA05.20-P-
Camshaft ENGINE 137
1000-01E
BA05.20-P-
Camshaft ENGINE 651
1000-01N
BA05.20-P-
Camshaft ENGINE 112, 113, 155...
1000-01B
BA05.20-P-
Camshaft bearing housing ENGINE 271
1000-03A
Camshaft, camshaft BA05.20-P-
ENGINE 275, 285
adjustment 1000-02I
Camshaft, camshaft BA05.20-P-
ENGINE 119
adjustment 1000-02B
Camshaft, camshaft BA05.20-P-
ENGINE 120
adjustment 1000-02F
Camshaft, camshaft BA05.20-P-
ENGINE 156, 159
adjustment 1000-02J
Camshaft, camshaft BA05.20-P-
ENGINE 103 /, 104 /, 111, 157, 271, 272, 273/, 276, 278
adjustment 1000-02A
BA05.10-P-
Gearwheel drive ENGINE 651
1000-02A
Timing chain drive, BA05.10-P-
ENGINE 640
toothed belt drive 1000-01N
Timing chain drive, BA05.10-N-
ENGINE 601, 602 /982 /983
toothed belt drive 1000-01B
Timing chain drive, ENGINE 103, 104, 111, 113, 119, 120, 155, 156, 159, 272, BA05.10-P-
toothed belt drive 273... 1000-01B
Timing chain drive, BA05.10-P-
ENGINE 112, 113...
toothed belt drive 1000-01C
Timing chain drive, BA05.10-P-
ENGINE 651
toothed belt drive 1000-01Q
Timing chain drive, BA05.10-P-
ENGINE 271
toothed belt drive 1000-01F
Timing chain drive, BA05.10-P-
ENGINE 266
toothed belt drive 1000-01K
Timing chain drive, BA05.10-P-
ENGINE 155.980
toothed belt drive 1000-01J
Timing chain drive, ENGINE 601, 602, 603, 604, 605, 606, 611, 612, 613, 628, BA05.10-P-
toothed belt drive 629, 646, 647, 648... 1000-01A
Timing chain drive, BA05.10-P-
ENGINE 137, 275, 285
toothed belt drive 1000-01H
Timing chain drive, BA05.10-P-
ENGINE 157, 276, 278
toothed belt drive 1000-01R
Timing chain drive, BA05.10-P-
ENGINE 166.940 /960 /961 /990 /991 /995
toothed belt drive 1000-01D
Timing chain drive, BA05.10-P-
ENGINE 642 /
toothed belt drive 1000-01L
Timing chain drive, BA05.10-P-
ENGINE 668.914 /940 /941 /942
toothed belt drive 1000-01E
TIMING CHAIN DRIVE, TOOTHED BELT DRIVE - BA05.10-P-1000-01B
Engine 103, 104, 111, 113, 119, 120, 155, 156, 159, 272, 273
MODIFICATION NOTES
18.4.07 Guide pulley on crankcase Engine 273
TIMING CHAIN, CHAIN TENSIONER
Engine Engine Engine Engine
Number Designation
103 104 111 113.940/941/942/943/944/945/946/948/960/961/963/96
BA05.10-
End piece of
P-1001- Nm 50 40 40 -
chain tensioner
01B
BA05.10- Chain tensioner
P-1002- housing in timing Nm - 80 80 -
01B case cover
BA05.10-
Bolts for top of
P-1003- Nm -- 10 -
guide rail
01B
BA05.10-
Threaded ring for
P-1004- Nm 30 - - -
chain tensioner
01B
BA05.10- Bolt, slide rail
P-1005- bridge to cylinder Nm -- - -
01B head
BA05.10-
Guide pulley on
P-1006- Nm -- - 58 (± 4.6)
crankcase
01B
Bolt for timing
BA05.10-
chain rivet
P-1007- Nm -- - -
element
01B
(reference value)
Chain
BA05.10- tensioner
P-1008- on M22x1.5 Nm - - - -
01B timing
case
BA05.10-
Torque to unlock
P-1009- Nm -- - -
chain tensioner
01B
TIMING CHAIN, CHAIN TENSIONER
Engine Engine Engine Engine
Number Designation
113.987/988/990/991 113.989 119 120
BA05.10-P-
End piece of chain tensioner Nm - - - 40
1001-01B
BA05.10-P- Chain tensioner housing in
Nm -- 25 80
1002-01B timing case cover
BA05.10-P-
Bolts for top of guide rail Nm 20 20 - -
1003-01B
BA05.10-P- Threaded ring for chain
Nm -- - -
1004-01B tensioner
BA05.10-P- Bolt, slide rail bridge to
Nm -- - 21
1005-01B cylinder head
BA05.10-P-
Guide pulley to crankcase Nm 58 58 - -
1006-01B
BA05.10-P- Bolt for timing chain rivet
Nm -- - -
1007-01B element (reference value)
BA05.10-P- Chain tensioner on
M22x1.5 Nm - - - -
1008-01B timing case
BA05.10-P- Torque on unlock chain
Nm -- - -
1009-01B tensioner
TIMING CHAIN, CHAIN TENSIONER
Engine Engine Engine
Number Designation
155 156 159
BA05.10-P-1001-
End piece of chain tensioner Nm - - -
01B
BA05.10-P-1002-
Chain tensioner housing in timing case cover Nm -- -
01B
BA05.10-P-1003-
Bolts for top of guide rail Nm -- -
01B
BA05.10-P-1004-
Threaded ring for chain tensioner Nm -- -
01B
BA05.10-P-1005-
Bolt, slide rail bridge to cylinder head Nm -- -
01B
BA05.10-P-1006-
Guide pulley to crankcase Nm -- -
01B
BA05.10-P-1007- Bolt for timing chain rivet element (reference
Nm -- -
01B value)
BA05.10-P-1008-
Chain tensioner on timing case M22x1.5 Nm - 75 75
01B
BA05.10-P-1009-
Torque on unlock chain tensioner Nm -- -
01B
TIMING CHAIN, CHAIN TENSIONER
Number Designation Engine 272 Engine 273
BA05.10-P-1001-01B End piece of chain tensioner Nm 50 50
BA05.10-P-1002-01B Chain tensioner housing in timing case cover Nm 70 70
BA05.10-P-1003-01B Bolts for top of guide rail Nm --
BA05.10-P-1004-01B Threaded ring for chain tensioner Nm --
BA05.10-P-1005-01B Bolt, slide rail bridge to cylinder head Nm --
BA05.10-P-1006-01B Guide pulley on crankcase Nm - 55
BA05.10-P-1007-01B Bolt for timing chain rivet element (reference value) Nm 32 32
BA05.10-P-1008-01B Chain tensioner on timing case M22x1.5 Nm 70 70
BA05.10-P-1009-01B Torque to unlock chain tensioner Nm 70 70
TIMING CHAIN DRIVE, TOOTHED BELT DRIVE - BA05.10-P-1000-01H
Engine 137, 275, 285
MODIFICATION NOTES
12.6.02 Value changed from 80 Nm to 120 Nm Figure in BA05.10-P-1001-01H for engine 137 modified
TIMING CHAIN, CHAIN TENSIONER
Number Designation Engine 137 Engine 275, 285
BA05.10-P-1001-01H Chain tensioner in cylinder head Nm 120 -
BA05.10-P-1002-01H End piece of chain tensioner Nm - 80
BA05.10-P-1003-01H Chain tensioner housing in timing case cover Nm - 120
CAMSHAFT, CAMSHAFT ADJUSTMENT - BA05.20-P-1000-02A
ENGINE 103, 104, 111, 157, 271, 272, 273, 276, 278
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine Engine Engine
Number Designation
103 104 111 157
Stage
Nm - 20 20 -
BA05.20-P- Bolt for camshaft sprocket/flange 1
1001-02A shaft Stage
Angle° - 90 60 -
2
Stage
Nm - - - -
BA05.20-P- Center bolt, camshaft adjuster to 1
1002-02A camshaft Stage
Angle° - - - -
2
BA05.20-P-
Nut, camshaft gear to flange shaft Nm - 65 65 -
1003-02A
BA05.20-P-
Bolt for camshaft bearing cap Nm 21 21 21 -
1004-02A
BA05.20-P- Bolt, camshaft sprocket to flange
M7x12 Nm - 18 - -
1005-02A shaft Hexagon bolt+washer
BA05.20-P- Bolt, camshaft sprocket to flange
M7 Nm 16 22 - -
1006-02A shaft internal torx bolt
Stage
Bolt, camshaft bearing housing, Nm - - - -
BA05.20-P- 1
upper and lower part to cylinder
1007-02A Stage
head Angle° - - - -
2
BA05.20-P- Bolt connecting camshaft solenoid to front
Nm - - - 5
1008-02A cover on the cylinder head
BA05.20-P- Center valve for pulse wheel/camshaft
Nm - - - 130
1009-02A adjuster to camshaft
Stage
Nm - - - 8
BA05.20-P- Bolt, auxiliary bearing cap to 1
1010-02A cylinder head Stage
Angle° - - - 90
2
Stage
Nm - 5 5 -
BA05.20-P- 1
Collar bolt, armature to stub shaft
1011-02A Stage
Angle° - 90 90 -
2
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine Engine Engine
Number Designation
271.8 271.9 272 273
Stage
Nm - - - -
BA05.20-P- Bolt for camshaft sprocket/flange 1
1001-02A shaft Stage
Angle° - - - -
2
Stage
Nm 130 90 145 145
BA05.20-P- Center bolt, camshaft adjuster to 1
1002-02A camshaft Stage
Angle° - - - -
2
BA05.20-P-
Nut, camshaft gear to flange shaft Nm - - - -
1003-02A
BA05.20-P-
Bolt for camshaft bearing cap Nm - - - -
1004-02A
BA05.20-P- Bolt, camshaft sprocket to flange
M7x12 Nm - - - -
1005-02A shaft Hexagon bolt+washer
BA05.20-P- Bolt, camshaft sprocket to flange
M7 Nm - - - -
1006-02A shaft internal torx bolt
Stage
Bolt, camshaft bearing housing, Nm 10 10 - -
BA05.20-P- 1
upper and lower part to cylinder
1007-02A Stage
head Angle° 90 90 - -
2
BA05.20-P- Bolt connecting camshaft solenoid to front
Nm 8 8 - -
1008-02A cover on the cylinder head
BA05.20-P- Center valve for pulse wheel/camshaft
Nm - - 145 145
1009-02A adjuster to camshaft
Stage
Nm - - 8 8
BA05.20-P- Bolt, auxiliary bearing cap to 1
1010-02A cylinder head Stage
Angle° - - - -
2
Stage
Nm - - - -
BA05.20-P- 1
Collar bolt, armature to stub shaft
1011-02A Stage
Angle° - - - -
2
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine
Number Designation
276 278
Stage
Nm - -
BA05.20-P- 1
Bolt for camshaft sprocket/flange shaft
1001-02A Stage
Angle° - -
2
Stage
Nm - -
BA05.20-P- 1
Center bolt, camshaft adjuster to camshaft
1002-02A Stage
Angle° - -
2
BA05.20-P-
Nut, camshaft gear to flange shaft Nm - -
1003-02A
BA05.20-P-
Bolt for camshaft bearing cap Nm - -
1004-02A
BA05.20-P- Bolt, camshaft sprocket to flange shaft Hexagon
M7x12 Nm - -
1005-02A bolt+washer
BA05.20-P- Bolt, camshaft sprocket to flange shaft internal
M7 Nm - -
1006-02A torx bolt
Stage
Nm - -
BA05.20-P- Bolt, camshaft bearing housing, upper and lower 1
1007-02A part to cylinder head Stage
Angle° - -
2
BA05.20-P- Bolt connecting camshaft solenoid to front cover on the
Nm 5 5
1008-02A cylinder head
BA05.20-P- Center valve for pulse wheel/camshaft adjuster to
Nm 130 130
1009-02A camshaft
Stage
Nm 8 8
BA05.20-P- 1
Bolt, auxiliary bearing cap to cylinder head
1010-02A Stage
Angle° 90 90
2
Stage
Nm - -
BA05.20-P- 1
Collar bolt, armature to stub shaft
1011-02A Stage
Angle° - -
2
CAMSHAFT, CAMSHAFT ADJUSTMENT - BA05.20-P-1000-02I
Engine 275, 285
CAMSHAFT
Engine 275,
Number Designation
285
1st stage NM 20
BA05.20-P-1001-
Bolt, camshaft sprocket M8x16 2nd
02I Angle° 90
stage
1st stage NM 14
BA05.20-P-1002- Bolt of camshaft bearing cap to cylinder 2nd
M7x85 Angle° -
02I head stage
CAMSHAFT, CAMSHAFT ADJUSTMENT - BA05.20-P-1000-02J
Engine 156, 159
MODIFICATION NOTES
6.8.09 Value changed: Bolt, camshaft adjuster on camshaft, 1st stage Engine 156
Value changed: Bolt, camshaft adjuster cover on cylinder head Engine 156
6.8.09 Value changed: Bolt, camshaft adjuster on camshaft, 1st stage Engine 156
Value changed: Bolt, camshaft adjuster cover on cylinder head Engine 156
6.8.09 Value changed: Bolt, camshaft adjuster on camshaft, 1st stage Engine 156
Value changed: Bolt, camshaft adjuster cover on cylinder head Engine 156
6.8.09 Value changed: Bolt, camshaft adjuster on camshaft, 1st stage Engine 156
Value changed: Bolt, camshaft adjuster cover on cylinder head Engine 156
CAMSHAFT, CAMSHAFT ADJUSTMENT
Engine Engine
Number Designation
156 159
Stage
Nm 45 45
BA05.20-P- 1
Bolt, camshaft adjuster to camshaft M12
1001-02J Stage
Angle° 90 90
2
BA05.20-P-
Bolt, camshaft adjuster cover to cylinder head M6 Nm 10 10
1002-02J
BA05.20-P- Bolt connecting bearing pin of camshaft drive
M6 Nm 9 9
1003-02J gear to crankcase
BA05.20-P- Bolt, engine wiring harness ground to camshaft adjuster
Nm 9 9
1004-02J cover
TEST & ADJUSTMENT VALUES
TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ENGINE TIMING - BE05.00-Z-9999AZ
MODEL all
Amount
by which BE05.30-
valve ENGINE 601, 602 /, 603 /, 604, 605 (except, 602.98 /98) P-1000-
stands 07C
back
by which
BE05.30-
valve
ENGINE 103 /, 104 / P-1000-
stands
07A
back
Amount
by which BE05.30-
valve ENGINE 111 P-1000-
stands 07B
back
Camshaft BE05.20-
code ENGINE 112, 113, 137, 155, 275, 285... P-1000-
numbers 01G
Camshaft BE05.20-
code ENGINE 601.911 /912 /913 /921, 602.911/912 /961 /962, 603 / P-1000-
numbers 01C
Camshaft BE05.20-
code ENGINE 166.940 /960 /961 /990 /991 /995 P-1000-
numbers 01H
Camshaft BE05.20-
code ENGINE 640 P-1000-
numbers 01L
Camshaft BE05.20-
code ENGINE 103 P-1000-
numbers 01D
Camshaft BE05.20-
code ENGINE 601.942 /970, 602.980 /984 /985/982 /983 N-1000-
numbers 01B
Camshaft BE05.20-
code ENGINE 104 P-1000-
numbers 01E
Camshaft BE05.20-
code ENGINE 628.960 /961 /962 /963, 629, 642 / P-1000-
numbers 01J
Camshaft BE05.20-
code ENGINE 668.914 /940 /941 /942 P-1000-
numbers 01I
Camshaft BE05.20-
code ENGINE 266.920 /940 /960 /980 P-1000-
numbers 01K
Camshaft BE05.20-
code ENGINE 604, 605, 606, 611, 612, 613, 646, 647, 648... P-1000-
numbers 01A
Camshaft BE05.20-
code ENGINE 119, 120 P-1000-
numbers 01F
Camshaft BE05.20-
ENGINE
code P-1000-
111.920 /921 /940 /941 /942 /943 /944 /945 /946 /947 /960 /961 /970 /973 /974 /975 /977
numbers 01B
Chain
BE05.10-
tensioner
ENGINE 157, 276, 278 P-1000-
basic
02A
dimension
Check
BE05.20-
values for
ENGINE 103 /, 104 /, 119, 120 P-1000-
camshaft
03C
bearings
Check
BE05.30-
values for
ENGINE 111, 166, 271, 604, 605, 606 /, 646.962 /963, 648.960 P-1000-
valve
02A
guides
Check
BE05.30-
values for
ENGINE 112, 113, 137, 155, 275, 285... P-1000-
valve seat
03C
rings
Check
BE05.30-
values for
ENGINE 604, 605, 606, 611, 612, 613, 646, 647, 648, 651... P-1000-
valve seat
03B
rings
Check BE05.30-
values for ENGINE 112, 113, 137, 155, 156, 157, 159, 272, 273, 275, 276, 278, 285... P-1000-
valves 01E
Check BE05.30-
values for ENGINE 604, 605, 606, 611, 612, 613, 646, 647, 648... P-1000-
valves 01B
Inspection
BE05.20-
data of
ENGINE 111, 271 P-1000-
camshaft
03A
bearings
Rocker BE05.30-
arm code ENGINE 113, 155.980 with CODE (479) Cylinder shutoff N-1000-
numbers 08A
Test BE05.20-
values for ENGINE 601, 602 /, 603 / P-1000-
camshaft 04A
Test
BE05.20-
values for
ENGINE 601, 602 /, 603 / (except, 602.98 /98) P-1000-
camshaft
03D
bearings
Test ENGINE 604, 605, 606 / BE05.20-
camshaft 03B
bearings
Test
BE05.20-
values for
ENGINE 602 N-1000-
camshaft
05B
bolts
Test
BE05.30-
values for
ENGINE 601.943, 602.980 /982 /983 /984 /985 N-1000-
valve
02D
guides
Test
BE05.30-
values for
ENGINE 120 P-1000-
valve
02B
guides
Test
BE05.30-
values for
ENGINE 275, 285 P-1000-
valve
02F
guides
Test
BE05.30-
values for
ENGINE 137.970 P-1000-
valve
02E
guides
Test
BE05.30-
values for
ENGINE 601, 602 /, 603 / (except, 602.982) P-1000-
valve
02C
guides
Test
BE05.30-
values for
ENGINE 112, 113, 155... P-1000-
valve
02D
guides
Test
BE05.30-
values for
ENGINE 601.943, 602.980 /982 /983 /984 /985 N-1000-
valve seat
03D
rings
Test
BE05.30-
values for
ENGINE 111 P-1000-
valve seat
03A
rings
Test
BE05.30-
values for
ENGINE 601.943, 602.980 /982 /983 /984 /985 N-1000-
valve
05C
springs
Test BE05.30-
values for ENGINE 120 P-1000-
valves 01C
Test BE05.30-
values for ENGINE 104 /, 111 P-1000-
valves 01A
Test BE05.30-
values for ENGINE 642 P-1000-
valves 01F
Test BE05.30-
values for ENGINE 601, 602.91 /96, 603.91 /96 P-1000-
valves 01D
Test BE05.30-
values for ENGINE 651 P-1000-
valves 01G
Test BE05.30-
values for ENGINE 601.943, 602.980 /982 /983 /984 /985 N-1000-
valves 01D
BE05.20-
Timing ENGINE 642 P-1000-
02K
BE05.20-
Timing ENGINE 668.914 /940 /941 /942 P-1000-
02G
BE05.20-
Timing ENGINE 103, 104 P-1000-
02D
BE05.20-
Timing ENGINE 119, 120 P-1000-
02E
BE05.20-
Timing ENGINE 271.910 /921 /940 /941 /942 /944 /946 /948 /950 /952 /954 /955 /956 P-1000-
02I
BE05.20-
Timing ENGINE 112, 113, 137, 155... P-1000-
02F
BE05.20-
Timing ENGINE 275, 285 P-1000-
02J
BE05.20-
Timing ENGINE 604, 605, 606, 611, 612, 613... P-1000-
02A
BE05.20-
Timing ENGINE 273 / P-1000-
02M
BE05.20-
Timing ENGINE 628.960 /962 P-1000-
02H
BE05.20-
Timing ENGINE 601, 602 /, 603 / P-1000-
02C
BE05.20-
Timing ENGINE 272 P-1000-
02L
BE05.20-
Timing ENGINE 601 /, 602 / /981 /982 /983 N-1000-
02B
BE05.20-
ENGINE
Timing P-1000-
111.920 /921 /940 /941 /942 /943 /944 /945 /946 /947 /960 /961 /970 /973 /974 /975 /977
02B
TIMING - BE05.20-P-1000-02J
Engines 275, 285
TEST VALUES FOR TIMING
Engine Engine
Number Designation 275.950/951/953/954, 275.980/981/982,
285.950 285.980
Intake valve
°
opens after 33 33
CA
TDC
Intake valve
°
closes after 4.6 10
Timing of intake/exhaust BDC CA
BE05.20-P-
camshaft with 2 mm valve
1001-02J
lift and new timing chain Exhaust °
valve opens 25, 9 24
CA
before BDC
Exhaust
°
valve closes 15 14
CA
before TDC
TIMING - BE05.20-P-1000-02M
TIMING
Engine
Number Designation
273.960/961/962/963/964/965/966/967/968/969/970/971
opens after
°
TDC...before 36 to 4
CA
Intake TDC
valve closes after
°
Left BDC...after 47 to 7
CA
BDC
cylinder opens after
°
head, BDC...before Cyl.5/7 17 to 23
CA
timing BDC
at 2 mm opens after
valve °
BDC...before Cyl.6/8 7 to 33
BE05.20- lift and CA
Exhaust BDC
P-1001- new
valve closes after
02M timing °
TDC...before Cyl.5/7 17 to 23
chain CA
TDC
closes after
°
TDC...before Cyl.6/8 17 to 23
CA
TDC
opens after
°
TDC...before 36 to 4
CA
Intake TDC
valve closes after
Right °
BDC...after 47 to 7
bank CA
BDC
cylinder opens after
head, °
BDC...before Cyl.1/2 7 to 33
BE05.20- timing CA
BDC
P-1002- at 2 mm
02M valve opens after
°
lift and BDC...before Cyl.3/4 17 to 23
CA
new Exhaust BDC
timing valve closes after °
chain TDC...before Cyl.1/2 17 to 23
CA
TDC
closes after
°
TDC...before Cyl.3/4 17 to 23
CA
TDC
opens after
°
TDC...before 37 to 3
CA
Intake TDC
Left
valve closes after
bank °
cylinder BDC...after 48 to 8
CA
head, BDC
BE05.20- timing opens after
°
P-1003- at 2 mm BDC...before Cyl.5/7 18 to 22
CA
02M valve BDC
lift and opens after
Exhaust °
used BDC...before Cyl.6/8 8 to 32
CA
timing valve BDC
chain closes after
°
TDC...before Cyl.5/7 18 to 22
CA
TDC
closes after
°
TDC...before Cyl.6/8 18 to 22
CA
TDC
opens after
°
TDC...before 38.2 to 1.8
CA
Intake TDC
valve closes after
Right °
BDC...after 49.9 to 9.2
bank CA
BDC
cylinder opens after
head, °
BDC...before Cyl.1/2 9.2 to 30.8
BE05.20- timing CA
BDC
P-1004- at 2 mm
02M valve opens after
°
lift and BDC...before Cyl.3/4 19.2 to 20.8
CA
used Exhaust BDC
timing valve closes after °
chain TDC...before Cyl.1/2 19.2 to 20.8
CA
TDC
closes after
°
TDC...before Cyl.3/4 19.2 to 20.8
CA
TDC
TIMING
Engine
Number Designation
273.920/921/922/923/924
opens after
°
TDC...before 36 to 4
Intake TDC CA
valve
closes after °
37.5...-2.5
BDC...after BDC CA
opens after
°
BDC...before Cyl.5/7 29 to 11
Left bank cylinder head, CA
BDC
BE05.20-P- timing at 2 mm valve
1001-02M lift and new timing opens after
°
chain BDC...before Cyl.6/8 9 to 31
CA
Exhaust BDC
valve closes after
°
TDC...before Cyl.5/7 20 to 20
CA
TDC
closes after
°
TDC...before Cyl.6/8 20 to 20
CA
TDC
opens after
°
TDC...before 36 to 4
CA
TDC
valve closes after °
37.5...-2.5
BDC...after BDC CA
opens after
°
BDC...before Cyl.1/2 9 to 31
CA
BDC
Right bank cylinder opens after
°
BE05.20-P- head, timing at 2 mm BDC...before Cyl.3/4 29 to 11
CA
1002-02M valve lift and new Exhaust BDC
timing chain valve closes after
°
TDC...before Cyl.1/2 20 to 20
CA
TDC
closes after
°
TDC...before Cyl.3/4 20 to 20
CA
TDC
opens after
°
TDC...before 37 to 3
Intake TDC CA
valve
closes after °
38.5...-1.5
BDC...after BDC CA
opens after
°
BDC...before Cyl.5/7 30 to 10
Left bank cylinder head, CA
BDC
BE05.20-P- timing at 2 mm valve
1003-02M lift and used timing opens after
°
chain BDC...before Cyl.6/8 10 to 30
CA
Exhaust BDC
valve closes after
°
TDC...before Cyl.5/7 21 to 19
CA
TDC
closes after
°
TDC...before Cyl.6/8 21 to 19
CA
TDC
opens after
°
TDC...before 38.2 to 1.8
Intake TDC CA
valve
closes after °
39.7...-0.3
BDC...after BDC CA
Right bank cylinder opens after
°
BE05.20-P- head, timing at 2 mm BDC...before Cyl.1/2 11.2 to 28.8
CA
1004-02M valve lift and used BDC
timing chain opens after
Exhaust BDC...before °
Cyl.3/4 31.2 to 28.8
valve CA
BDC
closes after
°
TDC...before Cyl.1/2 22.2 to 17.8
CA
TDC
closes after
°
TDC...before Cyl.3/4 22.2 to 17.8
CA
TDC
CHECK VALUES FOR VALVES - BE05.30-P-1000-01E
Engine 155, 156, 157, 159, 275, 276, 278, 285
CHECK VALUES FOR VALVES
Engine
Number Designation Engine 155 156/159 Engine 157
BE05.30-P- Valve disk Exhaust mm 43 (±0.1) 33.35 (±0.1) 28 (±0.1)
1001-01E dia. Intake mm 38 (±0.1) 40 (±0.1) 39.5 (±0.1)
BE05.30-P- Valve disk Exhaust when new mm 2.1 (±0.1) 1.75 (±0.1) 1.8 (±0.1)
1002-01E height Intake when new mm 1.7 (±0.1) 1.48 (±0.1) 1.6 (±0.1)
BE05.30-P- Valve seat Exhaust Angle° 45 (±15') 45 (±15') 45 (±15')
1003-01E angle (a) Intake Angle° 45 (±15') 45 (±15') 45 (±15')
BE05.30-P- Valve stem Exhaust mm 6.97 (-0.02) 5.97 (-0.015) 5.955 to 5.970
1004-01E dia. Intake mm 6.975 (-0.015) 5.98 (-0.015) 5.960 to 5.975
BE05.30-P- Valve length Exhaust mm 121.80 (±0.2) 103.55 107.3 (±0.2)
1005-01E (±0.015)
Intake mm 119.10 (±0.2) 106.67 (±0.2) 103.8 (±0.2)
CHECK VALUES FOR VALVES
Engine
Number Designation Engine 273.92 273.96/97
BE05.30-P- Valve disk dia. Exhaust mm 30 (±0.1) 32 (±0.1)
1001-01E Intake mm 39.5 (±0.1) 42 (±0.1)
BE05.30-P- Valve disk Exhaust when new mm 1.8 (±0.1) 1.8 (±0.1)
1002-01E height Intake when new mm 1.6 (±0.1) 1.6 (±0.1)
BE05.30-P- Valve seat angle Exhaust Angle° 45° 30' (±10') 45 (±15')
1003-01E (a) Intake Angle° 45 (±15') 45 (±15')
BE05.30-P- Valve stem dia. Exhaust mm 5.955 to 5.970 5.955 to 5.970
1004-01E Intake mm 5.960 to 5.975 5.960 to 5.975
BE05.30-P- Valve length Exhaust mm 107.3 (±0.2) 107.2 (±0.2)
1005-01E Intake mm 108.8 (±0.2) 107.8 (±0.2)
CHECK VALUES FOR VALVES
Engine 275,
Number Designation 285 Engine 276 Engine 278
BE05.30-P- Valve disk Exhaust mm 35±0.1 30 (±0.1) 28 (±0.1)
1001-01E dia. Intake mm 31±0.1 37 (±0.1) 37 (±0.1)
BE05.30-P- Valve disk Exhaust when new mm 1.6 1.8 (±0.1) 1.8 (±0.1)
1002-01E height Intake when new mm 1.1 1.7 (±0.1) 1.7 (±0.1)
BE05.30-P- Valve seat Exhaust Angle° 45±15' 45 (±15') 45 (±15')
1003-01E angle (a) Intake Angle° 45±15' 45 (±15') 45 (±15')
BE05.30-P- Valve stem Exhaust mm 6.970 5.955 to 5.970 5.955 to 5.970
1004-01E dia. Intake mm 5.975 5.960 to 5.975 5.960 to 5.975
BE05.30-P- Valve length Exhaust mm 104.30±0.2 107.3 (±0.2) 107.3 (±0.2)
1005-01E Intake mm 103.60±0.2 104.15 (±0.2) 104.15 (±0.2)
TEST VALUES FOR VALVE GUIDES - BE05.30-P-1000-02F
Engine 275, 285
INSPECTION AND SETTING DATA OF VALVE GUIDES
Engine 275,
Number Designation
285
12, 540...12,
Standard series mm
551
Standard I series (color: 12, 560...12,
mm
BE05.30-P-1001- gray) 571
Outer Ø of exhaust and inlet valve guide
02F Repair size I (color: 12, 590...12,
mm
brown) 601
Repair size II (color: 12, 740...12,
mm
red) 751
12, 500...12,
Standard series mm
511
Standard I series (color: 12, 520...12,
mm
BE05.30-P-1002- Bore Ø in cylinder head of exhaust and gray) 531
02F inlet valve guide Repair size I (color: 12, 550...12,
mm
brown) 561
Repair size II (color: 12, 700...12,
mm
red) 711
BE05.30-P-1003-
Overlap in cylinder head mm 0, 029...0, 051
02F
BE05.30-P-1004- L Exhaust mm 40
Length
02F L Inlet mm 43, 5
BE05.30-P-1005- A Inlet mm 16, 2±0, 2
Dimension
02F A Exhaust mm 12, 2±0, 2
CHECK VALUES FOR VALVE SEAT RINGS - BE05.30-P-1000-03C
Engines 112, 113, 137, 155, 275, 285
MODIFICATION NOTES
For valve seat
ring overlap in
the cylinder
head Value Value in series 1004 for engine
24.9.04 modified from 113.960/961/962/963/965/967/968/980/981/982/984/987/988/990/991/992
0.084...0.0100 modified
mm to
0.074...0.100
mm
Tolerance
figures
7.10.04 changed for
valve seat
angle
Test value for
gap between
separating
surface of
cylinder head
Changed for engine
and end face of
26.10.04 113.960/961/962/963/965/967/968/980/981/982/984/987/988/990/991/992/993
valve seat ring
and for engine 113.989
changed from
9.84...9.92 mm
exhaust to
9.57...9.65 mm
exhaust
CHECK VALUES FOR VALVE SEAT RINGS
Engines
Engines
Number Designation 112.912/914/915/920/921/922/923/940/941/
112.910/911
113.940/941/942/943/944
BE05.30- Standard mm 31.1 (+0.015) 37.1 (+0.015)
Intake valve seat ring
P-1001- Rep.
outer-Ø mm 32.1
03C size 1
BE05.30- Standard mm 35, 1 (-0, 01) 42, 1 (-0, 01)
Exhaust valve seat ring
P-1002- Rep.
outer outside diameter mm 36, 3
03C size 1
Standard mm 5.9 (-0.08) 5.9 (-0.08)
Intake Rep.
BE05.30- Height of mm 5.9 (-0.08)
size 1
P-1003- valve seat
03C ring Standard mm 7.9 (-0.08) 7.9 (-0.08)
Exhaust Rep.
mm 7.9 (-0.08)
size 1
Intake mm 0.084...0.115 0.084...0.115
P-1004- in cylinder head
Exhaust mm 0.074...0.100
03C
Distance between
BE05.30- Intake mm 6.86...6.94 8.22...8.30
contact face of cylinder
P-1005-
head and end face of
03C Exhaust mm 9.72...9.80
valve seat ring
BE05.30- Basic bore diameter of Standard mm 31.000...31.016 37.000...37.016
P-1006- inlet valve seat rings in Rep.
03C cylinder head mm 32.000...32.016
size 1
BE05.30- Basic bore diameter of Standard mm 35.000...35.016 42.000...42.016
P-1007- exhaust valve seat rings Rep.
03C in cylinder head mm 36.200...36.216
size 1
Bore depth of
BE05.30- Intake Standard mm 12.76 14.12
valve seat
P-1008-
rings in
03C Exhaust Standard mm 17.62 17.02
cylinder head
Width mm 0.8...1.2 0.8...1.2
Angle
Angle° 45(+ 30') 45(+ 30')
BE05.30- Inlet (a)
P-1009- valve/exhaust Angle
03C valve seat Correction Angle° 35 (±15') 35 (±15')
(ß)
Angle
Correction Angle° 58 (±15') 58 (±15')
(gamma)
CHECK VALUES FOR VALVE SEAT RINGS
Engine
Engine
Number Designation 112.960/961
112.976
AMG
Standard mm 37.1 (+0.015) 39.1 (+0.015)
BE05.30-P-
Intake valve seat ring outer- Ø Rep. size
1001-03C mm 38.3 40.30
1
Standard mm 42.1 (-0.01) 44.1 (-0.01)
BE05.30-P-
Exhaust valve seat ring outer-Ø Rep. size
1002-03C mm 43.3 45.30
1
Standard mm 5.9 (-0.08) 5.9 (-0.08)
Intake Rep. size
mm 5.9 (-0.08) 5.9 (-0.08)
BE05.30-P- 1
Height of valve seat ring
1003-03C Standard mm 7.9 (-0.08) 7.9 (-0.08)
Exhaust Rep. size
mm 7.9 (-0.08) 7.9 (-0.08)
1
BE05.30-P- Valve seat ring - overlap in cylinder Intake mm 0.084...0.115 0.084...0.115
1004-03C head Exhaust mm 0.074...0.100 0.074...0.100
Intake mm 8.22...8.30 8.50...8.58
1005-03C cylinder head and end face of valve
Exhaust mm 9.12...9.20 9.57...9.65
seat ring
Standard mm 37.000...37.016 39.000...39.016
BE05.30-P- Basic bore diameter of inlet valve seat
1006-03C rings in cylinder head Rep. size
mm 38.200...38.216 -
1
Standard mm 42.000...42.016 44.000...44.016
BE05.30-P- Basic bore diameter of exhaust valve
1007-03C seat rings in cylinder head Rep. size
mm 43.200...43.216 -
1
BE05.30-P- Bore depth of valve seat Intake Standard mm 14.12 14.40
1008-03C rings in cylinder head Exhaust Standard mm 17.02 17.47
Width mm 0.80...1.2 0.8...1.2
Angle (a) Angle° 45(+ 30') 45(+ 30')
BE05.30-P- Inlet valve/exhaust valve
1009-03C seat Correction Angle (ß) Angle° 35 (±15') 35 (±15')
Angle
Correction Angle° 58 (±15') 58 (±15')
(gamma)
CHECK VALUES FOR VALVE SEAT RINGS
Engine
Number Designation
113.960/961/962/963/964/965/967/968/971/980/981/982/98
BE05.30- Standard mm 39.1 (+0.015)
Intake valve seat ring
P-1001- Rep.
outer- Ø mm 40.3
03C size 1
BE05.30- Standard mm 44.1 (-0.01)
Exhaust valve seat ring
P-1002- Rep.
outer-Ø mm 45.3
03C size 1
Standard mm 5.9 (-0.08)
Intake Rep.
BE05.30- Height of mm 5.9 (-0.08)
size 1
P-1003- valve seat
03C ring Standard mm 7.9 (-0.08)
Exhaust Rep.
mm 7.9 (-0.08)
size 1
BE05.30-
Valve seat ring - overlap Intake mm 0.084...0.115
P-1004-
in cylinder head Exhaust mm 0.074...0.100
03C
Distance between
BE05.30- Intake mm 8.50...8.58
contact face of cylinder
P-1005-
head and end face of
03C Exhaust mm 9.57...9.65
valve seat ring
BE05.30- Basic bore diameter of Standard mm 39.000...39.016
P-1006- inlet valve seat rings in Rep.
03C cylinder head mm 40.200...40.216
size 1
Standard mm 44.000...44.016
BE05.30- Basic bore diameter of
03C in cylinder head size 1 mm 45.200...45.216
Bore depth of
BE05.30- Intake Standard mm 14.40
valve seat
P-1008-
rings in
03C Exhaust Standard mm
cylinder head
Width mm 0.80...1.2
Angle
Angle° 45(+ 30')
BE05.30- Inlet (a)
P-1009- valve/exhaust Angle
03C valve seat Correction Angle° 35 (Angle15')
(ß)
Angle
Correction Angle° 58 (Angle15')
(gamma)
CHECK VALUES FOR VALVE SEAT RINGS
Engine
Number Designation Engine 155
113.989
BE05.30-P- Standard mm 39.1 (+0.015) 37.1
Intake valve seat ring outer- Ø
1001-03C Rep. size 1 mm 40.3 38.3
BE05.30-P- Standard mm 44.1 (-0.01) 42.1
Exhaust valve seat ring outer-Ø
1002-03C Rep. size 1 mm 45.3 43.3
Standard mm 5.9 (-0.08) 5.9 (-0.08)
Intake
BE05.30-P- Rep. size 1 mm 5.9 (-0.08) 5.9 (-0.08)
Height of valve seat ring
1003-03C Standard mm 7.9 (-0.08) 7.9 (-0.08)
Exhaust
Rep. size 1 mm 7.9 (-0.08) 7.9 (-0.08)
BE05.30-P- Valve seat ring - overlap in cylinder Intake mm 0.084...0.115 0.084...0.115
1004-03C head Exhaust mm 0.074...0.0100 0.084...0.110
Distance between contact face of Intake mm 8.50...8.58 8.22...8.30
BE05.30-P-
cylinder head and end face of valve seat
1005-03C Exhaust mm 9.57...9.65 9.12...9.20
ring
BE05.30-P- Basic bore diameter of inlet valve seat Standard mm 39.000...39.016 37.000...37.016
1006-03C rings in cylinder head Rep. size 1 mm 40.200...40.216 38.200...38.216
BE05.30-P- Basic bore diameter of exhaust valve Standard mm 44.000...44.016 42.000...42.016
1007-03C seat rings in cylinder head Rep. size 1 mm 45.200...45.216 43.200...43.216
BE05.30-P- Bore depth of valve seat Intake Standard mm 14.40 14.12
1008-03C rings in cylinder head Exhaust Standard mm 17.47 17.02
Width mm 0.80...1.2 0.60...0.65
Angle (a) Angle° 45(+ 30') 45(+ 30')
BE05.30-P- Inlet valve/exhaust valve
1009-03C seat Correction Angle (ß) Angle° 35 (±15') 35 (±15')
Angle
Correction Angle° 58 (±15') 58 (±15')
(gamma)
CHECK VALUES FOR VALVE SEAT RINGS
Engines 275.
Number Designation
285
BE05.30-P- Standard mm 32.1
Intake valve seat ring outer-Ø
1001-03C Rep. size 1mm 33.3
BE05.30-P- Standard mm 36.1
Exhaust valve seat ring outer-Ø
1002-03C Rep. size 1mm 37.3
Standard mm 5.9 (-0.08)
Intake
BE05.30-P- Rep. size 1mm 5.9 (-0.08)
Height of valve seat ring
1003-03C Standard mm 5.9 (-0.08)
Exhaust
Rep. size 1mm 5.9 (-0.08)
BE05.30-P- Intake mm 0.084...0.115
Valve seat ring - overlap in cylinder head
1004-03C Exhaust mm 0.084...0.115
BE05.30-P- Distance between contact face of cylinder head and Intake mm 8.410...8.418
1005-03C end face of valve seat ring Exhaust mm 8.530...8.538
BE05.30-P- Basic bore diameter of inlet valve seat rings in Standard mm 32.000...32.016
1006-03C cylinder head Rep. size 1mm 33.185...33.216
BE05.30-P- Basic bore diameter of exhaust valve seat rings in Standard mm 36.000...36.016
1007-03C cylinder head Rep. size 1mm 37.185...37.216
BE05.30-P- Bore depth of valve seat rings in Intake Standard mm 14.31
1008-03C cylinder head Exhaust Standard mm 14.43
Width mm 0.75...0.95
Angle (a) Angle° 45(+ 30')
BE05.30-P-
Inlet valve/exhaust valve seat Correction Angle (ß) Angle° 35 (±15')
1009-03C
Angle
Correction Angle° 58 (±15')
(gamma)
BASIC KNOWLEDGE
ADJUSTABLE CAMSHAFT TIMING SOLENOID, COMPONENT DESCRIPTION - GF05.20-P-
2100AMG
ENGINE 156.980 in MODEL 164, 251 up to Model Year 8
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211, 219
ENGINE 156.984 in MODEL 216, 221 up to Model Year 8
Location
Fig. 190: Identifying Camshaft Solenoids
Courtesy of MERCEDES-BENZ USA
The camshaft solenoids are located at the front on respective cylinder head.
Task
The camshaft solenoids actuate camshaft adjustment, whereby camshafts are continuously adjusted up a 42°
crank angle. Adjustment of camshaft optimizes engine torque development and improves exhaust
characteristics.
Design
Solenoids are designed as proportional solenoids which means travel of the anchor and thus the location of the
control plunger in the integral control valve is dependent on the current strength in the coil.
Function
Solenoids are actuated at the ground end by the ME-SFI [ME] control unit (N3/10) by means of a PWM signal
(pulse width modulated signal). The voltage supply to the solenoid is via "terminal 87".
The integral control plungers are actuated via the map-dependent duty cycle of the PWM signal. To achieve
rapid adjustment of the armature, the maximum current (duty cycle 100%) is output for a short period (approx.
0.5 sec). Then a hold-in winding voltage with a lower duty cycle is set.
Solenoid actuate via the duty cycle of control plunger in control valves whereby more or less switching oil
(pressure oil) flows in the swivel motor adjuster.
The amount of switching oil in swivel motor adjuster is controlled according to the position of control plunger.
This is achieved by bore holes located at various points in the control valves as well as by oil ducts in the swivel
motor adjuster rotors.
The camshaft adjustment range is mechanically restricted by the shape of the swivel motor adjuster. If the
solenoids are no longer actuated then a rest occurs against the direction of rotation in which the camshafts are
mechanically locked (start position).
Camshaft adjustment (left exhaust camshaft)
Fig. 191: Identifying Camshaft Components
Courtesy of MERCEDES-BENZ USA
Swivel motor adjuster
Fig. 192: Identifying Swivel Motor Adjuster Components
Courtesy of MERCEDES-BENZ USA
COMPONENT DESCRIPTION FOR A CAMSHAFT SOLENOID - GF05.20-P-2100V
ENGINE 272.920 in MODEL 203 up to Model Year 8
ENGINE 272.922 in MODEL 211
ENGINE 272.940 in MODEL 203 up to Model Year 8
ENGINE 272.941 in MODEL 203 up to Model Year 8
ENGINE 272.942 in MODEL 171 up to Model Year 8
ENGINE 272.943 in MODEL 211, 219
ENGINE 272.944 in MODEL 211
ENGINE 272.945 in MODEL 251 up to Model Year 8
ENGINE 272.946 in MODEL 221 up to Model Year 8
ENGINE 272.960 in MODEL 203 up to Model Year 8
ENGINE 272.963 in MODEL 171 up to Model Year 8
ENGINE 272.965 in MODEL 221 up to Model Year 8
ENGINE 272.966 in MODEL 230 up to Model Year 8
ENGINE 272.967 in MODEL 164, 251 up to Model Year 8
ENGINE 272.970 in MODEL 203 up to Model Year 8
ENGINE 272.972 in MODEL 211
ENGINE 272.975 in MODEL 221 up to Model Year 8
ENGINE 272.985 in MODEL 211, 219
ENGINE 273.922 in MODEL 221 up to Model Year 8
ENGINE 273.923 in MODEL 164 up to Model Year 8
ENGINE 273.924 in MODEL 221 up to Model Year 8
ENGINE 273.960 in MODEL 211, 219
ENGINE 273.961 in MODEL 216, 221 up to Model Year 8
ENGINE 273.962 in MODEL 211
ENGINE 273.963 in MODEL 164, 251 up to Model Year 8
ENGINE 273.965 in MODEL 230 up to Model Year 8
ENGINE 273.967 in MODEL 209
ENGINE 273.968 in MODEL 221 up to Model Year 8
ENGINE 272.940 in MODEL 209
ENGINE 272.960 in MODEL 209
Location
The solenoids are located in front of the respective camshaft.
Fig. 193: Locating Camshaft Solenoids
Courtesy of MERCEDES-BENZ USA
Task
The solenoids actuate the control plunger on the vane-cell adjuster according to the performance map related
duty cycle. Depending on their position, more or less pressure oil flows from the hollow camshaft into the oil
galleries of the vane-type adjuster.
Design
The solenoids for camshaft adjustment are designed as proportional magnets, i.e. the direction of the armature
and thus the position of the control plunger in the vane-type adjuster are dependent on the intensity of the
current in the coil.
Shown on engine 272
Fig. 194: Camshaft Solenoid Function Diagram
Courtesy of MERCEDES-BENZ USA
Function
The solenoids before the camshafts are actuated by the ME control unit at the ground end by means of a PWM
signal (150 Hz). The voltage supply for the solenoid takes place from circuit 87. The vane-cell adjuster are
actuated according to the performance map related duty cycle.
The maximum current (duty cycle 100 %) is emitted for a short time about 0.5 seconds) for rapid adjusting of
the anchor. A hold-in winding voltage with a small duty cycle is then set afterwards. The coil resistance at room
temperature is approx. 7.5 ohms.
Depending on their position, the oil volume in the vane-type adjusters is controlled. This takes place through
differently arranged holes in the control plunger as well as through oil ducts in the vane-cell adjusters. The
adjusting range of the camshaft is limited by the forming of the vane-cell adjuster mechanically. If the solenoids
are no longer actuated then resetting takes place against the direction of rotation.
The following positions are possible:
Filling the oil gallery
Pressure oil flows out of the hollow camshafts into the vane-cell adjuster. The camshafts adjust
themselves to the respective direction of rotation. The inlet camshafts adjust to "advanced". The exhaust
camshafts adjust themselves due to their reversed direction of rotation to "retarded".
Oil gallery closed
Each camshaft position is detected by a camshaft Hall sensor. Once the requested adjustment has been
achieved then the respective solenoid will be actuated in such a way that oil galleries in the vane-cell
adjusters are closed.
Emptying the oil gallery
The camshafts adjust themselves against their direction of rotation.
MISCELLANEOUS NOTES
DISPOSAL OF SODIUM-FILLED VALVES - OS05.30-P-0001-01A
Exhaust valves filled with sodium
Collecting and storing
The sodium-cooled valves must be inspected for leaks and neutralized if any leakage exists. Neutralizing should
be performed in the open in a vessel containing a 2:1 mixture of spirit and water. After this, the cleaned valves
can be gathered together with other scrap items, in a closed removable open container for scrapping.
Disposal
The parts are scrapped by the scrap trade. Documentary proof of disposal, accompanying or delivery documents
as well as other disposal documents are not necessary.
Legal right in respect of information
The competent authority is obliged to provide information regarding waste disposal installations on request.
National or local legislation determines which authority is responsible for providing such information.
Disposal of larger quantities of leaktight valves is possible through:
Mercedes-Benz AG
Werk Marienfelde
Daimlerstrasse 145
Anlieferstelle KST 3153
Arbeitsvorbereitung TAI
SPECIAL TOOLS
000 589 10 68 00 CYLINDER BRUSH - WS05.00-P-0002C
FG 05/Set C
ENGINE all
Use/specification:
20 mm cylinder brush for cleaning valve guide and valve guide base bore
Fig. 195: Cleaning Valve Guide
Courtesy of MERCEDES-BENZ USA
Fig. 196: Identifying Cylinder Brush (000 589 10 68 00)
Courtesy of MERCEDES-BENZ USA
104 589 01 01 00 DOUBLE OPEN-END WRENCH - WS05.00-P-0047B
FG 05/Set B
ENGINES 104, 111 /979, 120, 156, 159, 166, 668, 266, 275
Use:
Open-end wrench, double 28.5 x 29.5 mm, length 258 mm to turn the camshaft in the assembly position.
Fig. 197: Identifying Double Open-End Wrench (104 589 01 01 00)
Courtesy of MERCEDES-BENZ USA
116 589 00 34 00 THREADED BOLT - WS05.00-P-0080B
FG 05/Set B
ENGINES 615, 275, 285
Use:
M 5 threaded Bolt for 150 mm long for impact extractor 116 589 20 33 00
Fig. 198: Identifying Threaded Bolt (116 589 00 34 00)
Courtesy of MERCEDES-BENZ USA
FG 05/01/Set B
ENGINE 110.92 /98 /99, 111, 115.97, 116, 117, 119, 155, 156, 157, 159, 271, 272, 273, 275, 276, 278, 601,
602, 603, 604, 605, 606, 612.965, 615, 616, 617, 628, 629, 640, 642, 651
Use:
M6 Threaded bolt, 50 mm long for impact extractor 116 589 20 33 00
Fig. 199: Identifying Threaded Bolt (116 589 01 34 00)
Courtesy of MERCEDES-BENZ USA
116 589 02 34 00 THREADED BOLT - WS05.00-P-0086B
FG 01/05/Set B
ENGINE 110.92 /98 /99 /99, 115.97, 116, 117 /, 119, 156, 159, 271, 601, 602.91 /93 /94 /96 /981,
603.91 /93 /96 /97 /97, 615 /, 616 / /, 617.91 /91 /93 /93 /95 /95
Use:
M 6 threaded bolt, 150 mm long for impact extractor 116 589 20 33 00
Fig. 200: Identifying Threaded Bolt (116 589 02 34 00)
Courtesy of MERCEDES-BENZ USA
116 589 06 63 00 MAGNETIC ROD - WS05.00-P-0088B
FG 05/Set B
ENGINE all
Use/specification:
Magnetic rod for removing valve halves
Fig. 201: Removing Valve Half
Courtesy of MERCEDES-BENZ USA
Fig. 202: Identifying Magnetic Rod (116 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
116 589 20 33 00 IMPACT EXTRACTOR - WS05.00-P-0089B
FG 05/01/03/07/ Set B
ENGINE 102.92 /93 /96 /96 /98 /98, 103, 104, 110.92 /98 /99 /99, 111, 116, 117, 119, 120, 155, 156, 157, 159,
271, 272, 273, 275, 276, 278, 285, 601, 602.91 /93 /94 /96 /981 /983, 603.91 /93 /96 /97 /97, 606, 612.965, 615,
616, 617.91 /95, 628, 629, 640, 642, 646, 651
Use:
Impact extractor for guide rail bolts (basic equipment)
Engine 629, 642
Slide hammer puller for engine oil pan
Fig. 203: Identifying Impact Extractor (116 589 20 33 00)
Courtesy of MERCEDES-BENZ USA
119 589 00 43 00 DRIFT - WS05.00-P-0098B
FG 05/Set B
ENGINES 104, 111, 112, 113, 119, 120, 137, 155, 266, 271 /951, 272, 273, 275, 285, 166, 604, 605, 606, 611,
612, 613, 628, 629, 640, 642 / /, 646, 651, 668
with inlet/exhaust valves (valve stem diameter 7 mm)
Use:
Drift for pressing valve stem seal onto valve guide.
Fig. 204: Identifying Drift (119 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
119 589 06 63 00 THRUST PIECE - WS05.00-P-0101B
FG 05/Set B
ENGINE 119, 120, 156, 159
Use/specification:
90 mm thrust piece for valve spring of lever pusher 111 589 18 61 00 on installed cylinder head/engine.
Valve spring plate 24. 28 mm dia.
Fig. 205: View Of Thrust Piece
Courtesy of MERCEDES-BENZ USA
Fig. 206: Identifying Thrust Piece (119 589 06 63 00)
Courtesy of MERCEDES-BENZ USA
123 589 00 34 00 THREADED BOLT - WS05.00-P-0102B
FG 05/Set B
ENGINE 102.92 /93 /96 /97 /98 /99, 103, 104, 110.92 /98, 156, 159, 110.99, 115.97, 602.93 /94, 603.93 /97,
615, 616, 617.91 /93 /95
Use/specification:
M 8 threaded bolts, 60 mm long for puller 115 589 20 33 00
Fig. 207: View Of M8 Threaded Bolt
Courtesy of MERCEDES-BENZ USA
Fig. 208: Identifying Threaded Bolt (123 589 00 34 00)
Courtesy of MERCEDES-BENZ USA
601 589 06 15 00 DRIFT PUNCH - WS05.00-P-0109C
FG 05/Set C
ENGINE 601, 602.91 /93 /94 /96 /981, 603.91 /93 /96 /97 /97
Use:
9 mm drift for knocking in valve guide (exhaust)
Fig. 209: Identifying Drift Punch (601 589 06 15 00)
Courtesy of MERCEDES-BENZ USA
601 589 08 21 00 RESIDUAL STROKE GAUGE - WS05.00-P-0110B
FG 05/Set B
ENGINE 601, 602.91 /93 /94 /96, 603.91 /96 /97
Use/specification:
Residual stroke gauge for residual stroke of hydraulic valve clearance differential element
Fig. 210: Measuring Residual Stroke Of Hydraulic Valve Clearance Differential Element
Courtesy of MERCEDES-BENZ USA
Fig. 211: Identifying Residual Stroke Gauge (601 589 08 21 00)
Courtesy of MERCEDES-BENZ USA
601 589 15 63 00 GUIDE SLEEVE - WS05.00-P-0111C
FG 05/Set C
ENGINE 601, 602.91 /93 /94 /96, 603.91 /93 /96 /97
Use/specification:
29.5/32.5 mm guide sleeve for broach 115 589 01 53 00 (valve guide base bore 14.41 mm dia.)
Fig. 212: View Of Guide Sleeve
Courtesy of MERCEDES-BENZ USA
Fig. 213: Identifying Guide Sleeve (601 589 15 63 00)
Courtesy of MERCEDES-BENZ USA
601 589 16 63 00 THRUST PIECE - WS05.00-P-0112B
FG 05/Set B
ENGINE 102.92 /93 /96 /97 /98, 103, 601, 602, 603
Use/specification:
Thrust piece for lever pusher 111 589 18 61 00
Valve spring plate 32 mm dia.
Fig. 214: Placing Thrust Piece For Lever Pusher
Courtesy of MERCEDES-BENZ USA
Fig. 215: Identifying Thrust Piece (601 589 16 63 00)
Courtesy of MERCEDES-BENZ USA
603 589 01 40 00 HOLDING WHEEL - WS05.00-P-0113B
FG 05/Set B
ENGINE 601, 602.91 /93 /94 /96 /983, 603.91 /93 /96 /97
Use/specification:
Holding wheel for timing chain
Fig. 216: Holding Timing Chain
Courtesy of MERCEDES-BENZ USA
Fig. 217: Identifying Holding Wheel (603 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
604 589 00 43 00 DRIFT - WS05.00-P-0114B
FG 05/Set B
ENGINES 604, 605, 606
with intake, exhaust valves (valve stem diameter 6 mm)
ENGINES 156, 159, 166, 266, 272 /979, 273, 611, 612 /965 /966, 613, 628, 629, 640, 642, 646, 647 /981, 648,
651, 668
Use:
Drift for pressing valve stem seal onto valve guide.
Fig. 218: Identifying Drift (604 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
606 589 00 37 00 PLIERS - WS05.00-P-0116B
FG 05/Set B
ENGINE 102, 103, 104, 110, 111, 112, 113, 116, 117, 119, 120, 137, 155, 156, 159, 166, 266, 271, 272, 273,
601, 602, 603, 604, 605, 606, 611, 612 /965 /966, 613, 615, 616, 617, 628, 629, 640, 642, 646, 647, 648, 651,
668
Further use FG 27/Set B WS27.00-P-3117B
Use:
Pliers for pulling off valve stem seal
Fig. 219: Identifying Pliers (606 589 00 37 00)
Courtesy of MERCEDES-BENZ USA
615 589 00 01 00 VALVE ADJUSTING WRENCH - WS05.00-P-0117A
FG 05/Set A
ENGINE 615, 616, 617.91 /93 /95
Use/specification:
14 mm valve adjusting wrench (2 pieces)
Fig. 220: Adjusting Valve
Courtesy of MERCEDES-BENZ USA
Fig. 221: Identifying Valve Adjusting Wrench (615 589 00 01 00)
Courtesy of MERCEDES-BENZ USA
615 589 00 03 00 HOLDING WRENCH - WS05.00-P-0118A
FG 05/Set A
ENGINE 615, 616, 617.91 /93 /95
Use/specification:
Holding wrench for valve spring plate
Fig. 222: Holding Valve Spring Plate
Courtesy of MERCEDES-BENZ USA
Fig. 223: Identifying Holding Wrench (615 589 00 03 00)
Courtesy of MERCEDES-BENZ USA
615 589 00 15 00 DRIFT PUNCH - WS05.00-P-0119C
FG 05/Set C
ENGINE 615, 616, 617.91 /93 /95
Use/specification:
10 mm drift punch for driving in the valve guide (inlet, outlet)
Fig. 224: Driving In Valve Guide
Courtesy of MERCEDES-BENZ USA
Fig. 225: Identifying Drift Punch (615 589 00 15 00)
Courtesy of MERCEDES-BENZ USA
616 589 00 34 00 THREADED BOLT - WS05.00-P-0120B
FG 05/Set B
ENGINE 102.92 /93 /96 /97 /98 /99, 103, 104, 110.92 /98 /99, 115.97, 120, 615, 616, 617.91 /93 /95
Use/specification:
M 8 threaded bolts, 150 mm long for impact extractor
116 589 20 33 00
Fig. 226: View Of Threaded Bolt
Courtesy of MERCEDES-BENZ USA
Fig. 227: Identifying Threaded Bolt (616 589 00 34 00)
Courtesy of MERCEDES-BENZ USA
617 589 00 15 00 DRIFT PUNCH - WS05.00-P-0122C
FG 05/Set C
ENGINE 615, 616, 617.91 /93 /95
Use/specification:
Drift punch 10 mm drift punch for driving in valve guide (inlet, outlet), uprated
Fig. 228: Driving In Valve Guide
Courtesy of MERCEDES-BENZ USA
Fig. 229: Identifying Drift Punch (617 589 00 15 00)
Courtesy of MERCEDES-BENZ USA
617 589 00 23 00 SLIP GAUGE BLADES - WS05.00-P-0123A
FG 05/Set A
ENGINE 102.983 /99, 110.92 /98 /99, 115.97, 116, 117, 615, 616, 617.91 /93 /95
Use/specification:
0.10 mm slip gauge blades (20 pieces) for slip gauge holder
Fig. 230: View Of Slip Gauge Holder
Courtesy of MERCEDES-BENZ USA
Fig. 231: Identifying Slip Gauge Blades (617 589 00 23 00)
Courtesy of MERCEDES-BENZ USA
617 589 00 40 00 SLIP GAUGE HOLDER - WS05.00-P-0124A
FG 05/Set A
ENGINE 102.92 /93 /96 /97 /98 /99, 110.92 /98 /99, 115.97, 116, 117, 615, 616, 617.91 /93 /95
Use/specification:
Slip gauge holder (colored red)
Fig. 232: Holding Slip Gauge
Courtesy of MERCEDES-BENZ USA
Fig. 233: Identifying Slip Gauge Holder (617 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
617 589 00 43 00 DRIFT PUNCH - WS05.00-P-0125B
FG 05/Set B
ENGINE 615, 616, 617.91 /93 /95
with intake and exhaust (valve shaft dia. 10 mm)
Use/specification:
Drift punch for pressing the valve-stem seal onto the valve guide
Fig. 234: Pressing Valve-Stem Seal Onto Valve Guide
Courtesy of MERCEDES-BENZ USA
Fig. 235: Identifying Drift Punch (617 589 00 43 00)
Courtesy of MERCEDES-BENZ USA
617 589 01 23 00 SLIP GAUGE BLADES - WS05.00-P-0126A
FG 05/Set A
ENGINE 102.92 /93 /96 /97 /98 /99, 110.98 /99, 115.97, 116, 117, 615, 616, 617.91 /93 /95
Use/specification:
0.15 mm slip gauge blades (20 pieces) for slip gauge holder
Fig. 236: View Of Slip Gauge Holder
Courtesy of MERCEDES-BENZ USA
Fig. 237: Identifying Slip Gauge Blades (617 589 01 23 00)
Courtesy of MERCEDES-BENZ USA
617 589 02 23 00 SLIP GAUGE BLADES - WS05.00-P-0127A
FG 05/Set A
ENGINE 102.92 /93 /96 /97 /98 /99, 110.92 /98 /99, 115.97, 615, 616, 617.91 /93
Use/specification:
0.30 mm slip gauge blades (5 pieces) for slip gauge holder
Fig. 238: View Of Slip Gauge Holder
Courtesy of MERCEDES-BENZ USA
Fig. 239: Identifying Slip Gauge Blades (617 589 02 23 00)
Courtesy of MERCEDES-BENZ USA
617 589 03 23 00 SLIP GAUGE BLADES - WS05.00-P-0128A
FG 05/Set A
ENGINE 102.92 /93 /96 /97 /98 /99, 615, 616, 617.91 /93 /95
Use/specification:
0.35 mm slip gauge blades (5 pieces) for slip gauge holder
Fig. 240: View Of Slip Gauge Holder
Courtesy of MERCEDES-BENZ USA
Fig. 241: Identifying Slip Gauge Blades (617 589 03 23 00)
Courtesy of MERCEDES-BENZ USA
617 589 04 23 00 SLIP GAUGE BLADES - WS05.00-P-0129A
FG 05/Set A
ENGINE 102.983 /99, 617.95
Use/specification:
0.40 mm slip gauge blades (5 pieces) for slip gauge holder
Fig. 242: View Of Slip Gauge Holder
Courtesy of MERCEDES-BENZ USA
Fig. 243: Identifying Slip Gauge Blades (617 589 04 23 00)
Courtesy of MERCEDES-BENZ USA
617 589 05 23 00 PLUG GAUGE - WS05.00-P-0130C
FG 05/Set C
ENGINE 615, 616, 617.91 /93 /95
Use/specification:
10 mm Plug gauge for monitoring valve guide
Fig. 244: Monitoring Valve Guide
Courtesy of MERCEDES-BENZ USA
Fig. 245: Identifying Plug Gauge (617 589 05 23 00)
Courtesy of MERCEDES-BENZ USA
606 589 00 31 00 SUPPORTS (1 PAIR) - WS05.00-P-0131C
FG 05/Set C
Engines 155, 604, 605, 606, 112, 113
Use:
Runs (1 pair) for the cylinder head to align the valve guides vertically during driving in and driving out.
Fig. 246: Supporting Cylinder Head
Courtesy of MERCEDES-BENZ USA
Fig. 247: Identifying Supports (1 Pair) (606 589 00 31 00)
Courtesy of MERCEDES-BENZ USA
606 589 00 15 00 DRIFT PUNCH - WS05.00-P-0132C
FG 05/Set C
ENGINE 604, 605, 606
Use/specification:
6 mm drift punch for knocking out valve guides.
Fig. 248: Knocking Out Valve Guides
Courtesy of MERCEDES-BENZ USA
Fig. 249: Identifying Drift Punch (606 589 00 15 00)
Courtesy of MERCEDES-BENZ USA
606 589 00 53 00 REAMER - WS05.00-P-0150C
FG 05/Set C
ENGINE 604, 605, 606
Use/specification:
Reamer Ø 5, 99H7 mm reamer for reaming valve guides in cylinder head
Fig. 250: Reaming Valve Guides In Cylinder Head
Courtesy of MERCEDES-BENZ USA
Fig. 251: Identifying Reamer (606 589 00 53 00)
Courtesy of MERCEDES-BENZ USA
605 589 00 33 02 PULLER BOLT - WS05.00-P-0154-01B
FG 05/01/Set B
ENGINE 104, 111, 119, 120, 155, 271, 272, 273, 601, 602, 603, 604, 605, 606, 612.965, 628, 629, 640, 642
Use:
Draw-in bolt M6 / M10 length 80 mm for pulling out slide rail bolts.
Fig. 252: Identifying Puller Bolt (605 589 00 33 02)
Courtesy of MERCEDES-BENZ USA
605 589 00 33 00 PULLER - WS05.00-P-0154B
FG 05/Set B
ENGINE 104, 111, 119, 120, 155, 271, 272, 273, 601, 602, 603, 604, 605, 606, 612.965, 628, 629, 640, 642
Part 605 589 00 33 02 Puller bolt FG 05 Set B WS05.00-P-0154-01B
Use:
Extractor (overall length 87 mm) for slide rail bolts with thread M6x14 mm.
Fig. 253: Identifying Puller (605 589 00 33 00)
Courtesy of MERCEDES-BENZ USA
210 589 00 40 00 MAGNETIC PIN - WS05.00-P-0155B
FG 05/15/Set B
ENGINES all
Further use FG 05/Set B WS05.00-N-0155B
Use:
Magnetic pin dia. 6 mm for removal & installation of the valve keepers, to remove and insert small parts.
Fig. 254: Identifying Magnetic Pin (210 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
601 589 05 43 00 DRIFT PUNCH - WS05.00-P-0156B
FG 05/Set B
ENGINE 601 /943, 602 /980, 603 with intake and exhaust (valve shaft dia. 8 and 9 mm)
Use/specification:
Drift punch for pressing the valve stem seal with metal casing onto the valve guide
Fig. 255: Pressing Valve Stem Seal Onto Valve Guide
Courtesy of MERCEDES-BENZ USA
Fig. 256: Identifying Drift Punch (601 589 05 43 00)
Courtesy of MERCEDES-BENZ USA
606 589 01 15 00 DRIFT PUNCH - WS05.00-P-0157C
FG 05/Set C
ENGINE 604, 605, 606 Intake/exhaust valves with 6 mm valve shaft diameter
Use:
6 mm drift punch for knocking valve guide into cylinder head (guide over 35 mm bucket tappet bore)
Fig. 257: Knocking Valve Guide Into Cylinder Head
Courtesy of MERCEDES-BENZ USA
Fig. 258: Identifying Drift Punch (606 589 01 15 00)
Courtesy of MERCEDES-BENZ USA
602 589 00 98 00 CASE - WS05.00-P-0158C
FG 03/05/18/Set C
ENGINE all
Use:
Case for storing individual assembly tool parts for timing chains
Fig. 259: Identifying Case (602 589 00 98 00)
Courtesy of MERCEDES-BENZ USA
602 589 02 33 00 CHAIN SEPARATING TOOL - WS05.00-P-0159C
FG 05/18/Set C
ENGINE all
Use:
Timing chain separating tool (basic unit) in combination with thrust spindle 602 589 04 63 00 or 602 589 05 63
00 for separating installed endless timing chain.
Fig. 260: Identifying Chain Separating Tool (602 589 02 33 00)
Courtesy of MERCEDES-BENZ USA
602 589 04 63 01 PRESSURE PINS - WS05.00-P-0160-01C
FG 03/05/Set C
ENGINE 166, 271, 601, 602, 603, 604, 605, 606, 611, 612 /965 /966, 613, 615, 616, 617, 629, 642, 646, 647,
648, 651, 668
Use:
Pressure pins dia. 4 mm (2 in total) for pressure screw 602 589 04 63 00 for chain separating tool 602 589 02 33
00
Fig. 261: Identifying Pressure Pins (602 589 04 63 01)
Courtesy of MERCEDES-BENZ USA
602 589 04 63 00 THRUST SPINDLE - WS05.00-P-0160C
FG 03/05/Set C
ENGINE 166, 601, 602, 603, 604, 605, 606, 611, 612, 613, 615, 616, 617, 629, 642, 646, 647, 648, 651, 668
ENGINE 612.981, 647.981
ENGINE 612.965 /966
ENGINE 271
Part 602 589 04 63 01 Pressure pins FG 03/05/Set C WS05.00-P-0160-01C
Use:
Pressure screw with pressure pin, dia. 4 mm (2 in total) for bush chains for chain separating tool 602 589 02 33
00.
Fig. 262: Identifying Thrust Spindle (602 589 04 63 00)
Courtesy of MERCEDES-BENZ USA
602 589 05 63 01 PRESSURE PINS - WS05.00-P-0161-01C
FG 05/18/Set C
ENGINE 102, 103, 104, 110, 111, 112, 113, 116, 117, 119, 120, 155, 166, 266, 272 /979, 273, 275, 285, 611,
612, 613, 629, 640, 642, 668
ENGINE 611.981 /987 /983, 612.981, 647.981
ENGINE 612.965/ 966
ENGINE 271
ENGINE 648 in MODEL 220
ENGINE 639
ENGINE 646, 647
Use:
Pressure pins 2.9 mm Ø (5 in total) for pressure screw 602 589 05 63 00 with chain separating tool 602 589 02
33 00
Fig. 263: Identifying Pressure Pins (602 589 05 63 01)
Courtesy of MERCEDES-BENZ USA
602 589 05 63 00 PRESSURE SCREW - WS05.00-P-0161C
FG 05/18/Set C
ENGINE 102, 103, 104, 110, 111, 112, 113, 116, 117, 119, 120, 155, 156, 157, 159, 166, 266, 272 /979, 273,
275, 276, 278, 285, 611, 612, 613, 629, 640, 642 /, 646, 647, 668
ENGINE 611.981 /983 /987, 612.981, 647.981
ENGINE 612.965 /966
ENGINE 648 in MODEL 220
ENGINE 639
Separate part 602 589 05 63 01 Pressure pins FG 05/18/Set C WS05.00-P-0161-01C
Use:
Pressure screw with pressure pin, dia. 2.9 mm (3 in total) roller-type chains in combination with chain
separating tool 602 589 02 33 00.
Fig. 264: Identifying Pressure Screw (602 589 05 63 00)
Courtesy of MERCEDES-BENZ USA
602 589 00 39 00 RIVETING TOOL - WS05.00-P-0162C
FG 05/18/Set C
ENGINES all
MODIFICATION NOTES
9.6.95 Replaces: 000 589 58 43 00
20.11.07 Replaced by 642 589 00 33 00 WS05.00-P-0260C
Use:
Rivet press tool for timing chains (basic unit).
Fig. 265: Identifying Riveting Tool (602 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
FG 05/Set C
ENGINE 166, 275, 285, 601, 602, 603, 604, 605, 606, 611, 612, 613, 615, 616, 617, 629, 640, 642, 648, 646,
647, 668
ENGINE 612.981, 647.981
ENGINE 612.965 /966
Use:
Assembly inserts, consisting of chain guide F5, thrust piece D9 and centering fork (2 each). For pressing on the
press seat center plate of the double bush chain in combination with a rivet press tool 602 589 00 39 00 or 642
589 00 33 00.
Fig. 266: Identifying Assembly Inserts (602 589 02 63 00)
Courtesy of MERCEDES-BENZ USA
602 589 03 63 00 THRUST PIECE - WS05.00-P-0164C
FG 05/Set C
ENGINE 166, 601, 602, 603, 604, 605, 606, 611, 612, 613, 615, 616, 617, 629, 642, 640, 648, 646, 647, 668
ENGINE 612.981, 647.981
ENGINE 612.965 /966
ENGINE 639
Use:
press tool 602 589 00 39 00 for riveting double bush chains with a press seat middle plate. Engine 640 thrust
piece D8 in combination with guide F6 640 589 01 63 00 for riveting the timing chain.
Fig. 267: Identifying Thrust Piece (602 589 03 63 00)
Courtesy of MERCEDES-BENZ USA
112 589 09 63 00 ASSEMBLY INSERTS - WS05.00-P-0165C
FG 05/18/Set C
ENGINE 102, 104, 110, 111, 112, 113, 116, 117, 119, 120, 156, 159, 166, 275, 611, 612, 613, 629, 668, 642,
646, 647, 648
ENGINE 612.981, 647.981
ENGINE 612.965 /966
ENGINE 648.960 in MODEL 220
ENGINE 642
Use:
Assembly inserts consisting of a chain guide F1 and thrust piece D5 for pressing on the outer plate and for
riveting the double bush chain in combination with a rivet press tool 602 589 00 39 00 or 642 589 00 33 00.
Fig. 268: Identifying Assembly Inserts (112 589 09 63 00)
Courtesy of MERCEDES-BENZ USA
606 589 02 15 00 DRIFT PUNCH - WS05.00-P-0167C
FG 05/Set C
ENGINE 111, 271, 104, 119, 120, 604.91, 605.91, 606.91 / Intake and exhaust valves with 7 mm valve shaft
diameter
REVISIONS
18.7.95 Replacement for: 119 589 02 15 00
Use:
7 mm drift punch for valve guide in cylinder head (guide via bucket tappet bore 35 mm)
Fig. 269: View Of Drift Punch For Valve Guide In Cylinder Head
Courtesy of MERCEDES-BENZ USA
Fig. 270: Identifying Drift Punch (606 589 02 15 00)
Courtesy of MERCEDES-BENZ USA
602 589 01 40 00 RETAINER DEVICE - WS05.00-P-0168C
FG 05/Set C
ENGINE 601, 602, 603, 606, 611.981 /987, 612.981, 647.981
Use:
Retaining device for timing chain on chain sprocket for pulling timing chain into engine (retaining device
prevents timing chain from jumping on chain sprocket).
Fig. 271: Retaining Timing Chain On Sprocket
Courtesy of MERCEDES-BENZ USA
Fig. 272: Identifying Retainer Device (602 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
604 589 00 40 00 RETAINING DEVICE - WS05.00-P-0169C
FG 05/Set C
ENGINE 604, 605, 606
Use:
Retaining device for timing chain on chain sprocket for pulling timing chain into engine (retaining device
prevents timing chain from jumping on chain sprocket)
Fig. 273: Retaining Timing Chain On Chain Sprocket
Courtesy of MERCEDES-BENZ USA
Fig. 274: Identifying Retaining Device (604 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
602 589 02 40 00 ASSEMBLY LINKS - WS05.00-P-0171C
FG 05/18/Set C
ENGINE all
Use:
Assembly links (3 in total) for simplex roller chain, duplex roller chain and duplex bushed roller chain for
connecting repair chain to installed chain
Assembly links must not be left in the engine.
Fig. 275: Identifying Assembly Links (602 589 02 40 00)
Courtesy of MERCEDES-BENZ USA
668 589 00 59 00 ASSEMBLY CARTRIDGE - WS05.00-P-0187C
FG 05/Set C
ENGINE 166, 266, 640, 668
Use:
Assembly cartridge for removing and installing three-grooved valve keys.
In combination with assembly tool for valve springs 111 589 25 61 00 and plate 668 589 00 32 00
Fig. 276: Identifying Assembly Cartridge (668 589 00 59 00)
Courtesy of MERCEDES-BENZ USA
668 589 00 32 00 PLATE - WS05.00-P-0188C
FG 05/Set C
ENGINE 166, 668
Use:
Plate for guiding assembly cartridge 668 589 00 59 00. In combination with assembly tool for valve springs
111 589 25 61 00 and assembly cartridge 668 589 00 59 00 for removing and installing three-grooved valve
keys.
Fig. 277: Identifying Plate (668 589 00 32 00)
Courtesy of MERCEDES-BENZ USA
668 589 01 59 00 INSERTION PLATE - WS05.00-P-0190C
FG 05/15/27/Set C
ENGINE 166, 668, 646, 647 /981, 648, 611, 613, 628, 612
ENGINE 648.960 in MODEL 220
Use:
Insertion plate for assembly board 112 589 11 59 00 and 111 589 02 59 00.
For clamping cylinder head for assembly work, e.g. valve assembly.
Fig. 278: Identifying Insertion Plate (668 589 01 59 00)
Courtesy of MERCEDES-BENZ USA
FG 05/01/Set C
ENGINES 137, 275
Use:
Retainer (2 pieces) for camshafts in the 30° after top dead center position. Position for loosening and tightening
mounting screws for the camshaft sprocket and for adjusting the timing
Fig. 279: Identifying Retainer Device (137 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
613 589 00 40 00 RETAINING DEVICE - WS05.00-P-0196C
FG 05/Set C
ENGINE 611, 612, 613, 647, 648
Use:
Retaining device for timing chain on chain sprocket for drawing timing chain into the engine
Fig. 280: Identifying Retaining Device (613 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
611 589 02 15 00 INSERTION DRIFT - WS05.00-P-0199B
FG 05/Set B
ENGINE 611, 612, 613, 647, 648 Ein-Ausla -Ventile mit Ventilschaft-Durchmesser 7 mm
Use:
7 mm insertion drift for valve guide in cylinder head.
Fig. 281: Identifying Insertion Drift (611 589 02 15 00)
Courtesy of MERCEDES-BENZ USA
628 589 00 15 00 DRIFT - WS05.00-P-0200C
FG 05/Set C
Use:
Drift for pulling off camshaft sprocket with timing chain installed.
NOTE: On OM 628 use only for right bank of cylinders.
Fig. 282: Identifying Drift (628 589 00 15 00)
Courtesy of MERCEDES-BENZ USA
628 589 00 61 00 RETAINING DEVICE - WS05.00-P-0201C
FG 05/Set C
ENGINE 628, 629
Use:
Retaining device for pulling off camshaft sprocket with timing chain installed at left bank of cylinders.
Fig. 283: Identifying Retaining Device (628 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
271 589 00 59 00 ASSEMBLY TOOL - WS05.00-P-0202C
FG 05/Set C
ENGINE all
Use:
This assembly tool is used for mounting cylinder heads.
Fig. 284: Identifying Assembly Tool (271 589 00 59 00)
Courtesy of MERCEDES-BENZ USA
285 589 01 40 00 RETAINING DEVICE - WS05.00-P-0204C
FG 05/Set C
ENGINE 275, 285
Use:
This retaining device makes it possible to replace the timing chain.
Fig. 285: Identifying Retaining Device (285 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
285 589 00 40 00 RETAINING DEVICE - WS05.00-P-0205C
FG 05/Set C
ENGINE 275, 285
Use:
Only for left bank of cylinders. This retaining device is designed for positioning the camshaft in 30 degrees
after TDC position.
This makes it possible to slacken and tighten the bolts attaching the camshaft sprocket.
NOTE: Use W 137 589 01 40 00 for the right bank of cylinders.
Fig. 286: Identifying Retaining Device (285 589 00 40 00)
Courtesy of MERCEDES-BENZ USA
628 589 03 40 00 RETAINING DEVICE - WS05.00-P-0213B
FG 05/Set B
ENGINE 628, 629
Use:
Drawing in timing chain. Hold timing chain meshed with camshaft sprocket.
Fig. 287: Identifying Retaining Device (628 589 03 40 00)
Courtesy of MERCEDES-BENZ USA
271 589 01 63 00 ASSEMBLY INSERTS - WS05.00-P-0215C
FG 05/Set C
ENGINE 271.9
ENGINE 272
ENGINE 272.979
ENGINE 273
ENGINE 271.951 in MODEL 906
Use:
Assembly inserts D3 and F3 for riveting the timing chain (G53).
Fig. 288: Identifying Assembly Inserts (271 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
271 589 02 63 00 ASSEMBLY INSERTS - WS05.00-P-0216C
FG 03/05/Set C
ENGINE 271
ENGINE 272
ENGINE 273
ENGINE 271.951 in MODEL 906
ENGINE 273.963
Further use FG 18/Set C WS18.00-P-0037C
Use:
Assembly inserts D10 and F10 to rivet the drive chain (G44HCF-2) for the Lanchester balance shaft.
Fig. 289: Identifying Assembly Inserts (271 589 02 63 00)
Courtesy of MERCEDES-BENZ USA
640 589 01 63 00 GUIDE - WS05.00-P-0218B
Group 05/Set B
ENGINE 640
ENGINE 668 in MODEL 168
ENGINE 639
Application:
Guide F6 in connection with thrust piece D8 (from W602 589 03 63 00) as well as rivet press tool 602 589 00
39 00 for riveting the timing chain.
Fig. 290: Identifying Guide (640 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
272 589 01 63 00 GUIDE - WS05.00-P-0222B
FG 05/Set B
ENGINE 272 /979, 273
Use:
Guide F4 to rivet the locking link with the thrust piece in combination with thrust piece D3 (assembly inserts
271 589 01 63 00) and rivet press tool 272 589 00 39 00.
Fig. 291: Identifying Guide (272 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
272 589 00 39 00 RIVET PRESS TOOL - WS05.00-P-0223B
FG 05/Set B
ENGINES 272 /979, 273
MODIFICATION NOTES
20.11.07 Replaced by 642 589 00 33 00 WS05.00-P-0260C
Use:
Rivet press tool (basic unit) to rivet timing chains.
Fig. 292: Identifying Rivet Press Tool (272 589 00 39 00)
Courtesy of MERCEDES-BENZ USA
272 589 00 63 00 ASSEMBLY INSERTS - WS05.00-P-0224B
FG 05/Set B
ENGINE 272 /979, 273
Use:
Assembly inserts, consisting of chain guide F11, thrust piece D12 and centering fork (2 each). to press on the
press fit center clip with a rivet press tool 272 589 00 39 00.
Fig. 293: Identifying Assembly Inserts (272 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
640 589 01 40 00 HOLD-DOWN DEVICE - WS05.00-P-0225B
Group 05/Set B
ENGINES 640, 639
Application:
The hold-down device holds the timing chain with camshaft sprocket in grip.
Fig. 294: Identifying Hold-Down Device (640 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
640 589 02 63 00 ASSEMBLY LINK - WS05.00-P-0226B
FG 05/Set B
ENGINES 640, 668
Use:
Assembly link for connecting the repair chain with the installed when changing the timing chain.
NOTE: The assembly links must not be left in the engine.
Fig. 295: Identifying Assembly Link (640 589 02 63 00)
Courtesy of MERCEDES-BENZ USA
272 589 03 63 00 ASSEMBLY LINK - WS05.00-P-0227B
FG 05/Set B
ENGINE 272 /979, 273
Use:
Assembly link for connecting the repair chain with the installed chain when changing the timing chain.
NOTE: Assembly links must not be left in the engine.
Fig. 296: Identifying Assembly Link (272 589 03 63 00)
Courtesy of MERCEDES-BENZ USA
642 589 01 40 00 TIE-DOWN SET - WS05.00-P-0229B
FG 05/Set B
ENGINE 642
MODIFICATION NOTES
9.10.06 Replaced by 642 589 04 40 00
Use:
Tie-down sets hold the timing chain in mesh with the camshaft sprocket.
Fig. 297: Identifying Tie-Down Set (642 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
642 589 00 31 00 HOLDDOWN DEVICE KIT - WS05.00-P-0230C
FG 05/Set C
ENGINE 642
Use:
Bearing bridge (2 pieces) for fixing camshafts for an opened valve cover.
Fig. 298: Identifying Holddown Device Kit (642 589 00 31 00)
Courtesy of MERCEDES-BENZ USA
271 589 10 63 01 PRESSURE PINS - WS05.00-P-0232-01C
FG05/Set C
ENGINE 271, 272, 273
ENGINE 156 in MODEL 164, 204, 209, 211, 216, 219, 221, 230, 251
ENGINE 272.979 in MODEL 906
ENGINE 273.963
Use:
Pressure pin with a 2.4 mm diameter for thrust spindle 271 589 10 63 00 to chain breaker tool 602 589 02 33
00.
Fig. 299: Identifying Pressure Pins (271 589 10 63 01)
Courtesy of MERCEDES-BENZ USA
271 589 10 63 00 THRUST SPINDLE - WS05.00-P-0232C
FG 05/Set C
ENGINE 271, 272, 273
ENGINE 156 in MODEL 164, 204, 209, 211, 216, 219, 221, 230, 251
ENGINE 272.979 in MODEL 906
ENGINE 273.963
Single part 271 589 10 63 01 Thrust pins FG05/Set C WS05.00-P-0232-01C
Use:
Pressure screw with pressure pin diameter 2.4 mm to separate bush chains using chain separating tool 602 589
02 33 00.
Fig. 300: Identifying Thrust Spindle (271 589 10 63 00)
Courtesy of MERCEDES-BENZ USA
272 589 00 61 00 DEPRESSOR - WS05.00-P-0233B
FG 05/Set B
ENGINE 132, 272, 273
MODIFICATION NOTES
14.2.06 Replaced by 273 589 00 61 00 WS05.00-P-0256B
Use:
Depressor for valve spring retainer in combination with valve assembly tool" 111 589 25 61 00. The associated
guide sleeve is used to mount valve key in depressor.
Fig. 301: Identifying Depressor (272 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
640 589 00 61 00 DEPRESSOR - WS05.00-P-0236B
FG 05/Set B
ENGINE 640, 642
Use:
Depressor for valve spring retainer.
Fig. 302: Identifying Depressor (640 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
271 589 02 40 00 ASSEMBLY LINK - WS05.00-P-0238C
FG 05/Set C
ENGINE 156, 271, 272, 273
ENGINE 272.979
ENGINE 273.963
Use:
Assembly link for connecting the old oil pump chain with the new oil pump chain while changing an oil pump
chain.
Fig. 303: Identifying Assembly Link (271 589 02 40 00)
Courtesy of MERCEDES-BENZ USA
629 589 00 61 00 ADAPTATION - WS05.00-P-0239C
FG 05/Set C
ENGINE 629
Use:
Adaptation is inserted in combination with W628 589 00 61 00 to guide the camshaft sprocket past the installed
timing chain on the left cylinder bank.
NOTE: Only use in combination with W628 589 00 61 00.
Fig. 304: Identifying Adaptation (629 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
156 589 00 31 00 GUIDE PINS - WS05.00-P-0249B
FG 05/Set B
ENGINE 156, 159
Use:
Two guide pins for guiding the timing case cover during installation.
Fig. 305: Identifying Guide Pins (156 589 00 31 00)
Courtesy of MERCEDES-BENZ USA
156 589 00 32 00 LOCATING PLATE - WS05.00-P-0250B
FG 05/Set B
ENGINE 156, 159
Use:
Locating plate for locking of sensor rotors of camshaft adjuster in assembly status.
Fig. 306: Identifying Locating Plate (156 589 00 32 00)
Courtesy of MERCEDES-BENZ USA
156 589 00 34 00 THREADED STUD - WS05.00-P-0251B
FG 05/Set B
ENGINE 156, 159
Use:
Threaded stud for knocking in/out camshaft sprocket pins when used with impact extractor W 116 589 20 33
00.
Fig. 307: Identifying Threaded Stud (156 589 00 34 00)
Courtesy of MERCEDES-BENZ USA
156 589 00 61 00 RETAINING DEVICE - WS05.00-P-0252B
FG 05/Set B
ENGINE 156, 159
Use:
This retaining device makes it possible to position the camshaft in the installed position. This makes it possible
to slacken and tighten the bolts attaching the camshaft gears.
NOTE: As of engine no.: 156 980 600 01 125.
Fig. 308: Identifying Retaining Device (156 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
156 589 00 15 00 DRIFT - WS05.00-P-0253B
FG 05/Set B
ENGINE 156, 159
Use:
Drift for hammering in the sealing ring on the oil centrifuge.
Fig. 309: Identifying Drift (156 589 00 15 00)
Courtesy of MERCEDES-BENZ USA
273 589 00 61 00 DEPRESSOR - WS05.00-P-0256B
FG 05/Set B
ENGINE 272, 273
ENGINE 272.979
MODIFICATION NOTES
14.2.06 Replacement for 272 589 00 61 00 WS05.00-P-0233B
Use:
Depressor for valve spring retainer in combination with assembly tool 111 589 25 61 00.
Fig. 310: Identifying Depressor (273 589 00 61 00)
Courtesy of MERCEDES-BENZ USA
642 589 04 40 00 TIE-DOWN SET - WS05.00-P-0257B
FG 05/Set B
ENGINE 642
MODIFICATION NOTES
9.10.06 Replacement for 642 589 01 40 00
Use:
Tie-down sets hold the timing chain in mesh with the camshaft sprocket.
Fig. 311: Identifying Tie-Down Set (642 589 04 40 00)
Courtesy of MERCEDES-BENZ USA
272 589 00 10 00 TORX SCREWDRIVER BIT T60 - WS05.00-P-0259B
FG 05/Set B
ENGINE 157, 272, 273, 276, 278
Use:
Torx screwdriver bit T60 for counterholding the camshaft, for loosening/tightening the central valve of the
camshaft adjuster.
NOTE: In combination with 000 589 01 40 00 or bit holder from the company Hazet
2251-1.
Fig. 312: Identifying Torx Screwdriver Bit T60 (272 589 00 10 00)
Courtesy of MERCEDES-BENZ USA
642 589 00 33 00 RIVETING TOOL - WS05.00-P-0260C
FG 05/18/Set C
ENGINE all
MODIFICATION NOTES
20.11.07 Replacement for 602 589 00 39 00 WS05.00-P-0162C
20.11.07 Replacement for 272 589 00 39 00 WS05.00-P-0223B
Use:
Rivet press tool (basic unit) to rivet timing chains.
Assembly inserts 651 589 04 63 00 should be used for engine 651.
Fig. 313: Identifying Riveting Tool (642 589 00 33 00)
Courtesy of MERCEDES-BENZ USA
651 589 01 40 00 TIE-DOWN SET - WS05.00-P-0262C
FG 03/05/Set C
ENGINE 651
Use:
Fixing of the camshaft to loosen or tighten the mounting bolts for the camshaft sprocket.
NOTE: 2 pieces are required.
Fig. 314: Identifying Tie-Down Set (651 589 01 40 00)
Courtesy of MERCEDES-BENZ USA
651 589 04 63 00 ASSEMBLY INSERTS - WS05.00-P-0263C
FG 05/Set C
ENGINE 651
Use:
Assembly inserts, consisting of chain guide F12 and D14 centering fork (2 each). For pressing on the outer
plates and for riveting the bush chain in combination with a rivet press tool 642 589 00 33 00.
Fig. 315: Identifying Assembly Inserts (651 589 04 63 00)
Courtesy of MERCEDES-BENZ USA
156 589 01 63 00 CLAMPING TOOL - WS05.00-P-0269B
FG 05/Set B
ENGINES 156, 159
Use:
Tool for immobilizing gears of camshaft adjuster.
Fig. 316: Identifying Clamping Tool (156 589 01 63 00)
Courtesy of MERCEDES-BENZ USA
111 589 25 61 00 VALVE ASSEMBLY TOOLS KIT - WS05.00-P-3137BA
FG 05/Set B
ENGINE 104, 111, 112, 113, 119, 120, 122, 132, 134, 135, 155, 156, 159, 160, 166, 266, 271, 272, 273, 601,
602, 603, 604, 605, 606, 611 /980, 612 /965 /966, 613, 628, 629, 639, 640, 642, 646, 647, 648, 651, 660, 668
ENGINE 648.960 in MODEL 220
Separate part 111 589 25 61 06 Thrust fork FG05/Set C WS05.00-P-3137-06C
Separate part 111 589 25 61 12 Fixing bracket FG05/Set C WS05.00-P-3137-12C
Separate part 111 589 25 61 19 Step spacing FG05/Set C WS05.00-P-3137-19C
Separate part 111 589 25 61 03 Lever handle FG05/Set C WS05.00-P-3137-03C
Separate part 111 589 25 61 05 Detent depressor FG05/Set C WS05.00-P-3137-05C
Use:
Assembly tool for valve springs in a plastic case.
NOTE: For engines with tappet holes in cylinder head assembly of the valve keys is
performed automatically by the assembly cartridges.
Fig. 317: Identifying Valve Assembly Tools Kit (111 589 25 61 00)
Courtesy of MERCEDES-BENZ USA
Consisting of:
Part 1 Empty case
Part 2 Impact pin
Part 3 Lever handle
Part 4 Extension
Part 5 Detent depressed for thrust piece
Part 6 Thrust fork for assembly cartridges
Part 7 Thrust piece for detent depressed
Part 8 Assembly cartridge length 83 mm (gasoline engine)
Part 9 Assembly cartridge length 102 mm (diesel engine)
Part 10 Pilot bushing length 28.6 mm (gasoline engine)
Part 11 Pilot bushing length 53 mm (diesel engine)
Part 12 Retaining fork M 6 X 15 mm
Part 13 Retaining fork M 7 X 25 mm
Part 14 Retaining fork M 7 X 30 (bolt length 60 mm)
Part 15 Retaining fork M 8 X 20 mm
Part 16 Threaded hook M6 X 23 mm
Part 17 Threaded hook M7 X 23 mm
Part 18 Threaded hook M8 X 20 mm
Part 19 Grid with a joint bearing
SPECIAL TOOLS: PASSENGER CARS: ENGINE TIMING - WS05.00-Z-9999AZ
MODEL all
WS05.00-P-
000 589 10 53 00 Reamer FG 05/Set C
0001C
000 589 10 68 00 Cylinder WS05.00-P-
FG 05/Set C
brush 0002C
WS00.00-P-
000 589 10 99 00 Tool kit FG FG 05/07/23/Set A
0030Z
000 589 10 99 01 Torque WS00.00-P-
FG 00/05/07/23/Set A
wrench 0030-01Z
000 589 10 99 17 Open end WS00.00-P-
FG 00 FG 05/Set A
wrench attachment, 15 mm 0030-17Z
000 589 10 99 18 Open end WS00.00-P-
FG 00 FG 05/07/set A
wrench attachment, 17 mm 0030-18Z
WS05.00-P-
000 589 11 53 00 Reamer FG 05/Set C
WS05.00-P-
000 589 15 53 00 Reamer FG 05/Set C
0004C
WS05.00-P-
000 589 21 53 00 Reamer FG 05/Set C
0005C
000 589 28 33 00 Puller dia. WS00.00-N-
FG 00/03/05/26/27/ 28/33/43/46/Set B
28-37 mm 3026Z
000 589 29 33 00 Internal WS00.00-N-
FG 00 FG 05/13/26/27/28/ 33/42/set C
extractor 3027Z
000 589 33 33 00 Counter WS00.00-N-
FG 00/03/05/26/27/ 28/33/43/46/Set B
stay 0051Z
000 589 58 43 00 WS05.00-N-
FG 05/Set C
Installation tool 0006C
000 589 69 03 00 Ring WS07.00-P-
FG 01/05/07/09/Set B
wrench bit 0088B
WS03.00-P-
001 589 65 09 00 Socket FG 03/01/05/27 Set B
0006B
001 589 78 21 00 WS01.00-N-
FG 01/03/05/set A
Compression tester 0006A
001 589 78 21 00 WS01.00-P-
FG 01/05/Set A
Compression tester 0006A
102 589 00 09 00 Valve WS05.00-P-
Function Group 05/ Set A
adjusting wrench 0007A
102 589 00 09 02 Phillips WS05.00-P-
Function Group 05/Set A
screwdriver, size PH2 0007-01A
WS05.00-P-
102 589 00 23 00 Drift FG 05/Set C
0008C
102 589 00 34 00 Threaded WS05.00-P-
FG 01/05/Set B
bolt 0009B
102 589 00 59 00 Assembly WS05.00-P-
FG 05/Set C
board 0010C
102 589 00 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0011C
102 589 01 23 00 Feeler WS05.00-P-
FG 05/Set C
gauge 0012C
WS05.00-P-
102 589 01 53 00 Reamer FG 05/Set C
0013C
102 589 01 59 00 WS05.00-P-
FG 05/Set C
Supporting bridge 0014C
WS05.00-P-
102 589 01 61 00 Support FG 05/Set B
0015B
102 589 01 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0016C
102 589 02 23 00 Plug WS05.00-P-
FG 05/Set C
gauge 0018C
WS05.00-P-
102 589 02 53 00 Reamer FG 05/Set C
0020C
102 589 02 59 00 Assembly WS05.00-P-
FG 05/Set C
board 0021C
102 589 02 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0022C
WS05.00-P-
102 589 03 40 00 Magnet FG 05/Set A
0023A
WS05.00-P-
102 589 03 53 00 Broach FG 05/Set C
0024C
102 589 03 59 00 WS05.00-P-
FG 05/Set B
Supporting bridge 0025B
102 589 04 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0026C
102 589 04 21 00 WS05.00-P-
FG 05/Set B
Measuring device 0027B
WS05.00-P-
102 589 04 53 00 Reamer FG 05/Set C
0028C
102 589 05 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0029C
102 589 08 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0030C
102 589 08 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0031C
102 589 09 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0032C
102 589 10 63 00 Thrust WS05.00-P-
FG 05/Set B
piece 0033B
102 589 15 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0034C
103 589 00 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0035C
103 589 00 59 00 Assembly WS05.00-P-
FG 05/Set C
board 0036C
WS05.00-P-
103 589 00 61 00 Support FG 05/Set B
0037B
103 589 01 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0039C
103 589 01 63 00 Assembly WS05.00-N-
FG 05/18/Set C
inserts 0040C
103 589 01 63 00 Assembly WS05.00-P-
FG 05/18/Set C
inserts 0040C
103 589 02 15 00 Staged WS05.00-P-
FG 05/Set C
drift 0042C
103 589 03 15 00 Staged WS05.00-P-
FG 05/Set C
drift 0043C
104 589 00 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0044C
104 589 00 23 00 Plug WS05.00-P-
FG 05/Set C
gauge 0045C
WS05.00-P-
104 589 00 53 00 Reamer FG 05/Set C
0046C
104 589 01 01 00 Double WS05.00-P-
FG 05/Set B
open-end wrench 0047B
104 589 01 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0048C
104 589 01 43 00 Drift WS05.00-P-
FG 05/Set B
punch 0049B
WS05.00-P-
104 589 01 53 00 Broach FG 05/Set C
0050C
104 589 01 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0051C
104 589 02 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0052C
110 589 00 01 00 Valve WS05.00-P-
FG 05/Set A
adjusting wrench 0053A
110 589 00 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0054C
WS05.00-P-
110 589 00 53 00 Broach FG 05/Set C
0055C
110 589 01 01 00 Double WS05.00-P-
FG 05/Set A
open-ended wrench 0057A
110 589 01 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0058C
WS05.00-P-
110 589 02 53 00 Reamer FG 05/Set C
0059C
110 589 03 31 00 Chain WS05.00-P-
FG 05/Set C
tensioner 0060C
WS05.00-P-
110 589 03 53 00 Reamer FG 05/Set C
0061C
110 589 03 59 00 Mounting FG 00/01/05/13/18/ 26/42/54/67/68/72/77/80/82/83/88/91/ WS00.00-P-
wedge Set K 0274K
110 589 04 61 00 Lever WS05.00-P-
FG 05/Set B
pusher 0063B
110 589 04 61 05 Retaining WS05.00-P-
FG 05/Set B
bracket 0063-01B
110 589 04 61 09 Thrust WS05.00-P-
FG 05/Set B
piece 0063-02B
110 589 04 61 24 Thrust WS05.00-P-
FG 05/Set B
piece 0063-03B
110 589 06 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0064C
WS05.00-P-
111 589 01 40 00 Thrust nut FG 05/Set C
0068C
111 589 01 59 00 WS05.00-N-
FG 05/Set C
Supporting bridge 0069C
WS05.00-P-
111 589 02 15 00 Drift FG 05/Set C
0070C
111 589 02 59 00 Assembly WS05.00-P-
FG 05/Set C
board 0071C
111 589 03 15 00 Retaining WS05.00-P-
FG 01/05/Set B
pins 0072B
111 589 18 61 00 Lever WS05.00-N-
FG 05/Set B
pusher 0073B
111 589 19 61 00 Retaining WS05.00-P-
FG 05/Set C
device 0172C
111 589 25 61 00 Valve WS05.00-P-
FG 05/Set B
assembly tools kit 3137BA
111 589 25 61 03 Lever WS05.00-P-
FG05/Set C
handle 3137-03C
111 589 25 61 05 Detent WS05.00-P-
FG05/Set C
depressor 3137-05C
111 589 25 61 06 Thrust WS05.00-P-
FG05/Set C
fork 3137-06C
111 589 25 61 12 Fixing WS05.00-P-
FG05/Set C
bracket 3137-12C
WS05.00-P-
111 589 25 61 19 Grid FG05/Set C
3137-19C
111 589 25 63 00 Thrust WS05.00-N-
FG 05/Set B
element 0074B
112 589 00 01 00 Open-end WS05.00-P-
FG 05/Set B
wrench 0177B
112 589 00 15 00 Extraction WS05.00-P-
FG 05/Set B
drift punch 0179B
112 589 00 25 00 Squeeze WS00.00-P-
FG 00/01/05/18
gun 0052Z
112 589 00 32 00 Fixing WS05.00-P-
FG 05/Set B
plate 0178B
112 589 01 03 00 Insertion WS05.00-P-
FG 05/01/Set B
tool 0180B
112 589 01 09 00 Spark WS15.00-P-
FG 05/15/Set A
plug wrench 0016A
112 589 01 32 00 Arresting WS05.00-P-
FG 05/Set B
plate 0186B
112 589 02 31 00 Guide WS05.00-P-
FG 05/Set B
shaft 0181B
112 589 03 31 00 Guide WS05.00-P-
FG 05/Set B
shaft 0182B
112 589 03 40 00 Retaining WS03.00-P-
FG 01/03/05/27/ Set B
lock 0037B
112 589 04 40 00 Retainer WS05.00-P-
FG 05/Set C
device 0191C
112 589 05 40 00 Retaining WS05.00-P-
FG 05/Set C
bearing 0189C
112 589 09 63 00 Assembly WS05.00-P-
FG 05/18/Set C
inserts 0165C
112 589 10 59 00 Support WS05.00-P-
FG 05/Set B
plate 0184B
112 589 11 59 00 Assembly WS05.00-P-
FG 05/Set C
board 0183C
WS05.00-P-
113 589 00 15 00 Drift FG 05/Set C
0197C
113 589 02 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0198C
115 589 00 34 00 Threaded WS05.00-P-
FG 05/Set B
bolt 0075B
WS05.00-P-
115 589 00 53 00 Broach FG 05/Set C
0076C
115 589 01 34 00 Threaded WS05.00-P-
FG 05/Set B
bolt 0077B
WS05.00-P-
115 589 01 53 00 Broach FG 05/Set C
0078C
WS05.00-P-
115 589 20 33 00 Puller FG 05/Set B
0079B
116 589 00 34 00 Threaded WS05.00-P-
FG 05/Set B
bolt 0080B
116 589 00 43 00 Drift WS05.00-P-
FG 05/Set B
punch 0081B
116 589 01 01 00 Holding WS05.00-P-
FG 05/Set B
wrench 0082B
116 589 01 34 00 Threaded WS05.00-P-
FG 05/01/Set B
bolt 0083B
116 589 01 43 00 Drift WS05.00-P-
FG 05/Set B
punch 0084B
116 589 02 01 00 Valve WS05.00-P-
FG 05/Set A
adjusting wrench 0085A
116 589 02 01 01 Open-end WS05.00-P-
FG 05/Set A
wrench 0085-01A
116 589 02 34 00 Threaded WS05.00-P-
FG 01/05/Set B
bolt 0086B
116 589 03 34 00 Threaded WS05.00-P-
FG 05/Set B
bolt 0087B
116 589 06 63 00 Magnetic WS05.00-P-
FG 05/Set B
rod 0088B
116 589 20 33 00 Impact WS05.00-P-
FG 05/01/03/07/ Set B
extractor 0089B
117 589 00 23 00 Slip WS05.00-P-
FG 05/Set A
gauge blades 0090A
117 589 00 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0091C
117 589 01 23 00 Slip WS05.00-P-
FG 05/Set A
gauge blades 0092A
117 589 03 23 00 Go/no-go WS05.00-P-
FG 05/Set C
gauge 0093C
117 589 04 23 00 Plug WS05.00-P-
FG 05/Set C
gauge 0094C
117 589 05 23 00 Plug WS05.00-P-
FG 05/Set C
gauge 0095C
117 589 06 23 00 Test WS05.00-P-
FG 05/Set B
gauge 0096B
119 589 00 01 00 Double WS05.00-P-
FG 05/Set B
open end wrench 0097B
WS05.00-P-
119 589 00 43 00 Drift FG 05/Set B
0098B
WS05.00-P-
119 589 00 53 00 Reamer FG 05/Set C
0151C
WS03.00-P-
119 589 01 14 00 Sleeve FG 03/05/Set B
0022B
119 589 01 53 00 Broaching WS05.00-P-
FG 05/Set C
tool 0152C
119 589 01 63 00 Clip WS05.00-P-
FG 05/Set B
remover 0099B
119 589 02 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0100C
119 589 05 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0153C
119 589 06 63 00 Thrust WS05.00-P-
FG 05/Set B
piece 0101B
120 589 07 21 00 WS18.00-P-
FG 18/01/05/09/Set B
Measuring rod 0024B
123 589 00 34 00 Threaded WS05.00-P-
FG 05/Set B
bolt 0102B
123 589 03 61 00 Lever WS05.00-P-
FG 05/Set B
pusher 0103B
123 589 03 61 13 Retaining WS05.00-P-
FG 05/Set B
bracket 0103-01B
129 589 00 91 00 Record FG 00/Set Z FG 01/05/06/07/09/14/15/18/20/22/25/26/ WS00.00-P-
plug 27/29/32/33/35/42/46/47/68/82/83/88/ 91/Set B 0255Z
137 589 00 40 00 Retaining WS05.00-P-
FG 05/set C
clamp 0193C
137 589 01 40 00 Retainer WS05.00-P-
FG 05/01/Set C
device 0194C
137 589 02 40 00 Retaining WS05.00-P-
FG 05/set C
device 0195C
152 589 00 40 00 Tie-down WS05.00-P-
FG 05/Set B
set 0056B
WS05.00-P-
156 589 00 15 00 Drift FG 05/Set B
0253B
156 589 00 31 00 Guide WS05.00-P-
FG 05/Set B
pins 0249B
156 589 00 32 00 Locating WS05.00-P-
FG 05/Set B
plate 0250B
156 589 00 34 00 Threaded WS05.00-P-
FG 05/Set B
stud 0251B
156 589 00 61 00 Retaining WS05.00-P-
FG 05/Set B
device 0252B
156 589 01 63 00 Clamping WS05.00-P-
FG 05/Set B
tool 0269B
159 589 00 40 00 Retaining WS01.00-P-
FG 01/03/05/Set B
lock 0154B
WS05.00-P-
166 589 00 15 00 Drift FG 05/Set C
0206C
166 589 00 59 00 Insertion WS05.00-P-
FG 05/Set C
plate 0185C
WS05.00-P-
166 589 01 15 00 Drift FG 05/Set C
0207C
168 589 01 40 00 Retaining WS05.00-P-
FG 05/Set C
device 0192C
210 589 00 40 00 Magnetic WS05.00-P-
FG 05/15/Set B
pin 0155B
210 589 01 16 00 Four- WS22.00-P-
FG 22/05/Set B
point drive 0006B
WS05.00-P-
266 589 00 31 00 Tensioner FG 05/Set B
0261B
266 589 00 40 00 Tie-down WS05.00-P-
FG 05/Set B
set 0220B
270 589 00 40 00 Retaining WS01.00-P-
FG 01/03/05/Set B
lock 0160B
270 589 00 61 00 Holding WS05.00-P-
FG 05/Set C
fixture 0019C
WS05.00-P-
270 589 01 07 00 Socket FG 05/Set C
0017C
WS05.00-P-
271 589 00 10 00 Socket FG 05/Set B
0268B
WS03.00-P-
271 589 00 15 00 Drift FG 03/05/Set C
0069C
WS05.00-P-
271 589 00 31 00 Key FG 05/Set B
0214B
271 589 00 59 00 Assembly WS05.00-P-
FG 05/Set C
tool 0202C
271 589 00 61 00 Retaining WS05.00-P-
FG 05/Set C
device 0203C
271 589 01 40 00 Retaining WS05.00-P-
FG 05/Set B
device 0217B
271 589 01 63 00 Assembly WS05.00-P-
FG 05/Set C
inserts 0215C
271 589 02 40 00 Assembly WS05.00-P-
FG 05/Set C
link 0238C
271 589 02 63 00 Assembly WS05.00-P-
FG 03/05/Set C
inserts 0216C
271 589 05 63 00 Assembly WS05.00-P-
FG 05/Set C
inserts 0266C
271 589 06 63 00 Guide WS05.00-P-
FG 05/Set B
plate 0267B
271 589 09 63 00 Assembly WS05.00-P-
FG 03/05/Set B
element 0228B
271 589 10 63 00 Thrust WS05.00-P-
FG 05/Set C
spindle 0232C
271 589 10 63 01 Pressure WS05.00-P-
FG05/Set C
pins 0232-01C
272 589 00 10 00 Torx WS05.00-P-
FG 05/Set B
screwdriver bit T60 0259B
272 589 00 39 00 Rivet WS05.00-P-
FG 05/Set B
press tool 0223B
WS05.00-P-
272 589 00 61 00 Depressor FG 05/Set B
0233B
272 589 00 63 00 Assembly WS05.00-P-
FG 05/Set B
inserts 0224B
272 589 00 91 00 Threaded WS01.00-P-
FG 01/05 Set B
adapter 0125B
WS05.00-P-
272 589 01 63 00 Guide FG 05/Set B
0222B
272 589 03 63 00 Assembly WS05.00-P-
FG 05/Set B
link 0227B
272 589 04 63 00 WS05.00-P-
FG 05/Set B
Compressed air adapter 0258B
WS05.00-P-
273 589 00 61 00 Depressor FG 05/Set B
0256B
276 589 00 40 00 Tie-down WS05.00-P-
FG 05/Set B
set 0271B
276 589 01 40 00 Tie-down WS05.00-P-
FG 05/Set B
set 0274B
278 589 01 63 00 Assembly WS05.00-P-
FG 05/Set C
insert 0273C
285 589 00 40 00 Retaining WS05.00-P-
FG 05/Set C
device 0205C
285 589 01 40 00 Retaining WS05.00-P-
FG 05/Set C
device 0204C
601 589 01 59 00 Assembly WS05.00-P-
FG 05/Set C
board 0104C
601 589 02 23 00 Go/no-go WS05.00-P-
FG 05/Set C
gauge 0105C
601 589 02 43 00 Drift WS05.00-P-
FG 05/Set B
punch 0106B
601 589 02 59 00 WS05.00-P-
FG 05/Set B
Supporting bridge 0107B
601 589 05 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0108C
601 589 05 43 00 Drift WS05.00-P-
FG 05/Set B
punch 0156B
601 589 06 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0109C
601 589 08 21 00 Residual WS05.00-P-
FG 05/Set B
stroke gauge 0110B
601 589 15 63 00 Guide WS05.00-P-
FG 05/Set C
sleeve 0111C
601 589 16 63 00 Thrust WS05.00-P-
FG 05/Set B
piece 0112B
602 589 00 39 00 Riveting WS05.00-P-
FG 05/18/Set C
tool 0162C
602 589 00 40 00 Retaining WS03.00-P-
FG 01/03/05/27 / Set B
lock 0028B
WS05.00-P-
602 589 00 98 00 Case FG 03/05/18/Set C
0158C
602 589 01 40 00 Retainer WS05.00-P-
FG 05/Set C
device 0168C
602 589 02 33 00 Chain WS05.00-P-
FG 05/18/Set C
separating tool 0159C
602 589 02 40 00 Assembly WS05.00-P-
FG 05/18/Set C
links 0171C
602 589 02 63 00 Assembly WS05.00-P-
FG 05/Set C
inserts 0163C
602 589 03 63 00 Thrust WS05.00-P-
FG 05/Set C
piece 0164C
602 589 04 63 00 Thrust WS05.00-P-
FG 03/05/Set C
spindle 0160C
602 589 04 63 01 Pressure WS05.00-P-
FG 03/05/Set C
pins 0160-01C
602 589 05 63 00 Pressure WS05.00-P-
FG 05/18/Set C
screw 0161C
602 589 05 63 01 Pressure WS05.00-P-
FG 05/18/Set C
pins 0161-01C
603 589 01 40 00 Holding WS05.00-P-
FG 05/Set B
wheel 0113B
604 589 00 40 00 Retaining WS05.00-P-
FG 05/Set C
device 0169C
WS05.00-P-
604 589 00 43 00 Drift FG 05/Set B
0114B
WS05.00-P-
605 589 00 33 00 Puller FG 05/Set B
0154B
605 589 00 33 02 Puller WS05.00-P-
FG 05/01/Set B
bolt 0154-01B
606 589 00 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0132C
606 589 00 31 00 Supports WS05.00-P-
FG 05/Set C
(1 pair) 0131C
WS05.00-P-
606 589 00 37 00 Pliers FG 05/Set B
0116B
WS05.00-P-
606 589 00 53 00 Reamer FG 05/Set C
0150C
606 589 01 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0157C
606 589 02 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0167C
WS01.00-P-
611 589 00 63 00 Connector FG 01/05/Set B
0057B
611 589 00 68 10 Round WS01.00-P-
FG 01/05/07/15/Set B
brushes (3 x) 0059-01B
611 589 01 40 00 Retainer WS03.00-N-
FG 03/05/Set B
device 3102B
611 589 01 63 00 Female WS01.00-P-
FG 01/05/Set B
connector 0056B
611 589 02 15 00 Insertion WS05.00-P-
FG 05/Set B
drift 0199B
611 589 02 63 00 WS01.00-P-
FG 01/05/Set B
Intermediate piece 0058B
613 589 00 40 00 Retaining WS05.00-P-
FG 05/Set C
device 0196C
615 589 00 01 00 Valve WS05.00-P-
FG 05/Set A
adjusting wrench 0117A
615 589 00 03 00 Holding WS05.00-P-
FG 05/Set A
wrench 0118A
615 589 00 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0119C
616 589 00 34 00 Threaded WS05.00-P-
FG 05/Set B
bolt 0120B
617 589 00 15 00 Drift WS05.00-P-
FG 05/Set C
punch 0122C
617 589 00 23 00 Slip WS05.00-P-
FG 05/Set A
gauge blades 0123A
617 589 00 40 00 Slip WS05.00-P-
FG 05/Set A
gauge holder 0124A
617 589 00 43 00 Drift WS05.00-P-
FG 05/Set B
punch 0125B
617 589 01 23 00 Slip WS05.00-P-
FG 05/Set A
gauge blades 0126A
617 589 02 23 00 Slip WS05.00-P-
FG 05/Set A
gauge blades 0127A
617 589 03 23 00 Slip WS05.00-P-
FG 05/Set A
gauge blades 0128A
617 589 04 23 00 Slip WS05.00-P-
FG 05/Set A
gauge blades 0129A
617 589 05 23 00 Plug WS05.00-P-
FG 05/Set C
gauge 0130C
WS05.00-P-
628 589 00 15 00 Drift FG 05/Set C
0200C
628 589 00 61 00 Retaining WS05.00-P-
FG 05/Set C
device 0201C
628 589 03 40 00 Retaining WS05.00-P-
FG 05/Set B
device 0213B
629 589 00 61 00 WS05.00-P-
FG 05/Set C
Adaptation 0239C
629 589 01 63 00 Engine WS01.00-P-
FG 01/03/05/27/ Set B
turning device 0137B
629 589 02 63 00 Engine WS01.00-P-
FG 01/03/05/27/ Set B
turning device 0142B
WS05.00-P-
640 589 00 61 00 Depressor FG 05/Set B
0236B
640 589 01 40 00 Hold- WS05.00-P-
Group 05/Set B
down device 0225B
WS05.00-P-
640 589 01 63 00 Guide Group 05/Set B
0218B
640 589 02 63 00 Assembly WS05.00-P-
FG 05/Set B
link 0226B
642 589 00 31 00 WS05.00-P-
FG 05/Set C
Holddown device kit 0230C
642 589 00 33 00 Riveting WS05.00-P-
FG05/18/Set C
tool 0260C
642 589 01 40 00 Tie-down WS05.00-P-
FG 05/Set B
set 0229B
642 589 04 40 00 Tie-down WS05.00-P-
FG 05/Set B
set 0257B
651 589 00 40 00 WS03.00-P-
FG 01/03/05/07/18/ 25/27/Set B
Counterholder 0114B
651 589 01 40 00 Tie-down WS05.00-P-
FG 03/05/Set C
set 0262C
651 589 02 40 00 Retaining WS01.00-P-
FG 01/03/05/Set B
lock 0084B
651 589 02 63 00 Assembly WS03.00-P-
FG 03/05/18/Set C
tool 0111C
651 589 04 63 00 Assembly WS05.00-P-
FG 05/Set C
inserts 0263C
WS05.00-P-
668 589 00 32 00 Plate FG 05/Set C
0188C
668 589 00 59 00 Assembly WS05.00-P-
FG 05/Set C
cartridge 0187C
668 589 00 68 00 Cylinder WS01.00-P-
FG 01/05/07/Set B
brush 0061B
668 589 00 68 05 Cylinder WS01.00-P-
FG 01/05/07/Set B
brushes 0061-01B
668 589 01 59 00 Insertion WS05.00-P-
FG 05/15/27/Set C
plate 0190C
ENGINE
Complete Engine - Testing & Repair - S-Class (221)
TESTING & REPAIR
INSPECT CYLINDERS WITH A LIGHT PROBE - AR01.00-P-0200SMG
ENGINE 156 in MODEL 216, 221
Fig. 1: Identifying Cylinder Inspection Lamp And Flexible Endoscope (Test Probe)
Courtesy of MERCEDES-BENZ USA
Remove/install
Do not touch parts which conduct high voltages.
Risk of death caused by
Persons who wear electronic implants (e.g. heart AS15.10-Z-
contact with parts conducting
pacemakers) should never perform any work on the 0001-01A
high voltages.
ignition system
Risk of injury to skin and
Wear safety gloves, protective clothing and safety AS00.00-Z-
eyes caused by handling hot
glasses, if necessary. 0002-01A
or glowing objects.
Risk of death caused by Align vehicle between columns of vehicle lift and
AS00.00-Z-
vehicle slipping or toppling position four support plates at vehicle lift support
0010-01A
off the lifting platform. points specified by vehicle manufacturer.
Turn key in ignition switch to On vehicles with code 889, Keyless Go:
1
position "0". Press Keyless Go start/stop button repeatedly until
transmitter card or transmitter key from vehicle and
store outside of transmission range (min. 2 m)
Open engine hood and raise to
2
vertical position
AR09.10-
3 Remove air filter housing P-
1150SMG
AR15.12-
4 Remove ignition coils P-
2003SMG
AR15.12-
5 Remove spark plugs P-
1010SMG
Rotate engine at crankshaft
center bolt in the engine's
direction of rotation until
6 Socket Fig. 2
piston of cylinder to be
inspected is at bottom dead
center
Connect cylinder inspection
Cylinder inspection light
lamp (1) and insert flexible
see GOTIS
endoscope (test probe) (2) of
http://gotis.aftersales.mercedes-benz.com
7 cylinder inspection lamp into
cylinder to be inspected Flexible endoscope
through tapped bore of the see GOTIS
spark plug http://gotis.aftersales.mercedes-benz.com
Checking
If there is "scoring" (wear to the cylinder), AR01.30-
Check cylinder wall, piston the cylinder wall has become rough and the honing P-
8
crown and valves marks are no longer visible.
5800SMG
In case of doubt, remove cylinder head:
AH01.00-
General information on
P-0300-
inspecting cylinder walls
01AMG
Inspect the other cylinders in
9
the same way
10 Install in the reverse order
Fig. 2: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
INSPECT CYLINDERS WITH A LIGHT PROBE - AR01.00-P-0200SX
ENGINE 273, 275 in MODEL 216
ENGINE 272, 273, 275 in MODEL 221
Shown on engine 272
Fig. 3: Inspecting Cylinder
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove spark plugs
AP15.10-P-
Replace spark plugs Engine 272, 273
1580SX
AP15.10-P-
Engine 275
1580SZ
Rotate engine at crankshaft center
bolt in the engine's direction of
2 Fig. 2
rotation until piston of cylinder to be
inspected is at bottom dead center
Connect up cylinder illumination
unit (1) and insert flexible endoscope
3
(2) through spark plug bore into
cylinder to be checked
Checking
If condition of the cylinder barrel is
not clearly recognizable, the cylinder head
4 Inspect cylinder walls must be removed. Absolutely observe
General information for checking the
cylinder barrel before removal:
General information on inspecting cylinder AH01.00-P-
walls 0300-01VA
Check other cylinders in the same
5
way
6 Install in the reverse order
Fig. 4: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
TEST THE COMPRESSION PRESSURE - AR01.00-P-1200L
ENGINE 137 in MODEL 215, 220
ENGINE 275 in MODEL 215, 216, 220, 221, 230
ENGINE 285 in MODEL 240
Shown on engine 285 in model 240
Fig. 5: Testing Compression Pressure
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of accident caused by vehicle
Secure vehicle to prevent it from
starting off by itself when engine is
moving by itself.
running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-fitting work
contusions and burns during starting 0005-01A
clothes. Do not touch hot or rotating
procedure or when working near the
parts.
engine as it is running
Only test compression pressure
Bring engine to operating temperature
1 when engine is at normal operating
(approx. 80°C)
temperature.
2 Remove a spark plug from each cylinder See: Replace spark plugs
AP15.10-P-
Model 215, 220, 230
1580L
AP15.10-P-
Model 216, 221
1580SZ
AP15.10-P-
Model 240
1580H
Model 215, 220, 230, 240
Do not crank engine via
electronic ignition switch control unit or AR01.10-P-
3.1 Crank engine with starter.
Start/Stop button since fuel can enter 0110V
into the cylinders and this can distort
the measuring result.
switch on compression recorder (01).
Crank engine for approx. 5
seconds in order to eliminate
combustion residues in cylinder.
Model 216, 221
Do not crank engine via
electronic ignition switch control unit or
Start/Stop button since fuel can enter
into cylinders and this can distort the
Connect up compression recorder (01) and measuring result. AR01.10-P-
3.2
crank engine 0010-01SX
To crank engine, press contact
switch on compression recorder (01).
Crank engine for approx. 5
seconds in order to eliminate
combustion residues in cylinder.
Checking
Press compression recorder (01) onto
4
spark plug hole
Model 215, 220, 230, 240
Do not crank engine via
electronic ignition switch control unit or
start/stop button, because by doing so
the fuel can enter into the cylinders and
this can cause the measuring result to be AR01.10-P-
5.1 Crank engine with starter. distorted. 0110V
To crank engine, press contact
switch on compression recorder (01).
Crank until no further pressure
rise is monitored on compression
recorder (01).
Model 216, 221
Do not crank engine via
electronic ignition switch control unit or
start/stop button, because by doing so
the fuel can enter into the cylinders and
Crank engine with compression recorder this can cause the measuring result to be
5.2
(01) distorted.
To crank engine, press contact
switch on compression recorder (01).
Crank until no further pressure
rise is monitored on compression
recorder (01).
Carry out test procedure on all cylinders
6
in the same way.
new value P-1001-01D
Compression pressure wear limit or *BE01.00-
limit value P-1002-01D
Compression pressure permissible
difference between individual cylinders
If pressure indicated is less
than the minimum compression *BE01.00-
Compare measurements obtained with the pressure or if the permissible difference
7 P-1003-01D
specified pressures between the individual cylinders is
exceeded:
?
Inspect cylinders for leaks
AR01.00-P-
Engine 137, 285
1300HV
AR01.00-P-
Engine 275
1300LA
8 Install in the reverse order
COMPRESSION PRESSURE
Engine 137.970, 275,
Number Designation
285
BE01.00-P-1001-
Compression installation tolerance or new value bar 12 to 14
01D
BE01.00-P-1002-
Compression pressure wear limit or limit value bar 10.0
01D
BE01.00-P-1003- Compression pressure permissible difference between
bar 1.5
01D individual cylinders
TEST COMPRESSION PRESSURE - AR01.00-P-1200SMG
ENGINE 156 in MODEL 216, 221
Fig. 6: Identifying Compression Tester
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well clear of AS00.00-Z-
installing or aligning hoods, doors, moving parts. 0011-01A
trunk lids, tailgates or sliding roof.
Risk of accident caused by vehicle
starting off by itself when engine is Secure vehicle to prevent it from moving
running. Risk of injury caused by by itself. AS00.00-Z-
contusions and burns during starting Wear closed and snug-fitting work clothes. 0005-01A
procedure or when working near the Do not touch hot or rotating parts.
engine as it is running
Test compression pressure only
Bring engine to operating temperature
1 when engine is at normal operating
(approx. 80°C)
temperature.
On vehicles with code 889,
Keyless Go: Press Keyless Go start/stop
Turn key in ignition switch to position button repeatedly until ignition is switched
2
"0". off Remove keyless go transmitter card or
transmitter key from vehicle and store
outside of transmission range (min. 2 m)
Open engine hood and raise to vertical
3
position
AR09.10-P-
4 Remove air filter housing
1150SMG
AR15.12-P-
5 Remove ignition coils
2003SMG
AR15.12-P-
6 Remove spark plugs
1010SMG
The engine is not cranked by
turning the key in ignition switch but by
actuating compression recorder contact
AR01.10-P-
switch.
Connect electrical supply lines for 0010-01GZ
7 Crank engine for about 5 seconds
compression recorder (01) to remove combustion residue from
cylinders.
Compression recorder Fig. 10
Electrical connection set Fig. 11
Checking
Press compression recorder (01) on The sealing cone of compression
8 tapped bore of spark plug of first recorder (01) must tightly seal tapped bore
cylinder of spark plug.
Crank engine with contact switch of
compression recorder (01) until increase
9
in pressure is no longer indicated on
compression recorder
Carry out testing procedure in cylinder
10 order on remaining cylinders in the
same way
Compression installation tolerance or new *BE01.00-
value P-1001-01B
Compression pressure permissible *BE01.00-
difference between individual cylinders P-1002-01B
Compression pressure wear limit or limit
Compare measurements obtained with value
11
the specified pressures If pressure indicated is less than the *BE01.00-
minimum compression pressure or if P-1003-01B
permissible difference between individual
cylinders is exceeded: ?
AR01.00-P-
Inspect cylinders for leaks
1300SMG
12 Install in the reverse order
COMPRESSION PRESSURE
Engine
Number Designation
156
BE01.00-P-1001-
Compression installation tolerance or new value bar 12 to 16
01B
bar < or =2.0
01B cylinders
BE01.00-P-1003-
Compression pressure wear limit or limit value bar 10
01B
Fig. 7: Identifying Compression Tester (001 589 76 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 8: Identifying Electrical Connection Kit (220 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
TEST COMPRESSION PRESSURE - AR01.00-P-1200SX
ENGINES 157, 273, 278 in MODEL 216
ENGINES 157, 272, 273, 276, 278 in MODEL 221
Fig. 9: Identifying Compression Tester
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of accident caused by vehicle starting offSecure vehicle to prevent it from
by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns during Wear closed and snug-fitting work
0005-01A
starting procedure or when working near the clothes. Do not touch hot or
engine as it is running rotating parts.
Only test compression
Bring engine to operating temperature (approx.
1 pressure when engine is at normal
80°C)
operating temperature.
2 Switch off ignition
Engine 272, 273 AR09.10-P-
3 Remove air filter housing
Engine 157, 276, 278 1150SX
AR15.12-P-
4 Remove ignition coils Engine 272, 273
2003SX
AR15.12-P-
Engine 157, 276, 278
2003MM
AP15.10-P-
5 Remove spark plugs See "Replace spark plugs".
1580SX
AR01.10-P-
6 Connect up compression recorder (01) Except engine 272.974
0010-01SX
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Fig. 10
Fig. 11
Crank engine using contact switch for Except engine 272.974
7.1 compression recorder (01) for approx. 5 To eliminate combustion
seconds residues from the cylinders.
Engine 272.974
7.2 Crank engine with ignition key for approx. 5 s To eliminate combustion
residues from the cylinders.
Checking
The sealing cone of the
Press compression recorder (01) on tapped compression recorder must
8 Fig. 10
bore of spark plug of first cylinder airproof tapped bore of spark plug.
Crank the engine with the contact switch of the
compression recorder (01) until the rise in
9.1 Except engine 272.974
pressure is no longer indicated on the
compression recorder (01)
Crank engine with ignition key with aid of
helper until the increase in pressure is no
9.2 Engine 272.974
longer indicated on the compression recorder
(01)
Carry out testing procedure in the cylinder
10 order on the remaining cylinders in the same
way
Compare measurements obtained with the Compression pressure installation *BE01.00-P-
11
specified pressures tolerance or new value 1001-01B
Compression pressure permissible
*BE01.00-P-
difference between individual
1002-01B
cylinders
Compression pressure wear limit *BE01.00-P-
or limit value 1003-01B
If pressure measured is
less than minimum compression
pressure or if permissible
difference between individual
cylinders is exceeded:?
? AR01.00-P-
Check cylinder leakage. 1300SX
12 Install in the reverse order
COMPRESSION PRESSURE
Number Designation Engine 157 Engine 272 Engine 273
BE01.00-P- Compression pressure bar 12 to 16 12 to 15 12 to 16
1001-01B installation tolerance or
new value
BE01.00-P- Compression pressure bar < or =1.5 < or =1.5 < or =1.5
1002-01B permissible difference
between individual
cylinders
BE01.00-P- Compression pressure wear bar 10 10 10
1003-01B limit or limit value
COMPRESSION PRESSURE
Number Designation Engine 276 Engine 278
BE01.00-P-1001- Compression pressure installation bar 12 to 16 12 to 16
01B tolerance or new value
BE01.00-P-1002- Compression pressure permissible bar < or =1.5 < or =1.5
01B difference between individual
cylinders
BE01.00-P-1003- Compression pressure wear limit bar 10 10
01B or limit value
Fig. 10: Identifying Compression Tester (001 589 76 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 11: Identifying Electrical Connection Kit (220 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
CONNECT CYLINDER LEAKAGE TESTING UNIT - AR01.00-P-1300-01VA
Fig. 12: Identifying Threaded Adapter (272 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
1. Calibrate cylinder leakage tester (04). Cylinder leakage tester (pressure loss) gotis://A 01 04.0
2. Screw threaded adapter (06) to high-pressure testing hose (05).
Fig. 13: Identifying Cylinder Leakage Tester, Threaded Adapter And High-Pressure Testing Hose
Courtesy of MERCEDES-BENZ USA
3. Turn threaded adapter (06) with high-pressure testing hose (05) in tapped bore for spark plug.
4. Mount high-pressure testing hose (05) on cylinder leakage tester (04).
Shown on engine 272.963
Fig. 14: Mounting High-Pressure Testing Hose On Cylinder Leakage Tester
Courtesy of MERCEDES-BENZ USA
FIRING ORDER - AR01.00-P-1300-03HA
Fig. 15: Identifying Firing Order (Engine 273)
Courtesy of MERCEDES-BENZ USA
Engine 137, 275, 285
Fig. 16: Identifying Firing Order (Engine 137, 275, 285)
Courtesy of MERCEDES-BENZ USA
FIRING ORDER - AR01.00-P-1300-03SLR
Engine 155, 156
Fig. 17: Identifying Firing Order
Courtesy of MERCEDES-BENZ USA
INSPECT CYLINDERS FOR LEAKS - AR01.00-P-1300LA
ENGINE 275
Fig. 18: Inspecting Cylinder For Leakage
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury to skin and eyes caused Wear safety gloves, protective clothing AS00.00-Z-
by handling hot or glowing objects. and safety glasses, if necessary. 0002-01A
Do not open cooling system unless
coolant temperature is below 90°C. Open
Risk of injury to skin and eyes caused
cap slowly and release the pressure. Do
by scalding from contact with hot AS20.00-Z-
not pour coolant into beverage
coolant spray. Risk of poisoning 0001-01A
containers.
caused by swallowing coolant.
Wear protective gloves, protective
clothing and safety glasses.
Bring engine to operating temperature Check the cylinder for leaks
1 only when the engine is at normal
(approx. 80°C)
operating temperature.
2 Switch off ignition
Unscrew cap (2) on expansion reservoir
3
(1)
4 Remove oil filler cap (3)
5 Remove spark plugs See: Replace spark plugs
AP15.10-P-
Model 215, 220, 230
1580L
AP15.10-P-
Model 216, 221
1580SZ
Crank engine at crankshaft
center bolt in direction of rotation of
Position piston of cylinder to be engine.
6 checked at top dead center using top
Fig. 2
dead center selector
*WH58.30-Z-
1015-05A
Calibrate testing unit and screw
Connect cylinder leakage testing unit connection hose into spark plug hole.
7
(04) *WH58.30-Z-
1015-05A
Checking
*BE01.00-P-
1001-02Z
*BE01.00-P-
1002-02Z
Pressurize cylinder with compressed air
If the crankshaft rotates: *BE01.00-P-
8 and read off pressure loss on cylinder
? 1003-02Z
leakage testing unit (04)
Install retaining lock for crankshaft.
AR03.30-P-
Model 215, 220, 230
5000B
AR03.30-P-
Model 216, 221
5000SZ
Check other cylinders in firing order of AR01.00-P-
9
the engine 1300-03HA
10 Install in the reverse order
CYLINDER LEAKAGE
All
Number Designation
engines
BE01.00-P-1001-
Cylinder leaktightness permissible loss total indication % < or =25
02Z
BE01.00-P-1002- Cylinder leaktightness permissible losses at valves and cylinder head
% < or =10
02Z gasket
BE01.00-P-1003-
Cylinder leaktightness permissible losses at pistons and piston rings % < or =20
02Z
Fig. 19: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
COMMERCIALLY AVAILABLE TOOLS
Number Designation
WH58.30-Z-1015-05A Cylinder leakage testing unit
INSPECT CYLINDERS FOR LEAKS - AR01.00-P-1300SMG
ENGINE 156 in MODEL 216, 221
Fig. 20: Identifying Cylinder Leakage Tester, Coolant Expansion Reservoir, Cap And Oil Filler Cap
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of accident caused by
vehicle starting off by itself
when engine is running. Risk of Secure vehicle to prevent it from moving by itself.
AS00.00-Z-
injury caused by contusions Wear closed and snug-fitting work clothes. Do not
0005-01A
and burns during starting touch hot or rotating parts.
procedure or when working
near the engine as it is running
Do not open cooling system unless coolant
Risk of injury to skin and eyes
temperature is below 90°C. Open cap slowly and
caused by scalding from contact
release the pressure. Do not pour coolant into AS20.00-Z-
with hot coolant spray. Risk of
beverage containers. 0001-01A
poisoning caused by
Wear protective gloves, protective clothing and
swallowing coolant.
safety glasses.
Bring engine to operating Only check cylinder for leaks when engine
1
temperature (approx. 80 °C) is at normal operating temperature.
On vehicles with code 889, Keyless Go:
Press Keyless Go start/stop button repeatedly until
Remove key from the ignition
2 ignition is switched off Remove keyless go
lock
transmitter card or transmitter key from vehicle and
store outside of transmission range (min. 2 m)
Open engine hood and raise to
3
vertical position
Unscrew cap (1) for coolant
4
expansion reservoir (2)
5 Remove the oil filler cap (3)
AR09.10-
6 Remove air filter housing P-
1150SMG
AR15.12-
7 Remove ignition coils P-
2003SMG
AR15.12-
8 Remove spark plugs P-
1010SMG
Position piston of cylinder to be Crank engine at crankshaft center bolt in
9 checked at top dead center with direction of rotation of engine.
the top dead center selector Socket Fig. 2
AR01.00-
P-1300-
Connect cylinder leakage 01VA
10
testing unit (04)
Cylinder leakage testing unit
http://gotis.aftersales.mercedes-benz.com
Checking
Cylinder leaktightness permissible loss total *BE01.00-
indication P-1001-02Z
Cylinder leaktightness permissible losses at valves *BE01.00-
Pressurize cylinder with and cylinder head gasket P-1002-02Z
compressed air and read off Cylinder leaktightness permissible losses at pistons
11 *BE01.00-
pressure loss on cylinder and piston rings
leakage testing unit (04) P-1003-02Z
If the crankshaft rotates: ?
AR03.30-
Install retaining lock for crankshaft P-
5000SMG
AR01.00-
Check other cylinders in firing
12 P-1300-
order of the engine
03SLR
13 Install in the reverse order
CYLINDER LEAKAGE
All
Number Designation
engines
BE01.00-P-1001-
Cylinder leaktightness permissible loss total indication % < or =25
02Z
BE01.00-P-1002- Cylinder leaktightness permissible losses at valves and cylinder head
% < or =10
02Z gasket
BE01.00-P-1003-
Cylinder leaktightness permissible losses at pistons and piston rings % < or =20
02Z
Fig. 21: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
CHECK CYLINDERS FOR LEAKS - AR01.00-P-1300SX
ENGINES 157, 273, 278 in MODEL 216
Shown on model 221.071 with code (487) Active Body Control (ABC)
Fig. 22: Checking Cylinder For Leaks
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of accident caused by vehicle starting Secure vehicle to prevent it from
off by itself when engine is running. Risk of moving by itself.
AS00.00-Z-
injury caused by contusions and burns Wear closed and snug-fitting work
0005-01A
during starting procedure or when working clothes. Do not touch hot or rotating
near the engine as it is running parts.
Bring engine to operating temperature Only check cylinder for
1 leaks when the engine is at a normal
(approx. 80°C)
operating temperature.
2 Remove key from ignition lock
Do not open cooling system unless
coolant temperature is below 90°C.
Risk of injury to skin and eyes caused by
Open cap slowly and release the
scalding from contact with hot coolant spray. AS20.00-Z-
pressure. Do not pour coolant into
Risk of poisoning caused by swallowing 0001-01A
beverage containers.
coolant.
Wear protective gloves, protective
clothing and safety glasses.
3 Unscrew cover (1) on expansion reservoir (2)
4 Remove the oil filler cap (3)
AP15.10-P-
5 Remove spark plugs See "Replace spark plugs".
1580SX
center bolt in direction of rotation of
Position piston of cylinder to be checked at engine.
6 top dead center with the top dead center Fig. 2
selector Cylinder leakage tester (pressure
loss) gotis://A 01 04.0
AR01.00-P-
7 Connect cylinder leakage tester (04)
1300-01VA
Cylinder leakage tester (pressure Fig. 12
loss) gotis://A 01 04.0
Checking
Charge cylinder with compressed air and read
Cylinder leakage: permissible loss *BE01.00-P-
8 off pressure loss on cylinder leakage tester
total indication 1001-02Z
(04)
Cylinder leaktightness: permissible
*BE01.00-P-
losses at valves and cylinder head
1002-02Z
gasket
Cylinder leaktightness: permissible *BE01.00-P-
losses at pistons and piston rings 1003-02Z
Check other cylinders in firing order of the
9 See "Firing order of the engine":
engine
AR01.00-P-
Engine 272, 273
1300-03HA
AR01.00-P-
Engine 157, 276, 278
1300-03MM
10 Install in the reverse order
CYLINDER LEAKAGE
Number Designation All engines
BE01.00-P-1001-02Z Cylinder leakage: permissible loss total % < or =25
indication
BE01.00-P-1002-02Z Cylinder leaktightness: permissible losses % < or =10
at valves and cylinder head gasket
BE01.00-P-1003-02Z Cylinder leaktightness: permissible losses % < or =20
at pistons and piston rings
Fig. 23: Identifying Wrench Socket (001 589 65 09 00)
Courtesy of MERCEDES-BENZ USA
Fig. 24: Identifying Threaded Adapter (272 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
DISCONNECT/CONNECT ENGINE WIRING HARNESS - AR01.00-P-2410SMG
ENGINES 156 in MODEL 216, 221
Fig. 25: Identifying Engine Wiring Harness Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 26: Identifying Engine Wiring Harness Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 27: Identifying Engine Wiring Harness Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Remove/install
Risk of injury caused by fingers being
pinched or crushed when removing, Keep body parts and limbs well AS00.00-Z-
installing or aligning hoods, doors, trunk lids, clear of moving parts. 0011-01A
liftgates or sliding roof
Align vehicle between columns of
vehicle lift and position four
Risk of death caused by vehicle slipping or AS00.00-Z-
support plates at vehicle lift
toppling off of the lifting platform. 0010-01A
support points specified by vehicle
manufacturer.
AH00.00-N-
Notes on self-locking nuts and bolts All models
0001-01A
Risk of explosion caused by oxyhydrogen gas.
No fire, sparks, open flames or
Risk of poisoning and caustic burns caused
smoking. Wear acid-resistant
by swallowing battery acid. Risk of injury AS54.10-Z-
gloves, clothing and glasses. Only
caused by burns to skin and eyes from battery 0001-01A
pour battery acid into suitable and
acid or when handling damaged lead-acid
appropriately marked containers.
batteries
Insulate ground line as a
protection against unintentional AR54.10-P-
1 Disconnect battery ground line
contact of detached ground line 0003SX
with ground point of battery.
All models
Vehicles with code 889,
Keyless Go: AH54.10-P-
Notes on battery
Switch engine off, remove 0001-01A
Keyless-Go cards from vehicle and
store outside of transmitter range.
2 Open engine hood
Remove left engine ground (W11/3) from
3
longitudinal member
To disconnect connector
Disconnect electrical connectors (9, 10) at
4 (9, 10) pull control unit (N3/10)
ME-SFI [ME] control unit (N3/10)
upwards out of the brackets.
5 Remove cover from fuse box
6 Disconnect electrical connectors (L, M)
Loosen nuts (1a) and unclip engine wiring Lay engine wiring harness
7
harness (4, 4d) at firewall (4, 4d) on engine.
8 Remove cap (6) from front prefuse box (F32)
Remove electrical line (4a, 4b) from front
9
prefuse box (F32)
Remove electrical line (4a, 4c) from starter
10
battery (G1/4)
11 Detach rubber seal (5) from bulkhead
12 Pull out protective cap (3) upwards
Unscrew nut (2) and lay engine wiring harness
13
(4) on engine
Remove cable tie (7) and disconnect electrical
14 connector (8) at ABC suction restrictor valve
(Y86/1)
AR61.20-P-
15 Remove bottom engine compartment paneling
1105SX
Unlatch connectors for O2 sensors from Unclip electrical feed
16
retaining clamps and disconnect lines from retaining clamps.
*BA22.10-
Model 216
Remove bolt (1d) and remove ground strap P-1004-03C
17
(49) from rear engine mount *BA22.10-
Model 221
P-1004-03D
Remove shield (105g) and disconnect
AR27.40-P-
18 connector for electronic transmission control
0700-01SX
(16)
Disconnect electrical connector (12) on
19 Intelligent servo module for DIRECT
SELECT (A80)
Disconnect electrical connector (11) on SPS
20
[PML] solenoid valve (Y10)
21 Install in the reverse order
STAR DIAGNOSIS diagnosis
22 Read out fault memory and erase if necessary
system
Connect STAR DIAGNOSIS and read out AD00.00-P-
fault memory 2000-04A
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
216.371/373/374/376/377/379
BA22.10-P-1004- Bolt connecting rear engine mount to
Nm 50
03C transmission bracket
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
221.02/05/07/095/12/15/17/195
BA22.10-P-1004- Bolt connecting rear engine mount to
Nm 50
03D transmission bracket
DISCONNECT/CONNECT ENGINE WIRING HARNESS - AR01.00-P-2410SX
ENGINES 272, 273 in MODEL 221
ENGINES 273 in MODEL 216
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 28: Identifying ME-SFI Control Unit And Electrical Connectors
Courtesy of MERCEDES-BENZ USA
Shown on model 221.171 with code (487) Active Body Control (ABC), 221 up to 1.06.2008 except code
(809) model year 2009
Fig. 29: Identifying Engine Wiring Harness Components
Courtesy of MERCEDES-BENZ USA
Shown on model 221.186
Fig. 30: Identifying Ground And Screw
Courtesy of MERCEDES-BENZ USA
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 31: Identifying O2 Sensor Connectors, Screws And Electrical Connectors
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of
Risk of death caused by vehicle slipping vehicle lift and position four support AS00.00-Z-
or toppling off of the lifting platform. plates at vehicle lift support points 0010-01A
specified by vehicle manufacturer.
Information on preventing damage to
AH54.00-P-
electronic components due to electrostatic
0001-01A
discharge
Do not touch components and open
lines of the high-voltage on-board
Risk of death when touching components electrical system.
AS54.00-Z-
on vehicles with high-voltage on-board Persons who are carriers of electronic
0001-01A
electrical system implants (e.g. cardiac pacemakers),
must not carry out any work on high-
voltage onboard electrical systems.
Model 221.095 / 195
Perform disable for the high-voltage After completing the work, AR54.10-P-
1 attach initial startup event log together 1150SXH
onboard electrical system
with the disconnection log to the
vehicle file.
Note on high-voltage on-board electrical AH54.00-P-
system 0010-01A
Insulate clamping device of the
Detach ground line(s) from ground line in order to prevent AR54.10-P-
2
battery/batteries inadvertent contact with the ground 0003SX
point of the battery.
Remove left engine ground (W11/3) from
3 Except model 221.095 /195
longitudinal member
Remove right engine ground (W11/2)
4 Vehicles with engine 273 and 4MATIC
from longitudinal member
Unscrew bolt (13) from front cover on Vehicles with engine 273 and 4MATIC *BA01.30-P-
5
cylinder head 1006-01O
Unclip cable duct from bulkhead; remove
6 Model 221.095 / 195
rubber seal (5) from bulkhead to do this
Detach high voltage line from high-
voltage battery and remove bracket for the Model 221.095 / 195
7
high voltage line from the bulkhead and *BA54.10-P-
lay high voltage line on the engine 1036-01C
Fig. 32
8 Remove cover (6) from prefuse box (F32)
Remove electrical lines (4a, 4b) from
9.1 Except model 221.095 /195
prefuse box (F32)
Detach electrical line (4) from prefuse box
9.2 Model 221.095 / 195
(F32) and lay on the engine
Vehicles up to 1.06.2008 except code
Remove electrical lines (4a, 4c) from
10 (809) model year 2009, except model
starter battery (G1/4)
221.095/ 195
11 Detach rubber seal (5) from bulkhead Except model 221.095 /195
Vehicles with engine 273 without
12 Remove bolt (1a) out of bulkhead
4MATIC
13 Pull out protective cap (3) upwards Except model 221.095 /195
Disconnect electrical connector to the
14 Model 221.095 / 195
vacuum pump
Detach control line from electrical
15 refrigerant compressor and place to one Model 221.095 / 195
side
Unscrew nut (2) and lay cable harness (4)
16 Except model 221.095 /195
on engine
17 control unit (N3/10)
18 Disconnect electrical connectors (9, 10)
Disconnect electrical connectors from AR15.12-P-
19 Model 221.095 / 195
rotor position sensor 2139SXH
Remove cable tie (7) and disconnect
Vehicles with code (487) Active Body
20 electrical connector (8) on suction
Control (ABC)
restrictor valve (Y86/1)
Unlatch connectors for O2 sensors Model 221.095 / 195
(G3/3x1, G3/4x1, G3/5x1, G3/6x1) from Disconnect electrical feed line
21
above from retaining clamps and from the retaining clamps and
disconnect disconnect cable tie.
Remove bottom engine compartment AR61.20-P-
22
paneling 1105SX
Unlatch connectors for O2 sensors Except model 221.095 /195
23 (G3/3x1, G3/4x1, G3/5x1, G3/6x1) from Unclip electrical feed lines
retaining clamps and disconnect from retaining clamps.
Remove bolt (1d) and remove ground Vehicles without 4MATIC *BA22.10-P-
24
strap (49) from rear engine mount Model 216 1004-03C
*BA22.10-P-
Model 221 1004-03D
Remove shield (105g) and disconnect
AR27.40-P-
25 connector for electronic transmission
0700-01SX
control (16)
*BA27.40-P-
1019-01A
*BA27.40-P-
1003-01E
Disconnect electrical connector on
electrical transmission oil pump and
26 Model 221.095 / 195
unclip subharness from transmission oil
pan
Disconnect electrical connector (12) on
27 intelligent servo module (A80) and unclip
from transmission oil pan
Disconnect electrical connector (11) on
28 solenoid valve (Y10) and unclip retaining
clips on front axle
29 Install in the reverse order
CYLINDER HEAD
Number Designation Engine 273
BA01.30-P-1006-01O Bolt, front cover to cylinder head M6 Nm 9
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model 216.371/373/374/ Model
Number Designation
376/377/379 216.386/394
BA22.10-P- Bolt connecting rear engine mount to
Nm 50 28
1004-03C transmission bracket
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model 221.02/05/07/
Number Designation
095/12/15/17/ 195
BA22.10-P-1004- Bolt connecting rear engine mount to
Nm 50
03D transmission bracket
HOUSING
Transmission 722.9 in Model 216,
Number Designation
221
BA27.40-P-1003- Bolt, heat shield to transmission
Nm 10
01E housing
HOUSING
Number Designation Transmission 722.9
BA27.40-P-1019-01A Bolt, leaf spring to transmission housing Nm 5
BATTERY
Number Designation Model 221
BA54.10-P-1036-01C Wiring harness to high-voltage battery Nm 5
Fig. 32: Identifying Set Of Protective Covers (001 589 01 91 00)
Courtesy of MERCEDES-BENZ USA
DISCONNECT/CONNECT ENGINE WIRING HARNESS - AR01.00-P-2410SZ
ENGINES 275 in MODEL 216, 221
Fig. 33: Identifying Engine Wiring Harness Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 34: Identifying Engine Wiring Harness Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 35: Identifying Engine Wiring Harness Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off of the
support points specified by vehicle 0010-01A
lifting platform.
manufacturer.
Information on preventing damage
AH54.00-P-
to electronic components due to
0001-01A
electrostatic discharge
Insulate clamping device of the ground AR54.10-P-
1 Detach ground lines from batteries line in order to prevent inadvertent contact
0003SX
with the ground point of the battery.
Remove cap (6r) from front
2
prefuse box (F32).
Remove electrical lines (4a, 4b)
3
from front prefuse box (F32)
Remove electrical lines (4a, 4c)
4
from starter battery (G1/4)
Detach rubber seal (5r) from
5
bulkhead
6 Remove bolt (1r) from bulkhead
Pull out protective cap (3r) from
7
the top
Unscrew nut (2) and place cable
8
harness (4r) on engine
Disconnect cable tie (7) and
9 electrical connector (8) at ABC
suction restrictor valve (Y86/1)
Remove left engine ground
10 (W11/3) from longitudinal
member
Unclip cover (6l) from front left
AR07.08-P-
11 fuse box and ME-SFI [ME] See Remove injection system control unit.
7008SZ
control unit (N3/10)
Disconnect electrical connectors
12 (9a) on ME-SFI [ME] control unit
(N3/10)
Disconnect electrical connectors
13
(9b) on SAM control unit (N10/1)
14 Remove bolt (1l) from bulkhead
Pull out protective cap (3l) from
15 the top and lay cable harness (4l)
on engine
Disconnect connectors for O2
16
sensors (G3/3x1, G3/4x1)
AR61.20-P-
Vehicles without code (Z07) Top protection
Remove bottom engine 1105SX
17
compartment paneling AR61.20-P-
Vehicles with code (Z07) Top protection
1105SXS
Unlatch connectors for O2 sensors
Unclip electric leads from retaining
18 (G3/5x1, G3/6x1) from retaining
clips.
clamps and disconnect
*BA22.10-P-
Remove bolt (1d) and remove Model 216 1004-03C
19 ground strap (49) from rear engine
mount *BA22.10-P-
Model 221 1004-03D
Remove shield (105g) and
disconnect connector for AR27.40-P-
20
electronic transmission control 0700-01SX
(16)
Disconnect electrical connector
21 (12) on intelligent servo module
(A80)
Disconnect electrical connector
22 (11) on SPS [PML] solenoid valve
(Y10)
23 Remove cable ties (11a)
24 Install in the reverse order
Read out fault memory and erase
25
if necessary
Connect STAR DIAGNOSIS and AD00.00-P-
read out fault memory 2000-04A
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
216.371/373/374/376/377/379
BA22.10-P-1004- Bolt connecting rear engine mount to
Nm 50
03C transmission bracket
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Model
Number Designation
221.02/05/07/095/12/15/17/195
BA22.10-P-1004- Bolt connecting rear engine mount to
Nm 50
03D transmission bracket
TESTING AND REPAIR WORK: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE
VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9156AB
ENGINE 156
AR01.00-P-
Check cylinders for leaks ENGINE 156 in MODEL 204, 212
1300CMG
AR01.00-P-
Check cylinders for leaks ENGINE 156 in MODEL 230.470
1300RMG
AR01.10-P-
Crank engine with starter ENGINE 156, 271, 272, 273, 642, 646, 651...
0110CW
AR01.10-P-
Crank engine with starter ENGINE 111, 112, 113, 156, 271...
0110PV
AR01.10-P-
Crank engine with starter ENGINE 156, 272, 273, 275, 642, 651...
0110SX
AR01.10-P-
Crank engine with starter. ENGINE 156 in MODEL 164, 251
0110GZS
AR01.10-P-
Crank engine with starter. ENGINE 156.983 in MODELS 211.077 /277, 219.377
0110TMG
Disconnect, connect engine AR01.00-P-
ENGINE 156 in MODEL 164
wiring harness 2410GZS
Disconnect, connect engine AR01.00-P-
ENGINE 156.982 in MODEL 209.377 /477
wiring harness 2410QMG
Disconnect, connect engine AR01.00-P-
ENGINE 156 in MODEL 251
wiring harness 2410RTS
Disconnect, connect engine AR01.00-P-
ENGINE 156.983 in MODEL 211.077 /277, 219.377
wiring harness 2410TMG
Disconnect/connect engine AR01.00-P-
ENGINES 156 in MODEL 204, 212
wiring harness 2410CMG
Disconnect/connect engine AR01.00-P-
ENGINE 156 in MODEL 230.470
wiring harness 2410RMG
Disconnect/connect engine AR01.00-P-
ENGINES 156 in MODEL 216, 221
wiring harness 2410SMG
AR01.00-P-
Inspect cylinders for leaks ENGINE 156 in MODEL 164, 251
1300GZS
AR01.00-P-
Inspect cylinders for leaks ENGINE 156 in MODEL 216, 221
1300SMG
ENGINE 156.983 in MODELS 211.077 /277, 219.377 AR01.00-P-
Inspect cylinders for leaks
ENGINE 156.982 in MODELS 209.377 /477 1300TMG
Inspect cylinders with a light AR01.00-P-
ENGINE 156 in MODEL 216, 221
probe 0200SMG
Inspecting cylinders with a light AR01.00-P-
ENGINE 156 in MODEL 204, 212
probe 0200CMG
Inspecting cylinders with a light AR01.00-P-
ENGINE 156 in MODEL 164, 251
probe 0200GZS
Inspecting cylinders with a light AR01.00-P-
ENGINE 156 in MODEL 230.470
probe 0200RMG
Inspecting cylinders with light ENGINE 156.983 in MODELS 211.077 /277, 219.377 AR01.00-P-
probe ENGINE 156.982 in MODELS 209.377 /477 0200TMG
Remove, install cylinder head AR01.20-P-
ENGINE 156 in MODEL 164, 251
cover 5014GZS
Remove, install cylinder head AR01.20-P-
ENGINE 156 in MODEL 216, 221
cover 5014SMG
Remove, install cylinder head ENGINE 156.983 in MODELS 211.077 /277, 219.377 AR01.20-P-
cover ENGINE 156.982 in MODELS 209.377 /477 5014TMG
Remove/install bottom part of AR01.45-P-
ENGINE 156 in MODEL 204, 212
oil pan 7555CMG
Remove/install bottom part of AR01.45-P-
ENGINE 156 in MODEL 164, 251
oil pan 7555GZS
Remove/install bottom part of AR01.45-P-
ENGINES 156 in MODEL 230.470
oil pan 7555RMG
Remove/install bottom part of ENGINES 156.982 in MODEL 209.377 /477 AR01.45-P-
oil pan ENGINES 156.983 in MODEL 211.077 /277, 219.377 7555TMG
AR01.20-P-
Remove/install centrifuge ENGINE 156.980 /982 /983 /984
2100AMG
AR01.20-P-
Remove/install centrifuge ENGINES 156 in MODEL 204, 212
2100CMG
AR01.20-P-
Remove/install centrifuge ENGINES 156 in MODEL 230.470
2100RMG
AR01.30-P-
Remove/install cylinder head ENGINES 156 in MODEL 204, 212
5800CMG
AR01.30-P-
Remove/install cylinder head ENGINES 156 in MODEL 164, 251
5800GZS
AR01.30-P-
Remove/install cylinder head ENGINES 156 in MODEL 230.470
5800RMG
AR01.30-P-
Remove/install cylinder head ENGINES 156 in MODEL 216, 221
5800SMG
ENGINES 156.983 in MODEL 211.077 /277, 219.377 AR01.30-P-
Remove/install cylinder head
ENGINES 156.982 in MODEL 209.377 /477 5800TMG
Remove/install cylinder head AR01.20-P-
ENGINES 156 in MODEL 204, 212
cover 5014CMG
Remove/install cylinder head AR01.20-P-
ENGINE 156 in MODEL 230.470
cover 5014RMG
AR01.10-P-
Remove/install engine ENGINES 156 in MODEL 204
2400CMG
AR01.10-P-
Remove/install engine ENGINES 156 in MODEL 212
2400EMG
AR01.10-P-
Remove/install engine ENGINES 156.982 in MODEL 209.377 /477
2400QMG
AR01.10-P-
Remove/install engine ENGINES 156 in MODEL 230.470
2400RMG
AR01.10-P-
Remove/install engine ENGINES 156 in MODEL 221, 216
2400SMG
AR01.10-P-
Remove/install engine ENGINE 156.983 in MODEL 211.077 /277, 219.377
2400TMG
Remove/install engine AR01.10-P-
ENGINES 156 in MODEL 164, 251
from/onto front axle carrier 2510GZS
Remove/install engine with AR01.10-P-
ENGINE 156 in MODEL 164, 251
front axle carrier 2500GZS
AR01.45-P-
Remove/install oil pan ENGINE 156 in MODEL 204, 212
7500CMG
AR01.45-P-
Remove/install oil pan ENGINES 156 in MODEL 164, 251
7500GZS
AR01.45-P-
Remove/install oil pan ENGINES 156.982 in MODEL 209.377 /477
7500QMG
AR01.45-P-
Remove/install oil pan ENGINES 156 in MODEL 230.470
7500RMG
AR01.45-P-
Remove/install oil pan ENGINE 156 in MODEL 216, 221
7500SMG
AR01.45-P-
Remove/install oil pan ENGINES 156.983 in MODEL 211.077 /277, 219.377
7500TMG
Remove/install oil pan bottom AR01.45-P-
ENGINE 156 in MODEL 216, 221
section 7555SMG
Remove/install timing case AR01.40-P-
ENGINE 156
cover 8000AMG
AR01.40-P-
Replace crankcase ENGINE 156
8400AMG
AR01.00-P-
Test compression pressure ENGINE 156 in MODEL 204, 212
1200CMG
AR01.00-P-
Test compression pressure ENGINE 272, 273, 156 in MODEL 230
1200RX
AR01.00-P-
Test compression pressure ENGINE 156 in MODEL 216, 221
1200SMG
ENGINE 156.983 in MODEL 211.077 /277, 219.377 AR01.00-P-
Test compression pressure
ENGINE 156.982 in MODEL 209.377 /477 1200TMG
AR01.00-P-
Testing compression pressure ENGINE 156 in MODEL 164, 251
1200GZS
TESTING AND REPAIR WORK: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE
VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9221AA
MODEL 221
Remove/install end cover MODEL 221.095/ 195 AR01.40-P-8913SXH
TESTING AND REPAIR WORK: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE
VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9273AB
ENGINE 273
AR01.00-P-
Check cylinders for leaks ENGINE 271, 272, 273...
1300CW
AR01.00-P-
Check cylinders for leaks ENGINES 272, 273 in MODEL 212
1300EWS
ENGINES 272, 273 in MODEL 164, 251 AR01.00-P-
Check cylinders for leaks
ENGINES 273 in MODEL 463 1300GZA
ENGINES 157, 273, 278 in MODEL 216 AR01.00-P-
Check cylinders for leaks
ENGINES 157, 272, 273, 276, 278 in MODEL 221 1300SX
AR01.00-P-
Crank engine ENGINE 272, 273...
0100T
AR01.10-P-
Crank engine with starter ENGINE 156, 271, 272, 273, 642, 646, 651...
0110CW
AR01.10-P-
Crank engine with starter ENGINES 272, 273, 642, 651 in MODEL 212
0110EW
AR01.10-P-
Crank engine with starter ENGINE 156, 272, 273, 275, 642, 651...
0110SX
Crank engine with starter. ENGINE 113, 272, 273 in MODEL 164, 251
0110GZ
AR01.10-P-
Crank engine with starter. ENGINE 272, 273 in MODEL 230
0110RX
ENGINE 271, 272, 273 in MODEL 211 ENGINE AR01.10-P-
Crank engine with starter.
272, 273 in MODEL 219 0110TS
Cranking engine using the AR01.10-P-
ENGINE 272, 273...
starter. 0110QB
Disconnect/connect engine AR01.00-P-
ENGINE 272, 273 in MODEL 164, 251
wiring harness 2410GZA
Disconnect/connect engine AR01.00-P-
ENGINES 272, 273 in MODEL 230
wiring harness 2410RX
Disconnect/connect engine ENGINES 272, 273 in MODEL 221 ENGINES 273 in AR01.00-P-
wiring harness MODEL 216 2410SX
AR01.00-P-
Inspect cylinders for leaks ENGINE 272, 273...
1300QB
AR01.00-P-
Inspect cylinders for leaks ENGINE 272, 273 in MODEL 230
1300RX
AR01.00-P-
Inspect cylinders for leaks ENGINE 272, 273 in MODELS 211, 219
1300TS
Inspect cylinders with a light ENGINE 273, 275 in MODEL 216 ENGINE 272, AR01.00-P-
probe 273, 275 in MODEL 221 0200SX
Inspect cylinders with light AR01.00-P-
ENGINE 272, 273 in MODEL 230
probe 0200RX
Inspect cylinders with a light ENGINE 272 in MODEL 204 ENGINE 272, 273 in AR01.00-P-
probe MODEL 207 0200CW
Inspecting cylinders with a light AR01.00-P-
ENGINES 272, 273 in MODEL 212
probe 0200EWS
Inspecting cylinders with a light ENGINES 272, 273 in MODEL 164, 251 ENGINES AR01.00-P-
probe 273 in MODEL 463 0200GZA
Inspecting cylinders with a light AR01.00-P-
ENGINE 272, 273...
probe 0200QB
Inspecting cylinders with light AR01.00-P-
ENGINE 272, 273 in MODELS 211, 219
probe 0200TS
ENGINE 272 in MODEL 204 ENGINE 272, 273 in AR01.40-P-
Measure cylinder bores
MODEL 207 9202CV
AR01.40-P-
Measure cylinder bores ENGINES 272, 273 in MODEL 212
9202EWS
AR01.40-P-
Measure cylinder bores ENGINES 113, 272, 273 in MODEL 164, 251
9202GZ
AR01.40-P-
Measure cylinder bores ENGINE 272, 273...
9202QB
AR01.40-P-
Measure cylinder bores ENGINE 272, 273 in MODELS 211, 219
9202TS
oil pan ENGINE 272, 273... 7555CV
Remove/install bottom part of AR01.45-P-
ENGINE 272, 273...
oil pan 7555CWX
Remove/install bottom part of ENGINES 272, 273 in MODEL 212 Engine with rear AR01.45-P-
oil pan sump 7555EW
Remove/install bottom part of AR01.45-P-
ENGINES 272, 273 in MODEL 164, 251
oil pan 7555GZA
Remove/install bottom part of AR01.45-P-
ENGINE 272, 273...
oil pan 7555QB
Remove/install bottom part of AR01.45-P-
ENGINES 272, 273 in MODEL 230
oil pan 7555RX
Remove/install bottom part of AR01.45-P-
ENGINE 272, 273...
oil pan 7555SW
Remove/install bottom part of AR01.45-P-
ENGINE 272, 273...
oil pan 7555SX
Remove/install bottom part of ENGINES 272, 273 in MODEL 211, 219 Engine with AR01.45-P-
oil pan rear sump 7555TS
Remove/install bottom part of ENGINES 272, 273 in MODEL 211 Vehicles with AR01.45-P-
oil pan front sump 7555TW
ENGINES 272 in MODEL 204 ENGINES 272, 273 in AR01.20-P-
Remove/install centrifuge
MODEL 207 2100CV
AR01.20-P-
Remove/install centrifuge ENGINES 272, 273 in MODEL 212
2100EWS
ENGINES 272, 273 in MODEL 164, 251 AR01.20-P-
Remove/install centrifuge
ENGINES 273 in MODEL 463 2100GZA
AR01.20-P-
Remove/install centrifuge ENGINE 272, 273...
2100QB
AR01.20-P-
Remove/install centrifuge ENGINES 272, 273 in MODEL 230
2100RX
ENGINES 273 in MODEL 216 ENGINES 272, 273 in AR01.20-P-
Remove/install centrifuge
MODEL 221 2100SX
AR01.20-P-
Remove/install centrifuge ENGINES 272, 273 in MODEL 211, 219
2100TS
AR01.20-P-
Remove/install centrifuge cover ENGINE 272, 273...
2120QB
AR01.30-P-
Remove/install cylinder head ENGINE 272, 273...
5800QB
AR01.30-P-
Remove/install cylinder head ENGINE 272, 273...
5800QC
ENGINES 272, 273 in MODEL 230 Left cylinder AR01.30-P-
Remove/install cylinder head
head 5800RX
ENGINES 272, 273 in MODEL 230 Right cylinder AR01.30-P-
Remove/install cylinder head
head 5800RY
Remove/install cylinder head ENGINE 272, 273... 5800SX
AR01.30-P-
Remove/install cylinder head ENGINE 272, 273...
5800SY
ENGINES 272, 273 in MODEL 211, 219 Left AR01.30-P-
Remove/install cylinder head
cylinder head 5800TS
ENGINES 272, 273 in MODEL 211, 219 Right AR01.30-P-
Remove/install cylinder head
cylinder head 5800TT
Remove/install cylinder head AR01.20-P-
ENGINE 272, 273...
cover 5014QB
Remove/install cylinder head AR01.20-P-
ENGINE 272, 273...
cover 5014QC
Remove/install cylinder head ENGINES 272, 273 in MODEL 230 Left cylinder AR01.20-P-
cover head cover 5014RX
Remove/install cylinder head ENGINE 272, 273 in MODEL 230 Right cylinder AR01.20-P-
cover head cover 5014RY
Remove/install cylinder head AR01.20-P-
ENGINE 272, 273...
cover 5014SX
Remove/install cylinder head AR01.20-P-
ENGINE 272, 273...
cover 5014SY
Remove/install cylinder head AR01.20-P-
ENGINE 272, 273...
cover 5014TS
Remove/install cylinder head AR01.20-P-
ENGINE 272, 273...
cover 5014TT
Remove/install engine AR01.10-P-
ENGINE 272, 273, 276, 278, 642...
from/onto front axle carrier 2510CWX
Remove/install engine AR01.10-P-
ENGINE 272, 273 in MODEL 164, 251
from/onto front axle carrier 2510GZA
Remove/install engine AR01.10-P-
ENGINE 272, 273, 275 in MODEL 230
from/onto front axle carrier 2510RX
Remove/install engine AR01.10-P-
ENGINE 272, 273, 275...
from/onto front axle carrier 2510SX
Remove/install engine AR01.10-P-
ENGINE 272, 273...
from/onto front axle carrier 2510TW
Remove/install engine with front ENGINES 272, 273 in MODEL 212 Vehicle with AR01.10-P-
axle carrier 4MATIC 2500EW
Remove/install engine with front AR01.10-P-
ENGINES 272, 273 in MODEL 164, 251
axle carrier 2500GZA
Remove/install engine with front AR01.10-P-
ENGINES 272, 273 in MODEL 230
axle carrier 2500RX
Remove/install engine with front AR01.10-P-
ENGINE 272, 273...
axle carrier 2500SW
Remove/install engine with front ENGINE 272, 273 in MODEL 221 (except AR01.10-P-
axle carrier 221.08 /18) ENGINE 273.961 in MODEL 216 2500SX
axle carrier ENGINES 273.962 in MODEL 211.090 /290 2500TW
Remove/install engine with AR01.10-P-
ENGINE 272, 273...
transmission 2401CV
Remove/install engine with ENGINES 272, 273 in MODEL 212 Vehicles without AR01.10-P-
transmission 4-MATIC 2401EW
Remove/install engine with AR01.10-P-
ENGINE 272, 273...
transmission 2401QB
Remove/install engine with AR01.10-P-
ENGINE 272, 273...
transmission 2401TS
ENGINE 272 in MODEL 204 On left cylinder head
Remove/install front cover on AR01.30-P-
ENGINE 272, 273 in MODEL 207 On left cylinder
cylinder head 5700CVL
head
Remove/install front cover on AR01.30-P-
ENGINE 272, 273...
cylinder head 5700CVR
Remove/install front cover on ENGINES 272, 273 in MODEL 212 Front cover at AR01.30-P-
cylinder head left cylinder head 5700EWL
Remove/install front cover on ENGINES 272, 273 in MODEL 212 Front cover at AR01.30-P-
cylinder head right cylinder head 5700EWR
Remove/install front cover on ENGINE 272, 273 in MODEL 164, 251 Cylinder AR01.30-P-
cylinder head head on the left 5700GZA
Remove/install front cover on ENGINE 272, 273 in MODEL 164, 251 Cylinder AR01.30-P-
cylinder head head on the right 5700GZC
Remove/install front cover on AR01.30-P-
ENGINE 272, 273...
cylinder head 5700QB
Remove/install front cover on AR01.30-P-
ENGINE 272, 273...
cylinder head 5700QC
Remove/install front cover on ENGINES 272, 273 in MODEL 230 Front cover at AR01.30-P-
cylinder head left cylinder head 5700RX
Remove/install front cover on ENGINES 272, 273 in MODEL 230 Front cover at AR01.30-P-
cylinder head right cylinder head 5700RY
Remove/install front cover on AR01.30-P-
ENGINE 272, 273...
cylinder head 5700SX
Remove/install front cover on AR01.30-P-
ENGINE 272, 273...
cylinder head 5700SY
Remove/install front cover on ENGINES 272, 273 in MODEL 211, 219 Front cover AR01.30-P-
cylinder head on left cylinder head 5700TS
Remove/install front cover on ENGINES 272, 273 in MODEL 211, 219 Front cover AR01.30-P-
cylinder head at right cylinder head 5700TT
Remove/install left cylinder ENGINES 272 (except 272.982) in MODEL 204 AR01.20-P-
head cover ENGINES 272, 273 (except 272.984) in MODEL 207 5013CV
Remove/install left cylinder AR01.20-P-
ENGINE 272, 273 (except 272.983) in MODEL 212
head cover 5013EL
Remove/install left cylinder AR01.20-P-
ENGINE 272, 273 in MODEL 164, 251
head cover 5013GZA
AR01.45-P-
Remove/install oil pan ENGINE 272, 273...
7500CV
ENGINES 273 in MODEL 212 Vehicle with rear AR01.45-P-
Remove/install oil pan
sump 7500EW
AR01.45-P-
Remove/install oil pan ENGINE 272, 273...
7500EWX
AR01.45-P-
Remove/install oil pan ENGINES 272, 273 in MODEL 164, 251
7500GZA
AR01.45-P-
Remove/install oil pan ENGINE 272, 273...
7500QB
AR01.45-P-
Remove/install oil pan ENGINE 272, 273 in MODEL 230
7500RX
AR01.45-P-
Remove/install oil pan ENGINE 272, 273...
7500SW
ENGINES 273 in MODEL 216, 221 Vehicles with AR01.45-P-
Remove/install oil pan
front sump 7500SX
AR01.45-P-
Remove/install oil pan ENGINE 272, 273...
7500TS
AR01.45-P-
Remove/install oil pan ENGINE 272, 273...
7500TW
ENGINE 272 in MODEL 204 ENGINE 272, 273 in AR01.20-P-
Remove/install oil separator
MODEL 207 9750CV
AR01.20-P-
Remove/install oil separator ENGINES 272, 273 in MODEL 212
9750EWS
AR01.20-P-
Remove/install oil separator ENGINE 272, 273 in MODEL 164, 251
9750GZA
AR01.20-P-
Remove/install oil separator ENGINE 272, 273...
9750QB
AR01.20-P-
Remove/install oil separator ENGINE 272, 273 in MODEL 230
9750RX
ENGINE 273 in MODEL 216 ENGINE 272, 273 in AR01.20-P-
Remove/install oil separator
MODEL 221 9750SX
AR01.20-P-
Remove/install oil separator ENGINE 272, 273 in MODELS 211, 219
9750TS
Remove/install right cylinder ENGINES 272 in MODEL 204 ENGINES 272, 273 in AR01.30-P-
head MODEL 207 5780CV
Remove/install right cylinder AR01.30-P-
ENGINES 272, 273 in MODEL 212
head 5780EW
Remove/install right cylinder AR01.30-P-
ENGINES 272, 273 in MODEL 164, 251
head 5780GZA
Remove/install right cylinder ENGINES 272 (except 272.982) in MODEL 204 AR01.20-P-
head cover ENGINES 272, 273 (except 272.984) in MODEL 207 5012CV
Remove/install right cylinder AR01.20-P-
ENGINES 272, 273 (except 272.983) in MODEL 212
head cover 5012EL
Remove/install right cylinder AR01.20-P-
ENGINES 272, 273 in MODEL 164, 251
head cover 5012GZA
ENGINES 272 in MODEL 204 ENGINES 272, 273 in AR01.30-P-
Remove/install the cylinder head
MODEL 207 5770CV
AR01.30-P-
Remove/install the cylinder head ENGINES 272, 273 in MODEL 212
5770EW
AR01.30-P-
Remove/install the cylinder head ENGINES 272, 273 in MODEL 164, 251
5770GZA
Remove/install timing case ENGINES 272 in MODEL 204 ENGINES 272, 273 in AR01.40-P-
cover MODEL 207 8000CV
Remove/install timing case AR01.40-P-
ENGINES 272, 273 in MODEL 212
cover 8000EWS
Remove/install timing case AR01.40-P-
ENGINES 272, 273 in MODEL 164, 251
cover 8000GZA
Remove/install timing case AR01.40-P-
ENGINE 272, 273...
cover 8000QB
Remove/install timing case AR01.40-P-
ENGINES 272, 273 in MODEL 230
cover 8000RX
Remove/install timing case AR01.40-P-
ENGINE 272, 273...
cover 8000SX
Remove/install timing case AR01.40-P-
ENGINES 272, 273 in MODEL 211, 219
cover 8000TS
AR01.00-P-
Test compression pressure ENGINE 271, 272, 273...
1200CW
AR01.00-P-
Test compression pressure ENGINE 272, 273 in MODEL 212
1200EWS
ENGINE 272, 273 (except 272.973) in MODEL 164, AR01.00-P-
Test compression pressure
251 1200GZA
AR01.00-P-
Test compression pressure ENGINE 272, 273, 156 in MODEL 230
1200RX
ENGINES 157, 273, 278 in MODEL 216 AR01.00-P-
Test compression pressure
ENGINES 157, 272, 273, 276, 278 in MODEL 221 1200SX
AR01.00-P-
Test compression pressure ENGINE 272, 273 in MODELS 211, 219
1200TS
AR01.00-P-
Testing compression pressure ENGINE 272, 273...
1200QB
TESTING AND REPAIR WORK: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE
VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9275AB
ENGINE 275
AR01.10-P-
Crank engine with starter ENGINE 156, 272, 273, 275, 642, 651...
0110SX
AR01.10-P-
Cranking engine with starter. ENGINE 112, 113, 137, 275, 285...
0110V
AR01.00-P-
Cranking the engine ENGINE 275, 628...
0100M
Disconnect, connect engine AR01.00-P-
ENGINE 112, 113, 275...
wiring harness 2410R
Disconnect/connect engine ENGINE 275 in MODEL 230 with CODE (P99) AR01.00-P-
wiring harness "AMG Black Series" special model 2410RBS
Disconnect/connect engine AR01.00-P-
ENGINES 275 in MODEL 216, 221
wiring harness 2410SZ
AR01.00-P-
Inspect cylinders for leaks ENGINE 275
1300LA
Inspect cylinders with a light AR01.00-P-
ENGINE 112, 113, 137, 275, 285...
probe 0200AU
Inspect cylinders with a light ENGINE 273, 275 in MODEL 216 ENGINE 272, 273, AR01.00-P-
probe 275 in MODEL 221 0200SX
Remove/install bottom part of ENGINES 137 in MODEL 215, 220 ENGINES 275 in AR01.45-P-
oil pan MODELS 215, 216, 220, 221, 230 7555L
AR01.30-P-
Remove/install cylinder head ENGINES 275 in MODELS 215, 216, 220, 221, 230
5800M
Remove/install cylinder head AR01.20-P-
ENGINES 275, 285
cover 5014H
AR01.40-P-
Remove/install end cover ENGINES 275 in MODELS 215, 216, 220, 221, 230
8913MC
AR01.40-P-
Remove/install end cover ENGINES 275 in MODEL 230
8913R
ENGINES 275 in MODEL 215, 220 with CODE (487) AR01.10-P-
Remove/install engine
Active Body Control (ABC) 2400MC
AR01.10-P-
Remove/install engine cover ENGINE 275...
2405IM
AR01.10-P-
Remove/install engine cover ENGINE 275, 285...
2405LA
Remove/install engine AR01.10-P-
ENGINE 272, 273, 275 in MODEL 230
from/onto front axle carrier 2510RX
Remove/install engine AR01.10-P-
ENGINE 272, 273, 275...
from/onto front axle carrier 2510SX
Remove/install engine with ENGINE 275 in MODEL 230 with CODE (P99) AR01.10-P-
front axle carrier "AMG Black Series" special model 2500RBS
Remove/install engine with ENGINE 275 in MODEL 230 except CODE (P99) AR01.10-P-
front axle carrier Special model "AMG Black Series" 2500RC
Remove/install engine with AR01.10-P-
ENGINES 275 in MODEL 216, 221
front axle carrier 2500SZ
Remove/install front cover on ENGINE 275 in MODEL 215, 216, 220, 221, 230 Left AR01.30-P-
cylinder head cover 5700ML
Remove/install front cover on ENGINE 275 in MODEL 215, 216, 220, 221, 230 AR01.30-P-
cylinder head Right cover 5700MR
AR01.45-P-
Remove/install oil pan ENGINE 137, 275...
7500L
AR01.45-P-
Remove/install oil pan ENGINE 275 in MODEL 230
7500RA
AR01.45-P-
Remove/install oil pan ENGINES 275 in MODEL 216, 221
7500SZ
Remove/install timing case AR01.40-P-
ENGINES 275
cover 8000M
ENGINE 137 in MODEL 215, 220 ENGINE 275 in
AR01.00-P-
Test the compression pressure MODEL 215, 216, 220, 221, 230 ENGINE 285 in
1200L
MODEL 240
CONNECT COMPRESSION RECORDER - AR01.10-P-0010-01GZ
Fig. 36: Identifying Compression Tester (001 589 76 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 37: Identifying Electrical Connection Kit (220 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
1. Remove cover (1) of left fuse and relay box in the engine compartment.
Installation: Check rubber seal in cover (1) and replace if necessary. The cover (1) must be
Illustrated on model 164.175
Fig. 38: Identifying Cover
Courtesy of MERCEDES-BENZ USA
2. Detach starter relay (2) from socket.
Illustrated on model 164.175
Fig. 39: Identifying Starter Relay
Courtesy of MERCEDES-BENZ USA
3. Plug corresponding adapter line from electrical connection kit into socket of relay base (see arrow).
4. Connect adapter line to compression recorder line.
5. Clip terminal clamp (4) of compression recorder onto connection (5).
Illustrated on model 164.175
Fig. 40: Clipping Terminal Clamp Of Compression Tester Onto Connection
Courtesy of MERCEDES-BENZ USA
CONNECT COMPRESSION RECORDER - AR01.10-P-0010-01SX
Fig. 41: Identifying Compression Tester (001 589 76 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 42: Identifying Electrical Connection Kit (220 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
1. Remove cover (1) of left fuse and relay box in the engine compartment.
For vehicles with engine 275, the ME-SFI [ME] control unit is located in the cover (1).
Installation: Check seal in cover (1); replace seal if necessary.
2. Unlock plug (2) on driver-side SAM control unit with fuse and relay module (N10/1) and detach.
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 43: Identifying Plug On Driver-Side SAM Control Unit With Fuse And Relay Module
Courtesy of MERCEDES-BENZ USA
3. Connect up compression recorder (01) on starter battery circuit 30 and with adapter line (11) from
electrical connection kit on plug position "7" of connector (2).
The plug positions on the connector (2) are numbered.
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 44: Connecting Compression Recorder
Courtesy of MERCEDES-BENZ USA
CRANK ENGINE WITH STARTER - AR01.10-P-0110SX
ENGINES 156, 272, 273, 275, 642, 651 (except, 272.974) in MODEL 221
ENGINES 156, 273, 275 in MODEL 216
ENGINES 642 in MODEL 212
ENGINES 642 in MODEL 218
Shown on model 221
Fig. 45: Identifying Compression Recorder And Handle
Courtesy of MERCEDES-BENZ USA
Attaching
Secure vehicle to prevent it from
Risk of accident caused by vehicle starting off by
moving by itself.
itself when engine is running. Risk of injury caused AS00.00-Z-
Wear closed and snug-fitting work
by contusions and burns during starting procedure or 0005-01A
clothes. Do not touch hot or
when working near the engine as it is running
rotating parts.
On vehicles with code
Bring transmission into neutral and switch off (889) Keyless Go, press Start-Stop
1
ignition button repeatedly until the ignition
is switched off.
Connect up electrical feed lines for compression AR01.10-P-
2 Engines 272, 273, 275, 642, 651
recorder (1) 0010-01SX
AR01.10-P-
Engine 156
0010-01GZ
Compression recorder Fig. 10
Electrical connection set Fig. 11
Crank engine by pressing contact switch at handle
3
(1a) for the compression recorder (1)
Removal
Disconnect electrical feed lines for compression AR01.10-P-
4 Engines 272, 273, 275, 642, 651
recorder (1) 0010-01SX
AR01.10-P-
Engine 156
0010-01GZ
Compression recorder Fig. 10
Electrical connection set Fig. 11
Fig. 46: Identifying Compression Tester (001 589 76 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 47: Identifying Electrical Connection Kit (220 589 00 99 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ENGINE - AR01.10-P-2400SMG
ENGINES 156 in MODEL 221, 216
Fig. 48: Identifying Engine Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 49: Identifying Engine Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 50: Identifying Engine Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Remove/install
Align vehicle between columns of vehicle lift
Risk of death caused by vehicle
and position four support plates at vehicle lift AS00.00-Z-
slipping or toppling off the lifting
support points specified by vehicle 0010-01A
platform.
manufacturer.
Risk of injury caused by fingers
being pinched or crushed when
Keep body parts and limbs well clear of moving AS00.00-Z-
removing, installing or aligning
parts. 0011-01A
hoods, doors, trunk lids, liftgates
or sliding roof
Risk of explosion caused by
oxyhydrogen gas. Risk of
poisoning and caustic burns No fire, sparks, open flames or smoking. Wear
caused by swallowing battery acid-resistant gloves, clothing and glasses. Only AS54.10-Z-
acid. Risk of injury caused by pour battery acid into suitable and appropriately 0001-01A
burns to skin and eyes from marked containers.
battery acid or when handling
damaged lead-acid batteries
Risk of accident caused by Secure vehicle to prevent it from moving by
vehicle starting off by itself when itself. AS00.00-Z-
engine is running. Risk of injury Wear closed and snug-fitting work clothes. Do 0005-01A
caused by contusions and burns not touch hot or rotating parts.
working near the engine as it is
running
AH00.00-
Notes on self-locking nuts and
All models N-0001-
bolts
01A
Vehicles with code (275) Memory package
(driver seat, steering column, mirrors)
Otherwise the driver seat and steering wheel
move into a different position if the driver door
is opened or closed for example. The upper
1 Deactivate easy entry/exit function
frame may be damaged when the holding
device is installed.
Deactivation ensues via buttons on the
steering wheel in the "Comfort" menu of the
multifunction display.
Vehicles with code (889) Keyless Go:
Turn key in ignition lock to Switch off engine, remove Keyless Go cards
2
position "0" from vehicle and store outside of the
transmission range.
Fix steering wheel in center
3 Holding device Fig. 51
position
Open engine hood and move to
4
vertical position
Insulate ground line as a protection against AR54.10-P-
5 Disconnect battery ground line unintentional contact of detached ground line 0003SX
with ground point of battery.
AH54.10-
Notes on battery All models
P-0001-01A
Secure vehicle on lifting platform AR00.60-P-
6
against falling over 0100SX
AR09.10-P-
7 Remove air filter housing
1150SMG
Vehicles with code (580) Automatic air
conditioning and with code (581) Comfort
AR83.30-P-
8 Discharge air conditioning system automatic air conditioning.
1760SX
Installation: Replace desiccant
cartridge.
AR01.00-P-
9 Disconnect engine wiring harness
2410SMG
Disconnect hose (2) at purge line
10
(3) on engine at the left front
Disconnect vacuum line (5) from Remove clip and lay vacuum line (5)
11
brake booster (20) on brake booster (20) to one side.
igniting, risk of poisoning caused pour fuels into suitable and appropriately
by inhaling and swallowing fuel marked containers. AS47.00-Z-
and risk of injury to eyes and Wear protective clothing when handling fuel. 0001-01A
skin caused by contact with fuel
AR07.03-P-
Detach fuel line (1) from fuel Release fuel pressure with pressure
12 1460-
distributor hose via service valve 01TMG
*BA07.03-
P-1001-01C
Pressure hose Fig. 52
*BF46.20-
Suction off hydraulic fluid out of Power steering
13 P-1001-01A
the power steering (6) oil reservoir
Hand pump Fig. 53
Empty expansion reservoir (7) for Vehicles with code 487, Active Body Control
14 Active Body Control system using (ABC).
a hand pump Hand pump Fig. 53
Remove power steering oil AR46.25-P-
15
reservoir (6) 1000SY
Detach oil line from expansion
Vehicles with code 487, Active Body Control
16 reservoir (7) for Active Body
(ABC).
Control system
Disconnect refrigerant line (8) at
17 separation point (8a) using a Detaching tool Fig. 54
detaching tool
AR20.00-P-
18 Drain coolant at radiator
1142SMG
AH20.00-
Notes on coolant All engines N-2080-
01A
*BF20.00-
Cooling system
P-1001-02U
Detach compensation line (9) on
19
thermostat housing
Detach coolant hose (10) on
20
thermostat housing
Disconnect air line (11) to
21 auxiliary air pump and place to
one side
AR20.40-P-
22 Remove electric fan
5000SMG
Remove bolts (12), locks (13) and unclip hood
Remove upper radiator
23 release cable. Unclip air ducting on the side and
crossmember
remove radiator crossmember upwards.
24
coolant pump (15)
Disconnect coolant hose (16) on
25
front plate connection
Remove lower engine AR61.20-P-
26
compartment paneling 1105SX
*BF18.00-
27 Drain engine oil Engine oil P-1001-01V
See: ?
Detach oil cooler lines from Remove/install oil cooler lines for automatic AR27.55-P-
28
automatic transmission on radiator transmission. 0600SX
Set of stop plugs Fig. 55
Installation: Replace sealing rings.
Disconnect engine oil lines (17) at
29 *BA18.30-
flange connections (18)
P-1016-01B
Detach refrigerant line (19) on *BA83.30-
30
condenser P-1005-01K
Unscrew exhaust system to See: ?
31 manifolds, brackets and on AR49.10-P-
transmission Remove/install components for exhaust system
7100SX
Transmission jack
See GOTIS
Support transmission with http://gotis.aftersales.mercedes-benz.com
32
transmission jack Transmission platform
See GOTIS
http://gotis.aftersales.mercedes-benz.c
Remove engine crossmember (21) AR22.10-P-
33
and engine mount (22) 1180SX
Disconnect propeller shaft (23) on Removal: The flex disk (24) remains
34
transmission on the propeller shaft (23).
Install rear engine crossmember
35
(21)
AR22.10-P-
36 Detach front engine mount Only remove bolts on the underside.
1260SX
Detach retaining plate (25) for *BA46.20-
37 pressure and return line to the P-1003-
power steering 01M
Unscrew bracket (26) of pressure
38
line
Disconnect electrical connector to
39
the power steering pump
40 Attach protective cover to cooler
Unscrew servo oil line (29) on
41
bracket (30)
Remove pressure line (27) at
42
power steering pump (28)
Engine hoist
Hook engine hoist into engine
43 See GOTIS
lifting eyes
http://gotis.aftersales.mercedes-benz.com
When lifting out the engine, ensure that
44 Lift out engine no components in the engine compartment are
damaged.
45 Install in the reverse order
AR20.00-P-
1142SMG
46 Fill cooling system
*BF20.00-
Coolant P-1001-02U
AR20.00-P-
47 Inspect cooling system for leaks
1010SX
Fill power steering pump and AR46.30-P-
48
bleed 0010SX
49 Check engine oil level
Check transmission oil level and AR27.00-P-
50
correct if necessary 0270W
51 Perform basic programming
Faults which may have been caused by
Read out fault memory and erase disconnecting wires or by a simulation must be
52
if necessary erased in the fault memory after completing the
work.
Connect STAR DIAGNOSIS and AD00.00-P-
STAR DIAGNOSIS diagnosis system
read out fault memory 2000-04A
INJECTORS, INJECTION VALVES, LINES
Number Designation Engine 156
BA07.03-P-1001-01C Union nut, fuel line to fuel distributor Nm 20
STEERING GEAR
Model 216 except Model 221 except
Number Designation
4MATIC 4MATIC
BA46.20-P- Bolt on clamp plate, high-pressure line /
Nm 20 20
1003-01M return line to rack-and-pinion steering
OIL COOLING SYSTEM
Number Designation Engine 156
BA18.30-P-1016-01B Oil line flange bolt on oil cooler Nm 9
AIR CONDITIONING
Number Designation Model 221 Model 216
BA83.30-P-1005-01K Bolt, high pressure line to fluid reservoir Nm 8 8
STEERING GEAR
Number Designation Model 216 Model 221
Filling capacity Liters approx.1.0 approx.1.0
BF46.20-P-1001- Power
01A steering MB steering gear BB00.40-P-0345- BB00.40-P-0345-
Sheet
oil 00A 00A
COOLING SYSTEM
Engine 156 in model
Number Designation
216, 221
Total filling capacity approx.Liters 10
up to -37°C 50/50
BF20.00-P-1001- Cooling Antifreeze/water
up to -45°C 55/45
02U system
Specifications for Operating Sheet BB00.40-P-0310-01A
Fluids Sheet BB00.40-P-0325-00A
ENGINE LUBRICATION SYSTEM
Engine 156 in model 216,
Number Designation
221
Filling capacity (oil and filter
BF18.00-P-1001- Engine Liters 9.4
change)
01V oil
Specifications for Operating Fluids Sheet BB00.40-P-0229-05A
Fig. 51: Identifying Holding Device (129 589 01 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 52: Identifying Pressure Hose (119 589 04 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 53: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
Fig. 54: Identifying Detaching Tool (211 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 55: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ENGINE COVER - AR01.10-P-2405IM
ENGINES 275.980 in MODEL 215.379, 220.179
ENGINES 275.981 /983 in MODEL 230.479
ENGINES 275.982 in MODEL 221.179, 216.379
Fig. 56: Identifying Engine Cover Components
Courtesy of MERCEDES-BENZ USA
Remove/install
1 Remove the air intake pipe
Unclip mounting clamps (5, 2
2
pieces) for rear engine cover (2)
Pull out rear engine cover (2) from Installation: Ensure that the rubbers in the guides
3
the guides (4) and remove it (4) are positioned correctly.
While unclipping, lift carefully in the area of the
respective mounting clamp (3) otherwise the front engine
4 Unclip mounting clip (3, 5 pieces) cover (1) can break.
Lift front engine cover (1) first to the front and
then laterally a little to the right and to the left.
5 Remove front engine cover (1)
6 Install in the reverse order
REMOVE/INSTALL ENGINE COVER - AR01.10-P-2405LA
ENGINE 275.950 in MODEL 215.376, 220.176
ENGINE 275.951 in MODEL 230.476
ENGINE 275.953 in MODEL 216.376, 221.176
ENGINE 275.954 in MODEL 230.477
ENGINE 285 in MODEL 240
Fig. 57: Identifying Engine Cover Components
Courtesy of MERCEDES-BENZ USA
Shown on engine 275
Fig. 58: Identifying Front Engine Cover And Mounting Clips
Courtesy of MERCEDES-BENZ USA
Fig. 59: Identifying Rear Engine Cover, Mounting Clip And Bracket
Courtesy of MERCEDES-BENZ USA
Remove/install
Lift the front engine cover (1) in the area of Only lift the front engine cover (1) as far as
1 the mounting clamp (3) (arrow) and unclip the necessary otherwise the engine cover can be
mounting clamp (3) damaged.
Lift the front engine cover (1) in the area of Only lift the front engine cover (1) as far as
2 the mounting clamps (4, 5) and unclip the necessary otherwise the engine cover can be
mounting clamps (4, 5) damaged.
Grip between the front engine cover
3 Unclip mounting clamps (6, 7) (1) and the rear engine cover (2) with one hand
and lift the front engine cover (1).
4 Remove front engine cover (1)
Only lift the rear engine cover (2) as far as
Lift the rear engine cover (2) and unclip the
5 necessary otherwise the engine cover can be
mounting clamps (8)
damaged.
6 Pull out the brackets (9) from the supports on
engine cover (2)
7 Install in the reverse order
POSITION PORTABLE LIFTING PLATFORM - AR01.10-P-2500-01A
The lifting platform (01) is variably adjustable in the vehicle longitudinal direction at the adjusting
screw (03). The mounting plates (2) guided in rails are also variably adjustable in the vehicle longitudinal
direction and transverse direction at the adjusting screw (04) to the transmission and front axle carrier. The
respectively individual mounting plates (2) can be adjusted for height by means of an adjusting rod (05) to the
required tilt of the transmission and front axle carrier.
Fig. 60: Identifying Portable Lifting Platform Components
Courtesy of MERCEDES-BENZ USA
Ensure that no cables of lines get caught when lowering.
1. Position lifting platform (01) with aggregate mount (02) under the front axle carrier (1).
Take note in doing so of even alignment of the mounting plates (2) on the engine / transmission
unit.
Fig. 61: Positioning Lifting Platform
Courtesy of MERCEDES-BENZ USA
2. Fix the whole engine / transmission unit by means of tensioning straps (3) to the mounting plates (2).
Fig. 62: Fixing Engine/Transmission Unit
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ENGINE WITH FRONT AXLE CARRIER - AR01.10-P-2500SW
ENGINES 272.975 in MODEL 221.08 /18
ENGINES 273.924 /968 in MODEL 221.08 /18
ENGINES 273.968 in MODEL 216.38
Fig. 63: Identifying Front Axle Carrier Components (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 64: Identifying Front Axle Carrier Components (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Fig. 65: Identifying Front Axle Carrier Components (3 Of 3)
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value changed: Self-locking nut on flex disk at transmission and front *BA41.10-P-1001-
25.6.10
propeller shaft, M12 01H
Remove/install
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
AH32.22-P-
Notes on AIRmatic
1000-02SX
Installation Only tighten nuts
and bolts of chassis components when
vehicle is in a ready-to-drive condition.
Set DIRECT SELECT gear selector
1 switch to position "N" and release
parking brake
Reduce pressure in front suspension
2
struts to zero using STAR DIAGNOSIS
AR54.30-P-
Vehicles with memory package (driver
3 Deactivate easy entry/exit function 1000-
seat, steering column, mirrors) code 275
02ESX
The steering wheel must not be turned
Move front wheels to straight-ahead when the steering coupling is detached,
4
position and secure steering wheel. otherwise the clock spring contact will be
Fig. 51
AR00.60-P-
5 Secure vehicle on vehicle lift
0100SX
AR09.10-P-
6 Remove air filter housing
1150SX
Suction refrigerant out of air AR83.30-P-
7
conditioning 1760SX
AR01.00-P-
8 Pinch off engine wiring harness
2410SX
Detach purge line (4) from vacuum line
9
(5)
Detach vacuum line (6) on resonance
10
intake manifold
Empty power steering expansion
11
reservoir Fig. 53
Open hose clamps (2) and detach hoses Seal lines.
12
(3a) from return lines (3b) Fig. 55
Unscrew nuts (1a) and remove return *BA46.30-
13
lines (3b) from longitudinal member P-1011-01F
Detach refrigerant line at separation
14
point (20) Fig. 54
Remove nut (1b) and detach refrigerant *BA83.55-
15
line (16) from fluid reservoir (16a) P-1002-01M
AR20.00-P-
16 Drain coolant at radiator
1142SX
Detach oil cooler lines from automatic AR27.55-P-
17
transmission on radiator 0600SYZ
Remove bolt (33a), open clamp (33b) Engine 273 AR09.41-P-
18
and remove coolant pipe (33) See "Disconnect Henn coupling". 1311-01AL
Detach coolant line (32b) from coolant AR09.41-P-
19 See "Disconnect Henn coupling".
pump (34) 1311-01AL
Remove coolant line (32c) from heating AR09.41-P-
20 See "Disconnect Henn coupling".
system shutoff valve 1311-01AL
Remove catalytic converter or front AR49.10-P-
21
exhaust system 7100SX
AR46.10-P-
22 Disconnect steering coupling
8000SX
Introduce colored identification
of propeller shaft position relative to
Detach propeller shaft (22) from transfer transfer case output flange in order to AR41.10-P-
23
case reproduce installation position created at 0050-02SX
plant when installing since drive line
vibrations can occur otherwise.
shaft on transfer case. 0050-07SX
*BA41.10-
P-1001-01H
24 Remove bracket (24)
25 Remove front wheels
AP40.10-P-
Remove/install wheels
4050SX
Disconnect electrical connector from
RPM sensors, right front brake pad Unclip electrical lines from AR33.10-P-
26
contact sensor and damping valve unit brackets. 0100-06SX
connector for front axle on left and right
Fix brake caliper with attached
Detach brake caliper from brake caliper AR42.10-P-
27 lines to upper transverse control arms
support 0070SX
using cable ties.
Remove upper transverse control arm AR33.20-P-
28
from steering knuckles 0500-01SX
*BA33.20-
P-1007-01M
Fig. 71
Fig. 72
Detach suspension struts from spring AR32.25-P-
29
control arms 1017SYZ
AR07.03-P-
30 Relieve fuel pressure
1460-01VA
*BA07.03-
P-1004-01B
Fig. 52
Remove fuel feed line (8) from fuel *BA07.03-
31
distributor rail (9) P-1001-01B
Fig. 55
Support front axle carrier using the AR01.10-P-
32
lifting platform 2500-01A
Remove bolts (23a) of rear engine *BA22.10-
33 Model 216
crossmember (23) P-1007-03C
*BA22.10-
Model 221 P-1007-03D
Remove front axle carrier bolts from AR33.10-P-
34
longitudinal member 0001SYZ
Lower engine-transmission unit with
35
front axle carrier
36 Install in the reverse order
AR46.30-P-
37 Fill power steering pump and bleed
0010SX
AR40.20-P-
38 Perform wheel alignment check
0200SX
Read out fault memory using STAR
39
DIAGNOSIS and erase if necessary
Connect STAR DIAGNOSIS and read AD00.00-P-
out fault memory 2000-04A
Risk of accident caused by vehicle
Secure vehicle to prevent it from moving
starting off by itself when engine is
by itself.
running. Risk of injury caused by AS00.00-Z-
Wear closed and snug-fitting work
contusions and burns during starting 0005-01A
clothes. Do not touch hot or rotating
procedure or when working near the
parts.
engine as it is running
Carry out engine test run and check
40
engine for proper operation and leaks
POWER STEERING PUMP
Model 216 without Model 221 without
Number Designation code 487 code 487
BA46.30-P-1011- Nut, return line Nm 10 10
01F bracket to
longitudinal member
REFRIGERANT COMPRESSOR
Engine Engine
Number Designation
272 273
BA83.55-P-1002- Nut connecting refrigerant line to air conditioning fluid
Nm 8 8
01M reservoir
PROPELLER SHAFT
Model Model
Number Designation
216 221
BA41.10-P-1001- Self-locking nut, flex disk to transmission or front
M12 Nm 68 68
01H propeller shaft
INJECTORS, INJECTION VALVES, LINES
Number Designation Engine 272 Engine 273
BA07.03-P-1001-01B Union nut, fuel line to fuel distributor Nm 20 20
BA07.03-P-1004-01B Protective cap on service valve Plastic Nm 2 -
Metal Nm 15 -
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Number Designation Model 221.08/094/18/ 194
BA22.10-P-1007-03D Bolt, rear engine crossmember to body Nm 45
ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS
Number Designation Model 216.386/394
BA22.10-P-1007-03C Bolt, rear engine crossmember to body Nm 45
WHEEL LOCATION, HUB
Model 221.08/09/18/19 with Model 216
Number Designation
4MATIC without code Z07 with 4MATIC
Self-locking nut, upper
BA33.20-P- Stage
wishbone follower joint to Nm 20 20
1007-01M 1
steering knuckle
Stage
Angle° 90 90
2
Fig. 66: Identifying Set Of Stop Plugs (129 589 00 91 00)
Courtesy of MERCEDES-BENZ USA
Fig. 67: Identifying Holding Device (129 589 01 21 00)
Courtesy of MERCEDES-BENZ USA
Fig. 68: Identifying Hand Pump (210 589 00 71 00)
Courtesy of MERCEDES-BENZ USA
Fig. 69: Identifying Detaching Tool (211 589 00 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 70: Identifying Pressure Hose (119 589 04 63 00)
Courtesy of MERCEDES-BENZ USA
Fig. 71: Identifying Puller (140 589 00 33 00)
Courtesy of MERCEDES-BENZ USA
Fig. 72: Identifying Thrust Washer M10x1.5 (210 589 04 63 00)
Courtesy of MERCEDES-BENZ USA
REMOVE/INSTALL ENGINE WITH FRONT AXLE CARRIER - AR01.10-P-2500SX
ENGINE 272, 273 in MODEL 221 (except 221.08 /18)
ENGINE 273.961 in MODEL 216
Shown on model 221.171 with code (487) Active Body Control (ABC)
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 73: Identifying Engine Components - Model 221.171 With Code 487 Active Body Control (1 Of 3)
Courtesy of MERCEDES-BENZ USA
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 74: Identifying Engine Components - Model 221.171 With Code 487 Active Body Control (2 Of 3)
Courtesy of MERCEDES-BENZ USA
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 75: Identifying Engine Components - Model 221.171 With Code 487 Active Body Control (3 Of 3)
Courtesy of MERCEDES-BENZ USA
Model 216
Fig. 76: Identifying Refrigerant Line And Separation Point (Model 216)
Courtesy of MERCEDES-BENZ USA
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 77: Identifying Engine Components - Model 221.171 With Code 487 Active Body Control
Courtesy of MERCEDES-BENZ USA
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 78: Identifying Front Axle Carrier & Bolts
Courtesy of MERCEDES-BENZ USA
Shown on model 221.171 with code (487) Active Body Control (ABC)
Fig. 79: Identifying Front Axle Carrier Components
Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES
Value modified: Self-locking nut of flex disk to transmission or front *BA41.10-P-1001-
29.6.10
propeller shaft, M12 01H
Remove/Install
AH00.00-N-
Notes on self-locking nuts and bolts
0001-01A
Notes on Active Body Control AH32.50-P-
suspension 0001-01N
AH32.22-P-
Notes on AIRmatic
1000-02SX
Installation: Tighten nuts and
bolts of chassis components only when
vehicle is in the ready-to-drive condition.
Set DIRECT SELECT gear selector
1 switch to position "N" and release
parking brake
Reduce pressure in front suspension
2 struts to zero using STAR Vehicles with AIRmatic
DIAGNOSIS
read out fault memory 2000-04A
AR54.30-P-
Vehicles with memory package (driver seat,
3 Deactivate easy entry/exit function 1000-
steering column, mirrors) code 275
02ESX
The steering wheel must not be turned
Turn front wheels to straight-ahead when the steering coupling is detached,
4 position and secure steering wheel otherwise the clock spring contact will be
with holding device destroyed.
Fig. 51
Do not touch components and open lines of
the high-voltage on-board electrical system.
Risk of death when touching
Persons who are carriers of electronic AS54.00-Z-
components on vehicles with high-
implants (e.g. cardiac pacemakers), must 0001-01A
voltage on-board electrical system
not carry out any work on high-voltage on-
board electrical systems.
Model 221.095 / 195
Perform disable for high-voltage on- Include initial startup event log AR54.10-P-
5
board electrical system together with the disable power event log in 1150SXH
the vehicle file after conclusion of the work.
Note on high-voltage on-board AH54.00-P-
electrical system 0010-01A
Insulate clamping device of the ground AR54.10-P-
Remove ground line(s) for battery
6 line in order to prevent inadvertent contact 0003SX
(batteries)
with the ground point of the battery.
AH54.10-P-
Notes on battery
0001-01A
AR00.60-P-
7 Secure vehicle on vehicle lift
0100SX
AR09.10-P-
8 Remove air filter housing
1150SX
Suction refrigerant out of air Vehicles with engine 272.974 and engine AR83.30-P-
9
conditioning 273 1760SX
AR01.00-P-
10 Detach engine wiring harness
2410SX
Detach purge line (4) from vacuum
11
line (5)
Detach vacuum line (6) on resonance
12.1 Except model 221.095 /195
intake manifold
Remove vacuum line (6) to
12.2 Model 221.095 / 195
connecting point for brake booster
AR07.03-P-
1460-01VA
Use service valve to reduce fuel
13 Fig. 52
pressure on fuel distributor rail (9)
Engine 272
P-1004-01B
Seal connections with plugs.
Remove fuel feed line (8) from fuel *BA07.03-
14
distributor rail (9) P-1001-01B
Fig. 55
Vehicles with AIRmatic without
electrohydraulic power steering (EHPS)
Empty expansion reservoir (10a) of In the case of vehicles with
15.1 AIRmatic the expansion reservoir is located
power steering
directly on the power steering pump.
Fig. 53
Vehicles with AIRmatic and EHPS
For vehicles with AIRmatic and
Empty expansion reservoir for power EHPS the expansion reservoir is located on
15.2 the right side of vehicle directly behind the
steering (EHPS)
lamp unit.
Fig. 53
Vehicles with code (487) Active Body
Empty expansion reservoir (10b) for Control (ABC)
16
the ABC system
Fig. 53
Detach return line (3b) from power
17.1 Vehicles with AIRmatic without EHPS
steering expansion reservoir (10a)
Remove return line (3b) from
expansion reservoir (10a) for power
17.2 Vehicles with AIRmatic and EHPS
steering and from the fan shroud and
lay return line (3b) on engine
Open clamp (12a) and detach oil line
Vehicles with code (487) Active Body
18 (14a) from power steering expansion
Control (ABC)
reservoir (10a)
Open hose clamp (12b) and detach oil
Vehicles with code (487) Active Body
19 line (14b) from ABC system
Control (ABC)
expansion reservoir (10b)
Except model 221.095 /195
Open clamp (2) and detach hose (3a) Close off lines with stop plugs.
20
from return line (3b)
Fig. 55
Remove pressure line D1 from AR46.25-P-
pressure line D2 for power steering Model 221.095 / 195 3015SXH
21
and close off connectors with stop
plugs Fig. 55
Remove nuts (1a) and remove return
22 Except model 221.095 /195
line (3b) from longitudinal member
Vehicles with code (487) Active Body
23 Remove bolt (7a) and detach Control (ABC)
(Y36/1) plugs.
Fig. 55
Remove bolts (15) and detach
Vehicles with code (487) Active Body
24 hydraulic line (17b) from front axle
Control (ABC)
carrier (31)
Remove refrigerant line (20) to Model 221 with engine 272
25.1 connecting point and condenser and
close off connectors with stop plugs Fig. 55
Model 221 with engine 273
Remove bolt (21) and detach
Installation: Replace seal ring.
25.2 refrigerant line (20) from refrigerant
compressor (A9) *BA83.55-
P-1003-01M
Disconnect refrigerant line (20) at Model 216
25.3 separation point (20a) using a
detaching tool Fig. 54
Engine 273
Remove nut (1b) and detach
Installation: Replace seal ring.
26 refrigerant line (16) from fluid
reservoir (16a) *BA83.55-
P-1002-01M
AR13.20-P-
27 Remove poly-V belt Engine 272 except engine 272.974
0001SX
Detach refrigerant compressor (A9)
AR83.55-P-
28 and put it on the side with connected Engine 272 except engine 272.974
5300SX
lines
AR20.00-P-
29 Drain coolant at radiator
1142SX
AH20.00-N-
Notes on coolant
2080-01A
Detach coolant line (32a) from valve AR09.41-P-
30 See "Disconnect Henn coupling".
(Y110) 1311-01AL
Detach coolant line (32b) from AR09.41-P-
31 See "Disconnect Henn coupling".
coolant pump (34) 1311-01AL
Remove coolant line (32c) from AR09.41-P-
32 See "Disconnect Henn coupling".
heating system shutoff valve 1311-01AL
Disconnect coolant line from power
33 electronics to expansion reservoir at Model 221.095 / 195
the connecting point
Disconnect coolant line from power Model 221.095 / 195
34 electronics to DC/DC converter at The coolant line remains on the power
connecting point electronics and on the front axle carrier.
Detach oil cooler lines from AR27.55-P-
35
automatic transmission on radiator 0600SX
Remove catalytic converter or front AR49.10-P-
36
exhaust system 7100SX
Loosen bolts (35) and remove cover
37
panel (35a)
Remove bolt (36) and remove
AR46.10-P-
38 steering coupling (36a) from lower
8000SX
steering shaft
39 Remove front wheels
AP40.10-P-
Remove/install wheels
4050SX
Remove tie rods from steering AR46.40-P-
40
knuckles 0200SX
Remove strut rods from front axle AR33.15-P-
41
carrier (31) 0160SX
AR33.15-P-
Vehicles with AIRmatic
Remove spring control arm from front 0170SX
42
axle carrier (31) Vehicles with code (487) Active Body AR33.15-P-
Control (ABC) 0170SY
Vehicles with AIRmatic
43 Detach link rods from stabilizer bar *BA32.20-
P-1001-02O
Vehicles with AIRmatic
The suspension strut does not need
Detach stabilizer bar from front axle
44 to be removed from the spring control arm.
carrier (31) and take to the rear
*BA32.20-
P-1003-02O
Remove brackets of RPM sensors on Vehicles with code (487) Active Body AR42.30-P-
45
steering knuckles Control (ABC) 0712SX
Vehicles with code (487) Active Body
Control (ABC)
Unscrew nuts (37a) and loosen nuts Nuts (37b) must be loosened so
46
(37b) that the suspension struts can move.
*BA32.25-
P-1001-04L
Support front axle carrier (31) with Ensure even alignment of support
lifting platform and aggregate mount plates.
47 and secure whole engine transmission Major assembly lifting platform / scissors
unit against slipping and falling down pallet forklift
with a tensioning strap gotis://A_01_07.1
Remove rear engine crossmember AR22.10-P-
48
(23) with the rear engine mount 1180SX
Introduce colored identification of
propeller shaft position relative to AR41.10-P-
49
transmission output flange in order when 0050-02SX
installing to reproduce installation position
transmission output flange vibrations can occur.
Installation: Mount propeller shaft AR41.10-P-
on transmission output flange. 0050-07SX
*BA41.10-
P-1001-01H
Installation: Install new bolts.
Remove bolts (31a) of longitudinal
50 *BA33.10-
members
P-1001-01K
Lower engine transmission unit with
51
front axle carrier (31)
52 Install in the reverse order
AR40.20-P-
53 Perform wheel alignment check
0200SX
Risk of accident caused by vehicle
starting off by itself when engine is
running. Risk of injury caused by Secure vehicle to prevent it from moving by
contusions and burns during starting itself. AS00.00-Z-
procedure or when working near the Wear closed and snug-fitting work clothes. 0005-01A
engine as it is running Do not touch hot or rotating parts.
Carry out engine test run and check
54
engine for proper operation and leaks
INJECTORS, INJECTION VALVES, LINES
Number Designation Engine 272 Engine 273
BA07.03-P-1001-01B Union nut, fuel line to fuel distributor Nm 20 20
Plastic Nm 2 -
BA07.03-P-1004-01B Protective cap on service valve
Metal Nm 15 -
SUSPENSION STRUTS
Model 216 without Model 221 with code
Number Designation
4MATIC Z07/Z07+Z19
Stage
Nm 35 30
BA32.25-P- Nut, front suspension strut 1
1001-04L to front end Stage
Nm - 35
2
SUSPENSION STRUTS
Model 221 with Model 221 without 4MATIC and
Number Designation
code 487 (ABC) except code 487, Z07/ Z07+Z19
Stage
Nm 35 30
BA32.25-P- Nut, front suspension 1
1001-04L strut to front end Stage
Nm --
2
FRONT AXLE STABILIZER BAR
Number Designation Model 221
BA32.20-P-1001-02O Nut, link rod to stabilizer bar Nm 90
BA32.20-P-1003-02O Bolt, torsion bar to front axle carrier Nm 50
FRONT AXLE CARRIER
Number Designation Model 216 Model 221
BA33.10-P-1001-01K Bolt, front axle carrier to longitudinal member Nm 180 180
REFRIGERANT COMPRESSOR
Engine Engine
Number Designation
272 273
BA83.55-P-1002- Nut connecting refrigerant line to air conditioning fluid
Nm 8 8
01M reservoir
BA83.55-P-1003-
Bolt, refrigerant line to refrigerant compressor Nm 20 20
01M
PROPELLER SHAFT
Model Model
Number Designation
216 221
BA41.10-P-1001- Self-locking nut of flex disk to transmission or front
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