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1. Engine not running reading approx 50 mA Engine at idle speed and operating temper ature reading fluctuates Engine at idle speed 20 C coolant tem perature simulated with 2 5 kQ tost cable Fig 07 3 20 Oo sensor plug disconnected Reading 5 15 mA Fig 07 3 18 49 07 3 lug EHA Resistance 19 5 OK control unit to temperature sensor plug for continuity see wiring diagram Repair interruption Test brown black wire terminal 10 and black wire terminal 12 between control unit and EHA for continuity Resistance approx 0 Q Replace control unit Repair interruption End of test 50 Engine 102 983 Engine 102 983 Testing acceleration enrichment and air flow sensor position indicator Connect test cable to EHA Set multimeter to mA Simulate 20 C with 2 5 kQ test cable Fig 07 3 20 Disconnect O sensor plug Start en gine increased idle speed Nominal value 5 I 5 mA Increase engine speed Stop engine Deflect air flow sensor plate with adjusting device from fuel quantity comparison tester until the upper edge of the air flow sensor plate is in alignment with lower edge of the cylindrical part of the air funnel Loosen plug of air flow sensor position indicator so that the voltage can be measured at the pins do not disconnect plug Switch on ignition Refer to Fig 07 3 22 Terminal 3 and terminal 1 approx 5 V 0 2 0 5
2. 1054 12255 Fig 05 5 B mm H H mm 9 2 9 8 Caution The valve keepers must not be interchanged with those of the other 102 engines Valve stem seals 202 and 203 Valve stem Material Wire ring ID seal Color D Intake Viton black 6 3 mm Exhaust Viton yellow 7 2 mm D D 203 GE GE ynn EEE ES 1054 1225 1054 12253 Fig 05 6 202 Intake valve stem seal 203 Exhaust valve stem seal Due to the different ID they are not interchangeable Engine 102 983 Checking and adjusting valve clearance The valve clearance is measured between cam base circle and cup type tappet arrows Fig 05 3 Valve clearance in mm Coolant temperature Valve up to 50 C 60 80 C engine cold engine warm Intake 0 10 0 20 0 15 0 25 Exhaust 0 25 0 35 0 30 0 40 If the valve clearance is too large or too small install a thicker or a thinner thrust plate 220 Rg 05 3 There are 23 thrust plates of varying thickness 0 025 mm increments 15 thrust plates are available for repair sector 0 05 mm increments The thickness dimension is stamped into thrust plate A storage box is available for storing thrust plates ref er to special tools For checking and adjusting refer to maintenance jobs The valve clearance must be checked during main tenance service every 24 000 km 15 000 miles and adjusted if required Chain drive SCOR N 1053 12 301 3 Fi
3. Mercedes Benz Mercedes Benz of North America Inc S 2347 SUP Service Mercedes Benz of North America Inc 1988 Reprinted 1993 All rights reserved Reproduction by any means elec tronic or mechanical including photocopying record ing or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from the publisher Published by Mercedes Benz of North America Inc Printed in U S A Order No S 2347 SUP DENTEN Introduction This supplementary manual is the product of existing technical publications It is intended to Supplement Service Manual Engine 102 and covers those areas where the 16 valve engine differs from the standard 8 valve engine In Group 07 3 additional information covers fuel system changes for 1987 The material in this manual is divided according to the Mercedes Benz Component Group System as outlined on the GROUP INDEX page This page will quickly direct the reader to the Major Component Group Mercedes Benz of North America Inc recommends that repairs to and maintenance of Mercedes Benz automobiles be performed by trained Mercedes Benz personnel at authorized Mercedes Benz dealerships The information contained in this special publication is ordinarily issued by Mercedes Benz of North America Inc in conjunction with supplementary service literature and special tools supplied only to its authorized dealers The
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5. B of the bracket 29 68 Engine 102 983 Intake manifold exhaust manifold Intake manifold The intake manifold is adapted to installation condi tions and to engine The diameter of the intake ducts per intake valve is approx 26 mm The intake ducts are fork shaped prior to cylinder head As a result each intake valve has one intake duct Fig 14 1 Exhaust manifold The exhaust manifold is designed as a steel pipe ma nifold and enters a dual pipe exhaust system The pipes of cylinder 1 and 4 as well as of cylinder 2 and 3 are joined The pipe diameter is approx 42 mm A sheet metal gasket per cylinder is installed as an exhaust manifold seal 114 28137 Fig 14 2 14 Repair note For removal and installation of exhaust manifold re move screw arrow from heater return flow pipe and pull return flow pipe in direction of engine Fig 14 3 During assembly proceed as follows Insert screw for holder on transmission bell hand tight 2 Tighten nuts for exhaust manifold on cylinder head 3 Tighten screw for holder Catalyst The exhaust system is equipped with two primary ca talysts Fig 14 4 and one under floor catalyst Fig 14 4 69 a 15 Engine 102 983 Electrical system engine Electronic ignitiin system with electronic timing Temperature sensor intake air with electronic con adjustment EZL trol 25 C The ignition system corresponts to that of mode
6. Fig 01 21 Fig 01 22 22 Engine 102 983 Valve cover Remove screws 114 of ignition cable channel cover 113 remove cover pull off spark plug connectors and put ignition cables aside Loosen hose clamp 128 and pull hose 103 from valve cover 81 Pull hose 110 from valve cover remove nuts 96 and remove valve cover Caution if the valve cover is stuck do not strike with a ham mer to loosen it the valve cover may crack Try to loosen the valve cover by pushing at one side with your hands if necessary carefully tap corners with a rubber mallet Camshaft sprockets Set engine to ignition TDC of 1st cylinder For this purpose turn crankshaft until the bores in the camshaft sprockets 2 mm dia arrows are aligned opposite each other Mark camshaft sprockets 4A and 4E and timing chain 21 in relation to each other Fig 01 24 Fig 01 25 01 23 01 Remove alternator air duct Disconnect wires to alter nator at terminal block Pull harness through com ponent compartment wall and put aside with air duct Remove screw 722 loosen screw 723 and rotate alternator 724 away from engine Unscrew chain tensioner 40 at hex head 82 mm Remove screws 241 and flange 239 24 Fig 01 26 Engine 102 983 Pig 01 27 Fig 01 28 Engine 102 983 01 Remove nuts 65 and remove bracket 27 together with slide rail 31 Mote If installed
7. Idle speeds depending on transmission are shown in the following table Idle speeds above 70 C coolant temperature Idle speed rom Manual transmission 890 50 Aoma shift lever position P or N ENER driving position engaged 670 50 1ws St Oiepe W10 X48 _N3 B112U 150r W10 0 75bl sw rae Q75br ws lt gt ad 0 75 io Ziar X48 dee a E B 075br ge g 0 75br ge f S27 2 k Q75gr ge Q75 br W11 0 75gr sw de br W11 Q75 br sw 0 75sw eee 0 75rt ws Q75rt ge 1072 1237112 Fig 07 3 12 Function diagram CIS E gasoline injection system B 2 Air flow sensor position indicator A 56 Plug connection throttle valve switch bl blue B 11 2 Coolant temperature sensor 2 pin X 60 1 Plug connection Oo sensor heating coil br brown B 18 Altitude correction capsule X 60 2 Plug connection Oo sensor signal ge yellow G 3 2 QOo9 sensor heated Y 1 Electrohydraulic actuator EHA gn green K 1 Overvoltage protection relay Y 6 Idle speed air valve gr grey N 3 CIS E control unit 25 pin connector rt red s 27 2 Micro switch deceleration shut off a to Indicator lamp Og sensor malfunction SW es black s 29 2 Throttle valve switch idle and full load contacts t to Fuel pump relay circuit 87 connector ws white w 10 Ground battery terminal 2 w ii Ground engine electric wire connection y to ignition control module connector X 48
8. intake air temperature 18 22 sensor plug pulled off at 4000 rpm with vacuum intake air temperature 29 33 sensor plug pulled off Conventional testers Multimeter SUN DMM 5 SUN EMT I 019 Engine tester Master 3 MCM 2110 Tachometer Available through the MBNA Standard Equipment Program 74 All Test 361 O MB Engine 102 983 15 For test procedure see engine 103 with the following exception Disconnect intake air temperature sensor plug arrow when checking ignition timing at 4000 rpm Fig 15 10 B 17 1 Intake air temperature sensor EZL Spark plugs with conical seat BERU BOSCH CHAMPION Designation Designation Designation Electrode gap Electrode gap Electrode gap Part number Part number Part number 14 K 6 DU 46 DC s7 YC 0 8 0 8 0 8 102 159 1203 102 159 1203 102 159 1203 19 18 Engine 102 983 Engine lubrication Lubrication circuit Fig 18 1 1 OU strainer 6 Bypass valve oil filter element 13 Camshaft intake 2 Oil pump 7 Oil to air cooler 14 Intermediate sprocket 3 Oil pressure relief valve 9 Chain tensioner 15 Idler sprocket 4 Thermostat 110 C 10 Camshaft sprocket exhaust 16 Oil pressure gauge instrument cluster in oil filter housing 11 Camshaft exhaust 17 Oil temperature gauge 5 Oil filter element 12 Camshaft sprocket intake 18 Oil pressure sensor 76 Engine 102 983 18 Oil filling capacities in liters for approved engine oils
9. refer to Specifications for service products Total quantity for initial filling 5 5 Quantity at oil and filter change 5 0 Oil pan max min 4 8 2 8 Oil filter A thermostat 332 b Fig 18 2 in the oil filter controls the oil flow through the oil to air cooler Opening begins at 110 C oil temperature Fully opened at 125 C oil temperature 324 323 320a Poi i Ns ASS z Wes P SS Ceo iA ASS i i S 2v a b 326 RNG WL Sr t 334 geg SC M Ei ll iv IOS 32 JAT O20 O29 238 Fig 18 2 320 Oil filter housing 334 Plug 320a Threaded bushing 335 Seal ring 321 Return tube 336 Cover 323 Valve cone 337 Seal ring 324 Compression spring 338 O ring 325 Spring retainer 339 Center bolt 326 Retaining ring A Connection to oil to air cooler 327 Valve cone B Connection from oil to air cooler 328 Valve seat ring 2 a Supply from oil pump 329 Compression spring b Return flow to oil pan 331 Oil filter element C Uncleaned oil to main oil duct 331 a Rubber seal d Cleaned oil to main oil duct 331 b Rubber seal f Connection for oil 332 a Slide temperature gauge 332 b Thermostat g Connection for oil 333 Compression spring 1 Filter element bypass valve 2 Return flow check valve pressure gauge Note The oil filter is sectioned in different planes to show its function properly Therefore the connections for hoses and sensors are not always shown in the cor rect position Even with the thermostat
10. remove the sheetmetal bracket which is attached at the two front cylinder head bolts and two eyes at timing chain housing cover Fig 01 29 Remove screws 10 four each sprocket knock back camshaft 1A and 1 E with a plastic hammer remove nuts 65 remove bearing caps 61 1 and 61 6 and then remove camshaft sprockets 4A and 4E Fig 01 30 Coolant return pipe between cylinder head and ther mostat housing Loosen hose clamp 38 remove screws 39 remove thermostat housing 29 and put aside Fig 01 31 25 01 Remove screws 402 and pull return pipe 399 out of cylinder head Note If the pipe cannot be pulled out by hand slightly rotate direction of arrow and force off with two screwdrivers also refer to Fig 01 13 Installation Priorto installation measure shaft length L of double hex socket head stretch bolts Double hex socket head stretch bolt Threads Shaft length New Max length replace MIZ 110 mm 113 mm Torque specifications and tightening diagram for cylinder head bolts are identical to other engines 102 Replace O rings and flange gasket on coolant return pipe cylinder head thermostat housing Install intake camshaft sprocket first then exhaust camshaft sprocket Note markings on timing chain and camshaft sprockets Check marking of camshaft sprockets in ignition TDC position of 1st cylinder For mounting and tensioning of poly V belt refer to ma
11. to the A C compressor control unit The CIS E control unit processes the signal and gives a specific signal to the idle speed air valve The control opening in the air valve becomes larger before the A C compressor is engaged and the idle speed deviates only slightly 07 3 Idle speed stabilization on engines with automatic transmission With the selector lever in a driving position the ground connection to the starter is interrupted at ter minal 50 of the starter lockout switch Ground is present in position P and N The control unit processes the signal change and transmits a defined voltage signal to the idle speed air valve so that a specific idle speed will result v WI 075gr sw O75 rt ws SRE 075 9n sw y 075gn sw ee B11 2 1073 12357 1 Fig 07 38 11 Function diagram of electronic idle speed control 1 Fuel distributor W 10 Ground battery bl blue 12 Intake manifold w 11 Ground engine electric wire connection br brown 92 Injection valve Y 6 Idle speed air valve ge yellow 93 Insulating sleeve Y 8 Cold start valve gn green B 11 2 Coolant temperature sensor 2 pin xX 48 Solder terminal in wiring harness gr grey N 3 CIS E control unit 25 pin connector V to overvoltage protection relay pin 2 circuit 87 rt red S 27 2 Micro switch deceleration shut off y to ignition control module connector teminal 1 SW black ws white 07 3 Engine 102 983
12. Designation and repair sizes are identical to other engines 102 1033 12241 1 Fig 03 5 Piston top Engine 102 983 Compared with rings of engine 102 985 the rectangu lar and baffle taper compression rings are lower in height by 0 25 mm Ring height 1 5 or 1 75 mm The chamfered oil control ring is made of a higher strength material The piston wrist pin has been reinforced ID 14 mm Length 65 mm Contrary to engine 102 985 the connecting rods on this engine are guided at the crank pins 03 1033 12240 Fig 03 6 141 Rectangular ring contact surface molyodenum laminated 1 5 mm high 142 Baffle taper compression ring with precision turned contact surface not laminated 1 75 mm high 143 Chamfered oil control ring with expander contact surfaces chromed 29 05 Engine timing valves ss ge 1054 12333 Fig 05 1 Camshaft The hollow bored camshafts are made of chilled cast iron and are left and right of identical design The bearings are supplied with oil through the longi tudinal bore At the rear end the camshaft is closed by a sheet metal cap Each camshaft is mounted in four bearings 28 mm dia 1091 309144 Fig 05 2 30 Engine 102 983 With the camshaft sprocket removed the camshaft can be rotated or counterheld at the 24 mm hex arrows lf the timing is correct the bores 2 mm dia in the camshaft sprockets arrows Fig 05 9 are opposite to
13. Og sensor indicator lamp Electronic clock tachometer Air flow sensor position Indicator Coolant temperature sensor Intake air temperature sensor Altitude correction capsule Electrical center Heated Oo sensor Overvoltage protection relay Fuel pump Fuel pump Electronic Ignition control unit CIS E control unit A C compressor control unit Fuel pump relay with starting valve control and rpm_ limiting Reference resistor Deceleration shut off Throttle valve switch Kick down switch Ground left front wheel housing at ignition coil Ground left rear wheel housing in trunk Ground battery kick down cut out CIS E microswitch full load idle 11 11 14 18 24 26 1 26 3 33 35 36 2 48 56 48 1 48 2 60 1 60 2 lt lt e A De D De e XX X KKK KK XK S OO OO Co oO ee a E ar 15 switt gt Ws eet saia 2 5sw rt wa 2 5 vi ws 0 75 rs bt LTS swige Ca o Af OTS brivi Aen e O7Sgn ge OiGbe Joe 0 75 gn ws O75gn ge KAREN AC CM e 2 An 1071 13 27114 Ground engine connectron point for ground wires Diagnostic Connector Connector Connector Connector Connector Connector socket terminal block circuit 50 tail lamp harness head lamp harness engine headlamp harness 1 pole diagnostic engine stop lamp harness 2 pole CIS E system to cruise control 1 pole circuit TD Ter
14. Solder terminal in wiring harness terminal 1 f to ignition control module EZL connector terminal 2 44 Engine 102 983 07 3 075 sw rt 29 2 Y1 Y8 E e eee e E eg a75rtlge a Geet amp amp gl 75rt ws 5 E L O75gr ge 5 7 2 kWp W 11 075br K wni CO 25rt i S Les X48 5 075br ge RS X48 5 75 gnige 075gn ge eee ees oe HE amp 0 75 bi ws S ON wr 75 bl ge DEE Cas ZS nae a GE a Re 3 A w3 oo S 2 l 5 Kw E i un e E 2 x KRAAAAAAA xn 1071 13 200 G3 Fig 07 3 13 Wiring diagram CIS E gasoline injection system A 1e e10 Indicator lamp O 2 sensor w 11 Ground engine electric wire connection A 1p5 Tachometer x 1 Diagnostic socket wire connector terminal TD B 2 Air flow sensor position indicator x 14 Plug connection circuit 50 B 11 2 Coolant temperature sensor 2 pin xX 18 Plug connection tail lamp harness B 17 2 Intake air temperature sensor x 24 Plug connection head lamp harness B 18 Altitude correction capsule x 33 Plug connection CIS E system to cruise control 1 pin F 1 Electrical center x 35 Plug connection circuit 30 circuit 61 battery G 3 2 O9 sensor heated X 48 Solder terminal in wiring harness K 1 Overvoltage protection relay X 56 Plug connection throttle valve switch M 3 Fuel pump X 60 1 Plug connection On sensor heating coil N 1 2 Ignition control module EZL X 60 2 Plug connection Oa
15. Vatve arrangement Fig 05 3 55 Cylinder head 56 Valve seat ring intake 57 Valve seat ring exhaust 58 Valve guide intake 59 Valve guide exhaust 160E Camshaft intake 160A Camshaft exhaust 196 Intake valve 197 Exhaust valve 198 Valve spring 199 Valve keeper 200 Valve spring retainer 201 Thrust ring 202 Valve stem seal intake valve 203 Valve stem seal exhaust valve 219 Valve tappet 220 Thrust plate E Intake A Exhaust 1013 12180 2 31 05 The intake and exhaust valves two each per cylinder are mounted overhead at an angle of 45 in relation to each other They are actuated by the intake or ex haust camshaft and case hardened cup type valve tappets 219 Intake and exhaust valves Valve seat angle 45 Inta ke valve Valve seat and valve stem bath nitrited Exhaust valve Valve seat is high quality sintered metal Valve stem induction hardened and filled with sodium 4 A EE 197 VFiiLliditititiititiikttitiitttididididititikitditiiddd 1054 9318 1 1054 9317 1 Fig 05 4 196 Intake valve 197 Exhaust valve D 38 mm D 33 mm Di 697 mm o DI 796 mm o L 111 65 mm L 111 5 mm Valve spring 198 Each valve has a double progressive valve spring The spring can be installed in either direction Color code yellow black Refer to special tool section for removal and installa tion tools 32 Engine 102 983 Valve keepers 199
16. each other in ignition TDC position of 1st cylinder Repair notes When replacing camshafts also replace valve tap pets When removing and installing camshafts note instal lation position of bearing caps Refer to Group 01 page 33 Carefully and uniformly tighten fastening nuts of bear ing caps Tightening torque 21 Nm CEET Engine 102 983 Checking valve timing Check valve timing on 1 cylinder Check intake camshaft begin of opening Check exhaust camshaft end of closing The test procedure is the same as on engine 110 see repair instructions on microfiche Engine 110 Mecha nical Il Testing and adjusting values Timing in crank angle degrees at 2 mm valve lift Slip gauge blade on intake camshaft in from outside and on exhaust camshaft from inside Hold down cup type tappet with suitable tool which has no sharp edges Minor deviations approx 4 5 are within tolerance and cannot be corrected If deviations are higher e g due to timing chain elongation install new chain Intake valve opens after TDC Camshafts Code number closes after BDC Exhaust valve opens before BDC closes before TDC with new timing chain Left 7 26 Right 32 13 with used timing chain approx 20 000 km 12 500 mi Left 8 27 Right 31 12 Installed are selectively 102 050 24 01 without code no or 102 050 28 01 with code no 25
17. fully opened a given oil quantity will still flow directly to oil filter element The oil cooler lines are screwed directly into oil filter housing Cup type tappet and cam lubrication Fig 18 1 The cup type tappet and cams are lubricated in an oil Sump Sump lubrication The oil sump is filled with the oil emerging laterally on camshaft bearings leak oil Oil temperature gauge For instrument refer to Group 54 The oil temperature is picked up on the oil filter by a temperature sensor 67 Fig 18 3 The operating temperature of the oil is 80 I 20 C An increase up to max 150 C is permitted If this va lue is exceeded check oil level first Level should not be above max mark 20 Engine cooling Coolant pump To provide sufficient clearance for the cylinder head the long feed connection B arrow has been moved downward Fig 20 1 B Coolant pump Engine 102 983 A Coolant pump Engine 102 985 Repair note Coolant pumps are not interchangeable Thermostat housing and thermostat The thermostat housing is sealed with an O ring to the coolant return flow pipe in the cylinder head 109 Fig 01 1 8 and is fastened by 4 screws Tightening torque 21 Nm The following temperature switches or temperature sensors are screwed into the thermostat housing Temperature sensor for coolant temperature gauge B 13 Engine 102 983 Fig 20 2 2 pin temperature sensor for CIS E inje
18. line 15 inclination Bore stroke mm 95 9 80 25 Comores ratio Io Firing order 3 4 2 Maximum speed rpm 6800 50 eee eee eee Engine output SAE i E kW rpm 125 5800 net bhp rpm 167 5800 Nm rpm 220 4750 net Ib ft rpm 162 4750 Crankshaft bearings 1 anti friction bearings Valve arrangement Overhead 4p per ar cylinder Camshaft arrangement 2 overhead camshafts Oil emeng lt C S Oil to air cooler Bn _ Cooling Coolant circulation pump thermostat with bypass line fan with visco clutch finned tube radiator Lubrication Pressure lubrication via gear type pump Oil filter Full flow filter Air cleaner Dry air filter with paper cartridge 11 00 Filling capacities Model Sales designation Engine Fuel tank reserve approx During initial oil filling approx During oil and filter change approx Marks on dipstick max min approx Cooling system with heater approx Electrical system Model Sales designation Engine Battery Voltage Capacity Starter Bosch Alternator 201 034 190 E 2 3 16 Model Years 1986 87 102 983 7018 5 5 5 5 0 4 8 2 8 8 0 201 034 190 E 23 16 102 983 12v 62 Ah 12 v 1 5 kW 14V70A General technical data Engine 102 983 01 Crankcase cylinder head crankcase ventilation Crankcase The oil deflector plate fastened to crankshaft bearing caps 1 3 prevents splashing of oi
19. of North America Inc assumes no liability for any damage to person or property caused by the utilization of this publication to effect maintenance or repair work on Mercedes Benz automobiles MERCEDES BENZ OF NORTH AMERICA INC Service and Parts Literature Table of contents Engine 102 983 07 3 Mechanically electronically controlled EE gasoline injection system CIS E Views of engine 102 983 7 Ek s2aceaaeteodeonaeetewe 37 Components and function 39 Longitudinal and cross sectional views Mixture preparation 05 40 Of engine 102 983 ccc eee eee eee 8 Component locations and electrical functions 0e 40 00 General technical data 9 Checking electrical components of CIS E injection system 47 01 Crankcase cylinder head crankcase Test and adjustment data 60 ventilation Model year 1987changes 61 Cylinder crankcase eee ees 13 OU pan 429 4 6406 e8 sues oe egos 13 09 Air Dier 67 Cylinder head ww eee ee ee 14 Camshaft bearings 0008 14 13 Belt drive Valve guides eee ee ee es 15 Single belt drive 0 68 Valve seat ringS 2 cee eee eee 16 Spark plug locations 16 14 Intake manifold exhaust manifold 69 Core plugs eee ee ee te te es 17 Connections 17 15 Electrical system engine Cylinder head gasket 18 Electronic ignition system with Valve cover J eee ee ee ee ee 18 electro
20. sensor signal N 3 CIS E control unit 25 pin connector Y 1 Electrohydraulic actuator EHA N 6 A C compressor cut out control unit Y 6 Idle speed air valve N 16 4 Fuel pump relay automatic transmission Y 8 Cold start valve R 17 1 Bridge CIS E S 27 2 Micro switch deceleration shut off e to wire connector circuit 30 fuse and relay box s 29 2 Throttle valve switch idle and full load contacts X to pressure switch A C compressor w 3 Ground left front wheel housing W 6 Ground in trunk on left wheel housing Note Unmarked ground connections are grounded on engine or chassis w 10 Ground battery The wire on terminal 6 circuit 87 K on the fuel pump relay connector does not apply to vehicles with manual transmission 45 07 3 Altitude correction Depending on altitude the amount of fuel is changed based on a signal from the altitude correction capsule B 18 With the ignition switched on or with the engine run ning the altitude correction capsule will receive a constant voltage signal approx 5 volts from the control unit Fig 07 3 14 En Engine 102 983 If the electronic control unit operates in a fixed mode correction for altitude will not take place With increasing altitude i e decreasing air pressure the mixture will be adapted to the altitude by a reduc tion of the voltage Measurements are made between terminal 1 and ter minal 3 of the altitude correction capsule Height above Ba
21. will be determined Note At deviating idle speed too high or too low the voltage signal must be checked on the air flow sen sor Idle speed air valve Designed as a single coil rotary actuator with a two pin connection The adjusting screw for bypass air was eliminated The idle speed air valve has the following functions 1 The electronic control unit supplies a specific volt age to the air valve which determines the respec tive valve opening and thereby the engine speed 2 The nominal idle speed is controlled depending on temperature between 1200 rom at 30 C to 890 50 rom at 70 C 3 With the ignition switched on engine not running the idle speed air valve is activated by a specific voltage The port for the fixed operating mode is closed and the control port is opened d lf the voltage supply fails the port for the fixed Operating mode is opened automatically N N N A N N Sez KE SE p KG WE SW NANI GC K Ml FH NRN AS Qo SI RX ASIS Ll RAAN 8 89 91 87 86 90 84 Fig 07 3 10 84 Spiral spring 89 Aperture valve 85 Shafl 90 Coil cap washer 86 Magnetic coil 91 Hollow shaft 87 Coil Jacket Pr ee ee kb wa Engine 102 983 Rpm stabilization on engines with A C compressor engaged When the air conditioning system is switched on the CIS E control unit terminal 19 is connected to volt age This signal goes over a time delay relay 350 ms
22. 0 075 0 120 mm CH Uf e SS LE ee 57 Repair note One repair size valve seat ring with a larger OD is available for intake and exhaust respectively Spark plug location The spark plug with threads M 14 x 1 25 and tapered sealing seat is centrally located in the combustion chamber Repair note Before unscrewing spark plugs clean out recesses with compressed air This will help prevent dirt from entering the combustion chambers when removing the spark plugs 16 En Engine 102 983 Fig 01 8 56 Intake valve seat ring D 39 100 39 120 mm D1 33mm D2 39 000 39 025 mm H 58 mm 57 Exhaust valve seat ring D 34 100 34 120 mm D1 28mm D2 34 000 34 025 mm H 5 4 mm SS Kg Gei ZE Fig 01 9 a Tapered sealing seat Engine 102 983 Core plugs The core holes in cylinder head are closed with 18 2 mm dia sheet metal plugs 59 the front and lateral oil ducts with 5 2 mm dia sheet metal plugs 57 and the bottom oil duct with a 5 mm dia dowel pin 58 Repair note Leaking plugs can be replaced similar to the other engines 102 Refer to special tools section 101 JOSIE Fig 01 10 Cylinder head right side 57 Sheet metal plug 5 2 mm dia 59 Sheet metal plug 18 2 mm dia e 101 30017 57 59 Fig 01 11 47 Threaded pipe connector for coolant to heater core 57 Sheet metal plug 5 2 mm dia 59 Sheet metal plug 18 2 mm dia 81 Thre
23. 00 Bosch KDJE P600 Push IR 100 button Engine at idle operating temperature Nenna value 35 to 45 at 890 50 min Perform idle speed stabilization test on E I KH Bega 09 o or 100 Test elise surdi according ion wiring dias pieconne plug from idle speed air vane Con nect panel EH to idle epee air valve The idle speed air Aue switches audibly This can also be felt Renla e idle speed air valve gram Switch on ignition Voltage on terminal 2 of ic idle speed air valve plug red yellow wire approx 12 Volts Test red white wire for continuity between ter minal 1 of idle speed air valve plug and terminal 3 of CIS E control unit plug Test et signals Repair Coolant temperature interruption sensor Air flow sensor position indicator d throttle valve switch or 56 e speed contact on CE control unit Fig 07 3 29 Engine 102 983 MATENEE OTTO Engine 102 983 07 3 Engine i Perform tests in both columns Automatic trans mission in gear engaged Engine at idle Engine at idle speed and operat speed and oper ing temperature ating temperature place selector Turn on A C com lever in a driving pressor automatic position transmission in p or N Nominal value 840 to 940 rpm Not OK Test input signa on control unit Measure voltage between terminal 16 and battery on control unit Measure voltage betwee
24. 17 2 Intake air temperature sensor CIS E Engine 102 983 Coolant temperature sensor NTC The coolant temperature is picked up by a dual tem perature sensor arrow One temperature is trans mitted to the CIS E control unit and the other to the electronic ignition control module EZL The nominal test values are the same for both temperature signals Their test values correspond with the coolant temper ature sensor of model 201 024 Fig 07 3 8 CIS E control unit It is located in the component compartment in driv ing direction on the right side arrow Fig 07 3 9 07 3 The basic control functions of start enrichment after Start enrichment warm up acceleration and full load enrichment as well as deceleration shutoff are the Same as previously however the control values are adapted to this engine Cranking enrichment after start enrichment During cranking the microprocessor in the control unit recognizes the cranking speed start of cranking above 30 rpm end of cranking approx 500 rom from rom impulses When the cranking speed is attained the control unit releases the start enrichment and the after start enrichment Extent and duration of enrich ment current on EHA depend on coolant temper ature The input of the cranking signal terminal 50 into the CIS E control unit is eliminated Acceleration enrichment It becomes effective in the warm up stage and with the engine at operating
25. 5 8 bar The pressure is set by manufacturer and cannot be adjusted Fig 07 3 3 40 Diaphragm pressure regulator 50 Supply system pressure 50a Line to fuel cooler 51 Fuel return flow 39 07 3 Mixture preparation The fuel requirement is adapted to the various engine load conditions by wider metering slots 29 in the metering sleeve 28 The air funnel in the air flow sen sor is designed for an air fuel mixture ratio of A 1 For better mixture preparation at idle air is injected around the injection valves similar to engines 1161 117 Note Due to the limited space fuel line 117 070 28 32 must be used for measuring lower chamber pressure at the pressure connection Fig 07 3 4 27 Control plunger 28 Metering sleeve 29 Metering slot Fig 07 3 5 d aM 2 Insulating sleeve 3 Plastic supporting ring a Fuel b c SS BS 1074 11544 Air Fuel air mixture 40 Engine 102 983 Overvoltage protection relay K1 The relay is located in the component compartment in driving direction on the right side K1 The wiring was correspondingly changed Fig 07 3 6 Intake air temperature sensor B17 2 The temperature signal is transmitted to the CIS E control unit The resistance values are identical to the coolant temperature sensor At low ambient temper atures a correction of the acceleration enrichment takes place Fig 07 3 7 B17 1 Intake air temperature sensor EZL B
26. DC position of the com pression stroke Fig 05 9 Repair note The camshaft sprockets need not be removed for re moval and installation of camshafts Single roller chain 21 The single roller chain has 134 links For repairs a timing chain with a connecting link is available The connecting link is riveted with the riveting tool 000 589 58 43 00 as on diesel engines and the rivet set 103 589 01 63 00 pater Mey Myla et ee Engine 102 983 Guide rail 32 Due to the longer timing chain drive the guide rail 32 prevents vibrations between intermediate sprocket and idler sprocket The guide rail is snapped into bracket 33 This bracket is fastened with a pin ina bore at the bottom and at the top with a timing chain housing cover screw at the boss arrow of the cylin der block Fig 05 10 Guide rail 31 Guides the timing chain between the sprockets and floats on the two pins 27a of bracket 27 and is se cured by the lockrings 34 The axial clearance of the guide rail 31 is limited through the use of two spring washers 28 05 Tensioning rail 22 KE Fig 05 12 Version A Version B Engines 102 92 93 96 980 Engine 102 983 The tensioning rail differs in shape and length from that of the other engines 102 They are not inter changeable intermediate sprocket 12 The intermediate sprocket floats on the shaft The shaft is pressed into the cylinder head and closed by a
27. V sensor position indicator Fig 07 3119 Fig 07 3 20 SES Fig 07 3121 07 3 J Test wires between air flow sensor plug and CIS E control unit plug for continuity see wiring diagram for wire colors and terminal E Resistance EE UO Repair Test rpm signali on 1 CIS E control unit ER ter minal 25 WEE Vottage 6 6 12 Volts Repair EN Test wires between CIS E control unit plug and EHA plug for continuity see wiring diagram for wire colors and terminal numbers Resistance approx 0 Q pK Noto OK Not OK ani CIS E control Repair unit DEENS End of test 52 Fig 07 3 22 Engine 102 983 1074 11131 2 Pee yy yyy AE Testing throttle valve switch Disconnect plug between throttle valve switch and CIS E control unit Test resistance of throttle valve switch Idle contact Idle position approx 0 Q Full load position approx Q Full load contact Idle position approx Q Full load position approx 0 Q Partial load position approx oO Note Without an idle speed signal idle speed will be irregular 07 3 Fig 07 3 23 X56 S 29 2 _ AA wh aaan aaa a 1074 12397 1 Fig 07 3 24 S 29 2 Throttle valve switch plug idle and full load contacts full load idle speed stabilization X 56 Throttle valve switch plug 1 Idle contact LL 2 Common 3 Full load contact VL 53 07 3 Engine 102 983 Testing c
28. aded pipe connector for crankcase ventilation coolant heating Cylinder head left side 01 1013 12251 7 57 58 57 Fig 01 12 Cylinder head front 57 Sheet metal plug 5 2 mm dia 58 Dowel pin 5 mm dia Connections A coolant return pipe 23 is inserted at the front of the cylinder head leading through the timing chain housing to a coolant chamber Sealing In the coolant passage with O ring 24 At the mounting flange with gasket 26 tGi 20819 Fig 01 13 A threaded connection for coolant to the heater core 47 and one for the crankcase ventilation heating 81 are screwed into the cylinder head left rear cor ner Fig 01 11 17 01 Cylinder head gasket The cylinder head gasket does not require retorquing There is only one gasket version for this engine independent of cylinder dia standard repair sizes 0 5 mm dia and 1 O mm dia The gasket has an adhesive strip on the sealing sur face It is identified by the stamped in part number and by the relief holes arrows Caution Do not interchange this cylinder head gasket with those of other 102 engines 191 3091868 Fig 01 14 Valve cover The valve cover is made of a magnesium alloy and is laminated with black plastic on the outside The ignition cable channel cover is plastic 113 It is fastened with three plastic screws 114 and sealed with a rubber gasket To prevent excessive tightening which could da
29. ction and EZL ignition system B 1 1 2 100 C temperature switch for fan clutch S 25 1 Thermovacuum valve for fuel evaporation system 38 Temperature switch for auxiliary fan 105 C and A C compressor cutout at 115 C S 25 5 The thermostat housing cover is made of plastic ar row The thermostat is the same as for the other 102 engines Fan clutch Function and layout of fan clutch are the same as for fan clutch of the engine 102 985 Diameter of the 5 blade fan is 430 mm Repair note The fan cannot be interchanged with fan of other en gines 102 in model 201 Radiator Light alloy cross flow radiator block depth 42 mm with screwed on light alloy oil to air cooler BEEN d Au a EA A weasels ee ste atest ANNE ENEE EE e KR RE ue Engine 102 983 22 Engine mounts All components of engine mounts are maintenance free The right and left front engine mounts are the same engine 102 985 has right and left different mounts The rear engine mount is identical with model 201 024 with engine 102 985 79 30 Engine 102 983 Throttle control The throttle position is controlled by a Bowden cable The length of the connecting rod to the throttle valve 30 connecting the accelerator pedal to the engine housing is 82 2 mm measured from center of ball joint to center of ball joint Fig 30 1 30 Bowden cable 34 Bearing Fig 30 3 33 Accelerator pedal 35 Return spring Fig 30 2
30. da control Altitude correction Engine 102 983 Components and function Fuel pump relay N16 3 or N16 4 The relay is located on the right side in the compo nent compartment N16 3 is used on manual transmissions and N16 4 on automatic transmissions with the following functions cold start valve activation rpm limitation kickdown shutoff N16 4 only Fig 07 3 1 Cold start valve activation lts function depends on coolant temperature and cranking speed signal Voltage supply is via the fuel pump relay The length of time during which the cold start valve injects fuel is dependent on the coolant temperature For example at 20 C the valve opens for 10 seconds Above 15 C the valve remains closed lf the engine starts before the cold start valve com pletes its cycle cold start injection is canceled imme diately Maximum engine speed cut out lf the fuel pump relay receives a certain frequency signal corresponding to the maximum engine rpm the contact between circuit 30 and 87 is interrupted and the fuel pump is turned off 07 3 Fuel pump package The fuel pump package is located at the left in front of the rear axle on the frame floor seen in driving di rection The fuel pump package is suspended on rub ber rings 35 Fig 07 312 14 Fuel accumulator M 3 Fuel pump 21 Fuel filter 35 Rubber rings Diaphragm pressure regulator 40 The system pressure was increased to approx
31. e 102 983 100 31585 1 100 30923 Longitudinal and cross sectional views of engine 102 983 1014 12 289 General technical data 00 This manual applies to the following passenger cars model years 1986 1987 Gasoline engines Model Year Model Sales Designation Engine 1986 1987 201 034 190 E2 3 16 102 983 00 General technical data Model 201 034 When ordering spare parts please specify chassis and engine numbers Certification Tag left door pillar Identification Tag left window post Vehicle Identification No Engine No Body No and Paintwork No Information Tag California version Vacuum line routing for emission control system 7 Emission Control Tag 8 Emission Control Tag Catalyst Information model year 1986 a nr Ga MA Model year 1986 Certification Tag left door pillar Identification Tag left window post Vehicle Identrficatlon No Engine No Body No and Paintwork No Information Tag California version Vacuum line routing for emission control system 7 Emission Control Tag On Om P WN Model year 1987 10 General technical data 00 Gasoline engine Model 201 034 Sales desandan NN 190 E 2 3 16 a GE Model Years 1986 87 0 SE 102 983 Operaia A stroke spark ignition mechanically electronically controlled g continuous fuel injection system with airflow sensor CIS E Number of oylinders 4 Cylinder arrangement In
32. er in 40 seconds approx 7 5 amps Engine 102 983 07 3 Model Year 1987 changes to Mechanically electronically controlled gasoline injection system CIS E ett EEO EE EEE EE ELL EES TTT TT Ne EE aes Engine 102 983 07 3 Mechanically electronically controlled gasoline injection system CIS E Fuel pump package The two fuel pumps are arranged in series A dia phragm damper is integrated in the fuel pumps on the suction side The fuel pump package is located as before on the left side in front of the rear axle on the frame floor Fig 07 3 1 55 Fuel filter M3 1 Fuel pump 57 Fuel accumulator M3 2 Fuel pump 63 07 3 0 75 br bl 0 75 br He 292 yI ROPE 10 75 rt ge f 07Srt ws m O75gr ge 1 5 rt ge 5 br QPSswittws H Gel Jusen 075an sw E g SE es 1 ed m i pepe T Lal PE Dn lU P sae LA ez Je l IA dg Al j H J Lij E a EE GENEE G3 2 B2 B12 S 075 swirt SCH 8 Y8 EEE at N 16 4 EXIT Engine 102 983 Wett 25 br X36 2 b E 075 br ws GS bri n Z i x Ibl rt atizn Fig 07 312 Wiring diagram CIS E gasoline injection system 1e10 1p7 2 11 2 17 2 18 3 2 1 1 3 1 3 2 1 2 3 6 16 4 Z2Z22222xA7 QO 70 D DOSS 17 1 27 2 29 2 30 1 lt 5 OD oo 10 64
33. erference suppression resistor is installed Note Twist spark plug connector prior to pulling Reference input resistor plug EZL R 16 1 H5 28406 Fig 15 5 Fig 15 6a 71 EXIT 15 Engine 102 983 VU WI E S a cS H o o P ES a e a 075 brge SE 0 75swirt La 0 75br ge EE wii W e tgn a a O br rt 0 75 br rt Ee 0 75 gn sw 0 75 gn s aera 0 75swige 0 75 sw ge W11 ke EI wn E o 0 75 gn ge 0 75rt sw mmm mene e owe cee emp ee ewe nee EKKO a 1153 13 32411 Fig 15 7 Wiring diagram electronic ignition system with electronic timing adjustment EZL B 11 2 Coolant temperature sensor w 11 Ground engine electric wire connection B 17 1 Intake air temperature sensor EZL x 11 Diagnostic socket terminal block terminal TD L 5 Position indicator flywheel flex plate a to CIS E control unit plug terminal 13 N 1 2 Ignition control module b to electrical center connector S terminal 11 circuit 30 R 16 1 Reference input resistor plug EZL C to electrical center connector S terminal 4 circuit 15 S 5 3 High voltage distributor d to CIS E control unit plug terminal 5 S 29 2 Throttle valve switch full load idle speed contacts e to CIS E control unit plug terminal 21 T 1 Ignition coil f to electrical center connector U terminal 6 circuit 15 R w 3 Ground front left wheelhous
34. f test 07 3 59 07 3 Test and adjustment data Engine 102 983 Static current at EHA Engine not running ignition ON approx 50 mA Coolant temperature Coolant temperature Resistance 2 2 2 8 KQ sensor 20 C basic warm up value Current on EI IA 5 15 mA Coolant temperature Resistance 290 370 Q 80 C Current on EHA value fluctuating Lambda control Engine at idle 50 10 Deceleration shutoff Current on EHA approx 45 mA Rpm Idle speed 890 50 rom and control range Max engine speed 6800 50 rpm Fuel pressures System pressure at idle with engine cold or at operating temperature Lower chamber pressure with engine at operating temp with the vehicle at Lower chamber pressure standstill at idle speed 5 7 5 9 bar 0 4 bar below previously measured system pressure 0 5 bar below previously measured system pressure at 20 C coolant temperature Acceleration enrichment above 3 8 bar Decel shutoff Return flow quantity at orifice in fuel distributor Fuel pump Bosch No Measuring instruction lower chamber pressure equal to system pressure 130 150 cc minute 0 580 254 974 with engine stopped and a voltage of min 11 5 volts at fuel pump Delivery capacity Current draw t For measuring delivery capacity the fuel tank should be at least half full 60 Measuring Fuel line point after diaphragm pressure regulator min 1 lit
35. g 05 7 1 Crankshaft 25 Guide rail 4A Camshaft sprocket exhaust 27 Holder 4E Camshaft sprocket intake 31 Guide rail 5 Crankshaft sprocket 32 Guide rail 12 Intermediate sprocket 33 Holder 18b Idler sprocket 35 Chain tensioner 21 Single roller chain A Check bores 22 Tensioning rail 05 33 05 Camshaft sprockets 4 A and 4 E The camshaft sprockets have a shaft end by which they are mounted in the cylinder head Bearing dia 28 mm same as camshaft bearing Each camshaft is fastened to a camshaft sprocket by four screws M 6 x 25 mm 10 The hole pattern of the four screws is non symmetrical Therefore they can only be screwed on in one position Tightening torque 12 Nm The bearings are supplied with oil via the hollow camshaft sprockets The front bore on the intake camshaft sprocket is closed with a sheet metal plug On the exhaust camshaft sprocket the bore is closed by the hex socket head screw for mounting the driver for the hydraulic oil pump of the level control system The camshaft sprockets are of a different design due to the shaft ends 101 30919 1 Fig 05 8 34 Engine 102 983 The camshaft assembly with camshaft sprocket is axially fixed by a collar on the shaft end of the respec tive camshaft sprocket running in a groove in the cylinder head When the two bores 2 mm dia in the camshaft sprockets are opposite each other arrows the pis ton of the 1st cylinder is in T
36. igher engine speeds the material for the fly wheel is of increased strength It is also lighter in weight than that of engine 102 985 The two 55 segments A on the back are located at an angle of 180 Fig 03 3 and 03 4 in relation to each other The installation position is fixed by a dowel pin for bore refer to arrow Together with the position indicator in crankcase the segments are transmitting a signal to the control mo dule of the ignition system ANF 28416 Fig 03 3 A Segments Arrow Locating bore Hex plate automatic transmission Due to the higher loads the flex plate is reinforced with 2 mm thick steel rings riveted to the ring gear engine 102 985 has one 2 4 mm thick steel ring The two 55 segments A spaced 180 apart Fig 03 3 and 03 4 produce together with the ignition po sition sensor in the engine block an alternating cur rent signal which is transmitted to the ignition control module Due to the segments the flywheel or the flex plate must be assembled to the crankshaft in a spe cific fixed position This position is determined by a dowel pin in the crankshaft flange 28 Engine 102 983 Fig 03 4 A Segments Arrow Locating bore Pistons The light alloy pistons are manufactured by a hot forging process to provide higher strength Four valve recesses are located on the flat piston top The piston play is 0 051 0 075 mm on engine 102 985 0 016 0 040 mm
37. in rela tion to each other Fig 01 8 and arefitted in the cylin der head with an interference fit of 0 012 0 041 mm The OD 13 mm is 1 mm smaller than on the other engines 102 They are also shorter Repair note The finished valve guides are available in four repair sizes Fig 01 6 Installation position of bearing caps 8 Bearing cap 1 bearing of exhaust camshaft SR sprocket Fig 01 5 Bearing caps 2 5 bearings of exhaust camshaft Fig 01 6 Bearing cap 6 bearing of intake camshaft sprocket Fig 01 5 58 L SE 59 1014 12374 Bearing caps 7 10 bearings of intake camshaft 58 Intake val id 59 Exhaust val id The bearing caps are fastened to the cylinder head C cia ee aad with M 8 studs wave washers and nuts D 13 023 13 041 mm D 13 023 13 041 mm D1 7 000 7 015 mm D1 8 000 8 015 mm i L 45 5 mm L 42 9 mm Tightening torque of nuts 21 Nm 58a Retaining ring 59a Retaining ring Repair notes In case of seizing or excessive scoring on camshaft bearings replace cylinder head and camshaft Replace only one bearing cap percamshaft since during simultaneous replacement of several bearing caps the camshaft may bind The bearing caps are correctly installed if the Stamped in code numbers are closest to the inner studs Figs 01 5 and 01 6 15 01 Valve seat rings The valve seat rings are press fitted in the cylinder head with an interference of
38. information outlined herein is intended for use by trained Mercedes Benz service and dealership personnel This manual can also be useful for Mercedes Benz owners in diagnosing vehicle systems and performing repairs Special tools required in performing certain service jobs are identified in the manual and are recommended for use Any part numbers given are only used for identification and easier differentiation between individual components and are not intended for ordering purposes All procedures illustratiqns and specifications contained in this manual were based on the latest information available at the time of publication All rights are reserved to make production design and specification changes at any time without notice and without obligation to give notice Any such changes will not be contained in this manual AN Caution The proper performance of service and repair procedures is essential for both the safety of the mechanic and the safe and efficient operation of the vehicle The use of incorrect service procedures and tools may greatly increase the risk of personal injury and render the vehicle unsafe The procedures in this manual are described in such a manner that the service may be performed safely and accurately However it is a general assumption that the reader is familiar with basic automotive repair procedures and Mercedes Benz vehicles You should not attempt to use this manual if this is not the case Mercedes Benz
39. ing ignition coil 72 Engine 102 983 15 Removal and iristallation of high voltage distributor Removal installation is as before Pay attention to the following items Ignition distributor cap is fastened with screws 2 Adjustment of ignition timing is no longer required The ignition timing is determined by the switching unit Removal and installation of spark plug connectors and spark plugs Note Clean ignition cable cover loosen the 3 screws and remove Fig 15 8 Loosen spark plug connectors by twisting to the right and left and pulling off Fig 15 9 73 15 Testing EZL electronic ignition system Test values Voltages Coil terminal 15 terminal 5 diagnostic socket Engine 102 983 Battery voltage between coil terminal 15 and 1 Ignition on terminal 5 and 4 diagnostic socket engine off Terminal 15 and terminal 31 4 pole round plug Battery voltage ignition control module Terminal 16 and terminal 31 Battery voltage Resistances test data at 0 C to 100 C Primary terminal 1 and 15 0 3 0 6 Q Ignition coil Secondary terminal 1 and 4 7 13 KQ Position sensor 680 I 200 Q Reference input resistor EZL 750 Q Dwell angle at cranking speed at 4000 rpm 1 0 54 or 9 49 30 60 or 27 54 Ignition timing firing point at cranking speed TDC 2 at idle below 20 at 4000 rpm without vacuum
40. intenance jobs section 26 Engine 102 983 Fig 01 32 1054 8490 1 Fig 01 33 ee Engine 102 983 Crankshaft assembly Crankshaft The crankshaft is similar to the other engines 102 with respect to material and dimensions All crankpin fillet radii are hardened On the other engines 102 only crankpins 3 and 4 as well as pin 1 at front end are hardened 113 116 111 49 48 319 1 104 7 Si SZ AK Ys DY NE A E a eee RS a 106 med Gasser LLY ay NE SS ST yx Sr GH 105 we N CE ja N a NS E A 301 L CG N Si ZE A SC i SZ e Op eg 9033 12 242 116 Fig 03 1 1 Crankcase 109 Woodruff key 27 Oil pan 110 Belleville washer 48 Timing chain housing cover 111 Vibration damper 49 Seal ring 113 Pulley 116 Screws M8x 16 301 Internal gear oil pump 302 External gear oil pump 319 Driving sleeve oil pump 104 Crankshaft 105 Crankshaft sprocket 106 Dowel pin 3 x 5 mm 107 Spacer 108 Screw M18x1 5x75 A dowel pin 147 for locating the flywheel or the flex plate is inserted in the rear flange E Fig 03 2 Repair sizes are identical to the other engines 102 Vibration damper 111 Due to the higher engine speeds and the resulting higher load the adhesive surfaces between rubber and metal were designed larger than on the vibration damper of engine 102 985 The TDC markings are located on the rubber surface 27 03 Flywheel manual transmission Due to h
41. is below 2 bar fuel pump M 3 1is defective If the pressure is above 4 bar fuel pump M 3 2 is defective 5 Disconnect pressure gauge unscrew connection fitting and install cap nut 6 Install fuel pump package cover Note This test can also be used on engines 103 116 and 117 equipped with two fuel pumps Fig 07 3 3 Fig 07 3 4 07 3 65 Engine 102 983 Air filter The air filter housing is adapted to the installation conditions It is fastened by one clip and two nuts The air is drawn in form outside the engine compart ment via plastic scoop arrow and air hose 1 The filter element is a plate type filter Note Two temperature sensors are installed in the air cleaner housing Repair note To prevent damage to the air filter housing disengage carefully rearward out of clip fastener after the two mounting nuts have been removed 09 Fig 09 1 Fig 09 2 B17 1 Intake air temperature sensor EZL B17 2 Intake air temperature sensor CIS E 67 13 Engine 102 983 Belt drive Single belt drive Similar to engine 102 985 all the accessories are driven by a poly V belt Shock absorber 28 for the tensioning device 1 of the poly V belt 27 and bracket 29 were changed The modified shock absorber can be recognized by its circular grooves Length of belt 1885 mm Repair note Fig 13 1 In case of repairs the shock absorber must be fast ened in bore
42. l 124 030 except for the following modifications The ignition control module was adapted to en gine 102 983 Position indicator with longer cable Flywheel or flex plate with two segments An additional intake air temperature sensor is ins talled in the air filter High voltage distributor with modified internal construction Fig 15 2 New spark plug connectors The intake air temperature sensor has an electronic device which retards the full load characteristic at Components of ignition system temperatures above 25 C flywheel or flex plate with segments High voltage distributor ignition distributor Two segments offset by 180 on the ring of the flex plate or flywheel are used for controlling ignition tim ing 8 96 408 Fig 15 3 The high voltage distributor is now only serving the Pig 15 1 purpose of high voltage distribution Flyweights DE vacuum control unit and inductance transmitter sys arrow Locating bore tem are no longer installed 70 Engine 102 983 15 Interference suppression resistors on distributor cap per connection 1 kQ distributor rotor 1 kQ Spark plug connector WIEN Fig 15 4 The distributor cap is attached to ignition distributor by special M 6 screws The protective cap for the in terference suppression is mounted on distributor cap and fastened with two star washers 3145 28401 Fig 15 6 A new spark plug connector with 1 kQ int
43. l at high engine speeds The crankcase corresponds with that of the engine 102 985 except for the following modifications The mounting bore for the TDC position indicator of the ignition system arrow is located above the star ter mounting flange Fig 01 2 Oil pan Fig 01 1 The oil pan was reinforced by additional ribs on the bottom The low oil level switch was moved higher on the oil pan due to the lower oil quantity circulated through the engine Repair note The oil pan can be removed without removing the engine 13 01 Engine 102 983 Cylinder head Cross flow cylinder head with roof shaped combus tion chambers E 220 Ss eS 220 200 eh e 199 ZEA 199 203 j 202 198 198 59 58 55 197 196 57 56 Fig 01 3 E Intake 1013 12180 2 A Exhaust Camshaft bearings The shaft ends of the camshaft sprockets are mount ed in the two bearings 1 and 6 Intake and exhaust camshafts are mounted directly in the cylinder head The four split bearing bores for each camshaft are half in the cylinder head and in mounted bearing caps 1901 30815 Fig 01 5 i All bearing caps are identical They are line bored to 101 30914 gether with the cylinder head and are identified with the numbers 1 to 10 During assembly jobs the origi Fig 01 4 nal installation position must be maintained 14 Engine 102 983 01 Valve guides The valve guides are located at an angle of 45
44. mage the cover each screw has a special washer Engine 102 983 The oil filler cap is plastic 90 Fig 01 15 82 Hose connection for engine ventilation 83 Hose connection for engine ventilation with bypass bore 1 6 mm dia 90 Oil filler cap 113 Ignition cable channel cover 114 Plastic screws Tightening torque 1 5 2 Nm Inside underside The oil separator plate 85 for the engine ventilation is fastened with 8 screws and sealed with silicone adhesive Valve cover gasket 93 made of rubber U section Rubber seal rings 112 for sealing spark plug re CESSES Fig 01 16 85 Oil separator plate 85a Oil drain tube E 93 Valve cover gasket 112 Rubber seal rings Engine 102 983 To make sure that the spark plug recesses and the ignition cable channels are not filled with water e g during an engine wash the valve cover has a drain hole at the rear arrow Fig 01 15 Assembly notes The valve cover M6 cap nuts should be tightened crosswise and in several steps Tightening torque 9 Nm The ignition cable channel has guide ribs and sym bols for correct installation of ignition cables 01 Fig 01 17 19 01 Positive crankcase ventilation PCV Operation The engine blow by gases flow from cylinder crank case to oil separator 90 in the valve cover The oil separated here flows back to the cylinder head through a drain pipe From the oil separator the engine bl
45. minal block circuits 30 61 battery Connector fuel pump wiring harness taillamp wiring harness Connector sleeve sholder joint in harness Plug connection throttle valve switch Connector sleeve circuit TD solder jointin harness Connector sleeve circuit 15 solder jointin harness Connector Og sensor heater Connector Electra hydraulic actuator Kick down Oo sensor signal EHA solenoid automatic transmission Idle speed air valve Starting valve to wire connector circuit 30 fuse and relay box to cruise control amplifier pin socket 5 to pressure switch A C compressor Note Unmarked ground connections are grounded on engine or chassis The wire on terminal 6 circuit 87 K on the fuel pump relay connector does not apply to vehicles with manual transmission Engine 102 983 Testing fuel pump delivery S pecial tools 103 589 00 21 00 103 589 02 63 00 Testing fuel pump delivery see Service Microfiche Job No 07 3 130 Nominal value 1 liter minimum in 40 seconds If this delivery quantity is not obtained determine cause by performing a pressure test Testing fuel pressure 1 Remove fuel pump package cover Fig 07 3 3 2 Unscrew cap nut on fuel pump M 3 1 Attach con nection fitting and pressure gauge 0 to 10 bar Fig 07 3 4 3 Unplug fuel pump relay and bridge terminals 7 and 8 circuit 30 and 87 4 Reading on pressure gauge must be between 2 and 4 bar If the pressure
46. n terminal 19 and ground Position P and N battery voltage With driving posi tion engaged voltage drops Compressor On approx 12 Volts Compressor Off approx 0 Volt Rees AR Repair Repair interrup interruption tion according to wiring diagram End of test 57 07 3 Engine 102 983 Testing lambda control Engine at idle Engine oil temperature 75 to 85 C Connect lambda tester to diagnostic socket Press 100 IR button End of test 58 ey iio EIT Engine 102 983 Testing O sensor Note The O2 sensor must be tested with the engine at operating temperature Function test With the engine running deflect airflow sensor plate slightly by hand The needle on the lambda tester must move to the lean mixture stop If not perform the following test Disconnect O sensor Ss Se connect male part of plug to ground Start engine test sensor voltage between fe male pale of plug and aroun Sensor r voltage See 450 mV Replace O sensor End of test Testing O sensor heater SE shut off Loosen sig of Greg eater to allow voltage testing Use caution danger of short circuit Pull off fuel pump relay and jump con nector terminals 7 and 8 Reading Approx 12 volts battery voltage Repair interruption ee Geinor i eater plug Connect test cable 102 589 04 63 00 with adapter plugs 903 589 03 63 00 Test current draw Nominal value above 0 5 A End o
47. nic timing adjustment EZL 70 Positive crankcase ventilation PCV 20 Components of ignition system 70 Removal and installation of Removal and installation of cylinder head cc eee ee es 21 high voltage distributor 73 Testing EPL electronic ignition system 74 03 Crankshaft assembly Spark plugs e EE EE A 15 Crankshaft cc eee ee eee 27 Vibration damper ceva eae 27 18 Engine lubrication Flywheel flex plate 0 28 Lubrication circuit diagram 76 RISIONS sisueedeoevebetades Gas 28 Oil filling capacities 00 17 Cup type tappet and cam lubrication 77 05 Engine timing valve train Oil temperature gauge 17 Camshaft 44 5 46 64 dete br be owe es 30 Testing and adjusting values 31 20 Engine cooling Valve arrangement 31 Coolant PUMP eceeeeeeeee 8 Intake and exhaust valves 32 Thermostat housing and Valve spring valve keepers 32 thermostat cee eee 78 Valve stem seals 1 cee eee 32 Fan cluteh sweneteeddawee so oe a 78 Checking and adjusting Radial ss s52newhovnawaaan ds 78 valve clearance cee es 33 Chain drive ec ec ee ee 33 22 Engine mounts IG Camshaft sprockets 5 34 Single roller chain 05 34 30 Throttle control _ 80 Guide rail tensioning rail 35 Intermediate sprocket 35 Hydraulic oil pump drive 36 Views of engin
48. old start valve modified For this reason the following description covers only the modifications and not the complete system CIS E electronic control unit with air fuel mixture adaptation by microprocessor and logic circuit Intake air temperature sensor on air filter Altitude correction capsule Electronic idle speed control by a single coil rotary air valve The bypass adjusting screw was elimi nated Throttle valve switch with idle and full load contact Deceleration shutoff microswitch O sensor replacement indicator was replaced by an O sensor malfunction indicator 37 07 3 Input signals affecting the electronically controlled mixture correction Coolant temperature Air flow sensor plate position and movement Full load contact system pressure Idle speed contact J microswitch and throttle valve switch differential pressure on actuator electr hydraulic actuator EHA gt control unit gt Engine speed lower chamber Lambda signal pressure tric pres sure altitud amp cor rection capsule idle speed air valve controls Engagement idl of A C idle speed compressor Selector lever position auto matic transmission Cruise control 38 Engine 102 983 controls Start enrichment After start enrichment Warm up enrichment Acceleration enrichment Full load enrichment Decel shutoff Lamb
49. old start valve activation ignition turned off Pull plug off coolant temper ature sensor Unplug green cable on ignition control module Crank engine and check vol ne at plug of cold start valve Minimum ER 10 V for 10 to 15 BEE Check wire from cold start valve to Fig 07 38 25 fuel pump relay terminal 4 circuit 87 V and ground wire to engine aroung for ORU Resistance PA UO Check voltage between fuel pump relay plug terminal 12 as well as ter minal 2 and engine ground Crank engine Minimum voltage at terminal 12 10 V Voltage at terminal 2 3 to 5 V 1074 13113 coolant temperature sensor plug Fig 07 3 26 EEN Gage fuel pump Repar iy EEN End SE ek 54 Engine 102 983 Testing intake air temperature sensor Unplug intake air temperature sensor Test al to ground gram Example 20 C 2 2 2 8 KQ temperature sensor Check wire between intake air temperature sensor and ground as well as wire to CIS E control unit terminal 11 for continuity 07 3 EECH E WE SE E Dee e 30000 KENE E S T Gage TE E EE S wm BL LL Fo ee a EE EE GR s00 AQA ww NAN Ken We e EE aoe TT BW ees SC SE DESS NEE ca 300 200 ee E EE ee GO 40 30 tbe been 20 10 J 30 20 0 20 40 60 80 100 120 Fig 07 3 27 Fig 07 3 28 Testing electronic idle speed contol Connect test cable to idle speed air valve and to lambda control tester 909 589 00 21
50. ow by gases flow into the combustion chambers depending on load condition intake manifold vacuum as follows Idie decel high intake manifold vacuum Through bypass bore 1 6 mm dia in hose connection 83 on the valve cover to idle speed air distributor 108 and through the insulating sleeve of the injec tion valves to combustion chambers f een EE Se Sa ke ee dg Ge EG A E S X Serr 7 S RR fn ES a K i gt KA A ei g gt A 7 USI K NGF Fig 01 18 1 Coolant pump 83 Hose connection with 1 6 mm throttle 103a 103c Vent lines 104 Coolant supply line for crankcase vent line 105 Idle speed air line 106 Heating water line copper tubing 20 Engine 102 983 Simultaneously additional clean air is drawn in from air cleaner 111 via hose line 103a 103c and fed to the combustion chambers via the oil separator together with the blow by gases Partial and full load operation low intake manifold vacuum Mainly via hose line 103a 103c to air cleanerclean side and with intake air to the combustion chambers To make sure that the vent line 103a 103c does not freeze at low outside temperatures it is heated with coolant The coolant line 106 is integrated in the vent line and is connected to the cylinder head via the supply line 104 The coolant is returned to the cool ant pump 1 via return line 109 107 Coolant connection line 108 Idle speed air dist
51. plug M 18 x 1 5 mm 14 and a sealing ring 15 towards the outside Fig 05 1 1 Repair note In case of noise complaints from the area of the cylin der head front check if spring washers 28 are in Stalled Fig 05 13 35 05 Repair note The intake camshaft sprocket the chain tensioner and the radiator shroud must be removed for removal and installation of the intermediate sprocket Hydraulic oil pump drive The hydraulic oil pump for level control is mounted to the cylinder head with a separate flange It is driven by the camshaft sprocket of the exhaust camshaft For layout refer to Fig 05 15 Fig 05 14 36 GN esch FSR 242 235 243 235a 241 Valve cover gasket Camshaft sprocket exhaust En Engine 102 983 85 97 ageet 73 66a 163a 237 55 236 245 238 Engine 102 983 07 3 Mechanically electronically controlled gasoline injection system CIS E The construction and function of the gasoline injec tion system is similar to engine 102 985 except for the following modifications Modifications Maximum engine speed cut out is controlled by the fuel pump relay Fuel pump same as models 107 and 126 with integrated suction damper Fuel pump package suspended on rubber rings System pressure increased to 5 8 bar Fuel distributor and airflow sensor adapted to engine Air enveloped injection valves Location of injection valves and c
52. ributor 109 Coolant return line 110 Crankcase vent line 111 Air filter Engine 102 983 01 Removal and installation of cylinder head Note Only repair instructions not described in microfiche Engine 102 Mechanical will be discussed in the fol lowing pages Tightening torques Nm Chain tensioner in crankcase 40 Camshaft sprockets 12 Camshaft bearing caps Exhaust manifold to cylinder head Thermostat housing to cylinder head 21 Coolant connecting pipe cylinder head thermostat housing to cylinder head Support exhaust manifold transmission to exhaust manifold Exhaust system to exhaust manifold 2 Valve cover Removal Air filter housing Disconnect plug from intake air temperature sensor 124 and crankcase ventilation hose 103c on air cleaner 121 Remove nuts 122 lift housing at the rear until it is released from studs slide back slightly direction of arrow and lift from air flow sensor Oil dipstic k guide tube Remove screw 46 and rotate clamp 47 away from bracket 45 Pull out oil dipstick 42 Fig 01 19 Fig 01 20 21 01 Poly V belt drive Loosen screw 25 by 1 4 2 turn slacken poly V belt 27 by turning tensioning nut 24 counterclockwise Remove poly V belt 27 Exhaust manifold Remove screw 119 from support bracket 118 and loosen screws 120 on transmission Engine 102 983
53. rometric pressure Voltage at altitude sea level correction capsule plug connected m mbar volts 0 1013 4 1 1000 899 31 2000 795 241 Engine 102 983 07 3 Checking electric components of CIS E injection system after checking fuel pressures and for internal leaks Special tools Adapter plugs for test cable 201 589 00 99 00 102 589 05 63 00 903589036300 102 589 04 63 00 On off ratio tester e g Bosch KDJE P 600 103589006300 909 589 00 21 00 Conventional testers Multimeter e g SUN DMM 5 Available through the MBNA Standard Equipment Program Testing overvoltage protection relay K 1 Switch on ignition test voltage from control unit plug terminal 1 to ground Battery voltage 1074 11132 Fig 07 3 15 End of test 47 07 3 Test fuse of overvoltage protection relay Fuse OK Fuse not OK Battery voltage prese unit plug of Replace overvoltage protection relay End of test 48 Fig 07 3 16 Engine 102 983 Engine 102 983 07 3 Testing coolant temperature sensor EI KA CH CH CH CH g 4 d Ke l HR Al id 7 d oC SR Oe D Test sensor resistance at two temperatures mr RE E Go i di Example Q 20 C 2 2 2 8 kO 80 C 290 370 y 074 11 16 0 30 20 0 20 40 60 80 100 120 C sensor
54. temperature The current to the EHA is dependent on acceleration Full load enrichment Effective with throttle valve fully opened Depending on the engine speed the current at the EHA can vary between 5 mA to 10 mA Lambda control is set by the control unit no regulation An idle speed contact is additionally integrated in the switch The idle speed signal is required by the elec tronic ignition switching unit Deceleration shutoff Changes to the deceleration shutoff are as follows Restart of fuel injection begins at an engine speed of 1500 rpm Deceleration shutoff occurs only if the engine speed exceeds 2500 rpm Current to the electrohydraulic actuator EHA is approx 45 mA New routing of wiring harness For complete wiring diagram refer to Fig 07 3 13 41 07 3 Logic circuit Input signals from the various sensors and switches are continuously monitored by the electronic control unit If for example with the engine at operating tem perature a rapid temperature change is simulated by unplugging the coolant temperature sensor the microprocessor in the control unit will compare this momentary temperature with the temperature in its memory The control unit will recognize the abrupt temperature change as a short circuit and is pro grammed to the fixed operating mode The control unit does not recognize gradual changes as malfunctions and will continue to operate nor mally Fi
55. xed operating mode In the event of an illogical signal received by the con trol unit i e system malfunction open or short cir cuit the control unit will automatically revert to a Fixed Operating Mode FOM This means that the engine will continue to run but not at its optimum electronically controlled performance level O sensor The O sensor replacement indicator is now an O sensor malfunction indicator The Oo sensor mal function light will come on only if a malfunction is present in the O sensor circuit The O sensor mal function indicator lamp receives voltage from the CIS E control unit The indicator lamp lights up briefly when ignition is turned on Electronic idle speed control The function of the electronic idle speed control is es sentially the same as previously The control unit processes the following information Engine speed ignition terminal TD Coolant temperature Idle speed signal microswitch Air flow sensor voltage Voltage altitude correction sensor Automatic transmission shift lever position A C compressor cut in signal 42 Engine 102 983 The function of the idle speed control system is ex tended by the air flow sensor voltage signal As a re sult the control unit recognizes the momentary air flow rate In combination with the engine speed the position of the microswitch and the coolant temper ature the activation of the idle speed air valve and thereby the idle speed

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