Mercedes W201 Service Manual / Repair Manual View larger

Mercedes W201 Service Manual / Repair Manual

English service manual / repair manual to vehicles Mercedes W201.

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LANGUAGE: English.
FORMAT: PDF file
PAGES: 4628
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MERCEDES W201 - SERVICE, REPAIR, WORKSHOP MANUAL


- English service manual to vehicles Mercedes W201.


CONTENTS:


01001
- Introduction
- How to use this manual
- Symbols
- Troubleshooting
- Circuit Identification
01002
- Index
- Active bass speaker system
- Anti-lock brake system
- Anti-lock brake system/acceleration slip control(abs/asr)
- Anti-theft alarm system
- Automatic antenna
- Automatic locking differential (asd)
- Auxiliary fan/coolant fan
- Auxillary relay box
- Cellular telephone
- Center console:
- Central locking system
- Charging system
- Cigar lighter
- Clock
- Component location
- Coolant fan
- Cruise control
- Diagnostic socket
- Electrical center
- Electronic accelerator system
- Electronic diesel system (eds)
- Electronic engine control
- Electronic idle speed control
- Engine overload protection
- Exhaust gas recirculation
- Fuel delivery
- Fuse circuit list
- Gauges
- Ground distribution
- Hall-effect speed sensor
- Headlamp wiper/washer
- Heated seats
- Horn
- Intake manifold preheater
- Ignition
- Lamps
- Orthopedic seats
- Outside heated mirrors
- Oxygen sensor replacement indicator
- Power distribution
- Power seats
- Power windows
- Preglow system
- Radio
- Rear defogger
- Right outside mirror
- Sliding roof
- Start
- Supplemental restraint system (srs)
- Tachometer
- Tempmatic climate control
- Transmission kickdown
- Transmission kickdown(diesel)
- Transmission upshift delay
- Warning indicators
- Warning system
- Wiper/washer
10001
- Introduction
- Group Index
10002
- Index
- 00-005 Instructions for use of service manual
- 00-010 Engine and vehicle identification
- 00-015 Vehicle identification number locations
- 00-020 Technical data
10003
- Index
- 15-600 Testing alternator with regulator in vehicle
- 15-642 Renewing fan assembly
- 15-700 Removal and installation of starter
10004
- Index
- 32-100 Removal and installation of damper strut
- 32-110 Removal and installation of rear shock absorber
- 32-120 Checking damper strut (front axle)
- 32-121 Checking shock absorber (rear axle)
- 32-200 Removal and installation of front spring
- 32-300 Removal and installation of torsion bar on front axle
- 32-310 Removal and installation of torsion bar on rear axle
10005
- Index
- 33-200 Removal and installation of front axle half
- 33-300 Adjusting end play of wheel bearings
- 33-310 Removal and installation of front wheel hub
- 33-320 Disassembling, checking, reconditioning and assembling front wheel hub
- 33-400 Removal and installation of steering knuckle
- 33-410 Checking steering knuckle
- 33-420 Removal and installation of steering knuckle arm
- 33-425 Checking supporting joint of the steering knuckle bearing
- 33-430 Renewing the sleeve for the supporting joint of the steering kruckle bearing mount
- 33-440 Renewing supporting joint of steering knuckle bearing
- 33-510 Removal and installation of wishbone
- 33-525 Checking bearing of wishbone
- 33-526 Renewing rubber mounts of wishbone
- 33-530 Checking wishbone (for vehicles following accident)
10006
- Index
- 35-010 Removal and installation of complete rear axle
- 35-040 Removal and installation of front and rear rubber mounts of rear axle suspension
- 35-110 Removal and installation of camber strut
- 35-111 Removal and installation of pulling strut
- 35-112 Removal and installation of track rod, renewing rubber mounts
- 35-113 Removal and installation of pushing strut
- 35-114 Removal and installation of spring link, renewing rubber mount and supporting joint
- 35-115 Removal and installation of wheel carrier
- 35-130 Removal and installation of rear axle shaft flange with angular ball bearing
- 35-520 Removal and installation of rear axle center piece
- 35-530 Renewing radial sealing ring on drive pinion
- 35-540 Renewing radial sealing ring on connecting flange of rear axle shaft
- 35-550 Disassembly and assembly of rear axle center piece, adjustment of wheel set
- 35-560 Reconditioning of differential
- 35-620 Removal and installation of rear axle shaft
- 35-660 Renewing rubber sleeves on rear axle shaft
- 35-670 Removal and installation of connecting flange of rear axle shaft
10007
- Index
- 40-010 Lifting vehicle with vehicle jack
- 40-013 Positioning of jacking-up shoes and jacks
- 40-100 Survey rims and tires
- 40-102 Rims
- 40-104 Tires
- 40-106 Tire inflation pressure
- 40-108 Snow chains
- 40-110 Removing and mounting of wheels
- 40-113 Removing and mounting hub cap for forged light alloy rims
10008
- Index
- 41-050 Removal and installation of propeller shaft
- 41-100 Removal and installation of propeller shaft intermediate bearing, replacement of radial ball bearing
- 41-200 Replacement of centering sleeve
10009
- Index
- 42-005 General information
- 42-010 Bleeding the brake system or renewing the brake fluid
- 42-012 Checking brake lines and brake hoses
- 42-015 Checking the brake system for leaks
- 42-035 Checking warning device in expansion tank
- 42-040 Checking and adjusting or removal and installation of mechanical stop lamp switch
- 42-110 Removal and installation of floating caliper on front axle
- 42-120 Removal and installation of fixed caliper on rear axle
- 42-160 Replacing brake pads
- 42-220 Removal and installation of brake disk on front axle
- 42-228 Removal and installation of brake disk on rear axle
- 42-260 Cleaning brake disks
- 42-310 Removal and installation of stepped tandem main cylinder
- 42-315 Disassembly, checkup and assembly of stepped tandem main cylinder
- 42-510 Removal and installation of parking brake lever
- 42-520 Removal and installation of front brake cable control
- 42-525 Removal and installation of rear brake cable control
- 42-530 Removal and installation of brake shoes of parking brake
- 42-540 Readjusting or adjusting brake shoes of parking brake
10010
- Index
- 43-023 Testing check valve
- 43-325 Checking brake unit
- 43-350 Removal and installation of brake unit
- 43-618 Removal and installation of piston vacuum pump
- 43-660 Testing piston vacuum pump
10011
- Index
- 46-110 Checking play of steering components
- 46-120 Checking start of manual restriction
- 46-130 Checking oil pressure of power steering pump
- 46-412 Steering gear - removal and installation of power steering
- 46-510 Removal and installation of pitman arm
- 46-520 Removal and installation of intermediate steering arm
- 46-540 Removal and installation of track rod
- 46-550 Removal and installation of drag link
- 46-560 Replacement of sleeves for ball joints of track rod and drag link
- 46-610 Removal and installation of steering wheel
- 46-640 Removal and installation of steering lock
- 46-710 Removal and installation of power steering pump
- 46-010 Differentiating characteristics of steering gears
- 46-220 Reconditioning of steering gear
- 46-720 Disassembly, checkup and reconditioning of power steering pump
- 46-740 Assembly of power steering pump
10012
- Index
- 54-005 Battery test, service and maintenance
- 54-100 Designation and layout of ground connecting points
- 54-140 Central electrics
- 54-150 Central electrics, remove and install
- 54-152 Electric connections of special equipment
- 54-250 Removal and installation of instrument cluster
- 54-251 Removal and installation of indicating instruments
- 54-253 Removal and installation of speedometer
- 54-255 Checking indicator for economic driving (ECONOMY)
- 54-256 Operation of transmitter for fuel gauge
- 54-257 Testing fuel gauge
- 54-258 Removal and installation of time clock/revolution counter
- 54-261 Testing electric outside temperature indicator
- 54-262 Renewing lamp carrier with acoustic turn signal checkup
- 54-264 Checking washer water level indicator
- 54-266 Operation of auxiliary instruments model 201.034
- 54-267 Removal and installation of auxiliary instruments
- 54-395 Sun visor with illuminated mirror
- 54-410 Warning device for safety belt, ignition key, light USA
- 54-500 Operation
- 54-504 Testing with adapter
- 54-506 Testing coding plug
- 54-541 Removal and installation of actuator
- 54-545 Removal and installation of switch, cruise control/Tempomat
- 54-550 Removal and installation of transmitter
- 54-561 Adjusting connecting rod
- 54-566 Removal and installation of coding plug
- 54-575 Removal and installation of switch on clutch pedal
- 54-579 Layout of plug connections
10013
- Index
- 67-100 Removal and installation of windshield glass
- 67-120 Removal and installation of ornamental frame on windshield
- 67-200 Removal and installation of rear window
- 67-220 Removal and installation of ornamental frame on rear window
10014
- Index
- 68-100 Removal and installation of instrument panel
- 68-105 Removal and installation of cover for speaker
- 68-120 Removal and installation of glove box cover
- 68-130 Removal and installation of lock on glove box cover
- 68-140 Removal and installation of glove box
- 68-150 Removal and installation of cover under instrument panel
- 68-200 Removal and installation of center console
- 68-230 Removal and installation of cover on shift lever
- 68-231 Removal and installation of cover on shift lever (automatic transmission)
- 68-400 Removal and installation of reveal molding on windshield top
- 68-405 Removal and installation of reveal molding laterally on windshield
- 68-430 Removal and installation of headlining
- 68-442 Removal and installation of edge protection under driver’ s and rear door
- 68-449 Removal and installation of paneling (trim) on rear pillar
- 68-458 Removal and installation of hat rack
- 68-470 Removal and installation of panelling (trim) on center pillar
- 68-485 Removal and installation of panelling (trim) on rear center piece
- 68-492 Removal and installation of damping elements on transmission tunnel, outside
- 68-495 Removal and installation of cover on rear pillar, outside
10015
- Index
- 72-050 Removal and installation of driver’s door
- 72-051 Renewing driver’s door
- 72-060 Removal and installation of rear compartment door
- 72-061 Renewing rear compartment door
- 72-100 Removal and installation of door lining on driver’s door
- 72-101 Removal and installation of door lining on rear door
- 72-140 Removal and installation of hand grip on door lining
- 72-160 Removal and installation of sealing rail inside
- 72-170 Removal and installation of sealing rail outside
- 72-185 Removal and installation of electric window opener on driver’s door
- 72-187 Removal and installation of electric window opener on rear door
- 72-197 Removal and installation of stationary window on rear door
- 72-198 Removal and installation of flexible window run channel
- 72-210 Removal and installation of door holder
- 72-220 Removal and installation of sealing frame on driver’s or rear door
- 72-230 Removal and installation of inside door actuation on driver’s door
- 72-231 Removal and installation of inside door actuation on rear door
- 72-240 Removal and installation of outside door handle on driver’s door
- 72-241 Removal and installation of outside door handle on rear door
- 72-250 Removal and installation of door lock on driver’s door
- 72-251 Removal and installation of door lock on rear door
10016
- Index
- 77-050 Removal and installation of headlining on sliding-lifting roof
- 77-100 Removal and installation of sliding roof cover
- 77-110 Adjustment of sliding roof cover
- 77-130 Removal and installation of sealing and holding rails on sliding-lifting roof cutout
- 77-140 Removal, installation and adjustment of teleflex control
- 77-150 Removal and installation of teleflex tube (sliding roof electrical, sliding-lifting roof)
- 77-170 Removal and installation of lifting angle on sliding-lifting roof
- 77-180 Removal and installation of motor and gearbox (sliding roof electrical, sliding roof electrical, sliding-lifting roof)
- 77-195 Testing and adjusting slip clutch of sliding roof motor (sliding roof electrical, sliding-lifting roof)
- 77-250 Removal and installation of wind deflector on sliding roof (sliding roof mechanical, electrical, sliding-lifting roof)
- 77-300 Removal and installation of sliding roof frame (sliding roof electrical, sliding, lifting roof)
10017
- Index
- Single door controlled system
- Multi-point controlled central locking system
10018
- Index
- 82-010 Rernoval and installation of dome lamps front and rear
- 82-040 Adjusting lamps, front
- 82-052 Removal and installation of lamp unit
- 82-062 Removal and installation of lamp unit bulbs
- 82-067 Removal and installation of lamp unit glass
- 82-252 Removal and installation of tail lamp unit
- 82-348 Removal and installation of licence plate lamp
- 82-395 Electric wiring diagram, heatable rear window
- 82-505 Removal and installation of radio
- 82-512 Removal and installation of speaker, front and rear
- 82-530 Operation of automatic antenna USA
- 82-535 Removal and installation of antenna
- 82-610 Removal and installation of profilated rubber of wiper blade
- 82-680 Removal and installation of wiper motor
- 82-760 Removal and installation of wiper linkage
- 82-765 Removal and installation of rubber seal under wiper gears
- 82-785 Electric wiring diagram of wiping-washing system
- 82-795 Windshield washer
- 82-800 operation of seat heater
- 82-833 Electrically adjustable outside rear view mirror
- 82-834 Outside rear view mirror with electrically heated plate glass
- 82-860 Electrical seat adjustment, front
- 82-865 Removal and installation of switch for electrical seat adjustment
- 82-980 Operation of anti-theft warning system (EBW)
10019
- Index
- 88-100 Removal and installation of front fender
- 88-200 Removal and installation of front bumper
- 88-210 Disassembly and reassembly of bumper front and rear
- 88-220 Removal and installation of rear bumper
- 88-300 Removal and installation of engine hood
- 88-302 Adjustment of engine hood
- 88-306 Removal and installation of engine hood hinge
- 88-310 Removal and installation of cable control for engine hood
- 88-320 Removal and installation of engine hood lock
- 88-400 Removal and installation of radiator shell
- 88-401 Removal and installation of radiator grille
- 88-402 Removal and installation of trim strips on radiator grille
- 88-405 Removal and installation of Mercedes star
- 88-500 Removal and installation of trunk lid
- 88-502 Removal and installation of trunk lid lock
- 88-505 Mounting the model identification on trunk lid
- 88-512 Removal and installation of hinge lever for trunk lid
- 88-800 Removal and installation of paneling on side wall
- 88-802 Removal and installation of protective strip on side wall
- 88-810 Removal and installation of panelling on doors and fenders, outside (model 201.034)
- 88-820 Removal and installation of rear spoiler
- 88-825 Marking and drilling holes for rear spoiler on trunk lid
- 88-830 Removal and installation of panelling on side member (model 201.034)
- 88-855 Removal and installation of rain strip on front wall pillar and roof
- 88-900 Removal and installation of outside rear view mirror
- 88-905 Removal and installation of electrically adjustable outside rear view mirror
- 88-910 Removal and installation of motor for electrically adjustable outside rear view mirror
10020
- Index
- 91-100 Removal and installation of driver’s seat
- 91-110 Removal and installation of front passenger’s seat
- 91-170 Removal and installation of rear seat and rear seat backrest
- 91-180 Removal and installation of cover on driver’ s seat cushion
- 91-182 Removal and installation of cover on driver’s seat backrest
- 91-500 Removal and installation of front safety belt
- 91-510 Removal and installation of rear safety belt
- 91-550 Exchange instructions for safety belts
10021
- Index
- 32 Suspension
- 33 Front axle
- 35 Rear axle
- 40 Chassis measurements, Wheels and tires
- 42 Brakes
- 46,47 Steering
- 49 Exhaust system
- 54 Electrical system
- 68 Interior
- 82 Electrical system, radio, dome lamp
- 83 Tempmatic climate control
- 88 Detachable body components, external paneling
- 91 Seats, restraint systems
10022
- Index
- 32 Suspension
- 35 Rear axle
- 54 Cruise control
- 80 Wiring diagram
10023
- Index
- 29, 32 Pedals, Suspension
- 33 Front axle
- 35 Rear axle
- 40 Wheels, chassis measurements
- 41,42 Propeller shaft, Brakes
- 46,49 Steering, Exhaust system
10024
- Index
- 54 Cruise control system
- 77 Sliding roof
- 82 Anti-theft alarm system
20001
- Introduction
- Group index
20002
- Index
- 00-005 Instructions for use of service manual
- 00-010 Model and system identification
- 00-015 Vehicle identification number locations
20003
- Index
- 83 -020 Operation and components of Tempmatic climate control
- 83-028 Control system
- 83-035 Testing refrigerating capacity of air conditioning system (quick test)
- 83-036 Testing refrigerating capacity and suction/high pressure of air conditioning system
- 83-038 Testing control quality at different temperature adjustments, as well as heating capacity
- 83-039 Testing system with socket box, volt and ohmmeter, and remedies
- 83-040 Testing compressor cutout and remedies
- 83-045 Testing vacuum system for blend air flaps, fresh air/recirculating air flap, defroster nozzle flaps, legroom flaps ...
- 83-045 ...and heater valve for leaks
- 83-100 Removal and installation of heater box
- 83-110 Removal and installation of heat exchanger
- 83-112 Pushbutton switch unit
- 83-113 Removal and installation of blower switch
- 83-115 Removal and installation of heater valve
- 83-117 Removal and installation of recirculating pump
- 83-120 Removal and installation of blower motor
- 83-122 Removal and installation of aspirator blower for in-car temperature sensor
- 83-130 Removal and installations, testing of in-car temperature sensor
- 83-132 Removal and installation, testing of outside temperature sensor
- 83-133 Removal and installation, testing of temperature sensor for air conditioning system
- 83-134 Removal, testing, installation and adjustment of potentiometer for flap position
- 83-138 Removal and installation, testing of switch for fresh air/recirculating air flap
- 83-140 Removal and installation of cover at air inlet
- 83-150 Removal and installation of outlets on instrument panel outside and center
- 83-153 Removal and installation of switchover valve unit with 4 or 5 connections
- 83-165 Removal and installation of vacuum elements
- 83-516 Removal and installation of rpm sensor on Nippondenso refrigerant compressor
- 83-517 Removal and installation of rpm sensor on starter ring gear (model 201.122)
- 83-520 Checking oil level in refrigerant compressor
- 83 -522 Removal and installation of refrigerant compressor
- 83-524 Reconditioning refrigerant compressor
- 83-526 Removal and installation of electromagnetic clutch
- 83-528 Removal and installation of condenser
- 83-530 Removal and installation of receiver-drier
- 83-531 Checking or removing and installing pressure switch for refrigerant compressor in receiver-drier
- 83-532 Testing or removing and installing pressure switch for auxiliary fan in receiver-drier
- 83-534 Removal and installation of expansion valve
- 83-538 Removal and installation of evaporator
- 83-546 Removal and installation of auxiliary fan
20004
- Model Year 1985
- Model Year 1986
- Model Year 1987
30001
- Introduction
- Group Index
30002
- Index
- 00-005 Instructions for use of service manual
- 00-010 Engine and vehicle identification
- 00-015 Vehicle identification number locations
- 00-020 Technical data
30003
- Index
- 01-001 Engine and Model Survey
- 01-005 Overview - Engines
- 01-006 Removal and installation of bottom engine compartment cover
- 01-010 Testing compression pressure
- 01-015 Testing cylinder leaktightness
- 01-020 Illuminating cylinders
- 01-030 Removal and installation of englne
- 01-040 Crankcase Ventilation - Function
- 01-110 Measuring, boring and honing cylinders
- 01-120 Facing crankcase parting surface
- 01-130 Removal and installation of steel balls in main oil gallery
- 01-140 Replacing core plug in crankcase
- 01-210 Removal and installation of timing case cover
- 01-222 Removal and installation of end cover
- 01-310 Removal and installation of oil pan
- 01-403 Repair instructions for crankcase, cylinder heads and cylinder head gaskets
- 01-406 Removal and installation of cylinder head cover
- 01-407 Reconditioning spark plug thread in cylinder head
- 01-415 Removal and installation of cylinder head
- 01-416 Matching measuring sensors to cylinder head
- 01-418 Facing cylinder head mating face
- 01-419 Enlarging camshaft bearing bores (repalr size)
- 01-420 Pressure-testing cylinder head
30004
- Index
- 03-310 Checking, replacing and torquing conrod bolts
- 03-313 Reconditioning and checking angles of bearing bores
- 03-316 Removal and installation of pistons
- 03-318 Checking and reconditioning crankshaft
- 03-320 Installation of crankshafts bearings
- 03-324 Replacing front crankshaft radial seal
- 03-327 Replacing rear crankshaft radial seal
- 03-330 Removal and installation of grooved ball bearing in crankshaft
- 03-342 Removal and installation of vibration damper or hub and belt pulley
- 03-345 Checking and correcting setting of TDC pulse generator
- 03-350 Removal and installation of crankshaft gear
- 03-410 Removal and installation of flywheel or flex plate
- 03-420 Remachining flywheel
- 03-430 Replacing ring gear on flywheel
30005
- Index
- 05-211 Checking and replacement of hydraulic valve clearance compensation element
- 05-214 Checking and correcting the installation position of hydraulic valve clearance compensating elements
- 05-215 Checking and adjusting camshaft timing
- 05-220 Removal and installation of camshaft
- 05-235 Removal and installation of rocker arm bearing supports with rocker arms
- 05-240 Replacement of rocker arms and rocker arm bearing supports
- 05-250 Removal and installation of valve springs
- 05-260 Checking valve springs
- 05-270 Replacement of valve stem seals
- 05-280 Checking and machining valves
- 05-285 Checking and replacing valve guides
- 05-290 Replacing valve seat ring
- 05-291 Machining valve seats
- 05-310 Removal and installation of chain tensioner
- 05-320 Replacement of timing chain
- 05-328 Installation of oil spray nozzle retroactively
- 05-330 Removal and installation of tensioner blade
- 05-340 Removal and installation of guide rails
- 05-412 Removal and installation of idler gear shaft
- 05-437 Removal and installation of oil pressure pump drive
30006
- Index
- 07.3-001 Model designation survey
- 07.3-004 Vehicle features
- 07.3-005 Parameters of mixture adaptation
- 07.3-013 Function diagram of KE injection system
- 07.3-105 Testing on/off ratio
- 07.3-110 Engine testing, adjustment
- 07.3-112 Testing electronic idle speed control
- 07.3-117 Determining fuel consumption by test drive
- 07.3-120 Testing fuel pressure and internal leaktightness
- 07.3-121 Testing electrical components
- 07.3-122 Testing continuity of inductor in fuel distributor
- 07.3-124 Testing start device
- 07.3-126 Testing start valve actuation
- 07.3-127 Performing cold start
- 07.3-128 Wiring diagrams
- 07.3-130 Testing fuel pump
- 07.3 -135 Testing fuel injectors
- 07.3-152 Testing, replacement of wide open throttle/closed throttle position switch
- 07.3-160 Performing fuel quantity comparison measurement
- 07.3-165 Testing fuel pump relay module
- 07.3-167 Testing kick-down switch
- 07.3-200 Removal and installation of mixture control unit
- 07.3-205 Removal and installation of fuel distributor
- 07.3-207 Replacing seal for control plunger
- 07.3-215 Removal and installation of fuel injectors
- 07.3-220 Replacement of air flow sensor
- 07.3-225 Removal and installation of mixture control unit with air guide housing
- 07.3-230 Removal and installation of throttle body
- 07.3-245 Replacement, centering air flow sensor plate and checking and adjustment of zero position of air flow sensor plate
- 07.3-250 Removal and installation of CFI control module
- 07.3-251 Replacement of engine coolant temperature sensor
- 07.3-255 Replacement of electrohydraulic actuator
- 07.3-258 Replacement of heated oxygen sensor
- 07.3-268 Replacement of rubber rings or pads for fuel pump set
- 07.3-269 Removal and installation of fuel pump set
- 07.3-285 Replacement of check valve for fuel pump
- 07.3-290 Survey of fuel pump sets
30007
- Index
- 09-400 Removal and installation of air cleaner
- 09-402 Replacing intake scoop
- 09-410 Replacing idle air distributor
30008
- Index
- 13-335 Instructions concerning replacement and tensioning of V-belts
- 13-340 Replacing and tensioning V-belts
- 13-342 Removal and installation of Poly V-belt drive
- 13-343 Checking condition of Poly V-belt
- 13-345 Installation and removal of Poly V-belt tensioning fixture
- 13-346 Changes to the Poly V-belt tensioning device
30009
- Index
- 14-001 Recognition features of vehicles in national version
- 14-050 Function of emission control system
- 14-116 Testing heated oxygen sensor malfunction indicator lamp
- 14-200 Removal and installation of catalytic converter
- 14-450 Removal and installation of intake manifold and replacing gasket
- 14-452 Replacement of preheating flange
- 14-455 Replacement of intake manifold
- 14-456 Testing partial intake manifold preheating (PMP)
- 14-460 Removal and installation of intake manifold bottom section, replacing gasket
- 14-470 Removal and installation of exhaust manifold
- 14-475 Testing exhaust gas recirculation (EGR)
- 14-487 General instructions for vehicles with catalytic converter (KAT)
- 14-489 Disposing of catalytic converters
30010
- Index
- 15-505 Instructions regarding work on transistorized ignition system
- 15-510 Function of distributor ignition system (DI)
- 15-512 Function of the breakerless transistorized ignition system (TSZ)
- 15-515 Testing ignition point
- 15-525 Analyzing oscilloscope images
- 15-530 Replacing spark plugs
- 15-535 Removal and installation of ignition or high voltage distributor
- 15-540 Testing distributor ignition system (DI)
- 15-542 Testing breakerless transistorized ignition (TSZ)
- 15-543 Testing ignition advance in warm-up phase (only TSZ)
- 15-547 Retrofitting corrugated hoses for ignition cables
30011
- Index
- 18-005 Oil circuit, oil pressure, overpressure and bypass valve, oil filter
- 18-025 Measuring oil consumption
- 18-110 Removal and installation of oil filter
- 18-210 Removal and installation of oil pump
- 18-215 Removal and installation of oil overpressure (bypass) valve
- 18-220 Checking oil level indicator
- 18-225 Function of low engine oil level indicator
30012
- Index
- 20-005 Coolant circuit and engine cooling
- 20-010 Draining, adding coolant - Antifreeze protection table
- 20-015 Cleaning, flushing engine cooling and heating system
- 20-016 Removing oil from engine cooling and heating system
- 20-017 Checking engine cooling system for leaks
- 20-110 Removal and installation of engine coolant thermostat
- 20-115 Removal and installatlon of engine coolant thermostat housing
- 20-210 Removal and installation of engine coolant pump
- 20-330 Solenoid fan coupling
- 20-335 Removal and installation of solenoid fan coupling
- 20-419 Notes on radiator
- 20-420 Removal and installation of radiator
- 20-425 Repairing radiator
- 20-430 Testing radiator or expansion tank pressure cap
- 20-440 Checking engine coolant level indicator
- 20-445 Function of engine coolant level indicator
30013
- Index
- 22-210 Function - hydraulic engine mounts
- 22-211 Removal and installation of front engine mounts
- 22-212 Removal and installation of rear engine mount
30014
- Index
- 30-300 Adjusting throttle control
- 30-315 Removal and installation of accelerator pedal lever with firewall bearing
- 30-325 Removal and installation of Bowden cable
- 30-330 Removal and installation of accelerator pedal
- 30-335 Lubricating throttle control linkage and throttle control shafts
30015
- Index
- 47-010 Function of fuel tank with surge bowl
- 47-020 Function of fuel gauge sending unit
- 47-030 Function of fuel tank ventilation
- 47-100 Removal and installation of fuel tank
- 47-120 Removal and installation of fuel gauge sending unit
- 47-200 Function of evaporative emission system
- 47-300 Testing evaporative emission system
- 47-400 Function of fuel cooler
30016
- Index
- 49-100 Removal and installation of exhaust system
- 49-120 Removal and lnstallatlon of exhaust system at push-In joint
- 49-140 Replacement of center and rear mufflers
- 49-180 Replacement of exhaust support bracket at transmission
40001a
- Introduction
- Table of contents
- Views of engine 102.9833
- 00 General, technical data
- 01 Crankcase, cylinder head, crankcase ventilation
- 03 Crankshaft assembly
- 05 Engine timing, Valve train
- 07.3 Mechanically/electronically controlled gasoline injection system (CIS-E)
- 09 Air filter
- 13 Belt drive
- 14 Intake manifold, exhaust manifold
- 15 Electrical system, engine
- 18 Engine lubrication
- 20 Engine cooling
- Engine mounts
- Throttle control
50001
- Introduction
- Group Index
50002
- Index
- 00-005 Instructions for use of service manual
- 00-010 Engine and vehicle identification
- 00-015 Vehicle identification number locations
- 00-020 Technical data
50003
- Index
- 01-008 Opening hood, setting vertical, warnings
- 01-010 Testing Compression Pressure
- 01-015 Testing cylinders for leaks
- 01-030 Draining, replacing engine (oil capacities)
- 01-140 Replacing freeze plug in engine block
- 01-210 Removing, installing timing cover
- 01-212 Removing, installing top front cover
- 01-222 Removing, installing rear main seal cover
- 01-310 Removing, installing Oil Sump or Front Axle Housing (4MATIC)
- 01-415 Removing, installing Cylinder Head
50004
- Index
- 03-310 Checking, Renewing and Tightening Conrod Bolts
- 03-324 Renewlng Front Crankshaft Radial Seal
- 03-327 Renewing Rear Crankshaft Radial Seal
- 03-342 Removing, Installing Belt Pulley, Flywheel Damper and Hub
- 03-410 Removing, Installing Flywheel of Driven Plate
- 03-420 Machining Flywheel
50005
- Index
- 05-220 Removing, Installing Camshaft
- 05-250 Removing, Installing Valve Springs
- 05-270 Renewing Valve Stem Seals
- 05-310 Removing, Installing Chain Tensioner
- 05-320 Renewing Timing Chain
- 05-330 Removing, Installing Tensioning Rail
- 05-335 Removing, Installing Guide Rail
- 05-460 Removing, Installing Crankshaft Gear
50006
- Index
- 07.3-100 Checking idling speed, readjusting or special emission test (ASU)
- 07.3-110 Testing, regulating engine
- 07.3-111 Performing cylinder comparison test with engine tester SUN 2110
- 07.3-112 Testing electronic idling speed control
- 07.3-115 Testing engine output and emissions on drum dynamometer
- 07.3-117 Determining fuel consumption by driving on road
- 07.3 120 Checking fuel pressures and for internal leaks
- 07.3-121 Testing electrical components of CIS-E injection system
- 07.3-122 Testing throttle (orifice) in fuel distributor for unobstructed passage
- 07.3-125 Testing starting unit
- 07.3-126 Testing starting valve activation
- 07.3-127 Performing cold start
- 07.3-128 Electric wiring diagrams
- 07.3-130 Testing fuel pump
- 07.3-135 Testing injection valves
- 07.3-152 Testing, replacing throttle valve switch
- 07.3-160 Perform fuel quantity comparison measurement
- 07.3-165 Testing relay fuel pump
- 07.3-200 Removal and installation of mixture control unit
- 07.3-205 Replacing fuel distributor
- 07.3-207 Replacing sealing ring for control piston
- 07.3-215 Removal and installation of injection valves
- 07.3-220 Replacing air volume meter
- 07.3-225 Removal and installation of mixture control unit with air guide housing
- 07.3-230 Removal and installation of throttle valve housing
- 07.3-245 Replacing, centering air flow sensor plate, testing and adjusting zero position of air flow sensor plate
- 07.3-250 Removal and installation of control unit
- 07.3-255 Replacing electrohydraulic actuator (EHA)
- 07.3-268 Replacing rubber rings or rubber buffers for fuel pump package
- 07.3-269 Removal and installation of fuel pump package
- 07.3-270 Removal and installation of fuel accumulator
- 07.3-275 Removal and installation of fuel filter
- 07.3-280 Removal and installation of fuel pump
50007
- Index
- 09-400 Removal and installation of air cleaner
- 09-402 Renewing of intake scoop
50008
- Index
- 13-342 Checking condition of poly V-belt and renewing
- 13-345 Removing, installing tensioning device
50009
- Index
- 14-001 Distinguishing features of vehicles with exhaust emission control system
- 14-050 Function of emission control system
- 14-116 Checking oxygen senso failure indication USA
- 14-450 Removal and installation of intake manifold, replacement of gasket
- 14-455 Renewal of intake manifold (intake manifold removed)
- 14-470 Removal and installation of exhaust manifold
- 14-480 Renewal of oxygen sensor
50010
- Index
- 15-505 Notes regarding jobs on breakerless transistorised ignition system
- 15-510 Function of the electronic ignition system with variable characteristics (EZL)
- 15-515 Checking ignition timing
- 15-525 Evaluation of oscilloscope image
- 15-530 Renewing spark plugs
- 15-535 Removal and installation of high-voltage distributor
- 15-540 Checking the electronic ignition system with variable characteristics (EZL)
50011
- Index
- 18-002 Engine oil and filter change
- 18-110 Removing, installing oil filter
- 18-210 Removing, installing oil pump
- 18-212 Renewing oil pump chain
- 18-215 Removing, installing oil pressure relief valve in oil pump
- 18-330 Removing, installing oil level sensor
- 18-415 Renewing oil level return lock
50012
- Index
- 20-010 Draining, pouring in coolant - Antifreeze protection table
- 20-017 Testing cooling system for leaks
- 20-110 Removing, installing coolant thermostat
- 20-210 Removing, installing coolant pump
- 20-312 Removing, installing viscous fan clutch
- 20-420 Removing, installing radiator
- 20-450 Removing, installing overflow tank
50013
- Index
- 22-211 Removing, installing front engine mounts
- 22-212 Removing, installing rear engine mounts
- 22-213 Rear engine mount (Freeway hop) Model 124 USA
- 22-220 Setting engine stop, Model 124 4MATIC
50014
- Index
- 30-300 Adjusting control linkage
- 30-315 Removal and installation of accelerator pedal with front wall mounting
- 30-325 Removal, installation and adjustment of Bowden cable
50015
- Index
- 47-010 Operation of fuel tank with surge bowl
- 47420 Operation of fuel gage pickup
- 47-030 Operation of fuel tank positive and negative ventilation
- 47-100 Removal and installation of fuel tank
- 47-120 Removal and installation of fuel gage pickup
- 47-200 Function of fuel evaporation system
- 47-300 Checking the fuel evaporation system
- 47-400 Function of fuel cooler
50016
- Index
- 49-100 Removal, installation of exhaust system
60001
- Introduction
- Group Index
60002
- Index
- 00-005 Instructions for use of service manual
- 00-010 Engine and vehicle identification
- 00-015 Vehicle identification number locations
- 00-020 Technical data
60003
- Index
- 01-010 Checking compression pressure
- 01-015 Checking cylinders for leaks
- 01-020 Evaluating cylinder bores
- 01-030 Removal and installation of engine (oil capacity)
- 01-040 Crankcase breather - operation
- 01-110 Measuring cylinder bores
- 01-115 Renewing, boring and honing cylinder liners
- 01-120 Facing cylinder crankcase parting surface
- 01-130 Knocking out and inserting steel balls in main oil duct
- 01-140 Replacing core hole cover in cylinder crankcase
- 01-210 Removal and installation of timing housing cover
- 01-222 Removal and installation of end cover
- 01-310 Removal and installation of oil pan
- 01-405 Cylinder head screws and tightening cylinder head screws
- 01-415 Removal and installation of cylinder head
- 01-417 Removal and installation of prechambers
- 01-418 Facing cylinder head parting surface
- 01-420 Pressure-testing cylinder head
60004
- Index
- 03-310 Checking, renewing and tightening connecting rod bolts
- 03-313 Reconditioning and squaring connecting rods
- 03 -316 Removal and installation of pistons
- 03-318 Checking and reconditioning of crankshaft
- 03-320 Mounting of crankshaft
- 03-324 Replacing front crankshaft radial sealing ring
- 03-327 Replacing rear crankshaft radial sealing ring
- 03-330 Removal and installation of radial ball bearing in crankshaft
- 03-341 Removal and installation of crankshaft pulley and hub
- 03-345 Checking and correcting adjustment of TDC transmitter
- 03-350 Removal and installation of crankshaft timing gear
- 03-410 Removal and installation of flywheel and driven plate
- 03-420 Refinishing of flywheel
- 03-430 Renewing ring gear of flywheel
60005
- Index
- 05-211 Checking and replacement of hydraulic valve clearance compensating elements
- 05-215 Checking camshaft timing
- 05-220 Removal and installation of camshaft
- 05-250 Removal and installation of valve springs
- 05-260 Checking valve springs
- 05-270 Replacing valve stem seals
- 05-280 Checking and machining valves
- 05-290 Replacing valve seat rings
- 05-291 Machining valve seats
- 05-310 Removal and installation of chain tensioner
- 05-320 Replacing timing chain
- 05-330 Removal and installation of tensioning rail
- 05-341 Removal and installation of slide rails
- 05-437 Removal and installation of drive for hydraulic oil pump
60006
- Index
- 07.1-001 Survey engine-injection pump-injection nozzle-nozzle holder
- 07.1-010 Operation of injection system
- 07.1-011 Operation of injection nozzles
- 0 7 .1-012 Operation of fuel preheater
- 07.1-100 Adjustment of idle speed
- 07.1-102 Checking pneumatic idle speed increase
- 07.1-104 Checking engine output and exhaust gas on chassis dynamometer

- 07.1-109 Checking injection timing (high-pressure method)
- 07.1-111 Checking injection timing (position pickup-RIV-method)
- 07.1-112 Checking injection timing with digital tester ( RIV-method)
- 07.1-115 Adjusting injection timing (high-pressure method) - following checkup
- 07.1-116 Adjusting injection timing (position pickup-RIV-method) - following checkup
- 07.1-117 Adjusting injection timing with digital tester (R IV-method) - following checkup
- 07.1-135 Checking injection nozzles
- 07.1-137 Disassembling, cleaning, assembling and adjusting injection nozzles (following checkup)
- 07.1-145 Checking fuel pump
- 07.1-150 Checking vacuum shutoff for leaks
- 07.1-200 Removal and installation of injection pump
- 07.1-210 Renewing delivery valve seal
- 07.1-220 Renewing vacuum control unit
- 07.1-230 Removal and installation of injection nozzle
- 07.1-235 Removal and installation of fuel pump
- 07.1-240 Removal and installation of injection timer
- 07.1-245 Renewing fuel filter
60007
- Index
- 09-400 Removal and installation of air cleaner
60008
- Index
- 13-340 Removal and installation of V-belt
60009
- Index
- 14-050 Operation of emission control system
- 14-100 Checking emission control system
- 14-180 Removal and installation of intake manifold
- 14-350 Removal and installation of exhaust manifold
60010
- Index
- 15-505 Operation of preglow system
- 15-510 Checking preglow system
- 15-515 Removal and installation of glow plugs
- 15-600 Testing alternator with regulator in vehicle
- 15-642 Renewing fan assembly
- 15-700 Removal and installation of starter
60011
- Index
- 18 -005 Oil circuit, oil pressure, pressure relief and bypass valve, oil filter
- 18-110 Removal and installation of oil filter
- 18-210 Removal and installation of oil pump
- 18-215 Removal and installation of oil pressure relief valve
60012
- Index
- 20-005 Coolant circuit and engine cooling
- 20-010 Draining and filling in coolant - Antifreeze table
- 20-015 Cleaning cooling system
- 20-110 Removal and installation of thermostat
- 20-210 Removal and installation of coolant pump
- 20-230 Removal and installation of coolant pump
- 20-330 Magnetic fan coupling
- 20-335 Removal and installation of magnetic fan coupling
- 20-420 Removal and installation of radiator
- 20-425 Repairing radiator
- 20-430 Checking expansion tank closing cap
60013
- Index
- 22-211 Removal and installation of front engine mounts
- 22-212 Removal and installation of rear engine mounts
- 22-215 Removal and installation of front engine stop
- 22-220 Adjusting engine stop
- 22-240 Removal and installation of engine shock absorber
60014
- Index
- 30-300 Adjusting accelerator linkage
- 30-315 Removal and installation of front wall bearing for accelerator lever
- 30-325 Removal, installation and adjustment of bowden cable
- 30-330 Removal and installation of accelerator pedal
- 30-335 Lubrication of control linkage and control shafts
60015
- Index
- 47-020 Operation of immersion tube transmitter for fuel readout
- 47-030 Operation of fuel tank positive and negative venting
- 47-100 Removal and installation of fuel tank
- 47-120 Removal and installation of immersion tube transmitter
60016
- Index
- 49-100 Removal and installation of exhaust system
70001
- Introduction
- Group Index
70002
- Index
- 00-005 Instructions for use of service manual
- 00-010 Engine and vehicle identification
- 00-015 Vehicle identification number locations
- 00-020 Technical data
70003
- Index
- 01-001 Engine and model survey
- 01-006 Removal and installation of noise capsule at bottom of engine compartment
- 01-008 Opening hood, setting vertical, warnings
- 01-010 Testing compression pressure
- 01-015 Checking cylinders for leaks
- 01-020 Evaluating cylinder bores
- 01-030 Removal and installation of engine (oil capacity)
- 01-040 Crankcase ventilation - Function
- 01-110 Measuring, boring and honing cylinder bores
- 01-115 Boring, honing and replacement of cylinder sleeves
- 01-120 Planing crankcase parting surface
- 01-130 Removal and installation of steel balls in main oil duct
- 01-140 Replacement of freeze plugs in crankcase
- 01-210 Removal and installation of timing cover
- 01-222 Removal and installation of end cover
- 01-310 Removal and installation of oil pan
- 01-400 Repair notes for cylinder heads and cylinder head gaskets
- 01-410 Refinishing precharnber sealing surface
- 01-415 Removal and installation of cylinder head
- 01-417 Removal and installation of prechambers
- 01-418 Facing cylinder head mating surface
- 01-419 Boring out camshaft bearing bores (repair stage)
- 01-420 Pressure-testing cylinder head
70004
- Index
- 03-310 Checking, replacing and tightening connecting rod bolts
- 03-313 Reconditioning and squaring connecting rods
- 03-316 Removal and installation of pistons
-